SM F300B SM

F(L)225F
F(L)250D
F(L)300B
SERVICE MANUAL
6CE-28197-3N-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.
F(L)225F, F(L)250D, F(L)300B

SERVICE MANUAL
©2010 by Yamaha Motor Co., Ltd.
1st Edition, May 2010
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 0
Safety while working .................................................... 0-1

Rotating part .............................................................................. 0-1
Hot part ...................................................................................... 0-1
0
Electric shock ............................................................................ 0-1
Propeller .................................................................................... 0-1
Handling of gasoline .................................................................. 0-1
Ventilation .................................................................................. 0-1
1
Self-protection ........................................................................... 0-2
Working with crane .................................................................... 0-2
Handling of gas torch ................................................................ 0-2
Part, lubricant, and sealant ........................................................ 0-2
2
Handling of sealant .................................................................... 0-3
Special service tool ................................................................... 0-3
Tightening torque ...................................................................... 0-3
Non-reusable part ...................................................................... 0-3
3
Disassembly and assembly ....................................................... 0-3
How to use this manual .................................................... 0-4 4

Manual format ........................................................................... 0-4
Abbreviation .............................................................................. 0-5
Lubricant, sealant, and thread locking agent ................. 0-7

5
Symbol ...................................................................................... 0-7
Special service tool ........................................................... 0-9

6
7
8
9
10
A
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, personal siphon gasoline by mouth. If you swallow
flotation device straps, and so on, can some gasoline, inhale a lot of gasoline
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 in
Electric shock 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 dling of the gas torch, see the operation
using an air compressor. manual issued by the manufacturer. 0
• Protect your hands and feet by wearing pro- • When using a gas torch, keep it away from
tective gloves and safety shoes when nec- the gasoline and oil, to prevent a fire.
essary. • Components become hot enough to cause
burns. Do not touch any hot components 1
directly.
2
3
Working with crane
• Outboard motors weighing 18.0 kg (39.7 lb)
4
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
three-point suspension.
and sealants, or those recommended by
Yamaha, when servicing or repairing the out-
5
• 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 6
the outboard motor can be lifted and carried
in a stable manner.
7
8
9
10
A
0-2
GEN
Handling of sealant Non-reusable part
• Wear protective gloves to protect your skin, Always use new gaskets, seals, O-rings, cot-
when using the sealants. ter pins, and so on, when installing or assem-
• See the material safety data sheet issued bling parts.
by the manufacturer. Some of the sealants
may be harmful to human health.
Disassembly and assembly

• Use compressed air to remove dust and dirt
Special service tool during disassembly.
Use the recommended special service tools • Apply engine oil to the contact surfaces of
to work safely, and to protect parts from dam- moving parts before assembly.
age.
• Install bearings so that the bearing identifi-

cation mark is facing in the direction indi-
Tightening torque
cated in the installation procedure. In
When tightening nuts, bolts, and screws, fol-
addition, make sure to lubricate the bear-
low the tightening instructions provided
ings liberally.
throughout the manual. If the tightening order
• Apply a thin coat of water resistant grease
is not specified, tighten the large sizes first,
to the lip and periphery of an oil seal before
and then tighten the small sizes, starting from
installation.
the center and moving outward.
• Check that moving parts operate normally
after assembly.
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 a
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 b in the following figure).
1
• Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
the lubrication points (see c in the following figure).
• Tightening torque specifications are provided in the exploded diagrams (see d in the following fig-
ure), and in the related detailed instructions. Some torque specifications are listed in stages as
2
torque figures or angles in degrees.
• Separate procedures and illustrations are used to explain the details of removal, checking, and
installation where necessary (see e in the following figure for an example page). 3
TIP:
For troubleshooting procedures, see Chapter 4, “Troubleshooting.”
4
5
6
7
8
9
10
A
0-4
GEN
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
ABYC American Boat and Yacht Council
API American Petroleum Institute
ATDC After Top Dead Center
ATF Automatic Transmission Fluid
AWG American Wire Gauge
BTDC Before Top Dead Center
C/E Check Engine
CCA Cold Cranking Ampere
DN Down side
DOHC Double Over Head Camshaft
ECM Electronic Control Module
ETV Electronic Throttle Valve
EN European Norm (European standard)
ENG Engine
EX Exhaust
EXH Exhaust
F Forward
GPS Global Positioning System
ID Identification
IEC International Electro-technical Commission
IN Intake
INT Intake
ISO International Organization for Standardization
LPS Lever Position Sensor
N Neutral
OCV Oil Control Valve
PCV Pressure Control Valve
PORT Port side
PTT Power Trim and Tilt
R Reverse
R.C. Remote Control (Digital Electronic Control)
RON Research Octane Number
SAE Society of Automotive Engineers
SPS Shift Position Sensor
STBD Starboard side
TCI Transistor-Controlled Ignition
TDC Top Dead Center
TPS Throttle Position Sensor
0-5
How to use this manual
Abbreviation Description
UP Up side
VCT Variable Camshaft Timing
W/F Water in Fuel 0
Y-COP Yamaha Customer Outboard Protection
YDIS Yamaha Diagnostic System
1
2
3
4
5
6
7
8
9
10
A
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.
Gasket Maker Sealant
ThreeBond 1280B Sealant
ThreeBond 1303 Thread locking agent
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
ThreeBond 1530D Sealant

0
LOCTITE 210 (red) Thread locking agent 1
LOCTITE 242 (blue) Thread locking agent 2
LOCTITE 271 (red) Thread locking agent 3
LOCTITE 572 (white) Sealant
4
Silicone sealant Sealant
5
6
7
8
9
10
A
0-8
GEN
Special service tool
For all markets except U.S.A. and Canada
Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division.
Engine lifting eye Peak voltage adapter B

90890-06820 90890-03172
Drilling plate Test harness (3 pins)

90890-06783 90890-06869
YDIS (CD-ROM, Ver. 1.33) Vacuum/pressure pump gauge set

60V-WS853-06 90890-06756
YDIS USB adapter and cable Test harness (1 pin)

60V-WS850-00 90890-06888
Digital circuit tester Test harness (2 pins)

90890-03174 90890-06887
0-9
Ignition tester (spark gap tester) Leakage tester
90890-06754 90890-06840
0
1
Test harness (2 pins) Compression gauge
90890-06867 90890-03160
2
3
Test harness (3 pins) Compression gauge extension
90890-06791 90890-06563 4
5
Fuel pressure gauge adapter Balance hanger

6
90890-06842 90890-06822
7
8
Fuel pressure gauge Rotor holder
90890-06786 90890-01235
9
10
A
0-10
GEN
Sheave holder Valve lapper
90890-01701 90890-04101
Valve spring compressor Valve seat cutter holder

90890-04019 90890-06316
Valve spring compressor attachment Valve seat cutter 30°

90890-06320 90890-06331
Valve guide remover/installer Valve seat cutter 45°

90890-06801 90890-06332
Valve guide reamer Valve seat cutter 60°

90890-06804 90890-06333
0-11
Valve seat cutter 30° Needle bearing attachment
90890-06327 90890-06612
0
1
Valve seat cutter 45° Bearing inner race attachment
90890-06325 90890-06640
2
3
Valve seat cutter 60° Piston ring compressor
90890-06324 90890-05158 4
5
Oil filter wrench Needle bearing attachment

6
90890-06830 90890-06653
7
8
Driver rod L3 Shift rod socket
90890-06652 90890-06679
9
10
A
0-12
GEN
Needle bearing attachment Center bolt
90890-06614 90890-06504
Ring nut wrench extension Ball bearing attachment

90890-06513 90890-06634
Ring nut wrench 6 Needle bearing attachment

90890-06677 90890-06611
Bearing housing puller claw L Bearing inner race attachment

90890-06502 90890-06661
Stopper guide plate Driver rod LL

90890-06501 90890-06605
0-13
Bearing outer race attachment Needle bearing attachment
90890-06623 90890-06680
0
1
Bearing inner race attachment Ball bearing attachment
90890-06640 90890-06655
2
3
Drive shaft ring nut wrench Bearing outer race puller assembly
90890-06674 90890-06523 4
5
Drive shaft holder 6 Bearing outer race attachment

6
90890-06520 90890-06628
7
8
Pinion nut holder Backlash indicator
90890-06715 90890-06836
9
10
A
0-14
GEN
Magnet base plate Slide hammer
90890-07003 90890-06531
Dial gauge set Puller head

90890-01252 90890-06514
Magnet base B Needle bearing attachment

90890-06844 90890-06607
Pinion shimming gauge Ring nut wrench

90890-06675 90890-06578
Pinion shimming gauge rod Bearing puller assembly

90890-06676 90890-06535
0-15
PTT oil pressure gauge assembly
90890-06580
0
1
Cylinder-end screw wrench
90890-06568
2
3
PTT piston vice attachment
90890-06572 4
5
Tilt rod wrench

6
90890-06569
7
8
9
10
A
0-16
SPEC
Specification 1
Model feature ..................................................................... 1-1

General feature ......................................................................... 1-1
Model designation ..................................................................... 1-2
Serial number ............................................................................ 1-2
Model data ......................................................................... 1-3

Dimension and weight ............................................................... 1-3
Performance .............................................................................. 1-3
Power unit ................................................................................. 1-4
Lower unit .................................................................................. 1-5
Bracket unit ............................................................................... 1-5
Fuel and oil requirement ............................................................ 1-6
Battery requirement ................................................................... 1-7
PTT fluid requirement ................................................................ 1-7
Electrical system technical data ...................................... 1-8

Ignition timing control system .................................................... 1-8
Fuel injection control system ................................................... 1-10
Engine speed control system .................................................. 1-11
VCT system ............................................................................. 1-12
Shift actuator ........................................................................... 1-13
PTT system ............................................................................. 1-13
Charging system ..................................................................... 1-14
Starting system ........................................................................ 1-14
Gauge/sensor .......................................................................... 1-15
Fuel system technical data ............................................ 1-17

Fuel system ............................................................................. 1-17
Power unit technical data ............................................... 1-18

Power unit ............................................................................... 1-18
Cylinder head assembly .......................................................... 1-19
Crankcase assembly ............................................................... 1-21
Lower unit technical data ............................................... 1-24

Lower unit assembly (regular rotation model) ......................... 1-24
Lower unit assembly (counter rotation model) ........................ 1-24
Bracket unit technical data ............................................ 1-25

PTT system ............................................................................. 1-25
Specified tightening torque ............................................ 1-26

Rigging information ................................................................. 1-26
Fuel system ............................................................................. 1-26
Power unit ............................................................................... 1-26
Lower unit (regular rotation model) ......................................... 1-27
Lower unit (counter rotation model) ......................................... 1-28
Bracket unit ............................................................................. 1-28
PTT unit ................................................................................... 1-29
0
General tightening torque .............................................. 1-30
1
2
4
5
6
7
8
9
10
A
SPEC
Specification
Model feature
General feature
F(L)225F, F(L)250D, and F(L)300B overall feature
• Newly developed 60° V6, DOHC, 24-valve, 4-stroke 4169.0 cm3 (254.4 cu. in) engine
• Low exhaust emissions conform to EU regulations
• All models can use Digital network control
• Y-COP (optional in non-European markets)
a Power unit e Lower unit

• Plastic cylinder head covers • Dual water inlets
• Shimless valve lifters • Drive shaft with a double taper roller bear-
• Large diameter intake valve heads ing
• Cylinder heads with integrated exhaust • Propeller shaft with 3 bearings (regular
cover rotation model)
• Crankcase and oil filter bracket with oil • Propeller damper cooling system
cooler • Patented shift damper system
• Crankshaft with integrated drive sprocket
• Sleeveless cylinders
• Compact VCT assemblies with narrow tim- a
ing belt
• Blowby gas reburning system b
• Vapor gas treatment
b Electrical
• Electronic fuel injection control
• Ignition timing control c
• VCT control
• Knock control
d
• Engine speed control
• ETV control
• Electronic shift control
• Fail-safe control
• New YDIS 1.33 version
• Multi-engine system for alert mode and e
auto engine speed synchronization
• Adjusting trolling speed function
• High-output stator assembly
• Isolator for house (accessory) battery
• Water-cooled Rectifier Regulator
c Bracket unit
• Same type of bracket as F250A
• Same type of PTT unit as F250A
d Upper case
• Lightweight bottom cowling
• Vibration reduction mounting
• Water-sealed outer wall
1-1
Model feature
Model designation
F 300 B E T X 0
a b c d e f
a Model description
F: 4-stroke regular rotation 1
FL: 4-stroke counter rotation
b Model name 300: 225/250/300
c
d
Product generation B: A and later
E: Electric starter
2
Functions
e T: PTT
f Transom height
X: UL (25 in)
U: SUL (30 in) 3
Serial number
Model name
Approved Starting
4
The outboard motor serial number is indi- model code serial No.
cated on a label affixed to the port clamp
F225FET 6CL 1000001–
bracket.
FL225FET
F250DET
6CM
6CG
1000001–
1000001–
5
FL250DET 6CH 1000001–
F300BET
FL300BET
6CE
6CF
1000001–
1000001–
6
7
c a 8
b
YAMAHA MOTOR CO., LTD.
d
e
9
MADE IN JAPAN
PAYS D'ORIGINE JAPON
10
a Model name
b Approved model code
c Transom height
d Serial number
e Model year code
A
1-2
SPEC
Specification
Model data
Dimension and weight
Model
Item Unit
F225FET FL225FET F250DET FL250DET
Overall length mm (in) 958.0 (37.7)
Overall width mm (in) 634.0 (25.0)
Overall height
X mm (in) 1890.0 (74.4)
2017.0
U mm (in) — 2017.0 (79.4)
(79.4)
Boat transom height
X mm (in) 643 (25.3)
770.0
U mm (in) — 770.0 (30.3)
(30.3)
Weight (without propeller)
X kg (lb) 260.0 (573)
268.0
U kg (lb) — 268.0 (591)
(591)
Model
Item Unit
F300BET FL300BET
Overall length mm (in) 958.0 (37.7)
Overall width mm (in) 634.0 (25.0)
Overall height
X mm (in) 1890.0 (74.4)
U mm (in) 2017.0 (79.4)
Boat transom height
X mm (in) 643.0 (25.3)
U mm (in) 770.0 (30.3)
Weight (without propeller)
X kg (lb) 260.0 (573)
U kg (lb) 268.0 (591)
Performance
Model
Item Unit
Maximum output
At 5500 r/min kW (HP) 165.5 (225) 183.8 (250)
Full throttle operating range r/min 5000–6000
Maximum fuel consumption
L (US gal,
At 5500 r/min 81.0 (21.4, 17.8) 91.0 (24.0, 20.0)
Imp gal)/hr
Engine idle speed r/min 650–750
Model
Item Unit
F300BET FL300BET
Maximum output
At 5500 r/min kW (HP) 220.6 (300)
Full throttle operating range r/min 5000–6000
1-3
Model data
Model
Item Unit
F300BET FL300BET
Maximum fuel consumption
At 5500 r/min
L (US gal,
Imp gal)/hr
97.0 (25.6, 21.3) 0
Engine idle speed r/min 650–750
Power unit
Model
1
Item Unit
Type 4-stroke, DOHC
Cylinder quantity
Total displacement cm3 (cu. in)
V6
4169.0 (254.4)
2
Bore stroke mm (in) 96.0 96.0 (3.78 3.78)
Compression ratio
Control system
10.3:1
Digital Electronic Control 3
Starting system Electric
Fuel system Fuel injection
Ignition control system
Advance type
TCI
Microcomputer
4
Maximum generator output V, A 12.0, 70.0
Spark plug LFR6A-11 (NGK)
Firing order
Cooling system
1–2–3–4–5–6 (normal operation)
Water
5
Exhaust system Propeller boss
Lubrication system Wet sump
Model
6
Item Unit
F300BET FL300BET
Type
Cylinder quantity
4-stroke, DOHC
V6 7
Total displacement cm³ (cu. in) 4169.0 (254.4)
Bore stroke mm (in) 96.0 96.0 (3.78 3.78)
Compression ratio
Control system
10.3:1
Digital Electronic Control
8
Starting system Electric
Fuel system Fuel injection
Ignition control system
Advance type
TCI
Microcomputer
9
Maximum generator output V, A 12.0, 70.0
Spark plug
Firing order
LFR6A-11 (NGK)
1–2–3–4–5–6 (normal operation) 10
Cooling system Water
Exhaust system Propeller boss
Lubrication system Wet sump
A
1-4
SPEC
Specification
Lower unit
Model
Item Unit
Gear shift positions F–N–R
Gear ratio 1.75 (21/12)
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 TL T TL
Model
Item Unit
F300BET FL300BET
Gear shift positions F–N–R
Gear ratio 1.75 (21/12)
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type Spline
Propeller direction (rear view) Clockwise Counter clockwise
Propeller mark T TL
Bracket unit
Model
Item Unit
Trim angle
At 12º boat transom degree –3 to 16
Tilt-up angle degree 67
Steering angle degree 32 + 32
Trim and tilt system PTT
Model
Item Unit
F300BET FL300BET
Trim angle
At 12º boat transom degree –3 to 16
Tilt-up angle degree 67
Steering angle degree 32 + 32
Trim and tilt system PTT
1-5
Model data
Fuel and oil requirement
Model
Item Unit
Fuel type
Minimum fuel octane number RON
Regular unleaded gasoline
91
0
4-stroke motor oil with combination of the fol-
Engine oil
lowing SAE and API oil classifications
Engine oil grade (*1)
API
SAE
SE, SF, SG, SH, SJ, SL
5W-30, 10W-30, 10W-40
1
Total engine oil quantity (oil pan L (US qt,
7.1 (7.50, 6.25)
capacity) Imp qt)
Gear oil type Hypoid gear oil 2
API GL-5
Gear oil grade (*2)
SAE 90, 80W-90
Gear oil quantity
L (US qt,
Imp qt)
1.040 (1.10, 0.92) 3
(*1) If the recommended engine oil grades are not available, use engine oil with an API classification
of SH, SJ, or SL and an SAE classification of 15W-40, 20W-40, or 20W-50.
(*2) Meeting both API and SAE requirements. 4
Model
Item Unit
F300BET FL300BET
Fuel type
Minimum fuel octane number RON
Premium unleaded gasoline
94
5
4-stroke motor oil with combination of the fol-
Engine oil
lowing SAE and API oil classifications
Engine oil grade (*1)
API SE, SF, SG, SH, SJ, SL 6
SAE 5W-30, 10W-30, 10W-40
Total engine oil quantity (oil pan L (US qt,
7.1 (7.50, 6.25)
capacity)
Gear oil type
Imp qt)
Hypoid gear oil 7
Gear oil grade (*2) API GL-5
SAE 90, 80W-90
Gear oil quantity
L (US qt,
Imp qt)
1.040 (1.10, 0.92) 8
(*1) If the recommended engine oil grades are not available, use engine oil with an API classification
of SH, SJ, or SL and an SAE classification of 15W-40, 20W-40, or 20W-50.
(*2) Meeting both API and SAE requirements. 9
10
A
1-6
SPEC
Specification
Battery requirement
Model
Item Unit
Minimum cold cranking amps
CCA/EN A 640.0
Minimum rated capacity
20HR/IEC Ah 80.0
Model
Item Unit
F300BET FL300BET
Minimum cold cranking amps
CCA/EN A 640.0
Minimum rated capacity
20HR/IEC Ah 80.0
PTT fluid requirement

Model
Item Unit
Fluid type ATF DEXRON II
Model
Item Unit
F300BET FL300BET
Fluid type ATF DEXRON II
1-7
Model data / Electrical system technical data
Electrical system technical data
Ignition timing control system
Model
Spark plug
Item Unit
0
Gap mm (in) 1.0–1.1 (0.039–0.043)
Cam position sensor
Input voltage
Ignition coil
V 12.0 1
Input voltage V 12.0
Pulser coil
Air gap mm (in) 0.4–1.1 (0.016–0.043) 2
Output peak voltage
At cranking (unloaded) V 7.6
At cranking (loaded)
At 1500 r/min (loaded)
V
V
6.9
23.9
3
At 3500 r/min (loaded) V 25.1
Resistance
At 20 °C (68 °F)
Air temperature sensor
Ω 396.0–594.0 4
Input voltage V 4.75–5.25
Resistance (*1)
At 20 °C (68 °F) kΩ 2.21–2.69 5
At 80 °C (176 °F) kΩ 0.32
Air pressure sensor
Input voltage
Output voltage (*1)
V 4.75–5.25
6
At –20.0 kPa (–0.20 kgf/
V 3.21
cm2, –2.9 psi)
At –46.7 kPa (–0.467 kgf/
cm2, –6.8 psi)
V 2.16 7
Engine temperature sensor
Input voltage
Resistance (*1)
V 4.75–5.25
8
At 5 °C (41 °F) kΩ 4.2–4.9
At 25 °C (77 °F) kΩ 1.9–2.1
At 100 °C (212 °F)
Thermoswitch
kΩ 0.166–0.204
9
Temperature
Switch ON
Switch OFF
°C (°F)
°C (°F)
84–90 (183–194)
68–82 (154–180)
10
Knock sensor
Resistance
At 20 °C (68 °F) kΩ 504.0–616.0
(*1) The figures are for reference only.
A
1-8
SPEC
Specification
Model
Item Unit
F300BET FL300BET
Spark plug
Gap mm (in) 1.0–1.1 (0.039–0.043)
Cam position sensor
Ignition coil
Pulser coil
Air gap mm (in) 0.4–1.1 (0.016–0.043)
Output peak voltage
At cranking (loaded) V 6.9
Resistance
At 20 °C (68 °F) Ω 396.0–594.0
Resistance (*1)
At 20 °C (68 °F) kΩ 2.21–2.69
At 80 °C (176 °F) kΩ 0.32
Air pressure sensor
Output voltage (*1)
At –20.0 kPa (–0.20 kgf/
V 3.21
cm2, –2.9 psi)
At –46.7 kPa (–0.467 kgf/
V 2.16
cm2, –6.8 psi)
Resistance (*1)
At 5 °C (41 °F) kΩ 4.2–4.9
At 25 °C (77 °F) kΩ 1.9–2.1
At 100 °C (212 °F) kΩ 0.166–0.204
Thermoswitch
Temperature
Switch ON °C (°F) 84–90 (183–194)
Switch OFF °C (°F) 68–82 (154–180)
Knock sensor
Resistance
At 20 °C (68 °F) kΩ 504.0–616.0
1-9
Fuel injection control system
Model
Item Unit
Fuel line
Pressure (*1)
0
Within 5 seconds after
kPa (kgf/
engine start switch turned 330.0 (3.30, 47.9)
to ON
cm2, psi)
kPa (kgf/
1
At 700 r/min 280.0 (2.80, 40.6)
cm2, psi)
Water detection switch
Input voltage V 4.75–5.25 2
Float height (*1) mm (in) 53.0 (2.10)
Fuel injector
Input voltage
Resistance (*1)
V 12.0
3
At 20 °C (68 °F) Ω 11.5–12.5
Low-pressure fuel pump
Input voltage
Resistance (*1)
V 12.0 4
At 20 °C (68 °F) Ω 0.5–4.0
High-pressure fuel pump
Input voltage
Resistance (*1)
V 12.0 5
At 20 °C (68 °F) Ω 0.2–3.0
Vapor shut-off valve
Input voltage V 12.0 6
Resistance
At 20 °C (68 °F) Ω 30.0–34.0
(*1) The figures are for reference only. 7
Model
Item Unit
F300BET FL300BET
Fuel line
Pressure (*1)
8
Within 5 seconds after
kPa (kgf/
engine start switch turned 330.0 (3.30, 47.9)
to ON
cm2, psi)
kPa (kgf/
9
At 700 r/min 280.0 (2.80, 40.6)
cm2, psi)
Input voltage V 4.75–5.25 10
Float height (*1) mm (in) 53.0 (2.10)
Fuel injector
Resistance (*1)
At 20 °C (68 °F) Ω 11.5–12.5
A
1-10
SPEC
Specification
Model
Item Unit
F300BET FL300BET
Resistance (*1)
At 20 °C (68 °F) Ω 0.5–4.0
Resistance (*1)
At 20 °C (68 °F) Ω 0.2–3.0
Resistance
At 20 °C (68 °F) Ω 30.0–34.0
Engine speed control system

Model
Item Unit
TPS
Output voltage (*1)
With throttle valve fully
closed
TPS1 V 0.37–0.63
TPS2 V 2.5–3.5
Throttle valve opening angle
(*1)
degree 4.5
closed
SPS
Output voltage
F V 0.2–1.5
N V 2.412–2.588
R V 3.5–4.8
Oil pressure sensor
Output voltage (*1)
At 392.0 kPa (3.92 kgf/cm2,
V 2.5
56.8 psi)
At 784.0 kPa (7.84 kgf/cm2,
V 4.5
113.7 psi)
1-11
Model
Item Unit
F300BET FL300BET
TPS
Output voltage (*1)
With throttle valve fully 0
closed
TPS1 V 0.37–0.63
TPS2
Throttle valve opening angle
V 2.5–3.5 1
(*1)
closed
Input voltage
degree
V
4.5
4.75–5.25
2
SPS
Output voltage
F V 0.2–1.5 3
N V 2.412–2.588
R V 3.5–4.8
Input voltage
Oil pressure sensor
V 4.75–5.25
4
Output voltage (*1)
At 392.0 kPa (3.92 kgf/cm2,
56.8 psi)
V 2.5 5
At 784.0 kPa (7.84 kgf/cm2,
V 4.5
113.7 psi)
6
VCT system
Item Unit
Model 7
OCV
Input voltage
Resistance
V 12.0
8
At 20 °C (68 °F) Ω 6.7–7.7
Item Unit
F300BET
Model
FL300BET
9
OCV
Resistance
At 20 °C (68 °F) Ω 6.7–7.7
10
A
1-12
SPEC
Specification
Shift actuator
Model
Item Unit
Shift actuator
Rod stroke (*1)
F mm (in) 78.2 (3.08)
N mm (in) 59.2 (2.33)
R mm (in) 41.1 (1.62)
Motor resistance (*1)
At 20 °C (68 °F) Ω 1.7
Model
Item Unit
F300BET FL300BET
Shift actuator
Rod stroke (*1)
F mm (in) 78.2 (3.08)
N mm (in) 59.2 (2.33)
R mm (in) 41.1 (1.62)
Motor resistance (*1)
At 20 °C (68 °F) Ω 1.7
PTT system
Model
Item Unit
Trim sensor
Free position resistance Ω 247.6–387.6
Setting resistance Ω 9.0–11.0
Model
Item Unit
F300BET FL300BET
Trim sensor
Free position resistance Ω 247.6–387.6
Setting resistance Ω 9.0–11.0
1-13
Charging system
Model
Item Unit
Lighting coil
Output peak voltage
0
At 1500 r/min (unloaded) V 38.0
At 3500 r/min (unloaded)
Resistance (*1)
V 83.2 1
At 20 °C (68 °F) Ω 0.1056–0.1584
Fuse A 100
Rectifier Regulator 2
Output peak voltage
3
Model
Item Unit
F300BET FL300BET
Lighting coil
Output peak voltage
4
At 1500 r/min (unloaded) V 38.0
At 3500 r/min (unloaded)
Resistance (*1)
V 83.2 5
At 20 °C (68 °F) Ω 0.1056–0.1584
Fuse
Rectifier Regulator
A 100
6
Output peak voltage
At 3500 r/min (loaded)
V 13.0
7
Starting system
Item Unit
Model
8
Y-COP
Input voltage
Starter motor
V 12.0 9
Type Sliding gear
Output kW 1.70
Cranking time limit second 30 10
Commutator
Standard diameter mm (in) 29.0 (1.14)
Wear limit mm (in) 28.0 (1.10)
Standard undercut mm (in) 0.5–0.8 (0.02–0.03)
A
1-14
SPEC
Specification
Model
Item Unit
Brush
Standard length mm (in) 15.5 (0.61)
Model
Item Unit
F300BET FL300BET
Y-COP
Input voltage 12.0
Starter motor
Type Sliding gear
Output kW 1.70
Cranking time limit second 30
Commutator
Standard undercut mm (in) 0.5–0.8 (0.02–0.03)
Brush
Gauge/sensor
Model
Item Unit
Water pressure sensor
Output voltage (*1)
At 392.0 kPa (3.92 kgf/cm2,
V 2.5
56.8 psi)
At 784.0 kPa (7.84 kgf/cm2,
V 4.5
113.7 psi)
Speed sensor
Output voltage (*1)
At 392.0 kPa (3.92 kgf/cm2,
V 2.5
56.8 psi)
At 784.0 kPa (7.84 kgf/cm2,
V 4.5
113.7 psi)
1-15
Model
Item Unit
F300BET FL300BET
Water pressure sensor
Input voltage
Output voltage (*1)
V 4.75–5.25
0
At 392.0 kPa (3.92 kgf/cm2,
V 2.5
56.8 psi)
At 784.0 kPa (7.84 kgf/cm2,
113.7 psi)
V 4.5 1
Speed sensor
Output voltage (*1)
At 392.0 kPa (3.92 kgf/cm2,
2
V 2.5
56.8 psi)
At 784.0 kPa (7.84 kgf/cm2,
113.7 psi)
V 4.5 3
4
5
6
7
8
9
10
A
1-16
SPEC
Specification
Fuel system technical data
Fuel system
Model
Item Unit
Fuel filter assembly
Holding pressure
kPa (kgf/
Positive pressure 200.0 (2.00, 29.0)
cm2, psi)
kPa (kgf/
Negative pressure 80.0 (0.80, 11.6)
cm2, psi)
Canister
Holding pressure
kPa (kgf/
cm2, psi)
Primer pump
Holding pressure
kPa (kgf/
cm2, psi)
Vapor separator tank
Float height mm (in) 67.5 ± 2.5 (2.66 ± 0.10)
Model
Item Unit
F300BET FL300BET
Holding pressure
kPa (kgf/
cm2, psi)
kPa (kgf/
Negative pressure 80.0 (0.80, 11.6)
cm2, psi)
Canister
Holding pressure
kPa (kgf/
cm2, psi)
Primer pump
Holding pressure
kPa (kgf/
cm2, psi)
Vapor separator tank
Float height mm (in) 67.5 ± 2.5 (2.66 ± 0.10)
1-17
Fuel system technical data / Power unit technical data
Power unit technical data
Power unit
Model
Item
Compression pressure
Unit
0
kPa (kgf/
Minimum (*1) 700.0 (7.00, 101.5)
cm2, psi)
Engine oil
Oil pressure (*2)
1
At 60 °C (140 °F) with SL
kPa (kgf/
10W-30 engine oil and at
750 r/min
cm2, psi)
350.0 (3.50, 50.8)
2
kPa (kgf/
10W-30 engine oil and at 590.0 (5.90, 85.6)
cm2, psi)
3000 r/min
Timing belt
3
Installation height mm (in) 2.5 (0.10)
Thermostat
Valve opening temperature
Fully open temperature
°C (°F)
°C (°F)
50.0–54.0 (122.0–129.0)
62.0 (144.0)
4
Fully open stroke mm (in) 4.3 (0.17)
Replacement engine oil quan-
tity (at periodic maintenance) 5
L (US qt,
Without oil filter replacement 6.0 (6.34, 5.28)
Imp qt)
With oil filter replacement
L (US qt,
Imp qt)
6.3 (6.66, 5.54) 6
(*1) Measuring conditions: Ambient temperature 20 °C (68 °F), with spark plugs removed from all
cylinders. The figures are for reference only.
(*2) For the checking method, see “Checking the oil pressure” (7-1). The figures are for reference 7
only.
Model
Item
Unit
F300BET FL300BET 8
kPa (kgf/
Minimum (*1) 700.0 (7.00, 101.5)
cm2, psi)
Engine oil
Oil pressure (*2)
9
kPa (kgf/
10W-30 engine oil and at
750 r/min
cm2, psi)
350.0 (3.50, 50.8)
10
kPa (kgf/
10W-30 engine oil and at 590.0 (5.90, 85.6)
cm2, psi)
3000 r/min
Timing belt
Installation height mm (in) 2.5 (0.10)
A
1-18
SPEC
Specification
Model
Item Unit
F300BET FL300BET
Thermostat
Valve opening temperature °C (°F) 50.0–54.0 (122.0–129.0)
Fully open temperature °C (°F) 62.0 (144.0)
Fully open stroke mm (in) 4.3 (0.17)
Replacement engine oil quan-
tity (at periodic maintenance)
L (US qt,
Without oil filter replacement 6.0 (6.34, 5.28)
Imp qt)
L (US qt,
With oil filter replacement 6.3 (6.66, 5.54)
Imp qt)
(*1) Measuring conditions: Ambient temperature 20 °C (68 °F), with spark plugs removed from all
cylinders. The figures are for reference only.
(*2) For the checking method, see “Checking the oil pressure” (7-1). The figures are for reference
only.
Cylinder head assembly

Model
Item Unit
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) 46.661–46.761 (1.8370–1.8410)
Exhaust mm (in) 46.960–47.060 (1.8488–1.8528)
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) 0.030 (0.0012)
Cylinder head
Warpage limit mm (in) 0.10 (0.0039)
Journal inside diameter mm (in) 25.000–25.021 (0.9843–0.9851)
Valve spring
Free length mm (in) 48.1 (1.89)
Tilt limit mm (in) 1.7 (0.07)
Valve
Clearance
Intake mm (in) 0.205 ± 0.035 (0.0081 ± 0.0014)
Exhaust mm (in) 0.345 ± 0.035 (0.0136 ± 0.0014)
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) 0.750–1.150 (0.0295–0.0453)
Exhaust mm (in) 0.900–1.300 (0.0354–0.0512)
1-19
Model
Item Unit
Valve stem
Diameter
Intake mm (in) 5.477–5.492 (0.2156–0.2162) 0
Exhaust mm (in) 5.464–5.479 (0.2151–0.2157)
Runout
Intake and exhaust
Valve guide
mm (in) 0.01 (0.0004)
1
Inside diameter
Valve guide clearance
Intake mm (in) 0.012–0.045 (0.0005–0.0018)
2
Exhaust mm (in) 0.025–0.058 (0.0010–0.0023)
Installation height mm (in) 11.300–11.700 (0.4449–0.4606)
Model
3
Item Unit
F300BET FL300BET
Valve lifter
Outside diameter mm (in) 30.970–30.980 (1.2193–1.2197) 4
Valve lifter clearance mm (in) 0.020–0.055 (0.0008–0.0022)
Camshaft
Cam lobe height
Intake mm (in) 46.661–46.761 (1.8370–1.8410)
5
Exhaust mm (in) 46.960–47.060 (1.8488–1.8528)
Cam lobe width
Intake and exhaust
Journal diameter
mm (in)
mm (in)
35.950–36.050 (1.4154–1.4193)
24.960–24.980 (0.9827–0.9835)
6
Runout mm (in) 0.030 (0.0012)
Cylinder head
Warpage limit mm (in) 0.10 (0.0039) 7
Journal inside diameter mm (in) 25.000–25.021 (0.9843–0.9851)
Valve spring
Free length
Tilt limit
mm (in)
mm (in)
48.1 (1.89)
1.7 (0.07)
8
Valve
Clearance
Intake
Exhaust
mm (in)
mm (in)
0.205 ± 0.035 (0.0081 ± 0.0014)
0.345 ± 0.035 (0.0136 ± 0.0014)
9
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) 10
Margin thickness
Intake mm (in) 0.750–1.150 (0.0295–0.0453)
Exhaust mm (in) 0.900–1.300 (0.0354–0.0512)
A
1-20
SPEC
Specification
Model
Item Unit
F300BET FL300BET
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) 0.01 (0.0004)
Valve guide
Inside diameter
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) 11.300–11.700 (0.4449–0.4606)
Crankcase assembly
Model
Item Unit
Piston
Diameter mm (in) 95.945–95.960 (3.7774–3.7779)
Measuring point mm (in) 13.500 (0.5315)
Piston clearance mm (in) 0.040–0.067 (0.0016–0.0026)
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) 22.011–22.018 (0.8666–0.8668)
Pin outside diameter mm (in) 21.996–22.005 (0.8660–0.8663)
Cylinder
Bore mm (in) 96.000–96.012 (3.7795–3.7800)
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) mm (in) 0.200–0.300 (0.0079–0.0118)
Side clearance mm (in) 0.030–0.050 (0.0012–0.0020)
2nd ring
Type Taper
Dimension height (B) mm (in) 1.170–1.190 (0.0461–0.0469)
End gap (*1) mm (in) 0.600–0.750 (0.0236–0.0295)
Oil ring
End gap (*1) mm (in) 0.150–0.600 (0.0059–0.0236)
1-21
Model
Item Unit
Connecting rod
Small end inside diameter
Big end inside diameter
mm (in)
mm (in)
22.010–22.024 (0.8665–0.8671)
55.990–56.010 (2.2043–2.2051) 0
Big end side clearance mm (in) 0.140–0.310 (0.0055–0.0122)
Oil clearance (*1) mm (in) 0.025–0.050 (0.0010–0.0020)
Crankshaft
1
Crankpin diameter mm (in) 52.980–53.000 (2.0858–2.0866)
Runout mm (in) 0.030 (0.0012)
Crankpin width
Crankcase
mm (in) 21.000–21.100 (0.8268–0.8307) 2
Model
3
Item Unit
F300BET FL300BET
Piston
Diameter mm (in) 95.945–95.960 (3.7774–3.7779) 4
Measuring point mm (in) 13.500 (0.5315)
Piston clearance mm (in) 0.040–0.067 (0.0016–0.0026)
Ring groove (top)
Ring groove (2nd)
mm (in)
mm (in)
1.230–1.250 (0.0484–0.0492)
1.220–1.240 (0.0480–0.0488)
5
Ring groove (oil) mm (in) 2.510–2.530 (0.0988–0.0996)
Pin boss inside diameter mm (in) 22.011–22.018 (0.8666–0.8668)
Pin outside diameter
Cylinder
mm (in) 21.996–22.005 (0.8660–0.8663) 6
Bore mm (in) 96.000–96.012 (3.7795–3.7800)
Piston ring
Top ring 7
Type Barrel
Dimension height (B) mm (in) 1.200 (0.0472)
Dimension width (T)
End gap (*1)
mm (in)
mm (in)
2.800–3.000 (0.1102–0.1181)
0.200–0.300 (0.0079–0.0118)
8
2nd ring
Type
Dimension height (B) mm (in)
Taper
1.170–1.190 (0.0461–0.0469)
9
End gap (*1) mm (in) 0.600–0.750 (0.0236–0.0295)
Side clearance mm (in) 0.030–0.070 (0.0012–0.0028) 10
Oil ring
End gap (*1) mm (in) 0.150–0.600 (0.0059–0.0236)
A
1-22
SPEC
Specification
Model
Item Unit
F300BET FL300BET
Connecting rod
Small end inside diameter mm (in) 22.010–22.024 (0.8665–0.8671)
Big end inside diameter mm (in) 55.990–56.010 (2.2043–2.2051)
Big end side clearance mm (in) 0.140–0.310 (0.0055–0.0122)
Crankshaft
Crankpin diameter mm (in) 52.980–53.000 (2.0858–2.0866)
Runout mm (in) 0.030 (0.0012)
Crankpin width mm (in) 21.000–21.100 (0.8268–0.8307)
Crankcase
1-23
Power unit technical data / Lower unit technical data
Lower unit technical data
Lower unit assembly (regular rotation model)
Model
Lower unit
Item Unit
F225F F250D F300B
0
kPa (kgf/
Holding pressure 68.6 (0.686, 9.9)
cm2, psi)
Forward gear backlash (*1)
Reverse gear backlash (*1)
mm (in)
mm (in)
0.04–0.59 (0.0016–0.0232)
0.15–0.88 (0.0059–0.0346)
1
Pinion shim (T3) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Forward gear shim (T1)
Reverse gear shim (T2)
mm
mm
2.00, 2.03, 2.06, 2.09, 2.12, 2.15
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 2
Propeller shaft shim (T4) mm 0.7, 0.8, 0.9, 1.0, 1.1, 1.2
Propeller shaft
Motive torque
N·m (kgf·m,
ft·lb)
0.44–1.32 (0.04–0.13, 0.32–0.97) 3
Runout mm (in) 0.02 (0.0008)
Drive shaft
Motive torque
N·m (kgf·m,
ft·lb)
0.27–1.94 (0.03–0.20, 0.20–1.43) 4
Runout mm (in) 1.0 (0.0394)
(*1) Figures obtained using the special service tools. 5
Lower unit assembly (counter rotation model)
Item Unit
FL225F
Model
FL250D FL300B 6
Lower unit
kPa (kgf/
Holding pressure 68.6 (0.686, 9.9)
Forward gear backlash (*1)
cm2, psi)
mm (in) 0.18–0.76 (0.0071–0.0299)
7
Reverse gear backlash (*1) mm (in) 0.19–0.84 (0.0075–0.0331)
Pinion shim (T3) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Forward gear shim (T2)
Reverse gear shim (T1)
mm
mm
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
2.00, 2.03, 2.06, 2.09, 2.12, 2.15
8
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) 9
Runout mm (in) 0.02 (0.0008)
Drive shaft
Motive torque
N·m (kgf·m,
ft·lb)
0.27–1.94 (0.03–0.20, 0.20–1.43) 10
Runout mm (in) 1.0 (0.0394)
(*1) Figures obtained using the special service tools.
A
1-24
SPEC
Specification
Bracket unit technical data
PTT system
Model
Item Unit
PTT
Hydraulic pressure
MPa (kgf/
Down 6.7–8.7 (67.0–87.0, 971.5–1261.5)
cm2, psi)
MPa (kgf/
Up 13.0–15.0 (130.0–150.0, 1885.0–2175.0)
cm2, psi)
Motor commutator
Standard undercut (*1) mm (in) 1.4 (0.06)
Motor brush
Model
Item Unit
F300BET FL300BET
PTT
Hydraulic pressure
MPa (kgf/
Down 6.7–8.7 (67.0–87.0, 971.5–1261.5)
cm2, psi)
MPa (kgf/
Up 13.0–15.0 (130.0–150.0, 1885.0–2175.0)
cm2, psi)
Motor commutator
Standard undercut (*1) mm (in) 1.4 (0.06)
Motor brush
1-25
Bracket unit technical data / Specified tightening torque
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.
0
Rigging information
Tightening torques
Part to be tightened
Water pressure sensor adapter
Screw size
—
N·m
23
kgf·m
2.3
ft·lb
17.0
1
Water pressure sensor — 18 1.8 13.3
Speed sensor — 18 1.8 13.3
Receiver screw M4 4 0.4 3.0 2
Fuel system
Part to be tightened Screw size

N·m
Tightening torques
kgf·m ft·lb
3
Fuel cup assembly — 5 0.5 3.7
1st 24 2.4 17.7
Intake manifold bolt
2nd
1st
M8
24
11
2.4
1.1
17.7
8.1
4
M6
2nd 11 1.1 8.1
Intake silencer bolt
Surge tank bracket bolt
M6
M6
7
11
0.7
1.1
5.2
8.1 5
Fuel pump cover bolt M6 5 0.5 3.7
Vapor separator drain screw — 2 0.2 1.5
Needle valve assembly screw
Float pin screw
M4
M4
2
2
0.2
0.2
1.5
1.5
6
Float chamber cover screw M5 2 0.2 1.5
Vapor separator cover bolt M4 2 0.2 1.5
Pressure regulator screw
Fuel cooler cover screw
M5
M5
4
4
0.4
0.4
3.0
3.0
7
Power unit

Tightening torques 8
N·m kgf·m ft·lb
Spark plug — 28 2.8 20.7
Power unit mounting bolts
1st
2nd
M10
42
42
4.2
4.2
31.0
31.0
9
Apron screw M6 3 0.3 2.2
PTT motor lead bolt M6 4 0.4 3.0
Pulser coil bolt
1st
M5 4
40
0.4
4.0
3.0
29.5
10
Flywheel magnet bolt M10
2nd 90°
Starter motor lead screw M4 2 0.2 1.5
Fuse box screw ø5 2 0.2 1.5
Terminal bolt M8 25 2.5 18.4
PTT relay nut — 5 0.5 3.7
Starter motor nut — 9 0.9 6.6
A
1-26
SPEC
Specification
Tightening torques
N·m kgf·m ft·lb
1st 6 0.6 4.4
Rectifier Regulator cover bolt M6
2nd 12 1.2 8.9
M8 25 2.5 18.4
Starter motor bracket bolt
M6 12 1.2 8.9
Starter motor bolt M8 30 3.0 22.1
Engine ECM bolt M6 7 0.7 5.2
Shift actuator bolt M6 19 1.9 14.0
Timing belt tensioner bolt — 39 3.9 28.8
Pulley bolt M10 39 3.9 28.8
1st 8 0.8 5.9
Camshaft cap bolts M7
2nd 17 1.7 12.5
Driven sprocket bolt M10 60 6.0 44.3
VCT bolt — 60 6.0 44.3
VCT cap — 32 3.2 23.6
Exhaust plug M18 56 5.6 41.3
Braided plug M14 23 2.3 17.0
OCV bolt M6 7 0.7 5.2
1st 39 3.9 28.8
M11
2nd 180°
Cylinder head bolt
1st 14 1.4 10.3
M8
2nd 28 2.8 20.7
Oil pump cover screw M6 4 0.4 3.0
1st 6 0.6 4.4
Oil cooler bolt M6
2nd 12 1.2 8.9
Bracket bolt M6 12 1.2 8.9
Oil filter union bolt UNF 49 4.9 36.1
Oil pressure sensor — 13 1.3 9.6
Oil filter — 18 1.8 13.3
Thermostat housing bolt M6 12 1.2 8.9
Thermostat cover bolt M6 12 1.2 8.9
Knock sensor — 32 3.2 23.6
Knock sensor bracket bolt M6 12 1.2 8.9
1st 14 1.4 10.3
Pulley bracket bolt M8
2nd 28 2.8 20.7
1st 40 4.0 29.5
Connecting rod bolt M9
2nd 90°
1st 55 5.5 40.6
M10
2nd 90°
Crankcase bolt
1st 14 1.4 10.3
M8
2nd 28 2.8 20.7
Lower unit (regular rotation model)

Tightening torques
N·m kgf·m ft·lb
Water inlet cover bolt M5 2 0.2 1.5
Drain screw — 9 0.9 6.6
Check screw — 9 0.9 6.6
1-27
Specified tightening torque
Tightening torques
N·m kgf·m ft·lb
Trim tab bolt M10 42 4.2 31.0
Propeller nut
Lower case mounting bolt (X-transom model)
—
M10
54
47
5.4
4.7
39.8
34.7 0
Lower case stud bolt (U-transom model) — 23 2.3 17.0
Lower case mounting nut (U-transom model) — 47 4.7 34.7
Lower case mounting bolt (U-transom model)
Water inlet cover screw
M10
M5
47
1
4.7
0.1
34.7
0.7
1
Propeller shaft housing ring nut — 155 15.5 114.3
Cover bolt M8 8 0.8 5.9
Drive shaft nut
Drive shaft ring nut
—
—
40
177
4.0
17.7
29.5
130.5
2
Pinion nut — 143 14.3 105.5
Lower unit (counter rotation model) 3

Tightening torques
N·m kgf·m ft·lb
Water inlet cover bolt
Drain screw
M5
—
2
9
0.2
0.9
1.5
6.6
4
Check screw — 9 0.9 6.6
Trim tab bolt M10 42 4.2 31.0
Propeller nut
Lower case mounting bolt (X-transom model)
—
M10
54
47
5.4
4.7
39.8
34.7
5
Lower case stud bolt (U-transom model) — 23 2.3 17.0
Lower case mounting nut (U-transom model)
Lower case mounting bolt (U-transom model)
—
M10
47
47
4.7
4.7
34.7
34.7 6
Water inlet cover screw M5 1 0.1 0.7
Propeller shaft housing ring nut — 155 15.5 114.3
Cover bolt
Drive shaft nut
M8
—
8
40
0.8
4.0
5.9
29.5
7
Drive shaft ring nut — 177 17.7 130.5
Pinion nut — 143 14.3 105.5
Bracket unit
8
Tightening torques
Adapter screw ø6
N·m
4
kgf·m
0.4
ft·lb
3.0 9
Upper mounting nut — 72 7.2 53.1
Lower mounting nut — 72 7.2 53.1
Upper mount bracket bolt
Lower mount bracket bolt
M10
M10
55
55
5.5
5.5
40.6
40.6
10
M10 42 4.2 31.0
Upper case bolt
M8 20 2.0 14.8
Anode screw M6 4 0.4 3.0
Drain bolt — 27 2.7 19.9
Oil strainer bolt M6 12 1.2 8.9
Exhaust manifold bolt
Oil pan bolt
M8
M8
20
20
2.0
2.0
14.8
14.8 A
1-28
SPEC
Specification
Tightening torques
N·m kgf·m ft·lb
Muffler bolt M8 20 2.0 14.8
Plate screw M6 4 0.4 3.0
Self-locking nut — 23 2.3 17.0
Grease nipple — 3 0.3 2.2
Trim sensor screw M6 4 0.4 3.0
PTT unit
Tightening torques
N·m kgf·m ft·lb
Reservoir mounting bolt M8 19 1.9 14.0
Reservoir cap — 7 0.7 5.2
PTT motor mounting bolt M8 19 1.9 14.0
Pump bracket bolt M5 7 0.7 5.2
Gear pump bolt M5 7 0.7 5.2
Manual valve — 2 0.2 1.5
Tilt ram — 65 6.5 47.9
Tilt piston screw M6 7 0.7 5.2
Pipe joint — 15 1.5 11.1
Pipe joint adapter — 20 2.0 14.8
Trim cylinder end screw — 160 16.0 118.0
Tilt cylinder end screw — 90 9.0 66.4
1-29
Specified tightening torque / General tightening torque
General tightening torque
This chart indicates the tightening torques for
standard fasteners with a standard ISO
thread pitch.
Width General torque
0
Screw
across specifications
size (B)
flats (A) N·m kgf·m ft·lb
8 mm M5 5 0.5 3.7 1
10 mm M6 8 0.8 5.9
12 mm M8 18 1.8 13.3
14 mm
17 mm
M10
M12
36
43
3.6
4.3
26.6
31.7 2
3
4
5
6
7
8
9
10
A
1-30
SPEC
Specification
— MEMO —
1-31
TECH
FEA
Technical features and description 2
Electronic control system ................................................ 2-1

Engine ECM component ........................................................... 2-2
Sensor, switch, and actuator ..................................................... 2-3
0
Electronic fuel injection control .................................................. 2-5
Ignition timing control ................................................................ 2-8
VCT control ............................................................................. 2-10
Knock control ........................................................................... 2-11
1
Engine speed control ............................................................... 2-12
ETV control .............................................................................. 2-14
Electronic shift control system ................................................. 2-15
Fail-safe control ....................................................................... 2-16
2
Charging system ..................................................................... 2-18
Digital network control ............................................................. 2-19
Sensor, switch ......................................................................... 2-21 3
Y-COP ............................................................................... 2-22
4
Power unit system .......................................................... 2-23
Shimless valve lifter ................................................................. 2-24
Sleeveless cylinder .................................................................. 2-24
Oil cooler ................................................................................. 2-25 5
Fuel system ..................................................................... 2-26
Fuel diagram ........................................................................... 2-26 6
Lubrication system ......................................................... 2-28
Lubrication diagram ................................................................. 2-28 7
Cooling system ............................................................... 2-29
Cooling diagram ...................................................................... 2-29
8
Intake and exhaust system ............................................ 2-31
Intake and exhaust diagram .................................................... 2-31
9
Lower unit ........................................................................ 2-32
Double taper roller bearing ...................................................... 2-32
Propeller shaft bearing (regular rotation model) ...................... 2-32
Propeller .................................................................................. 2-33
10
A
TECH
FEA Technical features and description
Electronic control system
This model uses an electronic fuel injection control, ignition timing control, knock control, engine
speed control, Digital Electronic Control, electronic shift control, ETV control, and fail-safe control.
The engine ECM performs these controls based on data received from each sensor and switch.
The engine ECM is equipped with a self-diagnosis function. This function can be used to check trou-
ble codes on the YDIS.
It is also equipped with Y-COP as an anti-theft measure.
Check valve
Air
Pressure regulator Filter

Canister
Check valve
High-pressure Low-pressure fuel pump
fuel pump Water separator
Fuel
Vapor separator Water
detection
Fuel injector switch
OCV
Vapor shut-off
Ignition valve
coil
TPS LPS
ETV
Air
Ignition
coil
Digital
OCV
Shift actuator Electronic
Fuel injector Control
ECM
Shift control
Valve control
Fuel control Cam position sensor
Pulser coil Engine
Ignition control Air pressure sensor start switch
Oil pressure sensor
6Y9 Engine SPS
Multifunction ECM Air temperature sensor
Engine
Color Gauge Knock sensor
Engine temperature sensor shut-off
Battery Thermoswitch switch
Water pressure sensor (optional)
Hub Speed sensor (optional)
Y-COP YDIS
2-1
Engine ECM component
d e f g
h
b
c
i 0
a
j
2
p
q
3
k
y
4
l
o n m
x
6
r
7
w
v u t
8
s
a ETV n SPS
b Air pressure sensor o Shift actuator 9
c Air temperature sensor p OCV (STBD)
d Pulser coil q Thermoswitch (STBD)
e Engine temperature sensor
f Vapor shut-off valve
r Cam position sensor (STBD IN)
s Oil pressure sensor
10
g Thermoswitch (PORT) t Fuel injector (STBD)
h OCV (PORT) u Ignition coil (STBD)
i Cam position sensor (PORT IN) v Knock sensor
j Fuel injector (PORT) w Engine ECM
k High-pressure fuel pump x Ignition coil (PORT)
l Low-pressure fuel pump y Cam position sensor (PORT EX)
m TPS A
2-2
TECH
Sensor, switch, and actuator
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.
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 sen- Determines the stroke. (For example, distinguishes the compression stroke
sor (PORT EX) 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 sen- Detects the advance angle on the port camshaft.
sor (PORT IN)
Cam position sen- Detects the advance angle on the starboard camshaft.
sor (STBD IN)
TPS 1 Detect the throttle valve opening. TPS 1 is the main sensor and TPS 2 is
TPS 2 the sub sensor. TPS 1 and TPS 2 mutually monitor each other for malfunc-
tions.
SPS 1 Detect the shift position. SPS 1 is the main sensor and SPS 2 is the sub
SPS 2 sensor. SPS 1 and SPS 2 mutually monitor each other for malfunctions.
ETV Opens and closes the throttle valve using a motor.
Shift actuator Drives the motor according to the engine ECM command for engaging or
disengaging the gearshift.
Air pressure sensor Detects the intake air pressure.
Air temperature Detects the intake air temperature.
sensor
Engine tempera- Detects the engine temperature.
ture sensor
Oil pressure sensor Detects the oil pressure.
Thermoswitch Detects engine overheating.
Knock sensor Detects engine knocking.
Engine shut-off Stops the engine forcibly.
switch
Fuel injector Injects fuel.
Ignition coil Activates the ignition.
Vapor shut-off Controls the amount of vapor gas to be sent from the vapor separator to
valve 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 Pressurizes the fuel and sends the fuel to the fuel rails.
pump
2-3
Low-pressure fuel Sends the fuel from the fuel tank to the vapor separator.
pump
0
1
2
3
4
5
6
7
8
9
10
A
2-4
TECH
Electronic fuel injection control
In electronic fuel injection control, the engine ECM determines the fuel injection timing and fuel
injection amount according to the signals from the sensors and performs the appropriate fuel injec-
tion. 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, vari-
ous compensations are made to determine the actual fuel injection timing and fuel injection amount.
Also, a fuel injector anti-sticking control has been adopted.
Pulser coil
Cam position sensor

Fuel injector
(PORT EX)
Cam position sensor

(PORT IN)
Cam position sensor

(STBD IN)
High-pressure
TPS fuel pump
SPS
Engine
ECM
LPS
Low-pressure fuel
Air pressure sensor
pump
Vapor shut-off
Thermoswitch
valve
Engine shut-off switch
Battery
2-5
Synchronous fuel injection
Synchronous fuel injection is fuel injection that occurs using a fixed timing, which is synchronized
with the crankshaft angle set by the engine ECM according to the signals from the pulser coil.
Fuel injection
type
Fuel injection timing Fuel injection amount Condition 0
Simultaneous All cylinders according to According to the fuel Until cylinder
fuel injection the fuel injection setting injection setting data when identification is
in the start-up
mode
data the engine temperature is
78–80 °C (172–176 °F) or
completed by the
pulser coil
1
Group fuel Each cylinder group (#1 more and the fuel injection Until engine
setting data when the
injection in the
start-up mode
and #4, #2 and #5, and #3
and #6) at BTDC 430° engine temperature is less
starting is detected
(500 r/min or more) 2
(BTDC 70° according to the than 78–80 °C (172–176
exhaust TDC) °F)
Group fuel
injection in the
Each cylinder group (#1
and #4, #2 and #5, and #3
According to the fuel
injection setting data for the
Until cylinder
identification is
3
normal and #6) according to the fuel octane rating and the completed by the
operating exhaust and compression knock learning value, which cam position
mode TDCs
2 times for every 2 turns of
are recorded in the engine
ECM
sensor (PORT EX) 4
the crankshaft
Sequential
fuel injection
Each cylinder according to
the injection completion
After cylinder
identification is 5
in the normal timing, which is set using completed by the
operating the exhaust TDC cam position
mode sensor (PORT EX)
6
Example: Group fuel injection in the start-up mode
#1 Compression Combustion Exhaust Intake Compression

7
#2 Intake Compression Combustion Exhaust Intake
#3 Exhaust Intake Compression Combustion Exhaust Intake
#4 Exhaust Intake Compression Combustion Exhaust
#5 Combustion
#6 Compression
Exhaust
Combustion Exhaust
Intake Compression
Intake
Combustion
Compression
8
Pulser coil
signal
Cam position
sensor (EX)
9
signal
Injection #1
Injection #2 10
Injection #3
Injection #4
Injection #5
Injection #6
A
2-6
TECH
Asynchronous fuel injection
Asynchronous fuel injection is fuel injection that occurs using the timing determined necessary by
the engine ECM according to the signals from the sensors, not synchronized with the crankshaft
angle set by the engine ECM. At engine start-up or during acceleration, if the changes in the signals
from the TPS or air pressure sensor exceed a predetermined level, fuel injection is performed simul-
taneously for all of the cylinders.
In the fuel injection cutoff mode, the fuel injection is cut off while the engine speed control is being
performed. See “Engine speed control” (2-12).
Fuel injection amount compensation
The fuel injection control makes compensations to the fuel injection amount according to the engine
operating conditions. The compensations are determined according to the signals from the following
sensors.
Compensation Corresponding sensor
For changes in intake air pressure Air pressure sensor
For changes in intake air temperature Air temperature sensor
During warm-up Engine temperature sensor
After start-up Engine temperature sensor
For atmospheric pressure Air pressure sensor
During dashpot function operation Air pressure sensor, LPS, SPS, and pulser coil
For changes in air and fuel ratio Air pressure sensor, engine temperature
sensor, and pulser coil
During acceleration Air pressure sensor and TPS
For retarded ignition timing Engine temperature sensor and pulser coil
Fuel injector anti-sticking control
After the engine start switch is turned to ON and before the high-pressure fuel pump starts operat-
ing, the engine ECM sends a signal once to actuate all of the fuel injectors simultaneously to pre-
vent the fuel injector valves from sticking.
2-7
Ignition timing control
In ignition timing control, the engine ECM uses signals from the sensors to assess engine operating
conditions and determines the basic ignition timing and ignition coil energization time. The engine
ECM also applies various restrictions and compensations to determine the actual ignition timing.
The ignition timing is also controlled according to the knock control. See “Knock control” (2-11). 0
Pulser coil 1
Cam position sensor
(PORT EX)
2
Cam position sensor
(PORT IN)
Cam position sensor

(STBD IN)
3
TPS
4
LPS
Engine
SPS
ECM Ignition coil
5
Air pressure sensor
6
7
Knock sensor
Engine shut-off switch 8

Battery
9
10
A
2-8
TECH
Basic ignition timing
The basic ignition timing is divided into 3 types: engine starting ignition timing, idling basic ignition
timing, and normal basic ignition timing.
Basic ignition timing Criteria Ignition cylinder
Engine starting ignition timing Engine is starting (less than All cylinders simultaneously
(BTDC 10°) 500 r/min)
Idling basic ignition timing Engine speed is at engine idle Each cylinder sequentially
speed
Normal basic ignition timing Engine speed is more than Each cylinder sequentially
engine idle speed
Ignition timing restriction
The advancing or retarding of the ignition timing is restricted according to the engine speed, engine
temperature, and dashpot function.
Restriction Corresponding sensor Details
Engine speed restriction Pulser coil The ignition timing is restricted
between BTDC 50° (advance
angle) and ATDC 20° (retard
angle) according to the engine
speed.
Engine temperature restriction Engine temperature sensor The ignition timing is restricted
between BTDC 50° (advance
angle) and ATDC 30° (retard
angle) according to the engine
temperature.
Dashpot function restriction Pulser coil and LPS The ignition timing is restricted
(when the throttle valve is to ATDC 20° when the
closed quickly) dashpot function operates.
Ignition timing compensation
The ignition timing control makes advance or retard compensations to the ignition timing according
to the engine operating conditions. The compensations are determined according to the signals
from the following sensors.
Compensation Corresponding sensor
After start-up Engine temperature sensor
For stable idle speed LPS and pulser coil
During dashpot function operation LPS, SPS, and pulser coil
For shift-cutout control Pulser coil and SPS
During acceleration Air pressure sensor and TPS
2-9
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 are advanced, retarded, or maintained in the current position to con-
trol the intake valve opening timing. 0
Pulser coil
Cam position sensor

1
(PORT EX)
Cam position sensor

(PORT IN)
2
Cam position sensor OCV (PORT)
(STBD IN) Engine 3
ECM
TPS
OCV (STBD)
4
LPS
Air pressure sensor

5
Engine temperature sensor 6
7
8
9
10
A
2-10
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 timing and
decreases the engine speed according to the amount of knocking to protect the engine from dam-
age.
If the knocking occurs frequently, the ignition timing is retarded until the knocking is no longer
detected, and the retarded ignition timing is maintained, using the learning function.
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
seconds
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.
2-11
Engine speed control
In engine speed control, the engine ECM decreases the engine speed to protect the engine from
damage.
Pulser coil
0
Air pressure sensor
1
Cam position sensor
(PORT EX)
Cam position sensor

Fuel injector 2
(PORT IN)
Cam position sensor

(STBD IN)
Ignition coil
3
TPS
Engine
ECM 4
LPS
ETV motor
SPS 5
Digital Electronic
Control ECM 6
Oil pressure sensor
Thermoswitch 7
6Y9 Multifunction
Color Gauge
Engine shut-off switch
8
Overheat control
Criteria Description
The thermoswitch is on. The engine ECM controls the throttle valve opening. As a 9
result, the engine speed cannot increase to more than 2000–
3000 r/min. Also, the alert buzzer sounds and the overheat
Low oil pressure control

alert indicator comes on.
10
The pressure decreases to less The engine ECM controls the throttle valve opening. As a
than 250 kPa (2.5 kgf/cm2, result, the engine speed cannot increase to more than 2000–
36.25 psi). 3000 r/min. Also, the alert buzzer sounds and the oil pressure
alert indicator comes on.
A
2-12
TECH
Skip-firing control
ETV is locked in Controls the Over 1501 r/min Firing and fuel injection will be
an open position. engine speed skipped for all of the cylinders.
when it has been 1399–1500 r/min Firing and fuel injection will be
determined that skipped for cylinders #1, #2, #3, #5,
the ETV is locked and #6.
in an open 1302–1398 r/min Firing and fuel injection will be
position. skipped for cylinders #2, #3, #5, and
#6.
1200–1301 r/min Firing and fuel injection will be
skipped for cylinders #2, #3, and #5.
skipped for cylinders #2 and #5.
skipped for cylinder #2.
Engine is over Controls the Over 6450 r/min Firing and fuel injection will be
revving. engine speed skipped for all of the cylinders.
when over 6399–6449 r/min Firing and fuel injection will be
revving is skipped for cylinders #1, #2, #3, #5,
detected. and #6.
skipped for cylinders #2, #3, #5, and
#6.
skipped for cylinders #2, #3, and #5.
skipped for cylinders #2 and #5.
skipped for cylinder #2.
Engine is rotating Stops the engine Engine reverse rotation is determined using 2
in reverse. if the engine parameters: presence or absence of the cam position
reverse rotation sensor (PORT EX) signal, and the actual advance angle
is detected. of the intake camshaft.
If the reverse rotation is detected, the engine ECM cuts
off the fuel injection and ignition to stop the engine.
Engine speed is Detects the Decreases the engine speed to less than 1500 r/min.
high when activation of shift
shifting gears. cutout control,
and controls the
engine speed.
Engine shut-off Cancels the fuel injection control and ignition control at all of the cylinders.
switch is on.
2-13
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 0
ETV control.
Pulser coil
1
LPS
2
TPS
3
Air pressure sensor

4
Engine
ETV motor

ECM
5
6
Thermoswitch
7
SPS
8
9
10
A
2-14
TECH
Electronic shift control system
The electronic shift control system operates the shift actuator based on the Digital Electronic Control
communication data transmitted by the Digital Electronic Control ECM.
Pulser coil Shift actuator
Cam position sensor

(PORT EX)
Fuel injector
Cam position sensor

(PORT IN)
Ignition coil
Cam position sensor Engine

(STBD IN) ECM
ETV motor
TPS
SPS Digital Electronic

Control ECM
2-15
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
0
Trouble
Item gauge Trouble conditions to be detected
code
display
13 Pulser coil C/E No signal 1
15 Engine Open or short circuit in the engine temperature sensor
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
23 Air temperature Output voltage is less than 0.10 V or more than 4.60 V.
C/E
sensor
24 Cam position
sensor (PORT C/E
Signal error (irregular) 3
EX)
29 Air pressure
sensor
C/E
Output voltage is less than 0.20 V or more than 4.50 V.
4
39 Oil pressure Output voltage is less than 0.30 V, more than 4.80 V for
sensor L (*1) 260 seconds, or more than 4.80 V when the engine is
71 Cam position
stopped.
Signal error (irregular)
5
sensor (PORT C/E
EX)
72 Cam position Signal error (irregular) 6
sensor (PORT C/E
IN)
73
74
OCV (STBD)
OCV (PORT)
C/E
C/E
Open or short circuit in the OCV circuit
Open or short circuit in the OCV circuit
7
86 Y-COP Open or short circuit in the Y-COP circuit
C/E Communication error continues for more than 3
seconds. 8
112, 113, ETV Open or short circuit in the ETV relay and ETV motor
114, 115, circuit
116, 117,
118, 119, 9
121, 122,
C/E
123, 129,
136, 137,
138, 139,
10
141, 142,
144, 145
124, 125, TPS Output voltage is less than 0.35 V or more than 4.80 V,
126, 127, C/E or the output voltage difference between TPS 1 and
128 TPS 2 is 2.30 V or more.
A
2-16
TECH
LAN
Trouble
Item gauge Trouble conditions to be detected
code
display
146, 147, SPS Open or short circuit in the SPS circuit, and shift
148, 149, actuator does not operate.
C/E
150, 153,
154, 155
156, 157 Extension Communication error between the engine ECM and
C/E
wiring harness Digital Electronic Control
160, 161, LPS Open or short circuit in the LPS circuit
162, 163,
164, 165,
166, 167,
168, 169,
170, 171, C/E
172, 173,
174, 175,
176, 177,
178, 179,
180, 181
(*1) Low oil pressure alert is displayed.
2-17
Charging system
This model features a high output charging system that provides up to 70 A.
This charging system also functions as a battery isolator that will charge a house (accessory) bat-
tery.
The engine ECM senses the voltage of the main battery and house (accessory) battery based on 0
the signals from the Rectifier Regulator.
If the main battery voltage decreases below 13.5 V when the house (accessory) battery is con-
nected, the regulator function of the Rectifier Regulator will be turned off by the engine ECM to
increase the efficiency of charging the main battery. 1
2
Lighting coil
(stator assembly)
3
Engine ECM
Fuse box 4
Rectifier
Regulator 5
Isolator lead
(optional) 6
House Main
7
battery battery
(optional)
8
9
10
A
2-18
TECH
Digital network control
This model features the newly developed 6Y9 Digital Electronic Control that includes the Digital
Electronic Control ECM.
Mutual authentication is performed between the Digital Electronic Control ECM and the engine
ECM. The Digital Electronic Control system operates only when the mutual authentication has suc-
ceeded.
The Digital Electronic Control ECM converts actions on the control lever related to the gear shift and
the throttle opening or closing into the electrical signals and transmits the signals to the engine
ECM. The engine ECM controls the operation of ETV and shift actuator based on the electrical sig-
nals.
The electric controlled shift-in or shift-out provides smooth, reliable, and quiet gear shift engage-
ment.
The 6Y9 Multifunction Color Gauge and the new engine start switch can be installed (optional).
6Y9 Multifunction
Color Gauge Y-COP
6Y9 Multifunction SET SET
Color Gauge CANCEL
MENU
CANCEL
MENU
Hub Hub
Control Control Control Control

lever lever lever lever
Engine start/ Main switch

stop button
LPS LPS LPS LPS LPS LPS Engine

start/stop
button
Engine shut-off
switch
Digital Digital Digital Digital
Electronic Electronic Electronic Electronic
Control ECM Control ECM Control ECM Control ECM
(PORT) (STBD) (PORT) (STBD) Station
selector
Station switch
Digital selector Digital
Electronic switch Electronic
Control ECM Control ECM
(center) (center)
Engine Engine Engine

ECM ECM ECM
2-19
Digital Electronic Control component
A b a D
i
f
b
a
e 0
c
g g
d
f 1
d 2
e
c
j
B b a C b a
3
f
4
f
c c
g g
d d
5
h
k
6
e e
l m n o p
7
8
9
A Single type (6X6) g Alert indicator
B Twin type (6X6) h Engine selector switch
C
D
Triple type (6X6)
Single type (6X7)
i Engine start switch
j Main switch 10
k 6Y9 Multifunction Color Gauge
a Control lever l Engine start/stop button (single type)
b PTT switch m Engine start/stop button (twin type)
c LPS n Engine start/stop button (triple type)
d Free throttle switch o Engine start/stop button (all type)
e Digital Electronic Control ECM p Station selector switch
f Active indicator A
2-20
TECH
Sensor, switch
Digital Electronic Control Converts actions on the control lever related to the gearshift and the
ECM throttle opening or closing into electrical signals and transmits the
signals to the engine ECM.
Receives digital signals transmitted from the engine ECM. Performs
mutual authentication with the engine ECM to perform various
controls.
LPS Detects the control lever position. LPS 1 is the main sensor and
LPS 2 is the sub sensor. LPS 1 and LPS 2 mutually monitor each
other for malfunctions.
Free throttle switch Enables engine speed to be increased while in neutral using the
control lever.
Active indicator Displays operational conditions of the Digital Electronic Control.
Active indicator Comes on when communication error occurs between the 6Y9
Digital Electronic Control and the engine ECM.
Engine selector switch Selects the outboard motor to be operated.
Engine start/stop button Starts and stops the engine while the system is activated.
Engine start switch Activates and deactivates the system.
Starts and stops the engine.
Main switch Activates (with the engine start switch ON) and deactivates the
system.
PTT switch Operates the PTT unit to adjust the trim/tilt angle of the outboard
motor.
Station selector switch Switches between the main station and substation.
6Y9 Multifunction Color Displays engine status and boat status on a single display.
Gauge
2-21
Electronic control system / Y-COP
Y-COP
Y-COP consists of a transmitter and a receiver. The receiver transmits an authorization ID to the
Digital Electronic Control ECM. If an authorization ID is not received or if the transmitted authoriza-
tion ID does not match the registered ID in the Digital Electronic Control ECM, the receiver cannot
perform data communication with the Digital Electronic Control ECM. Pushing the lock and unlock 0
buttons on the transmitter causes the receiver to recognize the lock and unlock state, and to send
data to the Digital Electronic Control ECM. The locked or unlocked state is maintained even when
the battery switch is turned to off.
Y-COP
1
Transmitter
Receiver Ignition coil

