F150a, B, F

F150A
FL150A
F150B
FL150B
SERVICE MANUAL
63P-28197-3P-12
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.
F150A, FL150A, F150B, FL150B

SERVICE MANUAL
©2013 by Yamaha Motor Co., Ltd.
2nd Edition, January 2013
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Contents
General information 0
Specification 1
Technical feature and description 2
Rigging information 3
Troubleshooting 4
Electrical system 5
Fuel system 6
Power unit 7
Lower unit 8
Bracket unit 9
Maintenance 10
Index
Appendix A
General information 0
Safety while working .................................................... 0-1

Rotating part .............................................................................. 0-1 0
Hot part ...................................................................................... 0-1
Electric shock ............................................................................ 0-1
Propeller .................................................................................... 0-1
Handling of gasoline .................................................................. 0-1
1
Ventilation .................................................................................. 0-1
Self-protection ........................................................................... 0-2
Working with crane .................................................................... 0-2
2
Handling of gas torch ................................................................ 0-2
Part, lubricant, and sealant ........................................................ 0-2
Handling of sealant .................................................................... 0-3 3
Special service tool ................................................................... 0-3
Tightening torque ...................................................................... 0-3
Non-reusable part ...................................................................... 0-3
Disassembly and assembly ....................................................... 0-3
4
How to use this manual .................................................... 0-4
Manual format ........................................................................... 0-4
5
Abbreviation .............................................................................. 0-5
Lubricant, sealant, and thread locking agent ................. 0-6 6

Symbol ...................................................................................... 0-6
Special service tool ........................................................... 0-8 7

8
9
10
A
Safety while working
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
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
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
How to use this manual
Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the following information as a guide for effective and quality service.
0
• Parts are shown and detailed in an exploded diagram and are listed in the component list (see “1”
in the following figure for an example page).
• The component list consists of part names and quantities, as well as bolt and screw dimensions
(see “2” in the following figure).
1
• Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
the lubrication points (see “3” in the following figure).
• Tightening torque specifications are provided in the exploded diagrams (see “4” in the following
figure), and in the related detailed instructions. Some torque specifications are listed in stages as
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 “5” in the following figure for an example page). 3
TIP:
For troubleshooting procedures, See Chapter 4, “Troubleshooting”.
4
3 4
1
5
Lower unit (regular rotation model, X-transom model)
2
1
10
9
8
8
9
7
43 N·m (4.3 kgf·m, 31.7 ft·lb)
12
13 0 6
7
1
55 N·m (5.5 kgf·m, 40.6 ft·lb)
Drive shaft and lower case (regular rotation model)
6 19
2
7
18
9 N·m (0.9 kgf·m, 6.6 ft·lb) 16
5 7 17
11 a When heating the lower case, heat the
14 20 entire installation area evenly. Otherwise,
5 4
7
15
3 3 the paint on the lower case could be
burned.
0
48 N·m (4.8 kgf·m, 35.4 ft·lb) 2
3
2
1
22
21
4 1
TIP:
Do not reuse a shim if deformed or
1
scratched.
8
23 Bearing outer race attachment “2”:
5
5 90890-06628
Driver rod LS “3”: 90890-06606
2
1
2
Installation depth “a”:
48 N·m (4.8 kgf·m, 35.4 ft·lb) 5
25
4 24
6 0.25–0.75 mm (0.010–0.030 in) 3
9 N·m (0.9 kgf·m, 6.6 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) 3. Install a new O-ring “1”.
7 1 4
9
No. Par t name Q’ty R em a r k s
1 Hose nipple 2
2
3
O -r i ng
Check screw
2
1
Not reusable
8 5
4 Gasket 2 Not reusable
5 B o lt 12 M10 × 45 mm 3. While holding the special service tool “1”,
6
7
Extension
Dowel
1
4 9 strike the tool to check that the taper
roller bearing outer race is installed prop-
6
8 Cover 2 Assembling the lower case erly.
9 Seal 2
10
11
12
13
14
Water pipe
Water pipe
Grommet
Bolt
Lower unit
1
1
1
1
1
M10 × 45 mm
10 • Use heat-resistant gloves. Otherwise,
burns could result.
• To prevent fires, remove any flammable
substances, such as gasoline and oil,
TIP:
If a high-pitched metallic sound is produced
when the special service tool is struck, the
outer race is installed properly.
7
8
10
15 Spacer 1 around the working area.
16 Propeller 1 • Keep good ventilation while working.
17 Spacer 1 Except SDS propeller
A 1
9
1. Install the original forward gear shims “1”.
8-6 2. Heat the area of the lower case where
the taper roller bearing outer race is to be 1 10
installed using a gas torch, and then 2
install a new taper roller bearing outer
race “2”.
2
2
A
5 8-24
A
0-4
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
ABYC American Boat and Yacht Council
API American Petroleum Institute
ATF Automatic Transmission Fluid
AWG American Wire Gauge
CCA Cold Cranking Ampere
DN Down side
DOHC Double Overhead Camshaft
ECM Electronic Control Module
EN European Norm (European standard)
EX Exhaust
F Forward
ID Identification
IEC International Electrotechnical Commission
IN Intake
ISO International Organization for Standardization
ISC Idle Speed Control
N Neutral
PCV Pressure Control Valve
PORT Port side
PTT Power Trim and Tilt
R Reverse
RON Research Octane Number
SAE Society of Automotive Engineers
SDS Shift Dampener System
STBD Starboard side
TCI Transistor-Controlled Ignition
TDC Top Dead Center
TPS Throttle Position Sensor
UP Up side
Y-COP Yamaha Customer Outboard Protection
YDIS Yamaha Diagnostic System
0-5
Lubricant, sealant, and thread locking agent
Symbol
Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication
points.
Symbol Name Application
0
Yamaha 4-stroke motor oil Lubricant
1
Hypoid gear oil Lubricant
2
Water resistant grease
Lubricant
(Yamaha grease A)
Low temperature resistant grease

3
Lubricant
(Yamaha grease C)
Corrosion resistant grease

(Yamaha grease D)
Lubricant 4
Molybdenum disulfide grease Lubricant
5
WR-No.2 grease Lubricant
6
Symbols in an exploded diagram or illustration indicate the type of sealant or thread locking agent
and the application points.
Symbol Name Application 7
Gasket Maker Sealant
8
ThreeBond 1280B Sealant
ThreeBond 1303N Thread locking agent

9
ThreeBond 1322 Thread locking agent 10
ThreeBond 1377B Thread locking agent
ThreeBond 1386B Sealant

A
0-6
Symbol Name Application
ThreeBond 1401 Thread locking agent
ThreeBond 1530D Sealant
LOCTITE 271 (red) Thread locking agent
LOCTITE 242 (blue) Thread locking agent
LOCTITE 572 (white) Sealant
Silicone sealant Sealant
0-7
Special service tool
For all markets except U.S.A. and Canada.
Special service tools with part numbers 90890-06883 and FIM20000ME are distributed by the
Marine Service Division.
Special service tools with part numbers other than 90890-06883 and FIM20000ME are distributed 0
by the Parts Division.
Drilling plate
90890-06783
Peak voltage adapter B
90890-03172 1
2
YDIS 2 starter kit Test harness (3 pins)

3
90890-06883 90890-06869
4
***
******
******
5
Diagnostic flash Vacuum/pressure pump gauge set
90890-06873 90890-06945
6
7
Digital circuit tester Test harness (3 pins) 8
90890-03189 90890-06847
9
10
A
0-8
Test harness (3 pins) Fuel pressure gauge
90890-06846 90890-06753
Ignition tester (spark gap tester) Leakage tester

90890-06754 90890-06840
Test harness (2 pins) Small end bearing installer

90890-06792 90890-06528
Test harness (3 pins) Vacuum gauge

90890-06791 90890-03159
Test harness (2 pins) Fuel injection meter

90890-06867 FIM20000ME
0-9
Compression gauge Hydro puller kit
90890-03160 90890-06593
0
1
Compression gauge extension Valve spring compressor
90890-06563 90890-04019
2
3
Flywheel holder Valve spring compressor attachment
90890-06522 90890-06320 4
5
Flywheel stopper Valve guide remover/installer

6
90890-06598 90890-06801
7
8
Flywheel puller Valve guide installer
90890-06521 90890-06810
9
10
A
0-10
Valve guide reamer Valve seat cutter 60°
90890-06804 90890-06324
Valve lapper Valve seat cutter 30°

90890-04101 90890-06326
Valve seat cutter holder Oil filter wrench

90890-06316 90890-06830
Valve seat cutter 30° Driver rod L3

90890-06327 90890-06652
Valve seat cutter 45° Needle bearing attachment

90890-06325 90890-06611
0-11
Bearing separator Ring nut wrench extension
90890-06534 90890-06513
0
1
Gear puller Ring nut wrench 4
90890-06540 90890-06512
2
3
Piston ring compressor Bearing housing puller claw L
90890-05158 90890-06502 4
5
Needle bearing attachment Stopper guide plate

6
90890-06653 90890-06501
7
8
Shift rod socket Center bolt
90890-06681 90890-06504
9
10
A
0-12
Stopper guide stand Bearing inner race attachment
90890-06538 90890-06640
Bearing puller assembly Needle bearing attachment

90890-06535 90890-06654
Driver rod SS Drive shaft holder 6

90890-06604 90890-06520
Needle bearing attachment Pinion nut holder

90890-06610 90890-06715
Bearing depth plate Needle bearing attachment

90890-06603 90890-06608
0-13
Ball bearing attachment Bearing outer race attachment
90890-06636 90890-06619
0
1
Driver rod LL Ball bearing attachment
90890-06605 90890-06633
2
3
Needle bearing attachment Bearing outer race puller assembly
90890-06612 90890-06523 4
5
Bearing outer race attachment Backlash indicator

6
90890-06628 90890-06706
7
8
Driver rod LS Magnet base plate
90890-06606 90890-07003
9
10
A
0-14
Dial gauge set Needle bearing attachment
90890-01252 90890-06607
Magnet base B Ring nut wrench

90890-06844 90890-06578
Pinion height gauge Bearing inner race attachment

90890-06671 90890-06660
Slide hammer handle Ball bearing attachment

90890-06531 90890-06629
Puller head PTT hydraulic gauge adapter

90890-06514 90890-06863
0-15
Hydraulic pressure gauge
90890-06776/06800
0
1
Cylinder end screw wrench
90890-06591
2
3
Trim & tilt wrench
90890-06587 4
5
Power tilt wrench

6
90890-06560
7
8
PTT piston vice attachment
90890-06572
9
10
A
0-16
Specification 1
Model feature ..................................................................... 1-1

General feature ......................................................................... 1-1
Model name designation ........................................................... 1-2
Serial number ............................................................................ 1-3
Model data ......................................................................... 1-4

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

Ignition timing control system .................................................... 1-7
Fuel injection control system ..................................................... 1-8
Engine speed control system .................................................... 1-8
PTT system ............................................................................... 1-8
Charging system ....................................................................... 1-9
Starting system .......................................................................... 1-9
Y-COP (standard for European market and
optional for Oceanian market) ................................................... 1-9
Gauge/sensor .......................................................................... 1-10
Fuel system technical data ............................................ 1-11

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

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

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

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

Rigging information ................................................................. 1-17
Electrical system ..................................................................... 1-17
0
Fuel system ............................................................................. 1-17
Power unit ............................................................................... 1-18
Lower unit (regular rotation model) ......................................... 1-19
1
Lower unit (counter rotation model) ......................................... 1-19
Bracket unit ............................................................................. 1-19
PTT unit ................................................................................... 1-20 2
General tightening torque ........................................................ 1-20
3
4
5
6
7
8
9
10
A
Model feature
Model feature
General feature
F150A, FL150A, F150B, FL150B overall feature
• Electronic fuel injected, 4-stroke, L4, DOHC, 16-valve, 2670.0 cm3 (162.9 cu. in) engine
• Low exhaust emissions conform to EU regulations
• Y-COP (standard for European market and optional for Oceanian market)
• Tilt limiter (F150A, FL150A [optional for European and Oceanian markets])
a. Power unit
• Shimless valve lifter a
b
• Multi-point electronic fuel injection
• Offset cylinder
• 4 throttle valves
• Large intake silencer
• Blowby gas reburning system
• Fuel cooler
• Vapor gas treatment c
• Freshwater flushing device
• Speed sensor and water pressure sensor d
(optional)
b. Electrical
• Electronic fuel injection control
• Digital ignition control e
• Vapor shut-off valve control
• ISC (Idle Speed Control)
• Over-rev control
• Self-diagnosis system with flash indicator
and YDIS (New YDIS version 2.00 or later)
• Conventional or LAN gauges acceptable
• Fail-safe control
• Alert systems including low oil pressure,
overheat, and water detection
c. Bracket unit
• New PTT unit
d. Upper case
• Labyrinth idle exhaust system
• Water-sealed outer wall
e. Lower unit
• Direct shifting system (without shifter)
• Patented shift damper system (SDS propel-
ler)
1-1
Model feature
Model name designation
F 150 A E T L 0
1 2 3 4 5
None: 2-stroke 1
E: Enduro
F: 4-stroke
1 Model category
L: Counter rotating propeller
T: High thrust (4-stroke) 2
D: Twin rotating propeller
K: Kerosene
2 Output horsepower
Z: HPDI
Example: 6/9.9/75/150/250/300
3
3 Model generation A/B/C/D/F/G/H/J/L/N/P/Q/R/S/T/U/V/X/Y (Repeat from A)
Level 1: Starting method
M: Manual start 4
E: Electric start
W: Electric start with manual start
Level 2: Control method

5
None: Remote control without tiller handle
H: Tiller handle
4 Model variation
C: Remote control with tiller handle 6
Level 3: Trim and tilt method
None: Manual tilt
D: Hydraulic tilt 7
P: PT (Power tilt)
T: PT/T (Power trim and tilt)
Level 4: Lubrication system (2-stroke model) 8

None: Premixed fuel with oil model
O: Oil injection model
S (15 in)
L (20 in)
9
Transom height
5 Y (22.5 in)
(Drive shaft length)
X (25 in)
U (31 in) 10
A
1-2
Model feature
Serial number
The outboard motor serial number is indi-
cated on a label affixed to the port clamp
bracket.
3 1
2 4
YAMAHA MOTOR CO., LTD.
MADE IN JAPAN
PAYS D'ORIGINE JAPON
1. Model name
2. Approved model code
3. Transom height
4. Serial number
Approved Starting
Model name
model code serial No.
F150AET 63P 1106291–
FL150AET 64P 1013389–
F150BET 6BM 1001267–
FL150BET 6BN 1000213–
1-3
Model data
Model data
Dimension and weight
Overall length 862 mm (33.9 in)
Overall width
Overall height L
511 mm (20.1 in)
F150AET 1714 mm (67.5 in)
0
FL150AET 1714 mm (67.5 in)
Overall height X
Transom height L
1842 mm (72.5 in)
F150AET 516 mm (20.3 in) 1
FL150AET 516 mm (20.3 in)
Transom height X 643 mm (25.3 in)
Weight (SUS) L *1 F150AET 223.0 kg (492 lb)
FL150AET 223.0 kg (492 lb)
2
Weight (SUS) X *1 228.0 kg (503 lb)
*1.With SUS (stainless steel) propeller

3
Performance
Maximum output F150AET 110.3 kW at 5500 r/min (150 HP at
5500 r/min) 4
FL150AET 110.3 kW at 5500 r/min (150 HP at
5500 r/min)
F150BET 110.3 kW at 5000 r/min (150 HP at
5000 r/min)
5
FL150BET 110.3 kW at 5000 r/min (150 HP at
5000 r/min)
Full throttle operating range F150AET 5000–6000 r/min
FL150AET 5000–6000 r/min
6
F150BET 4500–5500 r/min
FL150BET 4500–5500 r/min
Maximum fuel consumption F150AET 58.4 L/h at 5500 r/min (15.4 US gal/h at 7
5500 r/min, 12.8 Imp.gal/h at 5500 r/min)
FL150AET 58.4 L/h at 5500 r/min (15.4 US gal/h
at 5500 r/min, 12.8 Imp.gal/h at 5500 r/min)
F150BET 55.3 L/h at 5000 r/min (14.6 US gal/h at 8
5000 r/min, 12.2 Imp.gal/h at 5000 r/min)
FL150BET 55.3 L/h at 5000 r/min (14.6 US gal/h
Engine idle speed

at 5000 r/min, 12.2 Imp.gal/h at 5000 r/min)
650–750 r/min
9
10
A
1-4
Model data
Power unit
Type 4-stroke, DOHC L
Cylinder quantity 4
Total displacement 2670.0 cm3 (162.9 cu. in)
Bore × stroke 94.0 × 96.2 mm (3.70 × 3.79 in)
Compression ratio 9.00 : 1
Control system Remote control
Starting system Electric starter
Fuel system Fuel injection
Ignition control system TCI
Advance type Microcomputer
Maximum generator output 36 A
Spark plug LFR5A-11
Firing order 1–3–4–2
Cooling system Water
Exhaust system Propeller boss
Lubrication system Wet sump
Lower unit
Gear positions F-N-R
Gear ratio 2.00 (28/14)
Gear type Spiral bevel gear
Clutch type Dog clutch
Propeller drive system Spline
Propeller direction F150AET Clockwise
FL150AET Counter clockwise
F150BET Clockwise
FL150BET Counter clockwise
Propeller mark F150AET M, T
FL150AET ML, TL
F150BET M, T
FL150BET ML, TL
Bracket unit
Trim angle –4 to 16 degrees at 12º boat transom
Tilt-up angle 70 degrees
Steering angle 35 + 35 degrees
Trim and tilt system PTT
1-5
Model data
Fuel and oil requirement
Recommended fuel Regular unleaded gasoline
Minimum fuel octane number RON 90
Recommended engine oil
Engine oil grade *1, *2
4-stroke motor oil
API SE, SF, SG, SH, SJ, SL
0
SAE 5W-30, 10W-30, 10W-40
Total engine oil quantity (oil pan capacity) *3 5.2 L (5.50 US qt, 4.58 Imp.qt)
Gear oil type
Gear oil grade *2
Hypoid gear oil
API GL-4
1
SAE 90
Gear oil quantity F150AET 0.980 L (1.036 US qt, 0.862 Imp.qt)
FL150AET 0.870 L (0.920 US qt, 0.766 Imp.qt) 2
F150BET 0.980 L (1.036 US qt, 0.862 Imp.qt)
FL150BET 0.870 L (0.920 US qt, 0.766 Imp.qt)
*1.If the recommended engine oil grades are not available, use engine oil with an API classification 3
of SH, SJ, or SL and an SAE classification of 15W-40, 20W-40, or 20W-50.
*2. Meeting both API and SAE requirements.
*3. For engine oil level when checking engine oil, see “Power unit technical data” (1-12).
4
Battery requirement
Minimum cold cranking amps
Minimum rated capacity
CCA/EN 711.0 A
20HR/IEC 100.0 Ah 5
PTT fluid requirement
Fluid type ATF Dexron II
6
7
8
9
10
A
1-6
Electrical technical data
Ignition timing control system
Spark plug
Gap 1.0–1.1 mm (0.039–0.043 in)
Spark plug wire
Resistance (#1) 4.6–10.9 kΩ at 20 °C (68 °F)
Ignition coil
Input voltage 12 V
Output peak voltage (reference data) 210.0 V at cranking (loaded)
260.0 V at 1500 r/min (loaded)
Primary coil resistance 1.530–2.070 Ω at 20 °C (68 °F)
Secondary coil resistance 12.50–16.91 kΩ at 20 °C (68 °F)
Pulser coil
Output peak voltage (reference data) 3.5 V at cranking (unloaded)
3.0 V at cranking (loaded)
Resistance 459.0–561.0 Ω at 20 °C (68 °F)
Air temperature sensor

Input voltage 4.75–5.25 V
Resistance (reference data) 2.2–2.7 kΩ at 20 °C (68 °F)
0.32 kΩ at 80 °C (176 °F)
Air pressure sensor

Output voltage 3.21 V at –20.0 kPa (–0.20 kgf/cm2, –2.9 psi)
2.16 V at –46.7 kPa (–0.467 kgf/cm2, –6.8 psi)
Engine temperature sensor

Resistance (reference data) 128.0 kΩ at 5 °C (41 °F)
54.20–69.00 kΩ at 20 °C (68 °F)
3.120–3.480 kΩ at 100 °C (212 °F)
Thermoswitch
Input voltage (reference data) 11.5 V
Switch ON temperature 84–90 °C (183–194 °F)
Switch OFF temperature 68–82 °C (154–180 °F)
Shift cut-off switch

Free position resistance (reference data) 4.465–4.935 kΩ at 20 °C (68 °F)
1-7
Shift position switch

Fuel injection control system 0

Water detection switch
Fuel injector
1
Input voltage 12 V
Resistance (reference data) 11.50–12.50 Ω at 20 °C (68 °F)
High-pressure fuel pump

2
Input voltage 12 V
Vapor shut-off valve

3
Input voltage 12 V
Resistance 30.0–34.0 Ω at 20 °C (68 °F)
4
Engine speed control system
TPS
Output voltage (reference data) 0.703 V with throttle valve fully closed 5
4.033 V with throttle valve fully open
Throttle valve opening angle (reference data) 0.1 degrees with throttle valve fully closed
Input voltage
83.2 degrees with throttle valve fully open
4.75–5.25 V
6
ISC valve
Input voltage
Oil pressure sensor

12 V
7
Output voltage (reference data) 2.5 V at 392.0 kPa (3.92 kgf/cm2, 56.8 psi)
4.5 V at 784.0 kPa (7.84 kgf/cm2, 113.7 psi) 8
PTT system
Trim sensor
9
Free position resistance (reference data) 239–379 Ω
Setting resistance 9.0–11.0 Ω
10
A
1-8
Charging system
Lighting coil
Output peak voltage (reference data) 11.0 V at cranking (unloaded)
50.0 V at 1500 r/min (unloaded)
110.0 V at 3500 r/min (unloaded)
Fuse 50.0 A
Rectifier Regulator
Output voltage 13 V at 1500 r/min (loaded)
13 V at 3500 r/min (loaded)
Starting system
Starter motor
Type Sliding gear
Output 1.40 kW
Cranking time limit 30 seconds
Commutator
Standard diameter 29.0 mm (1.14 in)
Wear limit 28.0 mm (1.10 in)
Standard undercut 0.8 mm (0.03 in)
Brush
Standard length 15.5 mm (0.61 in)
Y-COP (standard for European market and optional for Oceanian market)
Receiver
Input voltage 12 V
Buzzer
Input voltage 12 V
Button cell battery - CR2016

Battery voltage (reference data) 3V
1-9
Gauge/sensor
Water pressure sensor
Output voltage (reference data) 2.5 V at 392.0 kPa (3.92 kgf/cm2, 56.8 psi)
4.5 V at 784.0 kPa (7.84 kgf/cm2, 113.7 psi)
0
Speed sensor
Input voltage
Output voltage (reference data)
4.75–5.25 V
2.5 V at 392.0 kPa (3.92 kgf/cm2, 56.8 psi)
1
4.5 V at 784.0 kPa (7.84 kgf/cm2, 113.7 psi)
2
3
4
5
6
7
8
9
10
A
1-10
Fuel system technical data
Fuel system technical data
Fuel system
Fuel pressure (reference data)
300.0 kPa (3.00 kgf/cm2, 43.5 psi) within 3 sec-
onds after engine start switch turned to ON
260.0 kPa (2.60 kgf/cm2, 37.7 psi) at engine idle
speed
Fuel filter assembly

Fuel inlet holding pressure
(positive pressure) 200 kPa (2.0 kgf/cm2, 29.0 psi)
Fuel outlet holding pressure
(negative pressure) 80 kPa (0.8 kgf/cm2, 11.6 psi)
Primer pump
Fuel inlet holding pressure
(positive pressure) 166.7 kPa (1.67 kgf/cm2, 24.2 psi)
Throttle link
Roller clearance 0.50 mm (0.02 in)
Vapor separator tank

Float height 55.0–61.0 mm (2.2–2.4 in)
Canister
Holding pressure (positive pressure) 19.6 kPa (0.20 kgf/cm2, 2.8 psi)
1-11
Power unit technical data
Power unit
Compression pressure
Minimum (reference data) *1 880.0 kPa (8.80 kgf/cm2, 127.6 psi) 0
Engine oil
Oil pressure *2 320.0 kPa (3.20 kgf/cm2, 46.4 psi) at 60 °C
(140 °F) with SL 10W-30 engine oil and at
700 r/min
1
500.0 kPa (5.00 kgf/cm2, 72.5 psi) at 62 °C
(144 °F) with SL 10W-30 engine oil and at
3000 r/min 2
Thermostat
Valve opening temperature 58–62 °C (136–144 °F)
Fully open temperature
Fully open stroke
70 °C (158 °F)
4.3 mm (0.17 in)
3
Replacement engine oil quantity
(at periodic maintenance)
Without oil filter replacement 4.3 L (4.55 US qt, 3.78 Imp.qt)
4
With oil filter replacement 4.5 L (4.76 US qt, 3.96 Imp.qt)
*1.Measuring conditions: Ambient temperature 20 °C (68 °F), fully open throttle, with spark plugs
removed from all cylinders.
5
*2. For the checking method, see “Checking the oil pressure” (7-1). The figures are for reference
only.
Cylinder head assembly

6
Valve
Clearance (Intake)
Clearance (Exhaust)
0.17–0.24 mm (0.0067–0.0094 in)
0.31–0.38 mm (0.0122–0.0150 in)
7
Margin thickness (Intake) 0.40–0.80 mm (0.0157–0.0315 in)
Margin thickness (Exhaust) 0.80–1.20 mm (0.0315–0.0472 in)
Seat contact width (Intake) 1.10–1.40 mm (0.0433–0.0551 in) 8
Seat contact width (Exhaust) 1.40–1.70 mm (0.0551–0.0669 in)
Camshaft
Cam lobe height (Intake)
Cam lobe height (Exhaust)
45.310–45.410 mm (1.7839–1.7878 in)
44.360–44.460 mm (1.7465–1.7504 in)
9
Cam lobe width (Intake and exhaust) 35.950–36.050 mm (1.4154–1.4193 in)
Journal diameter
Runout
24.960–24.980 mm (0.9827–0.9835 in)
0.030 mm (0.0012 in) 10
Cylinder head
Warpage limit 0.10 mm (0.0039 in)
Journal inside diameter 25.000–25.021 mm (0.9843–0.9851 in)
A
1-12
Valve lifter
Outside diameter 30.970–30.980 mm (1.2193–1.2197 in)
Valve lifter clearance (reference data) 0.020–0.055 mm (0.0008–0.0022 in)
Valve spring
Free length 48.08 mm (1.8929 in)
Tilt limit 1.7 mm (0.07 in)
Valve stem
Diameter (Intake) 5.477–5.492 mm (0.2156–0.2162 in)
Diameter (Exhaust) 5.464–5.479 mm (0.2151–0.2157 in)
Runout (Intake and exhaust) 0.01 mm (0.0004 in)
Valve guide
Inside diameter (Intake and exhaust) 5.504–5.522 mm (0.2167–0.2174 in)
Valve guide clearance (Intake) 0.012–0.045 mm (0.0005–0.0018 in)
Valve guide clearance (Exhaust) 0.025–0.058 mm (0.0010–0.0023 in)
Installation height 11.3–11.7 mm (0.44–0.46 in)
Crankcase assembly
Piston
Diameter 93.921–93.941 mm (3.6977–3.6985 in)
Measuring point 13.5 mm (0.53 in)
Piston clearance 0.075–0.081 mm (0.0030–0.0032 in)
Ring groove (Top) 1.23–1.25 mm (0.0484–0.0492 in)
Ring groove (2nd) 1.22–1.24 mm (0.0480–0.0488 in)
Ring groove (Oil) 2.51–2.53 mm (0.0988–0.0996 in)
Pin boss inside diameter 21.021–21.031 mm (0.8276–0.8280 in)
Pin outside diameter 21.008–21.017 mm (0.8271–0.8274 in)
Cylinder
Bore 94.000–94.017 mm (3.7008–3.7014 in)
Piston ring (Top)

Type Barrel
Dimension height (B) 1.170–1.185 mm (0.0461–0.0467 in)
Dimension width (T) 2.800–3.000 mm (0.1102–0.1181 in)
End gap (reference data) 0.20–0.30 mm (0.0079–0.0118 in)
Side clearance 0.04–0.08 mm (0.0016–0.0031 in)
Piston ring (2nd)

Type Taper
End gap (reference data) 0.30–0.45 mm (0.0118–0.0177 in)
Side clearance 0.03–0.07 mm (0.0012–0.0028 in)
1-13
Piston ring (Oil)

End gap (reference data)
Side clearance
0.15–0.60 mm (0.0059–0.0236 in)
0.04–0.13 mm (0.0016–0.0051 in)
0
Connecting rod
Small end inside diameter
Big end inside diameter
21.022–21.037 mm (0.8276–0.8282 in)
53.025–53.045 mm (2.0876–2.0884 in)
1
Big end side clearance 0.14–0.31 mm (0.006–0.012 in)
Big end oil clearance 0.030–0.057 mm (0.0012–0.0022 in)
Crankshaft 2
Journal diameter 51.980–52.000 mm (2.0465–2.0472 in)
Crankpin diameter 49.980–50.000 mm (1.9677–1.9685 in)
Runout
Crankpin width
0.03 mm (0.0012 in)
22.000–22.100 mm (0.8661–0.8701 in)
3
Journal oil clearance 0.021–0.046 mm (0.0008–0.0018 in)
4
5
6
7
8
9
10
A
1-14
Lower unit technical data
Lower unit technical data
Lower unit assembly (regular rotation model)
Lower unit
Holding pressure 69.0 kPa (0.69 kgf/cm2, 10.0 psi)
Gear backlash
Forward gear backlash *1 F150AET 0.15–0.61 mm (0.0059–0.0240 in)
F150BET 0.15–0.68 mm (0.0059–0.0268 in)
Reverse gear backlash *1 F150AET 0.33–0.67 mm (0.0130–0.0264 in)
F150BET 0.33–0.74 mm (0.0130–0.0291 in)
Available shim thicknesses

Pinion shim (T3) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 mm
Forward gear shim (T1) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 mm
Reverse gear shim (T2) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 mm
Propeller shaft
Runout 0.02 mm (0.0008 in)
Drive shaft
Runout 1.0 mm (0.04 in)
*1.Figures obtained using the special service tools.
Lower unit assembly (counter rotation model)

Lower unit
Holding pressure 69.0 kPa (0.69 kgf/cm2, 10.0 psi)
Gear backlash
Forward gear backlash *1 FL150AET 0.15–0.42 mm (0.0059–0.0165 in)
FL150BET 0.15–0.49 mm (0.0059–0.0193 in)
Reverse gear backlash *1 FL150AET 0.24–0.58 mm (0.0094–0.0228 in)
FL150BET 0.24–0.65 mm (0.0094–0.0256 in)
Available shim thicknesses

Pinion shim (T3) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 mm
Forward gear shim (T2) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 mm
Reverse gear shim (T1) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 mm
Propeller shaft shim (T4) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 mm
Propeller shaft
Free play 0.25–0.35 mm (0.0098–0.0138 in)
Runout 0.02 mm (0.0008 in)
Drive shaft
Runout 1.0 mm (0.04 in)
*1.Figures obtained using the special service tools.
1-15
Bracket unit technical data
Bracket unit technical data
PTT system
Hydraulic pressure
Down 5.85–8.85 MPa (58.5–88.5 kgf/cm2,
848.3–1283.3 psi)
0
Up 11.2–13.2 MPa (112.0–132.0 kgf/cm2,
Motor commutator
1624.0–1914.0 psi)
1
Standard diameter 22.00 mm (0.8661 in)
Limit 21.00 mm (0.8268 in)
Standard undercut 1.50 mm (0.0591 in) 2
Limit 1.00 mm (0.0394 in)
Motor brush
Standard length
Limit
10.00 mm (0.3937 in)
3.5 mm (0.14 in)
3
4
5
6
7
8
9
10
A
1-16
Specified tightening torque
Specified tightening torques are provided for specific nuts, bolts, and screws. When tightening these
fasteners, follow the tightening torque specifications indicated throughout the manual to meet the
design aims of the outboard motor.
Rigging information
Tightening torques
Part to be tightened Screw size
N·m kgf·m ft·lb
Shift cable locknut — 5 0.5 3.7
Throttle cable locknut — 5 0.5 3.7
Water pressure sensor adapter — 23 2.3 17.0
Water pressure sensor — 18 1.8 13.3
Speed sensor — 18 1.8 13.3
Battery cable nut — 9 0.9 6.6
Clamp screw M5 2 0.2 1.5
Receiver screw M4 4 0.4 3.0
Electrical system
Tightening torques
N·m kgf·m ft·lb
Control unit screw M6 4 0.4 3.0
Buzzer screw ø6 2 0.2 1.5
Transmitter screw ø2 0.1 0.01 0.1
Fuel system
Tightening torques
N·m kgf·m ft·lb
Fuel cup assembly — 5 0.5 3.7
Fuel pump screw M6 4 0.4 3.0
Fuel pump bolt M6 10 1.0 7.4
Intake silencer bolt M6 6 0.6 4.4
Throttle body assembly bolt M8 13 1.3 9.6
Fuel rail bolt M8 13 1.3 9.6
Fuel cooler bolt M6 5 0.5 3.7
Air pressure sensor screw M5 5 0.5 3.7
Vapor separator drain screw — 2 0.2 1.5
Vapor separator bolt M6 5 0.5 3.7
Float chamber plate screw M4 2 0.2 1.5
Needle valve screw M4 2 0.2 1.5
Float chamber cover screw M4 2 0.2 1.5
Pressure regulator screw M6 5 0.5 3.7
1-17
Power unit
Tightening torques
N·m kgf·m ft·lb
Spark plug
Power unit mounting bolt
—
M8
25
20
2.5
2.0
18.4
14.8
0
M10 42 4.2 31.0
Apron screw M6 4 0.4 3.0
PTT motor lead bolt
Flywheel magnet nut
M6
—
4
270
0.4
27.0
3.0
199.1
1
Drive sprocket bolt M5 7 0.7 5.2
Timing belt tensioner bolt — 39 3.9 28.8
Starter motor mounting bolt
Starter motor lead bolt
M8
M6
30
4
3.0
0.4
22.1
3.0
2
Terminal nut — 9 0.9 6.6
Ignition coil bolt
PTT relay nut
M6
— 4
7 0.7
0.4
5.2
3.0 3
Starter relay lead bolt M6 4 0.4 3.0
1st 9 0.9 6.6
Camshaft cap bolt M7
Driven sprocket bolt
2nd
M10
17
60
1.7
6.0
12.5
44.3
4
Cylinder head cover plate screw M4 2 0.2 1.5
1st 14 1.4 10.3
Cylinder head bolt

2nd
1st
M8
28
28
2.8
2.8
20.7
20.7
5
2nd M10 56 5.6 41.3
3rd 90°
Exhaust cover bolt
1st
M6
6 0.6 4.4 6
2nd 12 1.2 8.9
1st 6 0.6 4.4
Thermostat cover bolt M6
Exhaust cover plug

2nd
M14
12
23
1.2
2.3
8.9
17.0 7
M18 56 5.6 41.3
Oil pump cover screw M6 4 0.4 3.0
1st
2nd
M6
7
13
0.7
1.3
5.2
9.6
8
Balancer assembly bolt
1st 18 1.8 13.3
M8
2nd 31 3.1 22.9
1st
2nd
M6
7
13
0.7
1.3
5.2
9.6
9
Crankcase cover bolt
1st 18 1.8 13.3
M8
Oil filter
2nd
—
31
18
3.1
1.8
22.9
13.3 10
Oil pressure sensor — 18 1.8 13.3
Engine hanger bolt M6 12 1.2 8.9
Engine temperature sensor — 15 1.5 11.1
Cylinder block plug M14 23 2.3 17.0
Union bolt — 34 3.4 25.1
Relief valve — 32 3.2 23.6
A
1-18
Tightening torques
N·m kgf·m ft·lb
1st 13 1.3 9.6
Connecting rod bolt 2nd M9 23 2.3 17.0
3rd 90°
1st 30 3.0 22.1
Main bearing cap bolt M10
2nd 90°
1st 14 1.4 10.3
M8
2nd 28 2.8 20.7
Crankcase bolt
1st 30 3.0 22.1
M10
2nd 90°
Lower unit (regular rotation model)

Tightening torques
N·m kgf·m ft·lb
Drain screw — 9 0.9 6.6
Check screw — 9 0.9 6.6
Propeller nut — 55 5.5 40.6
Trim tab bolt M10 43 4.3 31.7
Lower case mounting bolt M10 48 4.8 35.4
Ring nut — 145 14.5 106.9
Pinion nut — 95 9.5 70.1
Water inlet cover screw M5 1 0.1 0.7
Lower unit (counter rotation model)

Tightening torques
N·m kgf·m ft·lb
Drain screw — 9 0.9 6.6
Check screw — 9 0.9 6.6
Propeller nut — 55 5.5 40.6
Trim tab bolt M10 43 4.3 31.7
Lower case mounting bolt M10 48 4.8 35.4
Ring nut — 145 14.5 106.9
Pinion nut — 95 9.5 70.1
Water inlet cover screw M5 1 0.1 0.7
Bracket unit
Tightening torques
N·m kgf·m ft·lb
Shift position switch screw M4 2.5 0.25 1.84
Shift cut-off switch screw M4 2.5 0.25 1.84
Shift bracket bolt — 19 1.9 14.0
Shift rod detent bolt — 18 1.8 13.3
Grease nipple — 1 0.1 0.7
Hose joint adapter screw ø6 5 0.5 3.7
Upper mounting nut — 72 7.2 53.1
Lower mounting nut — 72 7.2 53.1
Upper mount bolt M10 55 5.5 40.6
Baffle plate screw M6 4 0.4 3.0
1-19
Tightening torques
N·m kgf·m ft·lb
M8 20 2.0 14.8
Oil pan assembly bolt
Drain bolt
M10
—
42
28
4.2
2.8
31.0
20.7 0
Oil strainer bolt M6 12 1.2 8.9
Oil pan bolt M8 20 2.0 14.8
Exhaust manifold bolt
Muffler bolt
M8
M8
20
20
2.0
2.0
14.8
14.8
1
Self-locking nut — 15 1.5 11.1
Grease nipple — 3 0.3 2.2
Trim stopper nut
Trim sensor screw
—
M6
48
4
4.8
0.4
35.4
3.0
2
PTT unit

Tightening torques 3
N·m kgf·m ft·lb
Lower mounting shaft bolt M10 39 3.9 28.8
Reservoir cap
Main valve
—
—
7
11
0.7
1.1
5.2
8.1 4
Manual valve — 3 0.3 2.2
Tilt ram — 65 6.5 47.9
Tilt piston screw
Trim cylinder end screw
M6
—
7
160
0.7
16.0
5.2
118.0
5
Tilt cylinder end screw — 150 15.0 110.6
PTT motor mounting bolt M6 7 0.7 5.2
Reservoir mounting bolt M6
M4 4
7 0.7
0.4
5.2
3.0
6
Pump bracket bolt
M5 7 0.7 5.2
Plug
Gear pump bolt
—
M5
4
7
0.4
0.7
3.0
5.2 7
General tightening torque
This chart indicates the tightening torques for
standard fasteners with a standard ISO
8
thread pitch.
Width
across
Screw
size (B)
General torque
specifications 9
flats (A) N·m kgf·m ft·lb
8 mm M5 5 0.5 3.7
10 mm
12 mm
M6
M8
8
18
0.8
1.8
5.9
13.3
10
14 mm M10 36 3.6 26.6
17 mm M12 43 4.3 31.7
A
1-20
Technical feature and description 2
Electronic control system ................................................ 2-1

Engine ECM component ........................................................... 2-3
Engine speed control ................................................................. 2-5
Fail-safe control ......................................................................... 2-6
Additional features ............................................................ 2-7

optional for Oceanian market) ................................................... 2-7
Tilt limiter (F150A, FL150A [optional for European and
Oceanian markets]) ................................................................... 2-8
YDIS .................................................................................... 2-9

Overview ................................................................................... 2-9
New functions .......................................................................... 2-10
Logging .................................................................................... 2-11
Power unit system .......................................................... 2-12

Shimless valve lifter ................................................................. 2-12
Fuel system ..................................................................... 2-13

Fuel diagram ........................................................................... 2-13
Vapor gas diagram .................................................................. 2-14
Lubrication system ......................................................... 2-15

Lubrication diagram ................................................................. 2-15
Cooling system ............................................................... 2-16

Cooling diagram ...................................................................... 2-16
Intake and exhaust system ............................................ 2-17

Intake and exhaust diagram .................................................... 2-17
Lower unit ........................................................................ 2-18

Propeller (SDS) ....................................................................... 2-18
PTT unit ............................................................................ 2-19

Trim-up and tilt-up function ...................................................... 2-19
Trim-down and tilt-down function ............................................ 2-20
Trim ram retraction when tilting the outboard motor up ........... 2-21
Technical feature and description
Trim ram retraction when there is no load on the tilt ram and
trim ram ................................................................................... 2-21
Stationary condition ................................................................. 2-22
0
Shock-absorbing function ........................................................ 2-22
1
2
3
4
5
6
7
8
9
10
A
Electronic control system
This model uses an electronic fuel injection control, digital ignition control, over-revving control, alert
control, idle speed control, vapor shut-off valve control, which has been newly added to this model,
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 and flash indicator.
It is also equipped with Y-COP as an anti-theft measure (standard for European market and optional
for Oceanian market).
13. Vapor shut-off valve
14. Ignition coil
15. High-pressure fuel pump

17. Fuel injector
16. ISC valve
18. Idle speed control 19. Vapor shut-off valve control
1. Pulser coil
2. TPS
20. Fuel control 3. Air pressure sensor
4. Oil pressure sensor
21. Ignition control 5. Engine temperature sensor
22. Engine 6. Air temperature sensor
23. 6Y8 Multifunction ECM 7. Thermoswitch
Meter 8. Shift cut-off switch
9. Shift position switch
24. Y-COP 25. Hub 10. Water detection switch
11. Water pressure sensor (optional)
12. Speed sensor (optional)
27. YDIS
26. Battery
2-1
1. Pulser coil
2. TPS
3. Air pressure sensor
5. Engine temperature sensor
6. Air temperature sensor
0
7. Thermoswitch
8. Shift cut-off switch
9. Shift position switch 1
10. Water detection switch
11. Water pressure sensor (optional)
12. Speed sensor (optional)
2
14. Ignition coil
16. ISC valve
17. Fuel injector
3
18. Idle speed control
19. Vapor shut-off valve control
20. Fuel control 4
21. Ignition control
22. Engine ECM
23. 6Y8 Multifunction Meter
24. Y-COP 5
25. Hub
26. Battery
27. YDIS 6
7
8
9
10
A
2-2
Engine ECM component
1 4
5
17
8
6
11
10
9
7
12
16
13
14
15
2-3
Determines the engine operating conditions according to the