2
Hub Engine
3
ECM Fuel injector
Digital Electronic Control 4

ECM
Battery
6Y9 Multifunction Color

5
Gauge
State Operation 6
Unlocked Normal
Locked Stops fuel injection and ignition, and prevents
Communication error, improper wiring

the engine from starting.
The engine will start, but engine speed is
7
connection. limited to 2600 r/min.
Outputs a trouble code
8
TIP:
• The receiver can register up to 5 transmitters.
•
•
Additional transmitters cannot be registered if none of the transmitters is functioning properly.
The transmitter and receiver function within a distance of approximately 3 m (10 ft).
9
• Installation location requires special attention to avoid electrical interferences, obstructions, or
water exposure.
10
A
2-22
TECH
Power unit system
This model is equipped with a newly developed V6, 4-stroke engine that has 60° cylinder banks.
The cylinder heads feature plastic cylinder head covers, shimless valve lifters, and exhaust covers
that are integrated into the cylinder heads. The cylinder block features a crankcase equipped with
an oil cooler, a crankshaft with an integrated drive sprocket, and sleeveless cylinders. Other features
include compact VCT assemblies with a narrow timing belt, and a plastic bottom cowling.
These newly designed components have reduced the weight by 4% compared with previous V6
models.
a a
b b
c c
a Compact VCT assembly d Plastic bottom cowling

b Narrow timing belt e Cylinder head integrated with exhaust
c Plastic cylinder head cover cover
2-23
Power unit system
Shimless valve lifter
Newly designed valve lifters a have been adopted in place of the valve shims previously used b.
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.
A B
0
b 1
b
2
a
a
3
4
A Previous V6 model
B New V6 model
5
Sleeveless cylinder
To reduce the weight of the cylinder block, the newly designed cylinder block utilizes spray-coated
cylinders instead of steel-sleeved cylinders.
6
The inner walls of the cylinders are spray-coated using metal powder.
7
8
9
10
Metal powder
Cylinder inner wall
A
2-24
TECH
Oil cooler
The oil coolers a are incorporated into the crankcase b and oil filter bracket c to improve the cool-
ing performance. Engine oil that has lubricated the engine is cooled in the oil cooler in the crank-
case b, and returned to the oil pan. The oil that flows from the oil pan to the main journal will be
cooled in the oil filter bracket c.
a A
B
A Engine oil flow

B Cooling water flow
2-25
Power unit system / Fuel system
Fuel system
Fuel diagram
Pressure regulator
0
Fuel rail
Fuel
1
injector
Fuel rail
2
Fuel injector
3
4
Vapor separator
5
Low-pressure
Fuel cooler 6
fuel pump
Fuel filter (with water
Primer pump separator and water
detection switch)
7
8
9
10
Canister
A
2-26
TECH
Primer pump Boat fuel filter (optional) Boat fuel tank
Fuel filter (with water

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

injector #6 injector #4 injector #2 injector #1 injector #3 injector #5
Combustion Combustion Combustion Combustion Combustion Combustion

chamber #6 chamber #4 chamber #2 chamber #1 chamber #3 chamber #5
Intake manifold (PORT) Intake manifold (STBD)
A
B
C
A Fuel flow
B Air flow
C Vapor gas flow
2-27
Fuel system / Lubrication system
Lubrication system
Lubrication diagram
VCT assembly
VCT assembly OCV

0
1
OCV
2
3
4
Oil pressure sensor
5
Oil filter
Relief valve
Oil pump
6
Oil pan Strainer
A
Piston
OCV
Camshaft oil VCT 7
Crankpin (connecting rod passage assembly
big end)
Crankshaft main
Cylinder head oil passage Camshaft journal 8
journal
Cylinder block main gallery Valve and related parts
Oil pressure sensor

9
Oil filter
Relief valve Oil pump 10

Strainer
Oil pan
A Engine oil flow

A
2-28
TECH
Cooling system
The PCV has been removed to simplify the structure of the cooling system. The crankcase, vapor
separator, and Rectifier Regulator are cooled using the cooling water.
Cooling diagram
Thermostat Rectifier Regulator
Fuel cooler
D D
B
A
C
A
B
Oil cooler
Exhaust guide
Upper case
Water pump
Water inlet
E
E Cooling water flow
2-29
Cooling system
Thermostat (PORT) Thermostat (STBD)

Rectifier Regulator
0
Cylinder block (PORT) Cylinder block (STBD)
1
Cylinder head (PORT) Cylinder head (STBD)
Cooling water
outlet 2
Cylinder block
Fuel cooler 3
Oil cooler
(crankcase) 4
Oil cooler (oil filter
Exhaust guide Exhaust guide
bracket) 5
Oil pan Oil pan
6
Water pump Upper case
7
Lower case Trim tab
Water inlet Propeller boss

8
Water 9
A
A Cooling water flow

10
A
2-30
TECH
Intake and exhaust system
Intake and exhaust diagram
Throttle body
Intake manifold
Surge tank
Cylinder head
Intake manifold
Exhaust guide
Idle silencer
Exhaust manifold
Muffler
Propeller
A
B
A Intake air flow

B Exhaust gas flow
2-31
Intake and exhaust system / Lower unit
Lower unit
Double taper roller bearing
A double taper roller bearing a is used to receive the thrust load of the pinion and stabilize the axial
free play of the drive shaft b. The drive shaft b is secured in the lower case using a ring nut c. As
a result, the axial free play is removed and the pinion position is secured. 0
1
c
2
b a 3
Propeller shaft bearing (regular rotation model)

4
The propeller shaft is supported using 3 bearings to decrease the radial motion of the propeller
shaft. Because 2 bearings are taper roller bearings, axial free play also decreases.
5
6
7
8
9
10
A
2-32
TECH
Propeller
The newly designed propeller is a standard feature of this model.
When shifting gears, this propeller absorbs much of the resulting force and noise using the damper
a movement for smooth operation.
The damper a is replaceable.
When shifting gears, the protrusions a on the dedicated spacer b transmit the rotational force of
the propeller shaft directly to the propeller c.
a
b
A B
A Neutral
B Shift in
2-33
Lower unit
— MEMO —
0
1
2
3
4
5
6
7
8
9
10
A
2-34
RIG
GING
Rigging information 3
Outboard motor installation ............................................. 3-1
Dimension .......................................................................... 3-2

Exterior: F(L)225F, F(L)250D, F(L)300B ................................... 3-2
Clamp bracket ........................................................................... 3-3
Crate top cover pictograph description .......................... 3-4
Uncrating procedure ......................................................... 3-5
Outboard motor mounting ................................................ 3-6
Rigging grommet mounting ............................................. 3-8

Rigging grommet description ..................................................... 3-8
Installing the main harness ........................................................ 3-8
Installing the battery cable ......................................................... 3-9
Installing the rigging grommet ................................................... 3-9
Optional equipment ........................................................ 3-10

Installing the isolator lead ........................................................ 3-10
Installing the water pressure sensor ........................................ 3-10
Installing the speed sensor ...................................................... 3-11
Installing the Digital Electronic Control box and

switch panel ..................................................................... 3-12
Installing Y-COP (optional in non-European markets) 3-12

Registering the receiver ID to the ECM ................................... 3-12
Battery installation .......................................................... 3-15

Battery wiring without house (accessory) battery .................... 3-15
Battery wiring with house (accessory) battery ......................... 3-17
Digital network system diagram .................................... 3-21

Single outboard motor application ........................................... 3-21
Twin outboard motor application ............................................. 3-23
Triple outboard motor application ............................................ 3-26
Digital Electronic Control system reset ........................ 3-29

Rigging recommendation ............................................... 3-30
Extension length recommendation of battery cable ................ 3-30
Propeller selection .......................................................... 3-32

Propeller size ........................................................................... 3-32
0
Selection .................................................................................. 3-32
1
2
3
4
5
6
7
8
9
10
A
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.
This outboard motor is designed exclusively for use with the Digital Electronic Control, 6Y8
Multifunction Meter, and 6Y9 Multifunction Color Gauge. Do not use this outboard motor with
other control equipment or measuring devices.
3-1
Outboard motor installation / Dimension
Dimension
Exterior: F(L)225F, F(L)250D, F(L)300B
mm (in)
0
454 (17.9)
1
724 (28.5)
T1 (*1)
317 (12.5)
2
32°
3
X:1155 (45.5)
639 (25.2)
230 (9.1)
U:1272 (50.1)
728 (28.7)
4
X:239 (9.4)
75 (3.0) U:241 (9.5)
5
6
951 (37.4)
812 (32.0)
X:99 (3.9)
U:84 (3.3)
510 (20.1)
7
X:643 (25.3)
U:770 (30.3)
8
48 (1.9)
45 (1.8)
240 (19.5)
H (*2)
X:1078 (42.4)
U:1205 (47.4)
X:847 (33.3)
U:924 (36.4)
59 (2.
3)
9
216 (8.5)
67
°
10
25 (1.0)
12° –3°
X:53 (2.1)
U:59 (2.3) 673 (26.5)
(*1) Distance between the outboard motors in twin or triple installation

(*2) Transom height A
3-2
RIG
Clamp bracket
mm (in)
180 (7.1) 180 (7.1)

79 (3.1)
50.8 (2.0)
163.5 (6.4) 163.5 (6.4)

254 (10.0)
18.5 (0.7)
.5)
(0
411 (16.2)
13
55.5 (2.2)
13 (0.5)
52 (2.0)
125.4 (4.9) 125.4 (4.9)
3-3
Dimension / 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.
0
Stack limit: Maximum units for storage
Upward
1
2
Handle with care
Avoid water
3
4
Product barycentric position
5
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.
6
Shipper assumes no further liability to the transportation company.
Your claim should be filed against carrier for damage of any nature.
7
8
9
10
A
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.
NOTICE: Be careful not to damage
the outboard motor.
a
4. Remove the wrapping, and then check
the outboard motor for concealed
damage.
5. Remove the top cowling, and then

9. Lift up the outboard motor along with the
remove the flywheel magnet cover a.
bottom plate c carefully. NOTICE: Make
sure that the lifting harness does not
a damage any parts of the outboard
motor.
6. Install the special service tool b to the

flywheel magnet. NOTICE: When lifting
the outboard motor, make sure to use
the specified special service tool.
Other bolts and hanging jigs could
bend or break, causing the outboard
motor to fall.
10. Remove the clamp bracket bolts d.
b
d
Engine lifting eye b: 90890-06820
7. Install the lifting harness to the eye bolt 11. Remove the steering retainer, and then
a. install a hydraulic steering cylinder
following the recommendation of the
8. Tension the lifting harness. manufacturer.
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- 0
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
1
outboard motor to fully tilt up, and to fully
move to port and starboard. See “Dimension”
(3-2). T1 2
1. For single outboard motor installation,
place the outboard motor on the vertical
centerline of the boat transom.
TIP:
• Make sure that the distance e is equal to 3
A C/L distance f.
• For the distance (T1), see “Dimension” (3-
2). 4
a b 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 5
the boat transom. Place the other two out-
c d
board motors on both sides so that the dis-
B C/L
tance from the C/L of each outboard motor to
the C/L of the boat transom are equal.
6
C/L
a b
g h
7
c d
8
A Hull without strakes
B Hull with strakes
C/L: Centerline of transom 9
TIP: T1 T1
Make sure that the distance a is equal to
distance b, and the distance c is equal to
10
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.
A
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 transom outboard motor combination.
height than the outboard motors on both
sides. 3. Adjust the height of the scale m to the
• For the distance (T1), see “Dimension” (3- transom height (H), and place it on the
2). special service tool a. Secure the
special service tool a to the boat
2. Adjust the position of the outboard motor transom 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 “Dimension”
A (3-2).
4. When the outboard motor mounting

position has been determined, mark the
best-suited 4 symmetrical mounting
k
holes in 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.
B m
a
k k
n
C
H
p
m
k k C/L
k
C/L: Centerline of transom
Drilling plate a: 90890-06783
A Single outboard motor
B Twin outboard motor Mounting hole diameter p:
C Triple outboard motor 13.0 mm (0.5 in) or more
3-7
Outboard motor mounting / Rigging grommet mounting
5. Apply sealant to the mounting holes and
secure the outboard motor using the
included mounting bolts b, small
washers c, large washers d, and nuts
e. NOTICE: Make sure that there is
no clearance between the surfaces of
0
the boat transom and the clamp
brackets. Otherwise, the clamp
brackets or boat transom may be 1
damaged.
Rigging grommet mounting
b
c d
c e
Rigging grommet description 2
c d
b
c
e
e
3
d c
b
4
a
D
b
c d
ce
a Battery cable
b Isolator lead (optional)
5
c Extension wiring harness
d Fuel hose
e Flushing hose 6
Boat transom Installing the main harness
Mounting bolt 1. Remove the grommet holder a and rig-
thickness (D)
65–75 mm M12 × 130 mm
ging grommet b. 7
(2.56–2.95 in) (5.12 in)
75–95 mm M12 × 150 mm b
(2.95–3.74 in) (5.91 in) a 8
TIP:
The second hole from the top of each clamp
bracket is recommended for the upper
9
mounting bolt.
6. Install the mounting bolts, and then

tighten the nuts firmly. NOTICE: Make
2. Remove the plastic tie c that is fastening 10
the main wiring harness coupler a.
sure that the clamp brackets do not
bite into the boat transom.
7. Tighten the locknuts firmly.
A
3-8
RIG
a
a
3. Route the extension wiring harness Installing the rigging grommet

through the bottom cowling. 1. Route each harness through the proper
hole in the rigging grommet. See “Rig-
4. Connect the extension wiring harness ging grommet description” (3-8).
coupler b, and then fasten the main
wiring harness coupler a using the 2. Align the white tape a on the battery
plastic tie c. cable with the outer end of the rigging
grommet.
c
a
Installing the battery cable
1. Install the positive battery cable a and 3. Install the grommet holder a along with
negative battery cable b. the rigging grommet.
b a
2. Install the rubber cap a. 4. Install the rigging tube retainer b, and
then fasten it using the plastic tie c.
3-9
Rigging grommet mounting / Optional equipment
c
b
0
a
b 1
Optional equipment 2. Install a new gasket c and the adapter
Installing the isolator lead d, and then tighten the adapter d to the
specified torque. NOTICE: Do not
2
1. Remove the cap a.
reuse a gasket, always replace it with
a new one.
3
c
a 4
d
5
2. Connect the isolator lead coupler b.
Water pressure sensor adapter d:

23 N·m (2.3 kgf·m, 17.0 ft·lb) 6
3. Install the water pressure sensor e, and
then tighten it to the specified torque.
b 7
a
b b
8
TIP:
Pass the isolator lead a over the battery
e
cables b so that they do not cross over each
other.
9
Installing the water pressure sensor Water pressure sensor e:
See 6Y8 Multifunction Meter set up manual 18 N·m (1.8 kgf·m, 13.3 ft·lb) 10
for details of the components.
4. Remove the water pressure sensor
1. Remove the braided plug a and gasket harness a from the holder f.
b.
5. Remove the water pressure sensor
coupler b from the bracket g, and then
remove the cap c.
A
3-10
RIG
g
a c b
a
b
c
6. Connect the water pressure sensor 3. Remove the speed sensor coupler b
coupler b, and then fasten the water from the engine ECM bracket d, and
pressure sensor harness a using the then remove the cap c.
holder h.
c
b
b
a
d
h
4. Install the speed sensor e to the speed
Installing the speed sensor sensor adapter f, and then tighten the
See 6Y8 Multifunction Meter set up manual speed sensor e to the specified torque.
for details of the components.
1. Cut off the tip a of the nipple a. f
a Speed sensor e:
18 N·m (1.8 kgf·m, 13.3 ft·lb)
2. Install the extension hose b to the nipple 5. Install the speed sensor adapter f to the
a, and then fasten it using the plastic tie bottom cowling.
c.
3-11
Optional equipment / Installing the Digital Electronic Control box and switch panel /
Installing the Digital
Installing Electronic
Y-COP Control
(optional box and switch
in non-European panel
markets)
Installing Y-COP (optional in
non-European markets)
See the Yamaha Security System Y-COP
f
installation manual.
0
• Install the receiver so that the UP mark
is facing up.
• Do not install the receiver in a location
1
where it will be exposed to water.
6. Connect the speed sensor coupler b. • Do not cover the receiver with metal
objects. Otherwise, signals may not be
received.
2
b
1. Install the receiver a, and then tighten
the receiver screws b to the specified 3
torque.
4
a
7. Connect the extension hose b to the b
speed sensor adapter f.
a
5
b 6
f
b
7
Receiver screw b:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
8. Fasten the extension hose b using the
plastic tie g.
8
TIP:
• Mount the receiver within 3 m (10 ft) from
the steering position.
• For installation position and drill holes, see 9
g Yamaha Security System Y-COP installa-
tion manual.
2. Connect the Y-COP wires. See “Digital

10
b
network system diagram” (3-21).
Registering the receiver ID to the

Installing the Digital Electronic ECM
Control box and switch panel 1. Check that the engine start switch is
For the installation procedures, see the Digi-
tal network control service manual.
OFF.
A
3-12
RIG
2. Push the unlock button a of the B
transmitter. The buzzer of the receiver
will sound 2 short beeps.
d
A 6Y9 Multifunction Color Gauge

a B 6Y8 Multifunction Meter
3. Turn the engine start switch to ON. The TIP:

buzzer of the receiver will sound 1 • If the outboard motor is equipped with the
medium beep. 6Y9 Multifunction Color Gauge, Y-COP
mark c is displayed on the gauge when the
4. Turn the engine start switch to OFF. Initial engine start switch is turned to ON.
registration is complete. Y-COP is • If the outboard motor is equipped with the
unlocked. 6Y8 Multifunction Meter, “–” mark d is dis-
played on the tachometer when the engine
5. Push the lock button b of the transmitter. start switch is turned to ON.
Check that the buzzer of the receiver will
sound 1 short beep. 7. Push the unlock button a of the
transmitter. Check that the buzzer of the
b
receiver will sound 2 short beeps.
6. Turn the engine start switch to ON. a
A
A
3-13
Installing Y-COP (optional in non-European markets)
e
0
1
A 6Y9 Multifunction Color Gauge
B 6Y8 Multifunction Meter
2
TIP:
• If the outboard motor is equipped with the
6Y9 Multifunction Color Gauge, Y-COP
mark c will not be displayed when the
3
engine start switch is turned to ON.
• If the outboard motor is equipped with the
6Y8 Multifunction Meter, “0” mark e is dis-
played on the tachometer when the engine
4
start switch is turned to ON.
8. Turn the engine start switch to OFF.

5
6
7
8
9
10
A
3-14
RIG
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 wiring 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
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
3-15
STBD PORT
Outboard Outboard
Isolator lead
motor motor
0
Red Black Red Black

1
2
Black
3
Outboard
Isolator lead
motor
4
Black
5
Battery switch
ON/OFF 6
Red 7
STBD PORT
Outboard
motor
Outboard
motor
8
Isolator lead Isolator lead
9
Red Black Red Black
10
ON/OFF ON/OFF
Battery switch Battery switch

Black
A
3-16
RIG
STBD PORT
Outboard Outboard
motor motor
Battery switch
Battery switch Navigation systems Boat systems
Black Black
ON/OFF ON/OFF
Red
Red
Red Red
Black Black Black
Battery wiring 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.
3-17
Outboard
motor
Isolator lead 0
Battery switch Red
Battery switch
1
ON/OFF
1 2
Black 2
Red
House battery
3
Outboard
motor 4
Isolator lead
Red 5
Black
Black 6
House battery
7
Outboard
motor
Isolator lead
8
Black
Battery switch Red

9
1 2 10
Black
Red
House battery
A
3-18
RIG
STBD PORT
Outboard Outboard
motor motor
Black
Battery switch Red Red Black

Battery switch
ON/OFF
ON/OFF
1 2 Black
Black
Battery switch
House battery
STBD PORT
Outboard Outboard
motor motor
Black
Battery switch Red Battery switch Red Black
ON/OFF
1 2 1 2
Black Black
Battery switch
House battery
3-19
STBD PORT
Outboard Outboard 0
motor motor
Black
1
Battery switch Red Black
Red 2
Battery switch
1 2 1 2
3
House battery
4
Black Black
5
STBD PORT
Outboard
motor
Outboard
motor 6
Battery switch
7
Battery switch
ON/OFF Black
Red ON/OFF 8
Red
ON/OFF
Black Black 9
Black
Black
10
House battery House battery
A
3-20
RIG
Digital network system diagram
This outboard motor uses simple cabling of the digital network system of the Digital Electronic Con-
trol, 6Y8 Multifunction Meter, and 6Y9 Multifunction Color Gauge, making rigging simple and easy.
The diagram (Digital network system diagram) shown here is a sample digital network system dia-
gram using the 6Y9 system.
Single outboard motor application

(*1) Install the waterproof cap to the open terminals.
(*2) The extension wiring harness is available in 5 lengths types: 6.1 m (20.0 ft), 7.0 m (23.0 ft), 8.0
m (26.2 ft), 10.0 m (32.8 ft), and 12.0 m (39.4 ft). Select the one that fits the boat length.
(*3) Y-COP
a Engine ECM R : Red

b Extension wiring harness W : White
c Digital Electronic Control Y : Yellow
d Engine start switch (with engine shut-off
switch)
e Receiver
f Pigtail bus wire
g Fuse (10 A)
h Power wire
i Wire lead for 6Y9
j Main bus wire
k 6Y9 Multifunction Color Gauge
l Wire lead for 6Y9
m Wire lead for NMEA 0183
n GPS
o Wire lead for fuel tank (6Y9)
p Fuel tank (fuel tank sensor)
q Cap 1 (white)
r Hub
s Single hub
t Wire lead for 6Y9 Multisensor
u 6Y9 Multisensor
a Power port
b Bus port
c Device port
Color code
B : Black
Br : Brown
B/Br : Black/Brown
B/G : Black/Green
B/O : Black/Orange
B/P : Black/Pink
G : Green
L : Blue
O : Orange
P : Pink
3-21
NMEA
0183 0
B/Br
B/O
B/G
B/P
n L
Br
O
GPS W m
o 1
p p p p
l k
SET
2
CANCEL
MENU
j
b
c q
r
c
c
f g 3
f (*1)
R
Y
B
b
j
a
h 4
G
e (*3)
R
Y
B
5
6
c
i s
7
f
8
b (*2)
9
t
10
a
u
A
3-22
RIG
Twin outboard motor application
(*2) Connect to the all engine start/stop button (optional).
(*3) Y-COP
a Engine ECM Color code

b Extension wiring harness B : Black
c Digital Electronic Control (main station) Br : Brown
d Main switch B/Br : Black/Brown
e Engine start/stop button B/G : Black/Green
f Receiver B/O : Black/Orange
g Power wiring harness for twin and triple B/P : Black/Pink
types G : Green
h Pigtail bus wire L : Blue
i Fuse (5 A) O : Orange
j Fuse (5 A) P : Pink
k Fuse (10 A) R : Red
l Power wire W : White
m Station selector switch Y : Yellow
n Wire lead for 6Y9
o Main bus wire
p 6Y9 Multifunction Color Gauge
q Wire lead for 6Y9
r Wire lead for NMEA 0183
s GPS
t Wire lead for fuel tank (6Y9)
u Fuel tank (fuel tank sensor)
v Cap 1 (white)
w Hub
x Single hub
y Wire lead for 6Y9 Multisensor
z 6Y9 Multisensor
A Extension wire harness
B Extension wire harness
C In-line resister
D Cap 1 (red)
E Engine shut-off switch
F Digital Electronic Control (sub station)
a Power port
b Bus port
c Device port
A Main station
B Sub station
C –D Main station to sub station
3-23
NMEA
0183 0
B/Br
B/O
B/G
B/P
s L
Br
O
GPS W r
t 1
u u u u
q p
SET
2
CANCEL
MENU
o
b C
c v Y Y j
w
c
c
h
k Y
g 3
h i
R
Y
B
b
o
a
l
(*2)
4
R
Y
B
e
d
f (*3)
5
o
m 6
c x
7
n
C
A
h
8
B
C b
(*1)
b
(*1)
9
A y
C
10
B
C
a a
z
A
3-24
RIG
o
b D
h
c
q p
SET
c v
CANCEL
w
MENU
c v
b C A
D
a D
F m B
D
e
A
D
E
B
D
3-25
Triple outboard motor application
(*2) Connect to the all engine start/stop button (optional).
(*3) Y-COP 0
a Engine ECM Color code
b Extension wiring harness
c Digital Electronic Control (main station)
B
Br
: Black
: Brown 1
d Main switch B/Br : Black/Brown
e Engine start/stop button B/G : Black/Green
f Receiver
g Power wiring harness for twin and triple
B/O : Black/Orange
B/P : Black/Pink
2
types G : Green
h Pigtail bus wire L : Blue
i Fuse (5 A)
j Fuse (5 A)
O
P
: Orange
: Pink
3
k Fuse (10 A) R : Red
l Power wire W : White
m Station selector switch Y : Yellow 4
n Wire lead for 6Y9
o Main bus wire
p 6Y9 Multifunction Color Gauge
q Wire lead for 6Y9 5
r Wire lead for NMEA 0183
s GPS
t Wire lead for fuel tank (6Y9)
u Fuel tank (fuel tank sensor)
6
v Cap 1 (white)
w Hub
x Single hub
y Wire lead for 6Y9 Multisensor
7
z 6Y9 Multisensor
A Extension wire harness
B Extension wire harness 8
C In-line resister
D Cap 1 (red)
E Engine shut-off switch
F Digital Electronic Control (sub station)
9
a Power port
b Bus port
c Device port
10
A Main station
B Sub station
C –D Main station to sub station
A
3-26
RIG
NMEA
0183
B/Br
B/O
B/G
B/P
s L
Br
O
GPS W r
t
u u u u
q p
SET
CANCEL
MENU
o
b C
c v Y Y j
c k Y
w h g
c i
h
R
Y
B
b
o
a (*2)
l
R
Y
B
e
d
o f (*3)
A
C c x
B n
C
A h
C
B b b b
C (*1) (*1) (*1)
y
A
C
B
C
a a a
z
3-27
0
1
2
B
3
b
o
h p
D
D
4
c A
q
SET
c v
CANCEL
w
MENU
c
b
v
C
B
D 5
a D D
m A
F
6
e D
B
E
A
D 7
D
B
8
9
10
A
3-28
RIG
Digital Electronic Control system
reset
A Digital Electronic Control system reset is
required after the replacement of the Digital
Electronic Control ECM or the engine ECM.
1. Connect the YDIS to display “Remote

Control System Reset.” To connect and
operate the YDIS, see the YDIS (Ver.
1.33 or later) instruction manual.
2. Click the “Next” button or press the Enter

key on the keyboard.
5. Turn the engine start switch to OFF, and

then remove the extension wiring
harness of the Digital Electronic Control.
TIP:
The outboard motor will automatically identify
the newly connected Digital Electronic Con-
trol under any of the following conditions:
• When the extension wiring harness is con-
nected and the engine start switch is turned
to ON again.
• When the engine start switch is turned to
OFF, and then turned to ON again after
3. Click the “OK” button or press the Enter waiting for about 10 seconds until the
key on the keyboard. power to the engine ECM is shut off.
4. Click the “OK” button or press the Enter

key on the keyboard.
3-29
Digital Electronic Control system reset / Rigging recommendation
Rigging recommendation
Extension length recommendation of battery cable
Do not exceed the recommended extension length for the battery cable. Otherwise, the elec-
0
trical system could be damaged or operate improperly.
To extend the length of battery cables, follow the requirements in the tables for battery capacity,
cable size, and ambient temperature.
1
The maximum total extension length is the total combined length of the positive and negative battery
cables.
Select an extension battery cable and terminal that meet ABYC requirements or the equivalent. 2
Select the battery stud that is best-suited to the terminal size.
Solder the cable and terminal connections to prevent them from corroding.
Ambient temperature –5 °C to 35 °C (23–95 °F) 3
Battery requirements Cable specifications
Number of Maximum total extension length
Unit
Minimum
capacity
batteries in
parallel
(Positive battery cable + Negative battery cable)
20 mm2 30 mm2 50 mm2 60 mm2
4
(AWG4) (AWG2) (AWG1/0) (AWG2/0)
CCA/EN
20HR/IEC
640 Amps
80 Ah
1 — — — — 5
CCA/EN 620 Amps 4.4 m 6.7 m 11.1 m 13.4 m
1
20HR/IEC
CCA/EN
110 Ah
620 Amps
(14.4 ft)
6.2 m
(22.0 ft)
9.4 m
(36.4 ft)
15.6 m
(44.0 ft)
18.8 m
6
2
20HR/IEC 110 Ah (20.3 ft) (30.8 ft) (51.2 ft) (61.7 ft)
CCA/EN
20HR/IEC
670 Amps
110 Ah
1
5.0 m
(16.4 ft)
7.6 m
(24.9 ft)
12.6 m
(41.3 ft)
15.2 m
(49.9 ft) 7
CCA/EN 670 Amps 7.3 m 11.0 m 18.3 m 22.0 m
2
(24.0 ft) (36.4 ft) (60.0 ft) (72.2 ft)
20HR/IEC
CCA/EN
110 Ah
750 Amps
1
5.5 m 8.3 m 13.8 m 16.6 m
8
CCA/EN 750 Amps
20HR/IEC 120 Ah
2
8.1 m
(26.6 ft)
12.1 m
(39.7 ft)
20.1 m
(65.9 ft)
24.2 m
(79.4 ft) 9
10
A
3-30
RIG
Ambient temperature –15 °C (5 °F)

Battery requirements Cable specifications
Number of Maximum total extension length
Minimum batteries in (Positive battery cable + Negative battery cable)
Unit parallel
capacity 20 mm2 30 mm2 50 mm2 60 mm2
(AWG4) (AWG2) (AWG1/0) (AWG2/0)
CCA/EN 620 Amps 1.8 m 2.8 m 4.6 m 5.6 m
1
CCA/EN 620 Amps 2.6 m 3.9 m 6.5 m 7.8 m
2
CCA/EN 670 Amps 2.1 m 3.2 m 5.3 m 6.4 m
1
CCA/EN 670 Amps 3.0 m 4.6 m 7.6 m 9.2 m
2
CCA/EN 750 Amps 2.3 m 3.5 m 5.8 m 7.0 m
1
CCA/EN 750 Amps 3.4 m 5.1 m 8.5 m 10.2 m
2
3-31
Rigging recommendation / Propeller selection
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, 0
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 1
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) 2
Propeller size b Propeller pitch (in inches)
c Propeller type (propeller mark)
The size of the propeller is indicated on the
propeller boss end, and on the side of the
propeller boss.
d Number of propeller blades
3
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
4
in relation to boat speed and fuel consump-
a b c
tion.
Full throttle operating range:
5
5000–6000 r/min
6
7
b
a
c
8
a Propeller diameter (in inches)
b Propeller pitch (in inches) 9
c Propeller type (propeller mark)
10
A
3-32
RIG
Regular rotation model
Propeller size Material
3 X 14 1/2 X 19 T (*1)
3 X 15 X 17 T (*1)
3 X 14 3/4 X 23 T
3 X 15 3/4 X 13 T
3 X 15 3/4 X 15 T
3 X 15 1/2 X 17 T Stainless
3 X 15 1/4 X 19 T
3 X 15 X 21 T
4 X 15 X 21 T
4 X 15 X 22 T
4 X 15 X 23 T
Counter rotation model

Propeller size Material
3 X 14 1/2 X 19 TL (*1)
3 X 15 X 17 TL (*1)
3 X 14 3/4 X 23 TL
3 X 15 3/4 X 13 TL
3 X 15 3/4 X 15 TL
3 X 15 1/2 X 17 TL Stainless
3 X 15 1/4 X 19 TL
3 X 15 X 21 TL
4 X 15 X 21 TL
4 X 15 X 22 TL
4 X 15 X 23 TL
(*1) These propellers cannot be installed

using the type of spacer a that comes
with the propeller shaft as standard. Use
the previous type of spacer b instead.
a b
3-33
TRBL
SHTG
Troubleshooting 4
YDIS .................................................................................... 4-1

Feature ...................................................................................... 4-1
Hardware requirement ............................................................... 4-1
0
Function ..................................................................................... 4-2
Connecting the communication cable to the outboard motor .... 4-4
1
Troubleshooting the power unit ...................................... 4-5
Troubleshooting procedure ....................................................... 4-5
Troubleshooting the power unit using the YDIS ........................ 4-5
Trouble code and checking step ............................................... 4-8
2
Troubleshooting the power unit (trouble code not detected) ... 4-29
Troubleshooting the PTT unit .................................................. 4-35
Troubleshooting the lower unit ................................................ 4-36 3
4
5
6
7
8
9
10
A
TRBL
SHTG Troubleshooting
YDIS
This manual contains model-specific information. See the YDIS instruction manual for detailed infor-
mation.
Feature
The newly developed YDIS provides quicker detection and analysis of the 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 (D-sub-9 pin) port, USB port
Printer: Compatible with the operating systems mentioned previously
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.
4-1
YDIS
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 the malfunctioning parts. The trouble codes dis-
played 0
are the same as those described in this chapter. See “Trouble code and checking step” (4-8).
• Diagnosis record
Displays each part name and the engine ECM trouble codes that have been recorded. This 1
enables you to check the records 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-
8). 2
• Engine monitor
The status of each sensor 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.
3
Engine speed Battery voltage Shift cut-off
Intake pressure (*1)
Throttle position sensor
Fuel injection duration Overheat thermoswitch 4
Ignition timing Main switch (wakeup)
(main)
Throttle valve opening
Throttle position sensor (sub)
Engine temperature
Intake temperature
Main switch (Receive data)
Start stop switch 5
Throttle request Oil pressure (*2) Possible to start
LPS (main) Intake cam timing (STBD) Main relay
LPS (sub)
Active Remote Control
Intake cam timing (PORT)
Coolant Pressure (*3)
Electronic throttle relay
Fuel pump relay
6
Shift position sensor (main) Speed Shift relay
Shift position sensor (sub)

Engine stop lanyard switch
(*4)
PT/T up switch 7
Shift request Shift position judgment PT/T down switch
Atmospheric pressure Dual engine system switch
(*1) Intake air pressure 8
(*2) Engine oil pressure
(*3) Cooling water pressure
(*4) Engine shut-off switch
9
• Stationary test
Operation tests can be performed while the engine is stopped.
Ignite ignition coil (#1–#6)

Oil ctrl. valve drive (STBD)
(*1)
Operate electric fuel pump
(*3)
10
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 A
4-2
TRBL
• Active test
The test can be performed while the engine is running and the gear shift is set to the N position. It
is not possible to perform the test while the boat is moving.
Drop cylinder (#1–#6)
• 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 Engine temperature Throttle request
Battery voltage Intake pressure Shift position sensor
Throttle position sensor 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 in 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) ETV relay
Target TPS voltage for
Throttle request Overheat warning
ISC (*4)
Throttle position sensor 1 Engine stop mode Low oil pressure (*7)
Throttle position sensor 2 Engine start mode Engine hour
Intake pressure (*1) Engine stop mode with SW Trig
Engine stop lanyard
Battery voltage Code
switch (*5)
Target TPS voltage (*2) Main relay (*6) Active Remote Control
(*1) Intake air pressure
(*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) 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.
(*5) Engine shut-off switch
(*6) Main relay (ignition coil, fuel injector, VCT, engine ECM, low-pressure fuel pump, high-
pressure fuel pump, vapor shut-off valve, YDIS)
(*7) Low engine oil pressure
• Digital Electronic Control system reset

Mutual authentication is performed between Digital Electronic Control ECM and engine ECM.
4-3
YDIS
Connecting the communication cable to the outboard motor
0
a
1
a
2
3
b
4
5
6
a YDIS coupler (gray)
YDIS (CD-ROM, Ver. 1.33) a: 7
60V-WS853-06
YDIS USB adapter and cable b:
60V-WS850-00
8
9
10
A
4-4
TRBL
Troubleshooting the power unit
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 follow-
ing 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” (5-23).
TIP:
• When deleting the diagnosis record on the YDIS, make sure to check the time that the trouble
codes were detected.
• When checking the input voltage of a part, the coupler or connector must be disconnected. As a
result, the engine ECM determines that the part is disconnected and a trouble code is detected.
Therefore, make sure to delete the diagnosis record after checking the input voltage.
• 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 faulty.
4-5
Trouble code table
O: Indicated
—: Not indicated
Code No. Item YDIS diagnosis

YDIS diagno-
sis record 0
13 Pulser coil malfunction U U
Engine temp sensor malfunction
15 U U
17
(Engine temperature sensor malfunction)
Knock sensor malfunction U U
1
19 Battery voltage malfunction U U
Intake temp sensor malfunction
23
(Air temperature sensor malfunction)
U U
2
24 Cam position sensor (EXH) malfunction U U
27 Water in fuel U U
29
Intake press sensor malfunction
(Air pressure sensor malfunction)
U U 3
37 Intake air passage malfunction U U
Oil press sensor malfunction
39
(Oil pressure sensor malfunction)
U U
4
Engine stop lanyard switch ON
44 — —
(Engine shut-off switch ON)
68
69
Variable cam timing (STBD)
Variable cam timing (PORT)
—
—
—
—
5
71 Cam position sensor (STBD INT) malfunction U U
72 Cam position sensor (PORT INT) malfunction U U
73 OCV (STBD) malfunction U U 6
74 OCV (PORT) malfunction U U
86 Immobilizer malfunction (Y-COP malfunction) — U
112,113,
114,115,
Electronic throttle system malfunction
7
116,117,
118,119,
121,122,
123,129,
U U 8
136,137,
138,139,
141,142, 9
144,145
124,125, Throttle position sensor malfunction
126,127,
128
U U
10
146,147, Shift position sensor malfunction
148,149,
U U
150,153,
154,155
156, 157 ENG–R.C. communication error U U
A
4-6
TRBL
YDIS diagno-
Code No. Item YDIS diagnosis
sis record
160,161, Remote control system malfunction
162,163, (Digital Electronic Control)
164,165,
166,167,
168,169,
170,171,
172,173, U U
174,175,
176,177,
178,179,
180,181,
183,184,
186,187
The trouble codes 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181,
183, 184, and 186 are applicable only to the dual station model.
4-7
Trouble code and checking step
The descriptions enclosed by < > are applicable to the twin and triple engine installations.
—: Not applicable
Trouble LAN gauge
Item Condition Symptom Remarks Checking steps See page
code display
13 Pulser coil mal- Irregular signal C/E Engine does not restart Engine stops Measure the pulser coil air gap. 7-1
function suddenly. Measure the pulser coil output
5-47
peak voltage.
Measure the pulser coil resis-
5-47
tance.
Check for wiring continuity
5-47
between the pulser coil and the
A-7
engine ECM.
Check the protrusions on the fly-
7-14
wheel magnet for damage.
15 Engine temp sen- Out of specifica- C/E High engine idle speed Measure the engine tempera-
5-50
sor malfunction tion Degraded acceleration performance ture sensor input voltage.
Declining maximum engine speed Measure the engine tempera-
<Difference in engine 5-50
— ture sensor resistance.
idle speeds> Check for wiring continuity
<Engine speeds do not synchro- 5-50
between the engine temperature
nize> A-7
sensor and the engine ECM.
17 Knock sensor Irregular signal C/E High engine idle speed Measure the knock sensor resis-
5-52
malfunction <Difference in engine idle speeds> tance.
<Engine speeds do not synchro- — Check for wiring continuity
nize> 5-52
between the knock sensor and
A-7
the engine ECM.
4-8
9
8
7
6
5
4
3
2
1
0
A
10
Trouble LAN gauge
4-9
code display
19 Battery voltage Below specified C/E Engine does not restart (*1) Engine oper- Check the battery capacity and
10-3
TRBL
SHTG
malfunction voltage ates normally. specific gravity.
(*1) Depends Check the fuse. 5-3
on battery con- A-9
dition. Check the battery cable and ter-
—
minals for proper connection.
Measure the lighting coil output
5-40
peak voltage.
Measure the lighting coil resis-
5-40
tance.
Measure the Rectifier Regulator
5-42
output peak voltage.
Troubleshooting
Check the Rectifier Regulator for
5-42
continuity.
23 Intake temp sen- Out of specifica- C/E High engine idle speed Check the air temperature using
5-48
sor malfunction tion <Engine speeds do not synchro- the YDIS.
nize> Measure the air temperature
5-48
sensor input voltage.
— Measure the air temperature
5-48
sensor resistance.
5-48
between the air temperature
A-7
sensor and the engine ECM.
Descriptions of (*1) in the “Symptom” column are shown in the “Remarks.”
Trouble LAN gauge
code display
24 Cam position Irregular signal C/E High engine idle speed Measure the cam position sen-
5-29
sensor (EXH) Degraded acceleration performance sor input voltage.
malfunction Declining maximum engine speed Measure the cam position sen-
<Difference in engine speeds> 5-29
sor output voltage.
<Engine speeds do not synchro- —
nize> 5-29
between the cam position sen-
A-3
sor and the engine ECM.
Check the brim of the camshaft. 7-47
27 Water in fuel Water in fuel W/F Alert buzzer comes on while the Check the fuel filter for water. —
shift is in the N position Measure the water detection
5-34
switch input voltage.
Check the water detection
— 5-34
switch for continuity.
5-34
between the water detection
A-5
switch and the engine ECM.
29 Intake press sen- Out of specifica- C/E High engine idle speed Measure the air pressure sensor
5-49
sor malfunction tion Declining maximum engine speed input voltage.
<Difference in engine idle speeds> Measure the air pressure sensor
— output voltage.
nize> Check for wiring continuity
5-49
between the air pressure sensor
A-7
and the engine ECM.
4-10
9
8
7
6
5
4
3
2
1
0
A
10
Trouble LAN gauge
code display
4-11
37 Intake air pas- Air leak C/E High engine idle speed (*1) When the Check the gaskets of the intake
TRBL
SHTG
sage malfunction Impossible to shift-in (*1) engine speed is manifolds, surge tank, and throt- 6-14
Shift-cutout control (*2) more than 1500 tle body.
Over-revolution at full throttle r/min. Check the hose between the
<Difference in engine idle speeds> (*2) Control is vapor shut-off valve and the 6-20
<Engine speeds do not synchro- valid at trolling surge tank.
nize> position only. Check the vacuum hoses. 6-20
39 Oil press sensor Out of specifica- C/E High engine idle speed Check the oil pressure using the
7-1
malfunction tion <Difference in engine idle speeds> YDIS.
Measure the oil pressure sensor
5-33
input voltage.
— Measure the oil pressure sensor
5-33
Troubleshooting
output voltage.
5-33
between the oil pressure sensor
A-3
and the engine ECM.
5-49
sensor (STBD Degraded acceleration performance sor input voltage.
INT) malfunction Declining maximum engine speed Measure the cam position sen-
<Difference in engine idle speeds> 5-49
sor output voltage.
nize> 5-49
A-3
5-49
sensor (PORT Degraded acceleration performance sor input voltage.
INT) malfunction Declining maximum engine speed Measure the cam position sen-
<Difference in engine idle speeds> 5-49
sor output voltage.
nize> 5-49
A-3
Descriptions of (*1) and (*2) in the “Symptom” column are shown in the “Remarks.”
Trouble LAN gauge
code display
73 Oil control valve Irregular load C/E Degraded acceleration performance Check the OCV operation using
5-32
(STBD) malfunc- current value Declining maximum engine speed the YDIS.
tion <Engine speeds do not synchro- Measure the OCV input voltage. 5-32
nize> Measure the OCV resistance. 5-32
5-32
— between the OCV and the main
A-3
relay.
5-32
between the OCV and the
A-3
engine ECM.
Check the OCV filter. 7-53
74 Oil control valve Irregular load C/E Degraded acceleration performance Check the OCV operation using
5-32
(PORT) malfunc- current value Declining maximum engine speed the YDIS.
tion <Engine speeds do not synchro- Measure the OCV input voltage. 5-32
nize> Measure the OCV resistance. 5-32
5-32
— between the OCV and the main
A-3
relay.
5-32
between the OCV and the
A-3
engine ECM.
Check the OCV filter. 7-53
86 Immobilizer Communication C/E Declining maximum engine speed Check that the Y-COP is con-
3-21
error nected properly.
—
Measure the Y-COP input volt-
5-54
age.
112 Electronic throt- Throttle valve C/E High engine idle speed Engine speed Replace the engine ECM.
114 tle system mal- malfunction Throttle does not operate is set at
function <Difference in engine idle speeds> approximately 7-32
<Engine speeds do not synchro- 1500 r/min.
nize>
4-12
9
8
7
6
5
4
3
2
1
0
A
10
Trouble LAN gauge
code display
4-13
113 Electronic throt- Throttle valve C/E High engine idle speed Engine speed Measure the TPS output voltage
5-24
TRBL
SHTG
tle system mal- malfunction Throttle does not operate is set at using the YDIS.
function <Difference in engine idle speeds> approximately Check the throttle opening angle
<Engine speeds do not synchro- 1500 r/min. 5-24
using the YDIS.
nize> Check the ETV circuit. 5-25
A-3
Check the fuse. 5-3
A-3
Check the ETV motor relay. 5-25
115 Electronic throt- Throttle valve C/E High engine idle speed Engine speed Check the ETV circuit. 5-25
116 tle system mal- malfunction Throttle does not operate is set at A-3
function <Difference in engine idle speeds> approximately Check the throttle valve opera-
Troubleshooting
<Engine speeds do not synchro- 1500 r/min. tion. 6-23
nize>
118 tle system mal- malfunction Throttle does not operate is set at A-3
function <Difference in engine idle speeds> approximately Check the fuse. 5-3
<Engine speeds do not synchro- 1500 r/min. A-3
nize> Check the ETV motor relay. 5-25
Check the throttle body. 6-23
119 Electronic throt- Throttle valve C/E High engine idle speed Engine speed Check the ETV circuit.
tle system mal- malfunction Throttle does not operate is set at
5-25
function <Difference in engine idle speeds> approximately
A-3
nize>
tle system mal- malfunction Throttle does not operate is set at
7-32
function <Difference in engine idle speeds> approximately
1500 r/min.
122 Electronic throt- Throttle valve C/E High engine idle speed Engine speed Replace the throttle body (ETV
tle system mal- malfunction Throttle does not operate is set at motor malfunction).
function <Difference in engine idle speeds> approximately 6-20
nize>
Trouble LAN gauge
code display
tle system mal- malfunction Throttle does not operate is set at A-3
function <Difference in engine idle speeds> approximately Check the fuse. 5-3
nize> Check the ETV motor relay. 5-25
124 Throttle position Out of specifica- C/E High engine idle speed Measure the TPS output voltage
5-24
125 sensor malfunction Degraded acceleration performance using the YDIS.
tion Declining maximum engine speed Check the throttle opening angle
<Difference in engine idle speeds> — 5-24
using the YDIS.
<Engine speeds do not synchro- Check the ETV circuit. 5-25
nize> A-3
124 Throttle position Out of specifica- C/E High engine idle speed Engine speed Measure the TPS output voltage
5-24
125 sensor malfunction Throttle does not operate is set at using the YDIS.
126 tion <Difference in idle speeds> approximately Check the throttle opening angle
127 <Engine speeds do not synchro- 1500 r/min. 5-24
using the YDIS.
128 nize> Measure the TPS input voltage. 5-24
<Difference in maximum engine
Check the ETV circuit. 5-25
speeds>
A-3
127 Throttle position Out of specifica- C/E Degraded acceleration performance Measure the TPS output voltage
5-24
128 sensor malfunction Declining maximum engine speed using the YDIS.
tion <Engine speeds do not synchro- Check the throttle opening angle
nize> — 5-24
using the YDIS.
<Difference in maximum engine Check the ETV circuit. 5-25
speeds> A-3
4-14
9
8
7
6
5
4
3
2
1
0
A
10
Trouble LAN gauge
code display
4-15
129 Electronic throt- Throttle valve C/E Degraded acceleration performance Measure the TPS output voltage
5-24
TRBL
SHTG
tle system mal- malfunction Declining maximum engine speed using the YDIS.
function <Engine speeds do not synchro- Check the throttle opening angle
nize> — 5-24
using the YDIS.
Check the ETV circuit. 5-25
A-3
Electronic throt- Throttle valve C/E High engine idle speed Engine speed Measure the TPS output voltage
5-24
function <Difference in idle speeds> approximately Check the throttle opening angle
using the YDIS.
nize> Check the ETV circuit. 5-25
A-3
Troubleshooting
137 tle system mal- malfunction Throttle does not operate is set at
function <Difference in idle speeds> approximately 7-32
nize>
138 Electronic throt- Throttle valve C/E High engine idle speed Engine speed Check the battery cable and ter-
—
139 tle system mal- malfunction Throttle does not operate is set at minals for proper connection.
function <Difference in engine idle speeds> approximately Check the ETV circuit. 5-25
nize> Check the fuse. 5-3
A-3
141 Electronic throt- Throttle valve C/E High engine idle speed Engine speed Check the battery cables and
—
tle system mal- malfunction Throttle does not operate is set at terminals for proper connection.
A-3
Trouble LAN gauge
code display
5-24
using the YDIS.
nize> Check the throttle valve opera-
6-23
tion.
144 Electronic throt- Throttle valve C/E High engine idle speed Engine speed Check the battery cable and ter-
—
tle system mal- malfunction Throttle does not operate is set at minals for proper connection.
A-3
5-24
<Engine speeds do not synchro- 1500 r/min. using the YDIS. 5-24
nize>
146 Shift position Out of specifica- C/E Engine does not restart (*1) (*1) No crank- Measure the SPS input voltage. 5-26
147 sensor malfunction Alert indicator is on ing. Measure the SPS output volt-
tion <Engine speeds do not synchro- Engine oper- 5-26
age.
nize> ates normally Check for wiring continuity
unless it is 5-28
between the SPS and the
stopped. A-3
engine ECM.
Measure the shift actuator rod
5-28
stroke.
4-16
9
8
7
6
5
4
3
2
1
0
A
10
Trouble LAN gauge
code display
4-17
148 Shift position Out of specifica- C/E Normal operation is possible (*1) When Measure the SPS input voltage. 5-26
TRBL
SHTG
149 sensor malfunction Shift actuator does not operate (*1) either one of Measure the SPS output volt-
tion Alert indicator is on the trouble 5-26
age.
<Engine speeds do not synchro- codes 146 and Check for wiring continuity
nize> 147, and either between the SPS and the 5-26
one of the trou- engine ECM.
ble code 148
and 149 took
stroke.
place simulta-
neously.
These are 5-28
symptoms of
the center out-
Troubleshooting
board motor.
150 Shift position Out of specifica- C/E Engine does not restart (*1) (*1) In a shift-in Measure the SPS input voltage. 5-26
sensor (Main) tion Shift actuator does not operate position Measure the SPS output volt-
malfunction High engine idle speed 5-26
age.
Alert indicator is on Check for wiring continuity
nize> A-3
engine ECM.
5-28
stroke.
Shift position Out of specifica- C/E Engine does not restart (*1) (*1) In a shift-in Measure the SPS input voltage. 5-26
sensor (Sub) tion Shift actuator does not operate position Measure the SPS output volt-
malfunction Alert indicator is on 5-26
age.
<Engine speeds do not synchro- Check for wiring continuity
nize> 5-28
A-3
engine ECM.
5-28
stroke.
Trouble LAN gauge
code display
153 Shift position Out of specifica- C/E Engine does not restart (*1) (*1) In a shift-in Check the fuse. 5-3
sensor malfunction Unstable engine idle speed position A-3
tion Throttle does not operate Measure the shift actuator relay
Alert indicator is on 5-27
input voltage.
<Engine speeds do not synchro- Measure the shift actuator motor
nize> 5-27
resistance.
5-27
between the shift actuator and
A-3
the engine ECM.
Check the shift actuator relay. 5-27
5-27
between the shift actuator relay
A-3
and the engine ECM.
5-27
stroke.
Check the shift mechanism. 7-34
Check the lower unit. 8-9
8-14
8-68
8-71
4-18
9
8
7
6
5
4
3
2
1
0
A
10
Trouble LAN gauge
code display
4-19
TRBL
SHTG
sensor malfunction Shift does not disengage from the position A-3
tion shift-in position Measure the shift actuator relay
input voltage.
nize> Measure the shift actuator motor
5-27
resistance.
5-27
A-3
the engine ECM.
5-27
A-3
Troubleshooting
and the engine ECM.
5-27
stroke.
8-14
8-68
8-71
Trouble LAN gauge
code display
sensor malfunction Shift actuator does not operate position A-3
tion Alert indicator is on Measure the shift actuator relay
input voltage.
nize> Measure the shift actuator motor
5-27
resistance.
5-27
A-3
the engine ECM.
5-27
A-3
and the engine ECM.
5-27
stroke.
8-14
8-68
8-71
4-20
9
8
7
6
5
4
3
2
1
0
A
10
Trouble LAN gauge
code display
4-21
156 ENG–R.C. com- Communication C/E Alert indicator is on Check the extension wiring har-
TRBL
SHTG
157 munication error error <Engine speeds do not synchro- ness proper connection and —
nize> damage.
5-65
between the engine ECM and
A-3
the engine main harness.
—
Check the Digital Electronic See the
Control circuit. Digital
network
control
service
manual.
ENG–R.C. com- Communication Not dis- Engine does not restart Trouble codes Check that the extension wiring
Troubleshooting
munication error played Fully closed throttle 156 and 157 harness is connected properly —
Shift actuator rod returns to neutral detected simul- and that there is no damage.
LAN gauge does not operate taneously. Check for wiring continuity
Alert indicator is on 5-65
<Engine speeds do not synchro- A-3
engine main harness.
nize> Check the Digital Electronic See the
Unable to switch the active station in Control circuit. Digital
the case of dual station arrange- network
ment (trouble code 186) control
service
manual.
Trouble LAN gauge
code display
160 Remote control LPS Irregular sig- C/E Alert indicator is on Measure the LPS output voltage
161 system malfunc- nal <Engine speeds do not synchro- using the YDIS.
162 tion nize> — Check for wiring continuity
163 (Main station) between the LPS and the Digital
Electronic Control ECM. See the
Fully closed throttle When either Measure the LPS output voltage Digital
Shift actuator rod returns to the N one of the trou- using the YDIS. network
position ble codes 160 Check for wiring continuity control
Alert indicator is on and 161, and between the LPS and the Digital service
<Engine speeds do not synchro- either one of Electronic Control ECM. manual.
nize> the trouble
codes 162 and
163 took place
simultaneously.
164 Remote control LPS Irregular sig- C/E Fully closed throttle Replace the Digital Electronic
system malfunc- nal Throttle does not operate Control ECM
tion Shift actuator rod returns to the N (When replacing the Digital See the
(Main station) position Electronic Control ECM with a Digital
Shift actuator can be operated man- new one, resetting of Digital network
—
ually Electronic Control ECM is nec- control
Alert indicator is on essary) service
<Difference in idle speeds> manual.
<Engine speeds do not synchro-
nize>
4-22
9
8
7
6
5
4
3
2
1
0
A
10
Trouble LAN gauge
code display
4-23
165 Remote control LPS Irregular sig- C/E Fully closed throttle Measure the LPS output voltage
TRBL
SHTG
system malfunc- nal Throttle does not operate using the YDIS.
See the
tion Shift actuator rod returns to the N Check for wiring continuity Digital
(Main station) position between the LPS and the Digital network
Shift actuator does not operate — Electronic Control ECM. control
Alert indicator is on
service
<Difference in idle speeds>
manual.
nize>
166 Remote control LPS Irregular sig- C/E High engine idle speed (*1) These are Measure the LPS output voltage
167 system malfunc- nal Alert indicator is on symptoms of using the YDIS.
168 tion Degraded acceleration performance the center out- Check for wiring continuity
169 (Main station) Declining maximum engine speed board motor. between the LPS and the Digital
Troubleshooting
<Difference in idle speeds> (*1) Unstable Electronic Control ECM.
nize>
Fully closed throttle When either Measure the LPS output voltage See the
Shift actuator rod returns to the N one of the trou- using the YDIS. Digital
position ble codes 166 Check for wiring continuity network
Alert indicator is on and 167, and between the LPS and the Digital control
<Engine speeds do not synchro- either one of Electronic Control ECM. service
nize> the trouble manual.
codes 168 and
169 took place
simultaneously.
These are
symptoms of
the center out-
board motor.
Trouble LAN gauge
code display
See the
(Main station) position between the LPS and the Digital network
service
manual.
nize>
171 Remote control LPS Irregular sig- C/E High engine idle speed (*1) (*1) Unstable Measure the LPS output voltage
172 system malfunc- nal Degraded acceleration performance using the YDIS.
173 tion Declining maximum engine speed Check for wiring continuity
174 (Sub station) Alert indicator is on between the LPS and the Digital
<Difference in idle speeds> Electronic Control ECM.
nize> See the
<Difference in maximum engine Digital
speeds> network
Fully closed throttle When either Measure the LPS output voltage control
Shift actuator rod returns to the N one of the trou- using the YDIS. service
position ble codes 171 Check for wiring continuity manual.
Alert indicator is on and 172, and between the LPS and the Digital
<Engine speeds do not synchro- either one of Electronic Control ECM.
nize> the trouble
codes 173 and
174 took place
simultaneously.
4-24
9
8
7
6
5
4
3
2
1
0
A
10
Trouble LAN gauge
code display
4-25
175 Remote control LPS Irregular sig- C/E Fully closed throttle Replace the Digital Electronic
TRBL
SHTG
system malfunc- nal Throttle does not operate Control ECM.
tion Shift actuator rod returns to the N (When replacing the Digital
(Sub station) position Electronic Control ECM with a
Shift actuator does not operate — new one, resetting of Digital
Alert indicator is on Electronic Control ECM is nec-
<Difference in idle speeds> essary.) See the
<Engine speeds do not synchro- Digital
nize> network
176 Remote control LPS Irregular sig- C/E Fully closed throttle Measure the LPS output voltage control
system malfunc- nal Throttle does not operate using the YDIS. service
tion Shift actuator rod returns to the N Check for wiring continuity manual.
(Sub station) position between the LPS and the Digital
Troubleshooting
Shift actuator does not operate — Electronic Control ECM.
nize>
Trouble LAN gauge
code display
177 Remote control LPS Irregular sig- C/E High engine idle speed (*1) These are Measure the LPS output voltage
178 system malfunc- nal Degraded acceleration performance symptoms of using the YDIS.
179 tion Declining maximum engine speed the center out- Check for wiring continuity
180 (Sub station) (*2) board motor. between the LPS and the Digital
Alert indicator is on (*1) Unstable Electronic Control ECM.
<Difference in idle speeds> (*2) Throttle
<Engine speeds do not synchro- limited to 1/2
nize> opening
See the
Fully closed throttle When either Measure the LPS output voltage
Digital
Shift actuator rod returns to the N one of the trou- using the YDIS.
network
position ble codes 177 Check for wiring continuity control
Alert indicator is on and 178, and between the LPS and the Digital service
<Engine speeds do not synchro- either one of Electronic Control ECM. manual.
nize> the trouble
codes 179 and
180 took place
simultaneously.
These are
symptoms of
the center out-
board motor.
See the
(Sub station) position between the LPS and the Digital network
service
manual.
nize>
4-26
9
8
7
6
5
4
3
2
1
0
A
10
Trouble LAN gauge
code display
4-27
183 Remote control LPS Irregular sig- C/E Station selection is impossible Replace the Digital Electronic
See the
TRBL
SHTG
system malfunc- nal Alert indicator is on Control ECM.
Digital
tion (When replacing the Digital
network
— Electronic Control ECM with a
control
new one, resetting of Digital
service
Electronic Control ECM is nec-
manual.
essary.)
184 Remote control LPS Irregular sig- C/E Engine selection is impossible Replace the Digital Electronic
See the
system malfunc- nal Alert indicator is on Control ECM.
Digital
network
— Electronic Control ECM with a
control
service
manual.
Troubleshooting
essary.)
186 Remote control LPS Irregular sig- Not Sub station Digital Electronic Con- (*1) When main Turn off the engine start switch
—
system malfunc- nal displayed trol does not operate Digital Elec- once, and turn it on again.
tion Unable to change to the sub-station tronic Control Check the extension wiring har-
(Main station) Digital Electronic Control(*1) ECM detects a ness proper connection and —
Fully closed throttle communication damage.
Shift actuator rod returns to the N error (trouble Check for wiring continuity
position codes 156 and 5-65
Alert indicator is on 157) during A-3
the main wiring harness.
<Engine speeds do not synchro- operation at a
Check the Digital Electronic
nize> (*2) main station
Control circuit.
with dual sta-
tion composi- See the
tion. Digital
(*2) Failed network
engine is control
locked at idle service
speed with the manual.
shift actuator
rod set at the N
position.
Trouble LAN gauge
code display
187 Remote control LPS Irregular sig- C/E Replace the Digital Electronic
See the
system malfunc- nal Control ECM.
Digital
network
— — Electronic Control ECM with a
control
service
manual.
essary.)
4-28
9
8
7
6
5
4
3
2
1
0
A
10
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
— : Not applicable
Symptom 1: Engine does not crank.
See
Symptom 2 Cause Checking step
page
Starter motor does not Gear shift not in the N position Set the gear shift to the N position. 10-6
operate Blown fuse Check the fuse. 5-3
A-9
Starter relay malfunction Check the starter relay. 5-53
Engine start switch malfunction Check the engine start switch or main
5-53
switch.
LPS malfunction Check the LPS. See the
Digital
network
control
service
manual.
Short, open, or loose connec- Measure the starter relay input voltage. 5-53
tion in starter motor circuit Check the wiring harness continuity. A-9
Starter motor malfunction Disassemble and check the starter
5-59
motor.
Y-COP is locked Unlock Y-COP. 3-12
Starter motor operates, Starter motor malfunction Disassemble and check the starter
5-59
but the engine does not motor.
crank Stuck piston or crankshaft Disassemble and check the power unit. 7-75
Stuck drive shaft Check the drive shaft bushing. 9-16
4-29
Symptom 1: Engine will not start (engine cranks).
See
page
Engine ECM does not
operate
Main relay malfunction Check the main relay. 5-22
A-3 0
Blown fuse Check the fuse. 5-3
A-3
Short, open, or loose connec-
tion in engine ECM circuit
Check for wiring continuity between the
main relay and engine ECM.
5-23
A-3
5-23
1
engine ECM and ground. A-3
Engine ECM ID and Digital
Electronic Control ECM ID do
not match.
Digital Electronic Control system reset
using the YDIS. 3-29 2
Engine ECM malfunction Replace the engine ECM. 7-32
Spark plug does not

Extension wiring harness mal-
function
—
Check the extension wiring harness con-
tinuity.
Check the ignition spark.
5-65
5-45
3
spark (all cylinders) Spark plug malfunction Check the spark plug. 7-48
Short, open, or loose connec-
tion in ignition coil circuit
Check the ignition coil input voltage.
5-46
5-46 4
ignition coil and engine ECM. A-7
Check for wiring continuity between the 5-46
ignition coil and main relay.
A-7
5-46 5
ignition coil and ground. A-7
6
7
8
9
10
A
4-30
TRBL
See
page
Fuel not supplied (all — Measure the fuel pressure. 6-6
cylinders) Pinched or kinked fuel hose Check the fuel hose. 6-1
Fuel leakage Check the fuel line for leakage. 6-1
Clogged fuel filter element Check the fuel filter element for dirt and
6-12
obstructions.
High-pressure fuel pump mal- Check the high-pressure fuel pump oper-
5-37
function ation using the YDIS.
Measure the high-pressure fuel pump
5-37
resistance.
Short, open, or loose connec- Check the high-pressure fuel pump input
5-37
tion in high-pressure fuel pump voltage.
circuit Check for wiring continuity between the
5-37
high-pressure fuel pump and engine
A-5
ECM.
5-37
high-pressure fuel pump and high-pres-
A-5
sure fuel pump relay.
High-pressure fuel pump relay Check the high-pressure fuel pump relay.
5-38
malfunction
Short, open, or loose connec- Check the low-pressure fuel pump input
5-37
tion in low-pressure fuel pump voltage.
circuit Check for wiring continuity between the
5-37
low-pressure fuel pump and engine
A-5
ECM.
5-37
low-pressure fuel pump and main relay.
A-3
Low-pressure fuel pump mal- Check the low-pressure fuel pump resis-
5-37
function tance.
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. 7-53
Check the piston and piston rings for
7-78
damage.
Check the cylinder for scratches. 7-78
4-31
Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited
engine speed.
See
Spark plug does not Spark plug malfunction Check the ignition spark.
page
5-45 0
spark (some cylinders) Check the spark plug. 7-48
Short, open, or loose connec- Measure the ignition coil input voltage. 5-46
tion in ignition coil circuit Check for wiring continuity between the
ignition coil and engine ECM.
5-46
A-7 1
ignition coil and main relay. A-7
Ignition coil malfunction Exchange the ignition coil with a different
one, and then check the ignition spark.
— 2
Fuel pressure is low — Measure fuel pressure. 6-7
Fuel leakage Check the fuel leakage.
Pressure regulator malfunction Check the pressure regulator.
6-1
6-8
3
Clogged fuel filter Check the fuel filter for dirt and obstruc-
6-12
tions.
High-pressure fuel pump mal- Measure the high-pressure fuel pump
function resistance.
5-37 4
Fuel not supplied (some Fuel injector malfunction Check the fuel injector operation using
5-35
cylinders) the YDIS.
Measure the fuel injector resistance.
Short, open, or loose connec- Measure the fuel injector input voltage.
5-35
5-35
5
tion in fuel injector circuit Check for wiring continuity between the 5-35
fuel injector and main relay. A-5
fuel injector and engine ECM.
5-35
A-5
6
Clogged fuel injector filter Replace the fuel injector. 6-44
is low
—
Improper valve timing
Measure the compression pressure.
Check the valve timing.
7-1
7-39
7
Check the timing belt. 7-39
Compression leakage Check the valve for bends and sticking.
Check the piston and piston rings for
7-53
7-78
8
damage.
Check the cylinder for scratches. 7-78
9
10
A
4-32
TRBL
Symptom 1: High engine idle speed.
See
page
Air leakage (throttle valve–cyl- Check the gaskets of the intake mani- 6-14
—
inder head) folds, surge tank, and throttle body. 6-20
Symptom 1: Engine stalls, unstable engine idle speed, or poor acceleration.

See
page
Improper intake cam Stuck OCV plunger Check the OCV valve operation using
5-32
timing the YDIS.
Check the OCV plunger. 5-32
Clogged OCV filter Replace the OCV filter. 7-53
Clogged oil passage Check the oil passage. 2-28
Stuck VCT Replace the VCT assembly. 7-42
4-33
Symptom 1: Limited engine speed (below 2000–3000 r/min).
See
page
Buzzer comes on
Overheat alert
indicator comes on
Thermoswitch malfunction Measure the thermoswitch input voltage.
Check the thermoswitch for continuity.
5-51
5-51 0
Check for continuity between the ther- 5-51
moswitch and the engine ECM. A-7
Clogged cooling water inlet
Water pump malfunction
Check the cooling water inlet.
Check the impeller.
10-3
8-12 1
Check the Woodruff key. 8-12
Check the water pump housing. 8-12
Check the insert cartridge.
Check the outer plate cartridge.
8-12
8-12
2
Clogged cooling water pas- Check the cooling water passage.
2-29
sage
Buzzer comes on
Thermostat malfunction
Insufficient engine oil
Check the thermostat.
Check the engine oil.
7-72
10-4
3
Oil pressure alert indica- Check the engine oil leakage. 2-28
tor comes on Check the valve seals and valves. 7-53
—
Check the piston rings.
Measure the oil pressure.
7-79
7-1
4
Engine oil pressure decrease Check the oil pump. 7-67
Check the oil strainer.
Check the oil passage (power unit and
9-20
2-28
5
oil pump).
Replace the oil filter. 10-9
Symptom 1: Discharged battery. 6

See
page
Battery performance decrease Check the battery capacity and specific
gravity.
10-3 7
Check that the battery cables and termi-
—
nals are connected properly.
Short, open, or loose connec- Check that the charging circuit is con-
tion in charging circuit nected properly, and that there is no
damage.
A-9 8
—
Stator assembly malfunction Measure the lighting coil output peak
5-40
voltage.
Measure the lighting coil resistance. 5-40 9
Rectifier Regulator malfunction Measure the Rectifier Regulator output
5-42
peak voltage.
Check the Rectifier Regulator for conti-
nuity.
5-42 10
A
4-34
TRBL
Troubleshooting the PTT unit
Cause: Trouble causes of symptom 2
Symptom 1: PTT unit does not operate.
See
page
PTT relay does not oper- Blown fuse Check the fuse. 5-3
ate A-11
PTT switch malfunction Check the PTT switch. 5-68
PTT relay malfunction Check the PTT relay. 5-66
Short, open, or loose connec- Measure the PTT switch input voltage. 5-68
tion of the wiring harness Measure the PTT relay input voltage. 5-66
Check for continuity between the PTT 5-68
switch and the fuse holder. A-11
PTT switch and engine ECM. A-11
PTT relay and engine ECM. A-11
PTT motor does not PTT motor malfunction Check the PTT motor. 9-41
operate Short, open, or loose connec- Check for wiring continuity between the
A-11
tion of the PTT motor lead PTT motor and the PTT relay terminal.
PTT fluid pressure does — Measure the PTT fluid pressure 9-33
not increase Manual valve opened Check the manual valve. 9-35
Insufficient PTT fluid Add sufficient PTT fluid. 10-13
PTT fluid leakage Check the PTT fluid leakage. 10-14
Clogged fluid passage Disassemble and check the PTT unit. 9-45
9-51
Check the filter for dirt and obstructions. 9-45
Check the valves for damage. 9-48
Check the fluid passages for obstruc- 9-45
tions. 9-51
Gear pump malfunction Check the gear pump assembly. 9-48
Symptom 1: PTT unit does not hold the outboard motor up.
See
Symptom 2 Cause 1 Checking step
page
Decrease in PTT fluid Manual valve open Check the manual valve. 9-35
pressure in lower cham- Insufficient PTT fluid Add sufficient PTT fluid. 10-13
ber of PTT cylinders PTT fluid leakage Check the PTT fluid leakage. 10-14
Clogged or open fluid passage Disassemble and check the PTT unit. 9-45
9-51
Check the valves for damage. 9-48
Check the fluid passages for obstruc- 9-45
tions. 9-51
4-35
Troubleshooting the lower unit
Cause: Trouble causes of symptom 2 0
Symptom 1: Shift mechanism of the forward gear and reverse gear does not operate prop-
erly. 1
See
Symptom 2 Cause 1 Checking step
page
Shift rod does not operate
properly
Check the shift lever operation.
Check the shift rod for wear
7-34
8-12 2
9-1
— Shift mechanism malfunction Check the dog clutch. 8-18
(in lower unit) Check the forward gear, reverse gear,
and pinion for damage and wear.
8-18
8-25 3
8-25
4
5
6
7
8
9
10
A
4-36
ELEC
Electrical system 5
Electrical component ........................................................ 5-1

Port ............................................................................................ 5-1
Starboard ................................................................................... 5-2
Fuse holder ............................................................................... 5-3
Rear ........................................................................................... 5-5
Front .......................................................................................... 5-6
Top ............................................................................................ 5-7
Bottom cowling .......................................................................... 5-8
Wiring harness routing ..................................................... 5-9

Port ............................................................................................ 5-9
Starboard ................................................................................. 5-10
Rear ......................................................................................... 5-13
Front ........................................................................................ 5-14
Top .......................................................................................... 5-15
Bottom cowling ........................................................................ 5-16
Circuit diagram ................................................................ 5-17
ECM coupler layout ......................................................... 5-19
Checking the electrical component ............................... 5-21

Using the YDIS ........................................................................ 5-21
Measuring the peak voltage .................................................... 5-21
Using the digital tester ............................................................. 5-22
Engine control unit and component .............................. 5-22

Checking the main relay .......................................................... 5-22
Checking the engine ECM circuit ............................................ 5-23
Checking the ETV and TPS .................................................... 5-24
Checking the ETV motor relay ................................................ 5-25
Checking the ETV (TPS) circuit ............................................... 5-25
Checking the SPS ................................................................... 5-26
Checking the shift actuator relay ............................................. 5-27
Checking the shift actuator ...................................................... 5-27
Checking the SPS and shift actuator circuit ............................ 5-28
Checking the cam position sensor .......................................... 5-29
Checking the OCV ................................................................... 5-32
Checking the oil pressure sensor ............................................ 5-33
Fuel control unit and component .................................. 5-34

Checking the water detection switch ....................................... 5-34
Checking the fuel injector ........................................................ 5-35
Checking the low-pressure fuel pump and high-pressure
fuel pump ................................................................................. 5-37
Checking the high-pressure fuel pump relay ........................... 5-38
Checking the vapor shut-off valve ........................................... 5-39
Charging unit and component ....................................... 5-40

Checking the lighting coil (stator assembly) ............................ 5-40
Checking the Rectifier Regulator ............................................. 5-42 0
Ignition unit and component .......................................... 5-45
Checking the ignition spark ..................................................... 5-45 1
Checking the ignition coil ......................................................... 5-46
Checking the pulser coil .......................................................... 5-47
Checking the air temperature sensor ...................................... 5-48
Checking the air pressure sensor ............................................ 5-49 2
Checking the engine temperature sensor ............................... 5-50
Checking the thermoswitch ..................................................... 5-51
Checking the knock sensor ..................................................... 5-52
Checking the engine shut-off switch ........................................ 5-52 3
Starting unit and component ......................................... 5-53
Checking the starter relay ....................................................... 5-53
Checking the engine start switch and main switch .................. 5-53
4
Checking the engine start/stop button ..................................... 5-54
Checking Y-COP ..................................................................... 5-54
5
Starter motor ................................................................... 5-56
Removing the starter motor ..................................................... 5-58
Checking the starter motor operation ...................................... 5-58
Checking the magnet switch ................................................... 5-58 6
Checking the starter motor pinion ........................................... 5-58
Disassembling the starter motor .............................................. 5-59
Checking the armature (starter motor) .................................... 5-60
Checking the brush holder ...................................................... 5-61 7
Assembling the starter motor .................................................. 5-61
Installing the starter motor ....................................................... 5-63
6Y9 Multifunction Color Gauge sensor ......................... 5-63

8
Checking the water pressure sensor (optional) ....................... 5-63
Checking the speed sensor (optional) ..................................... 5-64
9
Outboard motor and Digital Electronic Control
connection ....................................................................... 5-65
Checking the extension wiring harness ................................... 5-65 10
Checking the main wiring harness .......................................... 5-65
PTT electrical system ..................................................... 5-66

Checking the PTT relay ........................................................... 5-66
Checking the PTT switch (bottom cowling) ............................. 5-68
Checking the trim sensor ......................................................... 5-69
A
ELEC
Electrical system
Electrical component
Port
a b c d
g f
a ETV (TPS)
b Vapor shut-off valve
c Thermoswitch (PORT)
d OCV (PORT)
e Fuel injector
f High-pressure fuel pump
g Low-pressure fuel pump
5-1
Starboard
0
a b c d
1
2
3
4
g
5
6
7
8
f e 9
a OCV (STBD)
10
b Thermoswitch (STBD)
c Fuse holder
d PTT relay
e Rectifier Regulator
f Oil pressure sensor
g Fuel injector
A
5-2
ELEC
Electrical system
Fuse holder
a b c d
l k j i h g
a Fuse (100 A) (engine battery) f Fuse (30 A) (ignition coil, VCT, fuel injec-
b Fuse (20 A) (engine start switch, PTT tor, and engine ECM)
switch, and Digital Electronic Control g Main relay
ECM) h Fuse (30 A) (starter relay)
c Fuse (100 A) (house [accessory] battery) i Fuse (15 A) (shift actuator)
d Fuse (15 A) (high-pressure fuel pump) j Shift actuator relay
e Fuse (10 A) (ETV) k ETV motor relay
l Fuel pump relay (high-pressure)
5-3
a b c d
1
2
3
n
4
m
5
e 6
f 7
l k j i h g
8
9
m Starter relay
10
n Fuse (10 A) (low-pressure fuel pump)
A
5-4
ELEC
Electrical system
Rear
h g f e d c
a Engine ECM
b Ignition coil
c Knock sensor
d Speed sensor coupler (optional)
e Joint connector 3
f Diode
g Joint connector 2
h Water pressure sensor coupler
5-5
Front
0
a b
1
2
3
4
5
6
7
8
c 9
a Starter motor
10
b YDIS coupler
c Water detection switch (in fuel cup assem-
bly)
A
5-6
ELEC
Electrical system
Top
d
c
e
f
g
b
h
a
k
l
a Cam position sensor (STBD IN) i Engine temperature sensor

b Joint connector 4 j Pulser coil
c Joint connector 1 k Air temperature sensor
d Cam position sensor (PORT EX) l Air pressure sensor
e Condenser m Lighting coil (stator assembly)
f Condenser
g Condenser
h Cam position sensor (PORT IN)
5-7
Bottom cowling
A
a b 0
c
1
2
3
d
e
4
f
B
a
5
6
b
7
c
8
9
a PTT switch A Regular rotation model

10
b SPS B Counter rotation model
c Shift actuator
d Water detection switch coupler
e Trim sensor coupler
f Extension wiring harness
A
5-8
ELEC
Electrical system
Wiring harness routing
Port
A B
E D
A Install the pulser coil coupler to the wiring the holders.

harness guide. D Install the holders to the intake manifold
B Install the holder to the intake manifold, so that the catch of each holder is facing
and then fasten the thermoswitch connec- up, and then fasten the main wiring har-
tors using the holder. ness using the holders.
C Install the holders to the intake manifold, E Route the main wiring harness through
connect the fuel injector couplers, and the guide.
then fasten the fuel injector leads using
5-9
Starboard
A B C
0
D
1
B
C
D C 2
A A D
3
E E
4
5
6
A J H G F E 7
a
a
8
a
a c a
e
b d f g g 9
A-A B C-C D-D E-E
a Wiring harness A Install the holders to the intake manifold,

10
b Ground lead and then fasten the main wiring harness
c Thermoswitch lead using the holder.
d PTT ground lead B Fasten the main wiring harness, ther-
e Lighting coil lead moswitch connectors, and cooling water
f Power supply lead hose using the plastic tie.
g Ground lead
A
5-10
ELEC
Electrical system
A B C
B
C
D C
A A D
E E
A J H G F E
a a
a
a c a
e
d f g g
b
A-A B C-C D-D E-E
C Install the holder to the bracket, and then F Install the holders to the intake manifold,
fasten the Rectifier Regulator lead and and then fasten the PTT motor lead using
isolator lead using the holder. the holder.
D Fit the section of the PTT motor lead G Install the terminal of the ground lead with
marked with white tape into the slot in the gray tape so that it contacts the stopper.
intake manifold. H Install the terminals of the ground leads
E Fasten the shift actuator lead and fuel that are fastened together using tape so
hose using the holder. that they contact the stopper.
5-11
A B C
0
D
1
B
C
D C 2
A A D
3
E E
4
5
6
A J H G F E 7
a
a
8
a
a c a
e
b d f g g 9
A-A B C-C D-D E-E
J Install the Rectifier Regulator ground lead

10
terminal and PTT relay ground lead termi-
nal so that they contact the stopper.
A
5-12
ELEC
Electrical system
Rear
B C
A A
B B
E
D
b
a a
b b a
b
b b
b b
A-A B-B C-C
a Ignition coil lead C Fasten the grommet of the main wiring

b Vapor gas hose harness using the holder.
D Fasten the main wiring harness and igni-
A Install the holder on the main wiring har- tion coil lead using the holder.
ness to the bracket. E Fasten the main wiring harness at the
B Fasten the main wiring harness using the white tape using the holder.
holder so that the catch of the holder is
facing up.
5-13
Front
0
A
1
2
3
4
5
6
A
B
8
9
A
A Fasten the PTT relay lead using the

10
holder.
B Align the starter motor lead with the arrow
mark on the terminal.
A
5-14
ELEC
Electrical system
Top
C
B
A Install the holders to the wiring harness

guide, and then fasten the main wiring
harness using the holders.
B Fasten the low-pressure fuel pump lead
and air pressure sensor lead using the
holder.
C Route the lighting coil leads under the
holder.
5-15
Bottom cowling
A
0
A
B 1
A
B
C
D 2
D f
C
3
g
a 4
D-D
a B 5
f
d
f
e
c
d
6
a g
A-A
a 7
c D-D
b
a
C-C
8
d
c D
9
D
B-B
a Flushing hose A Regular rotation model

10
b SPS lead B Counter rotation model
c Trim sensor lead
d Speedometer hose
e PTT motor lead
f PTT switch lead
g Vapor gas hose
A
5-16
ELEC
Electrical system
Circuit diagram
TIP:
The circled numbers in the illustration indicate the engine ECM terminal numbers.
Fuel
Fuel injector
injector #1
#1
Pulser
Pulser coil
coil
87
Fuel
Fuel injector
injector #2
#2
29
88
Fuel
Fuel injector
injector #3
#3
84 96
Fuel
Fuel injector
injector #4
#4
97
Cam
Camposition
positionsensor
sensor Fuel injector #5
(PORT EX) 39 114
(PORT EX)
Fuel
Fuel injector
injector #6
#6
104
Cam position
Cam position sensor
sensor
(PORT 40 Ignition
Ignition coil
coil #1
#1
(PORTIN) IN)
Cam position sensor

(STBD IN) 47 106
(STBD IN) Ignition
Ignition coil
coil #2
#2
5V
116
98
TPS 1 117
TPS 2 62
Ignition coil #3
Ground
Ground
69 110
Ignition coil #4
5V Engine
Engine
82 ECM
ECM
SPS 2 63 102
Ignition coil
Ignition coil #5
#5
Ground
Ground 78
5V
81
100
SPS 1 80
Ground
Ground
75 Ignition coil #6
101
70
111 ETV relay

Air
Air pressure
pressure sensor
sensor 74
120
61
Oil pressure sensor 76 94 ETV

motor
68 motor
95
103
a
a Indicates a connection between the symbols.
5-17
Circuit diagram
79
OCV (STBD)
Water pressure sensor 48 49
OCV (PORT)
0
50
Speed sensor
sensor 66
Trim sensor 27
73
1
Air
Airtemperature
temperaturesensor
sensor High-pressure Fuel pump relay
High-pressure
fuelpump
fuel pump (high-pressure)
fuel pump relay
Enginetemperature
Engine temperaturesensor
sensor
65
P 2
64 58
Thermoswitch
71 Low-pressure fuel pump
Thermoswitch
Thermoswitch
Water detection
switch
56 P
3
72 PTT relay
77 112
90 113 4
91
Engine 55 YDIS
Digital
Digital Electronic
Electronic ECM
92
Engine
Engine
ControlECM
Control ECM
93
ECM
43
Shift actuator
relay
5
start
start 53 51
switch
switch Knock sensor
67
83
6
38
34
Starter
Starter relay
relay Shift actuator
Engine
Engine shut-off
shut-off switch
switch
89 32
7
M 36 30
PTT switch (UP) 31
Starter motor
PTT switch (DN)

45
8
54
86
Main
Mainrelay
relay 44
52
41
42
9
37
Rectifier 99
Regulator
Regulator 118
10
85
– + – +
Battery
Battery Battery
Battery
House (accessory) battery
a Indicates a connection between the symbols.

A
5-18
ELEC
Electrical system
ECM coupler layout
87 88 89 90 91 92 93 94 95 61 62 63 64 65 66 67 27 28 29 30 31 32 33 34 35
96 97 98 99 100 101 102 103 68 69 70 71 72 73 36 37 38 39 40 41 42 43
104 105 106 107 108 109 110 111 74 75 76 77 78 79 44 45 46 47 48 49 50 51
112 113 114 115 116 117 118 119 120 80 81 82 83 84 85 86 52 53 54 55 56 57 58 59 60
No. Connecting part Color No. Connecting part Color

27 Trim sensor Pink 53 Wake up pulse (Digital Yellow
28 Electronic Control)
29 Pulser coil White/Red 54 PTT DN switch Light green
30 Shift ground Black 55 YDIS White/Black
31 Shift ground Black 56 Low-pressure fuel Blue/White

pump
32 Shift actuator Green/Black
57
33
58 High-pressure fuel Yellow/Green
34 Shift actuator Green/Red pump
35 59
36 Engine shut-off switch White 60
37 Main relay Yellow/Green 61 ETV power source Yellow/Green
38 Start switch Brown 62 TPS 2 Pink/White
39 Cam position sensor White/Blue 63 SPS 2 Pink
(PORT EX)
64 Engine temperature Black/Yellow
40 Cam position sensor White/Green sensor
(PORT IN)
65 Air temperature sensor Black/Yellow
41 Engine ECM ground Black
66 Speed sensor Blue
67 Shift power source Yellow/Green
43 Shift power source Red/Green
68 ETV motor Green/Black
44 Battery power source Red/Yellow
69 TPS ground Black
45 PTT UP switch Sky blue
70 Sensor power source Orange
46
71 Thermoswitch Pink
47 Cam position sensor White/Black
(STBD IN) 72 Water detection switch Blue/White
48 Water pressure sensor Blue/Black 73 Vapor shut-off valve Green/Black
49 OCV (STBD) Purple 74 Air pressure sensor Pink/Green
50 OCV (PORT) Purple 75 SPS 1 ground Black
51 Shift power source Red/Green 76 Oil pressure sensor Pink/White
52 Battery power source Red/Yellow 77 Sensor ground Black
5-19
ECM coupler layout
0
1
87 88 89 90 91 92 93 94 95 61 62 63 64 65 66 67 27 28 29 30 31 32 33 34 35
96 97 98 99 100 101 102 103
104 105 106 107 108 109 110 111
68
74
69 70 71 72
75 76 77 78
73
79
36
44
37 38 39 40 41 42
45 46 47 48 49 50
43
51
2
112 113 114 115 116 117 118 119 120 80 81 82 83 84 85 86 52 53 54 55 56 57 58 59 60
No. Connecting part Color No. Connecting part Color

3
78 SPS 2 ground Black 103 ETV ground Black
79
80
Sensor power source
SPS 1
Orange
Pink/White
104
105
Fuel injector #6 Purple/White
4
81 SPS 1 power source Orange 106 Ignition coil #1 Black/Orange
82 SPS 2 power source Orange 107
83 Knock sensor Green 108 5
84 Pulser coil ground Black 109
85 Isolator 110 Ignition coil #3 Black/Yellow
86 Engine ECM ground Black 111 ETV power source Red/Green 6
87 Fuel injector #1 Purple/Red 112 PTT relay Sky blue
88 Fuel injector #2 Purple/Black 113 PTT relay Light green
89
90
Starter relay
Digital Electronic Con-
Black
White
114
115
Fuel injector #5 Purple/Blue
7
trol 1 (H) 116 TPS power source Orange
91 Digital Electronic Con- Blue
trol 1 (L)
117
118
TPS 1
Rectifier Regulator
Pink
Blue/Green
8
92 Digital Electronic Con- White
trol 2 (H) 119
120 ETV power source Red/Green
93 Digital Electronic Con-
trol 2 (L)
Blue
9
94 ETV motor Green/Red
95 ETV ground Black
96
97
Fuel injector #3
Fuel injector #4
Purple/Yellow
Purple/Green
10
98 Ignition coil #2 Black/White
100 Ignition coil #5 Black/Blue
101 Ignition coil #6 Black/Brown
102 Ignition coil #4 Black/Green
A
5-20
ELEC
Electrical system
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, high-pressure fuel pump, fuel injector, sure that the leads do not contact any
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
YDIS (CD-ROM, Ver. 1.33): spark plugs or a weak battery. If one of these
60V-WS853-06 factors is present, the peak voltage cannot be
YDIS USB adapter and cable: measured properly.
60V-WS850-00
TIP:
• Before checking the electrical components,
make sure that the battery is fully charged.
DC V
• 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 and
CD-ROM to be used, see “YDIS” (4-1). Digital circuit tester: 90890-03174
Also, make sure to check the CD-ROM ver- Peak voltage adapter B: 90890-03172
sion before using it.
• To connect and operate the YDIS, see the TIP:
YDIS (Ver. 1.33 or later) instruction manual. • Before measuring the peak voltage, check
all of the wiring harnesses for corrosion.
Measuring the peak voltage Also, make sure that the wiring harnesses
are connected properly and that the battery
is fully charged.
When measuring the peak voltage, do not • Use the peak voltage adapter B with the
touch any of the connections of the digital recommended digital circuit tester.
tester probes. • Connect the positive pin of the peak voltage
adapter B to the positive terminal of the dig-
ital tester, and the negative pin to the nega-
tive terminal.
• When measuring the peak voltage, set the
digital circuit tester to the DC voltage
mode.
5-21
Checking the electrical component / Engine control unit and component
Using the digital tester 2. Connect the positive battery lead to the
The electrical technical data apply to the terminal a, connect the negative battery
measurements taken using the Yamaha rec- lead to the terminal b, and then check
ommended tester. for continuity between the terminals c
The resistance values shown are the values and d. Replace the relay if there is no
continuity. NOTICE: Do not reverse the
0
taken before the engine is started. The actual
resistance may vary depending on the envi- battery leads.
ronmental conditions and ambient tempera-
ture.
c
1
The input voltage changes depending on the
battery voltage. d a
If the tester probe cannot be inserted into the
coupler, prepare a test lead suitable for the
2
measurement.
b 3
Terminal
Battery lead
Connect
c
C
d
C
4
a b Disconnect
3. Measure the input voltage between the

terminal e and ground, and the terminal
5
Digital circuit tester: 90890-03174 f and ground.
Test lead:
Terminal, male a: (commercially avail-
able)
6
Terminal, female b: (commercially avail-
e
able)
f 7
Engine control unit and
component
Checking the main relay
1. Remove the relay cover and main relay
8
a. Main relay input voltage:
Terminal e–Ground
Terminal f–Ground
12.0 V (battery voltage)
9
4. Turn the engine start switch to ON, and
then measure the input voltage between
the terminals e and g.
10
a
A
5-22
ELEC
Electrical system
g e Wiring harness continuity:

Terminal 41–Ground

engine ECM coupler terminal 37 and
ground.
Main relay input voltage: c

Terminal e–Terminal g
5. Turn the engine start switch to OFF. 37
6. Install the main relay a and relay cover.
Checking the engine ECM circuit

1. Disconnect the engine ECM couplers a,
b, and c. Engine ECM input voltage:
a 4. Turn the engine start switch to ON, and

b
the engine ECM coupler terminal 53 and
c ground.
2. Check the wiring harness for continuity.
a b 53
99
Engine ECM input voltage

86
(reference data):
11.6 V
c
6. Remove the intake manifold (STBD).

42 41
7. Remove the fuse holder a, and then
disconnect the fuse holder coupler d.
5-23
Engine control unit and component
d 1
c 2
1. Connect the YDIS to display “Throttle
37
position sensor (main),” “Throttle valve 3
opening,” and “Throttle position sensor
44
(sub).”
52
2. Start the engine, warm it up for 5–10 4

minutes, and then stop it.
d
10
23 22
then measure the TPS output voltages 5
and the throttle valve opening angles
when the Digital Electronic Control is at
Wiring harness continuity:
Terminal 37–Terminal 10
the fully closed position.
6
Terminal 44–Terminal 23 TPS output voltage and throttle valve
Terminal 52–Terminal 22 opening angle (reference data):
9. Connect the engine ECM couplers a, b,

TPS 1
Item Fully closed
0.37–0.63
7
and c. V
TPS 2 2.5–3.5 V
10. Connect the fuse holder coupler d, and
then install the fuse holder a. Throttle valve opening angle 4.5° 8
11. Install the intake manifold (STBD). See TIP:
“Installing the intake manifold” (6-16). The actual TPS output voltage and throttle
valve opening angle may vary according to
9
Checking the ETV and TPS environmental conditions and engine temper-
TPS 1 and TPS 2 are components of the ature.
ETV, which cannot be disassembled.
10
Do not loosen the throttle stop screw nut 5. Disconnect the ETV coupler a.
or turn the throttle stop screw.
A
5-24
ELEC
Electrical system
then measure the TPS input voltage at
the ETV coupler. Check the wiring
harness if out of specification. See
“Checking the ETV (TPS) circuit” (5-25).
a
O B
ETV motor relay input voltage:

Terminal a–Ground

TPS input voltage: then measure the input voltage between
Orange (O)–Black (B) terminals b and c.
4.75–5.25 V b c
8. Connect the ETV coupler a.
Checking the ETV motor relay

1. Remove the relay cover and ETV motor
relay a.
ETV motor relay input voltage:

Terminal b–Terminal c
6. Install the ETV motor relay a and relay

a cover.
2. Check the ETV motor relay. See Checking the ETV (TPS) circuit
“Checking the main relay” (5-22). 1. Disconnect the engine ECM couplers a
and b.
terminal a and ground.
2. Disconnect the ETV coupler c.
5-25
c
a b
61 95
103
0
111
120
d
1
1
a b 5
2
e 12
62
69 68
94
Wiring harness continuity: 3
117 116 Terminal 111–Terminal 12
4
c Terminal 103–Ground
6 5 4 3 2 1
8. Connect the engine ECM couplers a
and b.
5
9. Connect the fuse holder couplers d and
e, and then install the fuse holder a.
6
Terminal 68–Terminal 2 10. Install the intake manifold (STBD). See
Terminal 69–Terminal 3 “Installing the intake manifold” (6-16).
Terminal 117–Terminal 4 Checking the SPS
7
Terminal 116–Terminal 5 1. Connect the YDIS to display “Shift posi-
tion sensor.”
4. Connect the ETV coupler c.
2. Operate the Digital Electronic Control to
8
measure the output voltage at the F, N,
and R positions.
disconnect the fuse holder couplers d N
9
and e. F R
a 10
d e
A
5-26
ELEC
Electrical system
2. Check the shift actuator relay. See
SPS output voltage:
“Checking the main relay” (5-22).
F 0.2–1.5 V
N 2.412–2.588 V 3. Measure the input voltage between the
R 3.5–4.8 V terminal a and ground.

then disconnect the SPS coupler a.

then measure the input voltage at the
SPS coupler. Check the wiring harness if
out of specification. See “Checking the
SPS and shift actuator circuit” (5-28).
a
A
Shift actuator relay input voltage:
Terminal a–Ground
a
B
O terminals b and c.
B
b c
SPS input voltage:

A SPS 1: Orange (O)–Black (B)
B SPS 2: Orange (O)–Black (B)
4.75–5.25 V
Shift actuator relay input voltage:
5. Turn the engine start switch to OFF, and Terminal b–Terminal c
then connect the SPS coupler a. 12.0 V (battery voltage)
Checking the shift actuator relay 5. Turn the engine start switch to OFF.
1. Remove the relay cover and shift actua-
tor relay a. 6. Install the shift actuator relay a and relay
cover.
Checking the shift actuator

1. Remove the intake manifold (PORT).
2. Operate the Digital Electronic Control to

check the shift actuator rod stroke a at
the positions F, N, and R.
5-27
N Checking the SPS and shift actuator

F R circuit
1. Disconnect the engine ECM couplers a
and b.
0
b 1
a a
2
2. Disconnect the SPS coupler c.
3
3. Remove the intake manifold (PORT), and
then disconnect the shift actuator motor
coupler d.
4
Shift actuator rod stroke a:
F 78.2 mm (3.08 in)
d
N
R
59.2 mm (2.33 in)
41.1 mm (1.62 in)
5
3. Disconnect the shift actuator motor
coupler b, and then measure the shift
actuator motor resistance.
6
c
b
7
a b
34 32 63 8
78 75
Shift actuator motor resistance

82 81 80
9
(reference data):
c d
1.7 Ω at 20 °C (68 °F)
4. Connect the shift actuator motor coupler

3 2 1
6 5 4
2 1 10
b, and then install the intake manifold
(PORT). See “Installing the intake
manifold” (6-16).
A
5-28
ELEC
Electrical system
9. Connect the engine ECM couplers a
and b.
a Terminal 32–d Terminal 2
a Terminal 34–d Terminal 1 10. Connect the fuse holder couplers e and
b Terminal 63–c Terminal 2 f, and then install the fuse holder a.
b Terminal 75–c Terminal 4
b Terminal 78–c Terminal 1 11. Install the intake manifolds (STBD and
b Terminal 80–c Terminal 5 PORT). See “Installing the intake
b Terminal 81–c Terminal 6 manifold” (6-16).
Checking the cam position sensor
5. Connect the SPS coupler c and shift 1. Disconnect the cam position sensor cou-
actuator motor coupler d.
plers a, b, and c.
cam position sensor coupler.
disconnect the fuse holder couplers e
and f. STBD IN a
a R/Y W/B B
e f
PORT IN
W/G
8. Check the wiring harness for continuity. b R/Y B
a b
31 30 67
43
51
e PORT EX
7
W/L
R/Y B
c
6 5 4
f 12

5-29
Cam position sensor input voltage:

d ECM
Red/Yellow (R/Y)–Black (B) 12 V 5V
White/Black (W/B)–Black (B)
(STBD IN)
0
White/Green (W/G)–Black (B)
(PORT IN)
White/Blue (W/L)–Black (B)
(PORT EX)
1
4.75–5.25 V
W/B
3. Turn the engine start switch to OFF. d
R/Y
W/G
W/L
2
4. Make 3 test leads.
b
B 3
c
e 4
d
a
a 5
f
then measure the output voltage when
moving a screwdriver close to the cam
position sensor. NOTICE: Make sure to
6
Test lead: remove the high-pressure fuel pump
Terminal, male a: 9E212-10303 fuse.
Terminal, female b: 9E212-11303 7
Terminal, female c: (commercially avail-
d
able)
d = 100 mm (3.94 in)
e = 50 mm (1.97 in)
8
f = Cutout area
g h k
5. Reduce the fuel pressure. See “Reducing
the fuel pressure” (6-6).
9
6. Remove the fuel rails.
7. Remove the cam position sensors d.

10
8. Connect the test leads to the cam
position sensor d and cam position
sensor coupler.
9. Connect the tester probes to the test

leads. A
5-30
ELEC
Electrical system
Cam position sensor output voltage:
White/Black (W/B)–Black (B) a b c
(STBD IN)
White/Green (W/G)–Black (B)
(PORT IN) 2 1 2 1 2 1
White/Blue (W/L)–Black (B)

(PORT EX)
n p
Position Voltage
g, k More than 4.8
h Less than 1.0
40 39
47 77
TIP:
Using analog circuit tester is recommended.
11. Turn the engine start switch to OFF. Wiring harness continuity:
aTerminal 1–Terminal 77
12. Disconnect the test leads, and then aTerminal 2–Terminal 47
install the cam position sensors d. bTerminal 1–Terminal 77
bTerminal 2–Terminal 40
13. Install the fuel rails.
cTerminal 1–Terminal 77
cTerminal 2–Terminal 39
14. Install the high-pressure fuel pump fuse.
19. Set the digital circuit tester to the diode
mode, and then check the wiring harness
16. Remove the fuse holder e, and then continuity.
disconnect the fuse holder coupler m. a b c
e 3 3 3
18
17. Disconnect the engine ECM couplers n

and p.
5-31
Wiring harness continuity STBD

(testing diode mode): R/Y
Tester probe Display a

value (refer-
ence data)
0
m Terminal a Terminal
0.512 V
18 3
a Terminal m Terminal
OL
1
3 18
m Terminal b Terminal
0.529 V PORT
18
b Terminal
3
m Terminal
OL
b
R/Y
2
3 18
m Terminal c Terminal
18
c Terminal
3
m Terminal
0.512 V
3
OL
3 18
OL: Indicates an overload 4
OCV input voltage:
20. Connect the cam position sensor
Red/Yellow (R/Y)–Ground
couplers a, b, and c and engine ECM
couplers n and p.
5
21. Connect the fuse holder coupler m, and
then install the fuse holder e.
22. Install the intake manifold (STBD). See

5. Remove the OCV.
6
6. Measure the OCV resistance.
“Installing the intake manifold” (6-16).
Checking the OCV 7

1. Check the operation of the OCV using
the YDIS “Stationary test” and check the
operating sound.
8
2. Disconnect the OCV couplers a and
b.
3. Turn the engine start switch to ON, and 9

then measure the input voltage between OCV resistance:
the OCV coupler and ground. 6.7–7.7 Ω at 20 °C (68 °F)
7. Remove the OCV. 10

8. Connect the battery leads to the
terminals and check the operation of the
spool valve. Replace the OCV if the
spool valve does not operate.
A
5-32
ELEC
Electrical system
a c
2 1
18
9. Disconnect the battery leads. 2 1 50 49
11. Remove the fuse holder a, and then Wiring harness continuity:
disconnect the fuse holder coupler c.
a Terminal 2–c Terminal 18
a b Terminal 1–d Terminal 50
14. Install the OCV, and then connect the

OCV couplers a and b.
15. Connect the engine ECM coupler d.

c
16. Connect the fuse holder coupler c, and
12. Disconnect the engine ECM coupler d. then install the fuse holder a.

Checking the oil pressure sensor

1. Disconnect the oil pressure sensor cou-
d pler a.
B O
a

then measure the input voltage at the oil
pressure sensor coupler.
5-33
Engine control unit and component / Fuel control unit and component
Oil pressure sensor input voltage:

Orange (O)–Black (B)
4.75 V–5.25 V
3. Remove the oil pressure sensor, and b 0

then connect the pressure pump a and
special service tool b.
4. Apply positive pressure to the oil 1

pressure sensor slowly, and then
measure the output voltage at the 7. Check the wiring harness for continuity.
specified pressures.
2
P/W a b
B
O
G/W B G
3 2 1 70
3
b
77 76
4
b a
5
Pressure pump a:
(commercially available)
8. Connect the engine ECM coupler b. 6
Test harness (3 pins) b: 90890-06869 9. Connect the oil pressure sensor coupler
a.
Oil pressure sensor output voltage
Fuel control unit and component
7
(reference data):
Pink/White (P/W)–Black (B) Checking the water detection switch
2.5 V at 392.0 kPa
(3.92 kgf/cm2, 56.8 psi)
1. Disconnect the water detection switch
coupler a.
8
4.5 V at 784.0 kPa
(7.84 kgf/cm2, 113.7 psi) 2. Turn the engine start switch to ON, and

water detection switch coupler.
9
then disconnect the special service tool
b and pressure pump a.
B L/W
6. Disconnect the engine ECM coupler b.
10
a
A
5-34
ELEC
Electrical system
Water detection switch input voltage:

Blue/White (L/W)–Black (B)
4.75–5.25 V
3. Turn the engine start switch to OFF, and e

then remove the filter cup assembly.
4. Check that the float a move smoothly.
5. Check the water detection switch for

continuity when the float a is in positions 7. Check the wiring harness for continuity.
A and B . NOTICE: Do not remove the
clip and float.
e
A a
2 1 72
77
b c a

B Terminal 2–Terminal 77
8. Connect the engine ECM coupler e.

d
b c a 9. Install the filter cup assembly. See “Fuel
filter assembly” (6-9).
10. Connect the water direction switch

coupler a.
Terminal Checking the fuel injector

Float position
b c 1. Check the operation of the fuel injector
A using the YDIS “Stationary test” and
B C C check the operating sound.
Float height d (reference data): 2. Disconnect the fuel injector couplers a.

53.0 mm (2.10 in)
6. Disconnect the engine ECM coupler e. then measure the input voltage between
the fuel injector coupler terminal and
ground.
5-35
STBD R/Y
a
a
0
b 1
PORT 8. Disconnect the engine ECM coupler c.
2
R/Y
c
a
3
4
Fuel injector input voltage:
Red/Yellow (R/Y)–Ground
5
4. Turn the engine start switch to OFF. a b
5. Measure the fuel injector resistance. 2 1

18 6
c
88 87
7
97 96
114
104
8
Fuel injector resistance (reference data):
11.5–12.5 Ω at 20 °C (68 °F) 9
7. Remove the fuse holder a, and then 10

disconnect the fuse holder coupler b.
A
5-36
ELEC
Electrical system

R/Y
Injector #1 a
Injector #2
Injector #3
Injector #4 Low-pressure fuel pump input voltage:
Terminal 1–Terminal 18 Red/Yellow (R/Y)–Ground
Terminal 2–Terminal 97 12.0 V (battery voltage)
Injector #5
Terminal 2–Terminal 114 5. Disconnect the high-pressure fuel pump
Injector #6 coupler b.
Terminal 2–Terminal 104 6. Connect the tester probes to the
terminals of the high-pressure fuel pump
10. Connect the fuse holder coupler b, and coupler b, and then measure the input
then install the fuse holder a. voltage within 5 seconds after turning the
engine start switch to ON.
“Installing the intake manifold” (6-16). B R/Y
12. Connect the engine ECM coupler c.
13. Connect the fuel injector couplers a. b
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. Red/Yellow (R/Y)–Black (B)
2. Disconnect the low-pressure fuel pump
coupler a. 7. Measure the resistance of the fuel pump
motors.
the low-pressure fuel pump coupler
terminal and ground.
5-37
a
c 5 1
12 7
2 1
17
0
b e
1
2 1
b
a
58 56 2
Low-pressure fuel pump a resistance Wiring harness continuity:
(reference data): a Terminal 1–c Terminal 7 3
0.5–4.0 Ω at 20 °C (68 °F) a Terminal 2–e Terminal 56
High-pressure fuel pump b resistance b Terminal 1–c Terminal 1
(reference data):
0.2–3.0 Ω at 20 °C (68 °F)
b Terminal 2–Ground
e Terminal 58–d Terminal 17
4
8. Remove the intake manifold (STBD). 12. Connect the fuse holder coupler c and
9. Remove the fuse holder c, and then

d, and then install the fuse holder c.
5
disconnect the fuse holder couplers c 13. Install the intake manifold (STBD). See
and d. “Installing the intake manifold” (6-16).
c
14. Connect the engine ECM coupler e.
6
15. Connect the low-pressure fuel pump
coupler a and high-pressure fuel pump
coupler b.
7
Checking the high-pressure fuel
d c pump relay
1. Remove the relay cover and high-pres-
8
10. Disconnect the engine ECM coupler e. sure fuel pump relay a.
9
a 10
e
11. Check the wiring harness for continuity. 2. Check the high-pressure fuel pump relay.
See “Checking the main relay” (5-22).
A
5-38
ELEC
Electrical system
3. Turn the engine start switch to ON, and 2. Turn the engine start switch to ON, and
then measure the input voltage between then measure the input voltage between
the terminal a and ground, and the the vapor shut-off valve coupler terminal
terminal b and ground. and ground.
R/Y
a
High-pressure fuel pump relay input Vapor shut-off valve input voltage:
voltage: Red/Yellow (R/Y)–Ground
Terminal a–Ground 12.0 V (battery voltage)
Terminal b–Ground
12.0 V (battery voltage) 3. Remove the vapor shut-off valve, and
then connect the special service tool a
4. Turn the engine start switch to ON, and to the vapor shut-off valve.
Vacuum/pressure pump gauge set a:
the terminals b and c.
90890-06756
4. Apply the specified negative pressure to

b c the vapor shut-off valve.
Specified negative pressure:
67.0 kPa (0.67 kgf/cm2, 9.7 psi)
5. Check that the vapor shut-off valve

opens and the negative pressure is
released when the battery leads are
connected to the vapor shut-off valve
High-pressure fuel pump relay input terminals. NOTICE: Do not connect
voltage: the battery leads to the vapor shut-off
Terminal b–Terminal c valve terminals for more than a few
12.0 V (battery voltage) seconds.

a
6. Install the high-pressure fuel pump relay
a and relay cover.
Checking the vapor shut-off valve

1. Disconnect the vapor shut-off valve cou-
pler a.
5-39
Fuel control unit and component / Charging unit and component
a a b
2 1
19 0
c
1
73
6. Remove the special service tool a.
7. Measure the resistance between the

2
vapor shut-off valve terminals.
Vapor shut-off valve resistance:
30.0–34.0 Ω at 20 °C (68 °F) Terminal 1–Terminal 73 3
9. Remove the fuse holder b, and then

12. Install the vapor shut-off valve, and then
connect the vapor shut-off valve coupler 4
disconnect the fuse holder coupler b. a.
b
13. Connect the fuse holder coupler b, and
then install the fuse holder b. 5
14. Install the intake manifold (STBD) and
intake silencer. See “Installing the intake
manifold” (6-16).
6
15. Connect the engine ECM coupler c.
b
Charging unit and component
7
10. Disconnect the engine ECM coupler c.
Checking the lighting coil (stator
assembly)
1. Remove the intake manifold (STBD). 8
c 2. Disconnect the lighting coil couplers a
and b.
9
a
b
10
3. Connect the special service tools a and

b. A
5-40
ELEC
Electrical system
TIP:
When measuring the lighting coil output peak
voltage under the cranking (unloaded) condi-
a
tion, remove the clip from the engine shut-off
b
switch to prevent the engine from starting.
7. Disconnect the special service tools a

and b.
8. Disconnect the lighting coil couplers c

a b and d, and then connect the special
service tools a and b.
Test harness (1 pin) a: 90890-06888
Test harness (2 pins) b: 90890-06887
4. Install the intake manifold (STBD). Check

that the connector of the special service
tools a and b are not covered by the c
intake manifold (STBD). See “Installing
the intake manifold” (6-16). d
5. Measure the lighting coil output peak

voltage between all combinations of the
terminals. Replace the stator assembly if
below specification.
STBD a b
9. Repeat steps 4 and 5.

G GG
a b
and b.
B R B 12. Measure the lighting coil resistance.

Lighting coil resistance (reference data):
G (Green)–G (Green)
G/W (Green/White)–G/W (Green/White)
0.1056–0.1584 Ω
Lighting coil output peak voltage:
13. Connect the lighting coil couplers.
Green (G)–Green (G)
Unloaded 14. Install the intake manifold (STBD).
r/min
Cranking 1500 3500 See “Installing the intake manifold” (6-
DC V 6.9 38.0 83.2 16).
5-41
Checking the Rectifier Regulator c b a
Do not connect the battery cables in

reverse. Otherwise, the Rectifier Regula- 0
tor could be damaged.
1. Remove the fuse cover a. 1

2. Measure the Rectifier Regulator output
peak voltage.
a
f
2
d e
5. Remove the fuse holder, and then

remove the Rectifier Regulator couplers 3
g, h, and k.
g
k
4
5
h
6
6. Set the digital circuit tester to the diode
mode, and then check the Rectifier
Rectifier Regulator output peak voltage:
Fuse (100 A)–Ground
Regulator for continuity.
m
7
Loaded
r/min
1500 3500 n
DC V 13.0 13.0
s
p
r
8
t
TIP:
u
Do not use peak voltage adapter B when
measuring the Rectifier Regulator output w
v 9
peak voltage. y
x

A
10
4. Disconnect the Rectifier Regulator B
couplers a, b, c, d, and e and
ground lead f.
A
5-42
ELEC
Electrical system
m Rectifier Regulator continuity

n (testing diode mode):
r s Tester probe Display value
t (reference data)
u p
m
n
y r
A
s
v
w t
x u
p OL
v
B w
x
Rectifier Regulator continuity y
(testing diode mode):
A
Tester probe Display value B
(reference data)
m 0.000 V
n
OL n
p
p
r 0.000 V
s
s
t
t
u
u r
m v OL
v
w
w OL
x
x
y
y
A
A
B
B
m 0.447 V
m
n 0.441 V
p
p 0.447 V
r
r
s
t
t
u
u s
n OL v
v
w OL
w
x
x
y
y
A
A
B
B
OL: Indicates an overload
5-43
Rectifier Regulator continuity Rectifier Regulator continuity

(testing diode mode): (testing diode mode):
Tester probe Display value Tester probe Display value

m
(reference data)
0.446 V

m
(reference data)
0
n 0.447 V n
p 0.446 V p
r r 1
s s OL
u t
t w
v
w OL
u
v
2
x x
y
A
y
A
0.445 V
0.445 V
3
B B OL
m 0.446 V m
n 0.447 V n 4
p 0.446 V p
r r
s
t
s
t
OL 5
u x
v u
w
x
OL v
w 6
y y 0.445 V
A A 0.445 V
B B OL 7
m m
n n
p
r
p
r
8
s OL s
t t
v
u
y
u
OL 9
w v
x w
y
A
0.445 V
0.446 V
x
A
10
B OL B
A
5-44
ELEC
Electrical system
Rectifier Regulator continuity

(testing diode mode): a
Tester probe Display value
2 2
1 1
(reference data)
m
n
D E
p
r
s
t
A OL
u 85 118
v
w
x Wiring harness continuity:
y Terminal 1–Terminal 118
B
m 0.809 V 9. Connect the Rectifier Regulator couplers
n 0.807 V and ground lead, and then install the fuse
p 0.809 V holder.
r OL
s 0.445 V 10. Install the intake manifold (STBD). See
t 0.440 V
B
u 0.443 V
Ignition unit and component
v 0.443 V
Checking the ignition spark
w 0.446 V 1. Remove the ignition coils.
x 0.443 V
y 0.809 V 2. Connect the special service tool a to an
A 0.807 V ignition coil.
TIP:
7. Disconnect the engine ECM couplers D Repeat steps 2–4 for each ignition coil.
and E.
3. Check the ignition spark using the YDIS

E “Stationary test.” WARNING! Do not
touch any of the connections of the
D special service tool.
OK
5-45
Charging unit and component / Ignition unit and component
Ignition tester (spark gap tester) a:

90890-06754 a
4. Disconnect the special service tool a.

0
5. Install the ignition coils.
Checking the ignition coil

1. Disconnect the ignition coil couplers a. c 1
2. Turn the engine start switch to ON, and 6. Check the wiring harness for continuity.
ignition coil coupler. b
2
a
R/Y B 3 2 1
102 101 100
110
98
106
3
a a
c
4
Ignition coil input voltage:

18
5
Red/Yellow (R/Y)–Black (B)

6
then disconnect the engine ECM coupler
b.
7
b
8
9

10
disconnect the fuse holder coupler c.
A
5-46
ELEC
Electrical system
3. Measure the pulser coil output peak
voltage.
Ignition coil #1
Terminal 1–Terminal 106 W/B W/R
Terminal 2–Ground B B
Terminal 3–Terminal 18 G G/W
Ignition coil #2 a a
Terminal 2–Ground
Ignition coil #3
a
Terminal 2–Ground
Ignition coil #4
Terminal 2–Ground a
Ignition coil #5
Terminal 2–Ground
Terminal 3–Terminal 18 Test harness (2 pins) a: 90890-06867
Ignition coil #6
Terminal 1–Terminal 101 Pulser coil output peak voltage:
Terminal 2–Ground White/Red (W/R)–Black (B)
Terminal 3–Terminal 18 Unload
Loaded
r/min ed
7. Connect the fuse holder coupler c, and Cranking 1500 3500
then install the fuse holder a. DC V 7.6 6.9 23.9 25.1

TIP:
• When measuring the pulser coil output
9. Connect the engine ECM coupler b and peak voltage under the cranking (unloaded)
ignition coil couplers a. condition, disconnect the coupler a to pre-
vent the engine from starting.
Checking the pulser coil • When measuring the pulser coil output
1. Disconnect the pulser coil coupler a. peak voltage under the cranking (loaded)
condition, remove the clip from the engine
a shut-off switch to prevent the engine from
starting.
4. Disconnect the special service tool a.
5. Measure the pulser coil resistance.

Pulser coil resistance:
White/Red (W/R)–Black (B)
396.0–594.0 Ω at 20 °C (68 °F)
2. Connect the special service tool a.
6. Disconnect the engine ECM couplers b
and c.
5-47
TIP:
• Check the air temperature sensor when the
engine is cold.
c • When checking the air temperature sensor,
remove the top cowling and do not start the
0
b engine.
4. Disconnect the air temperature sensor 1

coupler a.
then measure the input voltage at the air 2
a temperature sensor coupler.
2 1 a
B B/Y
3
b c
29
4
84 5
Air temperature sensor input voltage:
Black/Yellow (B/Y)–Black (B)
4.75–5.25 V 6
Terminal 2–Terminal 84 6. Turn the engine start switch to OFF.
8. Connect the engine ECM couplers b
and c.
7. Remove the air temperature sensor.
7
8. Place the air temperature sensor in a
9. Connect the pulser coil coupler a. container of water and heat the water
Checking the air temperature sensor

slowly. 8
1. Measure the ambient temperature.
2. Connect the YDIS to display “Intake

temperature” (air temperature).
9
3. Check that the difference between the
ambient temperature and the displayed
intake temperature is within ± 5 °C
10
(± 41 °F).
9. Measure the air temperature sensor

resistance at the specified water
temperatures.
A
5-48
ELEC
Electrical system
Air temperature sensor resistance

(reference data): B O
2.21–2.69 kΩ at 20 °C (68 °F)
a
0.32 kΩ at 80 °C (176 °F)
b Air pressure sensor input voltage:

Orange (O)–Black (B)
4.75–5.25 V
5. Remove the air pressure sensor.

6. Connect the special service tools a and
b b.
a
a
65
b
2 1
77

Terminal 2–Terminal 77 P/G
B
O
12. Connect the engine ECM coupler b. B
G/W G
b
13. Install the air temperature sensor, and
then connect the air temperature sensor
coupler a.
Checking the air pressure sensor

1. Remove the intake silencer. Vacuum/pressure pump gauge set a:
90890-06756
2. Disconnect the air pressure sensor Test harness (3 pins) b:
coupler a. 90890-06869
3. Turn the engine start switch to ON, and 7. Turn the engine start switch to ON.
then measure the input voltage at the air
8. Apply negative pressure to the air
pressure sensor coupler.
pressure sensor slowly, and then
measure the output voltage at the
specified pressure.
5-49
Air pressure sensor output voltage Checking the engine temperature

(reference data): sensor
Pink/Green (P/G)–Black (B) 1. Disconnect the engine temperature sen-
sor coupler a.
3.21 V at –20.0 kPa
(–0.20 kgf/cm2, –2.9 psi)
0
2.16 V at –46.7 kPa 2. Turn the engine start switch to ON, and
(–0.467 kgf/cm2, –6.8 psi) then measure the input voltage at the

engine temperature sensor coupler.
1
a
B B/Y
and b.
2
3
b
Engine temperature sensor input voltage:
Black/Yellow (B/Y)–Black (B) 4
4.75–5.25 V

5
12. Check the wiring harness for continuity. 4. Remove the engine temperature sensor.
b
5. Place the engine temperature sensor in a
container of water and heat the water 6
a slowly.
3 2 1
77
70
74
7
8
9
6. Measure the engine temperature sensor
13. Connect the engine ECM coupler b. resistance.
14. Install the air pressure sensor, and then

Engine temperature sensor resistance 10
(reference data):
connect the air pressure sensor coupler 4.2–4.9 kΩ at 5 °C (41 °F)
a. 1.9–2.1 kΩ at 25 °C (77 °F)
0.166–0.204 kΩ at 100 °C (212 °F)
15. Install the intake silencer.
A
5-50
ELEC
Electrical system
PORT
b
P B
8. Check the wiring harness for continuity. Thermoswitch input voltage:

Pink (P)–Black (B)
b 4.75–5.25 V
a 3. Turn the engine start switch to OFF.

64
2 1 4. Remove the thermoswitches.

77
5. Place the thermoswitches in a container
of water and heat the water slowly.

Terminal 2–Terminal 77 P B
9. Connect the engine ECM coupler b.
10. Install the engine temperature sensor,

and then connect the engine temperature
sensor coupler a.
6. Check the thermoswitches for continuity
Checking the thermoswitch at the specified temperatures. Replace if
1. Disconnect the thermoswitch connectors out of specification.
a and b.
f
f
then measure the input voltage at the f
g
thermoswitch connectors. c
h
e
STBD e
a
P B d
c Temperature
d Time
e No continuity
f Continuity
Thermoswitch continuity temperature:
g: 84–90 °C (183–194 °F)
h: 68–82 °C (154–180 °F)
5-51
7. Disconnect the engine ECM coupler k.
k
0
1
Knock sensor resistance:
8. Check the wiring harness for continuity. 504.0–616.0 kΩ at 20 °C (68 °F) 2
k
P B
3
71
77 b
4
Pink (P)–Terminal 71
5
Black (B)–Terminal 77 4. Check the wiring harness for continuity.
9. Connect the engine ECM coupler k. b 6

10. Install the thermoswitches, and then a
connect the thermoswitch connectors.
Checking the knock sensor

1
7
83
1. Disconnect the knock sensor coupler a.
8
a Wiring harness continuity:
5. Connect the engine ECM coupler b and

9
knock sensor coupler a.
Checking the engine shut-off switch

1. Disconnect the engine start switch cou-
10
2. Measure the knock sensor resistance. pler or main switch coupler.

then check the engine shut-off switch for
continuity between the terminals a and
b.
A
5-52
ELEC
Electrical system
A B
ON ON
OFF START OFF a
b b
a
a
Starter relay input voltage:

Terminal a–Ground
4. Connect the tester probes between the

terminals b and c, and then turn the
engine start switch to START and
measure the input voltage.
A Engine start switch
B Main switch b
Switch Terminal
position a b c
Clip removed C C
Clip installed
4. Connect the engine start switch coupler

or main switch coupler. Starter relay input voltage:
Terminal b–Terminal c
Starting unit and component 12.0 V (battery voltage)
Checking the starter relay
5. Install the starter relay a and relay
1. Remove the relay cover and starter
cover.
motor relay a.
Checking the engine start switch and
main switch
1. Disconnect the engine start switch cou-
a
pler or main switch coupler.
2. Check the engine start switch or main

switch for continuity at the engine start
switch coupler or main switch coupler.
2. Check the starter motor relay. See

“Checking the main relay” (5-22).

terminal a and ground.
5-53
Ignition unit and component / Starting unit and component
A B a
ON ON
OFF START OFF
b
0
c d
b d b
d
a
a 1
e
c e f
c
c d
2
Switch Terminal f
position a b c d e e
h
3
OFF C C g
ON C C
START
(*1)
C C C
Engine start/stop button continuity:
Button pushed in: 4
A : Terminal a–Terminal b
A Engine start switch B : Terminal c–Terminal d
B Main switch
(*1) Engine start switch only
C : Terminal e–Terminal f
D : Terminal g–Terminal h
5
Free:
3. Connect the engine start switch coupler No continuity
or main switch coupler.
A Single sub station 6
Checking the engine start/stop B PORT
button C STBD
1. Disconnect the engine start/stop button
coupler.
D Center 7
3. Connect the engine start/stop button
2. Check the engine start/stop button for coupler.
continuity at the engine start/stop button
Checking Y-COP
8
coupler.
1. Disconnect the Y-COP coupler a, and
then measure the Y-COP input voltage.
9
10
A
5-54
ELEC
Electrical system
Y-COP input voltage:

Red (R)–Ground
2. Connect the Y-COP coupler a.
5-55
Starting unit and component / Starter motor
Starter motor
20 21
1
1
1
9 4
0
21
2 14
3 9
1
10
4
5
11 2
4
15 16
6
17 3
22
12
18
4
23
4
19
7
7 13 4 24 5
5 25 6
8
26
No. Part name Q’ty Remarks 7

1 Brush spring 4
2 Brush assembly 1
3
4
Brush holder assembly
Washer set
1
1
8
5 Starting motor gear assembly 1
6 Bracket 1
7
8
Screw
Bolt
2
2
M4 16 mm
M5 127 mm
9
9 Planetary gear 3
10 Outer gear 1
11
12
Plate
Stator
1
1
10
13 Armature 1
14 Pinion assembly 1
15 Bracket 1
16 Bracket 1
17 Gasket 1 39
A
5-56
ELEC
Electrical system
20 21
1
1
9 4
1
21
2 14
3 9
10
4
5
11
4
15 16
17
6
22
12
4
18
23
19
7
7 13 4 24
5 25
8
26
No. Part name Q’ty Remarks

18 Bracket assembly 1
19 Pinion shaft 1
20 Cover 1
21 Bolt 2 M6 35 mm
22 Lever assembly 1
23 Seal set 1 39
24 Magnet switch 1
25 Washer 1
26 Nut 1
5-57
Starter motor
Removing the starter motor Checking the magnet switch
1. Connect the tester probes to the magnet
switch terminals a and b.
Before removing the starter motor, make
sure to disconnect the negative battery 2. Connect the negative battery cable a
to the starter motor body.
0
terminal.
3. Connect the lead b to the magnet switch
1. Remove the intake manifold (STBD). terminal c. 1
2. Remove the starter motor from the power 4. Connect the positive battery cable c to
unit. See “Removing the starter motor” the starter motor lead b, and then check
(7-31). the magnet switch continuity between the 2
terminals a and b. Replace if out of
Checking the starter motor operation specification. NOTICE: Do not connect
1. Connect the positive battery cable a to
the magnet switch terminal a, and then
the lead to the battery for more than 1
second.
3
connect the negative battery cable b to
the starter motor body.
a
2. Connect the lead c to the magnet switch
b 4
terminal b.
a c
3. Connect the lead c to the positive
battery terminal, and then check the 5
starter motor operation. WARNING! Do b
c
not touch the starter motor pinion.
a a c
a 6
b
c
b
Magnet switch terminal
7
Battery lead
a b
b
Connect
Disconnect
8
b TIP:
c
a The starter motor pinion should be pushed
out while the magnet switch is on.
9
TIP:
• Check the starter motor operation for a few
Checking the starter motor pinion
10
seconds.
• If the starter motor is disassembled for Before checking the starter motor pinion,
maintenance, make sure to check the oper- make sure to disconnect the battery
ation again after assembling it. cables.
4. Disconnect the negative and positive

battery cables from the battery terminals.
1. Check the pinion teeth. Replace the pin-
ion if cracked or worn.
A
5-58
ELEC
Electrical system
2. Turn the pinion counterclockwise to 4. Remove the rubber seal c, lever d, and
check that it operates smoothly and turn pinion shaft assembly e.
it clockwise to check that it locks in place.
Disassembling the starter motor

1. Remove the magnet switch a and spring
a.
a d
e c
a
5. Push the pinion stopper e down, and

2. Remove the stator assembly b. then remove the clip f.
g
f
h
f e
b e
3. Remove the plate b, outer gear c and Pipe f: (commercially available)

planetary gears d. g: 18.0mm (0.71 in)
h: 13.0mm (0.51 in)
b
6. Remove the pinion stopper k and pinion
assembly g.
c k
d g
5-59
Starter motor
7. Remove the E-clip m, and then remove
the shim n, brackets h, gasket i, and
shim p. k
k
0
p
n l
h
r 1
r
2
m i l
Checking the armature (starter

motor) 3
1. Check the commutator. Clean using
8. Remove the stator j. 600-grit sandpaper and compressed air if
9. Remove the armature k along with the

dirty.
4
brush holder assembly l from the
bracket m.
5
j
k
l 6
2. Measure the commutator diameter a.
Replace the armature if below
7
m specification.
8
10. Remove the plate r, and then remove
the armature k from the brush holder
assembly l.
9
a 10
Commutator standard diameter a:
29.0 mm (1.14 in)
Wear limit: 28.0 mm (1.10 in)
3. Measure the commutator undercut b.
A
5-60
ELEC
Electrical system
Brush holder assembly continuity:

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

Replace the brush assembly if below
specification.
Commutator standard undercut b:
0.5–0.8 mm (0.02–0.03 in)
4. Check the armature for continuity.

Replace if out of specification.
g f
c
Brush standard length f:
d e f
15.5 mm (0.61 in)
Wear limit g: 9.5 mm (0.37 in)
Assembling the starter motor

Armature continuity:
c d e f
• Do not apply grease or oil to the commu-
C C
tator of the armature.
Checking the brush holder • Do not reuse a gasket or seal set, always
1. Check the brush holder assembly for replace it with a new one.
continuity. Replace if out of specification.
1. Push the brushes a into the holders,
and then install the armature a to the
e
brush holder assembly b.
a
2. Install the plate b.
c b
d
c a
d b
5-61
Starter motor
a
g
a h
0
g e
a
b 1
k f
b a b
2
3. Install the armature a along with the 5. Install the pinion assembly h, pinion
brush holder assembly b to the bracket stopper m, and clip n. 3
c, and then install the stator d.
d
m
m
4
h n h
c
5
a h
b
b d 6
e
c
6. Install the pinion shaft assembly p, the 7
lever r, and a new rubber seal s.
c f p
r s 8
TIP:
Align the holes c and d in the plate b with
the holes e and f in the bracket c. 9
4. Install the shim g, the brackets e, a new
gasket f, and the shim h, and then
install the E-clip k onto the pinion shaft
10
r
g. p
7. Install the outer gear i, planetary gears

j, and plate k.
A
5-62
ELEC
Electrical system
k “Installing the intake manifold” (6-16).
6Y9 Multifunction Color Gauge

j sensor
Checking the water pressure sensor
i
(optional)
1. Disconnect the water pressure sensor
coupler a.

water pressure sensor coupler.
8. Install the stator assembly t. B O
Water pressure sensor input voltage:

t Orange (O)–Black (B)
4.75–5.25 V
3. Remove the water pressure sensor, and

then connect the pressure pump a and
9. Install a new gasket u, the spring v, and special service tool b.
the magnet switch l.
4. Apply positive pressure to the water
v pressure sensor slowly, and then
measure the output voltage at the
u specified pressures.
l
v
L/B
u B
O
G/W B G
l
b
Installing the starter motor a

1. Install the starter motor to the power unit.
See “Starter motor” (7-30). b
5-63
Starter motor / 6Y9 Multifunction Color Gauge sensor
8. Install the water pressure sensor, and
Pressure pump a:
then connect the water pressure sensor
coupler a.
Test harness (3 pins) b:
90890-06869
and c.
0
Water pressure sensor output voltage
(reference data):
Checking the speed sensor
Blue/Black (L/B)–Black (B)
2.5 V at 392.0 kPa
(optional) 1
1. Disconnect the speed sensor coupler a.
(3.92 kgf/cm2, 56.8 psi)
4.5 V at 784.0 kPa
(7.84 kgf/cm2, 113.7 psi)
then measure the input voltage at the 2
5. Turn the engine start switch to OFF, and speed sensor coupler.
b and pressure pump a. 3
6. Disconnect engine ECM couplers b and a
c.
B O
4
c 5
b
6
Speed sensor input voltage:
7. Check the wiring harness for continuity. Orange (O)–Black (B)
a
4.75–5.25 V 7
3. Remove the speed sensor, and then
connect the pressure pump a and
3 2 1
special service tool b. 8
b c 4. Apply positive pressure to the speed
sensor slowly, and then measure the
output voltage at the specified pressures. 9
48 79 77
10
A
5-64
ELEC
Electrical system
L
B b
O
G/W B G a
66
b 3 2 1
79 77
a Wiring harness continuity:

Pressure pump a:
(commercially available) 8. Install the speed sensor, and then
Test harness (3 pins) b: connect the speed sensor coupler a.
90890-06869
9. Connect the engine ECM coupler b.
Speed sensor output voltage
(reference data): Outboard motor and Digital
Blue (L)–Black (B) Electronic Control connection
2.5 V at 392.0 kPa Checking the extension wiring
(3.92 kgf/cm2, 56.8 psi) harness
4.5 V at 784.0 kPa 1. Check the extension wiring harness for
(7.84 kgf/cm2, 113.7 psi) continuity. Check the wire terminal num-
bers from a to r.
b and pressure pump a.
6. Disconnect the engine ECM coupler b. abc abc

defg defg
hkmn hkmn
pr pr
Checking the main wiring harness

1. Disconnect the main wiring harness cou-
pler a.
5-65
6Y9 Multifunction Color Gauge sensor /
Outboard motor and Digital Electronic Control connection / PTT electrical system
2. Disconnect the engine ECM couplers b
and c.
a Terminal 2–b Terminal 91
c
a Terminal 4–c Terminal 36
0
a Terminal 6–Ground
b a Terminal 8–c Terminal 53
1

a Terminal 12–d Terminal 5 2
disconnect the fuse holder coupler d. 6. Connect the fuse holder coupler d, and 3
then install the fuse holder a.
a
and c. 4
8. Connect the main wiring harness coupler
a.
5
d PTT electrical system
Checking the PTT relay
5. Check the wiring harness for continuity. 1. Measure the input voltage between the
terminals a and b.
6
b
b
a
38 36 a
7
4 3 2
53
8
12
7
11
6
10
5
9
c
8
15 14
93 92 91 90
PTT relay input voltage:

9
Terminal a–Terminal b
d
5 4 3 2. Disconnect the PTT relay coupler c.
10
PTT relay coupler terminal and ground.
A
5-66
ELEC
Electrical system
7. Connect the positive battery lead to the
R
connector g, connect the negative
battery lead to the connector f, and
then check the PTT relay for continuity.
c Lg
R
Sb
W/R B W/B a
PTT relay input voltage: f g h

Red (R)–Ground e
d a
4. Disconnect the PTT relay leads and PTT

motor leads. NOTICE: Before
disconnecting the PTT relay
terminals, make sure to disconnect
b
the negative battery terminal.
PTT relay continuity:
5. Connect the special service tool a.
a b d e
C C
6. Check the PTT relay for continuity.
Replace if out of specification. C C
8. Connect the positive battery lead to the

Lg connector g, connect the negative
R
Sb battery lead to the connector h, and
W/R B W /B then check the PTT relay for continuity.
a
h
f e Lg
g d a R
Sb
W/R B W/B a
f g h
b d a e
Test harness (3 pins) a:

90890-06791
PTT relay continuity:

b
a b d e f g h
C C PTT relay continuity:
C C a b d e
C C C C
C C C C
5-67
PTT electrical system
10. Remove the fuse holder b, and then 16. Install the intake manifold (STBD). See
disconnect the fuse holder coupler k. “Installing the intake manifold” (6-16).
17. Connect the engine ECM coupler m.

b
Checking the PTT switch (bottom
0
cowling)
1. Disconnect the PTT switch coupler a.
1
k PTT switch coupler terminal and ground.
11. Disconnect the engine ECM coupler m.