1. Engine ECM input signals from the sensors, and sends output signals to
operate the actuators to perform the various control functions.
2. Pulser coil
Detects the engine speed.
Detects the crankshaft angle.
0
3. Thermoswitch Detects engine overheating.
4. Ignition coil Activates the ignition.
Controls the amount of vapor gas to be sent from the vapor
1
separator to the intake system.
Detects the engine oil pressure.
Detects water intrusion in fuel filter.
2
8. Air temperature sensor Detects the intake air temperature.
10. ISC valve
Detects the intake air pressure.
Adjusts the flow of air to the engine when idling. 3
11. Engine temperature sensor Detects the engine temperature.
12. TPS Detects the throttle valve opening.
13. Shift position switch Detects the neutral position. 4
Detects the shift-in or shift-out condition for the forward gear-
shift.
15. High-pressure fuel pump Pressurizes the fuel and sends the fuel to the fuel rail. 5
16. Fuel injector Injects fuel.
17. Engine shut-off switch Stops the engine forcibly.
6
7
8
9
10
A
2-4
Engine speed control
The engine ECM decreases the engine speed to protect the engine from damage and to improve
the smoothness of gear shifting.
Control
Criteria Description
name
Fuel injection will be skipped
6200–6301 r/min
When engine speed for cylinders #1 and #4.
is more than a Fuel injection will be skipped
6302–6551 r/min
predetermined level for cylinders #1, #4 and #3.
(F150A, FL150A) Fuel injection for all cylinders
Over- Over 6551 r/min
will be skipped.
revving
Fuel injection will be skipped
control 5751–5852 r/min
When engine speed for cylinders #1 and #4.
is more than a Fuel injection will be skipped
5853–6102 r/min
predetermined level for cylinders #1, #4 and #3.
(F150B, FL150B) Fuel injection for all cylinders
Over 6102 r/min
will be skipped.
When using dual outboard
motors with a dual switch
Multi- panel, if the overheat control Fuel injection will be skipped
engine Multi-engine system or low oil pressure control is in stages to limit engine
system switch is ON activated, then these are to speed to approximately
control be activated in the same way 2000–3500 r/min.
for the other outboard motor
that is operating normally.
This allows smooth engagement and disengagement of the
dog clutch.
Shift cut- Shift cut-off switch is
400–729 r/min Retards ignition timing.
off ON, engine speed is
After firing will be skipped for
control 400–2000 r/min
730–1999 r/min cylinders #1 and #4, retards
ignition timing.
No determination on overheat Fuel injection will be skipped
will be made until the engine in stages to limit engine
Over- speed is more than 2000 speed to approximately
The thermoswitch is
heat r/min for 29 seconds or more 2000–3500 r/min.
ON
control after the engine has started, The overheat alert indicator
or until 74 seconds after the comes on, and the alert
engine has started. buzzer sounds.
The pressure
Fuel injection will be skipped in stages to limit engine speed to
Low oil decreases to less
approximately 2000–3500 r/min.
pressure than the specified
The low oil pressure alert comes on, and the alert buzzer
control value for the engine
sounds.
speed range.
2-5
Fail-safe control
If the electrical components malfunction, the engine ECM controls the ignition and fuel injection as
shown in the table.
Trouble
code
Item Trouble conditions to be detected 0
No signal is sent from one of two sensors 4 or more
13 Pulser coil
consecutive times.
Open or short circuit in the engine temperature sensor
circuit.
1
Output voltage is less than 0.18 V or more than 4.93 V.
15 Engine temperature sensor
When the engine starts: Set to 5 °C (41 °F), 20 °C
(68 °F), or 40 °C (104 °F) depending on the signal 2
from the air temperature sensor. *1
Open or short circuit in the TPS circuit.
18 TPS
Determines the fully closed position of the throttle
3
based on the signal from the air pressure sensor. *1
Voltage is less than 12 V for 2 minutes, even when
19 Battery voltage
engine speed is more than 2000 r/min.
Open or short circuit in the air temperature sensor
4
circuit.
23 Air temperature sensor
Set to 40 °C (104 °F). *1 5
Cranking while in gear.
28 Shift position switch Cranking while the shift position circuit is open-
circuited.
Open or short circuit in the air pressure sensor circuit.
6
29 Air pressure sensor
Temporarily sets air pressure levels based on the
engine speed and the TPS signal. *1
The shift position switch is off, the throttle is fully
7
37 Intake air passage closed, the ISC valve is fully closed, and the engine
39 Oil pressure sensor

speed is more than 1200 r/min.
Open or short circuit in the oil pressure sensor circuit. 8
Output voltage is more than 4.5 V, the switch is ON
45 Shift cut-off switch when the engine is started, or both the shift cut-off
switch and shift position switch are ON for 5 seconds.
9
46 Thermoswitch Not detected
Open or short circuit in the Y-COP circuit.
86 Immobilizer (Y-COP) Communication error continues for more than 3 10
seconds.
*1. Control mode when the part malfunctions.
A
2-6
Additional features
Additional features
Y-COP consists of a transmitter and a receiver. The receiver transmits an authorization ID to the
engine ECM. If an authorization ID is not received or if the transmitted authorization ID does not
match the registered ID in the engine ECM, the receiver cannot perform data communication with
the engine ECM. Pushing the lock and unlock buttons on the transmitter causes the receiver to rec-
ognize the lock and unlock state, and to send data to the engine ECM. The locked or unlocked state
is maintained even when the battery switch is turned to OFF.
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).
• Installation location requires special attention to avoid electrical interference, obstructions, or
water exposure.
1. Y-COP
2. Transmitter 7. Ignition coil
3. Receiver
8. Fuel injector
4. Hub 6. Engine
ECM
9. Alert indicator
5. Battery
1. Y-COP 6. Engine ECM

2. Transmitter 7. Ignition coil
3. Receiver 8. Fuel injector
4. Hub 9. Alert indicator
5. Battery
State Operation
Unlocked Normal
Stops fuel injection and ignition, and prevents
Locked
the engine from starting.
The engine will start, but engine speed is
Communication error, improper wiring
limited to 2000–3500 r/min.
connection.
Outputs a trouble code.
2-7
Additional features
Tilt limiter (F150A, FL150A [optional for European and Oceanian markets])
The outboard motors (with applicable serial numbers) covered by this manual can be fitted with an
optional tilt limiter that allows the tilt-up action to be halted at a set angle, preventing the outboard
motor from coming into contact with the motor well when tilted up.
This tilt limiter consists of a magnet affixed to a through tube, and a sensor on a swivel bracket. The 0
movement of the swivel bracket when tilting the outboard motor up will move the sensor position.
When the mark “a” on the magnet is aligned with the mark “b” on the sensor, power to the PTT for
tilting the outboard motor up will be cut off.
1
a 2
b
3
4
5
6
2. Tilt limiter unit
7
Sb
12 V
1. PTT switch (UP)
8
3. PTT relay
L
4. Output
6. Transistor switch
5. Signal
7. Sensor 9
B
10
1. PTT switch (UP) 5. Signal
2. Tilt limiter unit 6. Transistor switch
3. PTT relay 7. Sensor
4. Output
A
2-8
YDIS
YDIS
Overview
YDIS version 2.00 retains the functionality of former YDIS versions, while adding new functionality.
The screen has been redesigned, improving ease-of-use.
The CAN-Line transmission method, which enables connection to a hub, has been added to the
conventional transmission method (K-Line). Available functions will differ depending on the connec-
tion method.
TIP:
• There is no compatibility between the YDIS version 2.00 and version 1 series.
• Use of the Windows function “1” to change the screen size and to end programs is now possible.
• Displays the current level “2”.
• Displays the communications status.
Communicating: “3”
Communications error: “4”
• For connection methods, see “Connecting the communication cable” (4-5).
• For menu levels, see “Function” (4-2).
• For details of operation methods, see the YDIS (Ver. 2.00 or later) instruction manual.
• These tools are restricted for use by Yamaha service technicians of distributors or dealers only.
1
2
3 ECM RecGraph
2-9
YDIS
New functions
• By connecting the YDIS using CAN-Line, the CAN bus monitor function can check the names of
devices connected to the digital network, the bus load, and the number of error frames. This
enables checking of the connection status of the digital network.
0
3. Speed meter
1 Multisensor
4. Tachometer 2
3
4
Immobilizer
Speed meter
Tachometer
*1
1
2. Y-COP 5 Engine
2
3
Bus Load % 2.72
Peak Bus Load % 3.08

Error Frame frame/sec 0
Total Error Frame
USB adapter chip state
frame 0
Active 4
5
1. Multisensor
5. Engine
6
1. Multisensor 7
2. Y-COP
3. Speed meter
4. Tachometer
5. Engine
8
*1. Y-COP is displayed as “Immobilizer” on the YDIS screen.
• The settings function now enables switching of the language (English, French, Spanish, Japa-
9
nese).
• By connecting commercially available external instruments, the external input function enables
display of this information on the engine monitor. 10
• The new adapter has 1.6 MB of memory, meaning that logging of engine monitor information is
possible while the computer is not connected. The adapter has an internal battery, which is
recharged by being connected to the computer or to the outboard motor (while the engine start
switch is ON), and one hour of recharging is sufficient for 48 hours backup.
A
2-10
YDIS
Logging
In version 2.00, it is possible to configure items to be logged, and logging intervals. Configure log-
ging, and disconnect the USB cable between the computer and the adapter to start logging.
Because the computer is not connected during logging, the adapter can be placed within the top
cowling (K-Line). This enables logging under conditions that are the same as those during normal
use. This makes it easier to reproduce trouble conditions, and to investigate the causes of any
faults.
TIP:
• Starts and stops logging by connecting and disconnecting the USB cable between the computer
and adapter.
• The adapter has a built-in battery. Therefore during operation, this is recharged using electricity
from the engine. When the engine stops, backup uses the internal battery.
• Guaranteed for 48 hours continuous operation with the battery charged for one hour. If the internal
battery becomes depleted, recorded data will be deleted.
• Recording normal (default condition) engine data (engine speed ranges) enables comparison with
fault data.
1. Adapter
a e
b c b c b d
c
f
g
h
1. Adapter e. Logging stop

f. Adapter recording status
a. Logging start g. Recording (engine speed: 500 r/min or
b. Engine start more)
c. Engine stop h. Stop recording (engine speed: less than
d. Fault occurs. 500 r/min)
2-11
Power unit system
Power unit system
Shimless valve lifter
Newly designed valve lifters “1” have been adopted in place of the valve shims previously used “2”.
The valve lifters are available in different thicknesses “a”. Therefore, the valve clearance “b” can be
adjusted by replacing the current valve lifter with a new valve lifter of the appropriate thickness. 0
A B
1
2
b
2
a
1 3
4
5
A. Previous L4 model
B. New L4 model
6
7
8
9
10
A
2-12
Fuel system
Fuel system
Fuel diagram
5
10 3
12
2
9
12 6
11
6. Vapor separator 15
10. Pressure
regulator A
11. Fuel rail
9. High-pressure 12. 12. 12. 12.

15. Fuel cooler fuel pump Fuel injector Fuel injector Fuel injector Fuel injector
#1 #2 #3 #4
8. Filter 13. Intake manifold
7. Float chamber 14. 14. 14. 14.

Combustion Combustion Combustion Combustion
chamber #1 chamber #2 chamber #3 chamber #4
5. Filter
4. Low-pressure fuel pump 3. Fuel filter 2. Primer pump 1. Fuel tank
1. Fuel tank 10. Pressure regulator

2. Primer pump 11. Fuel rail
3. Fuel filter 12. Fuel injector
4. Low-pressure fuel pump 13. Intake manifold
5. Filter 14. Combustion chamber
6. Vapor separator 15. Fuel cooler
7. Float chamber
8. Filter A. Fuel flow
2-13
Fuel system
Vapor gas diagram
TIP:
When the engine is running, air is drawn from the atmosphere to purge the vapor gas that has accu-
0
mulated in the canister into the combustion chambers.
1
4
2
3
4
7
5
1
3
2
2. Filter
6
3. Canister
7. Filter 7
1. Vapor separator
5. Intake manifold
8
6. Combustion
chamber #1
6. Combustion
chamber #2
6. Combustion
chamber #3
6. Combustion
chamber #4 A 9
B
8. Atmosphere (cowl outside) D
10
1. Vapor separator 8. Atmosphere (cowl outside)
2. Filter
3. Canister A. Vapor gas flow
4. Vapor shut-off valve B. Air flow
5. Intake manifold D. Purified gas
6. Combustion chamber
7. Filter A
2-14
Lubrication system
Lubrication system
Lubrication diagram
16. Cylinder head
15. Intake and exhaust

valves
11 6 14. Camshaft
13. Camshaft journal

4
17
12. Crankcase
3 1
10. Sleeve
9. Piston
2
8. Crank pin
11. Balancer 7. Crankshaft main

(F150A, FL150A) journal
6. Oil pressure sensor 5. Main gallery
4. Oil filter
17. Relief valve

3. Oil pump
2. Oil strainer
A 1. Oil pan
1. Oil pan 11. Balancer (F150A, FL150A)

2. Oil strainer 12. Crankcase
3. Oil pump 13. Camshaft journal
4. Oil filter 14. Camshaft
5. Main gallery 15. Intake and exhaust valves
6. Oil pressure sensor 16. Cylinder head
7. Crankshaft main journal 17. Relief valve
8. Crank pin
9. Piston A. Engine oil flow
10. Sleeve
2-15
Cooling system
Cooling system
Cooling diagram
0
9
15
16
9. Thermostat
1
7. Cylinder block
10 8. Cylinder head 2
5 7. Cylinder block
10. PCV 3
6. Exhaust cover
4
17 11. Upper case 17. Flushing
(muffler) device
5. Exhaust guide
5
4
4. Oil pan
12. Lower case 6
3 3. Water pump
14. Trim tab
water inlet 15. Fuel cooler 7
2. Water inlet
16. Cooling water
2 13. Propeller boss pilot hole 8
1. Water
A 9
1. Water 11. Upper case (muffler)
2. Water inlet
3. Water pump
12. Lower case
13. Propeller boss
10
4. Oil pan 14. Trim tab water inlet
5. Exhaust guide 15. Fuel cooler
6. Exhaust cover 16. Cooling water pilot hole
7. Cylinder block 17. Flushing device
8. Cylinder head
A. Cooling water flow
9. Thermostat
10. PCV A
2-16
Intake and exhaust system
Intake and exhaust system
Intake and exhaust diagram
4. Exhaust cover
5. Exhaust guide
1. Intake silencer
6. Exhaust
manifold
2. Throttle body
3. Intake manifold
8. Propeller boss
7. Muffler
A
B
1. Intake silencer A. Intake air flow

2. Throttle body B. Exhaust gas flow
3. Intake manifold
4. Exhaust cover
5. Exhaust guide
6. Exhaust manifold
7. Muffler
8. Propeller boss
2-17
Lower unit
Lower unit
Propeller (SDS)
The optional Shift Dampener System (SDS) uses a damper “1” to reduce the shock when the out-
board motor is shifted into gear, and eliminates the clunk that is sometimes heard.
When shifting gears, the protrusions “a” on the dedicated spacer “2” transmit the rotational force of 0
the propeller shaft directly to the propeller “3”.
1
3
1
2
2
a
4
5
a 6
A B
A. Neutral
7
B. Shift in
8
9
10
A
2-18
PTT unit
PTT unit
Trim-up and tilt-up function
Pushing the UP button on the PTT switch causes the PTT motor “1” to activate the gear pump “2”,
generating the PTT fluid pressure. The PTT fluid pressure opens the up-main valve “3” at the same
time pushing the shuttle piston “4”, and this opens the down-main valve “5”.
The PTT fluid passes through the up passage and flows into the lower chambers of the trim cylin-
ders “6” and the lower chamber of the tilt cylinder “7”. The PTT fluid pressure pushes up the trim
rams “8”, and the PTT fluid in the upper chambers of the trim cylinders “6” returns to the reservoir
“9”.
The PTT fluid pressure pushes up the tilt ram “10”, and the PTT fluid in the upper chamber of the tilt
cylinder “7” passes through the down passage, returning to the gear pump. When tilt-up operation is
complete, the PTT fluid pressure increases. When this exceeds 12.2 MPa (122.0 kgf/cm2,
1769.0 psi), this causes the up-relief valve “11” to open, releasing the PTT fluid pressure. Addition-
ally, if the PTT fluid pressure is abnormally high exceeding 18.6 MPa (186.0 kgf/cm2, 2697.0 psi),
then the protection valve “12” will open to protect the PTT unit.
1
11
10
12
2 7
5
8
6
4
3
6
A
B
A. Return
B. Send
2-19
PTT unit
Trim-down and tilt-down function
Pushing the DN button on the PTT switch causes the PTT motor “1” to activate the gear pump “2”,
generating the PTT fluid pressure. The PTT fluid pressure opens the down-main valve “3” at the
same time pushing the shuttle piston “4”, and this opens the up-main valve “5”.
The PTT fluid passes through the down passage and flows into the upper chamber of the tilt cylinder 0
“6”. The PTT fluid pressure pushes down the tilt ram “7”, and the PTT fluid in the lower chamber of
the tilt cylinder “6” returns to the gear pump “2”.
When the tilt ram “7” drops, the trim rams “8” are pushed down due to the weight of the outboard
motor, and the PTT fluid is sucked up from the reservoir “9” to the upper chamber of the trim cylin- 1
ders “10”.
When tilt-down operation is complete, the PTT fluid pressure increases. When this exceeds 7.35
MPa (73.5 kgf/cm2, 1065.8 psi), this causes the down-relief valve “11” to open, releasing the PTT
fluid pressure. Additionally, if the PTT fluid pressure is abnormally high exceeding 26.5 MPa
2
(265.0 kgf/cm2, 3842.5 psi), then the protection valve “12” will open to protect the PTT unit.
1
3
11
4
9
7 5
6
12
7
2 6
10
8
3
8
9
10
4
10
5
A
B
A. Return B. Send A
2-20
PTT unit
Trim ram retraction when tilting the outboard motor up
When tilting the outboard motor up, applying the tilt lock lever and pushing the DN button on the PTT
switch applies fluid pressure to the tilt cylinder “1” upper chamber, in the same way as when tilting
the outboard motor down. Because the tilt lock lever is applied, the tilt ram “2” will not operate.
Accordingly, the PTT fluid pressure will increase, releasing PTT fluid from the down-relief valve “3”
to the gear pump side reservoir. The PTT fluid does not flow back inside the gear pump “4”, so the
gear pump “4” attempts to suck PTT fluid up. The passage “a” through which the PTT fluid is sucked
up from the reservoir is small in size, causing oil to be sucked up from the trim cylinder “5” lower
chambers, which have little resistance to suction. This allows the trim rams “6” to be retracted.
Trim ram retraction when there is no load on the tilt ram and trim ram
When the PTT unit has been removed from the outboard motor, operating the PTT motor towards
the DN side will cause the tilt ram “2” to operate in the same way as when tilting the outboard motor
down. If the tilt ram “2” lowers to the limit, PTT fluid pressure increases, releasing PTT fluid from the
down-relief valve “3” to the gear pump side reservoir. The PTT fluid does not flow back inside the
gear pump “4”, so the gear pump “4” attempts to suck PTT fluid up. The passage “a” through which
the PTT fluid is sucked up from the reservoir is small in size, causing oil to be sucked up from the
trim cylinder “5” lower chambers, which have little resistance to suction. This allows the trim rams “6”
to be retracted.
1
4
5 5
A
B
A. Return B. Send
2-21
PTT unit
Stationary condition
When the PTT switch is not pushed, the gear pump assembly will not pump the PTT fluid, the up-
main valve and down-main valve will remain closed, and the PTT fluid in the system will remain at a
constant pressure. As a result, the tilt ram and trim rams maintain their positions until the PTT switch
is pushed and the PTT fluid flows through the system again. 0
Shock-absorbing function
If the lower case strikes an obstacle while the boat is moving, a force causing the tilt ram “1” to
extend will be applied suddenly. Because this force will cause the PTT fluid pressure in the tilt cylin- 1
der upper chamber “a” to increase, the tilt piston absorber valves “2” will open so that PTT fluid
enters the space between the tilt piston “3” and the free piston “4” to decrease the PTT fluid pres-
sure. As a result, the damping effect of the tilt piston absorber valves “2” protects the PTT unit from
damage before the tilt piston “3” strikes the top of the tilt cylinder. After the collision, a force is gener-
2
ated as the outboard motor returns to its original position due to the weight of the outboard motor
and the thrust of the propeller. The PTT fluid enters the tilt cylinder upper chamber “a” through the
shock return valve “5” in the tilt piston “3”. The tilt ram “1” stops when it contacts the free piston “4”. 3
A B
4
1 1
5
6
a a
7
2
8
5
3
2
9
3
4 4
10
A. Fluid flow when the outboard motor

strikes an obstacle.
B. Fluid flow when the outboard motor
returns to the original position. A
2-22
Rigging information 3
Important reminder on rigging ......................................... 3-1

Outboard motor mounting instructions ...................................... 3-1
Crate handling ................................................................... 3-2

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

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

F150A, FL150A, F150B, FL150B .............................................. 3-5
Clamp bracket ........................................................................... 3-6
Outboard motor mounting ................................................ 3-7

Installing the outboard motor ..................................................... 3-7
Rigging grommet mounting ............................................. 3-9

Rigging grommet description ..................................................... 3-9
Installing the shift cable ............................................................. 3-9
Installing the throttle cable ....................................................... 3-11
Installing the 6Y8 Multifunction Meter harness ........................ 3-12
Installing the conventional gauge harness .............................. 3-12
Installing the main wiring harness ........................................... 3-13
Installing the rigging grommet ................................................. 3-13
Optional equipment ........................................................ 3-14

Installing the isolator lead ........................................................ 3-14
Installing the water pressure sensor ........................................ 3-14
Installing the speed sensor ...................................................... 3-15
Installing the tilt limiter ............................................................. 3-16
Setting the tilt limiter ................................................................ 3-18
Deactivating the tilt limiter ....................................................... 3-20

optional for Oceanian market) ....................................... 3-20
Installing Y-COP ...................................................................... 3-20
Registering the receiver ID to the ECM ................................... 3-20
Battery installation .......................................................... 3-22

Battery wiring without house (accessory) battery .................... 3-22
Rigging information
Battery wiring with house (accessory) battery ......................... 3-25

0
System diagram .............................................................. 3-29
Single outboard motor application
(6Y8 Multifunction Meter) ........................................................ 3-29
Single outboard motor application (conventional gauge) ........ 3-31
1
Twin outboard motor application (6Y8 Multifunction Meter) .... 3-33
Twin outboard motor application (conventional gauge) ........... 3-35
2
Rigging recommendation ............................................... 3-37
Extension length recommendation for battery cable ............... 3-37
3
Propeller selection .......................................................... 3-38
Propeller size ........................................................................... 3-38
Selection .................................................................................. 3-38 4
5
6
7
8
9
10
A
Important reminder on rigging
Important reminder on rigging
Outboard motor mounting instructions
• Overpowering a boat could cause severe instability. Do not install an outboard motor with
more horsepower than the maximum rating on the capacity plate of the boat. If the boat
does not have a capacity plate, consult the boat manufacturer.
• Improper mounting of the outboard motor could result in hazardous conditions, such as
poor handling, loss of control, or fire hazards.
Too much weight on the transom can change the center of gravity, buoyancy, operating bal-
ance, or performance of the boat, which could cause loss of control or swamping. Consult
the boat manufacturer for the maximum engine weight allowable on the transom, which is
different from the overall boat capacity. Overloading the transom with an outboard motor
that is too heavy could also damage the hull, transom, deck, or helm area, as well as the 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. These damages could cause loss of control.
3-1
Crate handling
Crate handling
Crate top cover pictograph description
The following pictographs are important when handling the crate.
Read the notice and understand what each pictograph means to prevent damage to the outboard
motor when handling, transporting, and storing the crate. 0
1
1
6 7
2
9 8 3
2
4
5
5
3
IMPORTANT
4
6
This unit delivered to carrier in a good condition.
For protection against loss due to damage, inspect thoroughly.
If damage is noted, make note on freight bill.
Shipper assumes no further liability to the transportation company.
Your claim should be filed against carrier for damage of any nature.
7
1. !WARNING 3. IMPORTANT
Wear suitable protective gear such as This unit delivered to carrier in a good 8
gloves and eye protection when handling condition.
and opening crate. For protection against loss due to dam-
2. NOTICE
• Use forklifts with forks that are at least
age, inspect thoroughly.
If damage is noted, make note on freight 9
1 m (40 in) in length. bill.
• Only stack with crate of the same size. Shipper assumes no further liability to
• Be sure unit is stacked securely (all four
corners fit securely on unit below it).
the transportation company.
Your claim should be filed against carrier
10
• Stack Limit - 2 units (at handling). for damage of any nature.
4. Lifting fork insert position
5. Product barycentric position
6. Stack limit: Maximum 4 units for storage
7. Upward indication
8. Care handling indication
9. Water avoidance indication A
3-2
Uncrating
Uncrating
TIP:
Uncrating procedure
Place a rag “1” between the flywheel magnet
and the lifting harness.
Wear gloves to avoid injury by sharp steel

edges while uncrating.
1. Check the crate for shipping damage.
2. Remove the top cover.