A
R 2
m 3
a 4
B

R
5
c m
6
3 2 1 a
113 112 A Regular rotation model 7

B Counter rotation model
k PTT switch input voltage:

Red (R)–Ground
8
16
3. Check the PTT switch for continuity.
Replace if out of specification. 9
10
b c d
13. Connect the PTT relay coupler c.
Sb
14. Connect the PTT relay leads, PTT motor R
Lg
leads, and PTT relay coupler.
15. Connect the fuse holder coupler k, and

then install the fuse holder b.
A
5-68
ELEC
Electrical system
Switch Terminal Wiring harness continuity:

position b c d Terminal 1–Terminal 54
UP C C Terminal 2–Terminal 16
Free Terminal 3–Terminal 45
DN C C
8. Connect the fuse holder coupler e, and
4. Remove the intake manifold (STBD). then install the fuse holder a.
5. Remove the fuse holder a, and then 9. Install the intake manifold (STBD). See
disconnect the fuse holder coupler e. “Installing the intake manifold” (6-16).
10. Connect the engine ECM coupler f.

a
11. Connect the PTT switch coupler a.
Checking the trim sensor

1. Disconnect the trim sensor coupler a,
and then remove the trim sensor.
6. Disconnect the engine ECM coupler f.
f
2. Turn the trim sensor lever b from the
position c to the position d, and then
measure the resistance as it gradually
changes.
c
a f
b
3 2 1
45 B P
54
d
e
16
Trim sensor resistance:

247.6–387.6 Ω at c
9.0–11.0 Ω at d (setting resistance)
5-69
PTT electrical system
3. Disconnect the engine ECM couplers e
and f.
0
f
e 1

2
a
2 1
3
e f 4
27
5
77
6
7
5. Connect the engine ECM couplers e
and f.
6. Install the trim sensor, and then connect 8

the trim sensor coupler a. See
“Adjusting the trim sensor” (9-29).
9
10
A
5-70
FUEL
Fuel system 6
Hose routing ...................................................................... 6-1

Fuel hose and blowby hose ....................................................... 6-1
Vapor gas hose ......................................................................... 6-2
Cooling water hose .................................................................... 6-4
Fuel system ....................................................................... 6-6

Reducing the fuel pressure ....................................................... 6-6
Disconnecting the quick connector ............................................ 6-6
Measuring the fuel pressure ...................................................... 6-7
Checking the pressure regulator ............................................... 6-8
Fuel filter assembly ........................................................... 6-9

Removing the fuel filter assembly ........................................... 6-11
Checking the fuel filter assembly ............................................. 6-11
Disassembling the fuel filter assembly .................................... 6-12
Checking the fuel filter element ............................................... 6-12
Checking the fuel cup assembly .............................................. 6-12
Assembling the fuel filter assembly ......................................... 6-12
Installing the fuel filter assembly ............................................. 6-12
Intake manifold ................................................................ 6-14

Removing the intake silencer .................................................. 6-15
Removing the intake manifold ................................................. 6-15
Checking the intake manifold .................................................. 6-16
Installing the intake manifold ................................................... 6-16
Installing the intake silencer .................................................... 6-18
Throttle body ................................................................... 6-20

Removing the throttle body and surge tank ............................. 6-22
Checking the ETV ................................................................... 6-23
Installing the throttle body and surge tank ............................... 6-23
Canister ............................................................................ 6-25

Removing the canister ............................................................. 6-26
Checking the canister .............................................................. 6-26
Checking the canister check valve .......................................... 6-26
Installing the canister ............................................................... 6-27
Low-pressure fuel pump ................................................ 6-29

Removing the low-pressure fuel pump .................................... 6-30
Checking the low-pressure fuel pump ..................................... 6-30
Checking the primer pump ...................................................... 6-30
Installing the low-pressure fuel pump ...................................... 6-31
Vapor separator ............................................................... 6-33
Draining the fuel ...................................................................... 6-35
Removing the vapor separator ................................................ 6-35
Checking the vapor shut-off valve ........................................... 6-36
Installing the vapor separator .................................................. 6-36 0
Vapor separator and high-pressure fuel pump ............ 6-37
Disassembling the vapor separator ......................................... 6-39
Checking the high-pressure fuel pump .................................... 6-40
1
Checking the vapor separator ................................................. 6-40
Checking the check valve ........................................................ 6-40
Assembling the vapor separator .............................................. 6-40 2
Fuel injector ..................................................................... 6-43
Removing the fuel injector ....................................................... 6-44
Checking the fuel rail ............................................................... 6-44 3
Installing the fuel injector ......................................................... 6-44
4
5
6
7
8
9
10
A
FUEL
Fuel system
Hose routing
Fuel hose and blowby hose
d g i
g
e
h
f
m h
b e
f
h
d
c c
b
a
a Fuel hose (joint to fuel filter assembly) a Primer pump

b Fuel hose (fuel filter assembly to joint) b Joint
c Fuel hose (joint to low-pressure fuel c Fuel filter assembly
pump) d Joint
d Fuel hose (low-pressure fuel pump to e Low-pressure fuel pump
vapor separator) f Vapor separator
e Fuel hose (vapor separator to joint) g Joint
f Fuel hose (joint to quick connector) h Quick connector
g Fuel hose (joint to quick connector) k Fuel rail
h Fuel hose (vapor separator to joint) m Fuel injector
i Blowby hose (cylinder head cover to n Pressure regulator
intake silencer) p Fuel cooler
6-1
Hose routing
Vapor gas hose

h
bd e
0
c 1
g
a 2
b
3
4
k
a
l e i 5
h
6
f
7
a g
f
j
b
f 8
d c
a Vapor gas hose (vapor separator to canis- h Vapor gas hose (check valve to bottom
9
ter tank port) cowling)
b Vapor gas hose (canister purge port to i Vapor gas hose (atmosphere to check
joint)
c Vapor gas hose (joint to vapor shut-off
valve)
j Vapor gas hose (check valve to joint)
10
valve) k Pressure regulator hose (pressure regula-
d Vapor gas hose (vapor shut off-valve to tor to surge tank)
joint) l Air pressure sensor hose (surge tank to air
e Vapor gas hose (joint to surge tank) pressure sensor)
f Vapor gas hose (canister atmospheric port
to joint)
g Vapor gas hose (joint to check valve) A
6-2
FUEL
Fuel system
bd e
g
a
k
a
l e i
a g
f
j
b
f
d c
a Vapor separator
b Joint
c Canister
d Joint
e Vapor shut-off valve
f Check valve
g Pressure regulator
h Air pressure sensor
6-3
Hose routing
Cooling water hose

f c
0
1
p
2
a
c g f
3
b
4
a
e c b a b h
c
5
q
i
6
o e
j
n k
m
7
l
b
e
8
d
a d r
a Cooling water hose (cylinder block to oil g Cooling water hose (thermostat cover
9
cooler) [STBD] to joint)
b Cooling water hose (cylinder block to fuel h Cooling water hose (joint to Rectifier Reg-
cooler)
c Cooling water pilot hose (fuel cooler to oil
ulator)
i Cooling water hose (Rectifier Regulator to
10
cooler) joint)
d Cooling water hose (oil filter bracket to cyl- j Cooling water hose (joint to joint)
inder block) k Cooling water hose (joint to cooling water
e Cooling water hose (oil cooler to oil filter outlet)
bracket) l Cooling water hose (flushing hose adapter
f Cooling water hose (oil cooler to joint) to joint)
A
6-4
FUEL
Fuel system
f c
a p
c g f
e c b a b h
c
q
i
o e
j
n k
m
l
e
b
d
a d r
m Cooling water hose (joint to joint) a Oil cooler

n Cooling water hose (joint to cylinder block b Fuel cooler (vapor separator)
[PORT]) c Rectifier Regulator
o Cooling water hose (joint to cylinder block d Cooling water outlet (on the bottom cowl-
[STBD]) ing)
p Cooling water hose (thermostat cover e Flushing hose adapter
[PORT] to cylinder block)
q Cooling water hose (thermostat cover
[STBD] to joint)
r Cooling water hose (joint to cylinder block)
6-5
Hose routing / Fuel system
Fuel system Disconnecting the quick connector
Reducing the fuel pressure
Before servicing the high-pressure fuel

Before disconnecting the quick connec-
tor, reduce the fuel pressure. Otherwise, 0
line or vapor separator, make sure to pressurized fuel could spray out.
reduce the fuel pressure in the fuel line.
Otherwise, pressurized fuel could spray
out.
1
2. Wrap a rag around the quick connector
1. Start the engine.
a, and then push the quick connector
tab a toward the stopper b.
2
2. Remove the fuse holder cover a, and
then remove the fuse (15 A) b. NOTICE: Do not push the quick
a
connector tab past the stopper.
Otherwise, the quick connector could 3
be damaged.
STBD
4
5
a
b
6
100A
100A
a
20
15
30
30
10
15
10
7
TIP:
After removing the fuse, wait until the engine PORT 8
stalls.
3. Disconnect the quick connector a from
the fuel rail.
3. After the engine stalls, crank the engine 2
or 3 times.
9
5. Install the fuse (15 A) b, and then install

a 10
the fuse holder cover a.
c
A
6-6
FUEL
Fuel system
TIP:
• After disconnecting the quick connector a,
be careful not to lose the retainer c.
• Cover the quick connector and fuel rail with a
a plastic bag to prevent damage and to pro-
tect them from dirt.
Measuring the fuel pressure

the fuel pressure” (6-6). a
2. Disconnect the quick connector from the

b
fuel rail. See steps 2 and 3 in
“Disconnecting the quick connector” (6- Fuel pressure gauge b: 90890-06786
6).
3. Connect the special service tool a to the then measure the fuel pressure within 5
quick connector and the fuel rail. seconds.
Fuel pressure (reference data):
330.0 kPa (3.30 kgf/cm2, 47.9 psi)
a TIP:
• The fuel pressure will decrease 5 seconds
after the engine start switch is turned to
ON.
• The high-pressure fuel pump does not
operate when the engine start switch is
Fuel pressure gauge adapter a: turned to ON again within 10 seconds after
90890-06842 turning the engine start switch to OFF.
4. Connect the special service tool b. 6. Start the engine and warm it up until the
WARNING! To prevent fuel from engine idle speed stabilizes at 650–750
leaking out, screw in the gauge gently r/min.
until it is connected firmly. Also, make
sure that the drain screw a is 7. Measure the fuel pressure.
tightened securely, before measuring
Fuel pressure (reference data):
the fuel pressure.
280.0 kPa (2.80 kgf/cm2, 40.6 psi)
at 700 r/min

6-7
Fuel system
Vacuum/pressure pump gauge set b:
and b. WARNING! Before
90890-06756
disconnecting the special service
tools, cover the end of the hose using
a clean and dry rag. Also, make sure
that the drain screw a is tightened
5. Block the end of the pressure regulator
hose a using a rubber plug. 0
securely, before measuring the fuel 6. Start the engine and let it idle.
pressure.
7. Check that the fuel pressure is reduced 1
10. Connect the quick connector to the fuel when negative pressure is applied to the
rail. pressure regulator.
11. After measuring the fuel pressure, cover 8. Turn the engine start switch to OFF. 2
the end of the hose with a clean and dry
rag so that the hose end is pointing 9. Disconnect the special service tool b,
down. Loosen the drain screw to drain
the remaining fuel from the hose and the
and then connect the pressure regulator
hose a.
3
gauge. WARNING! When storing the
fuel pressure gauge, make sure that 10. Reduce the fuel pressure. See “Reducing
the drain screw is tightened securely. the fuel pressure” (6-6).
4
Checking the pressure regulator 11. Disconnect the special service tools. See
1. Reduce the fuel pressure. See “Reducing steps 9–11 in “Measuring the fuel
the fuel pressure” (6-6). pressure” (6-7). 5
2. Disconnect the quick connector from the
fuel rail. See steps 2 and 3 in
“Disconnecting the quick connector” (6- 6
6).
3. Connect the special service tools. See

steps 3 and 4 in “Measuring the fuel 7
pressure” (6-7).
4. Disconnect the pressure regulator hose

a, and then connect the special service
8
tool b to the pressure regulator c.
c a
9
10
b A
6-8
FUEL
Fuel system
9
8
6 6
5
6
12 10
11
12
6
7 14
15
16 13
4
17
3 18
2
1
5 N·m (0.5 kgf·m, 3.7 ft·lb)

1 Joint 1
2 Clamp 1 39
3 Hose 1
4 Holder 1
5 Cover 1
6 Bolt 4 M6 × 16 mm
7 Holder 1
8 Bracket 1
9 Bolt 2 M6 × 25 mm
10 Grommet 2
11 Collar 2
12 Plastic tie 2
13 Fuel filter assembly 1
14 O-ring 1 39
15 Fuel filter element 1
16 Fuel cup assembly 1
17 Clip 1
6-9
5
6 6
8 0
12
6
10
1
11
12
2
6
7 14
3
15
16 13
4
17 4
3 18
2
1
5 N·m (0.5 kgf·m, 3.7 ft·lb)
5
6
18 Float 1
8
9
10
A
6-10
FUEL
Fuel system
Removing the fuel filter assembly
Cover the fuel components using a rag to
prevent fuel from spilling out.
1. Disconnect the water detection switch

coupler a. d
Checking the fuel filter assembly

1. Connect the special service tool a to the
2. Remove the cover a. fuel inlet a.
2. Block the fuel outlet b using a rubber

plug b, and then apply the specified
positive pressure. Replace the O-ring,
fuel cup assembly, or fuel filter assembly
if the specified pressure cannot be
maintained for 15 seconds or more.
3. Disconnect the fuel hoses b and c. b
a b
b a b
c
90890-06756
Specified positive pressure:

200.0 kPa (2.00 kgf/cm2, 29.0 psi)

fuel outlet b.
4. Remove the bracket d and fuel filter
assembly e.
6-11
4. Block the fuel inlet a using a rubber plug Checking the fuel cup assembly
b, and then apply the specified negative 1. Check the fuel cup assembly. Clean
pressure. Replace the O-ring, fuel cup using straight gasoline if there is foreign
assembly, or fuel filter assembly if the material or replace if cracked.
specified pressure cannot be maintained
for 15 seconds or more.
NOTICE: When cleaning the fuel cup 0
assembly, do not remove the clip and
float.
2. Check the water detection switch. See 1

“Checking the water detection switch” (5-
a 34).
Assembling the fuel filter assembly 2

1. Install the fuel filter element a, a new O-
b b
ring b, and the fuel cup assembly c,
a
and then tighten the fuel cup assembly c
to the specified torque. NOTICE: Do not
3
reuse an O-ring, always replace it with
a b a new one.
4
Specified negative pressure:
80.0 kPa (0.80 kgf/cm2, 11.6 psi) a
Disassembling the fuel filter 5

assembly b
1. Remove the fuel cup assembly a, O-ring
b, and fuel filter element c. 6
c
c
7
b
Fuel cup assembly c:
5 N·m (0.5 kgf·m, 3.7 ft·lb) 8
Installing the fuel filter assembly
a
1. Install the fuel filter assembly a to the
bracket b, and then install the bracket
9
b.
Checking the fuel filter element 10

1. Check the fuel filter element. Replace if
there is dirt or residue.
A
6-12
FUEL
Fuel system
2. Connect the fuel hoses c and d, and

then fasten them using the plastic ties e.
c
d
3. Install the cover f.
4. Connect the water detection switch

coupler a.
6-13
Fuel filter assembly / Intake manifold
Intake manifold
7 N·m (0.7 kgf·m, 5.2 ft·lb) 2
1
a 24 N·m (2.4 kgf·m, 17.7 ft·lb)
b 24 N·m (2.4 kgf·m, 17.7 ft·lb) 0
5
UP 6
12
4 3 7 1
14 8
12 16
2
12
8 3
9
15 12
4
9 14
12
10 11
5
12
12
a 11 N·m (1.1 kgf·m, 8.1 ft·lb)
11 10 6
b 11 N·m (1.1 kgf·m, 8.1 ft·lb) 15 13 13

1 Intake silencer 1
2 Intake silencer bolt 2 M6 × 20 mm
3
4
Joint
Plastic tie
1
1
8
5 Grommet 1
6 Air temperature sensor 1
7
8
Flywheel magnet cover
Intake manifold assembly
1
2
9
9 Gasket 2 39
10
11
Intake manifold
Gasket
2
2 39 10
12 Holder 9
13 Holder 2
14 Intake manifold bolt 8 M8 × 40 mm
15 Intake manifold bolt 10 M6 × 35 mm
16 Blowby hose 1
A
6-14
FUEL
Fuel system
Removing the intake silencer Removing the intake manifold
1. Disconnect the air temperature sensor 1. Remove the caps a, and then remove
coupler a. the PTT motor leads a.
2. Remove the PTT motor leads a from the

holder b.
a
a
2. Remove the blowby hose a. a
3. Remove the fuel injector lead b and

thermoswitch lead c from the holders
c.
STBD
3. Remove the intake silencer b and air
temperature sensor c.
c
4. Remove the plastic tie d, and then
remove the joint e. b
c
b
4. Remove the fuel injector lead d from the

e holders d.
6-15
Intake manifold
PORT STBD
0
d
d
1
2
f
5. Remove the main wiring harness e from Checking the intake manifold
the holders e. 1. Check the intake manifolds. Replace if 3
cracked or deformed.
Installing the intake manifold

4
Do not reuse a gasket, always replace it
e e
with a new one. 5
1. Install new gaskets a and b onto the
intake manifolds. Check that the tabs on
the gaskets a and b are properly and 6
firmly fitted into the grooves a and b in
the intake manifold.
6. Remove the intake manifolds f. a 7

PORT
8
a
9
f 10
b
b
2. Install the intake manifolds c and intake

manifold bolts d and e temporarily. A
6-16
FUEL
Fuel system
4. Tighten the intake manifold bolts e to
PORT
the specified torque in 2 stages and in
the order a, b, and so on.
PORT STBD
d
de
bc
ab e
e ea
c cd
e
Intake manifold bolt e (M6):
STBD 1st: 11 N·m (1.1 kgf·m, 8.1 ft·lb)
2nd: 11 N·m (1.1 kgf·m, 8.1 ft·lb)
TIP:
Tighten the intake manifold bolts e to the
same torque in both stages.
5. Fasten the main wiring harness c using

the holders f.
d
e c
3. Tighten the intake manifold bolts d to

the specified torque in 2 stages and in
the order a, b, and so on. c f
STBD PORT
c c d
d a a
b b
6. Fasten the fuel injector lead d using the
d d holders g.
Intake manifold bolt d (M8):

1st: 24 N·m (2.4 kgf·m, 17.7 ft·lb)
2nd: 24 N·m (2.4 kgf·m, 17.7 ft·lb)
TIP:
Tighten the intake manifold bolts d to the
6-17
Intake manifold
10. Route the PTT motor leads g through
PORT
the guide, and then fasten them using the
holder l.
g
0
g l
d
1
2
11. Install the drain hose m to the intake
7. Fasten the fuel injector lead e and manifold.
thermoswitch lead f using the holders 3
h.
STBD
4
f
m
h
e
5
Installing the intake silencer
1. Install the joint a, and then fasten it 6
using the plastic tie b.
2. Install the intake silencer c and air

temperature sensor d, and then tighten 7
8. Connect the PTT motor leads g to the the intake silencer bolt e to the specified
PTT relay i, and then tighten the PTT torque.
motor lead bolts j to the specified
torque.
e
c
8
9. Install the caps k.
i
j d
9
k UP
j 10
a
b
g
PTT motor lead bolt j: Intake silencer bolt e:
4 N·m (0.4 kgf·m, 3.0 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) A
6-18
FUEL
Fuel system
3. Install the blowby hose f.
4. Connect the air temperature sensor

coupler a.
6-19
Intake manifold / Throttle body
Throttle body
1 1 7
2
3
8
0
5 9
11 24
10
4
1
3
6
14 13
12
2
15
16
25
3
18 14
16
4
17
19 15
16
5
11 N·m (1.1 kgf·m, 8.1 ft·lb)
20
16 23 6
17 14 21 22

1 Bolt 4 M8 × 60 mm
2 Holder 1
3
4
Grommet
Bracket
2
1
8
5 Holder 1
6 Bracket 1
7
8
Bolt
Air pressure sensor
1
1
M6 × 20 mm 9
9 Hose 1
10
11
Throttle body
Gasket
1
1 39 10
12 Surge tank 1
13 Bolt 5 M8 × 30 mm
14 Surge tank bracket bolt 6 M6 × 16 mm
15 Bolt 2 M6 × 30 mm
16 Grommet 4
17 Collar 2
A
6-20
FUEL
Fuel system
1 1 7
2
8
3
5 9
11 24
4 10
3
6
14 13
12
15
25
16
18 14
16
17
19 15
16
11 N·m (1.1 kgf·m, 8.1 ft·lb)
20
16 23
17 14 21 22

18 Bracket 1
19 Bracket 1
20 Bracket 1
21 Bolt 2 M6 × 16 mm
22 Bracket 1
23 Holder 1
24 Hose 1
25 Hose 1
6-21
Throttle body
Removing the throttle body and
surge tank
1. Disconnect the air pressure sensor cou-
pler a and ETV coupler b.
f
0
2. Remove the YDIS coupler c and low-
pressure fuel pump coupler d.
a d
e
1
b
2
c 7. Remove the vapor gas hoses g and h
from the holder i, and then remove the 3
bracket j.
3. Remove the air pressure sensor a.
4. Remove the cooling water hose b from 4

the holder c. h
j g
a 5
b
c i 6
7
5. Remove the throttle body d. 8. Remove the brackets k and l.
8
9
d k
l
10
6. Disconnect the pressure regulator hose 9. Remove the surge tank m.

e and vapor gas hose f.
A
6-22
FUEL
Fuel system
m
c
b
2. Install the surge tank d.
10. Remove the air pressure sensor hose n,

pressure regulator hose e, and vapor
gas hose f.
n
e
f 3. Install the brackets e and f, and then

tighten the surge tank bracket bolts g to
Checking the ETV the specified torque.
1. Turn the throttle valve manually and
g
check that it moves smoothly.
Installing the throttle body and surge g

tank
1. Install the vapor gas hose a, pressure Surge tank bracket bolt g:
regulator hose b, and air pressure sen- 11 N·m (1.1 kgf·m, 8.1 ft·lb)
sor hose c.
4. Install the bracket h, and then install the
vapor gas hoses i and j to the holder
k.
6-23
Throttle body
7. Fasten the cooling water hose n using
the holder o.
8. Connect the air pressure sensor hose c,

h j
i
and then install the air pressure sensor
p.
0
n o
p
1
k
c
2
5. Connect the pressure regulator hose b
and vapor gas hose a.
9. Install the low-pressure pump coupler b
3
and YDIS coupler c.
10. Connect the ETV coupler d and air

pressure sensor coupler e.
4
e b
5
a d
6
b
c
6. Install a new gasket l and the throttle 7

body m. Check that the tab on the gasket
l is properly and firmly fitted into the
groove a in the surge tank.
NOTICE: Do not reuse a gasket,
8
always replace it with a new one.
9
10
m
l
a A
6-24
FUEL
Fuel system
Canister
6
3
5
4
12
11
9
8 14
9
8
10 13
7 7

1 Hose 1
2 Check valve 2
3 Hose 1
4 Joint 1
5 Hose 1
6 Hose 1
7 Bolt 2
8 Grommet 2
9 Collar 2
10 Bracket 1
11 Bracket 1
12 Bolt 1 M6 × 15 mm
13 Canister 1
14 Hose 1
6-25
Canister
Removing the canister
1. Disconnect the vapor gas hoses a, b
and c.
e
1
c
a
b
2
Checking the canister
1. Check the canister. Replace if cracked. 3
2. Remove the vapor gas hose a from the 2. Connect the special service tool a to the
holders d. atmospheric port a and block the other
ports using rubber plugs b. 4
3. Apply the specified positive pressure and
a
check that there is no air leakage.
Replace the canister if there is air
5
leakage.
d
d 6
a
7
3. Disassemble the vapor gas hose a. 8
a
b
9
90890-06756
Specified positive pressure:

10
19.6 kPa (0.196 kgf/cm2, 2.8 psi)
Checking the canister check valve

a canister check valve port.
4. Remove the canister e. A

6-26
FUEL
Fuel system
2. Apply positive pressure and check that 2. Connect the vapor gas hoses b, c, d,
air comes out of the opposite end of the e, and f to the joint g and check
canister check valve. Replace the valves h.
canister check valve if no air comes out.
d
a
f e
c
g
b
90890-06756
3. Connect the special service tool a to the 3. Fasten the vapor gas hoses a using the
opposite canister check valve port. holders i.
4. Apply positive pressure and check that

no air comes out of the opposite end of
the canister check valve. Replace the
canister check valve if air comes out. a
a i
4. Connect the vapor gas hoses b, j, and

Installing the canister k to the canister.
1. Install the canister a.
5. Connect the vapor gas hose f to the
bottom cowling.
6-27
Canister
0
b
j
k 1
f
2
3
4
5
6
7
8
9
10
A
6-28
FUEL
Fuel system
5 N·m (0.5 kgf·m, 3.7 ft·lb)
10
11
12
10
9 14
8
2
7
1 15
13
6
5 10
7 12 mm 9 mm 12 mm
5 (0.47 in) (0.35 in) (0.47 in)
3
5
4 12 mm
2 (0.47 in) 11

1 Hose 1
2 Holder 1
3 Plastic tie 1
4 Hose 1
5 Clamp 2
6 Joint 1
7 Bushing 2
8 Low-pressure fuel pump 1
9 Holder 1
10 Clamp 2
11 Holder 2
12 Hose 1
13 Holder 1
14 Cover 1
15 Pump cover bolt 2 M6 × 15 mm
6-29
Removing the low-pressure fuel 4. Remove the holder g, and then
pump disconnect the fuel hoses h and i.
0
1. Remove the vapor gas hoses a and b
i
from the holder c. h
1
g
5. Remove the cover j and low-pressure

2
fuel pump k.
a b
c
6. Remove the hose l from the low-
pressure fuel pump k and joint m.
3
4
2. Disconnect the low-pressure fuel pump
coupler a. 5
j
k
m
6
a
l
7
Checking the low-pressure fuel
pump
1. Check the low-pressure fuel pump. See
“Checking the low-pressure fuel pump
8
and high-pressure fuel pump” (5-37).
3. Remove the fuel hose d from the

holders e and f, and then disconnect
Checking the primer pump
9
the fuel hose d. primer pump inlet hose.
e 2. Block the fuel outlet a using a rubber 10

plug b, and then apply the specified
d positive pressure. Replace the primer
pump if the specified pressure cannot be
maintained for 30 seconds or more.
f
A
6-30
FUEL
Fuel system
6. Install the fuel hose h to the holders i
b
and j.
j
a
h
i g
a
c
Leakage tester a: 90890-06840
Specified positive pressure: 7. Install the clamp k temporarily onto the

170.0 kPa (1.70 kgf/cm2, 24.7 psi) fuel hose l.
Installing the low-pressure fuel 8. Connect the fuel hose l, and then
pump fasten it using the clamp k.
1. Install the clamps a temporarily onto the
fuel hose b. 9. Connect the fuel hose m to the joint and
fasten the fuel hose using the plastic tie
2. Connect the fuel hose b to the low- n, and then install the fuel hose to the
pressure fuel pump c and joint d, and holder o.
then fasten the fuel hose b using the
clamp a.
3. Install the low-pressure fuel pump c and m

cover e, and then tighten the pump l
cover bolts f to the specified torque. k
o n
10. Connect the low-pressure fuel pump

coupler a.
c e
d
f
a
a
a
b f
Pump cover bolt f:

5 N·m (0.5 kgf·m, 3.7 ft·lb)
4. Install the clamps g temporarily onto the

fuel hose h.
5. Connect the fuel hose h, and then

fasten it using the clamps g.
6-31
11. Fasten the vapor gas hoses p and q
using the holder r.
p
1
q
r
2
3
4
5
6
7
8
9
10
A
6-32
FUEL
Fuel system
Vapor separator
20 6
19
21
18
22
17
14
11
13
12
15 16
11
10
11
1 12
5 11
1
12 11
8
11 10
8
10
7 6
2
14 9
3
8 11
10
4

1 Hose 2
2 Joint 1
3 Joint 1
4 Hose 1
5 Hose 1
6 Holder 3
7 Holder 1
8 Clamp 2
9 Hose 1
10 Bolt 4 M6 × 35 mm
11 Collar 8
12 Grommet 4
13 Vapor separator assembly 1
14 Clamp 1
15 Hose 1
16 Plastic tie 1
17 Bolt 2 M6 × 15 mm
6-33
Vapor separator
20 6
19 0
21
18
22 1
17
2
14
11
15 16
12
13
3
11
10
11
1
1
5 11
12 4
12 11
8
8 11 10 5
10
7 6
2
14
3
8
9
11
10
6
4

18 Vapor shut-off valve 1
19 Bracket 1
20
21
Nut
Hose
1
1
8
22 Holder 1
9
10
A
6-34
FUEL
Fuel system
Draining the fuel 2. Disconnect the vapor gas hoses a, b,
1. Remove the intake manifold (PORT). and c, cooling water hose d, and fuel
hose e.
2. Disconnect the fuel hose a from the
vapor separator assembly b.
b
a a
b b
d c e
3. Loosen the drain screw c to drain the

fuel into a drain pan.
3. Remove the vapor separator assembly
f, and then disconnect the cooling water
hose g.
4. Tighten the drain screw c to the

g
specified torque.
f
Vapor separator drain screw c:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
5. Connect the fuel hose a to the vapor

separator assembly b.
4. Remove the vapor shut-off valve h and
6. Install the intake manifold (PORT). See bracket i.
Removing the vapor separator

Cover the fuel components using a rag to i
prevent fuel from spilling out. h
1. Disconnect the high-pressure fuel pump

coupler a and vapor shut-off valve cou-
pler b.
6-35
Vapor separator
5. Remove the cooling water hose d and 4. Install the vapor separator assembly g.
fuel hose j.
j
0
1
d e
Checking the vapor shut-off valve

2
1. Check the vapor shut-off valve exterior. f e
Replace if cracked.
2. Check the electrical performance of the

g 3
vapor shut-off valve. See “Checking the
vapor shut-off valve” (5-39).
5. Install the clamp h temporarily onto the 4
Installing the vapor separator fuel hose i.
1. Install the cooling water hose a and fuel
hose b. 6. Connect the fuel hose i, and then
fasten it using the clamp h.
5
b
7. Connect the cooling water hose a and
vapor gas hoses j, k, and l. 6
8. Connect the high-pressure fuel pump
coupler a and vapor shut-off valve
coupler b. 7
a
2. Install the vapor shut-off valve c and

bracket d. j
b
8
k
d
a
l i
h
9
a
c
10
3. Connect the cooling water hose e, and

then fasten the cooling water hose e
using the plastic tie f.
A
6-36
FUEL
Fuel system
Vapor separator and high-pressure fuel pump
2 N·m (0.2 kgf·m, 1.5 ft·lb) 5 2 N·m (0.2 kgf·m, 1.5 ft·lb)
4 5
6 10
2 7
3
4 N·m (0.4 kgf·m, 3.0 ft·lb)
1 8
12
24
25
25
16
11
13
26 21 20
27 14
4 N·m (0.4 kgf·m, 3.0 ft·lb) 22
23
19 15
2 N·m (0.2 kgf·m, 1.5 ft·lb)
28 17
2 N·m (0.2 kgf·m, 1.5 ft·lb)
2 N·m (0.2 kgf·m, 1.5 ft·lb) 18
29

1 Cover assembly 1
2 Pressure regulator screw 1 M5 × 12 mm
3 Holder 1
4 Pressure regulator 1
5 Vapor separator cover bolt 3 M4 × 12 mm
6 Cover 1
7 Gasket 1 39
8 Filter 1
9 Check valve 1
10 Float chamber cover 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
6
7
10 0
3
4 N·m (0.4 kgf·m, 3.0 ft·lb)
1 8 1
9
24
12
2
25
25
16 3
11
26 21
13 4
27 20
14
4 N·m (0.4 kgf·m, 3.0 ft·lb)
23 22
19 15 5
2 N·m (0.2 kgf·m, 1.5 ft·lb)
28 17
2 N·m (0.2 kgf·m, 1.5 ft·lb)
2 N·m (0.2 kgf·m, 1.5 ft·lb) 18 6
29

18 Holder 1
19 Needle valve assembly 1
20
21
Needle valve assembly screw
Pin
1
1
M4 × 8 mm
8
22 Float 1
23 Float pin screw 1 M4 × 8 mm
24
25
Float chamber assembly
Fuel cooler cover screw
1
3 M5 × 4 mm
9
26 Cover 1
39
27
28
Gasket
Drain screw
1
1 10
29 Drain hose 1
A
6-38
FUEL
Fuel system
Disassembling the vapor separator 5. Remove the cover k, gasket l, high-
1. Remove the drain screw a and drain pressure fuel pump m, and grommet n.
hose b.
a
l
m
b
n
2. Remove the fuel cooler cover c and

gasket d.
3. Remove the holder e, and then remove 6. Remove the screw o, and then remove
the pressure regulator f. the pin p, float q, and needle valve
assembly r.
e
o p
r
f c
4. Remove the cover g, gasket h, filter i,

and check valve j. 7. Remove the lead s and filter holder t,
and then remove the filter u, adapter v,
and damper w.
i g
v s
h
j u
t
w
6-39
Checking the high-pressure fuel 2. Apply positive pressure and check that
pump air comes out of the opposite end b of
1. Check the electrical performance of the the check valve. Replace the check valve
if no air comes out.
high-pressure fuel pump. See “Checking
the low-pressure fuel pump and high- 0
pressure fuel pump” (5-37).
b a a
Checking the vapor separator
1. Check the needle valve. Replace the
1
needle valve assembly if bent or worn.
2
90890-06756 3
opposite check valve port b.
4. Apply positive pressure and check that

4
2. Check the float. Replace if deteriorated.
no air comes out of the opposite end a
3. Check the filter. Clean if there is dirt or
residue.
of the check valve. Replace the check
valve if air comes out. 5
4. Place the cover assembly upside down,
and then measure the float height a.
a b a
6
a
7
Assembling the vapor separator 8
Float height a:
67.5 ± 2.5 mm (2.66 ± 0.10 in)
with a new one.
9
TIP:
To measure the height of the float, it should
1. Install the needle valve assembly a, and
then tighten the needle valve assembly 10
be resting on the needle valve. Do not press screw b to the specified torque.
the float.
2. Install the float c and pin d, and then
tighten the float pin screw e to the
Checking the check valve
specified torque.
check valve port a.
A
6-40
FUEL
Fuel system
b
d a
e
l
k
c 5. Install a new gasket m and the cover n,
and then tighten the float chamber cover
screws o to the specified torque.
o
Needle valve assembly screw b:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
n
Float pin screw e:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
m
3. Install the damper f, adapter g, filter
h, filter holder i, and lead j.
j
Float chamber cover screw o:
R/Y 2 N·m (0.2 kgf·m, 1.5 ft·lb)
h
6. Install the check valve p, the filter q, a
B new gasket r, and the cover s, and
then tighten the cover bolts t to the
i f
specified torque.
t
TIP:
Connect the Red/Yellow (R/Y) lead to the q s
positive terminal “+,” and the Black (B) lead to r
the negative terminal “–.” p
4. Connect the high-pressure fuel pump

coupler a, and then install the grommet
k and high-pressure fuel pump l.
6-41
Cover bolt t:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
7. Install the pressure regulator u and

holder v, and then tighten the pressure 0
regulator screw w to the specified
torque.
8. Install a new gasket x and the fuel 1

cooler cover y, and then tighten the fuel
cooler cover screws z to the specified
torque.
2
w
v z
3
u y
x
4
5
Pressure regulator screw w:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
6
Fuel cooler cover screw z:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
9. Install the drain hose A and drain screw

7
B, and then tighten the drain screw B to
the specified torque.
8
B 9
A
10
Drain screw B:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
A
6-42
FUEL
Fuel system
Fuel injector
2 8 9
8
10
1
8 8
7
5 4 11 12
1
6
4 6
8
6
5 6
4 2
4
6 3
6
5 6 6
5 4
6 1
6
5 4
6
6
5 1

1 Bolt 4 M6 × 25 mm
2 Quick connector 2
3 Fuel rail (PORT) 1
4 Holder 6
5 Fuel injector 6
6 O-ring set 6 39
7 Fuel rail (STBD) 1
8 Clamp 5
9 Hose 1
10 Joint 1
11 Hose 1
12 Hose 1
6-43
Fuel injector
Removing the fuel injector PORT
1. Disconnect the quick connectors. See

d
0
steps 2 and 3 in “Disconnecting the quick
connector” (6-6).
2. Remove the fuel hoses a, b, and c. 1

STBD
b a
2
c
d
3
4
5. Remove the holders e, and then remove
the fuel injectors b and O-rings c and
3. Disconnect the fuel injector couplers a.

d.
5
e
PORT
c
d 6
e
a b
7
e
STBD
8
Checking the fuel rail
1. Check the fuel rails. Replace if cracked or
9
a deformed.
2. Check the fuel injectors. See step 5 in

“Checking the fuel injector” (5-35).
10
4. Remove the fuel rails d. Installing the fuel injector
Do not reuse an O-ring, always replace it

with a new one.
A
6-44
FUEL
Fuel system
1. Install new O-rings a and b to fuel
STBD
injector c.
d
c
a d
b 5. Install the fuel hoses e, f, and g, and

then connect the quick connectors.
2. Install the fuel injectors c onto the fuel
rail a, and then install the holders b.
f e
b
b g
c
a
6. Connect the fuel injector couplers d.

PORT
3. Install the fuel rails c onto the cylinder
head.
4. Tighten the bolts d equally.

d
PORT
c
STBD
d
6-45
POWR
Power unit 7
Power unit (check and adjustment) ................................. 7-1

Checking the compression pressure ......................................... 7-1
Checking the oil pressure .......................................................... 7-1
0
Checking the pulser coil air gap ................................................ 7-1
Checking the valve clearance ................................................... 7-2
Adjusting the valve clearance .................................................... 7-4 1
Power unit assembly ........................................................ 7-6
Removing the power unit ........................................................... 7-8
Installing the power unit ........................................................... 7-10
2
Flywheel magnet ............................................................. 7-14
Removing the flywheel magnet ............................................... 7-15 3
Installing the flywheel magnet ................................................. 7-15
Wiring harness ................................................................ 7-17

Removing the wiring harness .................................................. 7-18
4
Installing the wiring harness .................................................... 7-20
Fuse box .......................................................................... 7-24 5

Junction box .................................................................... 7-25
Removing the Rectifier Regulator ........................................... 7-28 6
Removing the junction box ...................................................... 7-28
Installing the junction box ........................................................ 7-28
Installing the Rectifier Regulator ............................................. 7-29
7
Starter motor ................................................................... 7-30
Removing the starter motor ..................................................... 7-31
Installing the starter motor ....................................................... 7-31 8
Engine ECM ..................................................................... 7-32
Removing the engine ECM ..................................................... 7-33
Installing the engine ECM ....................................................... 7-33
9
Shift actuator ................................................................... 7-34
Removing the shift actuator assembly .................................... 7-35 10
Disassembling the shift actuator assembly ............................. 7-35
Assembling the shift actuator assembly .................................. 7-35
Installing the shift actuator assembly ...................................... 7-35
Timing belt ....................................................................... 7-37

Removing the timing belt ......................................................... 7-38
Checking the timing belt .......................................................... 7-39 A
POWR
Installing the timing belt ........................................................... 7-39
Camshaft .......................................................................... 7-42

Removing the driven sprocket and camshaft .......................... 7-45
Checking the sprocket ............................................................. 7-47
Checking the valve lifter .......................................................... 7-47
Checking the camshaft ............................................................ 7-47
Checking the spark plug .......................................................... 7-48
Installing the camshaft and driven sprocket ............................ 7-48
Cylinder head .................................................................. 7-53

Removing the cylinder head .................................................... 7-55
Disassembling the cylinder head ............................................. 7-55
Checking the cylinder head ..................................................... 7-55
Checking the cylinder head bolt .............................................. 7-56
Checking the valve spring ....................................................... 7-56
Checking the valve .................................................................. 7-56
Checking the valve guide ........................................................ 7-57
Replacing the valve guide ....................................................... 7-57
Checking the valve seat .......................................................... 7-58
Refacing the valve seat ........................................................... 7-59
Checking the cylinder head anode .......................................... 7-60
Assembling the cylinder head ................................................. 7-60
Installing the cylinder head ...................................................... 7-62
Oil cooler and oil pump assembly ................................. 7-63

Removing the oil filter bracket ................................................. 7-66
Removing the oil cooler ........................................................... 7-66
Removing the oil pump assembly ........................................... 7-66
Disassembling the oil pump assembly .................................... 7-66
Checking the oil pump assembly ............................................. 7-67
Checking the oil cooler ............................................................ 7-67
Checking the oil cooler anode ................................................. 7-67
Assembling the oil pump assembly ......................................... 7-67
Installing the oil pump assembly ............................................. 7-68
Installing the oil cooler ............................................................. 7-68
Installing the oil filter bracket ................................................... 7-69
Cylinder block sensor and switch ................................. 7-70

Removing the pulley bracket ................................................... 7-72
Removing the knock sensor .................................................... 7-72
Removing the thermostat ........................................................ 7-72
Checking the thermostat ......................................................... 7-72
Installing the thermostat .......................................................... 7-73
Installing the knock sensor ...................................................... 7-73
Installing the pulley bracket ..................................................... 7-73
Cylinder block ................................................................. 7-75

Disassembling the cylinder block ............................................ 7-77
Checking the piston diameter .................................................. 7-78
Checking the cylinder bore ...................................................... 7-78
Checking the piston ring .......................................................... 7-78
Checking the piston ring end gap ............................................ 7-79
Checking the piston ring groove .............................................. 7-79
Checking the piston ring side clearance .................................. 7-79
Checking the piston pin boss inside diameter ......................... 7-79
0
Checking the piston pin diameter ............................................ 7-80
Checking the connecting rod small end inside diameter and
big end inside diameter ........................................................... 7-80
Checking the connecting rod big end side clearance .............. 7-80
1
Checking the crankshaft .......................................................... 7-81
Checking the crankcase bolt ................................................... 7-81
Checking the crankpin oil clearance ........................................ 7-82
Selecting the crankpin bearing ................................................ 7-83
2
Crankpin bearing selection table ............................................. 7-85
Checking the crankshaft journal oil clearance ......................... 7-86
Selecting the crankshaft journal bearing ................................. 7-87
Crankshaft journal bearing selection table .............................. 7-89
3
Checking the cylinder block anode .......................................... 7-90
Assembling the cylinder block ................................................. 7-90
4
5
6
7
8
9
10
A
POWR
Power unit
Power unit (check and 10. Install the ignition coils.
adjustment)
11. Connect the fuel injector couplers.
Checking the compression pressure
1. Start the engine, warm it up for 5–10 min- Checking the oil pressure
utes, and then stop it. 1. Connect the YDIS to display “Oil pres-
sure.”
2. Remove the clip from the engine shut-off
switch. 2. Start the engine and warm it up until the
engine idle speed stabilizes at 650–750
3. Disconnect the fuel injector couplers.
r/min.
4. Remove the intake silencer.
3. Measure the oil pressure.
5. Remove the ignition coils and spark Oil pressure (reference data):
plugs. NOTICE: Before removing the 350.0 kPa (3.50 kgf/cm2, 50.8 psi) at
spark plugs, remove any dirt or dust 60 °C (140 °F) with SL 10W-30
in the spark plug wells that could fall engine oil and at 700 r/min
into the cylinders. 590.0 kPa (5.90 kgf/cm2, 85.6 psi) at
68 °C (154 °F) with SL 10W-30
6. Install the special service tools a and b engine oil and at 3000 r/min
into the spark plug hole.
Checking the pulser coil air gap
Do not turn the flywheel magnet counter-

a clockwise. Otherwise, the water pump
impeller could be damaged.
b
1. Remove the intake silencer.
2. Turn the flywheel magnet clockwise to

Compression gauge a: 90890-03160 align a protrusion a on the flywheel
Compression gauge extension b: magnet with the protrusion b on the
90890-06563 pulser coil.
7. Crank the engine until the reading on the 3. Measure the pulser coil air gap c.
compression gauge stabilizes, and then
measure the compression pressure.
a b
Minimum compression pressure
(reference data):
700.0 kPa (7.0 kgf/cm2, 101.5 psi)
at 20 °C (68 °F)
8. Remove the special service tools a and

b. c
9. Tighten the spark plugs to the specified Pulser coil air gap c:
torque. 0.4–1.1 mm (0.016–0.043 in)
Spark plug: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
7-1
Power unit (check and adjustment)
Checking the valve clearance 7. Turn the flywheel magnet c clockwise
Measure the valve clearances when the until the dowel hole e in the flywheel
engine is cold. magnet c is aligned between the VCT
assembly (STBD) d and driven sprocket
(STBD) e. 0
Do not turn the flywheel magnet counter-
8. Check that the “II” marks f on the VCT
clockwise. Otherwise, the water pump
assembly (PORT) and driven sprocket
impeller could be damaged.
(PORT) are aligned, and check that the 1
“I” marks g on the VCT assembly
1. Remove the blowby hose a. (STBD) and driven sprocket (STBD) are
aligned.
2
d
g
e
f
3
a 4
2. Remove the vapor gas hoses and
canister. See “Removing the canister” (6-
26). 5
3. Disconnect the ignition coil couplers a,
engine ECM couplers b, and knock e
sensor coupler c. c 6
4. Remove the bracket b and speed
sensor coupler d.
9. Remove the timing belt guide (STBD) 7
5. Remove the ignition coils and spark and cylinder head covers.
plugs.
10. Measure the valve clearances h and k
according to steps 11–13. 8
b a IN EX EX IN 9
a
b #2 #1
#4 #3
10
#6 #5
c d
6. Remove the engine ECM and engine PORT STBD

ECM bracket. A
7-2
POWR
Power unit
14. Install the cylinder head covers.
15. Install the timing belt guide (STBD), and

h h
then adjust the timing belt guide
clearance. See step 8 in “Installing the
timing belt” (7-39).
k k 16. Install the engine ECM bracket and

PORT STBD engine ECM.
17. Install the spark plugs and ignition coils,

Valve clearance: and then tighten the spark plugs to the
Intake h: specified torque.
0.205 ± 0.035 mm
(0.0081 ± 0.0014 in) Spark plug: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
Exhaust k:
18. Install the bracket b and speed sensor
0.345 ± 0.035 mm
coupler d.
(0.0136 ± 0.0014 in)
19. Connect the ignition coil couplers a,
TIP: engine ECM couplers b, and knock
Write down the measurement data. sensor coupler c.
11. Measure the intake and exhaust valve

clearances of the specified cylinders.
Adjust if out of specification. See
“Adjusting the valve clearance” (7-4). a
b
#1 #2 #3 #4 #5 #6 a
IN ✓ — — — ✓ ✓ b
EX ✓ ✓ ✓ — — —
✓: Specified cylinder
12. Turn the flywheel magnet c an

c d
additional 360° clockwise until the dowel
hole e in the flywheel magnet c is 20. Install the canister and vapor gas hoses.
aligned between the VCT assembly See “Installing the canister” (6-27).
(STBD) d and driven sprocket (STBD)
e. 21. Install the blowby hose a.
13. Measure the intake and exhaust valve

clearances of the specified cylinders.
Adjust if out of specification. See
“Adjusting the valve clearance” (7-4).
#1 #2 #3 #4 #5 #6
IN — ✓ ✓ ✓ — —
EX — — — ✓ ✓ ✓
a
✓: Specified cylinder
7-3
Power unit (check and adjustment)
Adjusting the valve clearance 9. Remove the VCT assemblies, driven
Adjust the valve clearances when the engine sprockets, and camshafts. See
is cold. “Removing the driven sprocket and
camshaft” (7-45).
0
TIP:
Make sure to keep the parts in the order of
TIP:
When adjusting the valve clearances, the fuel
removal.
1
line must be disconnected. Therefore, make 10. Measure the valve lifter thickness a, and
sure to reduce the fuel pressure before per- then write down the measurement data.
forming the disassembly procedure. 2
a
2. Disconnect the quick connectors. See
steps 2 and 3 in “Disconnecting the quick
connector” (6-6). 3
3. Remove the fuel hose (high-pressure).
4. Remove the wiring harness. See 4

“Removing the wiring harness” (7-18).
11. Select the necessary valve lifter by
5. Remove the wiring harness guide a.
calculating its thickness using the
following formula.
5
Calculation formula:
a
Necessary valve lifter thickness = Removed
valve lifter thickness + Measured valve clear- 6
ance – Specified valve clearance
Example:
Removed valve lifter thickness = 3.000 mm
Measured valve clearance = 0.255 mm
7
Specified valve clearance = 0.205 mm
Necessary valve lifter thickness
= 3.000 mm + 0.255 mm – 0.205 mm
= 3.050 mm
8
12. Install the necessary valve lifter into the
6. Remove the flywheel magnet, pulser coil,
and stator assembly. See “Removing the
cylinder head. 9
flywheel magnet” (7-15). 13. Install the camshafts, VCT assemblies,
and driven sprockets. See “Installing the
7. Remove the intake manifold (STBD). See
“Removing the intake manifold” (6-15).
camshaft and driven sprocket” (7-48). 10
14. Install the timing belt. See “Installing the
8. Remove the timing belt. See “Removing timing belt” (7-39).
the timing belt” (7-38).
15. Measure the valve clearances. See steps
11–13 in “Checking the valve clearance”
(7-2).
A
7-4
POWR
Power unit
16. Install the pulser coil and stator
assembly. See steps 1–3 in “Installing the
flywheel magnet” (7-15).
17. Install the flywheel magnet. See step 5 in

“Installing the flywheel magnet” (7-15).
18. Check the pulser coil air gap. See steps 2

and 3 in “Checking the pulser coil air
gap” (7-1).

20. Install the wiring harness guide a.
21. Install the wiring harness. See “Installing

the wiring harness” (7-20).
7-5
Power unit (check and adjustment) / Power unit assembly
Power unit assembly
3 N·m (0.3 kgf·m, 2.2 ft·lb)
17
18
19
0
16
13
1
16 1
16
5
6
16 15 14
2
11 16
2
4
12 17
3
8 3 3
7
12
22 23
24
19
16 4
18
22 16 17
16
5
21 20 16
a 42 N·m (4.2 kgf·m, 31.0 ft·lb)
9
9 9
b
a
42 N·m (4.2 kgf·m, 31.0 ft·lb)
42 N·m (4.2 kgf·m, 31.0 ft·lb)
6
10 10 b 42 N·m (4.2 kgf·m, 31.0 ft·lb)

1 Power unit assembly 1
2 Gasket 1 39
3
4
Dowel
Rigging tube retainer
2
1
8
5 Plastic tie 1
6
7
Rigging grommet
Bolt
1
2 M6 14 mm 9
8 Grommet holder 1
9 Power unit mounting bolt 7 M10 35 mm
10
11
Power unit mounting bolt
Apron screw
6
4
M10 140 mm
M6 20 mm
10
12 Grommet 4
13 Apron (STBD) 1
14 Apron (PORT) 1
15 Nut 4
16 Bolt 11 M6 14 mm
17 Bolt 3 M6 30 mm
A
7-6
POWR
Power unit
3 N·m (0.3 kgf·m, 2.2 ft·lb)
17
18
19
16
13
1
16
16
5
15 14
16
6
11 16
2 12 17
4
8 3 3
7
12
24 16
22 23
19
18
22 16 17
16
21 20 16
a 42 N·m (4.2 kgf·m, 31.0 ft·lb)
9 b 42 N·m (4.2 kgf·m, 31.0 ft·lb)
9 9 a 42 N·m (4.2 kgf·m, 31.0 ft·lb)
10 10 b 42 N·m (4.2 kgf·m, 31.0 ft·lb)

18 Collar 2
19 Grommet 2
20 Nut 2
21 Grommet 1
22 Bolt 2 M6 15 mm
23 Idle silencer 1
24 Rubber seal 1
7-7
Power unit assembly
Removing the power unit
1. Remove the plastic tie a, and then a
remove the rigging tube retainer b.
b 0
b
1
a
6. Remove the plastic tie h, and then
b disconnect the extension wiring harness
coupler c.
2
2. Remove the grommet holder c, and then
remove the rigging grommet d.
3
d
4
c h
c
7. Remove the PTT switch coupler d from
5
the bracket i, and then disconnect the
3. Remove the battery cable e. PTT switch coupler d.
8. Remove the SPS coupler e from the

6
bracket j, and then disconnect the SPS
coupler e.
e 7
e
8
j
4. Remove the clip f, and then remove the
shift lever g.
d
i
9
9. Remove the main wiring harness k from
the holder l. 10
g 10. Remove the brackets m and n.
5. Remove the PTT motor leads a and b. A

7-8
POWR
Power unit
l
n m
f
11. Disconnect the cooling water hose o. 15. Remove the aprons r, s, rubber seal
t, idle silencer u, and grommet v.
o
t
v u
12. Disconnect the vapor gas hose p. s
16. Install the special service tools w and x.
13. Disconnect the flushing hose q. 17. Hook a lifting harness y onto the special
service tools w and x, and then
suspend the power unit z.
18. Remove the power unit mounting bolts A

and B, and then remove the power unit
q z and dowels C.
14. Disconnect the trim sensor coupler f.
7-9
Power unit assembly
B y g e
B B w x g g c d
z f
A A h h
0
B B g g
b
1
C C a a
B
g
g
3
B A B g h
Engine lifting eye w: 90890-06820

Balance hanger x: 90890-06822
Engine lifting eye c: 90890-06820
Balance hanger d: 90890-06822 4
Installing the power unit Power unit mounting bolts g and h:
1. Clean the power unit mating surface, and
then install the dowels a and a new gas-
1st: 42 N·m (4.2 kgf·m, 31.0 ft·lb)
2nd: 42 N·m (4.2 kgf·m, 31.0 ft·lb)
5
ket b. NOTICE: Do not reuse a gas-
ket, always replace it with a new one. TIP:
2. Install the special service tools c and d.
Tighten the power unit mounting bolts to the
6
3. Hook a lifting harness e onto the special
service tools c and d, and then
suspend the power unit f.
5. Install the grommet i, idle silencer j,
and rubber seal k.
7
4. Install the power unit f, and then tighten 6. Install the aprons l and m, and then
the power unit mounting bolts g and h
to the specified torque in 2 stages.
tighten the apron screws n to the
specified torque.
8
9
10
A
7-10
POWR
Power unit
k
q
i j
m
10. Connect the cooling water hose r.
Apron screw n: 3 N·m (0.3 kgf·m, 2.2 ft·lb)
7. Connect the trim sensor coupler a.

11. Install the brackets s and t, and then
tighten the surge tank bracket bolts u to
a u
8. Connect the flushing hose o, and then

fasten it using the clamp p. s
p
u
o
Surge tank bracket bolt u:
11 N·m (1.1 kgf·m, 8.1 ft·lb)
12. Install the main wiring harness v to the

p holder w.
o
9. Connect the vapor gas hose q.
7-11
Power unit assembly
e
w
B
B
0
f
v
A
1
13. Connect the PTT switch coupler b, and PTT motor lead bolt A:
then install it to the bracket x. 4 N·m (0.4 kgf·m, 3.0 ft·lb) 2
14. Connect the SPS coupler c, and then 18. Install the shift lever C, and then install
install it to the bracket y. the clip D.
3
c C 4
y
x
b
D
5
15. Connect the extension wiring harness 19. Install the battery cable E.
coupler d, and then fasten it using the
plastic tie z.
6
E
7
8
20. Install the rigging grommet F, and then
d z
16. Install the PTT motor leads e and f,

install the grommet holder G. 9
and then tighten the PTT motor lead
bolts A to the specified torque.
17. Install the caps B.

F
10
G
A
7-12
POWR
Power unit
21. Install the tube retainer H, and then
fasten it using the plastic tie I.
7-13
Power unit assembly / Flywheel magnet
Flywheel magnet
1 1 4 N·m (0.4 kgf·m, 3.0 ft·lb)
7
a 40 N·m (4.0 kgf·m, 29.5 ft·lb)
b 90° 0
2
6
9
3
1 14 5 1
14 8
2
4 4
13
11 3
12
10
4
5
6

1 Bolt 6 M6 35 mm
2 Stator assembly 1
3
4
Base assembly
Dowel
1
2
8
5 Bracket 1
6
7
Plastic tie
Pulser coil bolt
1
2 M5 20 mm 9
8 Pulser coil 1
9 Flywheel magnet bolt 6 39 M10 50 mm
10
11
Flywheel magnet
Dowel
1
1
10
12 Holder 1
13 Bolt 1 M6 16 mm
14 Bolt 4 M6 30 mm
A
7-14
POWR
Power unit
Removing the flywheel magnet Installing the flywheel magnet
1. Loosen the flywheel magnet bolts a in
the order a, b, and so on, and then
remove the flywheel magnet and dowel. Do not reuse a flywheel magnet bolt,
NOTICE: Apply force in the direction always replace it with a new one.
of the arrow to prevent the special ser-
vice tool b from slipping off easily.
1. Install the dowel a to the base a.
2. Install the base a and pulser coil b, and

then tighten the pulser coil bolts c to the
b
specified torque.
3. Install the stator assembly d and holder

e and dowel f.
a
4. Connect the stator assembly couplers b
and pulser coil coupler c.
d c
d
b
c
f
b f
e
a aa
b
c a
Rotor holder b: 90890-01235
2. Disconnect the stator assembly couplers e

a and pulser coil coupler b.
3. Remove the holder c and stator d, and Pulser coil bolt c:

then remove the pulser coil e and base 4 N·m (0.4 kgf·m, 3.0 ft·lb)
c.
5. Install the flywheel magnet, and then
d tighten new flywheel magnet bolts g to
the specified torques in 2 stages and in
NOTICE: Apply force in the direction
b
e of the arrow to prevent the special
service tool h from slipping off easily.
a
c
7-15
Flywheel magnet
0
e 90° h
g 1
e
c
2
a
b 3
f
d
4
Rotor holder h: 90890-01235
Flywheel magnet bolt g:

1st: 40 N·m (4.0 kgf·m, 29.5 ft·lb) 5
2nd: 90°
TIP:
In the second tightening stage for the fly-
6
wheel magnet bolts g, mark the bolts and
flywheel magnet with identification marks e,
and then tighten the bolts 90° from the marks
on the flywheel magnet.
7
6. Check the pulser coil air gap. See steps 2
and 3 in “Checking the pulser coil air
8
gap” (7-1).
9
10
A
7-16
POWR
Power unit
Wiring harness
6 3
3 5
5 7
2
3
4 3 7

1 Wiring harness 1
2 Wiring harness guide 1
3 Bolt 5 M6 20 mm
4 Holder 1
5 Holder 2
6 Holder 1
7 Holder 2
8 Holder 1
9 Plastic tie 1
7-17
Wiring harness
Removing the wiring harness b a b
1. Disconnect the ignition coil couplers a,
engine ECM couplers b, and knock sen- k
sor coupler c.
2. Remove the speed sensor coupler d, g

0
joint connector e, and water pressure
sensor coupler f.
c 1
3. Remove the wiring harness a from the
holders b. 9. Disconnect the OCV couplers m, cam
4. Remove the holders g from the engine
position sensor couplers n, and
thermoswitch connectors p.
2
ECM bracket.
PORT
b
ga
n
3
m
b a
a 4
p
b
STBD
5
f e cd g
m
p 6
5. Disconnect the cam position sensor n
coupler (PORT EX) h.
7
h
10. Disconnect the oil pressure sensor

coupler r. 8
h
11. Remove the ground leads s.
9
6. Remove the condensers k.
7. Remove the wiring harness a from the

10
holders b and c.
8. Remove the holders g from the wiring

harness guide.
A
7-18
POWR
Power unit
PORT
x
w y
u
STBD
A
v t
s
13. Disconnect the PTT relay coupler B.
12. Remove the fuse box d, and then

disconnect the fuse holder couplers t
14. Disconnect the Rectifier Regulator
and u, Rectifier Regulator couplers v,
coupler D.
w, and x, power source coupler y, and
isolator coupler A.
D
15. Disconnect the shift actuator coupler E.
16. Remove the ground leads F, G, and H.
7-19
Wiring harness
E
e 0
H
F
G
1
17. Remove the starter motor lead J.
2
Installing the wiring harness
J
1. Install the wiring harness guide a. 3
4
a
18. Remove the holders L from the wiring
harness guide e, and then remove the
main wiring harness.
5
e 6
L
L
2. Install the main wiring harness, and then
7
install the holders a to the wiring
harness guide a.
8
a
9
19. Remove the wiring harness guide d.
a
a
10
A
7-20
POWR
Power unit
3. Install the starter motor lead b, and then
tighten the starter motor lead screw b to
h
b
b
8. Connect the fuse holder couplers k and
m, Rectifier Regulator couplers n, p,
and r, power source coupler s, and
Starter motor lead screw b: isolator coupler t.
2 N·m (0.2 kgf·m, 1.5 ft·lb)
9. Remove the fuse box c, and then tighten
4. Install the ground leads c, d, and e. the fuse box screw d to the specified
torque.
5. Connect the shift actuator coupler f.
f
c
d
e
c d
d
6. Connect the Rectifier Regulator coupler r

p s
g.
d m
g d
t
n k
Fuse box screw d:

2 N·m (0.2 kgf·m, 1.5 ft·lb)
10. Install the ground leads u.
7. Connect the PTT relay coupler h. 11. Connect the oil pressure sensor coupler
v.
7-21
Wiring harness
PORT STBD
X
w
A
0
u B
1
13. Install the holders D to the wiring
harness guide. 2
14. Fasten the wiring harness e using the
holders f and g.
STBD
15. Install the condensers E.

3
u f e f
E 4
v D
5
g
16. Connect the cam position sensor coupler

6
12. Connect the OCV couplers w, cam (PORT EX) F.
position sensor couplers x, and
thermoswitch connectors y (PORT) and
A (STBD), and then fasten the
F
7
thermoswitch connectors A (STBD)
using the holder B.
PORT F
8
X
w 9
17. Install the holders D to the engine ECM
bracket.
y 18. Install the wiring harness e to the

10
holders f.
19. Install the speed sensor coupler G, joint

couplers H, and water pressure sensor
coupler J.
A
7-22
POWR
Power unit
20. Connect the ignition coil couplers L,
engine ECM couplers M, and knock
sensor coupler N.
f
De
M L
L
J H NG D
7-23
Wiring harness / Fuse box
Fuse box
2 N·m (0.2 kgf·m, 1.5 ft·lb)
14
3
14
0
A 4
7 1
6
8
6 2
12
5
5
9
11
10
6 7
3
8
11
5
4
2
1
12
5
7
4 8 11 10 9 3
13 6
A

1 Fuse box assembly 1
2 Cover 1
3
4
Cover
Fuse puller
1
1
8
5 Relay 5
M5 10 mm
6
7
Screw
Fuse
4
3 100 A, spare is included. 9
8 Fuse 3 10 A, spare is included.
9 Fuse 2 20 A, spare is included.
10
11
Fuse
Fuse
3
3
30 A, spare is included.
15 A, spare is included.
10
12 Screw 13 M3 10 mm
13 Grommet 1
14 Fuse box screw 4 ø5 20 mm
A
7-24
POWR
Power unit
Junction box
a 6 N·m (0.6 kgf·m, 4.4 ft·lb)
b 12 N·m (1.2 kgf·m, 8.9 ft·lb)
20
19 24 21
25 22
15 23
16 18
17 28
25
30 27 26
29 9 N·m (0.9 kgf·m, 6.6 ft·lb)
14 7
6
5
38 9 8
11 8
2
1 31 32
33
3 7 37
13
4 10
35 36
10 34
4 2 12 6 25 N·m (2.5 kgf·m, 18.4 ft·lb)
9
5 N·m (0.5 kgf·m, 3.7 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb)
1

1 Cap 2
2 PTT motor lead bolt 2 M6 10 mm
3 PTT relay 1
4 Bolt 2 M6 20 mm
5 Junction box 1
6 Bolt 5 M6 30 mm
7 Grommet 5
8 Collar 5
9 Holder 2
10 Holder 2
11 Holder 1
12 Holder 1
13 Bracket 2
14 Bolt 1 M6 15 mm
15 Bolt 3 M6 35 mm
16 Rectifier Regulator 1
17 Gasket 1 39
7-25
Junction box
a 6 N·m (0.6 kgf·m, 4.4 ft·lb)

b 12 N·m (1.2 kgf·m, 8.9 ft·lb)
19 24
20
25
21
22
0
15 23
16 18
1
17 28
25
30 27 26 2
29 9 N·m (0.9 kgf·m, 6.6 ft·lb)
14 7
6
3
5
38 9 8
1
2
11 8
32
4
31
3
13
33
7 37
5
4 10
35 36
4 2 12
10
9
34
6 25 N·m (2.5 kgf·m, 18.4 ft·lb) 6
1

18 Cover 1
19 Rectifier Regulator cover bolt 6 M6 25 mm
20
21
Hose
Joint
1
1
8
22 Hose 1
23
24
Hose
Hose
1
1 9
25 Joint 2
26 Hose 1
27
28
Hose
Hose
1
1
10
29 Power source lead 1
30 Isolator lead 1
31 Bolt 1 M8 16 mm
32 Terminal 1
33 Terminal bolt 1 M8 20 mm
34 Bolt 2 M6 15 mm
A
7-26
POWR
Power unit
a 6 N·m (0.6 kgf·m, 4.4 ft·lb)

b 12 N·m (1.2 kgf·m, 8.9 ft·lb)
20
19 24 21
25 22
15 23
16 18
17 28
25
30 27 26
29 9 N·m (0.9 kgf·m, 6.6 ft·lb)
14 7
6
5
38 9 8
11 8
2
1 31 32
33
3 7 37
13
4 10
35 36
10 34
4 2 12 6 25 N·m (2.5 kgf·m, 18.4 ft·lb)
9
1

35 Bracket 1
36 Bracket 1
37 Bolt 2 M6 20 mm
38 Starter motor nut 1
7-27
Junction box
Removing the Rectifier Regulator
1. Remove the ground lead a.
b
2. Disconnect the cooling water hoses b
and c. 0
c
c
1
a 2
b a
3. Remove the power source lead a and
3. Remove the Rectifier Regulator a. isolator lead b. 3
4. Remove the terminal c and junction box
a d.
4
a b
5
4. Remove the cover b and gasket c.
d
6
7
b
8
c c
Installing the junction box

1. Install the junction box a.
9
2. Install the terminal b, and then terminal
Removing the junction box bolt c to the specified torque. 10
1. Disconnect the starter motor lead a.
3. Install the power source lead d and
2. Disconnect the PTT relay leads b and isolator lead e.
c.
A
7-28
POWR
Power unit
Installing the Rectifier Regulator
1. Install a new gasket a and the cover b,
e and then tighten the Rectifier Regulator
d
cover bolts c to the specified torques in
2 stages. NOTICE: Do not reuse a gas-
ket, always replace it with a new one.
a
c
b
a
c b
Terminal bolt c:
25 N·m (2.5 kgf·m, 18.4 ft·lb)
Rectifier Regulator cover bolts c:
4. Install the PTT relay leads a and b, and 1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
then tighten the PTT relay lead nuts f to 2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
2. Install the Rectifier Regulator d.
5. Install the starter motor lead c, and then
tighten the starter motor nut g to the
specified torque. d
6. Install the caps d.

f a
d
3. Install the ground lead a.
4. Connect the cooling water hoses b and

c.
b
c
c
g
PTT relay lead nut f:

5 N·m (0.5 kgf·m, 3.7 ft·lb)
Starter motor nut g:
9 N·m (0.9 kgf·m, 6.6 ft·lb)
b a
7-29
Junction box / Starter motor
Starter motor
25 N·m (2.5 kgf·m, 18.4 ft·lb)
1 2
1
6
2
3 7
3
7
30 N·m (3.0 kgf·m, 22.1 ft·lb)
4
8
4
5 7 5
2 N·m (0.2 kgf·m, 1.5 ft·lb)
12 N·m (1.2 kgf·m, 8.9 ft·lb) 6

1 Bracket 1
2 Starter motor bracket bolt 2 M8 35 mm
3
4
Dowel
Bracket
1
1
8
5 Starter motor bracket bolt 1 M6 40 mm
6
7
Starter motor
Starter motor bolt
1
3 M8 45 mm 9
8 Starter motor lead screw 1 M4 6 mm
10
A
7-30
POWR
Power unit
Removing the starter motor Starter motor bracket bolt (M6) d:
1. Remove the starter motor a. 12 N·m (1.2 kgf·m, 8.9 ft·lb)
Starter motor bracket bolt (M8) e:
2. Remove the brackets b and c.
25 N·m (2.5 kgf·m, 18.4 ft·lb)
Starter motor bolt g:
30 N·m (3.0 kgf·m, 22.1 ft·lb)
Installing the starter motor

1. Install the dowel a and brackets b and
c, and then tighten the starter motor
bracket bolts d and e to the specified
torque.
2. Install the starter motor f, and then

tighten the starter motor bolts g to the
specified torque.
c
f
e
a
g
g
b d g
7-31
Starter motor / Engine ECM
Engine ECM
5
6 0
8
1
4
7 N·m (0.7 kgf·m, 5.2 ft·lb)

2
4
3
5 3
4
4
6
2
5
7
3 4 6
2 1

1 Engine ECM 1
2 Engine ECM bolt 4 M6 20 mm
3
4
Bolt
Grommet
4
4
M6 30 mm 8
5 Collar 4
6
7
Holder
Holder
2
1 9
8 Bracket 1
10
A
7-32
POWR
Power unit
Removing the engine ECM
1. Remove the engine ECM a and bracket
b.
Installing the engine ECM

1. Install the bracket a and engine ECM b,
and then tighten the engine ECM bolts c
to the specified torque.
b
c
c c
Engine ECM bolt c:

7 N·m (0.7 kgf·m, 5.2 ft·lb)
7-33
Engine ECM / Shift actuator
Shift actuator
2 0
1 1
3
11
4
2
11 5 3
11
11 4
6
19 N·m (1.9 kgf·m, 14.0 ft·lb)

5
8
7
9
10
6

1 Shift actuator 1
2 Bracket 1
3
4
Nut
Pin
1
1
8
5 Bushing 1
6
7
Shift link assembly
Bolt
1
2 M6 25 mm 9
8 Bushing 1
9 Washer 1
10
11
Clip
Shift actuator bolt
1
4 M6 55 mm
10
A
7-34
POWR
Power unit
Removing the shift actuator Assembling the shift actuator
assembly assembly
1. Remove the shift actuator a. 1. Install the shift link assembly a, bushing
b, bushing c, pin d, washer e, and
clip f.
c
a
a b
e
2. Remove the bracket b. f
Installing the shift actuator assembly

1. Install the nut a to the bracket b.
b
Disassembling the shift actuator a

assembly
1. Remove the clip a, and then remove the
washer b, pin c, bushing d, bushing 2. Install the bracket b and shift actuator
e, and shift link assembly f. c, and then tighten the shift actuator
bolts d to the specified torque in the
order a, b, and so on.
c
d d b
f
b
a c
d
7-35
Shift actuator
c d
d
a
b 1
Shift actuator bolts d:
19 N·m (1.9 kgf·m, 14.0 ft·lb) 2
3
4
5
6
7
8
9
10
A
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
5 39 N·m (3.9 kgf·m, 28.8 ft·lb)
9 7
6 8 7
3
8
4

1 Timing belt 1
2 Timing belt tensioner 1
3 Pulley bolt 2 M10 55 mm
4 Washer 2
5 Pulley 2
6 Collar 2
7 Bolt 6 M6 14 mm
8 Guide 2
9 Guide 1
7-37
Timing belt
Removing the timing belt
b
When the timing belt is not installed, do
not turn the crankshaft or driven sprock- 0
ets. Otherwise, the pistons and valves or
intake and exhaust valves could collide
with each other and be damaged.
1
1. Align that the large “L” mark a on the
crankshaft with the rib b on the cylinder 4. Turn the timing belt tensioner gradually
block. clockwise using a hexagon wrench, and
then insert a 5.0 mm (0.2 in) diameter pin
2
2. Check that the “II” marks c on the VCT c into the hole e.
assembly (PORT) and driven sprocket
(PORT) are aligned, and check that the 3
“I” marks d on the VCT assembly c
(STBD) and driven sprocket (STBD) are
aligned.
4
d c
5
e
6
TIP:
a
• When turning the timing belt tensioner,
apply a force of 15 N·m (1.5 kgf·m, 11.1
7
ft·lb) or less.
b • Leave the pin c inserted into the hole e of
the timing belt tensioner until the timing belt
is installed again.
8
3. Remove the timing belt guides a and b.
5. Remove the timing belt d from the VCT
assembly (PORT) or driven sprocket
9
(STBD), and then remove it from the
a crankshaft.
10
a
A
7-38
POWR
Power unit
Timing belt tensioner bolt a:

d
39 N·m (3.9 kgf·m, 28.8 ft·lb)
Pulley bolt d:
39 N·m (3.9 kgf·m, 28.8 ft·lb)
2. Install the timing belt e onto the

crankshaft so that the part number b is
in the upright position and the belt
position mark c is aligned with the small
“L” mark on the crankshaft. NOTICE: Do
6. Remove the timing belt tensioner e and not apply grease or oil to the timing
pulleys f. belt.
e e
f
c b
Checking the timing belt

1. Check the interior and exterior of the tim-
c d e f g
ing belt. Replace if cracked, damaged, or
worn.
6CB-462**-**
Installing the timing belt

1. Install the timing belt tensioner a, collars 0123 63 88 146 172 h
b, and pulleys c, and then tighten the
timing belt tensioner bolt a and pulley
bolts d to the specified torque. h Belt teeth number
a d
TIP:
Before installing the timing belt, make sure
a d that the marks on the crankshaft and cylinder
c block are aligned. Also, make sure that the
b marks on the VCT assemblies and driven
sprockets are aligned. See steps 1 and 2 in
c
“Removing the timing belt” (7-38).
b
7-39
Timing belt
3. Install the timing belt onto the VCT
assemblies and driven sprockets by
aligning the belt position marks d, e, f, f
and g with the “L” marks in the order
listed. 0
f e 1
TIP:
• When turning the timing belt tensioner, 2
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
aligned with the marks “L”. See steps 2 3
and 3.
g d
6. Install the timing belt guides g and h. 4
g
4. Adjust the timing belt installation height

5
k to specification. g
6
7
k h
8
Timing belt installation height k:
2.5 mm (0.10 in)
5. Turn the timing belt tensioner gradually

9
clockwise using a hexagon wrench, and
7. Turn the crankshaft clockwise 2 full turns
then remove the pin f.
until the large “L” mark m on the
crankshaft is aligned with the rib n on 10
the cylinder block. Check that the marks
p and r on the VCT assemblies and
driven sprockets are aligned.
A
7-40
POWR
Power unit
r p
8. Adjust the timing belt guide clearance s.
g g
h
s
Timing belt guide clearance s:

0.5–1.5 mm (0.02–0.06 in)
7-41
Timing belt / Camshaft
Camshaft
60 N·m (6.0 kgf·m, 44.3 ft·lb) 1 6 9
34 35 4
3
2 7 0
27 28 8 9
33 29 14 8
30 16 14 15 1
23 9
11
30 18 20
30
22
19
6
2
32 7
31
21
10
1 5
3
32 8 2
12 14 8
28 N·m (2.8 kgf·m, 20.7 ft·lb) 3
31
25
24
14
9 4
35 17 15
34
32
29 13 5
27
28 20
33
30 26 18
29 a 8 N·m (0.8 kgf·m, 5.9 ft·lb)
19
a 8 N·m (0.8 kgf·m, 5.9 ft·lb)
6
30
28 30 b 17 N·m (1.7 kgf·m, 12.5 ft·lb) b 17 N·m (1.7 kgf·m, 12.5 ft·lb)

1 Cap 2
2 Gasket 2 39
3
4
VCT bolt
VCT assembly (PORT)
2
1
8
5 VCT assembly (STBD) 1
M10 35 mm
6
7
Driven sprocket bolt
Driven sprocket
2
2 9
8 Oil seal 4 39
9 Valve lifter 24
10
11
Camshaft (PORT IN)
Camshaft (PORT EX)
1
1
10
12 Camshaft (STBD EX) 1
13 Camshaft (STBD IN) 1
14 Dowel 4
15 Collar 8
16 Camshaft cap (EX) 2
17 Camshaft cap (IN) 2
A
7-42
POWR
Power unit
60 N·m (6.0 kgf·m, 44.3 ft·lb) 1 6
4 9
34 35 2 7
3
27 28 8 9
33 29 14 8
30 16 14 15
23 9
11
30 18 20
22
30 19
6
32 7
31 10
21 1 5
32 8 2
12 14 8
28 N·m (2.8 kgf·m, 20.7 ft·lb) 3
25 14
24 9
31
35 17 15
34
29 13
32
27
28 20
26 18 19
30
33 30 29 a 8 N·m (0.8 kgf·m, 5.9 ft·lb) a 8 N·m (0.8 kgf·m, 5.9 ft·lb)

18 Camshaft cap bolt 8 M7 48 mm
19 Camshaft cap bolt 24 M7 36 mm
20 Camshaft cap 12
21 Gasket 1 39
22 Cylinder head cover (PORT) 1
23 Bracket 1
24 Gasket 1 39
25 Cylinder head cover (STBD) 1
26 Bracket 1
27 Damper 2
28 Bolt 6
29 Nut 4
30 Grommet 6
31 Bolt 20 M6 30 mm
32 Holder 4
33 Bolt 6 M6 25 mm
34 Ignition coil 6
7-43
Camshaft
60 N·m (6.0 kgf·m, 44.3 ft·lb) 1 6 9
34 35 4
3
2 7 0
27 28 8 9
33 29 14 8
30 16 14 15 1
23 9
11
30 18 20
30
22
19
6
2
32 7
31
21
10
1 5
3
32 8 2
12 14 8
28 N·m (2.8 kgf·m, 20.7 ft·lb) 3
31
25
24
14
9 4
35 17 15
34
32
29 13 5
27
28 20
33
30 26 18
29 a 8 N·m (0.8 kgf·m, 5.9 ft·lb)
19
a 8 N·m (0.8 kgf·m, 5.9 ft·lb)
6
30

35 Spark plug 6
8
9
10
A
7-44
POWR
Power unit
Removing the driven sprocket and
camshaft a
When the timing belt is not installed, do

not turn the crankshaft or camshafts. Oth-
erwise, the pistons and valves or intake
and exhaust valves could collide with
60°
each other and be damaged.
3. Secure the VCT assemblies e and f

1. Remove the ignition coils a and spark
using the special service tool g, and
plugs b, and then remove the cylinder
then remove the VCT caps h.
head covers c and d.
NOTICE: When removing the VCT
c cap, do not secure the camshaft.
Otherwise, the VCT assembly could
be damaged. When removing the VCT
cap, do not turn the VCT assembly.
Otherwise, the intake and exhaust
valves could collide with each other
and be damaged.
h
f
a
d
h
e
2. Turn the crankshaft counterclockwise 60° g

gradually until the large “L” mark a on
the crankshaft is aligned with the mating
surface of the crankcase and cylinder
block. NOTICE: Do not turn the
crankshaft counterclockwise more
than 60°. Otherwise, the pistons and
Sheave holder g: 90890-01701
and be damaged.
4. Remove the special service tool g.
7-45
Camshaft
5. Secure the intake camshaft using a
wrench, and then remove the VCT
assemblies e and f. NOTICE: When i
removing the VCT bolt, do not secure
the VCT assembly. Otherwise, the VCT
assembly could be damaged. When
0
removing the VCT assembly, do not i
turn the intake camshaft. Otherwise,
the intake and exhaust valves could 1
collide with each other and be
damaged.
2
f
3
7. Remove the camshaft caps j, k, and
l in the order a, b, and so on. 4
PORT STBD j
j k k
e a a a a 5
c c c c
b b b b
6
d d d
6. Secure the exhaust camshaft using a
wrench, and then remove the driven
d
7
sprocket i. NOTICE: When removing
the driven sprocket, do not turn the l
l
exhaust camshaft. Otherwise, the
intake and exhaust valves could 8. Remove the camshafts m, n, o, and p
8
collide with each other and be and oil seals q, and then remove the
damaged. valve lifters r.
9
10
A
7-46
POWR
Power unit
q q Checking the camshaft

1. Check the edge and face of the flange on
p the camshafts (PORT) and intake cam-
shaft (STBD) that is used for the cam
position sensor. Replace the camshaft if
damaged, rough, or scratched.
q
o r
q
n
m
r TIP:
• Be careful not to scratch or damage the
TIP: face of the flange.
Make sure to keep the parts in the order of • If there is a scratch that is more than
removal. 0.2 mm (0.008 in) deep or more than
0.5 mm (0.020 in) wide on the surface of
Checking the sprocket the flange, a malfunction may occur in the
1. Check the VCT assemblies and driven cam position sensor signal.
sprockets. Replace the VCT assembly or
driven sprocket if cracked, damaged, or 2. Measure the cam lobe height a and
worn. width b.
Checking the valve lifter

1. Check the valve lifters. Replace if dam-
aged, scratched, or worn. a
2. Measure the valve lifter outside diameter

a.
Cam lobe height a:

Intake:
46.661–46.761 mm
(1.8370–1.8410 in)
Exhaust:
a
46.960–47.060 mm
(1.8488–1.8528 in)
Valve lifter outside diameter a: Cam lobe width b:
30.970–30.980 mm Intake and exhaust:
(1.2193–1.2197 in) 35.950–36.050 mm
(1.4154–1.4193 in)
7-47
Camshaft
3. Measure the camshaft runout.
a
0
1
2. Check the spark plug. Replace if the
Camshaft runout: 0.030 mm (0.0012 in) electrodes are eroded, or there is carbon
or other deposits.
2
4. Measure the camshaft journal diameter
c and camshaft journal inside diameter 3. Check the spark plug gap b. Replace if
d. Replace the camshaft, cylinder head
assembly, or both if out of specification.
out of specification. 3
c
4
d b 5
c
d Specified spark plug: LFR6A-11 (NGK)

Spark plug gap b:
6
1.0–1.1 mm (0.039–0.043 in)
Installing the camshaft and driven 7

Camshaft journal diameter c: sprocket
24.960–24.980 mm If the valve clearances are adjusted or any
(0.9827–0.9835 in)
Camshaft journal inside diameter d:
parts related to valve movement are replaced
after installing the timing belt, check the valve 8
25.000–25.021 mm clearances. See “Checking the valve clear-
(0.9843–0.9851 in) ance” (7-2).
Checking the spark plug 9

1. Clean the electrodes a using a spark • Do not reuse a gasket or oil seal, always
plug cleaner. replace it with a new one.
• When the timing belt is not installed, do 10
not turn the crankshaft or camshafts.
Otherwise, the pistons and valves or
intake and exhaust valves could collide
with each other and be damaged.
A
7-48
POWR
Power unit
1. Check that the large “L” mark a on the 4. Install the camshafts e, f, g, and h in
crankshaft is aligned with the mating sur- the proper positions and new oil seals i.
face of the crankcase and cylinder block.
i
e
a
6CB
P-IN
6CB
P-EX i
f
2. Apply a thin, even coat of sealant to the
mating surfaces of the camshaft caps a
and b and cylinder heads c.
6CB 6CB
PORT S-EX
a b S-IN
g d h
TIP:
c
Install the valve lifters in their original posi-
tions.
5. Check that the dowels a and b on the

camshafts (PORT) are aligned with the
mating surface of the cylinder head.
PORT
STBD
b a
a
b
c
6. Check that the dowels c and d on the

camshafts (STBD) are positioned 60°
from the mating surface of the cylinder
head.
TIP:
Do not block the oil passages or oil holes with
the sealant.
3. Install the valve lifters d.
7-49
Camshaft
STBD
PORT STBD
60°
d m 0
d d
60°
d d
c
b
b b
b
1
c c c c
7. Install the camshaft caps j, k, and l in
their proper positions so that the
stamped numbers are upside down.
a a a a
2
8. Install the camshaft cap bolts m and n. n
m
k 3
l
m
j
Camshaft cap bolts m and n:
1st: 8 N·m (0.8 kgf·m, 5.9 ft·lb) 4
n 2nd: 17 N·m (1.7 kgf·m, 12.5 ft·lb)
n l
n
l
l
n
10. Check that the dowels a and b on the
camshafts (PORT) are aligned, and 5
check that the dowels c and d on the
PORT STBD camshafts (STBD) are aligned.
1P
j k k
5S 5P
j
1S PORT 6
6S 6P 2S
7
2P
3P 7S 7P 3S
a
4P 8S 8P 4S
b 8
l l STBD
9
9. Tighten the camshaft cap bolts m and n
to the specified torques in 2 stages and d
in the order a, b, and so on. 10
c
11. Install the driven sprockets o.
A
7-50
POWR
Power unit
12. Secure the exhaust camshaft using a
wrench, and then tighten the driven e f
sprocket bolts p to the specified torque.
NOTICE: When tightening the bolt, do
not turn the exhaust camshaft.
and be damaged.
p
o
15. Secure the intake camshaft using a
wrench, and then tighten the VCT bolts
s to the specified torque.
NOTICE: When tightening the VCT
bolt, do not secure the driven
p sprocket. Otherwise, the VCT
assembly could be damaged. When
tightening the VCT bolt, do not turn
the intake camshaft. Otherwise, the
intake and exhaust valves could
collide with each other and be
damaged.
Driven sprocket bolt p: s
60 N·m (6.0 kgf·m, 44.3 ft·lb)
13. Install the VCT assemblies q and r.

q
r
VCT bolt s: 60 N·m (6.0 kgf·m, 44.3 ft·lb)
16. Install a new gasket t and the VCT cap

u, secure the VCT assembly using the
14. Check that the lower edges e and f of special service tool v, and then tighten
the driven sprockets and VCT the VCT cap u to the specified torque.
assemblies are aligned. NOTICE: When tightening the VCT
cap, do not secure the camshaft.
Otherwise, the VCT assembly could
be damaged. When tightening the VCT
cap, do not turn the driven sprocket.
and be damaged.
7-51
Camshaft
19. Turn the crankshaft clockwise 60°
u
gradually until the large “L” mark k on
t the crankshaft is aligned with the rib m
on the cylinder block. NOTICE: Do not
turn the crankshaft clockwise more
than 60°. Otherwise, the pistons and
0
u
and be damaged.
1
k
2
m
60°
3
v
Sheave holder v: 90890-01701 20. Install the cylinder head covers w and
x. 4
VCT cap u: 32 N·m (3.2 kgf·m, 23.6 ft·lb) w
17. Check that the “II” marks g on the VCT
assembly (PORT) and driven sprocket 5
(PORT) are aligned.
PORT
6
7
g
x
8
18. Check that the “I” marks h on the VCT
assembly (STBD) and driven sprocket
(STBD) are aligned.
21. Install the spark plugs, and then tighten
9
STBD
them to the specified torque.
Spark plug: 28 N·m (2.8 kgf·m, 20.7 ft·lb) 10
22. Install the ignition coils.
A
7-52
POWR
Power unit
Cylinder head
1 7 N·m (0.7 kgf·m, 5.2 ft·lb) 19
4
5 14 18
6 17 1
2 3 9 7 8
13
10
16 2
15
13 3 23
22
10 11 8
24
4
5
6
11 6
13 17 25
20 25
19 5 4 27
18
16 21 8 29 28
13 15 26
7 8
14 12 20 21 26
a 14 N·m (1.4 kgf·m, 10.3 ft·lb) 30
b 28 N·m (2.8 kgf·m, 20.7 ft·lb) 27
28
32
a 14 N·m (1.4 kgf·m, 10.3 ft·lb) 31 30
b 28 N·m (2.8 kgf·m, 20.7 ft·lb) 29
a 39 N·m (3.9 kgf·m, 28.8 ft·lb) 56 N·m (5.6 kgf·m, 41.3 ft·lb) 11
b 180° 23 N·m (2.3 kgf·m, 17.0 ft·lb) 12 10 10 11

1 OCV bolt 6 M6 35 mm
2 OCV assembly 2
3 Filter 2 39
4 Bolt 3 M6 20 mm
5 Cam position sensor 3
6 O-ring 3 39
7 Gasket 2 39
8 Dowel 4
9 Cylinder head (PORT) 1
10 Cylinder head bolt 16 M11 120 mm
13 Bolt 16 M8 25 mm
14 Anode assembly 8
15 Bolt 8 M6 20 mm
16 Gasket 8 39
17 Cover 8
7-53
Cylinder head
1 7 N·m (0.7 kgf·m, 5.2 ft·lb) 19

4
18
2 3
6
5
9 7 8
14
17 1 0
13
10
2
15
16
13 3
1
23
22
10 11 8
24
4
2
5
6
11 6
13 17 25
3
20 25
19 5 4 27
18 8 29 28
13 15
16 21
8 26
4
7
14 12 20 21 26
a 14 N·m (1.4 kgf·m, 10.3 ft·lb) 30
b 28 N·m (2.8 kgf·m, 20.7 ft·lb)
32
27
28
5
a 14 N·m (1.4 kgf·m, 10.3 ft·lb) 31 30
b 28 N·m (2.8 kgf·m, 20.7 ft·lb) 29
a 39 N·m (3.9 kgf·m, 28.8 ft·lb)

b 180°
56 N·m (5.6 kgf·m, 41.3 ft·lb) 11 6
23 N·m (2.3 kgf·m, 17.0 ft·lb) 12 10 10 11

18 Anode 8
19 Grommet 8
20
21
Exhaust plug
Gasket
2
2
M18 17 mm
39
8
22 Intake valve 12
23
24
Exhaust valve
Cylinder head (STBD)
12
1 9
25 Valve guide 24 39
26 Valve seal 24 39
27
28
Valve spring seat
Valve spring
24
24
10
29 Valve spring retainer 24
30 Valve cotter 48
31 Braided plug 1 M14 12 mm
32 Gasket 1 39
A
7-54
POWR
Power unit
Removing the cylinder head
1. Remove the OCVs a and filters a.
e
2. Remove the cylinder heads b and
gaskets c. NOTICE: Be careful not to f
scratch or damage the mating
surfaces of the cylinder head and
cylinder block.
a
c Valve spring compressor e: 90890-04019
Valve spring compressor attachment f:
90890-06320
TIP:
Make sure to keep the parts in the order of
removal.
Disassembling the cylinder head 3. Remove the valve seal g.

1. Remove the cam position sensors a,
anode assemblies b, exhaust plug c, g
and braided plug d.
b
c b
d
Checking the cylinder head

1. Remove carbon deposits from the com-
bustion chambers and check the cylinder
head for damage and scratches.
a
2. Check the cylinder head warpage in 6
directions. Replace the cylinder head if
2. Remove the intake and exhaust valves. above specification.
7-55
Cylinder head
a
1
Valve spring free length a:
48.1 mm (1.89 in) 2
2. Measure the valve spring tilt b. Replace
if above specification.
b
3
Cylinder head warpage limit:
0.10 mm (0.0039 in) 4
Checking the cylinder head bolt
1. Measure the diameters a and b of the
cylinder head bolt at the specified mea-
5
suring points c and d. Replace the cyl-
inder head bolt if the difference between Valve spring tilt limit b: 1.7 mm (0.07 in)
the diameters is above specification.
Checking the valve
6
1. Check the valve face. Replace if pitted or
b a worn.
2. Measure the valve margin thickness a.

7
d c
a 8
Cylinder head bolt diameter difference
limit:
9
a – b = Less than 0.20 mm (0.0079 in)
Measuring point c: 10.0 mm (0.39 in)
Measuring point d: 85.0 mm (3.35 in) 10
Checking the valve spring Valve margin thickness a:
1. Measure the valve spring free length a. Intake:
0.750–1.150 mm (0.0295–0.0453 in)
Exhaust:
0.900–1.300 mm (0.0354–0.0512 in)
A
7-56
POWR
Power unit
3. Measure the valve stem diameter b.
Valve guide inside diameter a:
Intake and exhaust:
5.504–5.522 mm (0.2167–0.2174 in)
b 2. Calculate the valve guide clearance.

Replace the valve guide if out of
specification.
Valve guide clearance:
Intake:
0.012–0.045 mm (0.0005–0.0018 in)
Exhaust:
0.025–0.058 mm (0.0010–0.0023 in)
Valve stem diameter b:
Intake: Replacing the valve guide
5.477–5.492 mm (0.2156–0.2162 in) After replacing a valve guide, check the valve
Exhaust: seat contact area.
5.464–5.479 mm (0.2151–0.2157 in)
1. Remove the valve guide a from the com-
4. Measure the valve stem runout. bustion chamber side using the special
service tool b.
a b
Valve stem runout:

Intake and exhaust: Valve guide remover/installer b:
0.01 mm (0.0004 in) 90890-06801
Checking the valve guide 2. Install a new valve guide c from the
Before checking the valve guides, make sure camshaft side to the specified position a
to check the valves. using the special service tool b.
NOTICE: Do not reuse a valve guide,
1. Measure the valve guide inside diameter
a.
b
a
a
c
7-57
Cylinder head
Valve guide remover/installer b:

a
90890-06801
Valve guide installation height a:

11.300–11.700 mm 0
(0.4449–0.4606 in)
3. Insert the special service tool d into the

valve guide c, and then ream the valve 1
guide.
Valve lapper a: 90890-04101
d
4. Measure the valve seat contact width a
2
where the blueing dye adhered to the
valve face. Reface the valve seat if the
c
valve is not seated properly or if the valve
seat contact width is out of specification.
3
Check the valve guide if the valve seat
contact width is uneven.
4
Valve guide reamer d: 90890-06804
TIP:
• To ream the valve guide, turn the special
5
a
service tool d clockwise.
• When removing the special service tool d,
do not turn it counterclockwise. 6
• After reaming the valve guide, make sure to
clean it.
4. Measure the valve guide inside diameter.

7
Valve guide inside diameter:
Intake and exhaust:
5.504–5.522 mm (0.2167–0.2174 in) 8
Checking the valve seat
1. Remove carbon deposits from the valve.
9
2. Apply a thin, even layer of Mechanic’s
blueing dye (Dykem) onto the valve seat.
3. Push the valve lightly against the valve

10
seat using the special service tool a. 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)
A
7-58
POWR
Power unit
Refacing the valve seat
45˚
a
After every lapping procedure, make sure
to clean off any remaining lapping com-
pound from the cylinder head and valves.
1. Reface the valve seat using the special

service tools.
a Slag or rough surface
3. Adjust the top edge of the valve seat

contact width using a 30° cutter.
30 45 60
30˚
b
Valve seat cutter holder: 90890-06316

Intake:
Valve seat cutter 30°: 90890-06331
Valve seat cutter 60°: 90890-06333 b Previous contact width
Exhaust:
4. Adjust the bottom edge of the valve seat
contact width using a 60° cutter.
b
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 60˚
using a downward force of 40–50 N
(4.0–5.0 kgf, 8.8–11.0 lbf).
b Previous contact width
5. Adjust the valve seat contact width to

specification using a 45° cutter.
7-59
Cylinder head
• If the valve seat contact area is too narrow
and situated near the bottom edge of the
b valve face, cut the bottom edge of the valve
c seat using a 60° cutter to center the area,
and then set its width using a 45° cutter. 0
45˚ b 1
c Specified contact width
2
6. Check the valve seat contact area of the 60˚
valve. See “Checking the valve seat” (7-
58).
Example:
3
• If the valve seat contact area is too wide 7. After refacing the valve seat to the
and situated in the center of the valve face, specified contact width, apply a thin,
cut the top edge of the valve seat using a
30° cutter, and then cut the bottom edge
even layer of lapping compound onto the
valve seat, and then lap the valve using
4
using a 60° cutter to center the area and set the special service tool a. NOTICE: Do
its width. not get the lapping compound on the
valve stem and valve guide. 5
30˚
a
b
6
60˚ 7
• If the valve seat contact area is too narrow
and situated near the top edge of the valve
Valve lapper a: 90890-04101 8
face, cut the top edge of the valve seat 8. Recheck the valve seat contact area of
using a 30° cutter to center the area, and the valve. See “Checking the valve seat”
then set its width using a 45° cutter. (7-58). 9
30˚ Checking the cylinder head anode
b 1. Check the anodes. Replace if eroded.
Clean if there is grease, oil, or scales. 10
NOTICE: Do not apply grease, oil, or
paint to the anodes.
Assembling the cylinder head

1. Install a new valve seal a. NOTICE: Do
not reuse a valve seal, always replace
b Previous contact width it with a new one. A
7-60
POWR
Power unit
4. Tap the valve spring retainer lightly using
a
a plastic hammer to seat the valve
cotters h securely.
2. Install the valve b, valve spring seat c,

valve spring d, and valve spring retainer
e in this order, and then install the
special service tools f and g.
h h
e
d
c
e
d
f
c
g
5. Install the cam position sensors i and
anode assemblies j.
6. Install the exhaust plug k and braided

plug l, and then tighten them to the
b specified torque.
b j
l k
Valve spring compressor f: 90890-04019 j

Valve spring compressor attachment g:
90890-06320
3. Compress the valve spring, and then

install the valve cotters h.
h
i
Exhaust plug k:
56 N·m (5.6 kgf·m, 41.3 ft·lb)
Braided plug l:
23 N·m (2.3 kgf·m, 17.0 ft·lb)
7-61
Cylinder head
Installing the cylinder head 90˚
f PORT b STBD f
e (T55) 90˚ e
Do not reuse a filter, gasket, or O-ring,
f f 0
a b b a
1. Install new filters a and the OCVs a,
and then tighten the OCV bolts b to the
specified torque.
d c c d 1
2. Install new gaskets c, the dowels d, h g
and the cylinder heads e, and then
tighten the cylinder head bolts f to the h
g h
2
k j i gg i j k h
specified torques in 2 stages and in the
order a, b, and so on. OCV bolt b: 7 N·m (0.7 kgf·m, 5.2 ft·lb)
Cylinder head bolt f a–h (M11): 3
3. Tighten the cylinder head bolts g and h 1st: 39 N·m (3.9 kgf·m, 28.8 ft·lb)
to the specified torques in 2 stages and 2nd: 180°
in the order i, j, and so on.
g
Cylinder head bolt g and h i–k (M8):
1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb) 4
2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
e f
h
a
TIP:
In the second stage, mark the M11 bolts and
5
cylinder heads with identification marks b,
1377B b
tighten the M11 bolts 90° from the marks,
and then tighten another 90°. 6
a
c 7
8
d d
9
10
A
7-62
POWR
Power unit
Oil cooler and oil pump assembly
49 N·m (4.9 kgf·m, 36.1 ft·lb)
13
19
14 20
18 N·m (1.8 kgf·m, 13.3 ft·lb)
15
17
21
16 21
22
18
22
1
23
19
5 25
2 24
6 20
31 26
30
4 32
3
32 4 N·m (0.4 kgf·m, 3.0 ft·lb) 27
7
27
12 28
11 33
10 29
8 9 34
12 N·m (1.2 kgf·m, 8.9 ft·lb) 35 a 6 N·m (0.6 kgf·m, 4.4 ft·lb)
12 N·m (1.2 kgf·m, 8.9 ft·lb) b 12 N·m (1.2 kgf·m, 8.9 ft·lb)
13 N·m (1.3 kgf·m, 9.6 ft·lb) 35

1 Oil filter 1
2 Union bolt 1
3 Oil pressure sensor 1
4 O-ring 1 39
5 Gasket 1 39
6 Bracket 1
7 Hose 1
8 Bracket bolt 1 M6 25 mm
9 Bracket bolt 5 M6 45 mm
10 Holder 1
11 Cover 1
12 Gasket 1 39
13 Oil filler cap 1
14 O-ring 1 39
15 Oil filler neck 1
16 O-ring 1 39
17 Holder 1
7-63
49 N·m (4.9 kgf·m, 36.1 ft·lb)

13
19
14 20
18 N·m (1.8 kgf·m, 13.3 ft·lb)
15
17 0
21
16
18
21
22 1
22
1
19
23 2
2 6
5 25
24
20
3
31 26
3
4 32
30
4
32 4 N·m (0.4 kgf·m, 3.0 ft·lb) 27
7
11
12 28
27
5
33 29
10
8 9 34
12 N·m (1.2 kgf·m, 8.9 ft·lb)
12 N·m (1.2 kgf·m, 8.9 ft·lb)
35 a 6 N·m (0.6 kgf·m, 4.4 ft·lb)
b 12 N·m (1.2 kgf·m, 8.9 ft·lb) 6
13 N·m (1.3 kgf·m, 9.6 ft·lb) 35

18 Bolt 2 M6 25 mm
19 Gasket 2 39
20
21
Bolt
Screw
12
2
M6 40 mm
M6 16 mm
8
22 Anode 2
23
24
Cover
Holder
1
1 9
25 Oil cooler 1
26 Hose 1
27
28
Plastic tie
Hose
2
1
10
29 Oil pump assembly 1
30 Relief valve 1
31 Oil seal 1 39
32 O-ring 2 39
33 Gasket 1 39
34 Oil seal 1 39
A
7-64
POWR
Power unit
49 N·m (4.9 kgf·m, 36.1 ft·lb)

13
19
14 20
18 N·m (1.8 kgf·m, 13.3 ft·lb)
15
17
21
16 21
22
18
22
1
23
19
5 25
2 24
6 20
31 26
30
4 32
3
32 4 N·m (0.4 kgf·m, 3.0 ft·lb) 27
7
27
12 28
11 33
10 29
8 9 34
12 N·m (1.2 kgf·m, 8.9 ft·lb) 35 a 6 N·m (0.6 kgf·m, 4.4 ft·lb)
12 N·m (1.2 kgf·m, 8.9 ft·lb) b 12 N·m (1.2 kgf·m, 8.9 ft·lb)
13 N·m (1.3 kgf·m, 9.6 ft·lb) 35

35 Oil seal 2 39
7-65
Removing the oil filter bracket
1. Remove the oil filter a. c
d
a
1
b
a
Oil filter wrench b: 90890-06830

2
2. Remove the oil pressure sensor c, O-
ring d, and oil filter union bolt e.
c
3
3. Remove the cover f, gasket g, oil filter b
bracket h, and gasket i.
Removing the oil pump assembly
1. Remove the oil pump assembly a, O-
4
i rings b, and oil seal c.
e h
5
c
d b 6
c
b a
f
g
7
Removing the oil cooler
1. Remove the cover a, oil cooler b, gas-
8
kets c, and anodes d.
Disassembling the oil pump
assembly
1. Remove the oil pump cover a, gasket 9
a, inner rotor b, outer rotor c, and oil
seals b and c.
10
A
7-66
POWR
Power unit
b a
c b
a
c
a
b
Driver rod L3 b: 90890-06652

a Needle bearing attachment c:
90890-06612
Checking the oil pump assembly TIP:

1. Check the inner surface of the oil pump Install an oil seal halfway into the oil pump
housing. Replace the oil pump assembly housing, and then install the other oil seal.
if scratched.
2. Install a new oil seal d into the oil pump
2. Check the gear teeth of the inner rotor
housing a.
and outer rotor. Replace the oil pump
assembly if the gear teeth are cracked or d
worn.
e
Checking the oil cooler a
1. Check the oil cooler. Replace if corroded
or cracked.
Checking the oil cooler anode

1. Check the anode. Replace if eroded.
Clean if there is grease, oil, or scales.
NOTICE: Do not apply grease, oil, or Bearing inner race attachment e:
paint to the anode. 90890-06640
3. Install the outer rotor b, the inner rotor

Assembling the oil pump assembly
c, a new gasket f, and the oil pump
cover d, and then tighten the oil pump
cover screws e to the specified torque.
Do not reuse an oil seal, always replace it
with a new one. 4. Install a new oil seal g so that it is facing
in the proper direction.
1. Install new oil seals a into the oil pump
housing a.
7-67
Installing the oil cooler
g
c
with a new one. 0
e
1. Install the anodes a.
d 2. Install a new gasket b, the oil cooler c,

1
b a new gasket d, and the cover e, and
then tighten the oil cooler bolts f to the
order a, b, and so on.
2
f
Oil pump cover screw e: d f

4 N·m (0.4 kgf·m, 3.0 ft·lb)
a
3
Installing the oil pump assembly
a
4
with a new one. e
1. Install new O-rings a and the oil pump

5
assembly b by aligning the oil pump
gear with the crankshaft.
f
6
b
c 7
f k
j h 8
g d
c
a
9
b
a e 10
f i l
a
Oil cooler bolt f:
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
b 2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
A
7-68
POWR
Power unit
Installing the oil filter bracket
h
Do not reuse a gasket or O-ring, always
replace it with a new one.
1. Install a new gasket a, the oil filter

bracket b, a new gasket c, the cover d, i
and the holder e, and then tighten the oil j
filter bracket bolts f and g to the speci-
fied torque in the order a, b, and so on. Oil filter union bolt h:
49 N·m (4.9 kgf·m, 36.1 ft·lb)
Oil pressure sensor j:
a
13 N·m (1.3 kgf·m, 9.6 ft·lb)
b
4. Add a small amount of engine oil through
the oil passage a of the oil filter bracket.
c
d
f
g e
g a
a
5. Install the oil filter k, and then tighten it
f to the specified torque.
g
f
d e
l k
g
c b
g g
Oil filter bracket bolt f and g:

12 N·m (1.2 kgf·m, 8.9 ft·lb)
k
2. Install the oil filter union bolt h, and then
tighten it to the specified torque. Oil filter wrench l: 90890-06830
3. Install a new O-ring i and the oil Oil filter k: 18 N·m (1.8 kgf·m, 13.3 ft·lb)
pressure sensor j, and then tighten the
oil pressure sensor to the specified
torque.
7-69
Oil cooler and oil pump assembly / Cylinder block sensor and switch
Cylinder block sensor and switch
1
34 33
a 14 N·m (1.4 kgf·m, 10.3 ft·lb)
b 28 N·m (2.8 kgf·m, 20.7 ft·lb) 13 0
2 12 14
3 1 34 9
11
6
11
9
12 N·m (1.2 kgf·m, 8.9 ft·lb) 10
1
1 24
26
4 12 22
7
6 13 8
23
25 29
2
10
33
5 20 14 27
14 28
3
21 30
17
14
29 31
4
16
32
18 14
19 27
28
5
15
32 N·m (3.2 kgf·m, 23.6 ft·lb)
6

1 Clamp 4
2 Hose 1
3
4
Hose
Joint
1
1
8
5 Hose 1
6
7
Clamp
Joint
2
1 9
8 Knock sensor bracket bolt 4 M6 25 mm
9 Housing 2
10
11
Gasket
Thermostat
2
2
39
10
12 Gasket 2 39
13 Cover 2
14 Plastic tie 6
15 Holder 2
16 Hose 1
17 Hose 1
A
7-70
POWR
Power unit
1
34 33
a 14 N·m (1.4 kgf·m, 10.3 ft·lb)
b 28 N·m (2.8 kgf·m, 20.7 ft·lb) 13
2 12 14
3 1 34 9
9 11
12 N·m (1.2 kgf·m, 8.9 ft·lb) 10
11
1 6 24
26
4 12 22
25 29
7 23
6 13 8
10
33
5 20 14 27
14 28
21 30
17
29 31
14
16
32
18 14
28
19 27
15
32 N·m (3.2 kgf·m, 23.6 ft·lb)

18 Joint 1
19 Hose 1
20 Bracket 1
21 Knock sensor 1
22 Pulley bracket bolt 4 M8 30 mm
23 Bracket 1
24 Engine temperature sensor 1
25 Hose 1
26 Holder 1
27 Bolt 2 M6 12 mm
28 Holder 2
29 Thermoswitch 2
30 Bolt 1 M6 16 mm
31 Bracket 1
32 Plastic tie 1
33 Thermostat cover bolt 4 M6 25 mm
34 Thermostat housing bolt 6 M6 25 mm
7-71
Removing the pulley bracket 3. Remove the thermoswitches f.
1. Remove the bracket a.
d
a
a
0
c
b
e
1
f
Removing the knock sensor

2
a
1. Remove the bracket a.
2. Remove the knock sensor b. Checking the thermostat 3

1. Suspend the thermostat in a container of
water.
a
2. Place a thermometer in the water and 4
heat the water slowly.
5
b
3. Remove the hoses c, d, and e and 6

joints f and g.
7
3. Measure the thermostat valve opening a
c at the specified water temperatures.
d
c
8
a
f d
9
g
e e
10
Removing the thermostat
1. Remove the hoses a and thermostat
covers b, and then remove the thermo- Water temperature Valve opening a
stats a and gaskets c. 50–54 °C
Starts opening
(122–129 °F)
2. Remove the thermostat housings d and above 62 °C 4.3 mm (0.17 in) or
gaskets e. (144 °F) above A
7-72
POWR
Power unit
Installing the thermostat f
Do not reuse a gasket, always replace it a

with a new one.
b
f a
1. Install the thermoswitches a.
f
d g b
2. Install new gaskets b and the thermostat
housings c, and then tighten the
thermostat housing bolts d to the
specified torque. e
g
c c
3. Install new gaskets e to the thermostats
a. 2. Install the knock sensor h to the bracket
i, and then tighten the knock sensor h
4. Install the thermostats a, thermostat to the specified torque.
covers f, and hoses g, and then tighten
the bolts h to the specified torque. 3. Install the bracket i, and then tighten
the knock sensor bracket bolts j to the
c d specified torque in the order a, b, and
a so on.
j
e
f i
a b
h
h
g b
d
Thermostat housing bolt d: c i
12 N·m (1.2 kgf·m, 8.9 ft·lb) a
Thermostat cover bolt h:
12 N·m (1.2 kgf·m, 8.9 ft·lb) Knock sensor h:
32 N·m (3.2 kgf·m, 23.6 ft·lb)
Installing the knock sensor Knock sensor bracket bolt j:
1. Install the hoses a, b, and c and joints 12 N·m (1.2 kgf·m, 8.9 ft·lb)
d and e, and then fasten the hoses
using the clamps f and g. Installing the pulley bracket
1. Install the bracket a, and then tighten
the timing belt pulley bracket bolts b to
7-73
b b
c
a 0
a
a d 1
2
Timing belt pulley bracket bolt b:
1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb) 3
2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
4
5
6
7
8
9
10
A
7-74
POWR
Power unit
Cylinder block
4 4 a 55 N·m (5.5 kgf·m, 40.6 ft·lb)
5 5 b 90°
1 3 a 55 N·m (5.5 kgf·m, 40.6 ft·lb)
b 90°
3 2 23
2
21
4 5
8 24
5
10 9
4 6
12
7 11
9
13 20
15
16 19
19 22
18 25
17
14
18
15 a 40 N·m (4.0 kgf·m, 29.5 ft·lb) a 14 N·m (1.4 kgf·m, 10.3 ft·lb)
b 90° b 28 N·m (2.8 kgf·m, 20.7 ft·lb)

1 Cylinder block 1
2 Anode 2
3 Screw 2 M5 26 mm
4 Screw 4 M6 25 mm
5 Anode 4
6 Screw 2 M6 45 mm
7 Anode 2
8 Oil seal 1 39
9 Thrust bearing 2
10 Crankshaft journal bearing (upper) 4
11 Crankshaft journal bearing (lower) 4
12 O-ring 2 39
13 Piston ring set 6
14 Piston 6
15 Clip 12 39
16 Piston pin 6
17 Connecting rod assembly 6
7-75
Cylinder block
4 4 a 55 N·m (5.5 kgf·m, 40.6 ft·lb)

5 5 b 90°
1
3
3 a 55 N·m (5.5 kgf·m, 40.6 ft·lb)
b 90°
0
2 23
2
21 1
4 5
5
8 24
2
10 9
4 6
3
12
7 11
9
13
15
20 4
16 19
19
18
22
25
5
17
14
18
15 a 40 N·m (4.0 kgf·m, 29.5 ft·lb) a 14 N·m (1.4 kgf·m, 10.3 ft·lb)
6
b 90° b 28 N·m (2.8 kgf·m, 20.7 ft·lb)

18 Connecting rod bolt 12 39 M9 42 mm
19 Crankpin bearing 12
20
21
Collar
Crankshaft
1
1
39 8
22 Crankcase 1
M10 105 mm
23
24
Crankcase bolt
Crankcase bolt
8
8 M10 130 mm 9
25 Crankcase bolt 16 M8 50 mm
10
A
7-76
POWR
Power unit
Disassembling the cylinder block
1. Remove the crankcase a. TIP:
• To prevent mixing the pistons, connecting
rods, and connecting rod caps, mark each
a
with an identification number b of the cor-
responding cylinder.
• Mark each connecting rod and connecting
rod cap with mark c on the side facing
toward the flywheel magnet end of the
crankshaft.
• Make sure to keep the parts in the order of
removal.
3. Remove the crankshaft d, crankshaft

journal bearings e, thrust bearings f,
and oil seal g.
d
2. Remove the connecting rod caps a, and
then remove the crankpin bearings b,
connecting rods, and piston assemblies g
c. e
f f
e e
a
c b
4. Remove the collar h.

b
h
c i
k
j d
b e
7-77
Cylinder block
Bearing splitter plate i: Piston diameter a:

(commercially available) 95.945–95.960 mm
Gear puller j: (commercially available) (3.7774–3.7779 in)
General cylindrical tool k:
d = 19 mm (0.7 in)
Measuring point b:
13.500 mm (0.5315 in) up from the
0
e = 90 mm (3.5 in) bottom of the piston skirt
5. Remove the piston pin clips l and piston

pin m, and then remove the connecting
Checking the cylinder bore
1. Measure the cylinder bore (D1–D6) at
1
rod f. measuring points a, b, and c, and in
direction d (D1, D3, D5), which is parallel
l to the crankshaft, and direction e (D2,
D4, D6), which is at a right angle to the
2
crankshaft.
m g
3
b a D2 D1
c d
D4 D3 e 4
f D6 D5
l
5
a 10.0 mm (0.39 in)
TIP: b 77.0 mm (3.03 in)
• Remove the piston pin from the side
marked with g.
c 106.0 mm (4.17 in) 6
• Make sure to keep the parts in the order of Cylinder bore (D1–D6):
removal. 96.000–96.012 mm
6. Remove the piston rings.

(3.7795–3.7800 in)
7
Checking the piston ring
1. Measure piston ring dimensions B and T.
Checking the piston diameter
1. Measure the piston diameter a at the a b 8
specified measuring point b.
B B
T T
9
c B
b
a T 10
A
7-78
POWR
Power unit
Piston ring dimension:

Top ring a:
a
B: 1.200 mm (0.0472 in)
T: 2.800–3.000 mm (0.1102–0.1181 in)
2nd ring b: b
B: 1.170–1.190 mm (0.0461–0.0469 in)
T: 3.800–4.000 mm (0.1496–0.1575 in) c
Oil ring c:
B: 2.400–2.470 mm (0.0945–0.0972 in)
T: 2.350–2.750 mm (0.0925–0.1083 in)
Piston ring groove:
Checking the piston ring end gap Top ring a:
1. Level the piston ring a in the cylinder 1.230–1.250 mm (0.0484–0.0492 in)
using a piston crown at the specified 2nd ring b:
measuring point a. 1.220–1.240 mm (0.0480–0.0488 in)
Oil ring c:
2. Measure the piston ring end gap b. 2.510–2.530 mm (0.0988–0.0996 in)
Checking the piston ring side

clearance
1. Measure the piston ring side clearance.
a
a a
b
b
Measuring point a (reference data): Piston ring side clearance:

20.0 mm (0.8 in) Top ring a:
Piston ring end gap b (reference data): 0.030–0.050 mm (0.0012–0.0020 in)
Top ring: 2nd ring b:
0.200–0.300 mm (0.0079–0.0118 in) 0.030–0.070 mm (0.0012–0.0028 in)
2nd ring: Oil ring c:
0.600–0.750 mm (0.0236–0.0295 in) 0.040–0.130 mm (0.0016–0.0051 in)
Oil ring:
0.150–0.600 mm (0.0059–0.0236 in) Checking the piston pin boss inside
diameter
Checking the piston ring groove 1. Measure the piston pin boss inside diam-
1. Measure the piston ring grooves. eter.
Replace the piston if out of specification.
7-79
Cylinder block
c 90˚ a
b
a b
0
c c
a
1
Connecting rod small end inside
diameter a:
22.010–22.024 mm
2
(0.8665–0.8671 in)
Piston pin boss inside diameter a: Connecting rod big end inside diameter b:
22.011–22.018 mm 55.990–56.010 mm
(2.2043–2.2051 in)
3
(0.8666–0.8668 in)
Connecting rod bolt a:

TIP:
When measuring the piston pin boss inside 1st: 40 N·m (4.0 kgf·m, 29.5 ft·lb) 4
diameter, do not measure it at the ring groove 2nd: 90°
b or oil groove c.
TIP:
• When checking the oil clearance, reuse the
5
Checking the piston pin diameter
removed connecting rod bolt.
1. Measure the piston pin diameter a.
• In the second tightening stage for the con-
necting rod bolts a, mark the connecting
rod bolts and the connecting rod cap with
6
a
identification marks c, and then tighten the
bolts 90° from the marks on the connecting
rod cap. 7
Checking the connecting rod big end
side clearance
1. Measure the connecting rod big end side
8
Piston pin outside diameter a: clearance a.
21.996–22.005 mm
(0.8660–0.8663 in)
9
Checking the connecting rod small
end inside diameter and big end
inside diameter
10
1. Tighten the bolts a to the specified
torques in 2 stages.
2. Measure the connecting rod small end

inside diameter a and big end inside
diameter b.
A
7-80
POWR
Power unit
Crankshaft journal diameter a:

72.976–72.996 mm
(2.8731–2.8739 in)
Crankpin diameter b:
52.980–53.000 mm
(2.0858–2.0866 in)
Crankpin width c:
a 21.000–21.100 mm
(0.8268–0.8307 in)
2. Measure the crankshaft runout.
Connecting rod big end side clearance a:

0.140–0.310 mm (0.0055–0.0122 in)
Checking the crankshaft Crankshaft runout: 0.030 mm (0.0012 in)

1. Measure the crankshaft journal diame-
ters a, crankpin diameters b, and Checking the crankcase bolt
crankpin widths c. 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-
ence between the diameters is above
specification.
A b a
a
d c
B b a
e c
c A M10 130 mm
b
B M10 105 mm
Crankcase bolt diameter difference limit:
a – b = Less than 0.20 mm (0.0079 in)
Measuring point c: 10.0 mm (0.39 in)
Measuring point d: 85.0 mm (3.35 in)
Measuring point e: 60.0 mm (2.36 in)
7-81
Cylinder block
Checking the crankpin oil clearance
1. Clean the crankpin bearings, connecting b
rod, connecting rod cap, and crankpin.
2. Install the crankpin bearings a into the

connecting rod a and connecting rod
a 0
cap b. d
a
a 1
b
c 2
3
TIP:
Install the crankpin bearings in the original
positions.
TIP:
• When checking the oil clearance, reuse the
4
removed connecting rod bolts.
3. Place a piece of Plastigauge (PG-1) on • Make sure that the marks d on the con-
the crankpin c, parallel to the necting rod a and connecting rod cap b
face toward the flywheel magnet end of the
5
crankshaft.
crankshaft.
• Do not turn the connecting rod until the
crankpin oil clearance measurement has 6
c been completed.
5. Tighten the bolts b to the specified

torques in 2 stages.
7
e
b 90˚ 8
TIP:
Do not place the Plastigauge (PG-1) over the
oil hole in the crankpin of the crankshaft. 9
4. Install the connecting rod a and
connecting rod cap b onto the crankpin
c.
Connecting rod bolt b:
10
1st: 40 N·m (4.0 kgf·m, 29.5 ft·lb)
2nd: 90°
A
7-82
POWR
Power unit
Example:
TIP:
In the second tightening stage for the con- Connecting rod big
necting rod bolts b, mark the connecting rod end inside diameter Number in table
bolts and the connecting rod cap with identifi- a
cation marks e, and then tighten the bolts 56.005 mm 05
90° from the marks on the connecting rod
2. Check the crankpin mark b on the
cap.
crankshaft.
6. Remove the connecting rod cap, and P1 P2 P4

then measure the width of the
compressed Plastigauge (PG-1) on the
crankpin.
P3 P5 P6
Crankpin oil clearance (reference data):

0.025–0.050 mm (0.0010–0.0020 in)
P1 P2 P3 P4 P5 P6
Selecting the crankpin bearing
3. Select the suitable colors c for the
When replacing the crankpin bearing, select
crankpin bearing from the “Crankpin
the bearing as follows:
bearing selection table.”
1. Measure the connecting rod big end
inside diameter a. c
c
a
Upper bearing Lower bearing

color color
Connecting rod big end inside diameter a: d Yellow Yellow
55.990–56.010 mm e Yellow Green
(2.2043–2.2051 in) f Green Green
g Blue Green
7-83
Cylinder block
Example:
If the connecting rod big end inside diameter
a is “05” h and the crankpin mark b is “81”
k, select the bearing colors in “g.” The
upper bearing color is blue and the lower
bearing color is green.
0
h
1
90 91 04 05 06 07
80 2
k 81
g
82
3
4
5
6
7
8
9
10
A
7-84
POWR
Power unit
Crankpin bearing selection table
a
90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 10
80
81
82
83 g
84
85
86
87
88 f
89
b 90
91
92
93 e
94
95
96
97 d
98
99
00
a Connecting rod big end inside diameter

b Crankpin mark
7-85
Cylinder block
Checking the crankshaft journal oil
clearance TIP:
Install the crankshaft journal bearings in the
After checking the crankshaft journal oil
original positions.
clearance, check the crankcase bolts. See
“Checking the crankcase bolt” (7-81).
6. Install the crankcase d, and then tighten
0
1. Clean the crankshaft journal bearings, the crankcase bolts e and f to the
crankshaft journals, and bearing portions
of the crankcase and cylinder block.
order a, b, and so on. 1
2. Place the cylinder block upside down. 7. Tighten the crankcase bolts g to the
3. Install the crankshaft journal bearings a

order q, r, and so on. 2
and crankshaft b into the cylinder block
c. e d
c
3
g
f
b
4
a 5
TIP:
Install the crankshaft journal bearings a in
the original positions.
6
4. Place a piece of Plastigauge (PG-1) on
each crankshaft journal a, parallel to the
7
crankshaft. b
90˚
a e
m
f
n
8
A B
w x
s
a
i
fe b
j
9
t
d c
v
l k
u 10
TIP: p o
z y
Do not place the Plastigauge (PG-1) over the
oil hole in each crankshaft journal. h g
C
5. Install the crankshaft journal bearings F E r g q D
into the crankcase.
A
7-86
POWR
Power unit
Crankcase bolts e and f a–p (M10): J1 J2 J3 J4

1st: 55 N·m (5.5 kgf·m, 40.6 ft·lb)
2nd: 90°
Crankcase bolt g q–F (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:
• Do not turn the crankshaft until the crank-
shaft journal oil clearance measurement
has been completed.
• In the second tightening stage for the M10 a
bolts e and f, mark the M10 bolts and the
crankcase with identification marks b, and
then tighten the bolts 90° from the marks on
the crankcase.
J1 J2 J3 J4
8. Remove the crankcase, and then J4 J3 J2 J1 b

measure the width of the compressed
Plastigauge (PG-1) on each crankshaft
journal.
2. Select the suitable colors c for the

crankshaft journal bearing from the
“Crankshaft journal bearing selection
table.”
Crankshaft journal oil clearance
(reference data): c
0.029–0.045 mm (0.0011–0.0018 in)
Selecting the crankshaft journal

bearing
When replacing the crankshaft journal bear-
ing, select the bearing as follows:
1. Check the crankshaft journal mark a on

the crankshaft and the cylinder block
mark b on the cylinder block.
7-87
Cylinder block
Upper bearing Lower bearing

color color
d Purple Purple
e
f
Purple
Yellow
Yellow
Yellow
0
g Yellow Red
h
k
Red
Red
Red
Green 1
m Green Green
n Green Brown
p Brown Brown 2
Example:
If the crankshaft journal mark a is “77” r
and the cylinder block mark b is “17” s,
select the bearing colors in “p.” The upper
3
bearing color is brown and the lower bearing
color is brown.
s
4
00 01 16 17 18 19 20 5
76
r 77
78
p 6
7
8
9
10
A
7-88
POWR
Power unit
Crankshaft journal bearing selection table
b
00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20
76
77 p
78
79
80 n
81
82 m
83
84 k
85
a 86 h
87
88 g
89
90 f
91
92 e
93
94
95 d
96
a Crankshaft journal mark

b Cylinder block mark
7-89
Cylinder block
Checking the cylinder block anode
1. Check the anodes. Replace if eroded. TIP:
Clean if there is grease, oil, or scales. • Face the mark b on the connecting rod a
NOTICE: Do not apply grease, oil, or in the same direction as the mark c on the
paint to the anodes. piston crown.
• Install the piston pin from the side marked
0
Assembling the cylinder block with c.
• Do not align the piston pin clip end with the
Before assembling the cylinder block, check
the crankcase bolts. See “Checking the groove d in the piston pin boss. 1
crankcase bolt” (7-81).
3. Install the oil rings e, 2nd ring f, and
Do not reuse a connecting rod bolt, collar,

top ring g.
2
4. Offset the piston ring end gaps. NOTICE:
oil seal, or piston pin clip, always replace
Be careful not to scratch the pistons
it with a new one.
or break the piston rings. 3
1. Install a new collar a by striking it using
e h
a plastic hammer.
#5 #4 4
a #3 f
g
45˚ 45˚
#2
#1 5
#5 #2
k 6
#1
#4 #3
2. Assemble the piston b, the connecting
rod a, the piston pin c, and new piston
pin clips d. TIP: 7
• Make sure that the “2R” marks h on the
d d 2nd ring f and “1R” marks k on the top
ring g are facing up.
• Make sure that the piston rings move
8
d c c smoothly.
b
5. Install the crankpin bearings e into the 9
connecting rod a and connecting rod
cap m.
a
e
a 10
d
m
b
A
7-90
POWR
Power unit
TIP:
Install the crankpin bearings in the original
positions.
6. Install the crankshaft journal bearings f.
f
j
f k
Piston ring compressor k: 90890-05158
9. Install the connecting rod caps m to the

TIP:
connecting rods, and then tighten new
Install the crankshaft journal bearings f in
bolts l to the specified torques in 2
the original positions.
stages.
7. Install a new oil seal g onto the r 90˚

crankshaft h, and then install the p
crankshaft and thrust bearings i. l
i m
Connecting rod bolt l:

1st: 40 N·m (4.0 kgf·m, 29.5 ft·lb)
2nd: 90°
TIP:
Install each thrust bearing with its grooves
facing outward.
8. Install the piston j so that the mark n

on the piston crown is facing toward the
flywheel magnet end of the crankshaft.
7-91
Cylinder block
TIP: p n
• Make sure that the marks p on the con-
necting rod and connecting rod cap m face
toward the flywheel magnet end of the
crankshaft.
q
r 0
• In the second tightening stage for the con- o
necting rod bolts l, mark the connecting
rod bolts and the connecting rod cap with
identification marks r, and then tighten the
o 1
bolts 90° from the marks on the connecting
rod caps.
• Make sure that the crankshaft turns 2
smoothly.
10. Install the crankshaft journal bearings m

in the original positions.
s 90˚ 3
e f
m n
11. Apply a thin, even layer of sealant onto
the mating surface of the crankcase n.
A
w
B
x 4
a qp b
i j
s t
m
d c 5
l k
v u
n
z
p o
y 6
m h g
F E r r q D
C
7
Crankcase bolts p and q a–p (M10):
TIP:
1st: 55 N·m (5.5 kgf·m, 40.6 ft·lb)
2nd: 90° 8
Do not apply any sealant to the crankshaft Crankcase bolt r q–F (M8):
journal bearings. 1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb)
2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
9
12. Install new O-rings o and the crankcase
n, and then tighten the bolts p and q to TIP:
• In the second tightening stage for the M10
the order a, b, and so on. bolts p and q, mark the M10 bolts and the 10
crankcase n with identification marks s,
13. Tighten the bolts r to the specified and then tighten the bolts 90° from the
torques in 2 stages and in the order q, marks on the crankcase.
r, and so on. • Make sure that the crankshaft turns
smoothly.
A
7-92
LOWR
Lower unit 8
Lower unit
(regular rotation model, X-transom model) .................... 8-1
Removing the lower unit ............................................................ 8-3
Disassembling the propeller ...................................................... 8-3
Checking the propeller .............................................................. 8-3
Checking the lower unit anode .................................................. 8-4
Assembling the propeller ........................................................... 8-4
Lower unit
(regular rotation model, U-transom model) .................... 8-6
Removing the lower unit ............................................................ 8-8
Disassembling the propeller ...................................................... 8-8
Checking the propeller .............................................................. 8-8
Checking the lower unit anode .................................................. 8-8
Assembling the propeller ........................................................... 8-8
Water pump and shift rod (regular rotation model) ....... 8-9
Removing the water pump and shift rod .................................. 8-11
Disassembling the water pump housing .................................. 8-11
Checking the water pump and shift rod ................................... 8-12
Assembling the water pump housing ...................................... 8-12
Propeller shaft housing (regular rotation model) ......... 8-14

Removing the propeller shaft housing assembly ..................... 8-16
Disassembling the propeller shaft assembly ........................... 8-17
Disassembling the reverse gear .............................................. 8-17
Disassembling the propeller shaft housing assembly ............. 8-17
Checking the propeller shaft .................................................... 8-18
Checking the dog clutch .......................................................... 8-18
Checking the propeller shaft housing ...................................... 8-18
Checking the reverse gear ...................................................... 8-18
Assembling the propeller shaft assembly ................................ 8-18
Assembling the reverse gear ................................................... 8-19
Assembling the propeller shaft housing assembly .................. 8-19
Drive shaft and lower case

(regular rotation model) .................................................. 8-21
Removing the drive shaft ......................................................... 8-23
Removing the forward gear ..................................................... 8-23
Disassembling the oil seal housing ......................................... 8-23
Disassembling the drive shaft ................................................. 8-23
Disassembling the forward gear .............................................. 8-24
Disassembling the lower case ................................................. 8-25
Checking the pinion ................................................................. 8-25
Checking the forward gear ...................................................... 8-25
Checking the drive shaft .......................................................... 8-25
Checking the lower case ......................................................... 8-25
Assembling the drive shaft ...................................................... 8-25
Assembling the forward gear ................................................... 8-27
Assembling the lower case ...................................................... 8-27
Assembling the oil seal housing .............................................. 8-28
Installing the forward gear ....................................................... 8-28
0
Installing the drive shaft ........................................................... 8-28
Installing the propeller shaft housing assembly ....................... 8-29
Installing the shift rod .............................................................. 8-31
Installing the water pump ........................................................ 8-31
1
Checking the lower unit for air leakage ................................... 8-32
Installing the lower unit (X-transom model) ............................. 8-33
Installing the lower unit (U-transom model) ............................. 8-34 2
Shimming (regular rotation model) ............................... 8-36
Shimming workflow ................................................................. 8-36
Shimming check sheet ............................................................ 8-37 3
Measuring the forward gear backlash and
reverse gear backlash before disassembly ............................. 8-39
Shimming ................................................................................ 8-42
Shim location ........................................................................... 8-42 4
Selecting the pinion shim (T3) ................................................. 8-43
Calculated value (B) table ....................................................... 8-46
Pinion shim (T3) selection table .............................................. 8-47
Measuring the forward gear backlash ..................................... 8-54 5
Adjusting the forward gear shim (T1) thickness ...................... 8-54
Forward gear shim (T1) selection table ................................... 8-56
Measuring the reverse gear backlash ..................................... 8-57
Adjusting the reverse gear shim (T2) thickness ...................... 8-57 6
Reverse gear shim (T2) selection chart .................................. 8-59
Selecting the propeller shaft shim (T4) .................................... 8-61
Lower unit
7
(counter rotation model, X-transom model) ................. 8-62
Removing the lower unit .......................................................... 8-64
Disassembling the propeller .................................................... 8-64 8
Checking the propeller ............................................................ 8-64
Checking the lower unit anode ................................................ 8-64
Assembling the propeller ......................................................... 8-64
9
Lower unit
(counter rotation model, U-transom model) ................. 8-65
Removing the lower unit .......................................................... 8-67 10
Disassembling the propeller .................................................... 8-67
Checking the propeller ............................................................ 8-67
Checking the lower unit anode ................................................ 8-67
Assembling the propeller ......................................................... 8-67
Water pump and shift rod (counter rotation model) .... 8-68
Removing the water pump and shift rod .................................. 8-70 A
LOWR
Disassembling the water pump housing .................................. 8-70
Checking the water pump and shift rod ................................... 8-70
Assembling the water pump housing ...................................... 8-70
Propeller shaft housing (counter rotation model) ........ 8-71

Removing the propeller shaft housing assembly ..................... 8-73
Disassembling the propeller shaft housing assembly ............. 8-73
Disassembling the forward gear .............................................. 8-73
Checking the propeller shaft .................................................... 8-74
Checking the dog clutch .......................................................... 8-74
Checking the propeller shaft housing ...................................... 8-74
Checking the forward gear ...................................................... 8-74
Assembling the propeller shaft housing assembly and
forward gear ............................................................................ 8-74
Drive shaft and lower case (counter rotation model) .. 8-76

Removing the drive shaft ......................................................... 8-78
Removing the reverse gear ..................................................... 8-78
Disassembling the oil seal housing ......................................... 8-78
Disassembling the drive shaft ................................................. 8-78
Disassembling the reverse gear .............................................. 8-78
Disassembling the lower case ................................................. 8-78
Checking the pinion ................................................................. 8-78
Checking the reverse gear ...................................................... 8-78
Checking the drive shaft .......................................................... 8-78
Checking the lower case ......................................................... 8-78
Assembling the drive shaft ...................................................... 8-78
Assembling the reverse gear ................................................... 8-78
Assembling the lower case ...................................................... 8-79
Assembling the oil seal housing .............................................. 8-79
Install the reverse gear ............................................................ 8-79
Installing the drive shaft ........................................................... 8-79
Installing the propeller shaft housing assembly ....................... 8-79
Installing the shift rod .............................................................. 8-80
Installing the water pump ........................................................ 8-80
Checking the lower unit for air leakage ................................... 8-80
Installing the lower unit (X-transom model) ............................. 8-80
Installing the lower unit (U-transom model) ............................. 8-80
Shimming (counter rotation model) .............................. 8-81

Shimming workflow ................................................................. 8-81
Shimming check sheet ............................................................ 8-82
reverse gear backlash before disassembly ............................. 8-84
Shimming ................................................................................ 8-87
Shim location ........................................................................... 8-87
Selecting the pinion shim (T3) ................................................. 8-88
Calculated value (B) table ....................................................... 8-88
Pinion shim (T3) selection table .............................................. 8-88
Selecting the propeller shaft shim (T4) .................................... 8-88
Propeller shaft shim (T4) selection table ................................. 8-90
Measuring the forward gear backlash ..................................... 8-91
Adjusting the forward gear shim (T2) thickness ...................... 8-91
Forward gear shim (T2) selection chart ................................... 8-93
Measuring the reverse gear backlash ..................................... 8-95
Adjusting the reverse gear shim (T1) thickness ...................... 8-95
Reverse gear shim (T1) selection table ................................... 8-97
0
1
2
3
4
5
6
7
8
9
10
A
LOWR
Lower unit
Lower unit (regular rotation model, X-transom model)
12 42 N·m (4.2 kgf·m, 31.0 ft·lb)
11
54 N·m (5.4 kgf·m, 39.8 ft·lb)
9 N·m (0.9 kgf·m, 6.6 ft·lb)
15
14
9 16
10 13
3
8 9 17
18
7 20 19
9 N·m (0.9 kgf·m, 6.6 ft·lb) 21
6
5 22 23
22
4
3 47 N·m (4.7 kgf·m, 34.7 ft·lb)
2 1 47 N·m (4.7 kgf·m, 34.7 ft·lb)
2 N·m (0.2 kgf·m, 1.5 ft·lb)

1 Water inlet cover (PORT) 1
2 Water inlet cover bolt 1 M5 40 mm
3 Gasket 2 39
4 Drain screw 1
5 Water inlet cover (STBD) 1
6 Self-locking nut 1
7 Hose nipple 1
8 O-ring 1 39
9 Dowel 2
10 Check screw 1
11 Trim tab bolt 1 M10 45 mm
12 Grommet 1
13 Lower unit 1
14 Propeller 1
15 Cotter pin 1 39
16 Propeller nut 1
17 Washer 1
8-1
12 42 N·m (4.2 kgf·m, 31.0 ft·lb)
11
54 N·m (5.4 kgf·m, 39.8 ft·lb) 0
9 N·m (0.9 kgf·m, 6.6 ft·lb)
15
9
14
16 1
10 13
3
8 9
18
17 2
7 20 19
3
9 N·m (0.9 kgf·m, 6.6 ft·lb) 21
4
6
5 22 23 5
22
4
3
2 1
47 N·m (4.7 kgf·m, 34.7 ft·lb)
47 N·m (4.7 kgf·m, 34.7 ft·lb) 6
2 N·m (0.2 kgf·m, 1.5 ft·lb)

18 Spacer 1
19 Damper 1 39
20
21
Spacer
Trim tab
1
1
8
22 Lower case mounting bolt 7 M10 45 mm
M10 70 mm
23 Lower case mounting bolt 1
9
10
A
8-2
LOWR
Lower unit
Removing the lower unit
• Make sure to disconnect the battery

cables from the battery, and remove the
d
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
outboard motor could fall suddenly and a
result in severe injuries.
• When loosening or tightening the pro-
b
peller nut, do not hold the propeller
using your hands. c
a
1. Drain the gear oil. See steps 1–6 in c
“Changing the gear oil” (10-10).
2. Remove the cotter pin. TIP:

When disassembling the lower unit, measure
3. Set the gear shift to the N position. the backlash before disassembly. See “Mea-
suring the forward gear backlash and reverse
4. Place a block of wood between the anti-
gear backlash before disassembly” (8-39).
cavitation plate and the propeller to
prevent the propeller from turning, and
then remove the propeller nut and Disassembling the propeller
propeller. 1. Remove the damper a.
b c a
5. Mark a the trim tab a and lower case, Driver rod L3 b: 90890-06652
and then remove the trim tab a. Needle bearing attachment c:
90890-06653
6. Remove the lower case mounting bolts
b and c, and then remove the lower Checking the propeller
unit d. 1. Check the propeller blades and splines.
Replace the propeller if cracked, dam-
aged, or worn.
8-3
Checking the lower unit anode Installation height c (reference data):
1. Check the trim tab. Replace if eroded. 4.0 mm (0.158 in)
paint to the trim tab.
TIP:
When installing the damper a, make sure
0
Assembling the propeller that the spacer d does not contact the pro-
peller boss.
1. Place a new damper a in the propeller
b. NOTICE: Do not reuse a damper, 1
always replace it with a new one. 3. Check the installation depth d of the
damper a.
a a b b d
2
a
a
3
4
TIP:
A
Align the mark a on the damper a with the
mark b on the propeller b. 5
2. Install the damper a using the special
service tool c and spacer d to the
specified height c. NOTICE: Be careful e
6
not to install the spacer in the f
opposite direction. a
B a 7
d
8
e
d
f
A Before tightening the propeller nut e to
9
d
c the specified torque.
c
B After tightening the propeller nut e to the
specified torque. 10
a Installation depth d (reference data):
9.4 mm (0.37 in)
Needle bearing attachment c:

90890-06653 A
8-4
LOWR
Lower unit
TIP:
The damper a will be in the proper position
(the damper a is in contact with the spacer
f) after the propeller nut e has been tight-
ened to the specified torque. Therefore, when
installing the propeller to the outboard motor,
make sure to tighten the propeller nut e to
the specified torque. See step 7 in “Installing
the lower unit (X-transom model)” (8-33).
8-5
Lower unit (regular rotation model, X-transom model) /
Lower unit (regular rotation model, U-transom model)
17
42 N·m (4.2 kgf·m, 31.0 ft·lb)
16
23 N·m (2.3 kgf·m, 17.0 ft·lb)
0
54 N·m (5.4 kgf·m, 39.8 ft·lb)
15
14 13
1
21
20
13 13 22 2
19
12 18
13
26 25
24
23
3
11 3
10
9
4
9 N·m (0.9 kgf·m, 6.6 ft·lb) 27
8
7
5
6 29
5 31
28
4 30
9 N·m (0.9 kgf·m, 6.6 ft·lb) 3
1 47 N·m (4.7 kgf·m, 34.7 ft·lb) 6
2 N·m (0.2 kgf·m, 1.5 ft·lb) 2 47 N·m (4.7 kgf·m, 34.7 ft·lb) 47 N·m (4.7 kgf·m, 34.7 ft·lb)

3
4
Gasket
Drain screw
2
1
39 8
6
7
Self-locking nut
Hose nipple
1
1 9
8 O-ring 1 39
9 Bolt 1 M6 20 mm
10
11
Adapter
Plastic tie
1
1
10
12 Extension 1
13 Dowel 4
14 Rubber seal 1
15 Lower case stud bolt 6
17 Grommet 1
A
8-6
LOWR
Lower unit
17
42 N·m (4.2 kgf·m, 31.0 ft·lb)
23 N·m (2.3 kgf·m, 17.0 ft·lb) 16
54 N·m (5.4 kgf·m, 39.8 ft·lb)

15
14 13
21
20
13 13 22
19
12 18 23
13 24
26 25
11 3
10
9
9 N·m (0.9 kgf·m, 6.6 ft·lb) 27
8
7 6 29 31
5
28
4 30
1

18 Check screw 1
19 Lower unit 1
20 Propeller 1
21 Cotter pin 1 39
22 Propeller nut 1
23 Washer 1
24 Spacer 1
25 Damper 1 39
26 Spacer 1
27 Trim tab 1
28 Lower case mounting nut 6
29 Washer 6
8-7
TIP:
the backlash before disassembly. See “Mea-
• Make sure to disconnect the battery
0
• When removing the lower unit with the
Disassembling the propeller
See “Disassembling the propeller” (8-3). 1
outboard motor could fall suddenly and
result in severe injuries. Checking the propeller
See “Checking the propeller” (8-3).
2
using your hands. Checking the lower unit anode
See “Checking the lower unit anode” (8-4).
1. Drain the gear oil. See steps 1–6 in
Assembling the propeller
3
See “Assembling the propeller” (8-4).
2. Remove the propeller and trim tab. See
steps 2–5 in “Removing the lower unit”
4
(8-3).
3. Remove the lower case mounting nuts

a, lower case mounting bolts b and c,
5
and then remove the lower unit d.
4. Remove the speedometer hose e, and

then remove the extension f.
6
f 7
d
8
e 9
b
10
c
A
8-8
LOWR
Lower unit
Water pump and shift rod (regular rotation model)
22
21 22
11
20
23
6 20
12
20
7
13 19
6 18
17
5
14
4
3 16
2 10
8 10
1
15

1 Shift rod 1
2 E-clip 1
3 O-ring 1 39
4 Plate 1
5 Oil seal 1 39
6 Bolt 3 M8 25 mm
7 Cover 1
8 Seal plate 1
9 Woodruff key 1
10 Dowel 2
11 Impeller 1
12 Outer plate cartridge 1
13 Gasket 1 39
14 Rubber seal 1
15 Plate 1
16 O-ring 1 39
17 Insert cartridge 1
8-9
22
11
20
21 22
0
23
6 20
12
20 1
7
19
6
13
18 2
17
5
4
14
3
3 16
2 10
1 8 10 4
15
9
5
6

18 O-ring 1 39
19 Water pump housing 1
20
21
Bolt
Oil seal
4
2
M8 45 mm
39
8
22 Cover 2
23 Seal 1
9
10
A
8-10
LOWR
Lower unit
Removing the water pump and shift Shift rod socket l: 90890-06679
rod
1. Remove the water pump housing a, 5. Remove the plate m, oil seal n, O-ring
dowels b, O-ring c, impeller d, and o, and shift rod p.
Woodruff key e.
n
d m
p o
b
p
b
e 90°
TIP:
2. Remove the cover f, and then remove To remove the shift rod p, lift it up slightly,
the outer plate cartridge g and gasket and then turn the shift rod p 90° counter-
h. clockwise to pull it up.
3. Remove the seal plate i, rubber seal j,
and plate k. Disassembling the water pump
housing
j 1. Remove the insert cartridge a and O-
f k ring b.
i
a
g
b
h
2. Remove the cover c and oil seals d.
4. Set the gear shift to the N position.
c
R
N d
8-11
3. Remove the cover e and seal f.
b
e
a
0
f
1
2. Install new oil seals c to the specified
Checking the water pump and shift
rod
depth a. 2
1. Check the water pump housing. Replace
e a
if deformed.
d
c 3
TIP:
If the engine overheated, the inside of the
water pump housing may be deformed.
Therefore, make sure to remove the insert
4
cartridge when checking the water pump
housing.
Needle bearing attachment d:
90890-06614
5
2. Check the impeller, insert cartridge, and
Driver rod L3 e: 90890-06652
outer plate cartridge. Replace if cracked
or worn.
Installation depth a:
10.25–10.75 mm (0.40–0.42 in)
6
3. Check the Woodruff key and the keyway
in the drive shaft. Replace the drive shaft
if deformed or worn. TIP:
Install an oil seal halfway into the water pump
7
4. Check the shift rod. Replace if cracked or housing, and then install the other oil seal.
worn.
Assembling the water pump housing

3. Install the cover f. 8
Do not reuse an O-ring or oil seal, always 9
f
1. Install the seal a and cover b.
10
4. Install a new O-ring g and the insert
cartridge h.
A
8-12
LOWR
Lower unit
i h
TIP:
Fit the protrusions b on the insert cartridge
h into the slots c in the water pump housing
i.
8-13
Water pump and shift rod (regular rotation model) /
Propeller shaft housing (regular rotation model)
7 9 8 10 12 11 13
3
4
14
0
8
1
1 23
2 13
12
11
2
10
9 18
7
8
21
22
3
20 31
8 30
19
6
5
29 4
17
31
16
15
25
5
28 30
27
1 N·m (0.1 kgf·m, 0.7 ft·lb) 26
25 155 N·m (15.5 kgf·m, 114.3 ft·lb) 6

24 8 N·m (0.8 kgf·m, 5.9 ft·lb)

3
4
Water pipe
Rubber seal
1
2
8
5 Water inlet cover screw 1 M5 45 mm
6
7
Water inlet cover (PORT)
Slider
1
1 9
8 Ball 2
9 Shift plunger 1
10
11
Spring
Dog clutch
1
1
10
12 Cross pin 1
13 Propeller shaft 1
14 Reverse gear shim (T2) —
15 Reverse gear 1
16 Thrust washer 1
17 Ball bearing 1 39
A
8-14
LOWR
Lower unit
7 9 8 10 12 11 13
3 14
4
1 23
2 13
12
11
10
9 18
8 22
7 21
20 31
8 30
19
6
29
5
17
31
16 25
15
28 30
27
1 N·m (0.1 kgf·m, 0.7 ft·lb) 26
25 155 N·m (15.5 kgf·m, 114.3 ft·lb)

24 8 N·m (0.8 kgf·m, 5.9 ft·lb)

18 O-ring 1 39
19 Washer 1
20 Propeller shaft shim (T4) —
21 Taper roller bearing 1 39
22 Propeller shaft housing 1
23 Rubber seal 1
24 Needle bearing 1 39
25 Oil seal 2 39
26 Key 1
27 Claw washer 1
28 Propeller shaft housing ring nut 1
29 Cover 1
30 Dowel 2
31 Cover bolt 2 M8 25 mm
8-15
Removing the propeller shaft
housing assembly
1. Remove the water pipe a and rubber
seals b. d
0
e
b
a
1
Ring nut wrench extension d:
90890-06513
Ring nut wrench 6 e: 90890-06677
2
5. Remove the propeller shaft housing ring
nut f and claw washer g. 3
f
2. Remove the cover c. g

4
c
5
6. Remove the propeller shaft housing
assembly.
6
j
3. Straighten the tab a on the claw washer
that is bent outward.
i 7
h
h 8
a
Bearing housing puller claw L h:

9
90890-06502
Stopper guide plate i: 90890-06501
4. Loosen the propeller shaft housing ring
Center bolt j: 90890-06504 10
nut. 7. Remove the O-ring k, propeller shaft
assembly l, and reverse gear shims m.
A
8-16
LOWR
Lower unit
k TIP:
l When removing the slider d, make sure that
the balls e do not fall out of position.
m
Disassembling the reverse gear
1. Remove the ball bearing a and thrust
washer b.
c d
a
8. Remove the taper roller bearing b, c
propeller shaft shims n, washer o, and a
reverse gear assembly c. b
Ball bearing attachment c: 90890-06634

Bearing separator d:
Disassembling the propeller shaft

housing assembly
c
o
n
b
• Use heat-resistant gloves. Otherwise,
Disassembling the propeller shaft burns could result.
assembly • To prevent fires, remove any flammable
1. Remove the spring a, and then remove substances, such as gasoline and oil,
the cross pin b, dog clutch c, slider d, around the working area.
balls e, and shift plunger f. • Keep good ventilation while working.
a
1. Remove the rubber seal a.
e f
a
d
c 2. Remove the oil seals b along with the

needle bearing c.
8-17
e
0
d c
e 1
c Propeller shaft runout:
b
0.02 mm (0.0008 in) 2
Checking the dog clutch
Driver rod L3 d: 90890-06652 1. Check the dog clutch, shift plunger, cross
Needle bearing attachment e: pin, spring, balls, and slider. Replace if
cracked or worn.
3
90890-06611
3. Heat the installation area of the taper Checking the propeller shaft housing
roller bearing outer race in the propeller 1. Check the water pipe. Replace if cor- 4
shaft housing f using a gas torch, and roded, cracked, or deformed.
then remove the taper roller bearing
outer race a. NOTICE: When heating
the propeller shaft housing, heat the
2. Check the propeller shaft housing.
Replace if cracked or damaged. 5
entire installation area evenly.
Otherwise, the propeller shaft housing Checking the reverse gear
could be damaged. 1. Check the teeth and dogs of the reverse
gear. Replace if cracked or worn.
6
f
Assembling the propeller shaft
assembly
1. Install the shift plunger a, balls b, and
7
slider c.
a c b a 8
Checking the propeller shaft
1. Check the propeller shaft. Replace if b
9
damaged or worn.
a
b
2. Measure the propeller shaft runout.
c
10
A
8-18
LOWR
Lower unit
TIP:
When installing the slider c, make sure that
the balls b do not fall out of position.
c c
2. Install the dog clutch d so that the hole
b b
a in the dog clutch d and the hole b in
the propeller shaft are aligned with the a
a
hole c in the slider c.
a Bearing inner race attachment c:

b 90890-06661

d a housing assembly
d
c burns could result.
• To prevent fires, remove any flammable
substances, such as gasoline and oil,
b c
around the working area.
• Keep good ventilation while working.
3. Install the cross pin e, and then install
the spring f.
e Do not reuse a bearing, oil seal, or O-ring,
1. Heat the installation area of the taper

f
roller bearing outer race in the propeller
shaft housing a using a gas torch, and
then install a new taper roller bearing
outer race a. NOTICE: When heating
f e the propeller shaft housing, heat the
entire installation area evenly. Other-
wise, the propeller shaft housing
could be damaged.
a
Assembling the reverse gear
1. Install the thrust washer a and a new
ball bearing b. NOTICE: Do not reuse
a bearing, always replace it with a new a
one.
8-19
2. While holding the special service tool b,
strike the tool to check that the taper
roller bearing outer race a is installed h
properly.
d 0
b
g
c
1
a Bearing inner race attachment h:
90890-06640 2
Depth d: 5.8–6.2 mm (0.228–0.244 in)
Driver rod LL b: 90890-06605
Bearing outer race attachment c:
90890-06623
TIP: 3
Install an oil seal halfway into the propeller
shaft housing, and then install the other oil
TIP:
If a high-pitched metallic sound is produced
seal.
4
when the special service tool is struck, the 5. Install the rubber seal i.
taper roller bearing outer race a is installed
properly. i
5
3. Install a new needle bearing d to the
specified depth b.
6
e
c
b
f 7
d
8
Driver rod L3 e: 90890-06652
Needle bearing attachment f: 9
90890-06653
Depth b: 25.1–25.5 mm (0.988–1.004 in)

10
TIP:
Face the bearing identification mark c on the
needle bearing d toward the propeller side.
4. Install new oil seals g to the specified

depth d.
A
8-20
LOWR
Lower unit
Drive shaft and lower case (regular rotation model)
40 N·m (4.0 kgf·m, 29.5 ft·lb) 10
9
177 N·m (17.7 kgf·m, 130.5 ft·lb)
8 14
11
7
12
6 13
1 5 19
18
4 17
16
21
15 20
23
22
24
2
25
26
3 27
143 N·m (14.3 kgf·m, 105.5 ft·lb)

1 Drive shaft 1
2 Pinion shim (T3) —
3 Washer 1
5 Claw washer 1
6 Drive shaft nut 1
7 Spacer 1
8 Drive shaft ring nut 1
9 Cover 1
10 Bolt 2 M8 20 mm
11 Oil seal housing 1
12 O-ring 1 39
13 Oil seal 2 39
14 Lower case 1
15 Dowel 1
16 Adapter 1
17 Roller bearing 1 39
8-21
40 N·m (4.0 kgf·m, 29.5 ft·lb) 10

9
177 N·m (17.7 kgf·m, 130.5 ft·lb)
0
8 14
7
11
12
1
6 13
1 5
18
19 2
4 17
16
3
15 20
21 4
23
22
24 5
2
25
3
26
27
6
143 N·m (14.3 kgf·m, 105.5 ft·lb)

18 Forward gear shim (T1) 1
19 Thrust bearing 1
20
21
Circlip
Washer
1
1
8
23
24
Forward gear
Needle bearing
1
1 39 9
25 Pinion 1
26 Washer 1
27 Pinion nut 1
10
A
8-22
LOWR
Lower unit
Removing the drive shaft Drive shaft holder 6 g: 90890-06520
1. Remove the oil seal housing a. Pinion nut holder h: 90890-06715
Removing the forward gear

1. Remove the forward gear a, thrust bear-
ing b, forward gear shim c, and adapter
a d.
a
b
2. Remove the drive shaft ring nut b and

spacer c.
d
Disassembling the oil seal housing

1. Remove the cover a, O-ring b, and oil
seals c.
b a
c
Drive shaft ring nut wrench d:

b
90890-06674
3. Loosen the pinion nut, and then remove

the pinion e, washer, drive shaft f,
pinion shims, and washer.
c
e
Disassembling the drive shaft

1. Straighten the tab a on the claw washer
a.
g
f
h
8-23
Disassembling the forward gear
a • Use heat-resistant gloves. Otherwise,

burns could result. 0
a • To prevent fires, remove any flammable
1
2. Secure the drive shaft nut b on the drive 1. Remove the circlip a, and then remove
shaft. the washer b and taper roller bearing c. 2
3. Loosen the drive shaft nut b, and then
a
remove the claw washer a.
b 3
c
4
b c
a 2. Remove the dowel d. 5

3. Heat the installation area of the roller
bearing in the adapter e using a gas
torch, and then remove the roller bearing 6
f. NOTICE: When heating the
adapter, heat the entire installation
Driveshaft holder 6 c: 90890-06520
4. Remove the taper roller bearing d.

area evenly. Otherwise, the adapter
could be damaged.
7
NOTICE: Make sure that the inner d
race of the taper roller bearing d is
placed properly on the blocks e. e
8
f
9
d
e 10
e
A
8-24
LOWR
Lower unit
Disassembling the lower case
TIP:
• Before removing the needle bearing, make
sure to remove the forward gear assembly.
• Before installing the special service tool,
burns could result.
make sure that the rollers are installed in
the needle bearing outer race.
• Keep good ventilation while working. Checking the pinion
1. Check the teeth of the pinion. Replace if
cracked or worn.
1. Heat the installation area of the needle
bearing in the lower case using a gas
Checking the forward gear
torch. NOTICE: When heating the
1. Check the teeth and dogs of the forward
lower case, heat the entire installation
area evenly. Otherwise, the paint on
the lower case could be burned.
Checking the drive shaft
1. Check the drive shaft. Replace if dam-
aged or worn.
2. Measure the drive shaft runout.
2. Remove the needle bearing a. Drive shaft runout: 1.0 mm (0.0394 in)
Checking the lower case

b 1. Check the lower case. Replace if cracked
c b or damaged.
Assembling the drive shaft

a c
a
Do not reuse a bearing, always replace it
with a new one.
Driver rod L3 b: 90890-06652
Needle bearing attachment c: 1. Install a new taper roller bearing a.
90890-06680 NOTICE: Do not press the threads b
of the drive shaft directly. Make sure
that the special service tool a and
blocks b do not contact the threads
c of the drive shaft.
8-25
Press load (bearing): 18 103 N (1800 kgf)
b 4. Turn the taper roller bearing 10 turns or

more to seat the bearing.
0
5. Install the claw washer c, and then
tighten the drive shaft nut d temporarily.
a
b a
a a
d
1
b
c c 2
Bearing inner race attachment a: f
90890-06640 3
f
g
2. Install a new taper roller bearing outer 4
race d and the taper roller bearing e.
NOTICE: Do not press the threads b
TIP:
of the drive shaft directly. Make sure
that the special service tool a and Make sure to fit the tab f on the claw washer
c into the slot g in the drive shaft.
5
blocks b do not contact the threads
c of the drive shaft.
6. Secure the drive shaft nut d on the drive
shaft.
6
b 7. Tighten the drive shaft nut d to the
specified torque.
7
d
b
8
a e
c e
a
d
b
d
9
Bearing inner race attachment a:
90890-06640 10
3. Turn the taper roller bearing 10 turns or Driveshaft holder 6 e: 90890-06520

more to seat the bearing, and then press
the drive shaft again using the specified Drive shaft nut d:
load. 40 N·m (4.0 kgf·m, 29.5 ft·lb)
A
8-26
LOWR
Lower unit
8. Hold the taper roller bearing outer race,
and then measure the motive torque of
b
the drive shaft.
Drive shaft motive torque: c
0.27–1.94 N·m (0.03–0.20 kgf·m, a
0.20–1.43 ft·lb)
9. Bend the tab h on the claw washer c to

secure the drive shaft nut d.
3. Install a new taper roller bearing d and

the washer e, and then install the circlip
d
f.
h
c f
d
Assembling the forward gear

burns could result. Assembling the lower case
• To prevent fires, remove any flammable 1. Install a new needle bearing a NOTICE:
substances, such as gasoline and oil, Do not reuse a bearing, always
around the working area. replace it with a new one.
c

with a new one.
a
1. Heat the installation area of the roller c
bearing in the adapter a using a gas a
torch, and then install a new roller bear-
ing b. NOTICE: When heating the b
adapter, heat the entire installation
area evenly. Otherwise, the adapter b
a
could be damaged.
Ball bearing attachment b: 90890-06655
2. Install the dowel c.
Bearing outer race puller assembly c:
90890-06523
8-27
Installing the forward gear
TIP: 1. Install the adapter a, original forward
• The needle bearing contains 24 rollers. gear shim b, thrust bearing c, and for-
• Face the bearing identification mark a on ward gear d.
the needle bearing toward the pinion side. 0
d
Assembling the oil seal housing
c
b 1
Do not reuse an oil seal or O-ring, always a
replace it with a new one. a
1. Install new oil seals a to the specified

2
depth a.
3
e
A
b
c TIP:
Make sure to fit the dowel e into the slot a
4
a a in the lower case.
Installing the drive shaft 5

1. Install the washer a, original pinion
Driver rod LL b: 90890-06605 shims b, and drive shaft c.
Bearing outer race attachment c:
90890-06628 6
c
Depth a: 0.25–0.75 mm (0.01–0.03 in) b
TIP:
a 7
Install an oil seal halfway into the oil seal
housing, and then install the other oil seal.
8
2. Install the cover d and a new O-ring e.
2. Install the pinion d and washer e, and
d
e
then tighten the pinion nut f to the
specified torque.
9
10
A
8-28
LOWR
Lower unit
d
e
g
0.045 m Am
g Drive shaft ring nut wrench k:

c 90890-06674
h
Torque wrench setting value
Drive shaft holder 6 g: 90890-06520 = 177 N·m ÷ (A + 0.045) A
Pinion nut holder h: 90890-06715 • 177 N·m (17.7 kgf·m, 130.5 ft·lb): Speci-
fied tightening torque for the drive shaft
Pinion nut f: ring nut
143 N·m (14.3 kgf·m, 105.5 ft·lb) • 0.045 m: Ring nut wrench length
• A m: Torque wrench length
TIP:
4. Install the oil seal housing l.
When installing the pinion d, lift up the drive
shaft c slightly and align the splines on the
drive shaft with the splines on the pinion.
l
3. Install the spacer i, and then tighten the
drive shaft ring nut j to the specified a
torque. NOTICE: The correct setting
value of the torque wrench varies
depending on its length. When
tightening the drive shaft ring nut to
the specified torque, use the following
calculation formula to obtain the
correct setting value.
k TIP:
Make sure to install the oil seal housing l so
that the notch a is facing forward.
Installing the propeller shaft housing

i assembly
j
Do not reuse a bearing or O-ring, always

8-29
1. Install the reverse gear a, the washer b,
the original propeller shaft shims c, and
a new taper roller bearing a. i
b
0
c
1
a
b
c TIP:
a Make sure to fit the protrusion b on the pro- 2
peller shaft housing into the slot c in the
2. Install a new O-ring d and the propeller claw washer i.
shaft housing assembly e.
5. Install the propeller shaft housing ring nut
3
j, and then tighten it to the specified
torque.
e
4
k
5
d l
j
6
Ring nut wrench extension k:
3. Install the original reverse gear shims f,
propeller shaft housing assembly e,
90890-06513
Ring nut wrench 6 l: 90890-06677
7
along with the propeller shaft assembly
g, and key h.
Propeller shaft housing ring nut j:
h g
155 N·m (15.5 kgf·m, 114.3 ft·lb) 8
6. Turn the propeller shaft 10 turns or more,
e and then tighten the propeller shaft
f housing nut j to the specified torque. 9
Propeller shaft housing ring nut j:
155 N·m (15.5 kgf·m, 114.3 ft·lb)
7. Bend one of the 4 tabs on the claw

10
washer outward, and bend the other 3
tabs inward.
4. Install the claw washer i.