1
3. Remove all of the bolts from the bottom
plate, and then remove the frame.
8. Remove the skeg holder “1”.

Be careful not to damage the outboard
motor.
4. Remove the wrapping, and then check

the outboard motor for concealed dam- 1
age.
5. Remove the top cowling, and then

remove the flywheel magnet cover “1”.
9. Lift up the outboard motor carefully along

1 with the bottom frame “1”.
Make sure that the lifting harnesses do

not damage any parts of the outboard
motor.
6. Install the lifting harnesses “1” to the

engine hangers “2”.
1
2
7. Tension the lifting harnesses. 10. Remove the bolts “1”.
3-3
Uncrating
0
1
1
11. Remove the steering retainer, and then
install a hydraulic steering cylinder or
steering cable following the recommen-
2
dation of the manufacturer.
3
4
5
6
7
8
9
10
A
3-4
External dimensions
External dimensions
F150A, FL150A, F150B, FL150B
TIP:
The dimension values may include reference values.
mm (in)
660 (26.0)
T1 *1
256 (10.1) 433 (17.0)
35°
L:1032 (40.6)
629 (24.8) X:1148 (45.2)
164 (6.5) 698 (27.5)
75 (3.0)
915 (36.0)
769 (30.3)
455 (17.9)
45 (1.8)
16 (0.6)
X:643 (25.3)
210 (8.3) L:516 (20.3)
162(6.4)
H *2
X:1073 (42.2)
L:946 (37.2)
L:60 (
2
X:80 .4)
X:864 (34.0)
L:787 (31.0)
(3.1)
°
70
12°
27(1.1)
L:35 (1.4) –4°

X:43 (1.7) 646 (25.4)
*1. Minimum distance between the outboard motors in twin or triple installation
*2. Transom height
3-5
External dimensions
Clamp bracket
TIP:
The dimension values may include reference values.
0
1
2
3
180 (7.1) 180 (7.1) mm (in)
163.5 (6.4) 163.5 (6.4) 50.8 (2.0)
4
82 (3.2)
5
254 (10.0)
13 (0.5)
367 (14.4)
6
18.5 (0.7)
55.5 (2.2)
7
102 (4.0) 102 (4.0)
8
52 (2.0)
13 (0.5)
125.4 (4.9) 125.4 (4.9)

9
10
A
3-6
Outboard motor mounting
Outboard motor mounting For twin outboard motor installation, place
Installing the outboard motor the outboard motors so that the distance from
Proper mounting of the outboard motor pro- the C/L of each outboard motor to the C/L of
vides better performance, maximum reliabil- the boat transom are equal on both sides.
ity, and the highest customer satisfaction.
This chapter contains the specifications nec- TIP:
essary to mount the outboard motor, and may • Make sure that distance “e” is equal to dis-
vary slightly depending on the applications. tance “f”.
When mounting the outboard motor, make • For the distance (T1), see “External dimen-
sure that there is sufficient clearance for the sions” (3-5).
outboard motor to fully tilt up, and to fully
move to port and starboard. See “External
C/L
dimensions” (3-5).
e f
1. For single outboard motor installation,
place the outboard motor on the vertical
centerline of the boat transom. For the
hull without strakes, make a same radius
(R) at both sides of hull, and have
another measurement points.
TIP: T1
Make sure that distance “a” is equal to dis-
tance “b”, and distance “c” is equal to dis-
tance “d”. C/L: Centerline of the transom
A C/L 2. Adjust the position of the outboard motor

so that the height of the anti-cavitation
plate “1” is equal to or slightly above the
bottom of the boat transom.
R a b R
TIP:
This mounting height information is for refer-
ence only. It is impossible to provide com-
c d plete instructions for every possible boat and
outboard motor combination.
B C/L
A
a b
c d 1
A. Hull without strakes

B. Hull with strakes
C/L: Centerline of the transom
3-7
Outboard motor mounting
C/L: Centerline of the transom
B
Drilling plate “1”: 90890-06783
6. Apply sealant to the mounting holes, and

then secure the outboard motor using the 0
included mounting bolts “1”, small wash-
1 ers “2”, large washers “3”, and nuts “4”.
1
1
Make sure that there is no clearance
A. Single outboard motor between the surfaces of the boat transom
B. Twin outboard motor and the clamp brackets. Otherwise, the
clamp brackets or boat transom may be
2
3. Install the special service tool “1”.
damaged.
4. Adjust the height of the scale “2” to the
transom height (H), and place it on the TIP:
3
special service tool “1”. Secure the spe- The second hole from the top of each clamp
cial service tool “1” to the boat transom bracket is recommended for the upper
using screws or vises. mounting bolt. 4
TIP:
For the transom height (H), see “External
dimensions” (3-5).
1
2
3 2
4
5
5. When the outboard motor mounting posi- 1
tion has been determined, mark the best
suited 4 symmetrical mounting holes on
2
4
6
3
the boat transom “3”. Drill the mounting 2
holes perpendicular to the surface of the
boat transom using a 13.0 mm (0.5 in) 7
“a” drill bit.
D
1
2 1 2
3 2
4
8
9
Boat transom
Mounting bolt
thickness (D)
3
55–65 mm
(2.17–2.56 in)
M12 × 115 mm
(4.53 in)
10
65–75 mm M12 × 130 mm
H (2.56–2.95 in) (5.12 in)
75–95 mm M12 × 150 mm
a (2.95–3.74 in) (5.91 in)
2
C/L A
3-8
Rigging grommet mounting
7. Install the mounting bolts, and then Installing the shift cable
tighten the nuts firmly.
Always perform the cable adjustment in

Make sure that the clamp brackets do not advance, following the procedures in the
bite into the boat transom. remote control operation manual.
8. Tighten the locknuts firmly. 1. Remove the rubber seal “1” from the
retaining plate “2”, and then remove the
retaining plate “2”.
1
2
Rigging grommet description
2. Fully screw in the shift cable joint “1” to
2 the shift cable “2”.
1
10
3
5 2
1
9
6
8 3. Move the remote control lever to the N
7
position.
1. Main wiring harness
4. Disengage the holder “1” from the shift
2. Water temperature lead (optional)
cable holder “2”.
3. Water pressure hose (optional)
4. Isolator lead (optional)
5. Battery cable TIP:
6. Gauge harness or 6Y8 Multifunction Shift cable position can be adjusted using the
Meter harness shift cable holder “2”.
7. Fuel hose
8. Speedometer hose
9. Shift cable
10. Throttle cable
3-9
TIP:
1 When it is not possible to ensure cable
screw-in length of 8.0 mm (0.31 in) or more,
2 remove the shift cable holder “3”, and then
reinstall it to the hole “b” or “c” to adjust the
0
length.
1 1
a 1
5. Install the shift cable “1” to the shift cable
holder “2” and fasten it using the holder
“3”.
2
1 2 3 2
3
3 b
c
2 1
4
6. Align the mark “a” on the bushing “1” with

5
the mark “b” on the plate “2”.
Dimension “a”: 8.0 mm (0.31 in) or more

6
a
1 2 8. Install the clip “1”, and then tighten the
shift cable locknut “2” to the specified
torque.
7
b
8
2
7. Adjust the shift cable joint “1”, and then
install the shift cable joint “1” to the pin
“2”. 9
1
The shift cable joint must be screwed in
8.0 mm (0.31 in) or more “a”. Shift cable locknut “2”:
10
5 N·m (0.5 kgf·m, 3.7 ft·lb)
9. Check the shift cable for proper opera-

tion.
A
3-10
Installing the throttle cable
1. Fully screw in the throttle cable joint “1” to
the throttle cable “2”.
2
1 5. Adjust the throttle cable joint “1”, and
then install the throttle cable joint “1” to
the pin “2” of the throttle lever 2.
2. Disengage the holder “1” from the throttle
cable holder “2”.
The throttle cable joint must be screwed
TIP: in 8.0 mm (0.31 in) or more “a”.
Throttle cable position can be adjusted using
the throttle cable holder “2”.
TIP:
• Pull the inner cable “3” to remove any free
play in the cable.
• When it is not possible to ensure cable
1 screw-in length of 8.0 mm (0.31 in) or more,
remove the throttle cable holder “4”, and
then reinstall it to the holes “b” or “c” to
adjust the length.
2 2
3. Install the throttle cable “1” to the throttle a 1

cable holder “2” and fasten it using the
holder “3”. 1
1 2 3 3
c
2 1
4. Move throttle lever 2 “1” so that it con-

tacts the stopper “2” on the cylinder
block. 4
Dimension “a”: 8.0 mm (0.31 in) or more
3-11
6. Install the clip “1”, and then tighten the
throttle cable locknut “2” to the specified
torque.
1
1
0
2
2 1
4. Connect the trim sensor coupler “a”.
2
Throttle cable locknut “2”:
5 N·m (0.5 kgf·m, 3.7 ft·lb)
7. Check the throttle cable for proper opera-

3
tion.
Installing the 6Y8 Multifunction a 4

Meter harness
1. Remove the cap “1”. Installing the conventional gauge
1 harness
1. Remove the gauge harness coupler “a”
5
from the bracket “1”.
1 6
7
2. Connect the 6Y8 Multifunction Meter har- a
ness coupler “a”.
8
2. Remove the cap “1”.
9
1
a 10
3. Remove the yellow tape “1” and caps “2”.
3. Connect the gauge harness coupler “a”.
A
3-12
Installing the rigging grommet
1. Route each harness through the proper
a hole in the rigging grommet. See “Rig-
ging grommet description” (3-9).
2. Align the white tape “a” on the battery

cable “1” with the inner end of the rigging
grommet.
a
4. Install the gauge harness coupler “a” to 1
the bracket “1”.
a
3. Align the white mark “a” on the fuel hose
“1” with the outer end of the rigging grom-
met.
Installing the main wiring harness 1

1. Route the main wiring harness “1”
through the bracket “2”.
a
2
1
4. Install the retaining plate “1”.
5. Install the rubber seal “2”.
2. Connect the main wiring harness coupler TIP:

“a”, and then secure the main wiring har- Make sure that the rubber seal is installed
ness coupler “a” using the holder “1”. securely.
3-13
Optional equipment
6. Install the rigging tube retainer “1”, and
then fasten it using the plastic tie “2”.
2
1
1
0
2
1
Water pressure sensor “1”:
Optional equipment
18 N·m (1.8 kgf·m, 13.3 ft·lb) 2
2. Remove the plug “1”.
Installing the isolator lead
1. Remove the cap “1” from the isolator
coupler. 3
1 1
4
1
5
3. Install a new gasket “1” and the water
pressure sensor adapter “2”, and then
2. Connect the isolator lead coupler “a”.
tighten the water pressure sensor
adapter “2” to the specified torque.
6
a
7
8
2 1
3. Route the isolator lead through the
Water pressure sensor adapter “2”:
9
proper hole in the rigging grommet. See
23 N·m (2.3 kgf·m, 17.0 ft·lb)
“Rigging grommet description” (3-9).
Installing the water pressure sensor

4. Remove the water pressure sensor cou-
pler “a” from the cap “1”.
10
See 6Y8 Multifunction Meter set up manual
for details of the components. 5. Connect the water pressure sensor cou-
pler “a” to the water pressure sensor “2”.
1. Install the water pressure sensor “1” to
the water pressure sensor adapter “2”,
and then tighten the water pressure sen-
sor “1” to the specified torque. A
3-14
Optional equipment
a 1
a 2
1
W
2
1
Installing the speed sensor 7. Install the speed sensor “1” to the speed
See 6Y8 Multifunction Meter set up manual sensor adapter “2”, and then tighten the
for details of the components. speed sensor “1” to the specified torque.
1. Remove the speedometer hose “1” from

the rigging grommet “2”, and then cut off 2
the tip “a” of the nipple “3”. 1
1
3
Speed sensor “1”:

18 N·m (1.8 kgf·m, 13.3 ft·lb)
2
8. Remove the bracket “1”.
2. Cut the extension hose “1” to 300.0 mm
(11.8 in).
1
3. Install the extension hose “1” to the nip-
ple “2”, and then fasten it using the plas-
tic tie “3”.
2 3 1
9. Connect the extension hose “1” to the

speed sensor adapter “2”, and then
install the speed sensor adapter “2”.
4. Cut the corrugated tube “1” to 300.0 mm

(11.8 in).
5. Cut the corrugated tube “2” to 270.0 mm

(10.6 in). 2
1
6. Install the corrugated tubes “1” and “2”.
3-15
Optional equipment
10. Remove the bracket “1” and cap “2” from 3. Install the holder “2” so that the protru-
the speed sensor coupler “a”. sion “a” on the magnet lever is aligned
with the groove “b” in the through tube
“1”, and the protrusion “c” on the holder is
1
aligned with the hole “d” in the through
tube “1”.
0
a
4. Install the collar “3” and tighten the clamp
screw “4” temporarily. 1
2
TIP:
11. Connect the speed sensor coupler “a” to

Tighten the clamp screw “4” to the extent that
the magnet lever can be moved manually to
2
the speed sensor “1”. adjust the tilt limiter.
a 2
a 1
3
d
c
c
4
4
3
1
d
5
12. Install the rubber seal in the area “a” of
the rigging grommet. b 1
6
5. Install the sensor “1” on the swivel
bracket.
7
a
8
1
Installing the tilt limiter
The models with dual steering cable cannot 9
be fitted with a tilt limiter.
1. Disconnect the battery cable from the

battery.
6. Fasten the tilt limiter lead “1” using the
holder “2”.
10
2. If there is any grease, clean the surface
of through tube “1” to which the holder is
to be installed.
A
3-16
Optional equipment
2
2
1
7. Remove the junction box cover. 11. Route the tilt limiter leads “1” through the
hole in the grommet “2” and into the bot-
8. Disconnect the battery cables “1” and tom cowling.
PTT motor leads “2”.
TIP:
TIP: Pass the tilt limiter leads one by one through
To pass the tilt limiter lead through the hole in the hole in the grommet.
the grommet, remove the PTT motor lead
temporarily.
1 2
12. Route the PTT motor leads “1” through

the hole in the grommet “2” and into the
9. Remove the PTT motor lead “1” from the bottom cowling.
holders “2” and “3”.
TIP:
Pass the PTT motor leads one by one
through the hole in the grommet.
1 2
1
2
10. Remove the plastic tie “1”, and then pull 13. Remove the plastic ties that hold the trim
the PTT motor lead “2” out of the bottom sensor lead.
cowling.
3-17
Optional equipment
14. Route the tilt limiter lead “1” in the same 18. Connect the tilt limiter couplers of the
manner as the trim sensor lead “2”, and main harness side with the tilt limiter cou-
then fasten them using new plastic ties plers “a” of the tilt limiter side of the same
“3” at the positions where original plastic wire colors.
ties were installed. 0
B
3
Sb 1
2 a a
3 L B
Sb
2
3
1
19. Connect the PTT motor leads “1”, and
15. Route the tilt limiter lead “1” and PTT
motor lead “2”, and then fasten them
then tighten the PTT motor lead bolt “2”
to the specified torque.
3
using the holders “3” and “4”.
20. Connect the battery cables “3”, and then
tighten the battery cable nut “4” to the 4
specified torque.
21. Install the rubber cap “5”.

5
4
5
2
2 6
3 3
1
4 1
7
16. Remove the yellow tape “1”.
17. Disconnect the tilt limiter coupler “a” and

PTT motor lead bolt “2”:
4 N·m (0.4 kgf·m, 3.0 ft·lb) 8
remove the cap “b”. Battery cable nut “4”:
9 N·m (0.9 kgf·m, 6.6 ft·lb)
a
22. Install the junction box cover. 9
Setting the tilt limiter
b
10
• Check that the outboard motor is
1 mounted securely.
• Never get under the outboard motor
while it is tilted.
A
3-18
Optional equipment
Make sure to keep the clearance of

50.8 mm (2.0 in) or more between the out-
board motor and the motor well.
25
35
45°
55°
°
°
65°
1. Check that there is no interference
between the steering system and the tilt
limiter when the outboard motor is
steered.
2. Connect the battery cables. a b
3. Decide the tilt up angle “a”.

5. Operate the PTT switch on the bottom
TIP: cowling to tilt the outboard motor up.
The tilt up angle can be set at any tilt setting
range. 6. Check that the outboard motor stops at
set position.
a
7. Tilt the outboard motor down to adjust
the position of the magnet “1” if the set-
ting angle needs to be adjusted.
TIP:
• To adjust the tilt up angle higher: “a”
• To adjust the tilt up angle lower: “b”
4. Align the mark “a” on the magnet with the

desired angle indicated on the sensor.
a
TIP:
The scales on the sensor indicate the
approximate angles from the full trim down 8. Tighten the clamp screw “1” to the speci-
position. fied torque, and then recheck the tilt up
angle.
Example:
If the desired tilt up angle is 35°, align the
mark “a” on the magnet with the scale mark
“b” on the sensor.
3-19
1. Install the receiver “1”, and then tighten
Clamp screw “1”:
the receiver screws “2” to the specified
2 N·m (0.2 kgf·m, 1.5 ft·lb)
torque.
Deactivating the tilt limiter
To fully tilt the outboard motor up, deactivate TIP: 0
the tilt limiter according to the following pro- Mount the receiver within 3 m (10 ft) from the
cedure. steering position.
1. Disconnect the tilt limiter couplers “a” and

1
“b”.
1
2 2
Sb
1
b
a 3
L 2
4
2. Connect the tilt limiter couplers “a” and
“b”. Receiver screw “2”:
4 N·m (0.4 kgf·m, 3.0 ft·lb) 5
Sb 2. Connect the Y-COP wires. See “System
a
diagram” (3-29).
6
Registering the receiver ID to the
b
ECM
L 1. Check that the engine start switch is
OFF.
7
Y-COP (standard for European 2. Push the unlock button “1” of the trans-
market and optional for mitter. The buzzer of the receiver will
sound 2 short beeps.
8
Oceanian market)
Installing Y-COP
See the Yamaha Security System Y-COP
installation manual.
9
• Install the receiver so that the “UP” 10
mark is facing up.
• Do not install the receiver in a location 1
where it will be exposed to water.
• Do not cover the receiver with metal 3. Turn the engine start switch to ON. The
objects. Otherwise, signals may not be buzzer of the receiver will sound 1
received. medium beep.
A
3-20
4. Turn the engine start switch to OFF. Initial
1
registration is complete. Y-COP is
unlocked.
5. Push the lock button “1” of the transmit-

ter. Check that the buzzer of the receiver
will sound 1 short beep.
8. Turn the engine start switch to OFF.
6. Turn the engine start switch to ON.
TIP:
If the outboard motor is equipped with the
6Y8 Multifunction Meter, “-” is displayed on
the tachometer when the engine start switch
is turned to ON.
7. Push the unlock button “1” of the trans-

mitter. Check that the buzzer of the
receiver will sound 2 short beeps.
TIP:
If the outboard motor is equipped with the
6Y8 Multifunction Meter, “0” is displayed on
the tachometer when the engine start switch
is turned to ON.
3-21
Battery installation
• Make sure to connect the battery properly and select the proper cable sizes. Otherwise, a
fire could result. 0
• 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.
1
Do not reverse the battery connections. Otherwise, the charging system could be damaged.
Battery wiring without house (accessory) battery

2
• When only one battery is used for one engine, connect the positive battery cable and isola- 3
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
4
both engine batteries. This cable must be sized equivalent to the engine battery cables or
larger AWG cable size in accordance with ABYC specifications.
5
1. Outboard motor
6
2. Isolator lead
3. Red
7
4. Black
8
9
1. Outboard motor 3. Red
2. Isolator lead 4. Black 10
A
3-22
STBD PORT
1. Outboard motor 1. Outboard motor
2. Isolator lead
3. Red 3. Red
4. Black 4. Black
4. Black

2. Isolator lead 4. Black
1. Outboard motor
2. Isolator lead
4. Red
5. Black
3. Battery switch
ON/OFF

3. Battery switch
3-23
STBD PORT
2. Isolator lead 2. Isolator lead 0

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

10
1. Outboard motor 4. Boat system
2. Battery switch 5. Black
3. Navigation system 6. Red
A
3-24
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.
1. Outboard motor
2. Isolator lead
3. Battery switch
4. Red
3. Battery switch
ON/OFF
1 2
5. Black
4. Red
6. House battery

3. Battery switch 6. House battery
3-25
1. Outboard motor
2. Isolator lead
0
3. Red
1
4. Black
4. Black
5. House battery 2
1. Outboard motor 4. Black 3
2. Isolator lead 5. House battery
3. Red
4
1. Outboard motor
2. Isolator lead 5
3. Black
5. Battery switch
4. Red 6
1 2 7
3. Black
4. Red
6. House battery
8
1. Outboard motor
2. Isolator lead
4. Red
5. Battery switch 9
3. Black 6. House battery
10
A
3-26
STBD 1. Outboard motor PORT

1. Outboard motor
2. Isolator lead 2. Isolator lead

3. Black
4. Battery switch 5. Red 3. Black

5. Red
4. Battery switch
ON/OFF
5. Red ON/OFF
1 2 3. Black
4. Battery switch
6. House battery
3. Black
1. Outboard motor 4. Battery switch

2. Isolator lead 5. Red

1. Outboard motor
3. Black
4. Battery switch
4. Battery switch 5. Red 5. Red 3. Black
ON/OFF
5. Red 5. Red
1 2 1 2
3. Black
4. Battery switch
6. House battery
3. Black

2. Isolator lead 5. Red
3-27

1. Outboard motor

0
3. Black
4. Battery switch
1
5. Red 3. Black
5. Red
5. Red 1 2
4. Battery switch
5. Red
1 2
2
3
6. House battery
3. Black 3. Black 4
2. Isolator lead
3. Black
5. Red
6. House battery
5
STBD 1. Outboard motor PORT 6
1. Outboard motor
3. Battery switch
3. Battery switch
7
ON/OFF
3. Battery switch
5. Black 8
4. Red ON/OFF 4. Red
4. Red ON/OFF 9
5. Black 5. Black 5. Black
10
5. Black 6. House battery 6. House battery

2. Isolator lead
3. Battery switch
5. Black
6. House battery A
3-28
System diagram
System diagram
Single outboard motor application (6Y8 Multifunction Meter)
13 14 15
*2
11 8
b 12 8
c
c 8
c 5
R
b *1 G
7
a B B
Y Y Y
6
10
8
4
1
2
P P 3
3-29
System diagram
1. Engine ECM
2. Speed sensor
3. Trim sensor
5. Remote control box
6. Fuse (10 A)
0
7. Power wire
8. Pigtail bus wire
9. Single hub 1
10. Main bus wire
11. Hub
12. Terminal resistor
13. Tachometer unit
2
14. Speedometer unit
15. Receiver
a. Power port
3
b. Bus port
c. Device port
*1. Install the waterproof cap to the open ter-

4
minal.
*2. Y-COP (standard for European market
and optional for Oceanian market) 5
Color code
B
G
: Black
: Green 6
P : Pink
R : Red
Y : Yellow 7
8
9
10
A
3-30
System diagram
Single outboard motor application (conventional gauge)
*1 7
W(+)
W
R R
W W
B
B W B R
2 3 4
W/R
G/W
Pu/W B
Gy G/W
O
O Pu
O/B P G/R
Pu
R Y L B G P G/R
Pu/W O
B W/R Gy G
1
B
W 12
G
L Y R R R B Y
5 Y
Y
O
L Y 9 8 *1
Pu
B
IN
6
O
10
UP
OUT
11
Gy G
P G/R
P P/W
P/B P/B
3-31
System diagram
2. Fuel management meter unit
3. Speedometer unit
4. Tachometer unit
5. Fuel tank (fuel level sensor)
6. Fuel flow sensor
0
7. GPS
8. Speedometer hose
9. Gauge harness 1
11. Fuel hose
12. Lamp switch
2
*1. When a GPS (NMEA0183) is used, a
speedometer hose is not required.
Color code
3
B : Black
G : Green
Gy
L
: Gray
: Blue
4
O : Orange
P
Pu
: Pink
: Purple 5
R : Red
W : White
Y : Yellow
G/R : Green/Red
6
G/W : Green/White
O/B : Orange/Black
P/B : Pink/Black
P/W : Pink/White
7
Pu/W : Purple/White
W/R : White/Red
8
9
10
A
3-32
System diagram
Twin outboard motor application (6Y8 Multifunction Meter)
16 16 17 18
11 B P B P/B
b
L W
c
12
c
9 12
c A B
12
b 19 19
20
a 13 22
14 7
b *1
c 6
12
c 15
9 c RR R
12
b Y B
a 14 23
13 R
Y B
b
8
c
12 Y
c
9 12
c
12
b 11
a
10
5
21
2
1 1
3 3
P P 4 P P 4
3-33
System diagram
1. Engine ECM
2. Speed sensor
3. Water pressure sensor
4. Trim sensor
0
7. Engine start switch (with engine shut-off
switch)
8. Fuse (10 A) 1
9. Hub
10. Power wire
11. Terminal resistor
12. Pigtail bus wire
2
13. Main bus wire
14. Cap (red)
15. Cap (white)
16. Tachometer unit
3
17. Fuel meter unit
18. Speedometer unit
19. Fuel tank (fuel level sensor) 4
20. GPS
21. Multisensor (speed, water temperature,
and water depth)
22. Receiver 5
23. Power distribution wire
a. Power port
b. Bus port
6
c. Device port
A. PORT
B. STBD
7
*1. Y-COP (standard for European market
and optional for Oceanian market) 8
Color code
B : Black
L : Blue 9
P : Pink
R : Red
W
Y
: White
: Yellow 10
P/B : Pink/Black
A
3-34
System diagram
Twin outboard motor application (conventional gauge)
13
L Y *1
5 YAMAHA
G
SPEED
R LY Y Y
Km/ h
knot
mph
km
mile
TRIP TIME BATT
set mode
Y
B W R R B
R L Y
W R L
*1 8 B W B B
R B G G
W(+) B 3 R B Y B YR
3 W Y
B YAMAHA
TACH
5
4
FUEL MANAGEMENT x100
B
r/min 3
TACH
5 1/h h 2
gph 1
4
Y
x100
Km/ L
WB
r/min 3
mpg
h 2
1 TTL ECON SYNC set mode
set mode
4 set mode
1
G G/W LY 2
Gy G/W B Gy G/W
W/R
P Pu/W O P Br Br
G/R G/R B G B G Sb Br Sb Br
P O Pu P R P R R B
G/R O/B P G/R R R
Pu Y L Y L Lg Br Lg Br
Gy Pu/W O Gy G W W L Y W W L Lg Br Lg Br
G Y
B P R BP R R B R B
W/R
B G Br G Sb Br Sb Br
Br
11 10
O/B
Pu/W
O
Pu B B
IN
Pu B
IN
7 Pu B
UP
11 10 7
OUT
UP
O
OUT
12 12
Gy G Gy G
P G/R P G/R
P P/W P P/W
P/ B P/ B P/B P/B
3-35
System diagram
2. Switch panel
3. Tachometer unit
4. Fuel management meter unit
5. Speedometer unit
6. Fuel tank (fuel level sensor)
0
7. Fuel flow sensor
8. GPS
9. Speedometer hose 1
10. Gauge harness
12. Fuel hose
13. Lamp switch
2
*1. When a GPS (NMEA0183) is used, a
speedometer hose is not required. 3
Color code
B : Black
Br
G
: Brown
: Green
4
Gy : Gray
L
Lg
: Blue
: Light green 5
O : Orange
P : Pink
Pu
R
: Purple
: Red
6
Sb : Sky blue
W : White
Y : Yellow
G/R : Green/Red
7
G/W : Green/White
O/B : Orange/Black
P/B : Pink/Black 8
P/W : Pink/White
Pu/W : Purple/White
W/R : White/Red
9
10
A
3-36
Rigging recommendation
Rigging recommendation
Extension length recommendation for battery cable
Do not exceed the recommended extension length for the battery cable. Otherwise, the elec-
trical system could be damaged or operate improperly.
To extend the length of battery cables, follow the requirements in the tables for battery capacity,
cable size, and ambient temperature.
The maximum total extension length is the total combined length of the positive and negative battery
cables.
Select an extension battery cable and terminal that meet ABYC requirements or the equivalent.
Select the battery stud that is best-suited to the terminal size.
Solder the cable and terminal connections to prevent them from corroding.
Ambient temperature above 0 °C (32 °F)
Battery requirements Cable specifications
Maximum total extension length
Minimum (Positive battery cable + Negative battery cable)
Unit
capacity 20 mm2 30 mm2 50 mm2
(AWG4) (AWG2) (AWG1/0)
CCA/EN 711 Amps 6.0 m 10.0 m 16.0 m
20HR/IEC 100 Ah (19.7 ft) (32.8 ft) (52.5 ft)
3-37
Propeller selection
Propeller selection
The size and type of propeller that is used will affect the performance of a boat and outboard motor
critically. Propellers greatly affect boat speed, acceleration, engine life, fuel economy, and even
boating and steering capabilities. An incorrect choice could adversely affect performance and could
also damage the engine seriously. 0
Use the following information as a guide for selecting a propeller that meets the operating conditions
of the boat and outboard motor.
Propeller size 1
The size of the propeller is indicated on the propeller boss end, and on the side of the propeller
boss.
2
a b c
a
b 3
c
4
a. Propeller diameter (in inches)
b. Propeller pitch (in inches)
c. Propeller type (propeller mark)
5
Selection
With the engine speed at full throttle operating range and under a maximum boat load, the engine 6
speed should be within the upper half of the full throttle operating speed range.
Full throttle operating range
(F150A, FL150A): 5000–6000 r/min
Full throttle operating range
7
(F150B, FL150B): 4500–5500 r/min
Regular rotation model 8

Blade Dia. (in) Pitch (in) Mark Material Part number Remarks
3 15 1/4 15 M Aluminum 6G5-45941-01
3
3
14 5/8
14 1/2
16
17
M
M
Aluminum
Aluminum
6G5-45952-00
6G5-45947-01
9
3 14 19 M Aluminum 6G5-45945-01
3
3
13 3/4
13 1/2
21
23
M
M
Aluminum
Aluminum
6G5-45943-01
6G5-45949-00
10
3 15 3/4 13 M Stainless steel 6G5-45932-00
3 13 3/4 17 M2 Stainless steel 6G5-45978-03
3 13 3/4 19 M2 Stainless steel 6G5-45974-03
3 13 3/8 23 M Stainless steel 6G5-45976-01 A
3-38
Propeller selection
3 14 1/4 17 M Stainless steel 68F-45972-00
3 15 1/4 15 M Stainless steel 6R4-45976-A0
3 15 1/2 17 T Stainless steel 6D0-45978-00
3 15 21 T Stainless steel 6D0-45972-00
3 15 1/2 17 T Stainless steel 6CE-45978-00 SDS *1
3 15 21 T Stainless steel 6CE-45972-00 SDS *1
4 15 21 T Stainless steel 6BR-45B70-00-00
4 15 21 T Stainless steel 6CE-45B70-00-00 SDS *1
*1. These propellers cannot be installed using the spacer “1”. Use the spacer “2” instead.
1 2
Counter rotation model

3 14 1/2 17 ML Aluminum 6K1-45947-00
3 14 19 ML Aluminum 6K1-45945-00
3 15 1/4 15 ML Stainless steel 6K1-45970-01
3 13 3/4 17 ML1 Stainless steel 6K1-45978-02
3 13 3/4 19 ML1 Stainless steel 6K1-45974-02
3-39
Propeller selection
3 14 1/4 17 ML Stainless steel 68G-45972-00
3 14 1/4 18 ML Stainless steel 68G-45978-00
3
3
13 3/4
13 3/4
19
21
ML
ML
Stainless steel
Stainless steel
68G-45974-00
68G-45976-00
0
3 15 1/4 15 ML Stainless steel 6R1-45976-A0
3
3
15 1/4
15 1/4
17
19
ML
ML
Stainless steel
Stainless steel
6R1-45978-A0
6R1-45970-A1 1
3
3
15 1/2
15 1/4
17
19
TL
TL
Stainless steel
Stainless steel
6D1-45978-00
6D1-45970-00
2
3 15 21 TL Stainless steel 6D1-45972-00
3
3
14 3/4
15 1/2
23
17
TL
TL
Stainless steel
Stainless steel
6D1-45974-00
6CF-45978-00 SDS *1
3
3 15 1/4 19 TL Stainless steel 6CF-45970-00 SDS *1
3 15 21 TL Stainless steel 6CF-45972-00 SDS *1
3 14 3/4 23 TL Stainless steel 6CF-45974-00 SDS *1 4
4 15 21 TL Stainless steel 6BS-45B70-00
4 15 22 TL Stainless steel 6BS-45B72-00
4
4
15
15
23
21
TL
TL
Stainless steel
Stainless steel
6BS-45B74-00
6CF-45B70-00 SDS *1
5
4 15 22 TL Stainless steel 6CF-45B72-00 SDS *1
4 15 23 TL Stainless steel 6CF-45B74-00 SDS *1
*1. These propellers cannot be installed using the spacer “1”. Use the spacer “2” instead.
6
1 2 7
8
9
10
A
3-40
Propeller selection
— MEMO —
3-41
Troubleshooting 4
YDIS .................................................................................... 4-1

Basic components ..................................................................... 4-1 0
Function ..................................................................................... 4-2
Connecting the communication cable ....................................... 4-5
1
Outboard motor troubleshooting ..................................... 4-6
Troubleshooting procedure ....................................................... 4-6
Troubleshooting the power unit using the YDIS ........................ 4-6
Trouble code and checking step ............................................... 4-8
2
Troubleshooting the power unit using the diagnostic
flash indicator .......................................................................... 4-10
Troubleshooting the power unit 3
(trouble code not detected) ..................................................... 4-11
Troubleshooting the PTT unit .................................................. 4-16
Troubleshooting the lower unit ................................................ 4-17 4
5
6
7
8
9
10
A
YDIS
YDIS
The Yamaha Diagnostic System uses precision fault diagnosis to offer better serviceability at a time
when there is increasing demand for service tools for electronically controlled products. It provides
quick, reliable, safe, and reasonable service, and is intended to obtain customer satisfaction. The
Yamaha Diagnostic System features updated software and expanded tool functions that allow it to 0
respond to new models and technologies, maintaining compatibility with regulations. This manual
contains the model-specific information. See YDIS (Ver. 2.00 or later) instruction manual for detailed
information.
1
Basic components
1
2
4
***
******
******
2 3
3
5 4
6 8
7
11
6
10
9 7
8
No.
1
Part name
YDIS 2 starter kit
Q’ty
1 90890-06883
Remarks 9
2 CD-ROM 1 Software and instruction manual
3
4
Adapter
USB cable
1
1 5 m (16.4 ft) 10
5 Adapter cap 1
6 AD harness 1 For external input
7 CAN-Line harness 1
8 K-Line harness 1
9 Power supply harness 1
10 Trigger switch harness 1
11 Trigger switch extension harness 1 A
4-1
YDIS
Function
YDIS version 2.00 comprises the following items. Items in grey do not apply to the models covered
by this manual.
1. Start 2. Engine 3. Diagnosis 4. Diagnosis
5. Diagnosis
Record
6. Engine Record
7. Engine operating
hours by RPM
8. Engine Monitor 9. Digital Display
10. Graph Display
11. Input Setting
12. Component Test 13. Stationary Test
14. Active Test
15. Data Logger 16. Logger Graph
17. ECM Rec Graph
18. Logging 19. Record Set
20. Show Data

22. Boat System 23. Tilt Limiter
24. R/C System 21. Clear Data

Reset
26. Engine oil

25. Maintenance
change record
27. Update
28. Setting
29. Off Line
31. Communication
30. CAN Information
List
32. Bus Statistics
4-2
YDIS
1. Start 17. ECM Rec Graph
2. Engine 18. Logging
3. Diagnosis 19. Record Set
4. Diagnosis 20. Show Data
5. Diagnosis Record
6. Engine Record
21. Clear Data
22. Boat System
0
7. Engine operating hours by RPM 23. Tilt Limiter
8. Engine Monitor
9. Digital Display
24. R/C System Reset
25. Maintenance 1
10. Graph Display 26. Engine oil change record
11. Input Setting 27. Update
12. Component Test
13. Stationary Test
28. Setting
29. Off Line
2
14. Active Test 30. CAN Information
15. Data Logger 31. Communication List
16. Logger Graph 32. Bus Statistics 3
4. Diagnosis
Displays diagnosis codes recorded in the engine ECM, item names, and current item conditions.
This enables detection of items with problems. The trouble codes displayed are the same as those 4
described in this chapter. See “Trouble code and checking step” (4-8).
5. Diagnosis Record
Displays diagnosis codes recorded in the engine ECM, item names, and when problems are 5
detected. The fault diagnosis history can be erased. The trouble codes displayed are the same as
those described in this chapter. See “Trouble code and checking step” (4-8).
7. Engine operating hours by RPM

6
Displays both operating hours and total operating hours for different engine speeds.
8. Engine Monitor
Displays engine ECM conditions (sensor information) in real time. “9. Digital Display” displays
7
these in digital form, and “10. Graph Display” displays these in graph form. Additionally, connect-
ing a commercially available external device and configuring “11. Input Setting” enables display of
the Engine Monitor. 8
Engine speed Throttle valve opening Engine shut-off switch
Intake air pressure ISC valve opening Shift position switch
Atmospheric pressure Fuel injection duration Multi-engine system 9
Ignition timing Intake air temperature Engine start switch
Battery voltage Engine temperature Thermoswitch
TPS voltage Oil pressure Shift cut-off switch
10
13. Stationary Test
When the engine is stopped and the shift is in the N position, operate the parts to check, and per-
form tests to check operating conditions and operating noise.
Activate ignition coil #1 & #4 Activate injector (#1–#4) Activate ISC valve
Activate ignition coil #2 & #3 Activate electric fuel pump
A
4-3
YDIS
14. Active test
While the engine is running and the shift is in the N position, operate the parts to check, and per-
form tests to check operating conditions and the engine condition.
Fully open ISC valve Fix ISC valve opening angle
16. Logger Graph

Displays in graph form engine operation data stored in the ECM for the last 13 minutes in 1 minute
intervals.
Engine speed TPS voltage Intake air pressure
Battery voltage Engine temperature Oil pressure
18. Logging
While the computer and engine are not connected, record “Engine Monitor” data using the
adapter. Use “19. Record Set” to set items to record.
“20. Show Data” saves logged data in the computer, and displays this data in graph form. “21.
Clear Data” deletes data and conditions stored in the adapter.
27. Update
It is possible to update the database when update information is provided.
28. Setting
Switches the language to use in the YDIS (English, French, Spanish, Japanese).
29. Off Line

Displays graph data saved in the Engine Monitor (Graph Display) and Logging even when the
computer is not connected to the outboard motor.
31. Communication List

By connecting the YDIS to a hub via a CAN-Line, displays the name of Yamaha genuine parts
connected to the Digital Network (6Y8 Meter). This enables checking that connections are correct.
32. Bus Statistics

By connecting the YDIS to a hub via a CAN-Line, displays the bus load connected to the Digital
Network (6Y8 Meter). If the bus load is higher than 40 %, then check the connection status.
4-4
YDIS
Connecting the communication cable
CAN-Line
2. Adapter cap 3. Adapter 4. USB cable 0

1. CAN-Line harness
1
2
3
5. Hub 5. Hub
4
1. CAN-Line harness 4. USB cable
2. Adapter cap
3. Adapter
5. Hub 5
K-Line
6
7
8
2. Adapter cap
1. Adapter 9
a. YDIS coupler 10
3. USB cable 4. K-Line harness
1. Adapter a. YDIS coupler (gray)

2. Adapter cap
3. USB cable
4. K-Line harness A
4-5
Outboard motor troubleshooting
Troubleshooting procedure
1. Before troubleshooting the outboard motor, check that fresh fuel of the specified type has been
used.
2. Check that all electrical connections are secure and free from corrosion, and that the battery is
fully charged.
3. Check the trouble code using the YDIS first, and then check the electronic control system follow-
ing the trouble code chart.
4. If a trouble code is not detected, check the power unit according to “Troubleshooting the power
unit (trouble code not detected)” (4-11).
5. Before using the YDIS to check the power unit, check the engine ECM circuit. See “Checking
the engine ECM circuit” (5-14).
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.
Troubleshooting the power unit using the YDIS