A
8-30
LOWR
Lower unit
1. Install a new O-ring a and a new oil seal
b to the plate c.
a
8. Install the dowels m, cover n, and then
tighten the cover bolts o to the specified
torque. 2. Install the plate c to the shift rod d.
o
c
n
d
m
Cover bolt o: 3. Install the shift rod d.

8 N·m (0.8 kgf·m, 5.9 ft·lb)
9. Install the rubber seals p and water pipe

q.
d
p
a
90° a
q
TIP:
Turn the shift rod d clockwise 90°, and then
push it down so that the tip a of the shift rod
d fits into the groove b in the shift slider.
Installing the shift rod
Installing the water pump
Do not reuse an oil seal or O-ring, always
Do not reuse a gasket or O-ring, always
8-31
1. Install the plate a, rubber seal b, and
seal plate c.
2. Install the dowels d, a new gasket e,

the outer plate cartridge f, the cover g,
and the Woodruff key h. k
0
b
c 1
g
h
d d a 2
f
TIP:
While turning the drive shaft clockwise, push 3
the water pump housing down to install it.
e
Checking the lower unit for air 4
3. Align the slot a in the impeller i with leakage
the Woodruff key h, and then install the 1. Remove the check screw a, and then
impeller i. install the special service tool b.
5
a
6
i h
a b
7
4. Install a new O-ring j. Leakage tester b: 90890-06840
8
2. Apply the specified pressure. Check that
the pressure is maintained in the lower
j unit for 10 seconds or more.
NOTICE: Do not overpressurize the
9
lower unit. Otherwise, the oil seals
could be damaged.
Holding pressure: 10
68.6 kPa (0.686 kgf/cm2, 9.9 psi)
5. Install the water pump housing k.

NOTICE: Do not turn the drive shaft
counterclockwise. Otherwise, the
water pump impeller could be
damaged. A
8-32
LOWR
Lower unit
Installing the lower unit (X-transom 4. Install the lower unit d, and then tighten
model) the lower case mounting bolts e and f
to the specified torque. NOTICE: Make
sure to align the splines on the lower
• Make sure to disconnect the battery unit shift rod with the splines on the
cables from the battery, and remove the upper case shift rod. Otherwise, the
clip from the engine shut-off switch. shift rods could be bent.
• When installing the lower unit with the
5. Install the trim tab g to its original
position, and then tighten the trim tab bolt
h to the specified torque.
• When loosening or tightening the pro- h
using your hands. c
d
1. Align a of the clip a with the mark b of
the bracket c.
c
e f
b c
a
a
e
2. Set the gear shift to the N position. Lower case mounting bolt e and f:
47 N·m (4.7 kgf·m, 34.7 ft·lb)
R Trim tab bolt h:
42 N·m (4.2 kgf·m, 31.0 ft·lb)
N
b 6. Install the spacer i, propeller j, spacer
F k, washer l, and propeller nut m.
m
l
Shift rod socket b: 90890-06679 k
3. Install the dowels c.

j
i
8-33
7. Place a block of wood between the anti- Installing the lower unit (U-transom
cavitation plate and the propeller to model)
prevent the propeller from turning, and
then tighten the propeller nut m to the
specified torque. • Make sure to disconnect the battery 0
• When installing the lower unit with the
1
2
Propeller nut m:
54 N·m (5.4 kgf·m, 39.8 ft·lb)
using your hands.
3
1. Check that the shift rod is in the N posi-
8. Install a new cotter pin n. NOTICE: Do tion. See steps 1 and 2 in “Installing the
not reuse a cotter pin, always replace lower unit (X-transom model)” (8-33). 4
it with a new one.
2. Install the lower case stud bolts a, and
then tighten it to the specified torque.
n m 5
6
a a
a
a
7
TIP:
If the slots in the propeller nut m are not Lower case stud bolt a:
aligned with the cotter pin hole, tighten the
propeller nut m until they are aligned.
23 N·m (2.3 kgf·m, 17.0 ft·lb) 8
3. Install the dowels b, rubber seal c, and
extension d, and then install the adapter
9. Fill the lower unit with gear oil up to the
proper level. See steps 7–10 in e and speedometer hose f. 9
4. Install the dowels g and lower unit h,
and then tighten the lower case mounting
nuts i and lower case mounting bolts j 10
and k to the specified torque.
NOTICE: Make sure to align the
splines on the lower unit shift rod with
the splines on the upper case shift
rod. Otherwise, the shift rods could be
bent.
A
8-34
LOWR
Lower unit
b
d
c
b
g h
g
f
e
j
k
i
Lower case mounting nut i:

47 N·m (4.7 kgf·m, 34.7 ft·lb)
Lower case mounting bolt j and k:
47 N·m (4.7 kgf·m, 34.7 ft·lb)
5. Install the trim tab and propeller. See

steps 5–8 in “Installing the lower unit (X-
transom model)” (8-33).

proper level. See steps 7–10 in
8-35
Drive shaft and lower case (regular rotation model) /
Shimming (regular rotation model)
Shimming workflow
Remove the water pump

assembly and cover. 0
Measure the backlash before
disassembly. 1
YES
Within specification? Shimming is not required.
2
NO
Disassemble the lower unit.
3
Select the pinion shims (T3).
Assemble the lower unit. 4

Measure the backlash.
5
Adjust the forward gear shim
NO
Within specification? thickness (T1) and reverse gear
YES
shim thickness (T2).
6
Select the propeller shaft
shims (T4).
7
Install the water pump
assembly.
8
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
9
housing, shimming is required.
10
A
8-36
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
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
Measuring point #2
Measuring point #3
Measuring point #4
Average
Round-down average
8-37
Forward gear shim (T1) thickness measurement in 2 places (mm)
Number of shim(s) Subtotal
2.00
2.03
2.06
0
2.09
2.12
2.15 1
Total
Reverse gear shim (T2) thickness measurement in 2 places (mm) 2

0.10
0.12 3
0.15
0.18
0.30
0.40
4
0.50
Total
5
6
7
8
9
10
A
8-38
LOWR
Lower unit
Measuring the forward gear backlash
and reverse gear backlash before
disassembly e
1. Remove the water pump assembly,
cover, and outer plate cartridge. See
steps 1–3 in “Removing the water pump h
and shift rod” (8-11). g
f
R Backlash indicator e: 90890-06836

Magnet base plate f: 90890-07003
N Dial gauge set g: 90890-01252
Magnet base B h: 90890-06844
F
6. Turn the drive shaft slowly clockwise and
counterclockwise and measure the
backlash between where the drive shaft
a stops in each direction.
Shift rod socket a: 90890-06679
3. Set up the special service tools b, c,

and d, and then tighten the center bolt
d to the specified torque.
b c
TIP:
Bearing housing puller claw L b: • Do not turn the drive shaft using too much
90890-06502 force. Otherwise, the forward gear will turn,
Stopper guide plate c: 90890-06501 leading to incorrect measurements.
Center bolt d: 90890-06504 • When turning the drive shaft, hold it using a
little force. A knocking sound may be heard
Center bolt d (shimming): when the drive shaft is turned, but this is
20 N·m (2.0 kgf·m, 14.8 ft·lb) the sound of the pinion contacting the
reverse gear and does not affect the back-
4. Install the special service tool e at the
lash measurement.
lowest possible position where the shaft
diameter is 22.4 mm (0.88 in).
7. Turn the drive shaft 180° clockwise and
5. Set up the special service tools f, g, measure the backlash again.
and h.
8-39
a
N
a
0
b
d
1
c 12. While turning the shift rod toward the R

2
position using the specified torque, turn
the drive shaft slowly clockwise and
TIP:
• Measure the backlash at 4 points: a, b,
3
c, and d, turning the drive shaft 180°
stops in each direction.
clockwise after each measurement.
• Write down the measurement data in the
shimming check sheet.
4
8. Determine the backlash average, and
then round down the average to the 1/ 5
100 place.
Example:
Measurement point a 0.25

(mm) 6
Measurement point b 0.26
Measurement point c
Measurement point d
0.26
0.24
7
Average 0.2525
Specified torque:
Round-down average 0.25
9. Check that the forward gear backlash

20 N·m (2.0 kgf·m, 14.8 ft·lb)
8
average is within specification. TIP:
• Do not turn the drive shaft using too much
Forward gear backlash:
0.04–0.59 mm (0.0016–0.0232 in)
force. Otherwise, the reverse gear will turn,
leading to incorrect measurements.
9
• When turning the drive shaft, hold it using a
TIP:
Adjust the shim thicknesses if the forward
gear backlash is out of specification.
when the drive shaft is turned, but this is 10
the sound of the pinion contacting the for-
ward gear and does not affect the backlash
10. Remove the special service tools from measurement.
the propeller shaft.
13. Repeat steps 7 and 8 to measure the
11. Set the gear shift to the R position. reverse gear backlash.
A
8-40
LOWR
Lower unit
14. Check that the reverse gear backlash
average is within specification.
Reverse gear backlash:
0.15–0.88 mm (0.0059–0.0346 in)
TIP:
Adjust the shim thicknesses if the reverse
15. Remove the special service tools, and

then install the outer plate cartridge,
cover, and water pump assembly. See
“Installing the water pump” (8-31).
8-41
Shimming
• Before selecting the forward gear shim (T1) and reverse gear shims (T2), make sure to select the
pinion shims (T3).
• When assembling the lower unit to measure the backlash after selecting the pinion shims (T3), do
not apply gear oil, grease, or sealant to the parts. 0
• When assembling the lower unit after shimming is completed, make sure to apply gear oil, grease,
and sealant to the specified areas.
Shim location 1
2
T3
3
4
5
6
7
8
9
10
T1 T2 T4 A
8-42
LOWR
Lower unit
Selecting the pinion shim (T3)
• Spray anti-rust lubricant on the gears and b b
bearings before installation. Do not apply
gear oil to the parts. Otherwise, correct a
measurements cannot be obtained.
• Keep the parts free of foreign material,
such as dirt and lint.
1. Obtain the calculated value (B) based on

marks (P) and (H) on the pinion. See
“Calculated value (B) table” (8-46). Pinion shimming gauge a: 90890-06675
Example: Pinion shimming gauge rod b:
When mark (P) is 000 a and mark (H) is 020 90890-06676
b, the calculated value (B) is 0.73 mm.
a 5. Measure the distance c between the
A special service tool a and the pinion c.
–011 –010 –009 –001 000
000
005
010
b c
015 c
B 020 0.73
025 a
030
A Mark (P)
B Mark (H)
2. Install the original pinion shims, drive

shaft, pinion, and drive shaft ring nut.
See steps 1–3 in “Installing the drive
shaft” (8-28). a
TIP:
• If the original shims are missing, install new
shims with a combined thickness of 0.70
mm.
measure the distance again.
• Do not reuse a shim if deformed or
scratched. d
3. Check that the drive shaft turns smoothly.
4. Set up the special service tools a and

b, and then remove the special service g e
tool b.
8-43
TIP: k
• Measure the distance at 4 points: d, e, f, A
and g, turning the drive shaft 90° clock- 0.51 0.52 0.53 0.54 0.55
wise after each measurement.
• Write down the measurement data in the
0.54
0.55 0
0.56
shimming check sheet. 0.57
7. Determine the distance average, and

0.58
0.66
0.68
1
then round down the average to the 1/
100 place. B 0.69
h 0.70 +0.18
Example:
(mm)
0.71
0.72
2
Measuring point d 0.70 A Pinion distance measurement (M)
Measuring point e
Measuring point f
0.71
0.71
B Calculated value (B) 3
Measuring point g 0.69 TIP:
Average 0.7025 • When the difference between the calcu-
Round-down average 0.70 lated value (B) and the pinion distance 4
measurement (M) is larger than ± 0.07 mm,
TIP: adjust the difference by the shims.
In the “Pinion shim (T3) selection table,” use
the round-down average for the pinion dis-
• If the shim thickness adjustment value is
positive, the current shim thickness must be 5
tance measurement (M). increased by that amount and, if the value
is negative, the current shim thickness must
8. Determine the pinion shim (T3) thickness
be decreased by that amount.
• The gray-colored cell on the selection table
6
adjustment using the calculated value (B)
indicates the specified pinion distance.
and pinion distance measurement (M).
See “Pinion shim (T3) selection table” (8-
47). 7
Example:
Calculated value (B) = 0.70 mm h
Pinion distance measurement (M) = 0.52 mm
k
8
Pinion shim (T3) thickness adjustment =
0.18 mm
The current shim thickness must be
increased by 0.18 mm.
9
10
A
8-44
LOWR
Lower unit
9. Calculate the new pinion shim (T3)
thickness.
New pinion shim (T3) thickness = Current
pinion shim thickness + Shim thickness
adjustment
Example:
Use the following formula when the shim
thickness adjustment value is positive.
Current pinion shim thickness = 0.70 mm
Shim thickness adjustment = 0.18 mm
New pinion shim (T3) thickness
= 0.70 mm + 0.18 mm
= 0.88 mm
thickness adjustment value is negative.
Current pinion shim thickness = 0.70 mm
Shim thickness adjustment = –0.09 mm
New pinion shim (T3) thickness
= 0.70 mm + (–0.09) mm
= 0.61 mm
Available shim thicknesses:
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.
• If the calculated shim thickness cannot be
obtained with a combination of the available
shims, increase or decrease the pinion dis-
tance measurement by 0.01 mm.
10. Remove the special service tool, and

then install the determined shims.
8-45
Calculated value (B) table
(mm)
A
000
005
–011
0.64
0.64
–010
0.65
0.65
–009
0.66
0.66
–008
0.67
0.67
–007
0.68
0.68
–006
0.69
0.69
–005
0.70
0.70
–004
0.71
0.71
–003
0.72
0.72
–002
0.73
0.73
–001
0.74
0.74
000
0.75
0.75
0
010 0.63 0.64 0.65 0.66 0.67 0.68 0.69 0.70 0.71 0.72 0.73 0.74
015 0.63 0.64 0.65 0.66 0.67 0.68 0.69 0.70 0.71 0.72 0.73 0.74
020
025
030
0.62
0.62
0.61
0.63
0.63
0.62
0.64
0.64
0.63
0.65
0.65
0.64
0.66
0.66
0.65
0.67
0.67
0.66
0.68
0.68
0.67
0.69
0.69
0.68
0.70
0.70
0.69
0.71
0.71
0.70
0.72
0.72
0.71
0.73
0.73
0.72
1
035 0.61 0.62 0.63 0.64 0.65 0.66 0.67 0.68 0.69 0.70 0.71 0.72
040 0.60 0.61 0.62 0.63 0.64 0.65 0.66 0.67 0.68 0.69 0.70 0.71
B
045
050
055
0.60
0.59
0.59
0.61
0.60
0.60
0.62
0.61
0.61
0.63
0.62
0.62
0.64
0.63
0.63
0.65
0.64
0.64
0.66
0.65
0.65
0.67
0.66
0.66
0.68
0.67
0.67
0.69
0.68
0.68
0.70
0.69
0.69
0.71
0.70
0.70
2
060 0.58 0.59 0.60 0.61 0.62 0.63 0.64 0.65 0.66 0.67 0.68 0.69
065 0.58 0.59 0.60 0.61 0.62 0.63 0.64 0.65 0.66 0.67 0.68 0.69
070
075
080
0.57
0.57
0.56
0.58
0.58
0.57
0.59
0.59
0.58
0.60
0.60
0.59
0.61
0.61
0.60
0.62
0.62
0.61
0.63
0.63
0.62
0.64
0.64
0.63
0.65
0.65
0.64
0.66
0.66
0.65
0.67
0.67
0.66
0.68
0.68
0.67
3
085 0.56 0.57 0.58 0.59 0.60 0.61 0.62 0.63 0.64 0.65 0.66 0.67
090 0.55 0.56 0.57 0.58 0.59 0.60 0.61 0.62 0.63 0.64 0.65 0.66
095
100
0.55
0.54
0.56
0.55
0.57
0.56
0.58
0.57
0.59
0.58
0.60
0.59
0.61
0.60
0.62
0.61
0.63
0.62
0.64
0.63
0.65
0.64
0.66
0.65 4
A
+001 +002 +003 +004 +005 +006 +007 +008 +009 +010 +011
000
005
010
0.76
0.76
0.75
0.77
0.77
0.76
0.78
0.78
0.77
0.79
0.79
0.78
0.80
0.80
0.79
0.81
0.81
0.80
0.82
0.82
0.81
0.83
0.83
0.82
0.84
0.84
0.83
0.85
0.85
0.84
0.86
0.86
0.85
5
015 0.75 0.76 0.77 0.78 0.79 0.80 0.81 0.82 0.83 0.84 0.85
020 0.74 0.75 0.76 0.77 0.78 0.79 0.80 0.81 0.82 0.83 0.84
025
030
035
0.74
0.73
0.73
0.75
0.74
0.74
0.76
0.75
0.75
0.77
0.76
0.76
0.78
0.77
0.77
0.79
0.78
0.78
0.80
0.79
0.79
0.81
0.80
0.80
0.82
0.81
0.81
0.83
0.82
0.82
0.84
0.83
0.83
6
040 0.72 0.73 0.74 0.75 0.76 0.77 0.78 0.79 0.80 0.81 0.82
045 0.72 0.73 0.74 0.75 0.76 0.77 0.78 0.79 0.80 0.81 0.82
B 050
055
060
0.71
0.71
0.70
0.72
0.72
0.71
0.73
0.73
0.72
0.74
0.74
0.73
0.75
0.75
0.74
0.76
0.76
0.75
0.77
0.77
0.76
0.78
0.78
0.77
0.79
0.79
0.78
0.80
0.80
0.79
0.81
0.81
0.80
7
065 0.70 0.71 0.72 0.73 0.74 0.75 0.76 0.77 0.78 0.79 0.80
070 0.69 0.70 0.71 0.72 0.73 0.74 0.75 0.76 0.77 0.78 0.79
075
080
085
0.69
0.68
0.68
0.70
0.69
0.69
0.71
0.70
0.70
0.72
0.71
0.71
0.73
0.72
0.72
0.74
0.73
0.73
0.75
0.74
0.74
0.76
0.75
0.75
0.77
0.76
0.76
0.78
0.77
0.77
0.79
0.78
0.78
8
090 0.67 0.68 0.69 0.70 0.71 0.72 0.73 0.74 0.75 0.76 0.77
095 0.67 0.68 0.69 0.70 0.71 0.72 0.73 0.74 0.75 0.76 0.77
100
A Mark (P)
0.66 0.67 0.68 0.69 0.70 0.71 0.72 0.73 0.74 0.75 0.76
9
B Mark (H) B (H)
A (P)
10
***
****
***
A
8-46
LOWR
Lower unit
Pinion shim (T3) selection table
The shim thickness does not have to be adjusted for the gray-colored cell.
(mm)
A
0.27 0.28 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38
0.54 +0.27 +0.26 +0.25 +0.24 +0.23 +0.22 +0.21 +0.20 +0.19 +0.18 +0.17 +0.16
0.55 +0.28 +0.27 +0.26 +0.25 +0.24 +0.23 +0.22 +0.21 +0.20 +0.19 +0.18 +0.17
0.56 +0.29 +0.28 +0.27 +0.26 +0.25 +0.24 +0.23 +0.22 +0.21 +0.20 +0.19 +0.18
0.57 +0.30 +0.29 +0.28 +0.27 +0.26 +0.25 +0.24 +0.23 +0.22 +0.21 +0.20 +0.19
0.58 +0.31 +0.30 +0.29 +0.28 +0.27 +0.26 +0.25 +0.24 +0.23 +0.22 +0.21 +0.20
0.59 +0.32 +0.31 +0.30 +0.29 +0.28 +0.27 +0.26 +0.25 +0.24 +0.23 +0.22 +0.21
0.60 +0.33 +0.32 +0.31 +0.30 +0.29 +0.28 +0.27 +0.26 +0.25 +0.24 +0.23 +0.22
0.61 +0.34 +0.33 +0.32 +0.31 +0.30 +0.29 +0.28 +0.27 +0.26 +0.25 +0.24 +0.23
0.62 +0.35 +0.34 +0.33 +0.32 +0.31 +0.30 +0.29 +0.28 +0.27 +0.26 +0.25 +0.24
0.63 +0.36 +0.35 +0.34 +0.33 +0.32 +0.31 +0.30 +0.29 +0.28 +0.27 +0.26 +0.25
0.64 +0.37 +0.36 +0.35 +0.34 +0.33 +0.32 +0.31 +0.30 +0.29 +0.28 +0.27 +0.26
0.65 +0.38 +0.37 +0.36 +0.35 +0.34 +0.33 +0.32 +0.31 +0.30 +0.29 +0.28 +0.27
0.66 +0.39 +0.38 +0.37 +0.36 +0.35 +0.34 +0.33 +0.32 +0.31 +0.30 +0.29 +0.28
0.67 +0.40 +0.39 +0.38 +0.37 +0.36 +0.35 +0.34 +0.33 +0.32 +0.31 +0.30 +0.29
0.68 +0.41 +0.40 +0.39 +0.38 +0.37 +0.36 +0.35 +0.34 +0.33 +0.32 +0.31 +0.30
0.69 +0.42 +0.41 +0.40 +0.39 +0.38 +0.37 +0.36 +0.35 +0.34 +0.33 +0.32 +0.31
B 0.70 +0.43 +0.42 +0.41 +0.40 +0.39 +0.38 +0.37 +0.36 +0.35 +0.34 +0.33 +0.32
0.71 +0.44 +0.43 +0.42 +0.41 +0.40 +0.39 +0.38 +0.37 +0.36 +0.35 +0.34 +0.33
0.72 +0.45 +0.44 +0.43 +0.42 +0.41 +0.40 +0.39 +0.38 +0.37 +0.36 +0.35 +0.34
0.73 +0.46 +0.45 +0.44 +0.43 +0.42 +0.41 +0.40 +0.39 +0.38 +0.37 +0.36 +0.35
0.74 +0.47 +0.46 +0.45 +0.44 +0.43 +0.42 +0.41 +0.40 +0.39 +0.38 +0.37 +0.36
0.75 +0.48 +0.47 +0.46 +0.45 +0.44 +0.43 +0.42 +0.41 +0.40 +0.39 +0.38 +0.37
0.76 +0.49 +0.48 +0.47 +0.46 +0.45 +0.44 +0.43 +0.42 +0.41 +0.40 +0.39 +0.38
0.77 +0.50 +0.49 +0.48 +0.47 +0.46 +0.45 +0.44 +0.43 +0.42 +0.41 +0.40 +0.39
0.78 +0.51 +0.50 +0.49 +0.48 +0.47 +0.46 +0.45 +0.44 +0.43 +0.42 +0.41 +0.40
0.79 +0.52 +0.51 +0.50 +0.49 +0.48 +0.47 +0.46 +0.45 +0.44 +0.43 +0.42 +0.41
0.80 +0.53 +0.52 +0.51 +0.50 +0.49 +0.48 +0.47 +0.46 +0.45 +0.44 +0.43 +0.42
0.81 +0.54 +0.53 +0.52 +0.51 +0.50 +0.49 +0.48 +0.47 +0.46 +0.45 +0.44 +0.43
0.82 +0.55 +0.54 +0.53 +0.52 +0.51 +0.50 +0.49 +0.48 +0.47 +0.46 +0.45 +0.44
0.83 +0.56 +0.55 +0.54 +0.53 +0.52 +0.51 +0.50 +0.49 +0.48 +0.47 +0.46 +0.45
0.84 +0.57 +0.56 +0.55 +0.54 +0.53 +0.52 +0.51 +0.50 +0.49 +0.48 +0.47 +0.46
0.85 +0.58 +0.57 +0.56 +0.55 +0.54 +0.53 +0.52 +0.51 +0.50 +0.49 +0.48 +0.47
0.86 +0.59 +0.58 +0.57 +0.56 +0.55 +0.54 +0.53 +0.52 +0.51 +0.50 +0.49 +0.48
A Pinion height measurement (M)

B Calculated value (B)
8-47
(mm)
0.39 0.40 0.41 0.42 0.43 0.44

A
0.45 0.46 0.47 0.48 0.49 0.50
0
0.54 +0.15 +0.14 +0.13 +0.12 +0.11 +0.10 +0.09 +0.08 +0.07
0.55 +0.16 +0.15 +0.14 +0.13 +0.12 +0.11 +0.10 +0.09 +0.08 +0.07
0.56
0.57
+0.17
+0.18
+0.16
+0.17
+0.15
+0.16
+0.14
+0.15
+0.13
+0.14
+0.12
+0.13
+0.11
+0.12
+0.10
+0.11
+0.09
+0.10
+0.08
+0.09
+0.07
+0.08 +0.07
1
0.58 +0.19 +0.18 +0.17 +0.16 +0.15 +0.14 +0.13 +0.12 +0.11 +0.10 +0.09 +0.08
0.59 +0.20 +0.19 +0.18 +0.17 +0.16 +0.15 +0.14 +0.13 +0.12 +0.11 +0.10 +0.09
0.60
0.61
+0.21
+0.22
+0.20
+0.21
+0.19
+0.20
+0.18
+0.19
+0.17
+0.18
+0.16
+0.17
+0.15
+0.16
+0.14
+0.15
+0.13
+0.14
+0.12
+0.13
+0.11
+0.12
+0.10
+0.11
2
0.62 +0.23 +0.22 +0.21 +0.20 +0.19 +0.18 +0.17 +0.16 +0.15 +0.14 +0.13 +0.12
0.63 +0.24 +0.23 +0.22 +0.21 +0.20 +0.19 +0.18 +0.17 +0.16 +0.15 +0.14 +0.13
0.64
0.65
+0.25
+0.26
+0.24
+0.25
+0.23
+0.24
+0.22
+0.23
+0.21
+0.22
+0.20
+0.21
+0.19
+0.20
+0.18
+0.19
+0.17
+0.18
+0.16
+0.17
+0.15
+0.16
+0.14
+0.15
3
0.66 +0.27 +0.26 +0.25 +0.24 +0.23 +0.22 +0.21 +0.20 +0.19 +0.18 +0.17 +0.16
0.67
0.68
0.69
+0.28
+0.29
+0.30
+0.27
+0.28
+0.29
+0.26
+0.27
+0.28
+0.25
+0.26
+0.27
+0.24
+0.25
+0.26
+0.23
+0.24
+0.25
+0.22
+0.23
+0.24
+0.21
+0.22
+0.23
+0.20
+0.21
+0.22
+0.19
+0.20
+0.21
+0.18
+0.19
+0.20
+0.17
+0.18
+0.19
4
B 0.70 +0.31 +0.30 +0.29 +0.28 +0.27 +0.26 +0.25 +0.24 +0.23 +0.22 +0.21 +0.20
0.71
0.72
+0.32
+0.33
+0.31
+0.32
+0.30
+0.31
+0.29
+0.30
+0.28
+0.29
+0.27
+0.28
+0.26
+0.27
+0.25
+0.26
+0.24
+0.25
+0.23
+0.24
+0.22
+0.23
+0.21
+0.22 5
0.73 +0.34 +0.33 +0.32 +0.31 +0.30 +0.29 +0.28 +0.27 +0.26 +0.25 +0.24 +0.23
0.74 +0.35 +0.34 +0.33 +0.32 +0.31 +0.30 +0.29 +0.28 +0.27 +0.26 +0.25 +0.24
0.75
0.76
+0.36
+0.37
+0.35
+0.36
+0.34
+0.35
+0.33
+0.34
+0.32
+0.33
+0.31
+0.32
+0.30
+0.31
+0.29
+0.30
+0.28
+0.29
+0.27
+0.28
+0.26
+0.27
+0.25
+0.26 6
0.77 +0.38 +0.37 +0.36 +0.35 +0.34 +0.33 +0.32 +0.31 +0.30 +0.29 +0.28 +0.27
0.78 +0.39 +0.38 +0.37 +0.36 +0.35 +0.34 +0.33 +0.32 +0.31 +0.30 +0.29 +0.28
0.79
0.80
+0.40
+0.41
+0.39
+0.40
+0.38
+0.39
+0.37
+0.38
+0.36
+0.37
+0.35
+0.36
+0.34
+0.35
+0.33
+0.34
+0.32
+0.33
+0.31
+0.32
+0.30
+0.31
+0.29
+0.30
7
0.81 +0.42 +0.41 +0.40 +0.39 +0.38 +0.37 +0.36 +0.35 +0.34 +0.33 +0.32 +0.31
0.82 +0.43 +0.42 +0.41 +0.40 +0.39 +0.38 +0.37 +0.36 +0.35 +0.34 +0.33 +0.32
0.83
0.84
+0.44
+0.45
+0.43
+0.44
+0.42
+0.43
+0.41
+0.42
+0.40
+0.41
+0.39
+0.40
+0.38
+0.39
+0.37
+0.38
+0.36
+0.37
+0.35
+0.36
+0.34
+0.35
+0.33
+0.34
8
0.85 +0.46 +0.45 +0.44 +0.43 +0.42 +0.41 +0.40 +0.39 +0.38 +0.37 +0.36 +0.35
0.86 +0.47 +0.46 +0.45 +0.44 +0.43 +0.42 +0.41 +0.40 +0.39 +0.38 +0.37 +0.36
A Pinion height measurement (M) 9

10
A
8-48
LOWR
Lower unit
(mm)
A
0.51 0.52 0.53 0.54 0.55 0.56 0.57 0.58 0.59 0.60 0.61 0.62
0.54 –0.07 –0.08
0.55 –0.07
0.56
0.57
0.58 +0.07
0.59 +0.08 +0.07
0.60 +0.09 +0.08 +0.07
0.61 +0.10 +0.09 +0.08 +0.07
0.62 +0.11 +0.10 +0.09 +0.08 +0.07
0.63 +0.12 +0.11 +0.10 +0.09 +0.08 +0.07
0.64 +0.13 +0.12 +0.11 +0.10 +0.09 +0.08 +0.07
0.65 +0.14 +0.13 +0.12 +0.11 +0.10 +0.09 +0.08 +0.07
0.66 +0.15 +0.14 +0.13 +0.12 +0.11 +0.10 +0.09 +0.08 +0.07
0.67 +0.16 +0.15 +0.14 +0.13 +0.12 +0.11 +0.10 +0.09 +0.08 +0.07
0.68 +0.17 +0.16 +0.15 +0.14 +0.13 +0.12 +0.11 +0.10 +0.09 +0.08 +0.07
0.69 +0.18 +0.17 +0.16 +0.15 +0.14 +0.13 +0.12 +0.11 +0.10 +0.09 +0.08 +0.07
B 0.70 +0.19 +0.18 +0.17 +0.16 +0.15 +0.14 +0.13 +0.12 +0.11 +0.10 +0.09 +0.08
0.71 +0.20 +0.19 +0.18 +0.17 +0.16 +0.15 +0.14 +0.13 +0.12 +0.11 +0.10 +0.09
0.72 +0.21 +0.20 +0.19 +0.18 +0.17 +0.16 +0.15 +0.14 +0.13 +0.12 +0.11 +0.10
0.73 +0.22 +0.21 +0.20 +0.19 +0.18 +0.17 +0.16 +0.15 +0.14 +0.13 +0.12 +0.11
0.74 +0.23 +0.22 +0.21 +0.20 +0.19 +0.18 +0.17 +0.16 +0.15 +0.14 +0.13 +0.12
0.75 +0.24 +0.23 +0.22 +0.21 +0.20 +0.19 +0.18 +0.17 +0.16 +0.15 +0.14 +0.13
0.76 +0.25 +0.24 +0.23 +0.22 +0.21 +0.20 +0.19 +0.18 +0.17 +0.16 +0.15 +0.14
0.77 +0.26 +0.25 +0.24 +0.23 +0.22 +0.21 +0.20 +0.19 +0.18 +0.17 +0.16 +0.15
0.78 +0.27 +0.26 +0.25 +0.24 +0.23 +0.22 +0.21 +0.20 +0.19 +0.18 +0.17 +0.16
0.79 +0.28 +0.27 +0.26 +0.25 +0.24 +0.23 +0.22 +0.21 +0.20 +0.19 +0.18 +0.17
0.80 +0.29 +0.28 +0.27 +0.26 +0.25 +0.24 +0.23 +0.22 +0.21 +0.20 +0.19 +0.18
0.81 +0.30 +0.29 +0.28 +0.27 +0.26 +0.25 +0.24 +0.23 +0.22 +0.21 +0.20 +0.19
0.82 +0.31 +0.30 +0.29 +0.28 +0.27 +0.26 +0.25 +0.24 +0.23 +0.22 +0.21 +0.20
0.83 +0.32 +0.31 +0.30 +0.29 +0.28 +0.27 +0.26 +0.25 +0.24 +0.23 +0.22 +0.21
0.84 +0.33 +0.32 +0.31 +0.30 +0.29 +0.28 +0.27 +0.26 +0.25 +0.24 +0.23 +0.22
0.85 +0.34 +0.33 +0.32 +0.31 +0.30 +0.29 +0.28 +0.27 +0.26 +0.25 +0.24 +0.23
0.86 +0.35 +0.34 +0.33 +0.32 +0.31 +0.30 +0.29 +0.28 +0.27 +0.26 +0.25 +0.24

8-49
(mm)
0.63 0.64 0.65 0.66 0.67 0.68

A
0.69 0.70 0.71 0.72 0.73 0.74
0
0.54 –0.09 –0.10 –0.11 –0.12 –0.13 –0.14 –0.15 –0.16 –0.17 –0.18 –0.19 –0.20
0.55 –0.08 –0.09 –0.10 –0.11 –0.12 –0.13 –0.14 –0.15 –0.16 –0.17 –0.18 –0.19
0.56
0.57
–0.07 –0.08
–0.07
–0.09
–0.08
–0.10
–0.09
–0.11
–0.10
–0.12
–0.11
–0.13
–0.12
–0.14
–0.13
–0.15
–0.14
–0.16
–0.15
–0.17
–0.16
–0.18
–0.17
1
0.58 –0.07 –0.08 –0.09 –0.10 –0.11 –0.12 –0.13 –0.14 –0.15 –0.16
0.59 –0.07 –0.08 –0.09 –0.10 –0.11 –0.12 –0.13 –0.14 –0.15
0.60
0.61
–0.07 –0.08
–0.07
–0.09
–0.08
–0.10
–0.09
–0.11
–0.10
–0.12
–0.11
–0.13
–0.12
–0.14
–0.13
2
0.62 –0.07 –0.08 –0.09 –0.10 –0.11 –0.12
0.63 –0.07 –0.08 –0.09 –0.10 –0.11
0.64
0.65
–0.09 –0.08
–0.07
–0.09
–0.08
–0.10
–0.09
3
0.66 –0.07 –0.08
0.67
0.68
–0.07
4
0.69
B 0.70 +0.07
0.71
0.72
+0.08
+0.09
+0.07
+0.08 +0.07 5
0.73 +0.10 +0.09 +0.08 +0.07
0.74 +0.11 +0.10 +0.09 +0.08 +0.07
0.75
0.76
+0.12
+0.13
+0.11
+0.12
+0.10
+0.11
+0.09
+0.10
+0.08
+0.09
+0.07
+0.08 +0.07
6
0.77 +0.14 +0.13 +0.12 +0.11 +0.10 +0.09 +0.08 +0.07
0.78 +0.15 +0.14 +0.13 +0.12 +0.11 +0.10 +0.09 +0.08 +0.07
0.79
0.80
+0.16
+0.17
+0.15
+0.16
+0.14
+0.15
+0.13
+0.14
+0.12
+0.13
+0.11
+0.12
+0.10
+0.11
+0.09
+0.10
+0.08
+0.09
+0.07
+0.08 +0.07
7
0.81 +0.18 +0.17 +0.16 +0.15 +0.14 +0.13 +0.12 +0.11 +0.10 +0.09 +0.08 +0.07
0.82 +0.19 +0.18 +0.17 +0.16 +0.15 +0.14 +0.13 +0.12 +0.11 +0.10 +0.09 +0.08
0.83
0.84
+0.20
+0.21
+0.19
+0.20
+0.18
+0.19
+0.17
+0.18
+0.16
+0.17
+0.15
+0.16
+0.14
+0.15
+0.13
+0.14
+0.12
+0.13
+0.11
+0.12
+0.10
+0.11
+0.09
+0.10
8
0.85 +0.22 +0.21 +0.20 +0.19 +0.18 +0.17 +0.16 +0.15 +0.14 +0.13 +0.12 +0.11
0.86 +0.23 +0.22 +0.21 +0.20 +0.19 +0.18 +0.17 +0.16 +0.15 +0.14 +0.13 +0.12

10
A
8-50
LOWR
Lower unit
(mm)
A
0.75 0.76 0.77 0.78 0.79 0.80 0.81 0.82 0.83 0.84 0.85 0.86
0.54 –0.21 –0.22 –0.23 –0.24 –0.25 –0.26 –0.27 –0.28 –0.29 –0.30 –0.31 –0.32
0.55 –0.20 –0.21 –0.22 –0.23 –0.24 –0.25 –0.26 –0.27 –0.28 –0.29 –0.30 –0.31
0.56 –0.19 –0.20 –0.21 –0.22 –0.23 –0.24 –0.25 –0.26 –0.27 –0.28 –0.29 –0.30
0.57 –0.18 –0.19 –0.20 –0.21 –0.22 –0.23 –0.24 –0.25 –0.26 –0.27 –0.28 –0.29
0.58 –0.17 –0.18 –0.19 –0.20 –0.21 –0.22 –0.23 –0.24 –0.25 –0.26 –0.27 –0.28
0.59 –0.16 –0.17 –0.18 –0.19 –0.20 –0.21 –0.22 –0.23 –0.24 –0.25 –0.26 –0.27
0.60 –0.15 –0.16 –0.17 –0.18 –0.19 –0.20 –0.21 –0.22 –0.23 –0.24 –0.25 –0.26
0.61 –0.14 –0.15 –0.16 –0.17 –0.18 –0.19 –0.20 –0.21 –0.22 –0.23 –0.24 –0.25
0.62 –0.13 –0.14 –0.15 –0.16 –0.17 –0.18 –0.19 –0.20 –0.21 –0.22 –0.23 –0.24
0.63 –0.12 –0.13 –0.14 –0.15 –0.16 –0.17 –0.18 –0.19 –0.20 –0.21 –0.22 –0.23
0.64 –0.11 –0.12 –0.13 –0.14 –0.15 –0.16 –0.17 –0.18 –0.19 –0.20 –0.21 –0.22
0.65 –0.10 –0.11 –0.12 –0.13 –0.14 –0.15 –0.16 –0.17 –0.18 –0.19 –0.20 –0.21
0.66 –0.09 –0.10 –0.11 –0.12 –0.13 –0.14 –0.15 –0.16 –0.17 –0.18 –0.19 –0.20
0.67 –0.08 –0.09 –0.10 –0.11 –0.12 –0.13 –0.14 –0.15 –0.16 –0.17 –0.18 –0.19
0.68 –0.07 –0.08 –0.09 –0.10 –0.11 –0.12 –0.13 –0.14 –0.15 –0.16 –0.17 –0.18
0.69 –0.07 –0.08 –0.09 –0.10 –0.11 –0.12 –0.13 –0.14 –0.15 –0.16 –0.17
B 0.70 –0.07 –0.08 –0.09 –0.10 –0.11 –0.12 –0.13 –0.14 –0.15 –0.16
0.71 –0.07 –0.08 –0.09 –0.10 –0.11 –0.12 –0.13 –0.14 –0.15
0.72 –0.07 –0.08 –0.09 –0.10 –0.11 –0.12 –0.13 –0.14
0.73 –0.07 –0.08 –0.09 –0.10 –0.11 –0.12 –0.13
0.74 –0.07 –0.08 –0.09 –0.10 –0.11 –0.12
0.75 –0.07 –0.08 –0.09 –0.10 –0.11
0.76 –0.07 –0.08 –0.09 –0.10
0.77 –0.07 –0.08 –0.09
0.78 –0.07 –0.08
0.79 –0.07
0.80
0.81
0.82 +0.07
0.83 +0.08 +0.07
0.84 +0.09 +0.08 +0.07
0.85 +0.10 +0.09 +0.08 +0.07
0.86 +0.11 +0.10 +0.09 +0.08 +0.07

8-51
(mm)
0.87 0.88 0.89 0.90 0.91 0.92

A
0.93 0.94 0.95 0.96 0.97 0.98
0
0.54 –0.33 –0.34 –0.35 –0.36 –0.37 –0.38 –0.39 –0.40 –0.41 –0.42 –0.43 –0.44
0.55 –0.32 –0.33 –0.34 –0.35 –0.36 –0.37 –0.38 –0.39 –0.40 –0.41 –0.42 –0.43
0.56
0.57
–0.31
–0.30
–0.32
–0.31
–0.33
–0.32
–0.34
–0.33
–0.35
–0.34
–0.36
–0.35
–0.37
–0.36
–0.38
–0.37
–0.39
–0.38
–0.40
–0.39
–0.41
–0.40
–0.42
–0.41
1
0.58 –0.29 –0.30 –0.31 –0.32 –0.33 –0.34 –0.35 –0.36 –0.37 –0.38 –0.39 –0.40
0.59 –0.28 –0.29 –0.30 –0.31 –0.32 –0.33 –0.34 –0.35 –0.36 –0.37 –0.38 –0.39
0.60
0.61
–0.27
–0.26
–0.28
–0.27
–0.29
–0.28
–0.30
–0.29
–0.31
–0.30
–0.32
–0.31
–0.33
–0.32
–0.34
–0.33
–0.35
–0.34
–0.36
–0.35
–0.37
–0.36
–0.38
–0.37
2
0.62 –0.25 –0.26 –0.27 –0.28 –0.29 –0.30 –0.31 –0.32 –0.33 –0.34 –0.35 –0.36
0.63 –0.24 –0.25 –0.26 –0.27 –0.28 –0.29 –0.30 –0.31 –0.32 –0.33 –0.34 –0.35
0.64
0.65
–0.23
–0.22
–0.24
–0.23
–0.25
–0.24
–0.26
–0.25
–0.27
–0.26
–0.28
–0.27
–0.29
–0.28
–0.30
–0.29
–0.31
–0.30
–0.32
–0.31
–0.33
–0.32
–0.34
–0.33
3
0.66 –0.21 –0.22 –0.23 –0.24 –0.25 –0.26 –0.27 –0.28 –0.29 –0.30 –0.31 –0.32
0.67
0.68
–0.20
–0.19
–0.21
–0.20
–0.22
–0.21
–0.23
–0.22
–0.24
–0.23
–0.25
–0.24
–0.26
–0.25
–0.27
–0.26
–0.28
–0.27
–0.29
–0.28
–0.30
–0.29
–0.31
–0.30 4
0.69 –0.18 –0.19 –0.20 –0.21 –0.22 –0.23 –0.24 –0.25 –0.26 –0.27 –0.28 –0.29
B 0.70 –0.17 –0.18 –0.19 –0.20 –0.21 –0.22 –0.23 –0.24 –0.25 –0.26 –0.27 –0.28
0.71
0.72
–0.16
–0.15
–0.17
–0.16
–0.18
–0.17
–0.19
–0.18
–0.20
–0.19
–0.21
–0.20
–0.22
–0.21
–0.23
–0.22
–0.24
–0.23
–0.25
–0.24
–0.26
–0.25
–0.27
–0.26 5
0.73 –0.14 –0.15 –0.16 –0.17 –0.18 –0.19 –0.20 –0.21 –0.22 –0.23 –0.24 –0.25
0.74 –0.13 –0.14 –0.15 –0.16 –0.17 –0.18 –0.19 –0.20 –0.21 –0.22 –0.23 –0.24
0.75
0.76
–0.12
–0.11
–0.13
–0.12
–0.14
–0.13
–0.15
–0.14
–0.16
–0.15
–0.17
–0.16
–0.18
–0.17
–0.19
–0.18
–0.20
–0.19
–0.21
–0.20
–0.22
–0.21
–0.23
–0.22
6
0.77 –0.10 –0.11 –0.12 –0.13 –0.14 –0.15 –0.16 –0.17 –0.18 –0.19 –0.20 –0.21
0.78 –0.09 –0.10 –0.11 –0.12 –0.13 –0.14 –0.15 –0.16 –0.17 –0.18 –0.19 –0.20
0.79
0.80
–0.08
–0.07
–0.09
–0.08
–0.10
–0.09
–0.11
–0.10
–0.12
–0.11
–0.13
–0.12
–0.14
–0.13
–0.15
–0.14
–0.16
–0.15
–0.17
–0.16
–0.18
–0.17
–0.19
–0.18
7
0.81 –0.07 –0.08 –0.09 –0.10 –0.11 –0.12 –0.13 –0.14 –0.15 –0.16 –0.17
0.82 –0.07 –0.08 –0.09 –0.10 –0.11 –0.12 –0.13 –0.14 –0.15 –0.16
0.83
0.84
–0.07 –0.08
–0.07
–0.09
–0.08
–0.10
–0.09
–0.11
–0.10
–0.12
–0.11
–0.13
–0.12
–0.14
–0.13
–0.15
–0.14
8
0.85 –0.07 –0.08 –0.09 –0.10 –0.11 –0.12 –0.13
0.86 –0.07 –0.08 –0.09 –0.10 –0.11 –0.12

10
A
8-52
LOWR
Lower unit
(mm)
A
0.99 1.00 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08
0.54 –0.45 –0.46 –0.47 –0.48 –0.49 –0.50 –0.51 –0.52 –0.53 –0.54
0.55 –0.44 –0.45 –0.46 –0.47 –0.48 –0.49 –0.50 –0.51 –0.52 –0.53
0.56 –0.43 –0.44 –0.45 –0.46 –0.47 –0.48 –0.49 –0.50 –0.51 –0.52
0.57 –0.42 –0.43 –0.44 –0.45 –0.46 –0.47 –0.48 –0.49 –0.50 –0.51
0.58 –0.41 –0.42 –0.43 –0.44 –0.45 –0.46 –0.47 –0.48 –0.49 –0.50
0.59 –0.40 –0.41 –0.42 –0.43 –0.44 –0.45 –0.46 –0.47 –0.48 –0.49
0.60 –0.39 –0.40 –0.41 –0.42 –0.43 –0.44 –0.45 –0.46 –0.47 –0.48
0.61 –0.38 –0.39 –0.40 –0.41 –0.42 –0.43 –0.44 –0.45 –0.46 –0.47
0.62 –0.37 –0.38 –0.39 –0.40 –0.41 –0.42 –0.43 –0.44 –0.45 –0.46
0.63 –0.36 –0.37 –0.38 –0.39 –0.40 –0.41 –0.42 –0.43 –0.44 –0.45
0.64 –0.35 –0.36 –0.37 –0.38 –0.39 –0.40 –0.41 –0.42 –0.43 –0.44
0.65 –0.34 –0.35 –0.36 –0.37 –0.38 –0.39 –0.40 –0.41 –0.42 –0.43
0.66 –0.33 –0.34 –0.35 –0.36 –0.37 –0.38 –0.39 –0.40 –0.41 –0.42
0.67 –0.32 –0.33 –0.34 –0.35 –0.36 –0.37 –0.38 –0.39 –0.40 –0.41
0.68 –0.31 –0.32 –0.33 –0.34 –0.35 –0.36 –0.37 –0.38 –0.39 –0.40
0.69 –0.30 –0.31 –0.32 –0.33 –0.34 –0.35 –0.36 –0.37 –0.38 –0.39
B 0.70 –0.29 –0.30 –0.31 –0.32 –0.33 –0.34 –0.35 –0.36 –0.37 –0.38
0.71 –0.28 –0.29 –0.30 –0.31 –0.32 –0.33 –0.34 –0.35 –0.36 –0.37
0.72 –0.27 –0.28 –0.29 –0.30 –0.31 –0.32 –0.33 –0.34 –0.35 –0.36
0.73 –0.26 –0.27 –0.28 –0.29 –0.30 –0.31 –0.32 –0.33 –0.34 –0.35
0.74 –0.25 –0.26 –0.27 –0.28 –0.29 –0.30 –0.31 –0.32 –0.33 –0.34
0.75 –0.24 –0.25 –0.26 –0.27 –0.28 –0.29 –0.30 –0.31 –0.32 –0.33
0.76 –0.23 –0.24 –0.25 –0.26 –0.27 –0.28 –0.29 –0.30 –0.31 –0.32
0.77 –0.22 –0.23 –0.24 –0.25 –0.26 –0.27 –0.28 –0.29 –0.30 –0.31
0.78 –0.21 –0.22 –0.23 –0.24 –0.25 –0.26 –0.27 –0.28 –0.29 –0.30
0.79 –0.20 –0.21 –0.22 –0.23 –0.24 –0.25 –0.26 –0.27 –0.28 –0.29
0.80 –0.19 –0.20 –0.21 –0.22 –0.23 –0.24 –0.25 –0.26 –0.27 –0.28
0.81 –0.18 –0.19 –0.20 –0.21 –0.22 –0.23 –0.24 –0.25 –0.26 –0.27
0.82 –0.17 –0.18 –0.19 –0.20 –0.21 –0.22 –0.23 –0.24 –0.25 –0.26
0.83 –0.16 –0.17 –0.18 –0.19 –0.20 –0.21 –0.22 –0.23 –0.24 –0.25
0.84 –0.15 –0.16 –0.17 –0.18 –0.19 –0.20 –0.21 –0.22 –0.23 –0.24
0.85 –0.14 –0.15 –0.16 –0.17 –0.18 –0.19 –0.20 –0.21 –0.22 –0.23
0.86 –0.13 –0.14 –0.15 –0.16 –0.17 –0.18 –0.19 –0.20 –0.21 –0.22

8-53
Measuring the forward gear backlash Adjusting the forward gear shim (T1)
• 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 and propeller shaft assembly.
See “Removing the propeller shaft hous- 0
• Keep the parts free of foreign material, ing assembly” (8-16).
• When measuring the forward gear or
reverse gear backlash, use the original
2. Remove the drive shaft ring nut, pinion,
and drive shaft. See steps 2 and 3 in 1
bearings and shims. “Removing the drive shaft” (8-23).
1. Install the adapter, original forward gear

shim, thrust bearing, and forward gear
3. Remove the forward gear, thrust bearing,
original forward gear shim, and adapter.
2
assembly. See “Installing the forward See “Removing the forward gear” (8-23).
gear” (8-28).
TIP:
4. Measure the thickness of the original
forward gear shim in 2 places.
3
• If the original shim is missing, install a new
TIP:
shim with a thickness of 2.00 mm.
• Do not reuse a shim if deformed or Do not reuse a shim if deformed or 4
scratched. scratched.
2. Install the drive shaft, pinion, and drive

shaft ring nut. See steps 1–3 in “Installing
5. Determine the forward gear shim (T1)
thickness using the “Forward gear shim
5
the drive shaft” (8-28). (T1) selection table” according to the
backlash measurement (BL1) from
3. Check that the drive shaft turns smoothly. “Measuring the forward gear backlash”
and the current shim thickness. See
6
4. Install the propeller shaft assembly and “Forward gear shim (T1) selection table”
propeller shaft housing assembly. See (8-56).
steps 1–5 in “Installing the propeller shaft Example: 7
housing assembly” (8-29). Backlash measurement (BL1) = 0.29 mm a
Current forward gear shim thickness = 2.06
6. Measure the forward gear backlash. See

mm b
Use the determined shim thickness of 2.03 8
mm instead of the current shim thickness.
steps 2–9 in “Measuring the forward gear
backlash and reverse gear backlash
before disassembly” (8-39).
a
(mm) 9
A
0.27 0.28 0.29
0.04–0.59 mm (0.0016–0.0232 in)
B
2.00
2.03 10
TIP: 2.06 2.03
In the “Forward gear shim (T1) selection 2.09
table,” use the round-down average for the b
backlash measurement (BL1).
A Backlash measurement (BL1)
B Current shim thickness
A
8-54
LOWR
Lower unit

2.00, 2.03, 2.06, 2.09, 2.12, 2.15 mm
TIP:
• The gray-colored cells on the selection
table indicate the range where the shim
adjustment is unnecessary. Shimming is
not required if the obtained forward gear
shim thickness is indicated by the gray-col-
ored cells.
• The values for the shim thickness specified
in the selection table are intended to obtain
the median value within the range for the
specified forward gear backlash.
• If the backlash measurement (BL1) is less
than 0.18 mm, install a new shim with a
thickness of 2.00 mm.
• If the backlash measurement (BL1) is more
• Use only 1 shim to obtain the required shim
thickness.
6. Install the adapter, determined forward

gear shim (T1), thrust bearing, and
forward gear. See “Installing the forward
gear” (8-28).
8-55
Forward gear shim (T1) selection table
(mm)
A
2.00
0.18 0.19 0.20 0.21 0.22 0.23 0.24 0.25 0.26 0
2.03 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00
B
2.06
2.09
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.00
2.03
2.00
2.03
2.00
2.03 1
2.12 2.00 2.00 2.00 2.03 2.03 2.03 2.06 2.06 2.06
2.15 2.03 2.03 2.03 2.06 2.06 2.06 2.09 2.09 2.09
A
2
0.27 0.28 0.29 0.30 0.31 0.32 0.33 0.34 0.35
2.00
2.03 2.00 2.00 2.00
2.03
2.06
2.03
2.06
2.03
2.06 3
2.06 2.03 2.03 2.03 2.09 2.09 2.09
B
2.09 2.06 2.06 2.06 2.12 2.12 2.12
2.12 2.09 2.09 2.09 2.15 2.15 2.15 4
2.15 2.12 2.12 2.12
A
0.36 0.37 0.38 0.39 0.40 0.41 0.42 0.43 0.44 5
2.00 2.06 2.06 2.06 2.09 2.09 2.09 2.12 2.12 2.12
2.03 2.09 2.09 2.09 2.12 2.12 2.12 2.15 2.15 2.15
B
2.06
2.09
2.12
2.15
2.12
2.15
2.12
2.15
2.15
2.15
2.15
2.15
2.15
2.15
2.15
2.15
2.15
2.15
2.15
2.15
6
2.12 2.15 2.15 2.15 2.15 2.15 2.15 2.15 2.15 2.15
2.15
7
8
9
10
A
8-56
LOWR
Lower unit
Measuring the reverse gear backlash
• Spray anti-rust lubricant on the gears and TIP:
bearings before installation. Do not apply Do not reuse a shim if deformed or
gear oil to the parts. Otherwise, correct scratched.
• Keep the parts free of foreign material, 3. Determine the reverse gear shim (T2)
such as dirt and lint. thickness adjustment using the “Reverse
• When measuring the forward gear or gear shim (T2) selection chart” according
reverse gear backlash, use the original to the backlash measurement (BL2) from
bearings and shims. “Measuring the reverse gear backlash.”
See “Reverse gear shim (T2) selection
1. Install the original reverse gear shims, chart” (8-59).
propeller shaft assembly, and propeller Example:
shaft housing assembly. See “Installing Backlash measurement (BL2) = 0.10 mm a
the propeller shaft housing assembly” (8- Reverse gear shim (T2) thickness adjustment
29). = 0.42 mm b
The current shim thickness must be
TIP: increased by 0.42 mm.
0.60
shims with a combined thickness of 0.50 b
mm. 0.40
B (mm)

scratched. 0.20
0
2. Check that the drive shaft turns smoothly. 0 5 10 15 20 25 3
3. Measure the reverse gear backlash. See a A (1/100 mm)

steps 11–14 in “Measuring the forward
gear backlash and reverse gear backlash A 0 5 10 15 20 25 3
B 0.52 0.47 0.42 0 0 0
0.15–0.88 mm (0.0059–0.0346 in) A Backlash measurement (BL2)
B Shim thickness adjustment
TIP:
In the “Reverse gear shim (T2) selection
chart,” use the round-down average for the
Adjusting the reverse gear shim (T2)

thickness
assembly, propeller shaft assembly, and
original reverse gear shims. See
“Removing the propeller shaft housing
assembly” (8-16).
2. Measure the thickness of each original

reverse gear shim in 2 places.
8-57
TIP: TIP:
• If the shim thickness adjustment value is • Use up to 3 shims to obtain the required
positive, the current shim thickness must be shim thickness.
increased by that amount and, if the value
0
be decreased by that amount. shims, decrease the shim thickness by
• The gray-colored area on the selection 0.01 mm.
chart indicates the range of the specified
backlash. Shimming is not required if the
1
5. Install the determined reverse gear shims
measured backlash is within the gray-col- (T2), propeller shaft assembly, and
ored area.
• The values for the shim thickness adjust-
propeller shaft housing assembly. See
“Installing the propeller shaft housing
2
ments specified in the selection chart are assembly” (8-29).
intended to obtain the median value within
the range for the specified reverse gear
backlash.
3
• The table that follows the selection chart
shows the shim thickness adjustments for
the points marked on the chart. 4
4. Calculate the new reverse gear shim (T2)
thickness.
Calculation formula: 5
New reverse gear shim (T2) thickness = Cur-
rent reverse gear shim thickness + Shim
thickness adjustment
Example:
6
Current reverse gear shim thickness = 0.75
mm
7
New reverse gear shim (T2) thickness
= 0.75 mm + 0.42 mm 8
= 1.17 mm
9
mm
New reverse gear shim (T2) thickness
= 0.75 mm + (–0.39) mm
10
= 0.36 mm
0.10, 0.12, 0.15, 0.18, 0.30, 0.40,
0.50 mm
A
8-58
Reverse gear shim (T2) selection chart
8-59
0.60
LOWR
0.40
0.20
–0.20
Lower unit
–0.40
B (mm)
–0.60
Continue next page

–0.80
–1.00
–1.20
–1.40
–1.60
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
A (1/100 mm)
A 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
B 0.52 0.47 0.42 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 –0.39 –0.44 –0.49

0.60
0.40
0.20
–0.20
–0.40
B (mm)
–0.60
–0.80
–1.00
–1.20
–1.40
–1.60
100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 182 190 195 200
A (1/100 mm)
A 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 182 190 195 200
B –0.49 –0.54 –0.59 –0.64 –0.69 –0.74 –0.79 –0.84 –0.89 –0.94 –0.99 –1.04 –1.09 –1.14 –1.19 –1.24 –1.29 –1.34 –1.39 –1.44 –1.49

8-60
9
8
7
6
5
4
3
2
1
0
A
10
LOWR
Lower unit
Selecting the propeller shaft shim
(T4)
1. Install the original propeller shaft shims,
propeller shaft assembly, and propeller
shaft housing assembly. See steps 1–6 in
“Installing the propeller shaft housing
assembly” (8-29).
TIP:
shims with a combined thickness of Propeller shaft motive torque:
2.00 mm. 0.44–1.32 N·m (0.04–0.13 kgf·m,
• Do not reuse a shim if deformed or 0.32–0.97 ft·lb)
scratched.
• Check that there is no free play in the pro- Available shim thicknesses:
peller shaft 0.7, 0.8, 0.9, 1.0, 1.1, 1.2 mm
2. Set the gear shift to the N position. TIP:

• Shimming is not required if the measure-
ment value is within specification.
R
• If the measurement value is below specifi-
cation, adjust the motive torque to specifi-
N
cation by increasing the propeller shaft
shim thickness by 0.10 mm.
F
• If the measurement value is above specifi-
cation, adjust the motive torque to specifi-
cation by decreasing the propeller shaft
a shim thickness by 0.10 mm.
• Use up to 3 shims to obtain the required
shim thickness.
3. Turn the propeller shaft 5 turns or more.
4. Install the washer b and propeller nut c.
c
b
5. Measure the motive torque of the

propeller shaft.
8-61
Shimming (regular rotation model) /
Lower unit (counter rotation model, X-transom model)
12 42 N·m (4.2 kgf·m, 31.0 ft·lb)
11
54 N·m (5.4 kgf·m, 39.8 ft·lb)
15
0
9 N·m (0.9 kgf·m, 6.6 ft·lb)
9 16 1
10 13
3 14
8 9 18
17 2
7 20 19
3
9 N·m (0.9 kgf·m, 6.6 ft·lb) 21
4
6
5 22 23 5
22
4
3
2 1
47 N·m (4.7 kgf·m, 34.7 ft·lb)
47 N·m (4.7 kgf·m, 34.7 ft·lb)
6
2 N·m (0.2 kgf·m, 1.5 ft·lb)

3
4
Gasket
Drain screw
2
1
39 8
6
7
Self-locking nut
Hose nipple
1
1 9
8 O-ring 1 39
9 Dowel 2
10
11
Check screw
Trim tab bolt
1
1 M10 45 mm
10
12 Grommet 1
13 Lower unit 1
14 Propeller 1
15 Cotter pin 1 39
16 Propeller nut 1
17 Washer 1
A
8-62
LOWR
Lower unit
12 42 N·m (4.2 kgf·m, 31.0 ft·lb)
11
54 N·m (5.4 kgf·m, 39.8 ft·lb)
15
9 N·m (0.9 kgf·m, 6.6 ft·lb)
9 16
10 13
3 14
8 17
9 18
7 20 19
9 N·m (0.9 kgf·m, 6.6 ft·lb) 21
6
5 22 23
22
4
47 N·m (4.7 kgf·m, 34.7 ft·lb)
3
2 1 47 N·m (4.7 kgf·m, 34.7 ft·lb)
2 N·m (0.2 kgf·m, 1.5 ft·lb)

18 Spacer 1
19 Damper 1 39
20 Spacer 1
21 Trim tab 1
8-63
2. Remove the propeller, trim tab, and lower

unit. See steps 2–5 in “Removing the
0
lower unit” (8-3).
TIP: 1
2
See “Disassembling the propeller” (8-3). 3
Checking the propeller
4
Checking the lower unit anode

5
6
7
8
9
10
A
8-64
LOWR
Lower unit
Lower unit (counter rotation model, U-transom model)
17
42 N·m (4.2 kgf·m, 31.0 ft·lb)
23 N·m (2.3 kgf·m, 17.0 ft·lb) 16
54 N·m (5.4 kgf·m, 39.8 ft·lb)

15
14 13
21
13 13 22
19 20
12 18 23
13 24
26 25
11 3
10
9
9 N·m (0.9 kgf·m, 6.6 ft·lb) 27
8
7 6 29 31
5
28
4 30
1

3 Gasket 2 39
4 Drain screw 1
7 Hose nipple 1
8 O-ring 1 39
9 Bolt 1 M6 20 mm
10 Adapter 1
11 Plastic tie 1
12 Extension 1
13 Dowel 4
14 Rubber seal 1
15 Lower case stud bolt 6
17 Grommet 1
8-65
Lower unit (counter rotation model, U-transom model)
17
42 N·m (4.2 kgf·m, 31.0 ft·lb)
16
23 N·m (2.3 kgf·m, 17.0 ft·lb)
0
54 N·m (5.4 kgf·m, 39.8 ft·lb)
15
14 13
1
21
13 13 22 2
19 20
12 18
13
26 25
24
23
3
11 3
10
9
4
9 N·m (0.9 kgf·m, 6.6 ft·lb) 27
8
7
5
6 29
5 31
28
4 30
9 N·m (0.9 kgf·m, 6.6 ft·lb) 3
1 47 N·m (4.7 kgf·m, 34.7 ft·lb) 6

18 Check screw 1
19 Lower unit 1
20
21
Propeller
Cotter pin
1
1 39
8
22 Propeller nut 1
23
24
Washer
Spacer
1
1 9
25 Damper 1 39
26 Spacer 1
27
28
Trim tab
Lower case mounting nut
1
6
10
29 Washer 6
A
8-66
LOWR
Lower unit
2. Remove the propeller and trim tab. See

steps 2–5 in “Removing the lower unit”
(8-3).
3. Remove the extension and lower unit.