1. Use the trouble codes displayed by the YDIS to check each part according to the “Trouble code
and checking step” table.
2. Delete the trouble codes after checking, repairing, or replacing a part and check that the trouble
codes are not detected again. If the same trouble codes are detected, the engine ECM may be
faulty.
3. Check the items listed in the table. If all of the items are in good condition, delete the trouble
codes, and then check the trouble codes again. If the same trouble codes are detected again,
the engine ECM is faulty.
4-6
Trouble code table
U: Indicate
—: Not applicable
Code
No.
Item
Diagnostic
flash indicator
YDIS diagnosis
YDIS diagno-
sis record 0
1 No trouble (functioning properly) U — —
13 Pulser coil U U U
15
18
Engine temperature sensor
TPS
U
U
U
U
U
U
1
19 Battery voltage U U U
23 Air temperature sensor U U U
28 Shift position switch U U U 2
29 Air pressure sensor U U U
37 Intake air passage U U U
39
44
Oil pressure sensor
Engine shut-off switch
U
U
U
U
U
—
3
45 Shift cut-off switch U U U
46 Thermoswitch U U U
86 Immobilizer *1 U — U 4
*1. When displayed on the YDIS screen, “*****” or “Immobilizer” represents Y-COP.
5
6
7
8
9
10
A
4-7
Trouble code and checking step
—: Not applicable
Trouble Item See
Symptom Checking steps
code (Condition) page
Measure the pulser coil output peak
5-22
voltage.
Pulser coil “Check Engine” is displayed.
13 Measure the pulser coil resistance. 5-22
(Irregular signal) Engine stall
Check for wiring continuity between
A-4
the pulser coil and the engine ECM.
“Check Engine” is displayed. Measure the engine temperature sen-
5-24
Higher idle speed sor input voltage.
Engine temperature Degraded acceleration per- Measure the engine temperature sen-
5-24
15 sensor formance. sor resistance.
(Out of specification) Declining maximum engine Check for wiring continuity between
speed. the engine temperature sensor and A-4
Overheat engine ECM.
Measure the TPS output voltage and
5-15
“Check Engine” is displayed. opening angle using the YDIS.
TPS Higher idle speed Measure the TPS input voltage. 5-15
18
(Out of specification) Degraded acceleration per- Check for wiring continuity between
formance A-2
the TPS and the engine ECM.
Adjust the TPS. 6-27
Check the lighting coil output peak
Battery voltage and battery 5-19
voltage.
alert are displayed.
Battery voltage Measure the lighting coil resistance. 5-19
Engine does not restart.
19 (Below specified volt- Measure the Rectifier Regulator out-
(Depends on battery condi- 5-19
age) put voltage.
tion)
Engine operates normally. Check the Rectifier Regulator for con-
5-19
tinuity.
Check the air temperature using the
5-23
YDIS.
Measure the air temperature sensor
5-23
Air temperature sen- input voltage.
“Check Engine” is displayed.
23 sor (Out of specifica- Measure the air temperature sensor
Higher idle speed 5-23
tion) resistance.
the air temperature sensor and A-4
engine ECM.
Check the gear shift operation. 10-7
Measure the shift position switch
5-26
input voltage.
Shift position switch Check the shift position switch for
28 Engine operates normally. 5-26
(Irregular signal) continuity.
the shift position switch and the A-4
engine ECM.
Measure the air pressure sensor
5-24
input voltage.
Measure the air pressure sensor out-
Air pressure sensor “Check Engine” is displayed. 5-24
29 put voltage.
(Out of specification) Higher idle speed
the air pressure sensor and the A-4
engine ECM.
4-8
Trouble Item See
Symptom Checking steps
code (Condition) page
Check the O-rings and gaskets of the
6-34
intake manifold.
37
Intake air passage
(Air leakage)
Engine operates normally
Check the intake manifold for cracks.
Check the vacuum hose.
6-38
6-4
0
except at idle.
Check the opening condition of TPS 5-15
and the ISC valve using the YDIS. 5-15
Check the oil pressure using the
YDIS.
7-1
1
Measure the oil pressure sensor input
5-16
voltage.
39
Oil pressure sensor “Check Engine” is displayed.
(Out of specification) Higher idle speed Measure the oil pressure sensor out-
put voltage.
5-16
2
the oil pressure sensor and the A-2
engine ECM.
Measure the shift cut-off switch input
3
5-26
voltage.
Measure the shift cut-off switch resis-
45
Shift cut-off switch
(Irregular signal)
Higher idle speed
tance.
5-26
4
the shift cut-off switch and the engine A-4
ECM.
Measure the thermoswitch input volt-
age.
5-25 5
Check the thermoswitch for continu-
Thermoswitch “Check Engine” is displayed. 5-25
46 ity.
(Irregular signal) Higher idle speed
the thermoswitch and the engine A-4
6
ECM.
Check that Y-COP is properly con-
86
Immobilizer *1
(Communication
Declining maximum engine
nected.
Measure the Y-COP input voltage.
3-29
5-30
7
error) speed
Check the Y-COP circuit. 5-30
*1. When displayed on the YDIS screen, “*****” or “Immobilizer” represents Y-COP.
8
9
10
A
4-9
Troubleshooting the power unit
using the diagnostic flash indicator 2 3
1. Connect the special service tool “1”.
c
TIP:
Before performing this diagnosis, make sure
to connect all of the electrical wires properly.
a a d a a a b
a. Light on, 0.33 seconds

b. Light off, 4.95 seconds
c. Light off, 0.33 seconds
d. Light off, 1.65 seconds
4. If a trouble code is detected, see “Trouble

code and checking step” (4-8).
1
a
a. Diagnostic test lead (Blue/White)

Diagnostic flash “1”: 90890-06873
2. Start the engine and let it idle.
3. Check the flash patterns of the trouble

codes.
TIP:
When more than one trouble code is
detected, the indicator of special service tool
flashes in the pattern of the lowest trouble
code. After that trouble code is corrected, the
indicator flashes in the pattern of the next
lowest the trouble code. This continues until
all the trouble codes are detected and cor-
rected.
Example: The illustration indicates code

number 23.
4-10
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 0
— : Not applicable
Symptom 1: Engine does not crank.
Symptom 2 Cause Checking steps

See
1
page
Gear shift not in the N position Set the gear shift to the N position. 10-7
Blown fuse
Starter relay malfunction
Check the fuse.
Check the starter relay.
5-3
5-27
2
Engine start switch malfunction Check the engine start switch. 5-28
Starter motor does not Neutral switch malfunction Check the neutral switch. —
operate
Short, open, or loose connec-
Measure the starter relay input voltage. 5-27
A-6
3
tion in starter motor circuit Check the wiring harness for continuity.
A-8
Disassemble and check the starter
Starter motor malfunction
Stuck piston or crankshaft

motor.
Disassemble and check the power unit.
5-35
7-61
4
Starter motor operates,
Check the drive shaft bushing. 9-18
but the engine does not
crank
Stuck drive shaft
Disassemble and check the lower unit.
8-19
8-60 5
Symptom 1: Engine will not start (engine cranks).
Symptom 2
Blown fuse
Cause Checking steps
Check the fuse.

See
page
5-3
6
Main relay malfunction Check the main relay. 5-13
Engine ECM does not
operate Short, open, or loose connec-
Check for wiring harness continuity
between the main relay and the engine
ECM.
A-2 7
tion in the engine ECM circuit
Check for continuity between the engine
A-2
ECM and ground.
Measure the pulser coil output peak volt-
age.
5-22
8
Pulser coil malfunction
Spark plug does not pro- Measure the pulser coil resistance. 5-22
duce a spark
(all cylinders)
tion in the pulser coil circuit
between the pulser coil and the engine
ECM.
A-4 9
Y-COP is locked. Unlock Y-COP. 3-20
10
A
4-11
See
page
— Measure the fuel pressure. 6-5
Check the fuel filter for dirt and obstruc-
Clogged filter 6-9
tions.
Fuel leakage Check the fuel line for leakage. 6-1
Check the high-pressure fuel pump oper-
5-18
High-pressure fuel pump mal- ation using the YDIS.
function Measure the high-pressure fuel pump
5-18
resistance.
Main relay malfunction Check the main relay. 5-13
Measure the high-pressure fuel pump
Fuel not supplied 5-18
input voltage.
(all cylinders)
between the high-pressure fuel pump A-2
tion in high-pressure fuel pump
and the main relay.
circuit
between the high-pressure fuel pump A-2
and engine ECM.
Check the fuel pump for leakage. 6-13
Fuel pump malfunction Check the diaphragm for tears. 6-14
Check the camshaft. 7-35
Y-COP is locked. Unlock Y-COP. 3-20
Improper valve timing Check the timing belt. 7-17
Measure the compression pressure. 7-1
Compression pressure Check the valve for bends or sticking. 7-41
is low Compression leakage Check the piston and piston rings for
7-61
damage.
Check the cylinder for scratches. 7-64
Check the ISC valve for sticking. 5-15
— Intake air passage malfunction Check the intake manifold and throttle
6-34
body for air leakage.
Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited
engine speed.
See
page
Check the throttle valve for proper move-
Throttle valve malfunction 6-25
ment.
Throttle valve does not Throttle valves do not synchro-
Synchronize the throttle valves. 6-29
move properly nize.
Throttle link and throttle cable 3-11
Adjust the throttle link and throttle cable.
are not installed properly. 6-27
4-12
See
page
Check the ignition spark. 5-21
Spark plug malfunction
Check the spark plugs. 7-25
Measure the spark plug wire resistance. 5-21 0
between the ignition coil and the engine A-4
ECM.
Spark plug does not pro-

tion in ignition coil circuit
between the ignition coil and the main A-4
1
duce a spark
relay
(some cylinders)
Measure the ignition coil input voltage. 5-21
Ignition coil malfunction

Measure the ignition coil output peak
voltage.
5-21
2
Measure the ignition coil resistance. 5-21
Pulser coil malfunction

Measure the pulser coil output peak volt-
age.
Measure the pulser coil resistance.
5-22
5-22
3
Measure the fuel pressure. 6-5
Fuel pressure is low

High-pressure fuel line mal-
function
Check the pressure regulator.
Check the fuel filter for dirt and obstruc-
6-5
6-43
4
tions.
Check the high-pressure fuel pump. 5-18
Fuel injector malfunction

Check the fuel injector operation using
the YDIS.
5-17 5
Measure the fuel injector resistance. 5-17
Measure the fuel injection volume. 6-32
Fuel not supplied

Measure the fuel injector input voltage.
5-17
6
(some cylinders) between the fuel injector and the main A-2
relay.
tion in fuel injector circuit
between the fuel injector and the engine A-2 7
ECM.
Clogged fuel injector filter Replace the fuel injector. 6-30
Engine ECM malfunction
Improper valve timing
Replace the engine ECM.
Check the timing belt.
7-28
7-17
8
Measure the compression pressure. 7-1
Measure the valve clearance. 7-1
Compression pressure
Check the camshaft for damage. 7-35
7-41
9
is low Compression leakage Check the valve and valve seat for wear.
7-43
Check the piston and piston ring for
damage.
Check the cylinder for scratches.
7-61
7-64
10
A
4-13
Symptom 1: High engine idle speed
See
page
Check the gaskets of the intake manifold
Air leakage (throttle valve–cyl- and throttle body. 6-34
inder head)
Check the intake manifold for cracks. 6-38
Throttle link and throttle cable 3-11
— Adjust the throttle link and throttle cable.
are not installed properly. 6-27
Check the ISC valve operation using the
5-15
ISC valve malfunction YDIS.
Measure the ISC valve input voltage. 5-15
Symptom 1: Limited engine speed

See
page
Check the pilot hole for cooling water dis-
10-5
charge.
Clogged cooling water inlet
Check the cooling water inlet. 10-8
Check the impeller. 8-11
Water pump impeller malfunc-
Check the Woodruff key. 8-11
Buzzer comes on, over- tion
Check the insert cartridge. 8-11
heat alert indicator
comes on Water leakage from water Check the water pump housing. 8-11
pump housing Check the outer plate cartridge. 8-11
Clogged cooling water pas-
Check the cooling water passages. 2-16
sages
PCV is open. Check the PCV. 7-50
Thermostat malfunction Check the thermostat. 7-50
Check the oil level. 10-5
Check for engine oil leakage. 2-15
Insufficient engine oil 7-41
Check the valve seals and valves.
7-43
Check the piston rings. 7-64
Buzzer comes on, oil
Measure the oil pressure. 7-1
pressure alert indicator
Check the oil pressure sensor. 5-16
comes on
Check the oil pump. 7-54
Engine oil pressure decrease Check the oil strainer. 9-22
Check the oil passages (power unit and
2-15
oil pump).
Replace the oil filter. 7-56
Check Y-COP for wiring harness continu-
— Y-COP malfunction 5-30
ity.
4-14
Symptom 1: Discharged battery
See
page
Battery performance decrease

Check the battery capacity and specific
gravity.
10-4
0
Check the battery cable and terminals
—
Short, open, or loose connec- for proper connections.
tion in charging circuit
—
Check the charging circuit for wiring con-
nection and damage.
Measure the lighting coil output peak
A-6
A-8 1
5-19
Lighting coil malfunction voltage.
Measure the lighting coil resistance.
Measure the Rectifier Regulator output
voltage.
5-19
5-19
2
Rectifier Regulator malfunction
Check the Rectifier Regulator for conti-
5-19
Symptom 1: Y-COP lock and unlock do not function.

nuity.
3
See
page
Y-COP transmitter malfunction

Check the button cell battery voltage. 5-31 4
There is an answer-back Replace with a spare transmitter. —
(beep) Short, open, or loose connec-
Check the Y-COP circuit. 5-30
tion of the wiring harness
Symptom 1: Y-COP lock and unlock function, but there is no answer-back (beep).
5
See
Buzzer malfunction Check the buzzer.

page
5-30 6
— Short, open, or loose connec- Measure the buzzer input voltage. 5-30
tion of the wiring harness Check the Y-COP circuit. 5-30
7
8
9
10
A
4-15
Troubleshooting the PTT unit
Troubleshooting consists of the following 3 items:
Cause: Trouble causes of symptom 2
Symptom 1: PTT unit does not operate.

See
page
Blown fuse Check the fuse. 5-3
PTT switch malfunction Check the PTT switch. 5-42
PTT relay malfunction Check the PTT relay. 5-41
Measure the PTT switch input voltage. 5-42
PTT relay does not oper- Measure the PTT relay input voltage. 5-41
ate Check for wiring harness continuity
Short, open, or loose connec- A-6
tion of the wiring harness between the PTT switch and the PTT
A-8
relay.
Check for wiring harness continuity A-6
between the PTT switch and the fuse. A-8
PTT motor malfunction Check the PTT motor. 9-35
PTT motor does not
Short, open, or loose connec- Check for continuity between the PTT A-6
operate
tion in PTT motor circuit motor and the PTT relay terminal. A-8
Bent tilt ram or trim ram Check the tilt ram and trim ram. 9-41
—
Stuck tilt ram or trim ram Disassemble and check the PTT unit. 9-41
Manual valve open Check the manual valve. 9-60
— Check the hydraulic pressure. 9-35
Insufficient PTT fluid Add sufficient PTT fluid. 10-14
PTT fluid leakage Check the PTT fluid leakage. 10-14
9-41
Disassemble and check the PTT unit. 9-48
PTT fluid pressure does 9-54
not increase 9-48
Clogged fluid passage Check the filter for dirt and obstructions.
9-54
9-41
Check the valves for damage.
9-54
Check the fluid passage for obstructions. 2-19
PTT motor malfunction Check the PTT motor. 9-48
Gear pump malfunction Check the gear pump operation. 9-54
4-16
Symptom 1: PTT unit does not hold the outboard motor up.
See
page
Manual valve open
Insufficient PTT fluid
Check the manual valve.
Add sufficient PTT fluid.
9-60
10-14 0
— Check the hydraulic pressure. 9-35
PTT fluid leakage Check the PTT fluid leakage. 10-14
PTT fluid pressure does
not increase Disassemble and check the PTT unit.
9-41
9-48 1
9-54
Clogged fluid passages 9-41
Check the valves for damage.
Check the fluid passages for obstruc-

9-54
2-19
2
tions.
Troubleshooting the lower unit

Troubleshooting consists of the following 3 items: 3
Cause: Trouble causes of symptom 2
4
Symptom 1: Shift mechanism of the forward gear and reverse gear does not operate prop-
erly.
See
5
page
—
Shift cable is not adjusted
properly.
Adjust the shift cable.
Check the shift rod for wear.

3-9
8-11
6
Shift rod does not operate
properly. 8-17
Check the detent mechanism.
Check the shift rod connection.

9-1
8-27 7
Check the dog clutch and related parts. 8-13
Shift mechanism malfunction
— 8-16
(in lower unit) Check the forward gear, reverse gear,
and pinion for damage and wear.
8-22
8-22 8
9
10
A
4-17
— MEMO —
4-18
Electrical system 5
Electrical component and wiring harness routing ......... 5-1

Port ........................................................................................... 5-1
Junction box assembly .............................................................. 5-3
Rear ........................................................................................... 5-5
Top ............................................................................................ 5-6
Bottom cowling .......................................................................... 5-7
ECM circuit ........................................................................ 5-9

Circuit diagram .......................................................................... 5-9
ECM coupler layout ................................................................. 5-11
Checking the electrical component ............................... 5-12

Using the YDIS ........................................................................ 5-12
Measuring the peak voltage .................................................... 5-12
Using the digital tester ............................................................. 5-13
Engine control unit and component .............................. 5-13

Checking the main relay .......................................................... 5-13
Checking the engine ECM circuit ............................................ 5-14
Checking the TPS ................................................................... 5-15
Checking the ISC valve ........................................................... 5-15
Checking the oil pressure sensor ............................................ 5-16
Fuel control unit and component .................................. 5-16

Checking the water detection switch ....................................... 5-16
Checking the fuel injector ........................................................ 5-17
Checking the high-pressure fuel pump .................................... 5-18
Checking the vapor shut-off valve ........................................... 5-18
Charging unit and component ....................................... 5-19

Checking the lighting coil (stator assembly) ............................ 5-19
Checking the Rectifier Regulator ............................................. 5-19
Ignition unit and component .......................................... 5-21

Checking the ignition spark ..................................................... 5-21
Checking the spark plug wire .................................................. 5-21
Checking the ignition coil ......................................................... 5-21
Checking the pulser coil .......................................................... 5-22
Checking the air temperature sensor ...................................... 5-23
Checking the air pressure sensor ............................................ 5-24
Checking the engine temperature sensor ............................... 5-24
Electrical system
Checking the thermoswitch ..................................................... 5-25

Checking the shift cut-off switch .............................................. 5-26
Checking the shift position switch ........................................... 5-26
0
Checking the engine shut-off switch ........................................ 5-27
Starting unit and component ......................................... 5-27

1
Checking the starter relay ....................................................... 5-27
Checking the engine start switch ............................................. 5-28
2
optional for Oceanian market) ....................................... 5-29
Checking Y-COP ..................................................................... 5-30 3
Checking the buzzer ................................................................ 5-30
Checking the Y-COP main wiring harness .............................. 5-30
Checking the button cell battery .............................................. 5-31 4
Starter motor ................................................................... 5-33
Removing the starter motor ..................................................... 5-35
Checking the starter motor pinion ........................................... 5-35
5
Disassembling the starter motor .............................................. 5-35
Checking the armature (starter motor) .................................... 5-37
Checking the brush holder ...................................................... 5-37
6
Assembling the starter motor .................................................. 5-38
Installing the starter motor ....................................................... 5-39
7
6Y8 Multifunction Meter sensor ..................................... 5-40
Checking the water pressure sensor (optional) ....................... 5-40
Checking the speed sensor (optional) ..................................... 5-40 8
PTT system ...................................................................... 5-41
Checking the PTT relay ........................................................... 5-41
Checking the PTT switch (on bottom cowling) ........................ 5-42
9
Checking the trim sensor ......................................................... 5-42
Checking the tilt limiter (optional) ............................................ 5-43
10
A
Electrical component and wiring harness routing
Port
A 2
B
3 4
1
10
8 6
7 E
1. Engine ECM 9. Oil pressure sensor

2. Starter motor 10. Fuse holder
3. Thermoswitch
4. Rectifier Regulator A. Run the pulser coil lead under the
5. Ignition coil breather hose and the wiring harness.
6. Vapor shut-off valve B. Run the oil pressure sensor lead behind
7. Speed sensor coupler the Rectifier Regulator coupler.
8. Water pressure sensor coupler
5-1
0
A 2
B
3 4
1
1
D
3
4
5
5
6
10
7
9 8
6
8 7 E
9
D. Install the ignition coil lead, water pres-

10
sure sensor lead, vapor shut-off valve
lead, and speed sensor lead to the
holder.
E. Install the ignition coil lead, vapor shut-off
valve lead, and speed sensor lead to the
holder.
A
5-2
Junction box assembly
a
14
2
13
A
A-A 11
12
10
9 7
D
B
8
5
E
4 3
1. Engine ECM 9. Fuse (20 A) (engine start switch, PTT

2. PTT relay switch)
3. Starter relay 10. Fuse (20 A) (engine ECM, ISC valve, fuel
4. Diode (connect to the PTT relay) injector, high-pressure fuel pump, ignition
5. Flash indicator connector coil, YDIS)
6. Fuse (30 A) (starter relay) 11. Fuse (50 A) (house battery)
7. Main relay 12. Fuse (50 A) (engine battery)
8. Fuse (30 A) (20 A) (spare) 13. Air temperature sensor
5-3
0
1
A 1
2
a
14
13
2 3
A
4
A
A-A 11
12
5
10
9 7
D
8
B
6
6
F
7
5
E 8
4 3 9
14. YDIS coupler D. Fasten the wiring harness, Rectifier Reg-

10
ulator lead, and power supply lead using
A. Route the starter motor lead and the the plastic tie.
power supply lead to the left side of the E. Install the starter motor lead, PTT motor
part “a”. lead, and isolator lead, and tilt limiter
B. Do not fasten the starter motor lead lead (F150A, FL150A) to the holder.
using a plastic tie. F. Route the ground lead between the PTT
relay and the starter relay. A
5-4
Rear
D
3
1
A
E
4
1. Spark plug wire B. Fasten the spark plug wires #1 and #2

2. High-pressure fuel pump coupler using the holder.
3. Fuel injector D. Fasten the spark plug wires #2 and #4
4. Shift cut-off switch coupler using the holder.
5. Shift position switch coupler E. Fasten the spark plug wires #3 and #4
using the holder.
A. Route the fuel injector lead behind the
fuel rail.
5-5
Top
A
0
1
2
1
2
3
E 4
6
5
B
3
F
E
6
D
7
5 8
4
9
1. Air pressure sensor B. F150B, FL150B

10
2. ISC valve D. Install the pulser coil coupler to the junc-
3. Lighting coil (stator assembly) tion box.
4. Pulser coil E. Bend the engine temperature sensor
5. Engine temperature sensor lead, and then fasten it using the holder.
6. TPS F. Fasten the engine temperature sensor
A. F150A, FL150A
lead using the plastic tie.
A
5-6
Bottom cowling
A
D
2
G
G E
3
H
H
4
5 B
6
F 10
7
3
9
11
G-G H-H
1. Shift cut-off switch 7. 6Y8 Multifunction Meter communication

2. Shift position switch lead
3. PTT switch 8. Trim meter lead
4. 6Y8 Multifunction Meter communication 9. Isolator lead
coupler 10. Trim sensor lead
5. Gauge harness coupler 11. PTT switch lead
6. Isolator coupler
5-7
A
D 0
1
2
1
G
G E 2
3
H
3
H
4
4
6
5 B
5
6
8
F 7
10
3
7
9
11
8
G-G H-H
A. Regular rotation model

10
B. Counter rotation model
D. Route the wiring harness along the
groove in the bottom cowling.
E. Install the PTT motor lead and isolator
lead to the holder.
F. Align the white paint mark on the flushing
hose with the outer end of the grommet. A
5-8
ECM circuit
ECM circuit
Circuit diagram
TIP:
The circled numbers in the illustration indicate the engine ECM terminal numbers.
1. Pulser coil #1 23. Fuel injector #1