See steps 3 and 4 in “Removing the
lower unit” (8-3).
TIP:

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

Checking the lower unit anode


8-67
Lower unit (counter rotation model, U-transom model) /
Water pump and shift rod (counter rotation model)
22
11
20
21 22
0
23
6 20
12
20 1
7
19
6
13
18 2
17
5
4
14
3
3 16
2
1 8
10
10 4
15
9
5
6

1 Shift rod 1
2 E-clip 1
3
4
O-ring
Plate
1
1
39 8
5 Oil seal 1 39
M8 25 mm
6
7
Bolt
Cover
3
1 9
8 Seal plate 1
9 Woodruff key 1
10
11
Dowel
Impeller
2
1
10
12 Outer plate cartridge 1
13 Gasket 1 39
14 Rubber seal 1
15 Plate 1
16 O-ring 1 39
17 Insert cartridge 1
A
8-68
LOWR
Lower unit
22
21 22
11
20
23
6 20
12
20
7
13 19
6 18
17
5
14
4
3 16
2 10
8 10
1
15

18 O-ring 1 39
19 Water pump housing 1
20 Bolt 4 M8 45 mm
21 Oil seal 2 39
22 Cover 2
23 Seal 1
8-69
Removing the water pump and shift
rod
1. Remove the water pump. See steps 1–4
in “Removing the water pump and shift
rod” (8-11). 0
2. Remove the plate a, oil seal b, O-ring
c, and shift rod d.
1
b
a
c
2
d
90° 3
4
TIP:
To remove the shift rod d, lift it up slightly,
5
and then turn the shift rod d 90° clockwise to
pull it up.
6
Disassembling the water pump
housing
See “Disassembling the water pump hous-
ing” (8-11).
7
Checking the water pump and shift
rod 8
See “Checking the water pump and shift rod”
(8-12).
Assembling the water pump housing

9
See “Assembling the water pump housing”
(8-12).
10
A
8-70
LOWR
Lower unit
Propeller shaft housing (counter rotation model)
7 9 8 10 12 11 17 8 N·m (0.8 kgf·m, 5.9 ft·lb)
16
3
4
15
14
8
13
1 12
2
11
10 20
9 18 30
8 19
29
7
8
6
5 17 28
24
22 27 30
24 26 29
21 25
1 N·m (0.1 kgf·m, 0.7 ft·lb)

23
155 N·m (15.5 kgf·m, 114.3 ft·lb)

3 Water pipe 1
4 Rubber seal 2
5 Water inlet cover screw 1 M5 45 mm
7 Slider 1
8 Ball 2
9 Shift plunger 1
10 Spring 1
11 Dog clutch 1
12 Cross pin 1
13 Forward gear shim (T2) —
14 Forward gear 1
15 Thrust washer 1
17 Propeller shaft 1
8-71
7 9 8 10 12 11 17 8 N·m (0.8 kgf·m, 5.9 ft·lb)

16
3
4 0
15
14
8
13
1
1 12
2
2
11
10 20
9 18
7
8 19
29
30
3
8
6
5 17 28
4
24
21
22 24
25
26
27 29
30
5
1 N·m (0.1 kgf·m, 0.7 ft·lb)
23 6
155 N·m (15.5 kgf·m, 114.3 ft·lb)

18 O-ring 1 39
19 Thrust bearing 1
20
21
Propeller shaft shim (T4)
Propeller shaft housing
—
1
8
22 Rubber seal 1
39
23
24
Needle bearing
Oil seal
1
2 39 9
25 Key 1
26 Claw washer 1
27
28
Propeller shaft housing ring nut
Cover
1
1
10
29 Dowel 2
30 Cover bolt 2 M8 25 mm
A
8-72
LOWR
Lower unit
Removing the propeller shaft 3. Heat the installation area of the taper
housing assembly roller bearing outer race in the propeller
1. Remove the water pipe, cover, propeller shaft housing c using a gas torch, and
shaft housing ring nut, and claw washer. then remove the forward gear d.
See steps 1–5 in “Removing the propel- NOTICE: When heating the propeller
ler shaft housing assembly” (8-16). shaft housing, heat the entire
installation area evenly. Otherwise,
2. Remove the propeller shaft housing the propeller shaft housing could be
assembly, key, and forward gear shims. damaged.
Slide hammer a: 90890-06531 d

Puller head b: 90890-06514
Disassembling the propeller shaft

housing assembly 4. Remove the propeller shaft e, thrust
bearing f, and propeller shaft shims g.
• Use heat-resistant gloves. Otherwise, g

burns could result.
• To prevent fires, remove any flammable f
e
1. Remove the dog clutch. See “Disassem-
bling the propeller shaft assembly” (8-
17). 5. Remove the oil seals and needle
bearing. See step 2 in “Disassembling
2. Remove the rubber seal a and O-ring the propeller shaft housing assembly” (8-
b. 17)
Disassembling the forward gear

b a 1. Remove the taper roller bearing a and
thrust washer b.
8-73
c d
a housing assembly and forward gear
c
a
b
• Use heat-resistant gloves. Otherwise, 0
burns could result.
d
1
90890-06607
Bearing separator d:
2
(commercially available) Do not reuse a bearing, oil seal, or O-ring,
Checking the propeller shaft
1. Check the propeller shaft. Replace if 1. Install the needle bearing and oil seals.
3
damaged or worn. See steps 3 and 4 in “Assembling the
2. Measure the propeller shaft runout.

propeller shaft housing assembly” (8-19).
4
2. Install the original propeller shaft shims
a and thrust bearing b.
b 5
6
a
Propeller shaft runout: 7

0.02 mm (0.0008 in)
3. Install the propeller shaft c and taper
Checking the dog clutch
See “Checking the dog clutch” (8-18).
roller bearing inner race a.
8
a
Checking the propeller shaft housing
See “Checking the propeller shaft housing”
(8-18).
9
Checking the forward gear c
1. Check the teeth and dogs of the forward
10
A
8-74
LOWR
Lower unit
4. Heat the installation area of the taper
roller bearing outer race b in the d
propeller shaft housing using a gas torch,
h
and then install the taper roller bearing d g
outer race b. NOTICE: When heating f
the propeller shaft housing, heat the
entire installation area evenly. h
Otherwise, the propeller shaft housing g
could be damaged. f
Ring nut wrench d: 90890-06578
b 7. Install the dog clutch. See “Assembling

the propeller shaft assembly” (8-18).
8. Install the rubber seal i.
5. While holding the special service tool d,

strike the tool to check that the taper
roller bearing e is installed properly.
d
d
e
Ring nut wrench d: 90890-06578
TIP:
If a high-pitched metallic sound is produced
when the special service tool is struck, the
taper roller bearing outer race is installed
properly.
6. Install the thrust washer f and forward

gear g using the dog clutch h and
special service tool d.
8-75
Propeller shaft housing (counter rotation model) /
Drive shaft and lower case (counter rotation model)
40 N·m (4.0 kgf·m, 29.5 ft·lb) 10
9
177 N·m (17.7 kgf·m, 130.5 ft·lb)
0
8 14
7
11
12
1
13
6
1 5
18
19
2
4 17
16
3
15 4
22
21
23
20
5
2
24
3
25
26
6
143 N·m (14.3 kgf·m, 105.5 ft·lb)

1 Drive shaft 1
2 Pinion shim (T3) —
3
4
Washer
Taper roller bearing
1
1 39
8
5 Claw washer 1
6
7
Drive shaft nut
Spacer
1
1 9
8 Drive shaft ring nut 1
9 Cover 1
10
11
Bolt
Oil seal housing
2
1
M8 20 mm
10
12 O-ring 1 39
13 Oil seal 2 39
14 Lower case 1
15 Dowel 1
16 Adapter 1
17 Roller bearing 1 39
A
8-76
LOWR
Lower unit
40 N·m (4.0 kgf·m, 29.5 ft·lb) 10

9
177 N·m (17.7 kgf·m, 130.5 ft·lb)
8 14
11
7 12
13
6
1 5 19
18
4 17
16
15
22
21
20
23
2
24
25
3 26
143 N·m (14.3 kgf·m, 105.5 ft·lb)

18 Reverse gear shim (T1) 1
19 Thrust bearing 1
20 Circlip 1
22 Reverse gear 1
24 Pinion 1
25 Washer 1
26 Pinion nut 1
8-77
Removing the drive shaft
See “Removing the drive shaft” (8-23). c d b
c
Removing the reverse gear d
1. Remove the reverse gear a, thrust bear- 0
ing b, reverse gear shim c, and adapter
d.
a 1
b
Driver rod L3 c: 90890-06652
c Needle bearing attachment d:
90890-06653
2
d
3. Disassemble the adapter. See steps 2
and 3 in “Disassembling the forward
gear” (8-24)
3
Disassembling the lower case
See “Disassembling the lower case” (8-25). 4
Checking the pinion
Disassembling the oil seal housing
See “Disassembling the oil seal housing” (8-
23).
See “Checking the pinion” (8-25).
5
Checking the reverse gear
1. Check the teeth and dogs of the reverse
Disassembling the drive shaft
See “Disassembling the drive shaft” (8-23).
6
Checking the drive shaft
Disassembling the reverse gear
See “Checking the drive shaft” (8-25).
1. Remove the circlip a.
Checking the lower case
7
a See “Checking the lower case” (8-25).
Assembling the drive shaft

See “Assembling the drive shaft” (8-25).
8
Assembling the reverse gear
9
2. Remove the needle bearing b. with a new one.
10
1. Assemble the adapter. See steps 1 and 2
in “Assembling the forward gear” (8-27).
2. Install a new needle bearing a to the

specified installation depth a.
A
8-78
LOWR
Lower unit
b d
c c b
a
b a c
b
a a
Needle bearing attachment b:

90890-06653
Driver rod L3 c: 90890-06652 e
Installation depth a:
TIP:
9.2–9.6 mm (0.36–0.38 in)
Make sure to fit the dowel e into the slot a
in the lower case.
TIP:
Face the bearing identification mark b on the
Installing the drive shaft
needle bearing a up.
See “Installing the drive shaft” (8-28).
3. Install the circlip d. Installing the propeller shaft housing

assembly
d
Do not reuse a bearing or O-ring, always

1. Install a new O-ring a.
2. Install the original forward gear shims b,

propeller shaft housing c, and key d.
Assembling the lower case
See “Assembling the lower case” (8-27).
d
Assembling the oil seal housing
See “Assembling the oil seal housing” (8-28). c
b
Install the reverse gear
1. Install the adapter a, original reverse
gear shim b, thrust bearing c, and
reverse gear d.
a
8-79
3. Install the claw washer, ring nut, cover, Installing the lower unit (U-transom
and water pipe. See steps 4, 5, and 7–9 model)
in “Installing the propeller shaft housing 1. Check that the shift rod is in the N posi-
assembly” (8-29).
Installing the shift rod

tion. See steps 1 and 2 in “Installing the
lower unit (X-transom model)” (8-33). 0
1. Install the plate to the shift rod. See steps 2. Install the extension and lower unit. See
1 and 2 in “Installing the shift rod” (8-31). steps 2–4 in “Installing the lower unit (U-
transom model)” (8-34). 1
2. Install the shift rod a.
3. Install the trim tab and propeller. See
steps 5–8 in “Installing the lower unit (X-
transom model)” (8-33).
2
a 4. Fill the lower unit with gear oil up to the
3
90° a
a
4
b
5
TIP:
Turn the shift rod a counterclockwise 90°,
and then push it down so that the tip a of the
shift rod a fits into the groove in the shift
6
slider.
Installing the water pump

7
See “Installing the water pump” (8-31).
Checking the lower unit for air

leakage
8
See “Checking the lower unit for air leakage”
(8-32).
9
Installing the lower unit (X-transom
model)
1. Install the lower unit, trim tab, and propel-
ler. See steps 1–8 in “Installing the lower
10
unit (X-transom model)” (8-33).

A
8-80
LOWR
Lower unit
Shimming (counter rotation model)
Shimming workflow
Remove the water pump

assembly and cover.
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? thickness (T2) and reverse gear
shim thickness (T1).
YES
Install the water pump
assembly.
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.
8-81
Shimming check sheet
Lower case deviation
Serial number P F R Remarks
0
Pinion height
Measurements
(mm)
1
Measuring point #1
Measuring point #2
Measuring point #3
2
Measuring point #4
Average
Round-down average 3
(M)
Forward gear backlash (mm) 4

Measurements
Measuring point #1
Measuring point #2
5
Measuring point #3
Measuring point #4
Average
6
Round-down average
Reverse gear backlash (mm) 7

Measurements
Measuring point #1 8
Measuring point #2
Measuring point #3
Measuring point #4
Average
9
Round-down average
10
A
8-82
LOWR
Lower unit
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)

2.00
2.03
2.06
2.09
2.12
2.15
Total
8-83
Measuring the forward gear backlash
and reverse gear backlash before
disassembly e
1. Remove the water pump assembly,
cover, and outer plate cartridge. See 0
steps 1–3 in “Removing the water pump h
and shift rod” (8-11). g

f
1
R Backlash indicator e: 90890-06836
Magnet base plate f: 90890-07003
Dial gauge set g: 90890-01252
2
N
Magnet base B h: 90890-06844
F
6. Turn the drive shaft slowly clockwise and
3
a stops in each direction.
4
3. Set up the special service tools b, c,
and d, and then tighten the center bolt
d to the specified torque.
5
b c
6
b
7
d
Bearing housing puller claw L b:

TIP:
8
90890-06502 force. Otherwise, the forward gear will turn,
Stopper guide plate c: 90890-06501 leading to incorrect measurements.
Center bolt d: 90890-06504 • When turning the drive shaft, hold it using a
9
Center bolt d (shimming): when the drive shaft is turned, but this is
15 N·m (1.5 kgf·m, 11.1 ft·lb)
4. Install the special service tool e at the

the sound of the pinion contacting the
reverse gear and does not affect the back- 10
lash measurement.
lowest possible position where the shaft
diameter is 22.4 mm (0.88 in).
5. Set up the special service tools f, g, measure the backlash again.
and h.
A
8-84
LOWR
Lower unit
a i
b
d
12. Apply a load to the reverse gear by

installing the propeller j, spacer k, and
c washer l (without the spacer m).
13. Tighten the propeller nut n to the

TIP:
specified torque.
• Measure the backlash at 4 points: a, b,
c, and d, turning the drive shaft 180° m
clockwise after each measurement.
j
• Write down the measurement data in the n
shimming check sheet. l
k
8. Determine the backlash average, and
then round down the average to the 1/
100 place.
Example:
(mm) Propeller nut (shimming) n:
Measurement point a 0.25 25 N·m (2.5 kgf·m, 18.4 ft·lb)
Measurement point b 0.26
14. Set the gear shift to the R position.
Measurement point c 0.26
Measurement point d 0.24
Average 0.2525 R
Round-down average 0.25
N
9. Check that the forward gear backlash a
0.18–0.76 mm (0.0071–0.0299 in)
TIP: Shift rod socket a: 90890-06679

Adjust the shim thicknesses if the forward
gear backlash is out of specification. 15. While turning the shift rod toward the R
position using the specified torque, turn
the drive shaft slowly clockwise and
10. Remove the special service tools from
the propeller shaft.
11. Remove the cover i. stops in each direction.
8-85
i
0
o
1
Cover bolt o:
8 N·m (0.8 kgf·m, 5.9 ft·lb) 2
Specified torque:
15 N·m (1.5 kgf·m, 11.1 ft·lb) 3
TIP:
force. Otherwise, the reverse gear will turn,
4
leading to incorrect measurements.
• When turning the drive shaft, hold it using a
when the drive shaft is turned, but this is
5
the sound of the pinion contacting the for-
ward gear and does not affect the backlash
measurement. 6
16. Repeat steps 7 and 8 to measure the
reverse gear backlash.
7
17. Check that the reverse gear backlash
Reverse gear backlash: 8
0.19–0.84 mm (0.0075–0.0331 in)
TIP:
Adjust the shim thicknesses if the reverse
9
18. Remove the special service tools, and 10

then install the outer plate cartridge,
cover, and water pump assembly. See
“Installing the water pump” (8-31).
19. Install the cover i, and then tighten the

cover bolts o to the specified torque.
A
8-86
LOWR
Lower unit
Shimming
• Before selecting the forward gear shim (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
T3
T2 T4
T1
8-87
Selecting the pinion shim (T3) Dial gauge set a: 90890-01252
See “Selecting the pinion shim (T3)” (8-43). Magnetic base B b: 90890-06844
Calculated value (B) table

See “Calculated value (B) table” (8-46).
Propeller shaft free play:
0.25–0.35 mm (0.0098–0.0138 in) 0
Pinion shim (T3) selection table 6. Round the measurement value to the 1/
See “Pinion shim (T3) selection table” (8-47). 10 place if out of specification.
1
Selecting the propeller shaft shim TIP:
(T4) In the “Propeller shaft shim (T4) selection
1. Install the original propeller shaft shims.
See steps 2–8 in “Assembling the propel-
table,” use the rounded measurement value
for the free play measurement.
2
ler shaft housing assembly and forward
gear” (8-74).
7. Determine the propeller shaft shim (T4)
thickness adjustment using the “Propeller 3
TIP: shaft shim (T4) selection table” according
• If the original shims are missing, measure to the free play measurement. See
the free play without any shims.
“Propeller shaft shim (T4) selection table”
(8-90).
4
scratched. Example:
Free play measurement = 1.1 mm a
2. Install the propeller shaft housing
assembly. See step 2 in “Installing the
Propeller shaft shim (T4) thickness adjust-
ment = 0.8 mm b
5
propeller shaft housing assembly” (8-79) The current shim thickness must be
and steps 4 and 5 in “Installing the
propeller shaft housing assembly” (8-29).
increased by 0.8 mm.
6
3. Turn the propeller shaft 10 turns or more. a
(mm)
4. Set up the special service tools a and A 1.0 1.1 7

b.
B +0.7 +0.8
5. Measure the propeller shaft free play.
b 8
b
A Free play measurement
B Shim thickness adjustment 9
a
10
A
8-88
LOWR
Lower unit
9. Remove the special service tools, and
TIP: then install the determined propeller
• If the shim thickness adjustment value is shaft shims.
positive, the current shim thickness must be
be decreased by that amount.
• The gray-colored cell on the selection table
indicates the specified propeller shaft free
play. Shimming is not required if the mea-
sured propeller shaft free play is 0.25–0.35
mm.
ments specified in the selection table are
intended to obtain the specified propeller
shaft free play of 0.3 mm.
8. Calculate the new propeller shaft shim

(T4) thickness.
New propeller shaft shim (T4) thickness =
Current propeller shaft shim thickness +
Shim thickness adjustment
Example:
Current propeller shaft shim thickness = 0.8
mm
New propeller shaft shim (T4) thickness
= 0.8 mm + 0.2 mm
= 1.0 mm
Current propeller shaft shim thickness = 0.8
mm
New propeller shaft shim (T4) thickness
= 0.8 mm + (–0.1) mm
= 0.7 mm
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.
8-89
Propeller shaft shim (T4) selection table
The shim thickness does not have to be adjusted for the gray-colored cell.
(mm)
A
B
0.0
–0.3
0.1
–0.2
0.2
–0.1
0.3 0.4
+0.1
0.5
+0.2
0.6
+0.3
0.7
+0.4
0.8
+0.5
0.9
+0.6
0
A 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9
B +0.7 +0.8 +0.9 +1.0 +1.1 +1.2 +1.3 +1.4 +1.5 +1.6 1
A 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9
B +1.7 +1.8
A Free play measurement
+1.9 +2.0 +2.1 +2.2 +2.3 +2.4 +2.5 +2.6
2
3
4
5
6
7
8
9
10
A
8-90
LOWR
Lower unit
Measuring the forward gear backlash 2. Measure the thickness of each original
• Spray anti-rust lubricant on the gears and forward gear shim in 2 places.
bearings before installation. Do not apply
gear oil to the parts. Otherwise, correct TIP:
measurements cannot be obtained. Do not reuse a shim if deformed or
• Keep the parts free of foreign material, scratched.
• When measuring the forward gear or 3. Determine the forward gear shim (T2)
reverse gear backlash, use the original thickness adjustment using the “Forward
bearings and shims. gear shim (T2) selection chart” according
to the backlash measurement (BL2) from
1. Install the original forward gear shims
“Measuring the forward gear backlash.”
and propeller shaft housing assembly.
See “Forward gear shim (T2) selection
See step 2 in “Installing the propeller
chart” (8-93).
shaft housing assembly” (8-79) and steps
Example:
4–6 in “Installing the propeller shaft hous-
Backlash measurement (BL2) = 0.10 mm a
ing assembly” (8-29).
Forward gear shim (T2) thickness adjustment
= 0.34 mm b
TIP: The current shim thickness must be
• If the original shims are missing, install new increased by 0.34 mm.
shims with a combined thickness of 0.50
mm. 0.60
• Do not reuse a shim if deformed or b
0.40
scratched.
B (mm)
0.20
0
3. Measure the forward gear backlash. See 0 5 10 15 20 25 3
steps 2–9 in “Measuring the forward gear a A (1/100 mm)
backlash and reverse gear backlash
before disassembly” (8-84). A 0 5 10 15 20 25 3
0.18–0.76 mm (0.0071–0.0299 in) B 0.44 0.39 0.34 0.26 0 0 0

TIP: B Shim thickness adjustment
In the “Forward gear shim (T2) selection
chart,” use the round-down average for the
Adjusting the forward gear shim (T2)

thickness
assembly and original forward gear
shims. See steps 1–5 in “Removing the
propeller shaft housing assembly” (8-16)
and step 2 in “Removing the propeller
shaft housing assembly” (8-73).
8-91
TIP: TIP:
• If the shim thickness adjustment value is • Use up to 3 shims to obtain the required
positive, the current shim thickness must be shim thickness.
0
be decreased by that amount. shims, decrease the shim thickness by
• The gray-colored area on the selection 0.01 mm.
chart indicates the range of the specified
backlash. Shimming is not required if the
1
5. Install the determined forward gear shims
measured backlash is within the gray-col- (T2), and propeller shaft housing
ored area.
assembly. See step 2 in “Installing the
propeller shaft housing assembly” (8-79)
2
ments specified in the selection chart are and steps 4–6 in “Installing the propeller
intended to obtain the median value within shaft housing assembly” (8-29).
the range for the specified forward gear
backlash.
3
• The table that follows the selection chart
shows the shim thickness adjustments for
the points marked on the chart. 4
4. Calculate the new forward gear shim (T2)
thickness.
Calculation formula: 5
New forward gear shim (T2) thickness = Cur-
rent forward gear shim thickness + Shim
thickness adjustment
Example:
6
mm
7
New forward gear shim (T2) thickness
= 0.75 mm + 0.34 mm 8
= 1.09 mm
9
mm
New forward gear shim (T2) thickness
= 0.75 mm + (–0.31) mm
10
= 0.44 mm
0.10, 0.12, 0.15, 0.18, 0.30, 0.40,
0.50 mm
A
8-92
Forward gear shim (T2) selection chart
8-93
0.60
LOWR
0.40
0.20
–0.20
Lower unit
–0.40
B (mm)
–0.60
Continue next page

–0.80
–1.00
–1.20
–1.40
–1.60
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
A (1/100 mm)
A 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
B 0.44 0.39 0.34 0.26 0 0 0 0 0 0 0 0 0 0 0 –0.31 –0.36 –0.41 –0.46 –0.51 –0.56

0.60
0.40
0.20
–0.20
–0.40
B (mm)
–0.60
–0.80
–1.00
–1.20
–1.40
–1.60
100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 182 190 195 200
A (1/100 mm)
A 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 182 190 195 200
B –0.56 –0.61 –0.66 –0.71 –0.76 –0.81 –0.86 –0.91 –0.96 –1.01 –1.06 –1.11 –1.16 –1.21 –1.26 –1.31 –1.36 –1.41 –1.46 –1.51 –1.56

8-94
9
8
7
6
5
4
3
2
1
0
A
10
LOWR
Lower unit
Measuring the reverse gear backlash Adjusting the reverse gear shim (T1)
• 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 steps 1–5 in “Removing
measurements cannot be obtained. the propeller shaft housing assembly” (8-
• Keep the parts free of foreign material, 16) and step 2 in “Removing the propeller
such as dirt and lint. shaft housing assembly” (8-73)
• When measuring the forward gear or
reverse gear backlash, use the original 2. Remove the ring nut, pinion, and drive
bearings and shims. shaft. See steps 2 and 3 in “Removing
the drive shaft” (8-23).
1. Install the adapter assembly, original
reverse gear shim, thrust bearing, and 3. Remove the reverse gear, thrust bearing,
reverse gear assembly. See “Install the original reverse gear shim, and adapter.
reverse gear” (8-79). See “Removing the reverse gear” (8-78).
TIP: 4. Measure the thickness of the original

• If the original shim is missing, install a new reverse gear shim in 2 places.
shim with a thickness of 2.00 mm.
• Do not reuse a shim if deformed or TIP:
scratched. Do not reuse a shim if deformed or
scratched.
2. Install the drive shaft, pinion, and drive
shaft ring nut. See steps 1–3 in “Installing 5. Determine the reverse gear shim (T1)
the drive shaft” (8-28). thickness using the “Reverse gear shim
(T1) selection table” according to the
3. Check that the drive shaft turns smoothly. backlash measurement (BL1) from
“Measuring the reverse gear backlash”
4. Install the propeller shaft housing and the current shim thickness. See
assembly. See step 2 in “Installing the “Reverse gear shim (T1) selection table”
propeller shaft housing assembly” (8-79) (8-97).
and steps 4–6 in “Installing the propeller
shaft housing assembly” (8-29).
6. Measure the reverse gear backlash. See

steps 11–17 in “Measuring the forward
gear backlash and reverse gear backlash
0.19–0.84 mm (0.0075–0.0331 in)
TIP:
In the “Reverse gear shim (T1) selection
table,” use the round-down average for the
8-95
Example:
Backlash measurement (BL1) = 0.49 mm a
mm b
Use the determined shim thickness of 2.03
mm instead of the current shim thickness.
0
a
A
(mm) 1
0.47 0.48 0.49
2.00
B
2.03
2.06 2.03
2
2.09
b
3
2.00, 2.03, 2.06, 2.09, 2.12, 2.15 mm 4
TIP:
• The gray-colored cells on the selection
table indicate the range where the shim
5
adjustment is unnecessary. Shimming is
not required if the obtained reverse gear
shim thickness is indicated by the gray-col- 6
ored cells.
• The values for the shim thickness specified
in the selection table are intended to obtain
the median value within the range for the 7
specified reverse gear backlash.
• If the backlash measurement (BL1) is less
8
• If the backlash measurement (BL1) is more
• Use only 1 shim to obtain the required shim
9
thickness.
6. Install the adapter, determined reverse 10

gear shim (T1), thrust bearing, and
reverse gear. See “Install the reverse
gear” (8-79).
A
8-96
LOWR
Lower unit
Reverse gear shim (T1) selection table
(mm)
A
0.38 0.39 0.40 0.41 0.42 0.43 0.44 0.45 0.46
2.00
2.03 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00
2.06 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00
B
2.09 2.00 2.00 2.00 2.00 2.00 2.00 2.03 2.03 2.03
2.12 2.00 2.00 2.00 2.03 2.03 2.03 2.06 2.06 2.06
2.15 2.03 2.03 2.03 2.06 2.06 2.06 2.09 2.09 2.09
A
0.47 0.48 0.49 0.50 0.51 0.52 0.53 0.54 0.55
2.00 2.03 2.03 2.03
2.03 2.00 2.00 2.00 2.06 2.06 2.06
2.06 2.03 2.03 2.03 2.09 2.09 2.09
B
2.09 2.06 2.06 2.06 2.12 2.12 2.12
2.12 2.09 2.09 2.09 2.15 2.15 2.15
2.15 2.12 2.12 2.12
A
0.56 0.57 0.58 0.59 0.60 0.61 0.62 0.63 0.64
2.00 2.06 2.06 2.06 2.09 2.09 2.09 2.12 2.12 2.12
2.03 2.09 2.09 2.09 2.12 2.12 2.12 2.15 2.15 2.15
2.06 2.12 2.12 2.12 2.15 2.15 2.15 2.15 2.15 2.15
B
2.09 2.15 2.15 2.15 2.15 2.15 2.15 2.15 2.15 2.15
2.12 2.15 2.15 2.15 2.15 2.15 2.15 2.15 2.15 2.15
2.15
8-97
— MEMO —
0
1
2
3
4
5
6
7
8
9
10
A
8-98
BRKT
Bracket unit 9
Shift rod and SPS .............................................................. 9-1

Removing the shift rod and SPS ............................................... 9-2
Installing the shift rod and SPS ................................................. 9-2
Cowling lock lever ............................................................. 9-3

Removing the cowling lock lever ............................................... 9-5
Removing the flushing hose ...................................................... 9-5
Installing the flushing hose ........................................................ 9-5
Installing the cowling lock lever ................................................. 9-6
PTT switch and bottom cowling ...................................... 9-7

Removing the PTT switch ......................................................... 9-9
Installing the PTT switch ........................................................... 9-9
Upper case and mount ................................................... 9-10

Removing the upper case ....................................................... 9-12
Installing the upper case ......................................................... 9-12
Upper case ....................................................................... 9-15

Disassembling the upper case ................................................ 9-16
Checking the exhaust guide anode ......................................... 9-16
Checking the drive shaft bushing ............................................ 9-16
Assembling the upper case ..................................................... 9-16
Oil pan and exhaust manifold ........................................ 9-18

Disassembling the oil pan and exhaust manifold .................... 9-20
Checking the oil pan and exhaust manifold ............................. 9-20
Checking the oil strainer .......................................................... 9-20
Assembling the oil pan and exhaust manifold ......................... 9-20
Steering arm .................................................................... 9-22

Removing the steering arm ..................................................... 9-23
Installing the steering arm ....................................................... 9-23
Clamp bracket and swivel bracket ................................ 9-25

Removing the clamp bracket ................................................... 9-27
Checking the clamp bracket anode ......................................... 9-27
Installing the clamp bracket ..................................................... 9-27
Adjusting the trim sensor ......................................................... 9-29
PTT unit ............................................................................ 9-31

Removing the PTT unit ............................................................ 9-32
Checking the hydraulic pressure ............................................. 9-33
Bleeding the PTT unit .............................................................. 9-35
Installing the PTT unit .............................................................. 9-36
PTT motor ........................................................................ 9-38
Removing the reservoir ........................................................... 9-40
Removing the PTT motor ........................................................ 9-40
Disassembling the PTT motor ................................................. 9-40
Checking the armature (PTT motor) ........................................ 9-41
Checking the brush ................................................................. 9-41
0
Assembling the PTT motor ...................................................... 9-42
Installing the reservoir ............................................................. 9-43
Installing the PTT motor .......................................................... 9-43 1
PTT gear pump ................................................................ 9-45
Disassembling the gear pump housing ................................... 9-48
Checking the gear pump ......................................................... 9-48
2
Assembling the gear pump assembly ..................................... 9-49
PTT cylinder ..................................................................... 9-51 3

Removing the tilt ram .............................................................. 9-53
Removing the trim ram ............................................................ 9-53
Disassembling the tilt ram ....................................................... 9-53
Disassembling the trim ram ..................................................... 9-54 4
Checking the tilt cylinder and PTT body .................................. 9-54
Checking the valve .................................................................. 9-54
Assembling the tilt ram ............................................................ 9-55
Assembling the trim ram .......................................................... 9-56 5
Installing the tilt cylinder .......................................................... 9-56
Installing the trim ram .............................................................. 9-56
Installing the tilt ram ................................................................ 9-57
6
7
8
9
10
A
BRKT
Bracket unit
Shift rod and SPS
1
3 2
4
5
1
1
9
10
11
12
11

1 Bolt 4 M6 25 mm
2 SPS 1
3 Clip 1
4 Bushing 1
5 Washer 1
6 Circlip 1
7 Shift rod 1
8 Shift lever 1
9 Bushing 2
10 Bracket 1
11 Dowel 2
12 Grommet 1
9-1
Shift rod and SPS
Removing the shift rod and SPS h
1. Remove the clip a, shift lever b, SPS g
c, bushing d, and washer e.
f
e
0
a
c 1
d
e
b c
d 2
b
a
b
3
2. Remove the shift rod f, bushings g,
bracket h, and grommet i. 4. Fit the protrusion a on the SPS i into
the slot b in the tip of the shift rod e, 4
and then turn the SPS i in the direction
of the arrow to install it.
f 5. Install the shift lever j, and then install

5
the clip k.
b
6
g
i 7
h a
i
k 8
i
Installing the shift rod and SPS j 9

1. Install the grommet a. e
2. Install the dowels b, bracket

bushings d, and shift rod e.
c,
10
3. Install the circlip f, washer g, and
bushing h.
A
9-2
BRKT
Bracket unit
Cowling lock lever
4 N·m (0.4 kgf·m, 3.0 ft·lb) 22
21
9 11 20
21 21
11 19
22 20 22 24
18 17
19 19
17 23
18 15 11 18
17 10 11 11 17
12 16 25
1 11
6 16 13 13 14
5
4 16
3
2
1 7
2
8
30
17
11
17 26
29 15
27
28

1 Hose 1
2 Plastic tie 3
3 Joint 1
4 Joint 1
5 Gasket 1
6 Adapter 1
7 Grommet 1
8 Guide 1
9 Holder 1
10 Bracket 1
11 Bolt 7 M6 12 mm
12 Plastic tie 1
13 Flushing hose adapter screw 2 ø6 20 mm
14 Bracket 1
15 Water outlet 2
16 Hook 3
17 Bushing 6
9-3
Cowling lock lever
4 N·m (0.4 kgf·m, 3.0 ft·lb) 22

21
9 11
22
21
11
20
19
22
21
24
0
20
18 17
19 19
17 23
18
17 10 11 12
11
15 11
16 25
18
17
1
1 11
6 16 13 13 14
5
4 16
2
3
2
1 7
2
8 3
30
4
17
11 5
17 26
29 15
27
6
28

18 Washer 3
19 Wave washer 3
20
21
Lever
Bolt
2
3 M8 12 mm
8
22 Spring 3
23
24
Cowling lock lever (STBD)
Lever
1
1 9
25 Clamp 1
26 Cowling lock lever (PORT) 1
27
28
Grommet
Cowling lock lever (front)
1
1
10
29 Bracket 1
30 Holder 1
A
9-4
BRKT
Bracket unit
Removing the cowling lock lever 3. Remove the plastic ties j, and then
1. Remove the spring a, and then remove remove the grommet k, flushing hose
the hook b. i, trim sensor lead a, and PTT motor
lead b.
2. Remove the lever c, wave washer d,
washer e, bushing f, cowling lock lever
g, and bushing h. i j
a b
c h
d g
e a
j
b f k
Installing the flushing hose

1. Route the flushing hose a, trim sensor
lead a, and PTT motor lead b through
Removing the flushing hose the grommet b, and then fasten them
1. Remove the adapter a, plastic tie b, using plastic ties c around the grommet
joint c, joint d, and gasket e. b.
2. Install the grommet b and guide d.

a
e c a b d
b d c
c
c
a
b c da
a
c
b
TIP:
Align the white paint mark c on the flushing
2. Remove the holder f, bracket g, and hose a with the outer end of the grommet b,
guide h, and then pull out the flushing and align the white tape d on the PTT motor
hose i, trim sensor lead a, and PTT lead b with the inner end of the grommet b.
motor lead b.
h 3. Route the flushing hose a, trim sensor
g
lead a, and PTT motor lead b, and then
f i
fasten the flushing hose a, trim sensor
lead a, and PTT motor lead b using the
b bracket d.
a
4. Fasten the flushing hose a and trim
sensor lead a using the holder e.
9-5
Cowling lock lever
d h
a
e a f
e b
b g
d
c
0
a
1
5. Install the flushing hose adapter f, and
then tighten the flushing hose adapter
screws g to the specified torque.
2
6. Route the flushing hose a through the
joint h, install it to the hose joint i, and
then fasten the flushing hose a using the
3
plastic tie j.
7. Install the hose joint to the adapter f

along with the gasket k.
4
k
f 5
j i
h
g 6
a
7
8
Flushing hose adapter screw g:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
Installing the cowling lock lever 9

1. Install the bushing a, cowling lock lever
b, bushing c, washer d, wave washer
e, and lever f. 10
2. Install the hook g, and then install the
spring h.
A
9-6
BRKT
Bracket unit
PTT switch and bottom cowling
A 1
2
11
12
9
8 9 13
3 4 9
8 14
4 8 13
7
14
1 5
6 12
25 A
26
13 1
13
8 8 4 3
10
10 15 5
2
24 15 1
16 17
8
18 20
10
17 19
19
22 21
A Counter rotation 23
model 21

1 Gasket 2 39
2 Cover 1
3 PTT switch 1
4 Bolt 5 M8 12 mm
5 Holder 2
6 Grommet 1
7 Bracket 1
8 Grommet 12
9 Bolt 6 M6 35 mm
10 Collar 6
11 Rubber seal 1
12 Grommet 2
13 Bolt 4 M6 16 mm
14 Grommet 2
15 Bracket 2
16 Rubber seal 1 39
17 Drain hose 2
9-7
PTT switch and bottom cowling
A 1
2
11
9
12 0
8 9 13
3 4 9
8 14
7
4 8 13
14
1
1 5
6 12
25 A
2
26
13 1
13
8 8 4 3
3
10
10 15 5
24 15
2
1 4
16 17
8
10
18 20
5
17 19
19
A Counter rotation 23
22 21
6
model 21

18 Drain hose 1
19 Bolt 4 M6 16 mm
20
21
Drain box
Rubber seal
1
2
8
22 Drain box 1
39
23
24
O-ring
Dipstick
1
1 9
25 Dipstick guide 1
26 Bottom cowling 1
10
A
9-8
BRKT
Bracket unit
Removing the PTT switch A Regular rotation model
1. Remove the holder a, and then remove B Counter rotation model
the PTT switch b and gasket c.
A
STBD
c
b
B
PORT
c
b
A Regular rotation model

B Counter rotation model
Installing the PTT switch

1. Install a new gasket a, the PTT switch
b, and the holder c. NOTICE: Do not
a new one.
A
STBD
a
b
B
PORT
a
b
9-9
PTT switch and bottom cowling / Upper case and mount
Upper case and mount
6 55 N·m (5.5 kgf·m, 40.6 ft·lb)
7
8 8
3
4
5
6
9 0
2
1
4 1
1 15
10 11 10 12 13
16 2
14
14
26
12
13
3
10 12
26 11 14
25
10
10 15 4
11
24
23
22
20
10
17
5
21
18 16
24 23 17
19
6
18 55 N·m (5.5 kgf·m, 40.6 ft·lb)

1 Upper mount 2
2 Plate 1
3
4
Stopper
Collar
1
2
8
5 Plate 1
M14 207 mm
6
7
Upper mounting bolt
Damper
2
1 9
8 Upper mount bracket bolt 3 M10 45 mm
9 Bracket 1
10
11
Lower mount
Lower mount
4
2
10
12 Washer 2
13 Ground lead 1
14 Lower mounting bolt 2 M14 227 mm
15 Bracket 2
16 Lower mount bracket bolt 4 M10 45 mm
17 Bolt 1 M6 20 mm
A
9-10
BRKT
Bracket unit
6 55 N·m (5.5 kgf·m, 40.6 ft·lb)

7
8 8
5 9
4
3 6
2
1
4
1 15
10 11 10 12 13
16
14
14
26
12
13
10 12
26 11 14
25
10
10 15
11
23
24 22 10
20 17
21
18 16
23 17
24 19
18 55 N·m (5.5 kgf·m, 40.6 ft·lb)

18 Bolt 1 M6 10 mm
19 Ground lead 1
20 Hose 1
21 Adapter 1
22 Plastic tie 1
23 Washer 2
24 Lower mounting nut 2
25 Upper mounting nut 2
26 Washer 2
9-11
Removing the upper case 6. Remove the upper mount bracket bolts
1. Drain the remaining engine oil. e, upper mount bracket h, damper i,
upper mounts j, plates k, stopper l,
2. Disconnect the ground lead a and collars m, plate n, and upper mounting
speedometer hose b, and then remove
the adapter c.
bolts o. 0
o i e
3. Loosen the lower mount bracket bolts d. n
j
k
l
m o
1
h
d
2
c
b
a
c
b
a
7. Remove the lower mount bracket bolts
d, lower mount brackets p, lower
3
mounts q and r, lower mounting bolts
4. Loosen the upper mount bracket bolts e. s, and washers t.
4
e
t
s
5
r p
r
q 6
d
5. Remove the upper mounting nuts f and
lower mounting nuts g, and then remove
Installing the upper case
1. Install the plate a, collars b, stopper c, 7
the upper case assembly a. plate d, and upper mounts e to the
upper mounting bolts f.
f 8
a
b
f c
e
f 9
b
g e
d 10
a
2. Install the damper g, upper mount
g assembly a, and upper mount bracket
h, and then tighten the upper mount
bracket bolts i temporarily.
A
9-12
BRKT
Bracket unit
i i
a g q
p q
h
c
s
3. Install the washers j and lower mounts
k and l to the lower mounting bolts m. b
r s r
4. Install the lower mount brackets n, and
then tighten the lower mount bracket Upper mounting nut p:
bolts o temporarily. 72 N·m (7.2 kgf·m, 53.1 ft·lb)
Lower mounting nut s:
72 N·m (7.2 kgf·m, 53.1 ft·lb)
j
m 7. Tighten the upper mount bracket bolts i
to the specified torque in the order a, b,
k n and so on.
b a c
l
k
k l k j o
i
m
TIP:
The ground lead should be installed on the
Upper mount bracket bolt i:
same side as originally installed.
55 N·m (5.5 kgf·m, 40.6 ft·lb)
5. Install the upper case assembly b to the 8. Tighten the lower mount bracket bolts o
bracket assembly c. to the specified torque.
6. Install the upper mounting nuts p, 9. Connect the ground lead t.

washers q and r, and lower mounting
nuts s, and then tighten the upper 10. Install the speedometer hose u, and
mounting nuts p and lower mounting then connect it to the speedometer hose
nuts s to the specified torque. adapter v.
NOTICE: When tightening the lower
mounting nut, make sure that the
ground lead does not turn along with
the bolt.
9-13
v
0
u
t
v
u
t
1
Lower mount bracket bolt o:
55 N·m (5.5 kgf·m, 40.6 ft·lb) 2
3
4
5
6
7
8
9
10
A
9-14
BRKT
Bracket unit
Upper case
27 N·m (2.7 kgf·m, 19.9 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 10 10
4 N·m (0.4 kgf·m, 3.0 ft·lb) 8 8 10
20 N·m (2.0 kgf·m, 14.8 ft·lb) 9
7 9
6 6 10
2
3
4
1 5
11
16
12
13
15
14

1 Bolt 1 M6 14 mm
2 Drain bolt 1 M14 12 mm
3 Gasket 1 39
4 Cover 1
5 Damper 1
6 Dowel 2
7 Upper case bolt 2 M8 30 mm
8 Anode screw 2 M6 15 mm
9 Anode 2
10 Upper case bolt 4 M10 45 mm
11 Rubber seal 1
12 Rubber seal 1 39
13 Rubber seal 1
14 Circlip 1
15 Drive shaft bushing 1
16 Upper case 1
9-15
Upper case
Disassembling the upper case
1. Remove the drain bolt a, gasket b,
cover c, and damper d.
m 0
d
l
c
b k
1
a
2
2. Remove the anodes e.
3. Remove the oil pan assembly a and

dowels f.
Bearing puller assembly l: 90890-06535
Stopper guide plate m: 90890-06501 3
Checking the exhaust guide anode
4. Remove the rubber seals g, h, and i.
e
4
e NOTICE: Do not apply grease, oil, or
paint to the anode.
f
Checking the drive shaft bushing
5
1. Check the drive shaft bushing. Replace if
cracked or worn.
Assembling the upper case

6
a
Do not reuse a gasket, always replace it 7

g with a new one.
i
h 1. Install the bushing a. 8
5. Remove the circlip j. c 9
j c
b b 10
a
a
6. Remove the drive shaft bushing k. A
9-16
BRKT
Bracket unit
Needle bearing attachment b: m j

90890-06611 ml j
k
Driver rod L3 c: 90890-06652 l
2. Install the circlip d. i
d
k
a
f
h
g
3. Install the rubber seal e into the upper e
case.
Upper case bolt j (M10):

e 42 N·m (4.2 kgf·m, 31.0 ft·lb)
Upper case bolt k (M8):
20 N·m (2.0 kgf·m, 14.8 ft·lb)
Anode screw m:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
6. Install the damper n, the cover o, and a

new gasket p, and then tighten the drain
bolt q to the specified torque.
4. Insert the tip of the water pipe f into the
rubber seal e, install a new rubber seal
g, the rubber seal h, the dowels i, and
the oil pan assembly a, and then tighten n
the upper case bolts j and k to the
specified torque. o
p
5. Install the anodes l, and then tighten
the anode screws m to the specified q
torque.
Drain bolt q:
27 N·m (2.7 kgf·m, 19.9 ft·lb)
9-17
Upper case / Oil pan and exhaust manifold
Oil pan and exhaust manifold
1
13
6 0
7 13 14
8 1
2
15
12 N·m (1.2 kgf·m, 8.9 ft·lb)
9 16
2
3
4
3 10
11
17
3
3 17 17
4
3 10
10 4
17
3 10 17 20
12
17 5
3
3
3 17
3
5 20 N·m (2.0 kgf·m, 14.8 ft·lb) 19
18
6

1 Exhaust guide 1
2 Gasket 1 39
3
4
Oil pan bolt
Dowel
9
2
M8 35 mm 8
5 Oil pan 1
39
6
7
Gasket
Oil strainer
1
1 9
8 Oil strainer bolt 3 M6 25 mm
9 Gasket 1 39
10
11
Exhaust manifold bolt
Exhaust manifold
4
1
M8 60 mm
10
12 Rubber seal 1 39
13 Dowel 2
14 Gasket 1 39
15 Plate 1
16 Gasket 1 39
17 Muffler bolt 9 M8 35 mm
A
9-18
BRKT
Bracket unit
1
13
6
7 13 14
8
2
15
12 N·m (1.2 kgf·m, 8.9 ft·lb)
9 16
3 10 17
3
4 11
3 17 17
4
3 10
10
17
3 10 17 20
12
17
3
3
3 17
3 18
5 20 N·m (2.0 kgf·m, 14.8 ft·lb) 19

18 Muffler 1
19 Water pipe 1
20 Rubber seal 1
9-19
Oil pan and exhaust manifold
Disassembling the oil pan and 2. Check the exhaust guide, exhaust
exhaust manifold manifold, and muffler. Replace if
1. Remove the water pipe a, rubber seal corroded or cracked.
b, muffler c, gasket d, plate e, and
gasket f. 3. Check the oil pan. Replace if corroded or
cracked.
0
2. Remove the rubber seal g, exhaust
Checking the oil strainer
manifold h, and gasket i.
g c
1. Check the oil strainer. Clean if there is 1
dirt or residue.
a
h
Assembling the oil pan and exhaust
manifold 2
b Do not reuse a gasket, always replace it
with a new one.
3
i
d
1. Install the dowels a and new gaskets b
and c onto the exhaust guide d. 4
e
2. Install the oil strainer a, and then tighten
the oil strainer bolts e to the specified
torque.
5
f
a b
e
3. Remove the oil pan j, and then remove
the oil strainer k and gasket l. e
6
j a
k
c
a d
7
8
l Oil strainer bolt e:

9
12 N·m (1.2 kgf·m, 8.9 ft·lb)
3. Install the oil pan f, and then tighten the

oil pan bolts g temporarily.
10
Checking the oil pan and exhaust

manifold
1. Clean the removed parts. A
9-20
BRKT
Bracket unit
g f g p q
q
q
g s
q
g
r
l
q
g
o
n
4. Install a new gasket h, the exhaust
manifold i, and a new rubber seal j,
and then tighten the exhaust manifold m
bolts k temporarily.
Muffler bolt q:
5. Tighten the exhaust manifold bolts k to 20 N·m (2.0 kgf·m, 14.8 ft·lb)
the specified torque, and then tighten the
oil pan bolts g to the specified torque.
j
k i
k
g h
Exhaust manifold bolt k:

20 N·m (2.0 kgf·m, 14.8 ft·lb)
Oil pan bolt g:
20 N·m (2.0 kgf·m, 14.8 ft·lb)
6. Install the dowels l, a new gasket m,

the plate n, a new gasket o, and the
muffler p, and then tighten the muffler
bolts q to the specified torque.
7. Install the rubber seal r and water pipe

s.
9-21
Oil pan and exhaust manifold / Steering arm
Steering arm
1
0
1
2
3
4
5
3
2
4
2 5
6
3
7
6

1 Steering arm 1
2 Washer 2
3
4
Bushing
O-ring
2
1 39
8
5 Bushing 1
6
7
Steering yoke
Circlip
1
1 9
10
A
9-22
BRKT
Bracket unit
Removing the steering arm
1. Remove the circlip a.
a a
2. Remove the steering yoke b.

f k
g j
b i
h
c
Installing the steering arm
d 1. Install the bushing a and washer b, and
then install the steering arm c.
d
2. Install the bushing d, a new O-ring e,
the bushing f, and the washer g.
NOTICE: Do not reuse an O-ring,

90890-06612
Gear puller d: (commercially available)
3. Remove the steering arm e, and then

remove the washer f and bushing g.
4. Remove the washer h, bushing i, O-

ring j, and bushing k. c
d
b
e
a f
g
3. Install the steering yoke h so that the

steering arm c and steering yoke h are
both facing in the same direction (a and
b are aligned).
9-23
Steering arm
0
1
c a
2
h 3
4. Hold the steering arm c, and then strike
the steering yoke h using a copper 4
hammer until the groove for installing the
circlip is visible.
5. Install the circlip i.

5
c
6
7
h 8
h
i
i
6. Inject grease into the grease nipple on
9
the swivel bracket. See “Lubricating the
outboard motor” (10-12).
10
A
9-24
BRKT
Bracket unit
Clamp bracket and swivel bracket
4 4 N·m (0.4 kgf·m, 3.0 ft·lb)

5
8
3 3 N·m (0.3 kgf·m, 2.2 ft·lb)
6 7
9
10
2 2 9
21 30
1
14 2 11
15
17
29
23 N·m (2.3 kgf·m, 17.0 ft·lb)

17
4 N·m (0.4 kgf·m, 3.0 ft·lb) 2

2
15
24 20 14 12
24 16
23 17
25
23 17
9
22 19 30
26
23 25 23 18 13
24 24
31
31
28 27
33
32
32

1 Clamp bracket (STBD) 1
2 Grease nipple 6
4 Holder 1
5 Screw 1 M6 12 mm
6 Trim sensor 1
7 Trim sensor screw 2 M6 16 mm
8 Tilt stop lever 1
9 Bushing 3
10 Tilt stop lever 1
11 Nut 2
12 Through tube 1
13 Clamp bracket (PORT) 1
14 Washer 2
15 Bushing 2
16 Ground lead 1
17 Plate screw 4 M6 10 mm
9-25
4 4 N·m (0.4 kgf·m, 3.0 ft·lb)

5
3
8
6 7 3 N·m (0.3 kgf·m, 2.2 ft·lb) 0
9
2
21
2
30 9
10
1
1
14 2 11
15
17
29
2
23 N·m (2.3 kgf·m, 17.0 ft·lb)
17
4 N·m (0.4 kgf·m, 3.0 ft·lb) 2 3

2
15
24 20 14 12
23
24 16
17
4
25
23 17
9
23 25 23
26
22 19 30
18 13
5
24 24
31
28 27
31
33
6
32
32

18 Friction plate 1
19 Trim stopper 2
20
21
Ground lead
Friction plate
1
1
8
22 Collar 1
23
24
Distance collar
Pin
2
2 9
25 Pin 1
26 Spring 1
27
28
Hook
Bolt
1
1 M6 10 mm
10
29 Swivel bracket 1
30 Anode 1
31 Plate 2
32 Bolt 4 M6 25 mm
33 Ground lead 1
A
9-26
BRKT
Bracket unit
Removing the clamp bracket
1. Remove the PTT unit. See “Removing
the PTT unit” (9-32).
2. Remove the anode a. k k

i
j
3. Remove the ground leads b and c.
4. Remove the self-locking nut d and

through tube e, and then disassemble
the clamp brackets f and g.
7. Remove the tilt stop levers l and m,
distance collar assembly n, collar o,
and bushings p.
b p
p
c
l
m
d
n
g p
o
a f
Checking the clamp bracket anode
5. Remove the trim sensor h.
paint to the anodes.
h Installing the clamp bracket

1. Assemble the distance collar assembly.
6. Remove the spring i, hook j, and pins

k.
Distance a:
30.3–30.4 mm (1.19–1.20 in)
9-27
2. Install the bushings a, collar b, distance 5. Install the plates j and k, and then
collar assembly b, and tilt stop levers d tighten the plate screw l to the specified
and e. torque.
a 0
e
d l
a k 1
l
b j
a
b
l
2
Plate screw l:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
6. Install the trim stopper m.

3
3. Install the pins f, hook g, and spring
h.
4
f f
b 5
m
h 7. Install the through tube n so that its

6
cutout (flat) corner d is pointing down.
f
8. Tighten the
temporarily.
self-locking nut o 7
g
9. Install the anode p and ground lead q.
Distance b: 2.0 mm (0.08 in)
10. Tighten the self-locking nut o to the
8
4. Route the trim sensor lead c through the
specified torque.
clamp bracket (STBD), and then install
the trim sensor i. 11. Install the ground leads r and s and
grease nipples t, and then tighten the
9
grease nipples to the specified torque.
i 10
A
9-28
BRKT
Bracket unit
t Adjusting the trim sensor

t
t After tilting the swivel bracket up, make

s sure to support it using the tilt stop lever.
t
o r Otherwise, the swivel bracket could sud-
denly lower.
1. Fully tilt the swivel bracket up, and then

t n
support it using the tilt stop lever a.
p q n
Self-locking nut o:
23 N·m (2.3 kgf·m, 17.0 ft·lb)
Grease nipple t:
2. Loosen the trim sensor screws b.
3 N·m (0.3 kgf·m, 2.2 ft·lb)
3. Adjust the position of trim sensor, and
12. Inject grease into the grease nipples until
then tighten the trim sensor screws b
grease comes out from the bushings e.
temporarily.
b a
e
TIP:
• To decrease the resistance, turn the trim
sensor cam in direction a.
• To increase the resistance, turn the trim
sensor cam in direction b.
4. Fully tilt the swivel bracket down.
5. Measure the trim sensor setting

resistance. Check that the resistance is
within specification.
9-29
c d
0
d
c 1
Digital circuit tester: 90890-03174
Trim sensor setting resistance

2
(reference data):
Terminal c –Terminal d
9.0–11.0 Ω 3
support it using the tilt stop lever.
7. Tighten the trim sensor screws b to the

4
specified torque. Check that the trim
sensor resistance is within specification.
Trim sensor screw b:
5
4 N·m (0.4 kgf·m, 3.0 ft·lb)
8. Fully tilt the swivel bracket down.

6
7
8
9
10
A
9-30
BRKT
Bracket unit
PTT unit
2
4
5
6
1
7
8
8
8
8

1 Shaft 1
2 Circlip 1
3 Plastic tie 4
4 Bolt 1 M6 14 mm
5 Holder 1
6 Bushing 4
7 PTT unit 1
8 Bolt 8 M10 45 mm
9 Bolt 1 M6 10 mm
9-31
PTT unit
Removing the PTT unit
e
When removing the PTT unit with the

power unit installed, make sure to sus- f 0
pend the outboard motor.

1
5. Connect the PTT motor leads a to the
a
battery terminals to fully retract the PTT
rams.
2
a 3
2. Remove the plastic ties b and holder c.

Lg Sb 4
b Battery
5
b Ram PTT motor lead
c terminal

b
b
Down
Light green (Lg)
Sky blue (Sb)
6
6. Remove the PTT unit g.
3. Disconnect the ground lead d.

7
8
d 9
d
4. Remove the circlip e and shaft f.

10
g
A
9-32
BRKT
Bracket unit
Checking the hydraulic pressure
a
Check the hydraulic pressure. Check the
internal parts if out of specification. b
Before removing the reservoir cap, make c

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 c:
3. Remove the reservoir cap a, and then 90890-06580
check the fluid level in the reservoir.
TIP:
Place the PTT unit in the drain pan.
8. Connect the PTT motor leads to the

battery terminals to fully retract the trim
rams, and then measure the hydraulic
a pressure when the reading on the
pressure gauge stabilizes.
TIP:
If the fluid is at the proper level, a small
amount of fluid should flow out of the filler
hole. Lg Sb
4. If the fluid is below the proper level, add

the recommended fluid.
Recommended PTT fluid: ATF DEXRON II
Battery
Ram PTT motor lead
5. Install the reservoir cap a, and then terminal
tighten it to the specified torque. Light green (Lg)
Down
Reservoir cap a: Sky blue (Sb)
7 N·m (0.7 kgf·m, 5.2 ft·lb)
Hydraulic pressure (down):
6. Loosen the pipe joints b, and then 6.7–8.7 MPa (67.0–87.0 kgf/cm2,
remove the pipe joint at the end a. 971.5–1261.5 psi)
7. Install the special service tool c. 9. Reverse the PTT motor leads between
the battery terminals to fully extend the
trim rams.
9-33
PTT unit
battery terminals to fully extend the trim
rams, and then measure the hydraulic
pressure when the reading on the
pressure gauge stabilizes. 0
Sb Lg
1
Sb Lg
Battery
Ram PTT motor lead
Sky blue (Sb)

terminal

2
Up
Light green (Lg)
10. Remove the special service tool c. 3

11. Install the pipe joints b, and then tighten
Pipe joint b: Ram PTT motor lead
Battery 4
terminal
15 N·m (1.5 kgf·m, 11.1 ft·lb)
Sky blue (Sb)
Up
Light green (Lg) 5
rams. Hydraulic pressure (up):
13. Loosen the pipe joints d, and then

remove the pipe joint at the end b.
13.0–15.0 MPa
(130.0–150.0 kgf/cm2, 6
1885.0–2175.0 psi)
14. Install the special service tool c.
b
16. Reverse the PTT motor leads between
the battery terminals to fully retract the 7
trim rams.
b 8
d
Lg Sb
9
c 10
PTT oil pressure gauge assembly c:
90890-06580
A
9-34
BRKT
Bracket unit
Battery Manual valve a:

Ram PTT motor lead
terminal 2 N·m (0.2 kgf·m, 1.5 ft·lb)
Light green (Lg)
Down 3. Check the fluid level. See steps 3–5 in
Sky blue (Sb) “Checking the hydraulic pressure” (9-33).
17. Remove the special service tool c. 4. Connect the PTT motor leads to the
18. Install the pipe joints d, and then tighten
rams.
Pipe joint d: 5. Reverse the PTT motor leads between
15 N·m (1.5 kgf·m, 11.1 ft·lb) the battery terminals to fully extend the
PTT rams.
19. After measuring the hydraulic pressure,
connect the PTT motor leads to the
battery terminals to fully extend the PTT
rams.
Lg Sb
Sb Lg
Sb Lg
20. Place the PTT unit in an upright position.
21. Repeat steps 3–5 to check the fluid level. Battery

Ram PTT motor lead
terminal
Bleeding the PTT unit Light green (Lg)
1. Place the PTT unit in an upright position. Down
Sky blue (Sb)
2. Turn the manual valve a clockwise to Sky blue (Sb)
Up
close it. Light green (Lg)
a
TIP:
If the PTT rams do not move up and down
easily, push and pull on the PTT rams to
assist operation.
9-35
PTT unit
6. Check the fluid level when the PTT rams
are fully extended. If the fluid level is low,
add sufficient fluid, and then repeat
steps 4 and 5.
Installing the PTT unit

0
• After tilting the swivel bracket up, make b

1
sure to support it using the tilt stop b
lever.
• When installing the PTT unit with the
b 2
pend the outboard motor.
1. Connect the PTT motor leads to the bat- c 3

tery terminals to retract the PTT rams.
4. Pass the PTT motor lead a through the

hole b in the clamp bracket (STBD). 4
Lg Sb 5. Connect the PTT motor leads a to the
battery terminals to extend the PTT
rams.
5
a
6
Battery
Ram PTT motor lead b
terminal
Down
Light green (Lg)
Sky blue (Sb)

Sb Lg 7
a
Ram PTT motor lead
Battery
8
terminal
Sky blue (Sb)
a Up
Light green (Lg) 9
6. Insert the shaft d from the port side, and
then install the circlip e.
10
3. Install the bushings b to the tilt ram end
and swivel bracket, and then install the
PTT unit c.
A
9-36
BRKT
Bracket unit
7. Connect the ground lead f.
f
f
8. Fasten the PTT motor lead a and trim

sensor lead b using the plastic ties g,
and then install the holder h.
g g
a
h
g
g
b
9-37
PTT unit / PTT motor
PTT motor
7 N·m (0.7 kgf·m, 5.2 ft·lb)
8 14
19 N·m (1.9 kgf·m, 14.0 ft·lb)
13
0
7 14
8 8
12
1
15
19 N·m (1.9 kgf·m, 14.0 ft·lb) 16
5
6 4 2
17
3 11
18
16
3
19 19
2 20
1
10
19
19
4
9 20 11
20
5
21
20
6
22

1 Spacer 1
2 Filter 1
3
4
Sheet
O-ring
1
1 39
8
5 Reservoir cap 1
39
6
7
O-ring
Reservoir
1
1 9
8 Reservoir mounting bolt 3 M8 20 mm
9 Joint 1
10
11
O-ring
PTT motor mounting bolt
1
3
39
M8 20 mm
10
12 PTT motor assembly 1
13 Stator 1
14 Bolt 2 M5 12 mm
15 Wave washer 1
16 Bearing 2 39
17 Armature 1
A
9-38
BRKT
Bracket unit
7 N·m (0.7 kgf·m, 5.2 ft·lb)
8 14
19 N·m (1.9 kgf·m, 14.0 ft·lb)
13
7 14
8 8
12
15
19 N·m (1.9 kgf·m, 14.0 ft·lb) 16
6 4
5
17
11 16
3
18
19 19
2 20
1 19
10 19
9 20 11
20
21
20
22

18 O-ring 1 39
19 Spring 4
20 Brush 4
21 Motor base assembly 1
22 Oil seal 1 39
9-39
PTT motor
Removing the reservoir Disassembling the PTT motor
1. Remove the stator a, and then remove
the armature b. NOTICE: Secure the
end of the armature shaft using a pair
Before removing the reservoir, make sure
that the PTT rams are fully extended. Oth- of pliers, and then remove the arma- 0
erwise, fluid could be expelled forcefully ture along with the motor base assem-
from the PTT unit due to internal pres- bly. Otherwise, the armature could
sure. separate from the motor base assem-
bly due to the magnetic force of the 1
stator and damage the brushes.
1. Remove the reservoir a, O-ring b, filter
c, and spacer d.
a
a
2
3
c
d b
4
2. Remove the springs c and brushes d.
d c
b
c d 5
d
TIP:
Place a container under the PTT unit to catch
c d c 6
the fluid.
Removing the PTT motor 7

1. Remove the PTT motor assembly a, O- 3. Remove the bearing e.
ring b, and joint c.
a e
e
8
b f
c f f
9
a e
10
Bearing splitter f:
A
9-40
BRKT
Bracket unit
TIP:
Before removing the bearing, measure and
write down the bearing depth a.
4. Remove the bearing g.
h
g a
h
Motor commutator standard diameter:
g f f 23.0 mm (0.91 in)
f 3. Measure the commutator undercut b.
g b
b
Bearing splitter f:
Bolt h (commercially available):
M8 15 mm
TIP: Motor commutator undercut b

Before removing the bearing, measure and (reference data): 1.4 mm (0.06 in)
write down the bearing depth b. Wear limit: 0.9 mm (0.04 in)
4. Check the armature for continuity.

Checking the armature (PTT motor) Replace if out of specifications.
1. Check the commutator. Clean using 600-
grit sandpaper and compressed air if
dirty.
c
d
e f
Digital circuit tester: 90890-03174
Armature continuity:
2. Measure the commutator diameter a. c d e f
Replace the armature if below C C
specification.
Checking the brush
1. Measure the length of each brush.
Replace if below specification.
9-41
PTT motor
1. Install a new oil seal a.
0
b
a
a
1
Motor brush standard length a:
11.5 mm (0.45 in)
Wear limit b: 4.5 mm (0.18 in)
2. Install the brushes b and springs c. 2
b c
2. Check the motor base assembly for c b
continuity. Replace if there is no
continuity.
b
b
c 3
f g c b
e h c 4
Sb c
3. Install a new bearing d to the specified
depth.
5
Lg d
Sb: Sky blue 6
Lg: Light green
Motor base assembly continuity:
Terminal c–Terminal e
d a
7
Terminal c–Terminal g
Terminal e–Terminal g
Terminal d–Terminal f
Terminal d–Terminal h
8
Terminal f–Terminal h
d
3. Check the motor base assembly.
Replace the motor base assembly if the
9
base is cracked or damaged. Depth a (reference data):
20.10 mm (0.79 in)
Assembling the PTT motor
4. Install a new bearing e to the specified 10
depth b.
• Do not reuse a bearing, oil seal, or O-

ring, always replace it with a new one.
• Do not apply grease or oil to the commu-
tator of the armature.
A
9-42
BRKT
Bracket unit
b
e
Installing the reservoir
e
Depth b (reference data): with a new one.
0.95 mm (0.04 in)
5. Push the brushes b into the holders, 1. Install the spacer a, filter b, and sheet
and then install the armature f. c.
b 2. Install a new O-ring d and the reservoir

e, and then tighten the reservoir
f mounting bolts f to the specified torque.
3. Install a new O-ring g and the reservoir

cap h, and then tighten the reservoir cap
h to the specified torque.
f e
f
f c
b
b
a
6. Install the wave washer g.
g
h
g
d
Reservoir mounting bolt f:

19 N·m (1.9 kgf·m, 14.0 ft·lb)
Reservoir cap h:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
7. Install the stator h.
Installing the PTT motor
1. Install the joint a.
9-43
PTT motor
TIP:
Align the protrusion b on the armature shaft
with the slot c in the joint.
a 0
1
2. Fill the gear pump housing with the
recommended fluid to the proper level a. 2
3
a
4
Recommended PTT fluid: ATF DEXRON II 5
3. Turn the joint a using a screwdriver to
remove any air between the pump gear
teeth. 6
4. Remove all of the air bubbles using a
syringe or suitable tool.
5. Install a new O-ring b and the PTT

7
motor assembly c, and then tighten the
PTT motor mounting bolts d to the
specified torque. NOTICE: Do not 8
a new one.
d c
d
9
d
b 10
a
c b
PTT motor mounting bolt d:

19 N·m (1.9 kgf·m, 14.0 ft·lb)
A
9-44
BRKT
Bracket unit
PTT gear pump
7 N·m (0.7 kgf·m, 5.2 ft·lb)
1 5 5
1
9
6
2 10
7 11
3 8
12
4
1
31 7 N·m (0.7 kgf·m, 5.2 ft·lb)

13 13
32 14 14
32
33 15 18 34
33 16 17
17
35 35
36 36 19
37 37 20
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 Gear pump bolt 3 M5 40 mm
2 Plate 1
3 Filter 1
4 Seal 1
5 Valve lock screw 2
6 Spring 1
7 Valve pin 1
8 Valve seal 1 39
9 Spring 1
10 Valve support pin 1
11 O-ring 1 39
12 Ball 1
13 E-clip 2
14 Main valve seal 2
15 Down-main valve 1
16 O-ring 1 39
17 Spring 2
9-45
PTT gear pump
7 N·m (0.7 kgf·m, 5.2 ft·lb)

1 5 5
1
6
9
0
2 10
7 11
3 8
4
12
1
1
31 7 N·m (0.7 kgf·m, 5.2 ft·lb)

13 13
2
32 14 14
32
18
33
33
15
16
17
17
34
3
35 35
36 36 19
37 37 19
20
21 4
24
30
22
22
23
5
38 25
39 25
26 26
40
27
28
30
27
28
6
2 N·m (0.2 kgf·m, 1.5 ft·lb) 29 29

18 Up-main valve 1
19 Ball 2
20
21
Relief valve seat
O-ring
1
1 39
8
22 Ball 2
23
24
Manual release plate
Filter
1
1 9
25 Ball 2
26 Valve pin 2
27
28
Spring
Spacer
2
2
10
29 O-ring 2 39
30 Pin 2
31 Bracket 1
32 Washer 2
33 Pump bracket bolt 2 M5 25 mm
34 Gear pump assembly 1
A
9-46
BRKT
Bracket unit
7 N·m (0.7 kgf·m, 5.2 ft·lb)

1 5 5
1
9
6
2 10
7 11
3 8
12
4
1
31 7 N·m (0.7 kgf·m, 5.2 ft·lb)

13 13
32 14 14
32
33 15 18 34
33 16 17
17
35 35
36 36 19
37 37 20
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
9-47
PTT gear pump
Disassembling the gear pump 4. Remove the bracket k, and then remove
housing the filter l, spacers m, springs n, valve
1. Remove the manual valve a, and then pins o, and balls p and q.
remove the gear pump assembly b.
m
0
2. Remove the filters c.
n
c k
o
p
1
c m l
n
o
q 2
p
b
3
5. Remove the gear housing c, and then
a remove the springs r, down-main valve
s, and up-main valve t. 4
3. Remove the valve lock screws d, and
then remove the spring e, valve support 6. Remove the drive gear d, driven gear
pin f, ball g, spring h, valve pin i,
and valve seal j.
e, balls u, and pins v.
5
c
r
d d
h e s
v
6
i f
r
j g
e d
t 7
u
A B 8
b
a
Checking the gear pump
1. Check the drive gear a and driven gear
9
d d
b. Replace the gear pump assembly if
A Down-relief valve
damaged or worn.
10
2. Check the up-relief valve c and down-
B Up-relief valve relief valve d. Clean if there is dirt or
residue.
TIP:
Before removing the valve lock screws d, 3. Check the main valves e. Clean if there
measure and write down the screw depth a is dirt or residue.
and screw height b.
A
9-48
BRKT
Bracket unit
4. Check the main valves f and g. Clean
c
if there is dirt or residue. d
b
d c
e
a d
a
b c
b
a
f
f
g
4. Install the balls g, the valve pins h, the
e springs i, the spacers j, and new O-
rings k.
e
5. Install the balls l and manual release
plate m.
Assembling the gear pump assembly
6. Install the bracket n, and then tighten
Lubricate the parts using ATF DEXRON II
the pump bracket bolts o temporarily.
during assembly.
7. Check that the gear pump turns
smoothly, and then tighten the pump
• When assembling the PTT unit, do not bracket bolts o to the specified torque.
use a rag. Otherwise, dust and particles
could get on the PTT unit components, o k
causing poor performance. j
• Do not reuse an O-ring or valve seal, i
always replace it with a new one. h
n
g
1. Install a new O-ring a to the down-main k
valve b. j
i
2. Install the drive gear a, driven gear b, l
h
down-main valve b, up-main valve c, m
springs d, and pins e.
g
3. Install the balls f and the gear housing
c.
Pump bracket bolt o:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
8. Install a new valve seal p, the valve pin

q, and the spring r, and then install the
valve lock screw s.
9. Install a new O-ring t to the valve

support pin u.
9-49
PTT gear pump
10. Install the ball v, valve support pin u,
and spring w, and then install the valve F
C F F
lock screw x.
B C
s
r
x
w
A B
A
E
0
q y
u
p t
v
z
D
1
G H
2
A B I
Gear pump bolt F:
d
e 7 N·m (0.7 kgf·m, 5.2 ft·lb) 3
x Manual valve H:
s
2 N·m (0.2 kgf·m, 1.5 ft·lb)
15. Install the PTT motor. See “Installing the 4

PTT motor” (9-43).
A Down-relief valve
B Up-relief valve 16. Check the hydraulic pressure. See
“Checking the hydraulic pressure” (9-33). 5
Installation depth d (reference data):
1.07–1.27 mm (0.042–0.050 in) TIP:
Installation height e (reference data):
1.95–2.45 mm (0.077–0.096 in)
If the hydraulic pressure is out of specifica-
tion, adjust the relief lock screws to adjust the
6
pressure.
TIP:
• Install the valve lock screw s and valve 7
lock screw x to the depth d and height e
that were measured before removing them.
• If installing new parts, install them accord-
ing to the preceding reference data. 8
11. Install the filter y to the seal z.
12. Install the filters A, the spacers B, new

9
O-rings C, and the gear pump assembly
D.
13. Install the seal z and plate E, and then

10
tighten the gear pump bolts F to the
specified torque.
14. Install a new O-ring G, the manual valve

H, and the circlip I, and then tighten the
manual valve H to the specified torque.
A
9-50
BRKT
Bracket unit
PTT cylinder
160 N·m (16.0 kgf·m, 118.0 ft·lb)
24
90 N·m (9.0 kgf·m, 66.4 ft·lb) 25
65 N·m (6.5 kgf·m, 47.9 ft·lb)
16 26
20 27
21
1 3 22
4 12 19
5 23
2 6 13 15 N·m (1.5 kgf·m, 11.1 ft·lb)
7 28
14
29
9 9
18 30
9 9
31
17
8 32
10 33
17
11
15 N·m (1.5 kgf·m, 11.1 ft·lb)
15
20 N·m (2.0 kgf·m, 14.8 ft·lb)
7 N·m (0.7 kgf·m, 5.2 ft·lb)

1 Dust seal 1 39
2 Tilt cylinder end screw 1
3 O-ring 1 39
4 Backup ring 1
5 O-ring 1 39
6 Spring 1
7 Adapter 1
8 Tilt piston assembly 1
9 Ball 4
10 O-ring 1 39
11 Backup ring 1
12 Tilt ram assembly 1
13 Free piston 1
14 O-ring 1 39
15 Tilt cylinder 1
16 Tilt cylinder assembly 1
17 Bushing 2
9-51
PTT cylinder
160 N·m (16.0 kgf·m, 118.0 ft·lb)

24
90 N·m (9.0 kgf·m, 66.4 ft·lb)
65 N·m (6.5 kgf·m, 47.9 ft·lb)

25
0
16
20
26
27
1
21
1 3 22
4
5
12 19
23
2
2 6 13 15 N·m (1.5 kgf·m, 11.1 ft·lb)
7
14 28
29
3
9 9
9
18 30 4
9
31
17
8
10
17 33
32 5
11
7 N·m (0.7 kgf·m, 5.2 ft·lb)

15
15 N·m (1.5 kgf·m, 11.1 ft·lb)
20 N·m (2.0 kgf·m, 14.8 ft·lb)
6

18 Pipe 1
19 Trim ram assembly 2
20
21
Backup ring
O-ring
2
2 39
8
22 Spring 2
23
24
Circlip
Circlip
2
2 9
25 Dust seal 2 39
26 Trim cylinder end screw 2
27
28
O-ring
Circlip
2
1
39
10
29 Shaft 1
30 Spacer 1
31 O-ring 1 39
32 Pipe joint adapter 1
33 Pipe 1
A
9-52
BRKT
Bracket unit
Removing the tilt ram 5. Cover the tilt cylinder opening with a rag
i, and then blow compressed air
through the hole a to remove the free
Before removing the tilt cylinder, make piston j. 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
fully from the PTT unit due to internal piston and PTT fluid could be expelled
pressure. forcefully.
i
1. Remove the pipes a and b and pipe
joint adapter c.
2. Remove the circlip d, shaft e, and tilt j

cylinder assembly f.
a
f d
e Removing the trim ram
1. Loosen the trim cylinder end screws a,
and then remove the trim ram assem-
blies.
a
b
a
3. Loosen the tilt cylinder end screw g, and
then remove the tilt ram assembly. b
a
Cylinder-end screw wrench b:

90890-06568
h
2. Drain the fluid.
g
Disassembling the tilt ram
1. Remove the tilt piston absorber valves
a.
Cylinder-end screw wrench h:

90890-06568
4. Drain the PTT fluid.
9-53
PTT cylinder
Checking the tilt cylinder and PTT
a a body
1. Check the PTT body a and tilt cylinder
a. Replace if corroded or cracked.
a
0
2. Check the inner surfaces of the PTT
body a and tilt cylinder a. Replace if
a scratched.
1
3. Check the tilt piston b, trim pistons c,
free piston b, and dust seals c and d
of tilt cylinder end screw e and trim
cylinder end screws f. Replace if
2
scratched.
2. Remove the tilt piston b.
4. Check the trim rams d and tilt ram e.
Clean using 400–600-grit sandpaper if
3
there is rust or, replace if bent or
corroded.
5. Check the pipes g and h. Replace if

4
b corroded or cracked.
b
d
f
5
a b
e d
c
e
c 6
a
PTT piston vice attachment a:
90890-06572 b 7
Tilt rod wrench b: 90890-06569
Disassembling the trim ram

1. Remove the circlip a, adapter a, spring a
8
b, O-ring c, and backup ring d.
g
h 9
d
c
Checking the valve
b
a 1. Check the tilt piston absorber valves a.
Clean if there is dirt or residue.
10
a
A
9-54
BRKT
Bracket unit
a
a
j
a
a
a
i
Assembling the tilt ram
• When assembling the PTT unit, do not

use a rag. Otherwise, dust and particles PTT piston vice attachment i:
could get on the PTT unit components, 90890-06572
causing poor performance. Tilt rod wrench j: 90890-06569
• Do not reuse a dust seal or O-ring,
always replace it with a new one. Tilt ram a: 65 N·m (6.5 kgf·m, 47.9 ft·lb)
4. Install a new O-ring k and the backup

1. Install a new dust seal a, the backup ring l.
ring b, and new O-rings c and d to the
tilt cylinder end screw e. 5. Install the balls m, absorber valve pins
b, and springs c.
a a
d b 6. Install the washers d, plate e, washer
f, and tilt piston screw g, and then
tighten the tilt piston screw g to the
d specified torque.
c g
e
b e e f
c
e
2. Install the tilt cylinder end screw e, l c
spring f, adapter g, and tilt piston h. b
k d
l m
e c
g c
b
m k b
m
f
c
b c
m b
h
m
3. Tighten the tilt ram a to the specified
torque.
Tilt piston screw g:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
9-55
PTT cylinder
Assembling the trim ram 1. Install a new O-ring a to the free piston
b.
2. Push the free piston b into the tilt

cylinder c until it bottoms out. 0
could get on the PTT unit components,
3. Install the tilt cylinder c.
causing poor performance.
• Do not reuse a dust seal or O-ring,
4. Install a new O-ring d and the pipe joint
adapter e, and then tighten the pipe joint
1
adapter e to the specified torque.
1. Install the backup ring a, a new O-ring
b, the spring c, the adapter a, and the 5. Install the pipes f and g, and then
tighten the pipe joints a to the specified
2
circlip d to the trim piston b.
torque.
b
b b
b
a
3
c
a
a a
b
4
d
c
a
d 5
2. Install a new dust seal e, the circlip f, e
and a new O-ring g to the trim cylinder g a a
end screw h, and then install the trim
cylinder end screw h onto the trim ram a
f 6
c.
Pipe joint adapter e:
f
e
e f 20 N·m (2.0 kgf·m, 14.8 ft·lb)
Pipe joint a: 15 N·m (1.5 kgf·m, 11.1 ft·lb)
7
c h
Installing the trim ram
g 8
When assembling the PTT unit, do not use
h
g a rag. Otherwise, dust and particles could
get on the PTT unit components, causing 9
Installing the tilt cylinder poor performance.