14 40
2. Pulser coil #2 24. Fuel injector #2
15 39
3. TPS 5V 25. Fuel injector #3
10 41
26. Fuel injector #4
34 17
6
4. Air pressure sensor 33 28. ISC valve

20
5. Oil pressure sensor 29 18
21
6. Water pressure
11 19
sensor
29. Ignition coil #1, 4

7. Speed sensor 12 22
8. Ground
8 30. Ignition coil #2, 3
44
35 31. Oil pressure alert indicator
10. Air temperature sensor 24
7 21. Engine
ECM
32. Overheat alert indicator
9
11. Shift cut-off switch 28
12. Engine shut-off switch 33. Diagnostic flash indicator

4 27
13. Thermoswitch
37 34. Alert buzzer
3 BZ
14. Trim sensor
36 35. Multi-engine system switch
15. Water detection switch 36. Tachometer

5 2 T
31 37. High-pressure fuel pump
43 P
32
42 1 38. 6Y8
Multifunction
17. YDIS 26 23 Meter
30
13
18. Engine start switch 16
19. Rectifier
Regulator
22. Main relay
20. Battery
5-9
ECM circuit
1. Pulser coil #1
2. Pulser coil #2
3. TPS
0
7. Speed sensor
8. Ground
9. Engine temperature sensor 1
12. Engine shut-off switch
13. Thermoswitch
2
14. Trim sensor
17. YDIS
3
18. Engine start switch
19. Rectifier Regulator
20. Battery 4
21. Engine ECM
22. Main relay
24. Fuel injector #2 5
28. ISC valve
6
31. Oil pressure alert indicator
32. Overheat alert indicator
7
33. Diagnostic flash indicator
34. Alert buzzer
35. Multi-engine system switch 8
36. Tachometer
38. 6Y8 Multifunction Meter
9
Indicates a connection between the
symbols.
10
A
5-10
ECM circuit
ECM coupler layout
1 2 3 4 5 6 7 8 9 10111213141516171819202122
23242526272829303132333435363738394041424344
No. Connecting part Color No. Connecting part Color

6Y8 Multifunction 31 Shift position switch Blue/Green
1 White
Meter 32 Ground Black
2 Tachometer Green 33 Air pressure sensor Pink/Green
3 Alert buzzer Pink 34 TPS Pink
4 Engine shut-off switch White Engine temperature
35 Black/Yellow
5 Water detection switch Blue/White sensor
6 Vapor shut-off valve Green/Black 36 Trim sensor Pink
7 Air temperature sensor Black/Yellow 37 Thermoswitch Pink
8 Sensor ground Black 38 — —
9 Shift cut-off switch Blue/Yellow 39 Fuel injector #2 Purple/Black
10 Sensor power source Orange 40 Fuel injector #1 Purple/Red
11 Water pressure sensor Blue/White 41 Fuel injector #3 Purple/Yellow
12 Speed sensor Blue 42 Ground Black
13 Engine start switch Yellow High-pressure fuel
43 Blue
pump
14 Pulser coil #1 White/Red
44 Ignition coil #2, 3 Black/White
15 Pulser coil #2 White/Black
16 Main relay Yellow/Green
17 Fuel injector #4 Purple/Green
18 ISC valve Green/Black
19 ISC valve Green
20 ISC valve Green/Red
21 ISC valve Green/Yellow
22 Ignition coil #1, 4 Black/Orange
6Y8 Multifunction
23 Blue
Meter
Low oil pressure alert
24 Pink/White
indicator
25 — —
26 YDIS White/Black
Diagnostic flash indi-
27 Blue/White
cator
Overheat alert indica-
28 Pink/Black
tor
29 Oil pressure sensor Pink/White
30 Battery power source Red/Yellow
5-11
Checking the electrical component
Checking the electrical
TIP:
component • Before measuring the peak voltage, check
Using the YDIS all of the wiring harnesses for corrosion.
When checking the TPS, ISC valve, high-
pressure fuel pump, fuel injector, or each
Also, make sure that the wiring harnesses
are connected properly and that the battery
0
sensor, use the YDIS. is fully charged.
• Use peak voltage adapter B with the rec-
TIP:
• When deleting the diagnosis record in the
ommended digital circuit tester.
• Connect the positive pin of peak voltage
1
YDIS, make sure to check the time that the adapter B to the positive terminal of the dig-
trouble codes were detected.
• When checking the input voltage of a part,
ital tester, and connect the negative pin to
the negative terminal. 2
the coupler or connector must be discon- • When measuring the peak voltage, set the
nected. As a result, the engine ECM deter- digital circuit tester to the DC voltage mode.
mines that the part is disconnected and a
trouble code is detected. Therefore, make
3
sure to delete the diagnosis record after
checking the input voltage.
• To connect and operate the YDIS, see the
YDIS (Ver. 2.00 or later) instruction manual.
DC V 4
Measuring the peak voltage
5
When measuring the peak voltage, do not Digital circuit tester: 90890-03189
touch any of the connections of the digital
tester probes.
Peak voltage adapter B: 90890-03172 6
Using the digital tester
The electrical technical data applies to the
When measuring the peak voltage

measurements taken using the Yamaha rec- 7
ommended tester.
between the terminals of an electrical
The resistance values shown are the values
component using the digital tester, make
sure that the leads do not contact any
metal parts. Otherwise, the electrical com-
taken before the engine is started. The actual
resistance may vary depending on the envi- 8
ronmental conditions and ambient tempera-
ponent may short-circuit and be dam-
ture.
aged.
The input voltage changes depending on the
battery voltage.
9
To check the electrical components or mea- If the tester probe cannot be inserted into the
sure the peak voltage, use the special ser- coupler, prepare a test lead suitable for the
vice tools. A malfunctioning electrical
component can be checked easily by mea-
measurement. 10
suring the peak voltage. The specified engine
speed when measuring the peak voltage is
affected by many factors such as fouled
spark plugs or a weak battery. If one of these
factors is present, the peak voltage cannot be
measured properly.
A
5-12
Engine control unit and component
c
d a
1 2
Test lead: Relay terminals continuity:

Terminal, male “1”: 9E212-10303 Terminal “c”–Terminal “d”
Terminal, female “2”:
(commercially available) 3. Measure the input voltage between the
terminal “a” and ground, and the terminal
Engine control unit and “b” and ground.
component
Checking the main relay
1. Remove the main relay “1”.
a
b
1
Main relay input voltage:

Terminal “a”–Ground
Terminal “b”–Ground
12 V (battery voltage)
2. Connect the positive battery lead to the
terminal “a”, connect the negative battery 4. Turn the engine start switch to ON, and
lead to the terminal “b”, and then check then measure the input voltage between
for continuity between the terminals “c”, terminals “a” and “b”.
and “d”. Replace the relay if out of speci-
fication.
Do not reverse the battery leads.
5-13
42 32
a
0
b 1
2
Wiring harness continuity:
Main relay input voltage:
Terminal “a”–Terminal “b” Terminal 32–Ground 3
12 V (battery voltage) Terminal 42–Ground
5. Turn the engine start switch to OFF, and

then install the main relay.
3. Measure the input voltage at the engine
ECM coupler terminal and ground. 4
Checking the engine ECM circuit
1. Disconnect the engine ECM coupler “a”. 16
5
a
6
7
Engine ECM input voltage:

8
Terminal 16–Ground
2. Check for continuity between the engine
ECM coupler terminals and ground. 4. Turn the engine start switch to ON, and
9
then measure the input voltage at the
engine ECM coupler terminal and
ground. 10
A
5-14
TPS output voltage and throttle

13 valve opening angle (reference data):
Item Fully closed “a” Fully open “b”
Output
0.703 V 4.033 V
voltage
Opening
0.1° 83.2°
angle
4. Disconnect the TPS coupler “a”, and then

measure the TPS input voltage at the
TPS coupler.
Engine ECM input voltage

(reference data): O B
Terminal 13–Ground
11.2 V
6. Connect the engine ECM coupler.

TPS input voltage:
Checking the TPS Orange (O)–Black (B)
1. Connect the YDIS to display “TPS”. 4.75–5.25 V
2. Start the engine and warm it up for 5–10 5. Turn the engine start switch to OFF.
minutes, and then stop it.
6. Connect the TPS coupler.
3. Turn the engine start switch to ON, and
then measure the TPS output voltage Checking the ISC valve
and throttle valve opening angles when 1. Check the operation of the ISC valve
the remote control lever is at the fully using the YDIS “Stationary test” and
closed position “a” and fully open position check the operating sound.
“b”.
2. Start the engine, and then check the
N engine speed increases using the YDIS
F a R “Active test”.
3. Disconnect the ISC valve coupler “a”.

then measure the ISC valve input voltage
at the ISC valve coupler terminal and
b ground.
5-15
Fuel control unit and component
a P/W
B
O
G/W B G
R/Y
2
0
R/Y
1
ISC valve input voltage:
Red/Yellow (R/Y)–Ground
2 1 2
5. Turn the engine start switch to OFF. Pressure pump “1”:
6. Connect the ISC valve coupler.
(commercially available) 3
Test harness (3 pins) “2”: 90890-06869
Checking the oil pressure sensor
1. Disconnect the oil pressure sensor cou-
pler “a”.
Oil pressure sensor output voltage
(reference data): 4
Pink/White (P/W)–Black (B)
2.5 V at 392.0 kPa
B O
(3.92 kgf/cm2, 56.8 psi)
4.5 V at 784.0 kPa
5
(7.84 kgf/cm2, 113.7 psi)

then disconnect the special service tool
6
and pressure pump.
a

6. Install the oil pressure sensor. See “Cyl-
inder block (F150A, FL150A)” (7-52).
7
then measure the input voltage at the oil
pressure sensor coupler. 7. Connect the oil pressure sensor coupler.
Oil pressure sensor input voltage: Fuel control unit and component
8
Orange (O)–Black (B) Checking the water detection switch
4.75 V–5.25 V
3. Remove the oil pressure sensor, and

1. Disconnect the water detection switch
coupler “a”. 9
then connect the pressure pump “1” and
special service tool “2”.
4. Apply positive pressure to the oil pres-

water detection switch coupler. 10
sure sensor slowly, and then measure
the output voltage at the specified pres-
sures.
A
5-16
Water detection switch continuity:

B L/W Continuity:
Float position “B”
No continuity:
Float position “A”
6. Install the fuel cup assembly. See “Fuel

filter” (6-7).
a
7. Connect the water detection switch cou-
Water detection switch input voltage: pler.
Blue/White (L/W)–Black (B)
4.75–5.25 V Checking the fuel injector
1. Check the operation of the fuel injectors
3. Turn the engine start switch to OFF, and using the YDIS “Stationary test” and
then remove the fuel cup assembly. check the operating sound.
4. Check that the float “1” moves smoothly. 2. Disconnect the fuel injector couplers “a”.
5. Check the water detection switch for con- 3. Turn the engine start switch to ON, and
tinuity when the float “1” is in positions then measure the input voltage between
“A” and “B”. the fuel injector coupler terminal and
ground.
Do not remove the clip and float.

R/Y
A
1 a
B
Fuel injector input voltage:
1 12 V (battery voltage)
5. Measure the fuel injector resistance.
5-17
0
1
Fuel injector resistance (reference data): High-pressure fuel pump resistance
11.50–12.50 Ω at 20 °C (68 °F) (reference data):
0.3–10.0 Ω at 20 °C (68 °F)
2
6. Connect the fuel injector couplers.
6. Connect the high-pressure fuel pump
Checking the high-pressure fuel
pump
coupler. 3
1. Check the operation of the high-pressure Checking the vapor shut-off valve
fuel pump using the YDIS “Stationary 1. Disconnect the vapor shut-off valve cou-
test” and check the operating sound. pler “a”. 4
2. Disconnect the high-pressure fuel pump 2. Turn the engine start switch to ON, and
coupler “a”. then measure the input voltage between
3. Connect the tester probes to the termi-

the vapor shut-off valve coupler terminal 5
and ground.
nals of the high-pressure fuel pump cou-
pler, and then measure the input voltage
within 3 seconds after turning the engine R/Y 6
start switch to ON.
a L R/Y
a
7
8
Vapor shut-off valve input voltage:
9
High-pressure fuel pump input voltage: 3. Remove the vapor shut-off valve, and
Red/Yellow (R/Y)–Blue (L) then connect the special service tool “1”
12 V (battery voltage) to the vapor shut-off valve.
Vacuum/pressure pump gauge set “1”:
10
90890-06945
5. Measure the high-pressure fuel pump
4. Apply the specified negative pressure to
motor resistance.
the vapor shut-off valve.
Specified negative pressure:
67.0 kPa (0.67 kgf/cm2, 9.7 psi)
A
5-18
Charging unit and component
5. Check that the vapor shut-off valve 3. Measure the lighting coil output peak
opens and the negative pressure is voltage between all combinations of the
released when the battery leads are connectors. Replace the stator assembly
connected to the vapor shut-off valve if below specification.
terminals.
TIP:
When measuring the lighting coil output peak
Connect the battery leads to the vapor voltage under the cranking (unloaded) condi-
shut-off valve terminals for only a few sec- tion, remove the clip from the engine shut-off
onds. switch to prevent the engine from starting.
1
1 1
G
G
G
6. Remove the special service tool.
7. Measure the resistance between the

vapor shut-off valve terminals.
Vapor shut-off valve resistance: Test harness (3 pins) “1”: 90890-06847
30.0–34.0 Ω at 20 °C (68 °F)
Lighting coil output peak voltage:
8. Install the vapor shut-off valve, and then Green (G)–Green (G)
connect the vapor shut-off valve coupler. Unloaded
r/min
Cranking 1500 3500
Charging unit and component DC V 11.0 50.0 110.0
Checking the lighting coil (stator
assembly) 4. Measure the lighting coil resistance.
1. Disconnect the lighting coil coupler “a”. Lighting coil resistance (reference data):
0.2–0.3 Ω at 20 °C (68 °F)
a
5. Disconnect the special service tool, and
then connect the lighting coil coupler.
Checking the Rectifier Regulator
Do not connect the battery cables in

reverse. Otherwise, the Rectifier Regula-
2. Connect the special service tool “1”. tor could be damaged.
1. Disconnect the Rectifier Regulator cou-

pler “a”.
5-19
Charging unit and component
a a
0
1 1
2. Connect the special service tool “1”, and 4. Set the digital circuit tester to the diode
then measure the Rectifier Regulator
output voltage.
mode, and then check the Rectifier Reg-
ulator for continuity.
2
TIP:
Do not use peak voltage adapter B when
a
b 3
measuring the Rectifier Regulator output volt- c
age.
R
d
e 4
R f
B
1
R R B
d
5
e
1
a 6
b
c
f
7
8
Rectifier Regulator output voltage:
Red (R)–Black (B)
r/min
1500
Loaded
3500
9
DC V 13 13
3. Disconnect the special service tool “1”

and lighting coil coupler “a”.
10
A
5-20
Ignition unit and component
3. Check the ignition spark using the YDIS
Rectifier Regulator continuity
“Stationary test”.
(testing diode mode):
Tester probe Display value
(+) (–) (reference data)
Do not touch any of the connections of
b
OL the special service tool.
c
a d 0.439 V OK
e 0.434 V
f OL
a
OL
c
b d 0.440 V
e 0.436 V 1
f OL
a
OL Ignition tester (spark gap tester) “1”:
b
c d 0.439 V 90890-06754
e 0.441 V 4. Remove the special service tool, and
f OL then connect the spark plug wire.
a
b Checking the spark plug wire
d c OL 1. Remove the spark plug wires.
e
2. Measure the spark plug wire resistance.
f
a
b
e c OL
d
f
a 0.436 V
b 0.435 V
f c 0.437 V
d 0.774 V
e 0.772 V Spark plug wire resistance:
#1: 4.6–10.9 kΩ at 20 °C (68 °F)
OL: Indicates overload #2: 3.3–8.0 kΩ at 20 °C (68 °F)
#3: 3.8–9.3 kΩ at 20 °C (68 °F)
5. Connect the Rectifier Regulator coupler #4: 4.2–10.0 kΩ at 20 °C (68 °F)
and lighting coil coupler.
3. Install the spark plug wires.
Checking the ignition spark Checking the ignition coil
1. Disconnect the spark plug wire from the 1. Disconnect the ignition coil couplers “a”
spark plug. and “b”.
2. Connect the spark plug wire to the spe-

cial service tool “1”.
5-21
Ignition coil output peak voltage:
#1, #4 “A”:
ignition coil coupler terminal and ground.
Black/Orange (B/O)–Ground
R/Y
a
#2, #3 “B”:
Black/White (B/W)–Ground
0
Loaded
r/min
Cranking 1500 3500
DC V 210.0 260.0 270.0 1
6. Disconnect the special service tool and
b spark plug wires from the ignition coils.
7. Measure the ignition coil resistance.

2
Ignition coil input voltage:
Red/Yellow (R/Y)–Ground B A
12 V (battery voltage) 3
4. Connect the ignition coil coupler “a”. 4

5. Connect the special service tool “1”, and
then measure the ignition coil output
peak voltage.
Ignition coil resistance:
5
TIP: Primary coil “A”:
1.530–2.070 Ω at 20 °C (68 °F)
• When measuring the ignition coil output
peak voltage under the cranking (loaded) Secondary coil “B”: 6
condition, disconnect all fuel injector cou- 12.50–16.91 kΩ at 20 °C (68 °F)
plers to prevent the engine from starting.
• Measure the output peak voltage of ignition
coil (for cylinders #2 and #3) in the same
8. Connect the spark plug wires and ignition
coil couplers. 7
way.
Checking the pulser coil
1. Disconnect the pulser coil coupler “a”.
8
1 a
9
R/Y
B/O
B/W
R
B/W 10
A
R/Y 1
B/W
B a

2. Connect the special service tool “1”. A
5-22
3. Measure the pulser coil output peak volt- Checking the air temperature sensor
age. 1. Measure the ambient temperature.
TIP: 2. Connect the YDIS to display “Intake air

• When measuring the pulser coil output temperature”.
peak voltage under the cranking (unloaded)
condition, disconnect the coupler “a” to pre- 3. Check that the difference between the
vent the engine from starting. ambient temperature and the displayed
• When measuring the pulser coil output intake temperature is within ± 5 °C
peak voltage under the cranking (loaded) (± 9 °F).
condition, remove the clip from the engine
shut-off switch to prevent the engine from TIP:
starting. • Check the air temperature sensor when the
engine is cold.
W/R W/R • When checking the air temperature sensor,
B B remove the top cowling and do not start the
W/B W/B
B engine.
W/R W/B
a 1
4. Disconnect the air temperature sensor
coupler “a”.
a 5. Turn the engine start switch to ON, and

then measure the input voltage at the air
temperature sensor coupler.
B B/Y
1 a
Pulser coil output peak voltage:

Air temperature sensor input voltage:
White/Red (W/R)–Black (B)
Black/Yellow (B/Y)–Black (B)
White/Black (W/B)–Black (B)
4.75–5.25 V
Unload-
Loaded
r/min ed 6. Turn the engine start switch to OFF, and
Cranking 1500 3500 then remove the air temperature sensor.
DC V 3.5 3.0 21.0 39.0
7. Place the air temperature sensor in a
4. Disconnect the special service tool, and container of water and heat the water
then measure the pulser coil resistance. slowly.
Pulser coil resistance:
8. Measure the air temperature sensor
White/Red (W/R)–Black (B)
resistance.
White/Black (W/B)–Black (B)
459.0–561.0 Ω at 20 °C (68 °F)
5. Connect the pulser coil coupler.
5-23
1
2
0
1
Air temperature sensor resistance P/G
B
(reference data):
2.2–2.7 kΩ at 20 °C (68 °F)
O
B
G/W G
2
2
0.32 kΩ at 80 °C (176 °F)
9. Install the air temperature sensor, and

then connect the air temperature sensor
3
coupler.
Checking the air pressure sensor

1. Disconnect the air pressure sensor cou-
90890-06945 4
pler “a”.

Air pressure sensor output voltage:
Pink/Green (P/G)–Black (B)
5
then measure the input voltage at the air
3.21 V at –20.0 kPa
pressure sensor coupler.
(–0.20 kgf/cm2, –2.9 psi)
a 2.16 V at –46.7 kPa
(–0.467 kgf/cm2, –6.8 psi)
6
B O 7. Turn the engine start switch to OFF.
8. Disconnect the special service tools.

7
9. Install the air pressure sensor. See
“Intake manifold and vapor separator” (6-
34).
8
Air pressure sensor input voltage:
10. Connect the air pressure sensor coupler.
Orange (O)–Black (B)
4.75–5.25 V
Checking the engine temperature
9
3. Turn the engine start switch to OFF. sensor
4. Remove the air pressure sensor.