1. Fill the trim cylinders with the recom-
mended fluid up to the proper level a.
10
could get on the PTT unit components,
causing poor performance.
• Do not reuse an O-ring, always replace it
with a new one.
A
9-56
BRKT
Bracket unit
a a
b
2. Install the trim ram assemblies, and then
a
tighten the trim cylinder end screws a to
4. Install the tilt piston assembly into the tilt

a
cylinder, and then tighten the tilt cylinder
end screw a to the specified torque.
b
a
b
90890-06568
Trim cylinder end screw a:

160 N·m (16.0 kgf·m, 118.0 ft·lb) a
Installing the tilt ram

When assembling the PTT unit, do not use 90890-06568
a rag. Otherwise, dust and particles could
get on the PTT unit components, causing Tilt cylinder end screw a:
poor performance. 90 N·m (9.0 kgf·m, 66.4 ft·lb)
1. Place the tilt cylinder end screw a at the

bottom of the tilt ram assembly.
2. Fill the tilt cylinder with the recommended

fluid up to the proper level a.
3. Add a small amount of the recommended

fluid through the PTT body hole b.
9-57
PTT cylinder
— MEMO —
0
1
2
3
4
5
6
7
8
9
10
A
9-58
MNT
Maintenance 10
Outline .............................................................................. 10-1

Maintenance interval chart 1 ................................................... 10-1
Maintenance interval chart 2 ................................................... 10-2
Predelivery check ............................................................ 10-3

Checking the battery ............................................................... 10-3
Checking the cooling water pilot hole ...................................... 10-3
Checking the engine oil level ................................................... 10-4
Checking the communication between the engine and
the Digital Electronic Control ................................................... 10-4
Checking the engine start switch and engine shut-off switch
(single outboard motor application) ......................................... 10-5
Checking the engine start/stop button and engine shut-off
switch (twin or triple outboard motor application) .................... 10-5
Checking the fuel system ........................................................ 10-5
Checking the gear oil level ...................................................... 10-5
Checking the gear shift and throttle operation ......................... 10-6
Checking the outboard motor mounting height ....................... 10-6
Checking the PTT system ....................................................... 10-6
Checking the steering system ................................................. 10-6
Test run ................................................................................... 10-6
Break-in ................................................................................... 10-7
After test run ............................................................................ 10-7
General periodic maintenance ....................................... 10-7

Checking the anode ................................................................ 10-7
Checking the battery ............................................................... 10-7
Checking the cooling water passage ....................................... 10-7
Checking the engine idle speed .............................................. 10-8
Changing the engine oil ........................................................... 10-8
Checking the engine oil level ................................................... 10-9
Replacing the oil filter .............................................................. 10-9
Checking the engine start switch and engine shut-off switch
(single outboard motor application) ....................................... 10-10
Checking the engine start/stop button and engine shut-off
switch (twin or triple outboard motor application) .................. 10-10
Checking the fuel filter ........................................................... 10-10
Checking the fuel system for fuel leakage ............................. 10-10
Changing the gear oil ............................................................ 10-10
Checking the gear oil level .................................................... 10-12
Replacing the OCV filter ........................................................ 10-12
Lubricating the outboard motor ............................................. 10-12
Checking the propeller .......................................................... 10-13
Checking the PTT fluid level .................................................. 10-13
Checking the PTT operation .................................................. 10-14
Checking the spark plug ........................................................ 10-14
Checking the timing belt ........................................................ 10-14
Replacing the timing belt ....................................................... 10-14
Checking the thermostat ....................................................... 10-14
Checking the top cowling ...................................................... 10-14
Checking the valve clearance ............................................... 10-14
Checking the water pump ...................................................... 10-14
0
1
2
3
4
6
6
7
8
9
10
A
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 qual-
ity. Any parts of inferior quality may cause a malfunction, and the resulting loss of control could
endanger the operator and passengers. Yamaha genuine parts and accessories are available
from Yamaha dealers.
• The service intervals provided in the maintenance interval charts are based upon “typical” operat-
ing conditions that include speed variations, sufficient time for engine warm up and cool-down,
medium to light load, and an average cruising speed in the 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 start-
ing and stopping or shifting. In most cases, the frequent maintenance pays off in increased engine
life and greater owner satisfaction.
• The maintenance cycle on these charts is based on usage of 100 hours per year and regular
flushing of the cooling water passages. Adjust the maintenance frequency when operating the
engine under adverse conditions, such as extended trolling.
• Disassembly or repairs may be necessary depending on the outcome of maintenance checks.
• Expendable or consumable parts and lubricants will lose their effectiveness over time and through
normal usage regardless of the warranty period.
• When operating the outboard motor in salt water, or in muddy, turbid (cloudy), or acidic water, flush
the engine using clean water after each use.
Maintenance interval chart 1

Initial Every See
Item Actions 20 hours 100 hours 300 hours 500 hours
page
(3 months) (1 year) (3 years) (5 years)
Anodes (external) Check/Replace 8-4
U
9-27
Anodes (cylinder head Check/Replace 7-60
U
exhaust passage)
Anodes (cylinder head, Replace 7-60
cylinder block thermostat 7-67
U
portion, oil cooler cover, 7-90
exhaust guide) 9-16
Battery (electrolyte level, Check/Charge/Replace 10-3
U U
terminal)
Cooling water leakage Check/Replace U U 10-7
Cowling lock lever Check U 10-14
Engine starting condition/ Check 10-5
U U
Noise
Engine idle speed/Noise Check U U 10-8
Engine oil Replace U U 10-8
Engine oil filter Replace U 10-9
Fuel filter (can be Check/Replace 6-12
U U
disassembled)
Fuel hose (high pressure) Check/Replace U U 6-1
10-1
Outline
Initial Every See

Item Actions 20 hours 100 hours 300 hours 500 hours
page
(3 months) (1 year) (3 years) (5 years)
Fuel hose (low pressure) Check/Replace U U 6-1
Fuel pump Check/Replace
U
6-30 0
6-40
Fuel/Oil leakage Check U U 6-1
Gear oil
Greasing points
Replace
Lubricate
U
U
U
U
10-10
10-12
1
Impeller/Water pump Check/Replace 8-12
U
housing
Impeller/Water pump Replace
U
8-12 2
housing
OCV filter Replace U 10-12
PTT unit
Propeller/Propeller nut/
Check
Check/Replace
U U 10-14
8-3
3
U U
Cotter pin
U
Spark plugs
Ignition coils/Ignition coil
Check/Replace
Check/Replace
U U
7-48
5-46 4
leads
Pilot water Check U U 10-3
Thermostat
Timing belt
Check/Replace
Check/Replace
U
U
7-72
7-39
5
Valve clearance Check/Adjust 7-2
U
Water inlet Check U U

7-4
10-7
6
Engine start switch/Main Check/Replace 10-5
switch/Engine start/stop
button/Engine shut-off
switch
U U
7
Wiring harness Check/Replace —
U U
connections/Lead
coupler connections 8
Yamaha meter/Gauge Check U U —
— :Not applicable
9
TIP:
When using lead high-sulfur gasoline, checking the valve clearance may be required more fre-
quently than every 500 hours.
10
Maintenance interval chart 2
Every See
Item Actions
1000 hours page
Exhaust guide/Exhaust Check/Replace 9-20
U
manifold
Timing belt Replace U 7-37 A
10-2
MNT
Maintenance
Predelivery check
To make the delivery process smooth and
efficient, complete the predelivery checks as
a
explained in the following procedures.
Checking the battery
Battery electrolyte is dangerous; it con-

tains sulfuric acid, which is poisonous
and highly caustic. Always follow these 2. Check the specific gravity of the
preventive measures: electrolyte. Fully charge the battery if
• Avoid bodily contact with electrolyte as below specification.
it can cause severe burns or permanent Representative examples:
eye injury. Recommended battery capacity:
• Wear protective eye gear when handling CCA/EN: 640.0 A
or working near batteries. 20HR/IEC: 80.0 Ah
Antidote (EXTERNAL): Electrolyte specific gravity:
• SKIN - Wash with water. 1.280 at 20 °C (68 °F)
• EYES - Flush with water for 15 minutes
and get immediate medical attention.
TIP:
Antidote (INTERNAL):
• Batteries vary depending on the manufac-
• Drink large quantities of water or milk
turer. The procedures mentioned in this
followed with milk of magnesia, beaten
manual may not always apply. Therefore,
egg, or vegetable oil. Get immediate
see the instruction manual of the battery.
medical attention.
• Disconnect the negative battery cable first,
Batteries produce explosive, hydrogen
and then disconnect the positive battery
gas. Always follow these preventive mea-
cable.
sures:
• For more information about the battery
• Charge batteries in a well-ventilated
requirements, see “Extension length rec-
area.
ommendation of battery cable” (3-30).
• Keep batteries away from fire, sparks, or
open flames (for example, welding
equipment and lighted cigarettes). Checking the cooling water pilot 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
mark a, add distilled water until the level
is between the maximum and minimum
level marks.
10-3
Predelivery check
Checking the engine oil level
1. Place the outboard motor in an upright
position. NOTICE: If the outboard
motor is not level, the oil level indi-
cated on the dipstick may not be cor- 0
rect.
2. Start the engine and warm it up for 5–10

minutes. 1
3. Stop the engine and leave it off for 5–10
minutes.
2
4. Remove the top cowling.
1. Move the control lever to the F, N, and R
5. Remove the dipstick a and wipe it clean.
positions to check the SPS output volt-
age and shift request in each position.
3
6. Insert the dipstick a completely for a
correct measurement and remove it SPS output voltage:
again. F position: 0.20–0.79 V
N position: 2.24–2.77 V
4
7. Check that the oil level indicated on the R position: 4.21–4.80 V
dipstick a is between the upper mark a
and the lower mark b. If the engine oil is
not at the proper level, add or extract
Shift request:
F position: 100%
5
engine oil. N position: 0%
R position: –100%
a
a 2. Move the control lever to the F fully open
6
position, F position, N position, R posi-
tion, and R fully open position, and then
check the LPS output voltage and throttle
request in each position.
7
b LPS output voltage:
F fully open position: 4.41–4.71 V
F position: 2.66–2.92 V
8
Checking the communication N position: 2.07–2.33 V
between the engine and the Digital R position: 1.47–1.74 V
Electronic Control R fully open position: 0.29–0.59 V 9
Check the SPS output voltage, shift request,
LPS output voltage, and throttle request that Throttle request:
are displayed on the YDIS engine monitor. Fully open F position: 100%
F position, N position, R position: 0% 10
R Fully open position: 100%
Fail: Over 4.8 V and less than 0.2 V
A
10-4
MNT
Maintenance
Checking the engine start switch and
engine shut-off switch (single ON
outboard motor application) OFF
1. Check that the engine starts when the c
engine start switch a is turned to START.
2. Check that the engine stops when the

engine start switch a is turned to OFF.
a d
3. Check that the engine stops when the b b
clip b is removed from the engine shut-
off switch c.
ON Checking the fuel system

OFF START 1. Check that the fuel hoses are connected
b securely. To check the fuel hose connec-
tions, see “Fuel hose and blowby hose”
(6-1). NOTICE: This outboard motor is
equipped with a 4-stroke engine.
a c Never use pre-mixed fuel or 2-stroke
outboard motor oil.
Checking the engine start/stop
button and engine shut-off switch Checking the gear oil level
(twin or triple outboard motor 1. Place the outboard motor in an upright
application) position.
1. Turn the main switch a to ON, and then
2. Remove the check screw a, and then
push the engine start/stop buttons b.
check the gear oil level.
Check that the engine starts.
2. Start the engine. Check that the engine

stops when the main switch a is turned
to OFF.
3. Start the engine. Check that the engine

stops when the engine start/stop buttons
b are pushed. a
4. Check that the engine stops when the

clip c is removed from the engine shut-
TIP:
off switch d.
If the oil is at the proper level, a small amount
of oil should flow out of the check hole.
3. Install a new gasket and the check screw

a, and then tighten the check screw a
a new one.
10-5
Predelivery check
Check screw a: 9 N·m (0.9 kgf·m, 6.6 ft·lb) Checking the PTT system
1. Check that the outboard motor tilts up
Checking the gear shift and throttle and down smoothly when the PTT switch
is pushed.
operation
1. Check that the gear shift operates
2. Check that there is no abnormal noise
0
smoothly when the remote control lever
produced when the outboard motor is
is moved from the N position to the F or R
position.
tilted up or down.
1
3. Check that there is no interference with
2. Check that the throttle operates smoothly
cables, hoses, or leads when the tilted-up
when the remote control lever is moved
from the F or R position to the fully open
position.
outboard motor is steered.
2
4. Check that the trim meter points down
when the outboard motor is fully tilted
Checking the outboard motor
mounting height
down.
3
1. Check that the anti-cavitation plate a is Checking the steering system
aligned with the bottom b of the boat. If 1. Check that the steering operates
the mounting height is too high, cavita-
tion will occur and propulsion will
smoothly. 4
decrease. Besides, the engine speed will 2. Check that there is no interference with
increase abnormally and cause the cables, hoses, or leads when the
engine to overheat. If the mounting
height is too low, water resistance will
outboard motor is steered. 5
increase, which will decrease engine effi- Test run
ciency and performance. 1. Start the engine, and then check that the
gear shift operates smoothly. 6
2. Warm up the engine, and then check the
engine idle speed.
7
a 3. Operate the boat at trolling speed.
b
4. Operate the outboard motor according to
the break-in procedure. 8
5. Check that the outboard motor does not
TIP:
The appropriate mounting height depends on
tilt up when the remote control lever is
moved to the R position and that water 9
the combination of the boat and outboard does not flow in over the transom.
motor. To determine the appropriate mount-
ing height, test run the outboard motor at dif-
ferent heights.
6. Check that the PTT operates smoothly
while the outboard motor is running.
10
2. Check that the clamp brackets are TIP:
secured using the clamp bolts. The test run is part of the break-in operation.
A
10-6
MNT
Maintenance
Break-in
Operate the engine under load (in gear with a TIP:
propeller installed) for 10 hours as follows: When using the flushing device (flushing
hose joint adapter), flush the cooling water
1. For the first hour a of operation: passages without starting the engine.
Operate the engine at varying speeds up
to 2000 r/min or approximately 1/2 throt- General periodic maintenance
tle. Checking the anode
2. For the second hour b of operation:
Increase the engine speed until the boat
is on plane (but do not fully open the Do not apply grease, oil, or paint to the
throttle), and then back off on the throttle anodes or the trim tab.
while keeping the boat at a planing
speed. 1. Check the anodes and trim tab. see
“Checking the cylinder head anode” (7-
3. For the remaining 8 hours c of 60), “Checking the cylinder block anode”
operation: (7-90), “Checking the oil cooler anode”
Operate the engine at any engine speed. (7-67), “Checking the lower unit anode”
However, do not operate the engine at (8-4), “Checking the exhaust guide
full throttle for more than 5 minutes at a anode” (9-16), and “Checking the clamp
time. bracket anode” (9-27).
4. After the first 10 hours of operation: Checking the battery

Operate the engine normally. 1. Check the battery. See “Checking the
battery” (10-3).
Checking the cooling water passage

a b c 1. Remove the water inlet covers a and b
and trim tab c.
A 0 1 2 10 2. Check the water inlet covers a and b

and cooling water inlets. Clean if
clogged.
A Hour
After test run

1. Check for water in the gear oil.
2. Check for fuel leakage in the cowling.
3. Flush the cooling water passages using

fresh water. NOTICE: When flushing
the cooling water passages, do not
start the engine. Otherwise, the water
pump could be damaged and the
engine could be severely damaged
due to overheat.
10-7
Predelivery check / General periodic maintenance
e
b
0
a
d
1
b
Checking the engine idle speed
c b 1. Start the engine and warm it up for 5–10
minutes.
2
a
2. Check the engine idle speed using the
Yamaha genuine tachometer (on-board
meter) or the YDIS. To connect and
3
operate the YDIS, see the “YDIS (Ver.
3. Install the water inlet covers a and trim
tab b, and then tighten the water inlet
1.33 or later) instruction manual.”
4
cover bolt c, water inlet cover screw d, Changing the engine oil
and the trim tab bolt e to the specified The engine oil should be extracted using an
torque. oil changer.
5
Water inlet cover bolt c:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
Change the engine oil after the first 20
Water inlet cover screw d:
1 N·m (0.1 kgf·m, 0.7 ft·lb)
hours of operation or 3 months, and every
100 hours or at 1-year intervals thereafter.
6
Trim tab bolt e:
42 N·m (4.2 kgf·m, 31.0 ft·lb)
TIP:
position. NOTICE: If the outboard
7
motor is not level, the oil level indi-
After installing the water inlet covers, make
cated on the dipstick may not be cor-
sure that there is no rattling.
rect. 8
4. Place the lower unit in water, and then 2. Start the engine and warm it up for 5–10
start the engine. minutes.
5. Check that cooling water is discharged 3. Stop the engine and leave it off for 5–10
9
from the cooling water pilot hole. If there minutes.
is no water flow, check the cooling water
passages inside the outboard motor. 4. Remove the top cowling. 10
5. Remove the oil filler cap a. Remove the
dipstick b and extract the engine oil
using the oil changer c.
A
10-8
MNT
Maintenance
10. Check that the oil level indicated on the
a dipstick b is between the upper mark a
and the lower mark b.
b
a
c b
b
11. Start the engine and check that the oil

pressure alert indicator does not come
on. Also, check that there is no oil
leakage. NOTICE: If the oil pressure
alert indicator comes on or if there is
oil leakage, stop the engine and find
the cause. Continued operation with a
6. Fill the engine with the specified amount problem could cause severe engine
of the recommended engine oil through damage.
the oil filler hole. Install the oil filler cap a
and dipstick b. NOTICE: Do not Checking the engine oil level
overfill the engine with engine oil. 1. Check the engine oil level. See “Check-
Otherwise, the engine could be ing the engine oil level” (10-4).
damaged or oil could leak. If the
engine oil is above the upper level, Replacing the oil filter
extract the excess engine oil until the 1. Extract the engine oil using an oil
oil is at the proper level. changer. See steps 1–5 in “Changing the
Recommended engine oil: engine oil” (10-8).
4-stroke motor oil with combinations of
2. Place a rag under the oil filter, and then
the following SAE and API oil classifica-
remove the oil filter.
tions:
API: SE, SF, SG, SH, SJ, SL
SAE: 5W-30, 10W-30, 10W-40
Replacement engine oil quantity
(at periodic maintenance):
Without oil filter replacement:
6.0 L (6.34 US qt, 5.28 lmp qt)
7. Leave the outboard motor off for 5–10

minutes. a
8. Remove the dipstick b and wipe it clean. Oil filter wrench a: 90890-06830
9. Insert the dipstick b completely for a

TIP:
correct measurement and remove it
Make sure to clean up any oil spills.
again.
10-9
General periodic maintenance
3. Install a new oil filter b, and then tighten Checking the engine start/stop
it to the specified torque. button and engine shut-off switch
(twin or triple outboard motor
a application)
1. Check the engine start/stop button and
0
engine shut-off switch. See “Checking
the engine start/stop button and engine
shut-off switch (twin or triple outboard
motor application)” (10-5).
1
b Checking the fuel filter
Oil filter b: 18 N·m (1.8 kgf·m, 13.3 ft·lb)

1. Check the fuel filter. See “Checking the
fuel filter element” (6-12).
2
4. Fill the engine with the specified amount Checking the fuel system for fuel
of the recommended engine oil through
the oil filler hole.
leakage 3
1. Check the fuel joint and fuel hose con-
Recommended engine oil: nections. See “Fuel hose and blowby
4-stroke motor oil with combinations of
the following SAE and API oil classifica-
hose” (6-1).
4
tions: Changing the gear oil
API: SE, SF, SG, SH, SJ, SL
SAE: 5W-30, 10W-30, 10W-40
Replacement engine oil quantity Never get under the lower unit while it is
5
(at periodic maintenance): tilted.
With oil filter replacement:
6.3 L (6.66 US qt, 5.54 lmp qt) 6
5. Install the oil filler cap and dipstick, and Do not reuse a gasket, always replace it
then start the engine and warm it up for with a new one.
5–10 minutes. 7
1. Remove the water inlet covers a.
6. Stop the engine, and then leave it off for
a
5–10 minutes.
8
7. Check the oil level. If the oil level is low,
add engine oil up to the proper level.
Checking the engine start switch and 9

engine shut-off switch (single a
outboard motor application)
1. Check the engine start switch and engine
shut-off switch. See “Checking the
10
2. Tilt the outboard motor so that the drain
engine start switch and engine shut-off
screw is at the lowest point.
switch (single outboard motor applica-
tion)” (10-5). 3. Place a drain pan under the gear oil drain
hole.
A
10-10
MNT
Maintenance
4. Remove the drain screw b and gasket
c. NOTICE: If there is a significant
amount of metal particles on the
magnetic drain screw, the lower unit
may have a problem.
f
5. Remove the check screw d and gasket d
e and let the oil drain completely.
NOTICE: After the gear oil has been
drained, check the used oil. If the oil is
milky, water is getting into the lower
case, which can cause gear damage.
Recommended gear oil:

d e Hypoid gear oil
API: GL-5
a
SAE: 90, 80W-90
a Oil quantity:
1.040 L (1.10 US qt, 0.92 lmp qt)
b
c
Check screw d: 9 N·m (0.9 kgf·m, 6.6 ft·lb)
9. Remove the gear oil pump, install a new

gasket g and the drain screw b, and
then tighten the drain screw b to the
specified torque.
TIP:
Before installing the magnetic drain screw,
make sure to remove all metal particles.

position.
7. Insert the gear oil pump into the drain

hole, and then fill the lower unit slowly b
with gear oil until oil flows out of the g
check hole and no air bubbles are visible.
Drain screw b: 9 N·m (0.9 kgf·m, 6.6 ft·lb)
8. Install a new gasket f and the check
10. Install the water inlet covers a, and then
screw d, and then tighten the check
tighten the water inlet cover bolt h to the
screw d to the specified torque.
specified torque.
10-11
0
h
a
1
Water inlet cover bolt h:
2 N·m (0.2 kgf·m, 1.5 ft·lb) 2
Checking the gear oil level
1. Check the gear oil level. See “Checking
the gear oil level” (10-5). 3
Replacing the OCV filter
1. Remove the OCV assemblies.
2. Replace the OCV filter a of each OCV

4
assembly.
5
6
a
7
3. Install the OCV assemblies.
Lubricating the outboard motor 8

1. Apply water resistant grease to the spec-
ified lubrication points.
9
10
A
10-12
MNT
Maintenance
2. Apply low temperature resistant grease 2. Remove the reservoir cap b and O-ring
to the specified lubrication points. c, and then check the fluid level in the
reservoir. WARNING! Before removing
the reservoir cap, make sure that the
PTT rams are fully extended.
Otherwise, fluid could be expelled
forcefully from the unit due to internal
pressure.
3. Apply corrosion resistant grease to the

specified lubrication points.
b c
TIP:
If the fluid is at the proper level, a small
amount of fluid should flow out of the filler
hole when the reservoir cap is removed.
3. If the fluid is below the proper level, add

Checking the propeller the recommended fluid.
1. Check the propeller. See “Checking the
propeller” (8-3). Recommended PTT fluid: ATF DEXRON II
4. Install a new O-ring and the reservoir cap

Checking the PTT fluid level
b, and then tighten the reservoir cap b
Never get under the outboard motor while a new one.
it is tilted.
Reservoir cap b:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
1. Fully tilt the outboard motor up, and then
10-13
Checking the PTT operation
1. Fully tilt the outboard motor up and down a a
a few times and check that the outboard
motor tilts up and down smoothly. Check
the PTT fluid level if the tilt operation is 0
not smooth.
b
2. Check the PTT unit for fluid leakage.
b 1
Checking the spark plug
1. Check the spark plugs. See “Checking
TIP:
the spark plug” (7-48).
• To loosen the fitting, move the stopper b in 2
Checking the timing belt direction a.
• To tighten the fitting, move the stopper b in
1. Check the timing belt. See “Checking the
timing belt” (7-39).
direction b.
3
Replacing the timing belt 4. Tighten the nut a.
1. Replace the timing belt. See “Timing belt”
(7-37). 5. Recheck the fitting. Replace the rubber
seal of the bottom cowling if the free play
4
Checking the thermostat cannot be adjusted.
1. Check the thermostat. See “Checking the
thermostat” (7-72). Checking the valve clearance
1. Check the valve clearance. See “Check-
5
Checking the top cowling ing the valve clearance” (7-2).
1. Check the fitting by pushing the top cowl-
ing. Adjust if there is free play. Checking the water pump 6
1. Check the water pump housing and
impeller. See “Checking the water pump
and shift rod” (8-12).
7
8
2. Loosen the nut a.

9
3. Move the stopper b up or down slightly
to adjust its position.
10
A
10-14
Index i
Index
A. Bottom cowling .................................. 5-8, 5-16

Bracket unit........................................ 1-5, 1-28
Abbreviation ................................................0-5
Bracket unit technical data ....................... 1-25
Active test ...................................................4-3 Break-in .................................................... 10-7
Adjusting the forward gear shim (T1)
thickness .................................................8-54
Adjusting the reverse gear shim (T1) C.
thickness .................................................8-95 Calculated value (B) table ............... 8-46, 8-88
Adjusting the reverse gear shim (T2) Camshaft .................................................. 7-42
thickness ........................................8-57, 8-91 Canister .................................................... 6-25
Adjusting the trim sensor ..........................9-29 Changing the engine oil............................ 10-8
Adjusting the valve clearance .....................7-4 Changing the gear oil ............................. 10-10
After test run .............................................10-7 Charging system.............................. 1-14, 2-18
Assembling the cylinder block...................7-90 Charging unit and starting unit....................A-9
Assembling the cylinder head ...................7-60 Charging units and component................. 5-40
Assembling the drive shaft...............8-25, 8-78 Checking the air pressure sensor............. 5-49
Assembling the forward gear ....................8-27 Checking the air temperature sensor ....... 5-48
Assembling the fuel filter assembly...........6-12 Checking the anode.................................. 10-7
Assembling the gear pump assembly .......9-49 Checking the armature (PTT motor)......... 9-41
Assembling the lower case ..............8-27, 8-79 Checking the armature (starter motor) ..... 5-60
Assembling the oil pan and exhaust Checking the battery........................ 10-3, 10-7
manifold ..................................................9-20 Checking the brush................................... 9-41
Assembling the oil pump assembly...........7-67 Checking the brush holder........................ 5-61
Assembling the oil seal housing.......8-28, 8-79 Checking the cam position sensor............ 5-29
Assembling the Checking the camshaft ............................. 7-47
propeller .......................... 8-4, 8-8, 8-64, 8-67 Checking the canister ............................... 6-26
Assembling the propeller shaft Checking the canister check valve ........... 6-26
assembly.................................................8-18 Checking the check valve ......................... 6-40
Assembling the propeller shaft housing Checking the clamp bracket anode .......... 9-27
assembly.................................................8-19 Checking the communication between
Assembling the propeller shaft housing the engine and the Digital
assembly and forward gear.....................8-74 Electronic Control ................................... 10-4
Assembling the PTT motor .......................9-42 Checking the compression pressure .......... 7-1
Assembling the reverse gear ...........8-19, 8-78 Checking the connecting rod big end side
Assembling the shift actuator assembly....7-35 clearance ................................................ 7-80
Assembling the starter motor ....................5-61 Checking the connecting rod small end inside
Assembling the tilt ram..............................9-55 diameter and big end inside diameter .... 7-80
Assembling the trim ram ...........................9-56 Checking the cooling water passage ........ 10-7
Assembling the upper case.......................9-16 Checking the cooling water pilot hole ....... 10-3
Assembling the vapor separator ...............6-40 Checking the crankcase bolt .................... 7-81
Assembling the water pump Checking the crankpin oil clearance......... 7-82
housing ..........................................8-12, 8-70 Checking the crankshaft ........................... 7-81
Asynchronous fuel injection ........................2-7 Checking the crankshaft journal oil
clearance ................................................ 7-86
B. Checking the cylinder block anode ........... 7-90
Checking the cylinder bore ....................... 7-78
Basic ignition timing ....................................2-9 Checking the cylinder head ...................... 7-55
Battery installation.....................................3-15 Checking the cylinder head anode ........... 7-60
Battery requirement ....................................1-7
Checking the cylinder head bolt ............... 7-56
Battery wiring with house (accessory) Checking the dog clutch .................. 8-18, 8-74
battery .....................................................3-17 Checking the drive shaft .................. 8-25, 8-78
Battery wiring without house (accessory)
Checking the drive shaft bushing ............. 9-16
battery .....................................................3-15 Checking the electrical component........... 5-21
Bleeding the PTT unit ...............................9-35 Checking the engine ECM circuit ............. 5-23
i-1
Index
Checking the engine idle speed................10-8 Checking the main wiring harness............ 5-65
Checking the engine oil level ...........10-4, 10-9 Checking the OCV.................................... 5-32
Checking the engine shut-off switch .........5-52 Checking the oil cooler ............................. 7-67
Checking the engine start switch and Checking the oil cooler anode .................. 7-67
engine shut-off switch (single outboard
motor application) ........................10-5, 10-10
Checking the oil pan and exhaust
manifold .................................................. 9-20
0
Checking the engine start switch and main Checking the oil pressure ........................... 7-1
switch ......................................................5-53 Checking the oil pressure sensor ............. 5-33
Checking the engine start/stop button ......5-54
Checking the engine start/stop button and
Checking the oil pump assembly.............. 7-67
Checking the oil strainer ........................... 9-20
1
engine shut-off switch (twin or triple outboard Checking the outboard motor mounting
motor application) ........................10-5, 10-10 height...................................................... 10-6
Checking the engine temperature
sensor .....................................................5-50
Checking the pinion ......................... 8-25, 8-78
Checking the piston diameter ................... 7-78
2
Checking the ETV .....................................6-23 Checking the piston pin boss inside
Checking the ETV (TPS) circuit ................5-25 diameter.................................................. 7-79
Checking the ETV and TPS ......................5-24
Checking the ETV motor relay ..................5-25
Checking the piston pin diameter ............. 7-80
Checking the piston ring ........................... 7-78
3
Checking the exhaust guide anode...........9-16 Checking the piston ring end gap ............. 7-79
Checking the extension wiring harness ....5-65 Checking the piston ring groove ............... 7-79
Checking the forward gear...............8-25, 8-74
Checking the fuel cup assembly ...............6-12
Checking the piston ring side clearance... 7-79
Checking the pressure regulator ................ 6-8
5
Checking the fuel filter ............................10-10 Checking the primer pump ....................... 6-30
Checking the fuel filter assembly ..............6-11 Checking the
Checking the fuel filter element.................6-12
Checking the fuel injector..........................5-35
propeller............... 8-3, 8-8, 8-64, 8-67, 10-13
Checking the propeller shaft............ 8-18, 8-74
6
Checking the fuel rail ................................6-44 Checking the propeller shaft
Checking the fuel system..........................10-5 housing .......................................... 8-18, 8-74
Checking the fuel system for fuel
leakage .................................................10-10
Checking the PTT fluid level................... 10-13
Checking the PTT operation ................... 10-14
7
Checking the gear oil level.............10-5, 10-12 Checking the PTT relay ............................ 5-66
Checking the gear pump...........................9-48 Checking the PTT switch
Checking the gear shift and throttle
operation .................................................10-6
(bottom cowling) ..................................... 5-68
Checking the PTT system ........................ 10-6
8
Checking the high-pressure fuel pump .....6-40 Checking the pulser coil ........................... 5-47
Checking the high-pressure fuel pump Checking the pulser coil air gap ................. 7-1
relay ........................................................5-38
Checking the hydraulic pressure...............9-33
Checking the Rectifier Regulator .............. 5-42
Checking the reverse gear .............. 8-18, 8-78
9
Checking the ignition coil ..........................5-46 Checking the shift actuator ....................... 5-27
Checking the ignition spark.......................5-45 Checking the shift actuator relay .............. 5-27
Checking the intake manifold....................6-16
Checking the knock sensor.......................5-52
Checking the spark plug ................ 7-48, 10-14
Checking the speed sensor ...................... 5-64
10
Checking the lighting coil Checking the sprocket .............................. 7-47
(stator assembly) ....................................5-40 Checking the SPS .................................... 5-26
Checking the lower case..................8-25, 8-78
Checking the lower unit
Checking the SPS and shift actuator
circuit ...................................................... 5-28
10
anode .............................. 8-4, 8-8, 8-64, 8-67 Checking the starter motor operation ....... 5-58
Checking the lower unit for air Checking the starter motor pinion............. 5-58
leakage ..........................................8-32, 8-80 Checking the starter relay......................... 5-53
Checking the low-pressure fuel pump.......6-30 Checking the steering system .................. 10-6
Checking the low-pressure fuel pump and Checking the thermostat................ 7-72, 10-14
high-pressure fuel pump .........................5-37 Checking the thermoswitch ...................... 5-51
Checking the magnet switch .....................5-58
Checking the main relay ...........................5-22
Checking the tilt cylinder and PTT body ... 9-54
Checking the timing belt ................ 7-39, 10-14
A
i-2
Index
Checking the top cowling ........................10-14 Disassembling the lower case ......... 8-25, 8-78
Checking the trim sensor ..........................5-69 Disassembling the oil pan and exhaust
Checking the valve...........................7-56, 9-54 manifold .................................................. 9-20
Checking the valve clearance ..........7-2, 10-14 Disassembling the oil pump assembly ..... 7-66
Checking the valve guide..........................7-57 Disassembling the oil seal
Checking the valve lifter............................7-47 housing .......................................... 8-23, 8-78
Checking the valve seat............................7-58 Disassembling the
Checking the valve spring.........................7-56 propeller...........................8-3, 8-8, 8-64, 8-67
Checking the vapor separator...................6-40 Disassembling the propeller shaft
Checking the vapor shut-off valve....5-39, 6-36 assembly ................................................ 8-17
Checking the water detection switch.........5-34 Disassembling the propeller shaft housing
Checking the water pressure sensor assembly ....................................... 8-17, 8-73
(optional) .................................................5-63 Disassembling the PTT motor .................. 9-40
Checking the water pump .......................10-14 Disassembling the reverse gear ...... 8-17, 8-78
Checking the water pump and shift rod ...8-12, Disassembling the shift actuator
8-70 assembly ................................................ 7-35
Checking Y-COP.......................................5-54 Disassembling the starter motor ............... 5-59
Circuit diagram..........................................5-17 Disassembling the tilt ram ........................ 9-53
Clamp bracket.............................................3-3 Disassembling the trim ram ...................... 9-54
Clamp bracket and swivel bracket ............9-25 Disassembling the upper case ................. 9-16
Connecting the communication cable to the Disassembling the vapor separator .......... 6-39
outboard motor..........................................4-4 Disassembling the water pump
Cooling diagram........................................2-29 housing .......................................... 8-11, 8-70
Cooling system .........................................2-29 Disassembly and assembly ........................ 0-3
Cooling water hose .....................................6-4 Disconnecting the quick connector............. 6-6
Cowling lock lever .......................................9-3 Double taper roller bearing ....................... 2-32
Crankcase assembly.................................1-21 Draining the fuel ....................................... 6-35
Crankpin bearing selection table...............7-85 Drive shaft and lower case (counter rotation
Crankshaft journal bearing selection model)..................................................... 8-76
table ........................................................7-89 Drive shaft and lower case (regular rotation
Crate top cover pictograph description .......3-4 model)..................................................... 8-21
Cylinder block ...........................................7-75
Cylinder block sensor and switch..............7-70 E.
Cylinder head............................................7-53
ECM coupler layout .................................. 5-19
Cylinder head assembly............................1-19
ECM record data graph .............................. 4-3
Electric shock ............................................. 0-1
D. Electrical component .................................. 5-1
Data logger .................................................4-3 Electrical system technical data ................. 1-8
Diagnosis ....................................................4-2 Electronic control system............................ 2-1
Diagnosis record .........................................4-2 Electronic fuel injection control ................... 2-5
Digital Electronic Control component........2-20 Electronic shift control system .................. 2-15
Digital Electronic Control system Engine control unit......................................A-3
reset .................................................3-29, 4-3 Engine control units and components ...... 5-22
Digital network control...............................2-19 Engine ECM ............................................. 7-32
Digital network system diagram ................3-21 Engine ECM component............................. 2-2
Dimension ...................................................3-2 Engine monitor ........................................... 4-2
Dimension and weight.................................1-3 Engine speed control................................ 2-12
Disassembling the cylinder block..............7-77 Engine speed control system ................... 1-11
Disassembling the cylinder head ..............7-55 ETV control............................................... 2-14
Disassembling the drive shaft ..........8-23, 8-78 Extension length recommendation of battery
Disassembling the forward gear ......8-24, 8-73 cable ....................................................... 3-30
Disassembling the fuel filter assembly......6-12 Exterior: F(L)225F, F(L)250D, F(L)300B .... 3-2
Disassembling the gear pump housing.....9-48
i-3
Index
F. Installing the canister................................ 6-27

Installing the clamp bracket ...................... 9-27
Fail-safe control ........................................2-16
Installing the cowling lock lever .................. 9-6
Feature........................................................4-1 Installing the cylinder head ....................... 7-62
Flywheel magnet.......................................7-14
Forward gear shim (T1) selection table ....8-56
Installing the Digital Electronic Control box and
switch panel............................................ 3-12
0
Forward gear shim (T2) selection Installing the drive shaft................... 8-28, 8-79
chart ........................................................8-93 Installing the engine ECM......................... 7-33
Front...................................................5-6, 5-14
Fuel and oil requirement .............................1-6
Installing the flushing hose ......................... 9-5
Installing the flywheel magnet .................. 7-15
1
Fuel control unit and components.............5-34 Installing the fuel filter assembly............... 6-12
Fuel diagram .............................................2-26
Installing the fuel injector .......................... 6-44
Fuel filter assembly .....................................6-9
Fuel hose and blowby hose ........................6-1
Installing the intake manifold .................... 6-16
Installing the intake silencer ..................... 6-18
2
Fuel injection amount compensation ..........2-7
Installing the isolator lead ......................... 3-10
Fuel injection control system.....................1-10 Installing the junction box ......................... 7-28
Fuel injector ..............................................6-43
Fuel injector anti-sticking control.................2-7
Installing the knock sensor ....................... 7-73
Installing the lower unit
3
Fuel system..................... 1-17, 1-26, 2-26, 6-6 (U-transom model)......................... 8-34, 8-80
Fuel system technical data .......................1-17 Installing the lower unit
Fuel unit ..................................................... A-5
Function ......................................................4-2
(X-transom model)......................... 8-33, 8-80
Installing the low-pressure fuel pump ....... 6-31
5
Fuse box ...................................................7-24 Installing the main harness......................... 3-8
Fuse holder .................................................5-3 Installing the oil cooler .............................. 7-68
G.
Installing the oil filter bracket .................... 7-69
Installing the oil pump assembly............... 7-68
6
Gauge/sensor ...........................................1-15 Installing the power unit............................ 7-10
General feature ...........................................1-1 Installing the propeller shaft housing
General Periodic Maintenance..................10-7
General tightening torque .........................1-30
assembly ....................................... 8-29, 8-79
Installing the PTT motor ........................... 9-43
7
Installing the PTT switch............................. 9-9
Installing the PTT unit............................... 9-36
H.
Handling of gas torch ..................................0-2
Installing the pulley bracket ...................... 7-73
Installing the Rectifier Regulator............... 7-29
8
Handling of gasoline ...................................0-1 Installing the reservoir .............................. 9-43
Handling of sealant .....................................0-3 Installing the rigging grommet .................... 3-9
Hardware requirement ................................4-1
Hose routing................................................6-1
Installing the shift actuator assembly........ 7-35
Installing the shift rod....................... 8-31, 8-80
9
Hot part .......................................................0-1 Installing the shift rod and SPS .................. 9-2
How to use this manual...............................0-4 Installing the speed sensor....................... 3-11
I.
Installing the starter motor ............... 5-63, 7-31
Installing the steering arm ........................ 9-23
10
Ignition timing compensation ......................2-9 Installing the thermostat ........................... 7-73
Ignition timing control ..................................2-8 Installing the throttle body and
Ignition timing control system......................1-8
Ignition timing restriction .............................2-9
surge tank............................................... 6-23
Installing the tilt cylinder ........................... 9-56
10
Ignition unit................................................. A-7 Installing the tilt ram.................................. 9-57
Ignition units and components ..................5-45 Installing the timing belt ............................ 7-39
Install the forward gear .............................8-28 Installing the trim ram ............................... 9-56
Install the reverse gear .............................8-79 Installing the upper case........................... 9-12
Installing the battery cable ..........................3-9 Installing the vapor separator ................... 6-36
Installing the camshaft and driven Installing the water pressure sensor......... 3-10
sprocket ..................................................7-48 Installing the water pump................. 8-31, 8-80
Installing the wiring harness ..................... 7-20
A
i-4
Index
Installing Y-COP (optional in non-European Model designation ...................................... 1-2
markets) ..................................................3-12 Model features............................................ 1-1
Intake and exhaust diagram......................2-31
Intake and exhaust system .......................2-31 N.
Intake manifold..........................................6-14
Non-reusable part....................................... 0-3
J. O.
Junction box..............................................7-25
Oil cooler .................................................. 2-25
Oil cooler and oil pump assembly............. 7-63
K. Oil pan and exhaust manifold ................... 9-18
Knock control ............................................2-11 Optional equipment .................................. 3-10
Outboard motor and Digital Electronic
L. Control connection.................................. 5-65
Outboard motor installation ........................ 3-1
Low oil pressure control ............................2-12
Outboard motor mounting........................... 3-6
Lower unit ..........................................1-5, 2-32
Outline ...................................................... 10-1
Lower unit (counter rotation model) ..........1-28
Overheat control ....................................... 2-12
Lower unit (counter rotation model, U-transom
model) .....................................................8-65
Lower unit (counter rotation model, X-transom P.
model) .....................................................8-62 Part, lubricant, and sealant......................... 0-2
Lower unit (regular rotation model) ...........1-27 Performance ............................................... 1-3
Lower unit (regular rotation model, U-transom Pinion shim (T3) selection table ...... 8-47, 8-88
model) .......................................................8-6 Port ...................................................... 5-1, 5-9
Lower unit (regular rotation model, X-transom Power unit.................................1-4, 1-18, 1-26
model) .......................................................8-1 Power unit (check and adjustment) ............ 7-1
Lower unit assembly Power unit assembly .................................. 7-6
(counter rotation model)..........................1-24 Power unit system .................................... 2-23
Lower unit assembly Power unit technical data ......................... 1-18
(regular rotation model)...........................1-24 Predelivery check ..................................... 10-3
Lower unit technical data ..........................1-24 Propeller ............................................ 0-1, 2-33
Low-pressure fuel pump ...........................6-29 Propeller selection .................................... 3-32
Lubricant, sealant, and thread locking Propeller shaft bearing
agent .........................................................0-7 (regular rotation model) .......................... 2-32
Lubricating the outboard motor ...............10-12 Propeller shaft housing
Lubrication diagram ..................................2-28 (counter rotation model) ......................... 8-71
Lubrication system ....................................2-28 Propeller shaft housing
(regular rotation model) .......................... 8-14
M. Propeller shaft shim (T4) selection
table........................................................ 8-90
Maintenance interval chart 1.....................10-1
Propeller size............................................ 3-32
Maintenance interval chart 2.....................10-2
PTT cylinder ............................................. 9-51
Manual format .............................................0-4
PTT electrical system ............................... 5-66
Measuring the forward gear
PTT fluid requirement ................................. 1-7
backlash.........................................8-54, 8-91
PTT gear pump......................................... 9-45
PTT motor................................................. 9-38
reverse gear backlash before
PTT switch and bottom cowling.................. 9-7
disassembly ...................................8-39, 8-84
PTT system ..................................... 1-13, 1-25
Measuring the fuel pressure .......................6-7
PTT unit ................................. 1-29, 9-31, A-11
Measuring the peak voltage......................5-21
Measuring the reverse gear
backlash.........................................8-57, 8-95 R.
Model data ..................................................1-3 Rear................................................... 5-5, 5-13
i-5
Index
Reducing the fuel pressure .........................6-6 Reverse gear shim (T1) selection
Refacing the valve seat.............................7-59 table........................................................ 8-97
Registering the receiver ID to the ECM ....3-12 Reverse gear shim (T2) selection chart.... 8-59
Removing the canister ..............................6-26 Rigging grommet description ...................... 3-8
Removing the clamp bracket ....................9-27
Removing the cowling lock lever.................9-5
Rigging grommet mounting ........................ 3-8
Rigging information................................... 1-26
0
Removing the cylinder head .....................7-55 Rigging recommendations........................ 3-30
Removing the drive shaft .................8-23, 8-78 Rotating part ............................................... 0-1
Removing the driven sprocket and
camshaft .................................................7-45 S.
1
Removing the engine ECM .......................7-33
Safety while working................................... 0-1
Removing the flushing hose........................9-5
Removing the flywheel magnet.................7-15
Removing the forward gear.......................8-23
Selecting the crankpin bearing ................. 7-83
Selecting the crankshaft journal 2
bearing.................................................... 7-87
Removing the fuel filter assembly .............6-11
Selecting the pinion shim (T3) ......... 8-43, 8-88
Removing the fuel injector ........................6-44
Removing the intake manifold...................6-15
Removing the intake silencer....................6-15
Selecting the propeller shaft
shim (T4) ....................................... 8-61, 8-88 3
Selection................................................... 3-32
Removing the junction box........................7-28
Self-protection ............................................ 0-2
Removing the knock sensor......................7-72
Removing the lower unit ... 8-3, 8-8, 8-64, 8-67
Removing the low-pressure fuel pump .....6-30
Sensor, switch, and actuator ...................... 2-3
Sensor,switch ........................................... 2-21 5
Serial number ............................................. 1-2
Removing the oil cooler ............................7-66
Shift actuator ................................... 1-13, 7-34
Removing the oil filter bracket...................7-66
Removing the oil pump assembly .............7-66
Removing the power unit ............................7-8
Shift rod and SPS ....................................... 9-1
Shim location ................................... 8-42, 8-87 6
Shimless valve lifter .................................. 2-24
Removing the propeller shaft housing
Shimming......................................... 8-42, 8-87
assembly........................................8-16, 8-73
Removing the PTT motor..........................9-40
Removing the PTT switch ...........................9-9
Shimming (counter rotation model) .......... 8-81
Shimming (regular rotation model) ........... 8-36 7
Shimming check sheet .................... 8-37, 8-82
Removing the PTT unit .............................9-32
Shimming workflow.......................... 8-36, 8-81
Removing the pulley bracket.....................7-72
Removing the Rectifier Regulator .............7-28
Removing the reservoir.............................9-40
Single outboard motor application ............ 3-21
Skip-firing control...................................... 2-13
Sleeveless cylinder................................... 2-24
8
Removing the reverse gear.......................8-78
Special service tool.............................. 0-3, 0-9
Removing the shift actuator assembly ......7-35
Removing the shift rod and SPS.................9-2
Removing the starter motor .............5-58, 7-31
Specified tightening torque ....................... 1-26
Starboard........................................... 5-2, 5-10
Starter motor.................................... 5-56, 7-30
9
Removing the steering arm.......................9-23
Starting system ......................................... 1-14
Removing the thermostat..........................7-72
Removing the throttle body and
surge tank ...............................................6-22
Starting units and component................... 5-53
Stationary test............................................. 4-2
Steering arm ............................................. 9-22
10
Removing the tilt ram ................................9-53
Symbol........................................................ 0-7
Removing the timing belt ..........................7-38
Removing the trim ram..............................9-53
Removing the upper case .........................9-12
Synchronous fuel injection.......................... 2-6
10
Removing the vapor separator..................6-35 T.
Removing the water pump and Test run .................................................... 10-6
shift rod ..........................................8-11, 8-70 Throttle body............................................. 6-20
Removing the wiring harness....................7-18 Tightening torque........................................ 0-3
Replacing the OCV filter .........................10-12 Timing belt ................................................ 7-37
Replacing the oil filter................................10-9 Top .................................................... 5-7, 5-15
Replacing the timing belt.........................10-14
Replacing the valve guide.........................7-57
Triple outboard motor application ............. 3-26
Trouble code and checking step................. 4-8
A
i-6
Index
Trouble code table ......................................4-6
Troubleshooting procedure .........................4-5
Troubleshooting the lower unit..................4-36
Troubleshooting the power unit...................4-5
Troubleshooting the power unit (trouble code
not detected) ...........................................4-29
Troubleshooting the power unit using the
YDIS..........................................................4-5
Troubleshooting the PTT unit....................4-35
Twin outboard motor application...............3-23
U.
Uncrating procedure ...................................3-5
Upper case................................................9-15
Upper case and mount..............................9-10
Using the digital tester ..............................5-22
Using the YDIS .........................................5-21
V.
Vapor gas hose...........................................6-2
Vapor separator ........................................6-33
Vapor separator and high-pressure fuel
pump .......................................................6-37
VCT control ...............................................2-10
VCT system ..............................................1-12
Ventilation ...................................................0-1
W.
Water pump and shift rod (counter rotation
model) .....................................................8-68
Water pump and shift rod (regular rotation
model) .......................................................8-9
Wiring harness ..........................................7-17
Wiring harness routing ................................5-9
Working with crane .....................................0-2
Y.
Y-COP.......................................................2-22
YDIS............................................................4-1
6.
6Y9 Multifunction Color Gauge
sensor .....................................................5-63
i-7
Appendix A
Wiring diagram ................................................................. A-2

How to use the wiring diagram ................................................. A-2
Engine control unit .................................................................... A-3
0
Fuel unit .................................................................................... A-5
Ignition unit ............................................................................... A-7
Charging unit and starting unit ................................................. A-9
PTT unit .................................................................................. A-11
1
2
3
5
6
7
8
9
10
10
10
A
— MEMO —
A-1
Wiring diagram
How to use the wiring diagram
Composition of the wiring diagrams
The wiring diagram consists of five categories. The engine control unit, fuel unit, ignition unit, charg-
ing unit and starting unit, and PTT unit.
0
Legend symbols in the wiring diagrams
a b c d e 1
BZ
a Double colors wire
2
b No wire connector
c A wire is not included in the selected wiring unit.
d Alert buzzer
e Optional parts
3
Color code
B : Black Pu : Purple 5
B/Br : Black/Brown Pu/B : Purple/Black
B/G : Black/Green Pu/G : Purple/Black
B/L
B/O
: Black/Blue
: Black/Orange
Pu/G
Pu/L
: Purple/Green
: Purple/Blue
6
B/W : Black/White Pu/R : Purple/Red
Pu/W : Purple/White
B/Y
Br
: Black/Yellow
: Brown Pu/Y : Purple/Yellow 7
G : Green R : Red
G/B : Green/Black R/G : Red/Green
G/R : Green/Red R/Y
Sb
: Red/Yellow
: Sky blue
8
L : Blue
L/B : Blue/Black W : White
L/G
L/W
: Blue/Green
: Blue/White
W/B
W/G
: White/Black
: White/Green
9
Lg : Light green W/L : White/Blue
W/R : White/Red
O
P
: Orange
: Pink Y : Yellow 10
P/G : Pink/Green Y/G : Yellow/Green
P/W : Pink/White
10
10
A
A-2
Engine control unit
a Fuse (30 A) (starter relay)
b Fuse (15 A) (high-pressure fuel pump)
c Fuse (10 A) (ETV)
d Fuse (15 A) (shift actuator)
e Fuse (30 A) (ignition coil, VCT, fuel injector, engine ECM)
f Fuse (10 A) (low-pressure fuel pump)
g Fuse (20 A) (engine start switch, PTT switch, Digital Electronic Control ECM, high-pressure fuel
pump)
h Fuse (100 A) (engine battery)
k Fuse (100 A) (house [accessory] battery)
m Starter motor relay
n Fuel pump relay (high-pressure)
p ETV motor relay
r Shift actuator relay
s Main relay
t Fuse (100 A) (house [accessory] battery) (optional)
u Condenser (connect to cam position sensor)
v Condenser (connect to cam position sensor)
A To Digital Electronic Control

B To 6Y9 Multifunction Color Gauge hub
C To YDIS
A-3
YAMAHA MOTOR CO., LTD.
May 2010 – ** × 1 ABE

(E_1)
Engine control unit
Br Y W R B B
OFF Y
Br A B
ON P
a c d e
START W b
B
G 4 1
W
Y
R
R
Br
B
B
R 8 5 Fuse box
f s R
12 9 n p r
BZ 16 13 k
G
B Y
B
R
10
11
12
14
15
g Battery
2
3
6
7
8
9
W B m t
W
R
Y
R
R
L
L
B
B
B
SET
30
31
B
B PULL h R R B
32 G/B B House
W
34 G/R B (accessory)
B
Engine start switch battery
37 Y/G B
10
11
12
17
18
20
22
23
12
27 36 44 52
1
2
3
4
5
7
4
5
6
39 W/L
40 W/G 10 1 6 1
41 B 23 11 14 7
R
R
R
R
R
Br
Br
Y/G
Y/G
Y/G
Y/G
R/G
R/G
B
R/G
R/G
R/Y
R/Y
R/Y
R/Y
42 B
43 R/G
44 R/Y 1 13
R/Y 1
R/Y 2
47 W/B R/Y R/Y 3
48 L/B B 4
49 Pu B 5
50 Pu B B 6
51 R/G
52 R/Y
53 Y
55 W/B
R/Y 13
35 43 51 60 58 Y/G R/Y 14
R/Y 15
R/Y 16
61 Y/G R/Y 18
62 P/W 12 24
63 P
61 68 74 80 66 L
67 Y/G Joint connector 1
68 G/B
69 B
70 O
1 13
75 B
76 P/W B 7
77 B B 8
78 B B 9
79 O B 10
80 P/W B 11
81 O
67 73 79 86 82 O O 13
O 14
O 15
86 B
87 96 104 112
89 B
90 W 12 24
91 L
R/Y
92 W Joint connector 2
93 L
B
Engine ECM G/R
94
95 B B 1
u
B
B
B
B
1 13
99 B
B
B
B
B
B
B
B 6
L/B
P/W
G/R
G/B
P/W
O
B
B
L
10
11
O
W/G
P
B
1
2
3
4
5
6
7
8
9
O
R/Y
P
B
B
P/W
103
R/Y
W/L
B 10
R/Y
W/B
Pu
R/Y
O
B
G/R
G/B
B 11
B
B
W/B
12
R/Y
B
R/Y
Pu
B
95 103 111 120 111 R/G
12 1 O 17
B
116 O O 18
117 P
B
B
12 24
120 R/G C Water pressure
Cam position sensor
Shift actuator Joint connector 4
OCV (STBD) sensor
Cam position Oil pressure Cam position Speed sensor
sensor (STBD IN) SPS sensor ETV (TPS) OCV (PORT) (PORT IN) sensor (PORT EX) Joint connector 3
A-4
Fuel unit
c Fuse (10 A) (ETV)
g Fuse (20 A) (engine start switch, PTT switch, Digital Electronic Control ECM, high-pressure
fuel pump)
p ETV motor relay
s Main relay

A-5
Fuel unit
Br Y W R B B
Y
A B
OFF
Br 4 1
ON P c d e
B
START W
8 5
9
a b
12
G 16 13 R
W
Y
R
R
Br
B
B
R Fuse box
f s
n p r
BZ k
10
11
12
14
15
2
3
6
7
8
9
G
B Y
B Battery
W
R
Y
R
R
L
L
B
B
B
R
W B g t
m R R B
SET B
PULL B h House
B (accessory)
W B
battery
Engine start switch
27 36 44 52 37 Y/G 1 13
10
17
18
19
22
23
3
4
5
7
10 1
23 11
R
R
R
Y/G
Y/G
R
R
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
41 B
42 B
44 R/Y
6 1
14 7
R/Y 16
52 R/Y
53 Y R/Y 19
R/Y 20
R/Y 21
35 43 51 60 56 L/W R/Y 22 12 24
R/Y 23
58 Y/G R/Y 24 Joint connector 1
1 13
61 68 74 80
B 8
B 10
72 L/W
73 G/B
77 B
67 73 79 86
12 24
86 B Joint connector 2
87 Pu/R
88 Pu/B B 1
B 2
87 96 104 112 90 W 1 13
91 L
Engine ECM 92 W
93 L
96 Pu/Y
97 Pu/G
B
99 B B 12
B
B
B
B
B
B
B
R/Y
L/W
R/Y
G/B
R/Y
11
12
1
2
3
5
7
8
104 Pu/W
L/W
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
B
12 24
95 103 111 120
Joint connector 4
B
B
114 Pu/L 12 1
#1 #3 #5 #2 #4 #6
Fuel injector Water detection switch Low-pressure High-pressure Fuel injector

fuel pump fuel pump Joint connector 3
A-6
Ignition unit
c Fuse (10 A) (ETV)
fuel pump)
p ETV motor relay
s Main relay
u Condenser (connect to the air pressure sensor)

A-7
Ignition unit
Br Y W R B B B
OFF Y
Br
A
c d e
B
ON P
START W
a b
4 1 R
G 8 5
W
Y
R
R
Br
B
B
R 12 9 Fuse box
f s
16 13 n p r
BZ k
G
B Y
B Battery
10
11
12
14
15
2
3
4
5
6
7
8
9
R
g t 1 13
29 W/R W B m
W
W
W
R
Y
R
R
Br
L
L
B
B
B
R R B
27 36 44 52 SET
PULL h House
36 W B (accessory)
37 Y/G W B
38 Br B battery
Engine start switch B
41 B
42 B
10
16
18
22
23
3
4
5
R/Y 16
44 R/Y 10 1 R/Y 17
23 11
Y/G
R/Y
R/Y
R/Y
R/Y
R
R
R
R
R
6 1
14 7
12 24
52 R/Y Joint connector 1
35 43 51 60 53 Y
B 1
B 2 1 13
3
B 4
B 5
B 6
B 8
64 B/Y
61 68 74 80 65 B/Y
70 O R/Y 17
71 P R/Y 18
R/Y 19
R/Y 20
74 P/G R/Y 21 12 24
R/Y 22
R/Y 23
77 B Joint connector 2
67 73 79 86 1 13
83 G B 4
84 B B 5
86 B B 7
B 8
B 9
90 W B 12
91 L P 13
92 W P 14
Engine ECM 93 L P 15
87 96 104 112 O 16
O 18
98 B/W R/Y 20
99 B 12 24
100 B/L
101 B/Br
102 B/G Joint connector 4
O 1
B
B/Br
106 B/O P/G
B/W
B/G
B/Y
R/Y
R/Y
R/Y
B/O
R/Y
R/Y
R/Y
W/R
B/Y
B/L
B/Y
B
B
B
B
B 1
G
B
P/G
B 2
110 B/Y B 3
O
B
P
B
B 5
95 103 111 120 #1 #3 #5 #2 #4 #6 B 7
P
B
B
B 8
B
B
B
B 11
B
Air temperature Thermoswitch Knock sensor
sensor (STBD) 12
Pulser coil
Air pressure Engine temperature Joint connector 3
Ignition coil Ignition coil Thermoswitch (PORT)
sensor sensor
A-8
Charging unit and starting unit
c Fuse (10 A) (ETV)
fuel pump)
p ETV motor relay
s Main relay
t Fuse (100 A) (house [accessory] battery)

A-9
Charging unit and starting unit
R
R
Br Y W R B B
OFF Y
Br
ON P
START W A
G
c d e
W
Y
R
R
Br
B
B
R
4 1
a b
BZ 8 5
G 12 9
B B 13 f s
Y
16 n p r
R k
W B
10
11
12
14
15
2
3
6
7
8
9
SET
PULL g
m
W
R
Y
R
R
L
L
B
B
B
B
W
h
Engine start switch
B
27 36 44 52 B
B
10
17
22
23
3
4
5
9
37 Y/G
10 1
23 11
R
R
R
R
R
Br
Y/G
Y/G
R/Y
R/Y
41 B
42 B
44 R/Y
6 1
14 7
52 R/Y
53 Y
35 43 51 60
58 Y/G
B
61 68 74 80
B
R R
Br
Starter motor Battery
t
85 R
86 B R R B
67 73 79 86
House
90 W (accessory) Rectifier
87 96 104 112 91 L battery Regulator
92 W
93 L
R +1
R +2
G G
99 B Lighting coil G G AC 1
Engine ECM AC 1
G G AC 1
B
AC 2
B
B
B
B
B
B
G G AC 2
G G AC 2
1
2
3
5
7
8
G G
R +1
118 L/G R +2
95 103 111 120 B
R R R
L/G L/G L/G
12 1
B
B
B
B
B
Joint connector 3
A-10
PTT unit
c Fuse (10 A) (ETV)
fuel pump)
p ETV motor relay
s Main relay
u Diode (connect to PTT relay)

A-11
PTT unit
10 1
23 11
Br Y W R B B
OFF Y
a c d e
ON
Br b B
P
START W A
B
G f s
n p r
W
Y
R
R
Br
B
B
R
4 1
k R
BZ 8 5
G 12 9
B Y
B 16 13 g
R m Battery
W B
h t
10
11
12
14
15
2
3
6
7
8
9
SET
PULL R R B
W
R
Y
R
R
L
L
B
B
B
B House
W
(accessory)
Engine start switch battery
10
16
17
18
22
23
3
4
5
27 36 44 52 27 P B
B
R
R
R
R
R
Y/G
Y/G
R/Y
R/Y
R/Y
B 6 1 1 13
Y/G 14 7
37
41 B
42 B Lg 7
Lg 8
44 R/Y Lg 9
45 Sb Sb 10
Sb 11
Sb 12
52 R/Y
53 Y R/Y 16
35 43 51 60 54 Lg
Sb
Lg
12 24
58 Y/G
u
61 68 74 80 Joint connector 1
R
1 13
B 3
77 B
B 12
86 B
67 73 79 86
90 W R 19
87 96 104 112 91 L R 20 12 24
92 W R 21
93 L R 22
Joint connector 4
R
99 B
Engine ECM
Sb
Lg
B
B
B
B
B
B
112 Sb
113 Lg
1
2
3
5
7
8
Sb
Sb
Lg
Lg
P
B
R
95 103 111 120
12 1
B
B
B
B
PTT relay
PTT motor
Joint connector 3 PTT switch Trim sensor
A-12
A-13

SM F300B SM

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Copyright:

Available Formats

SM F300B SM

Uploaded by

Copyright:

Available Formats

F(L)225F

F(L)225F, F(L)250D, F(L)300B

Safety while working .................................................... 0-1

How to use this manual .................................................... 0-4 4

Lubricant, sealant, and thread locking agent ................. 0-7

Special service tool ........................................................... 0-9

Disassembly and assembly

• Install bearings so that the bearing identifi-

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

ThreeBond 1280B Sealant

ThreeBond 1303 Thread locking agent

ThreeBond 1303N Thread locking agent

ThreeBond 1322 Thread locking agent

ThreeBond 1377B Thread locking agent

Symbol Name Application

ThreeBond 1530D Sealant

Engine lifting eye Peak voltage adapter B

Drilling plate Test harness (3 pins)

YDIS (CD-ROM, Ver. 1.33) Vacuum/pressure pump gauge set

YDIS USB adapter and cable Test harness (1 pin)

Digital circuit tester Test harness (2 pins)

Fuel pressure gauge adapter Balance hanger

Valve spring compressor Valve seat cutter holder

Valve spring compressor attachment Valve seat cutter 30°

Valve guide remover/installer Valve seat cutter 45°

Valve guide reamer Valve seat cutter 60°

Oil filter wrench Needle bearing attachment

Ring nut wrench extension Ball bearing attachment

Ring nut wrench 6 Needle bearing attachment

Bearing housing puller claw L Bearing inner race attachment

Stopper guide plate Driver rod LL

Drive shaft holder 6 Bearing outer race attachment

Dial gauge set Puller head

Magnet base B Needle bearing attachment

Pinion shimming gauge Ring nut wrench

Pinion shimming gauge rod Bearing puller assembly

Tilt rod wrench

Model feature ..................................................................... 1-1

Model data ......................................................................... 1-3

Electrical system technical data ...................................... 1-8

Fuel system technical data ............................................ 1-17

Power unit technical data ............................................... 1-18

Lower unit technical data ............................................... 1-24

Bracket unit technical data ............................................ 1-25

Specified tightening torque ............................................ 1-26

a Power unit e Lower unit

PTT fluid requirement

Engine speed control system

Cylinder head assembly

Part to be tightened Screw size

Part to be tightened Screw size

Lower unit (regular rotation model)

Lower unit (counter rotation model) 3

Electronic control system ................................................ 2-1

Pressure regulator Filter

Cam position sensor

Cam position sensor

Cam position sensor

Air temperature sensor