1. Disconnect the engine temperature sen-
sor coupler “a”. 10
5. Connect the special service tools “1” and 2. Turn the engine start switch to ON, and
“2”. then measure the input voltage at the
engine temperature sensor coupler.
6. Apply negative pressure to the air pres-
the output voltage.
A
5-24
a B B/Y then measure the input voltage at the
thermoswitch connectors.
B P
Engine temperature sensor input voltage:
Black/Yellow (B/Y)–Black (B)
4.75–5.25 V
Thermoswitch input voltage (reference
3. Turn the engine start switch to OFF. data):
Pink (P)–Black (B)
4. Remove the engine temperature sensor.
11.5 V
5. Place the engine temperature sensor in a
container of water and heat the water
slowly. 4. Remove the thermoswitch.
6. Measure the engine temperature sensor 5. Place the thermoswitch in a container of
resistance. water and heat the water slowly.
6. Check the switch for continuity at the

specified temperatures. Replace if out of
specification.
P B
Engine temperature sensor resistance

(reference data):
128.0 kΩ at 5 °C (41 °F)
54.20–69.00 kΩ at 20 °C (68 °F)
3.120–3.480 kΩ at 100 °C (212 °F)
d
7. Install the engine temperature sensor.
d d
See “Cylinder block (F150A, FL150A)”
e
(7-52). a
f
c
c
8. Connect the engine temperature sensor
coupler.
b
Checking the thermoswitch
1. Disconnect the thermoswitch connectors. a. Temperature
b. Time
5-25
c. No continuity
Shift cut-off switch resistance:
d. Continuity
4.465–4.935 kΩ at “a” position at
Thermoswitch continuity temperature: 20 °C (68 °F)
“e”: 84–90 °C (183–194 °F)
“f”: 68–82 °C (154–180 °F)
0 Ω at “b” position at 20 °C (68 °F)
0
6. Install the shift cut-off switch. See “Shift
7. Install the thermoswitch. rod and shift bracket” (9-1).
8. Connect the thermoswitch connectors. 7. Connect the shift cut-off switch coupler. 1
Checking the shift cut-off switch Checking the shift position switch
1. Disconnect the shift cut-off switch cou-
pler “a”.
1. Disconnect the shift position switch cou-
pler “a”.
2
2. Turn the engine start switch to ON, and 2. Turn the engine start switch to ON, and
shift cut-off switch coupler.
shift position switch coupler.
3
B L/Y B L/G
4
5
a a
6
Shift cut-off switch input voltage: Shift position switch input voltage:
7
Blue/Yellow (L/Y)–Black (B) Blue/Green (L/G)–Black (B)
4.75–5.25 V 4.75–5.25 V
3. Turn the engine start switch to OFF. 3. Turn the engine start switch to OFF.
8
4. Remove the shift cut-off switch. 4. Remove the shift position switch.
5. Measure the shift cut-off switch resis- 5. Check the shift position switch for conti-
9
tance. nuity.
a
b
b
a
10
A
5-26
Starting unit and component
Shift position switch continuity: Starting unit and component

Continuity: Checking the starter relay
Switch position “a” 1. Measure the input voltage between the
No continuity: starter relay terminal “a” and ground.
Switch position “b”
6. Install the shift position switch. See “Shift

rod and shift bracket” (9-1).
7. Connect the shift position switch coupler.

a
Checking the engine shut-off switch
1. Disconnect the 10-pin coupler or engine
start switch coupler.
Terminal “a”–Ground:
then check the engine shut-off switch for
continuity. 2. Disconnect the starter relay leads, and
2. ON then remove the starter relay.
A
1. OFF 3. START b
a Before disconnecting the starter relay ter-

minals, make sure to disconnect the neg-
ative battery terminal.
B 3. Connect the positive battery lead to the

relay connector “a”, and the negative bat-
tery lead to the relay lead “b”, and then
a check for continuity between terminals
b “c” and “d”. Replace the starter relay if
out of specification.
1. OFF c d
2. ON
3. START
A. 704 remote control

B. 703 remote control
Engine shut-off switch continuity:
Br a
Clip removed:
Terminal “a”–Terminal “b”
3. Turn the engine start switch to OFF. B b

4. Connect the 10-pin coupler or engine
Relay terminals continuity:
Battery lead connected:
Terminal “c”–Terminal “d”
5-27
Starting unit and component
4. Install the starter relay, and then connect
the starter relay leads.
Checking the engine start switch

1. Disconnect the 10-pin coupler or engine
0
2. Check the engine start switch for continu-
ity. 1
A
d b
a
2
2. ON e
c
1. OFF 3. START
B
3
c
d
a 4
b e
1. OFF
5
2. ON
3. START
A. 704 remote control

6
B. 703 remote control
Engine start switch continuity:
Switch position OFF: 7
Switch position ON:
Switch position START:
8
Terminal “d”–Terminal “e”
Terminal “c”–Terminal “e” 9
3. Connect the 10-pin coupler or engine
10
A
5-28
11
3 11
2
4
9 11
11
4 N·m (0.4 kgf·m, 3.0 ft·lb) 6

7 1
2 N·m (0.2 kgf·m, 1.5 ft·lb) 10
No. Part name Q’ty Remarks

1 Cover 1
2 Control unit assembly 1
3 Transmitter 2
4 Screw 2 M6 15 mm
5 Buzzer 1
6 Bracket 1
7 Screw 1 ø6 19 mm
8 Main wiring harness 1
9 O-ring 1
10 Plastic tie 1
11 Seal 4
5-29
Checking Y-COP
1. Disconnect the Y-COP coupler “a”, and
then measure the Y-COP input voltage. Y P
0
1
a 3. Measure the Y-COP buzzer input voltage.
2
B 3
R Y 4
Y-COP input voltage: Y-COP buzzer input voltage:
Red (R)–Black (B)
Yellow (Y)–Ground
5
2. Connect the Y-COP coupler. Checking the Y-COP main wiring
Checking the buzzer

harness
1. Remove the Y-COP main wiring harness
6
1. Remove the Y-COP buzzer “1”. “1”.
7
1
1 8
9
2. Connect the battery leads to the Y-COP
buzzer connectors, and then check that
the Y-COP buzzer comes on. Replace 10
the Y-COP buzzer if it does not come on.
A
5-30
2. Check the wiring harness for continuity.
c a 3
a
ih g ba 4 2
rq o j
4
e d P
b
ab
cd
Y
f
g
1 a
Y
b W
h
P b
Wiring harness continuity: W
a. Terminal 1–b. Terminal 3
a. Terminal 2–d. Pink (P)
a. Terminal 7–b. Terminal 2 Control unit screw “4”:
a. Terminal 8–f. White (W) 4 N·m (0.4 kgf·m, 3.0 ft·lb)
a. Terminal 9–g. White (W)
a. Terminal 10–b. Terminal 4 Checking the button cell battery
a. Terminal 15–b. Terminal 1 Replace the button cell battery in the trans-
a. Terminal 17–h. Red (R) mitter once in the first year, and once every
a. Terminal 17–e. Yellow (Y) two years thereafter.
a. Terminal 18–c. White (W)
1. Remove the transmitter cover “1”.
3. Install the Y-COP main wiring harness
“1”, O-ring “2”, and control unit “3”, and
then tighten the control unit screws “4” to
the specified torque.
Do not connect the connectors “a” and

“b”. Otherwise, Y-COP may not operate
properly. 1
2. Push the Yamaha logo on the transmitter

cover “1” and remove the button cell
battery “2”.
Do not touch the button cell battery

directly. Otherwise, button cell battery
could be corroded.
5-31
2
1
1
[4] [2]
0
1
[5] [6] 1
3. Measure the button cell battery voltage. [1] [3]
TIP: 2 2
2 1 2
2
When disposing of button cell battery, make
Transmitter screw “2”:
sure to follow local disposal regulations.
0.1 N·m (0.01 kgf·m, 0.1 ft·lb) 3
-
+ 4
5
Button cell battery voltage - CR2016
(reference data): 3 V
6
4. Install the button cell battery “1” so that
the positive side is facing the transmitter
cover “2”.
7
1
1
8
9
2
5. Install the transmitter cover “1”, and then

10
tighten the transmitter screws “2” to the
specified torque in the order [1], [2], and
so on.
A
5-32
Starter motor
Starter motor
19 20
1 1 13
9 21
1
1 22
21
9 14
2
3 15
10
14
16
6
11 23
17 14
4 24
18
12
8
25
7 26
27

1 Brush spring 4
2 Brush assembly 1
3 Brush holder assembly 1
4 Starting motor gear assembly 1
5 Washer set 1
6 Bracket 1
7 Bolt 2 M6 117 mm
8 Screw 2 M4 16 mm
9 Planetary gear 3
10 Plate 1
11 Stator 1
12 Armature 1
13 Clutch assembly 1
14 Washer set 1
15 Bracket 1
16 Bracket 1
17 Outer gear 1
5-33
Starter motor
19 20 0
1 1 13
9 21
1
1
9 14
21
22
1
2
3 15
10
2
14
16
5
3
6
11 23 4
17 14
4 24
12
18 5
8
25
7 26 6
27
No. Part name Q’ty Remarks 7

18 Pinion shaft 1
19 Pinion 1
20
21
Pinion stopper set
Bolt
1
2 M6 37 mm
8
22 Cover 1
23 Lever assembly 1
24
25
Seal set
Magnet switch
1
1
Not reusable 9
26 Washer 1
27 Nut 1
10
A
5-34
Starter motor
Removing the starter motor Pipe “3”: (commercially available)
“a”: 21.0 mm (0.83 in)
“b”: 26.0 mm (1.02 in)
Before removing the starter motor, make
sure to disconnect the negative battery 3. Remove the pinion stopper “1”, pinion
terminal. “2”, and spring “3”.
1. Remove the starter motor from the power 1

unit. See “Removing the starter motor”
(7-21).
2
Checking the starter motor pinion
1. Check the pinion teeth. Replace the pin- 3
ion if cracked or worn.
2. Turn the pinion counterclockwise to

check that it operates smoothly and turn 4. Remove the stator assembly “1”.
it clockwise to check that it locks in place.
Disassembling the starter motor

1. Remove the magnet switch “1” and
spring “2”.
1
2
5. Remove the plate “1”, outer gear “2”, and

planetary gears “3”.
1
1
2. Push the pinion stopper “1” down, and

3
then remove the clip “2”.
b
a 3
6. Remove the rubber seal “1”, lever “2”,

1
and pinion shaft assembly “3”.
2
5-35
Starter motor
3
0
2 1
4
3
1 1
2
2
7. Remove the E-clip “1”, and then remove 9. Remove the stator “1”.
the clutch assembly “2”.
10. Remove the armature “2”, along with the
3
TIP: brush holder assembly “3”, from the
Push the clutch assembly “2” down com-
pletely onto the pinion shaft “3” in direction
bracket “4”.
4
“a”, turn it one spline in direction “b”, and then
remove it in direction “c”. Do not disassemble the stator. Do not
remove the magnets “5” from it.
5
1 5
c 2 2
2
c
6
3
1 a b
3
7
3 a b
4 8
8. Remove the shim “1”, bracket “2”, gasket
“3”, and shim “4”. 11. Remove the plate “1”, and then remove 9
the armature “2” from the brush holder
assembly “3”.
10
A
5-36
Starter motor
2 a
2
1
1
Commutator standard undercut “a”:
0.8 mm (0.03 in)
3 Wear limit: 0.2 mm (0.01 in)
Checking the armature (starter 4. Check the armature for continuity.

Replace if out of specification.
motor)
1. Check the commutator. Clean using
600-grit sandpaper and compressed air if
dirty.
a
d
b c
Armature continuity:
Continuity:
“a”–“b”
No continuity:
2. Measure the commutator diameter “a”.
“a”–“c”
Replace the armature if below specifica-
“a”–“d”
tion.
Checking the brush holder
1. Check the brush holder assembly for
continuity. Replace if out of specification.
e
a
a c b
Commutator standard diameter “a”: d

29.0 mm (1.14 in) c a
Wear limit: 28.0 mm (1.10 in)
e
3. Measure the commutator undercut “a”.
d b
5-37
Starter motor
3. Install the armature “1”, along with the
Brush holder assembly continuity:
brush holder assembly “2”, to the bracket
Brush “a”–Brush “b”
“3”, and then install the stator “4”.
Brush “a”–Terminal “e”
Brush “b”–Terminal “e”
Brush “c”–Brush “d” TIP: 0
Align the holes “a” and “b” in the plate “5” with
2. Measure the length “a” of each brush. the holes “c” and “d” in the bracket “3”.
Replace the brush assembly if below
specification. 4
1
a
b
a
2
1
5
b 3
2
Brush standard length “a”:

c
4
15.5 mm (0.61 in) d
3
Wear limit “b”: 9.5 mm (0.37 in)
Assembling the starter motor

3 5
Do not apply grease or oil to the commu-
4. Install the shim “1”, a new gasket “2”, the
brackets “3”, and the shim “4”.
6
tator of the armature.
1. Push the brushes “1” into the holders,

and then install the armature “2” to the
7
brush holder assembly “3”.
4
2. Install the plate “4”.
2
1
8
2
2 9
3
1
3
5. Push the clutch assembly “1” down com-
10
4
pletely onto the pinion shaft “2” in direc-
4 tion “a”, turn it one spline in direction “b”,
and then slide it in direction “c”.
3 1 6. Install the E-clip “3”.
A
5-38
Starter motor
2
TIP:
Make sure that the clutch assembly “1” does 1
not come out from the pinion shaft “2”.
1
1
c 1 2
c b a
3 b a
2
2 9. Install the spring “1”, pinion “2”, pinion
b a
stopper “3”, and clip “4”.
3 3
2 4
7. Install the pinion shaft assembly “1”, the 2
lever “2”, a new rubber seal “3”, the plan-
etary gears “4”, the outer gear “5”, and 1
the plate “6”.
5
10. Install a new gasket “1”, the spring “2”,
and the magnet switch “3”.
4 3
1 2 2
3
C
2
2 1
1
3
8. Align the protrusion “a” on the stator “1”
with the slot “b” in the cover assembly
“2”, and then assemble the starter motor.
Installing the starter motor

1. Install the starter motor to the power unit.
See “Installing the starter motor” (7-21).
5-39
6Y8 Multifunction Meter sensor
6Y8 Multifunction Meter sensor Water pressure sensor output voltage
Checking the water pressure sensor (reference data):
(optional) Blue/White (L/W)–Black (B)
1. Disconnect the water pressure sensor
coupler “a”.
2.5 V at 392.0 kPa
(3.92 kgf/cm2, 56.8 psi)
0
4.5 V at 784.0 kPa
2. Turn the engine start switch to ON, and (7.84 kgf/cm2, 113.7 psi)
water pressure sensor coupler. 5. Turn the engine start switch to OFF, and
1
a and pressure pump.
B O
6. Install the water pressure sensor, and
2
then connect the water pressure sensor
coupler. See “Installing the water pres-
sure sensor” (3-14). 3
Checking the speed sensor
(optional)
Water pressure sensor input voltage: 1. Disconnect the speed sensor coupler “a”. 4
4.75–5.25 V
3. Remove the water pressure sensor, and

speed sensor coupler. 5
then connect the pressure pump “1” and a
4. Apply positive pressure to the water pres- B O

6
the output voltage.
L/W
7
B
O
G/W B G
2
Speed sensor input voltage: 8
4.75–5.25 V
3. Remove the speed sensor, and then con- 9

nect the pressure pump “1” and special
service tool “2”.
1
4. Apply positive pressure to the speed sen-
10
2 sor slowly, and then measure the output
voltage.
Pressure pump “1”:
(commercially available)
A
5-40
PTT system
L PTT relay input voltage:

B Terminal “a”–Terminal “b”
O
G/W B G 12 V (battery voltage)
2 3. Disconnect the battery power source,

ground lead, PTT motor leads, and PTT
relay coupler.
Before disconnecting the PTT relay termi-

nals, make sure to disconnect the battery
1
negative terminal.
2
4. Connect the special service tool “1”.
Pressure pump “1”:
(commercially available) Test harness (2 pins) “1”: 90890-06867
5. Check the PTT relay for continuity.
Speed sensor output voltage Replace if out of specification.
(reference data):
Blue (L)–Black (B)
2.5 V at 392.0 kPa Lg
(3.92 kgf/cm2, 56.8 psi) Sb
G/W G 1
4.5 V at 784.0 kPa c
e f b
(7.84 kgf/cm2, 113.7 psi)
a
and pressure pump.
6. Install the speed sensor, and then con- d

nect the speed sensor coupler. See
“Installing the speed sensor” (3-15).
PTT relay continuity:
PTT system Terminal “b”–Terminal “c”
Checking the PTT relay Terminal “b”–Terminal “d”
1. Remove the junction box cover Terminal “b”–Terminal “e”
Terminal “d”–Terminal “f”
2. Measure the input voltage between the
PTT relay terminal “a” and terminal “b”. 6. Connect the positive battery lead to the
terminal “a”, and the negative battery
lead to the terminal “b”, and then check
the PTT relay for continuity. Replace the
PTT relay if out of specification.
a
5-41
PTT system
Checking the PTT switch (on bottom
Lg cowling)
Sb 1. Disconnect the PTT switch coupler “a”.
G/W G
a b
d 2. Measure the input voltage between the 0
PTT switch coupler terminal and ground.
c
a
1
R
e
2
PTT relay continuity:
Terminal “c”–Terminal “e” 3
Terminal “b”–Terminal “d” PTT switch input voltage:
Red (R)–Ground
7. Connect the positive battery lead to the
terminal “a”, and the negative battery
4
lead to the terminal “b”, and then check 3. Check the PTT switch for continuity.
the PTT relay for continuity. Replace the Replace the PTT switch if out of specifi-
PTT relay if out of specification. cation.
5
Lg
Sb
G/W G
d
c
b
a 6
a b
Sb
c
R
Lg 7
e PTT switch continuity:
Switch position UP:
8
Switch position DN:
PTT relay continuity: Terminal “b”–Terminal “c” 9
4. Connect the PTT switch coupler.
Terminal “b”–Terminal “e”
8. Disconnect the special service tool. Checking the trim sensor

1. Disconnect the trim sensor coupler “a”,
10
9. Connect the PTT relay coupler, battery and then remove the trim sensor.
power source, ground lead, and PTT
motor leads.
10. Install the PTT relay and junction box

cover.
A
5-42
PTT system
Tilt limiter input voltage:

Sky blue (Sb)–Ground
a 12 V (battery voltage)
3. Connect the battery leads to the tilt lim-

iter couplers.
4. Loosen the screw “1”, and then measure

the output voltage when sliding the mag-
net “2” against the tilt limiter.
2. Measure the trim sensor resistance. b
2
3. Turn the trim sensor lever “1” from the
position “a” to the position “b”, and then
measure the resistance as it gradually a
changes.
a
1 Sb B L
Trim sensor resistance (reference data):

239–379 Ω at “a”
9.0–11.0 Ω at “b” (setting resistance) Tilt limiter output voltage:
Blue (L)–Ground
4. Connect the trim sensor coupler. 12.0 V (battery voltage) at “a”
0 V at “b”
Checking the tilt limiter (optional)
1. Disconnect the tilt limiter couplers “a”, 5. Connect the tilt limiter couplers.
“b”, and “c”.
6. Set the tilt limiter. See “Setting the tilt lim-
2. Measure the input voltage at the tilt limiter” (3-18).
iter coupler “a” with the up side of the
PTT switch pushed.
c Sb
a
b
5-43
PTT system
— MEMO —
0
1
2
3
4
5
6
7
8
9
10
A
5-44
Fuel system 6
Hose routing ...................................................................... 6-1

Fuel hose ................................................................................... 6-1
Air hose, pressure regulator hose, and vapor gas hose ............ 6-2
Blowby hose and cooling water hose ........................................ 6-4
Fuel system ....................................................................... 6-5

Reducing the fuel pressure ....................................................... 6-5
Measuring the fuel pressure ...................................................... 6-5
Checking the pressure regulator ............................................... 6-5
Fuel filter ............................................................................ 6-7

Removing the fuel filter assembly ............................................. 6-8
Checking the fuel filter assembly ............................................... 6-8
Disassembling the fuel filter assembly ...................................... 6-9
Checking the fuel filter element ................................................. 6-9
Checking the fuel cup assembly ................................................ 6-9
Checking the primer pump ........................................................ 6-9
Assembling the fuel filter assembly ........................................... 6-9
Installing the fuel filter assembly ............................................. 6-10
Fuel pump ........................................................................ 6-11

Removing the fuel pump assembly ......................................... 6-13
Checking the fuel pump assembly .......................................... 6-13
Disassembling the fuel pump assembly .................................. 6-14
Checking the diaphragm and valve ......................................... 6-14
Assembling the fuel pump assembly ....................................... 6-14
Installing the fuel pump assembly ........................................... 6-15
Canister and vapor shut-off valve ................................. 6-17

Removing the canister ............................................................. 6-18
Removing the vapor shut-off valve .......................................... 6-18
Checking the canister .............................................................. 6-18
Checking the vapor shut-off valve ........................................... 6-19
Installing the vapor shut-off valve ............................................ 6-19
Installing the canister ............................................................... 6-19
Intake silencer ................................................................ 6-21
Throttle link ...................................................................... 6-22

Removing the throttle link ........................................................ 6-23
Checking the throttle link ......................................................... 6-23
Fuel system
Installing the throttle link .......................................................... 6-23

0
Throttle body ................................................................... 6-25
Removing the throttle body assembly ..................................... 6-26
Checking the TPS ................................................................... 6-26
Installing the throttle body assembly ....................................... 6-26
1
Throttle body and throttle link adjustment ................... 6-27
Adjusting the throttle link ......................................................... 6-27
2
Adjusting the throttle valve reference opening angle .............. 6-27
Checking the synchronization of the throttle valve .................. 6-29
3
Fuel injector ..................................................................... 6-30
Removing the fuel injector ....................................................... 6-31
Removing the fuel cooler ......................................................... 6-31 4
Checking the fuel rail and fuel injector .................................... 6-32
Installing the fuel cooler ........................................................... 6-32
Installing the fuel injector ......................................................... 6-33 5
Intake manifold and vapor separator ............................ 6-34
Draining the fuel ...................................................................... 6-37
Removing the intake manifold ................................................. 6-37
6
Removing the vapor separator ................................................ 6-37
Checking the fuel filter ............................................................. 6-38
Checking the intake manifold .................................................. 6-38 7
Checking the air pressure sensor ............................................ 6-38
Checking the ISC valve ........................................................... 6-38
Installing the vapor separator .................................................. 6-39
Installing the intake manifold ................................................... 6-40
8
Vapor separator and high-pressure fuel pump ............ 6-42
Disassembling the vapor separator ......................................... 6-43
9
Checking the high-pressure fuel pump .................................... 6-43
Checking the vapor separator ................................................. 6-43
Assembling the vapor separator .............................................. 6-44
10
A
Hose routing
Hose routing
Fuel hose
8
9
k
2
10 f
3
b
8
c
1 A
d
9
a
g
6
e
k
11
e m
12
3 4 h
5 d
1. Fuel hose (primer pump to joint) 12. Fuel hose (fuel cooler to vapor separator)
2. Fuel hose (joint to fuel filter assembly)
3. Fuel hose (fuel filter assembly to joint) a. Primer pump
4. Fuel hose (joint to fuel pump) b. Joint
5. Fuel hose (joint to fuel pump) c. Fuel filter assembly
6. Fuel hose (fuel pump to joint) d. Joint
7. Fuel hose (fuel pump to joint) e. Fuel pump
8. Fuel hose (joint to filter) f. Filter
9. Fuel hose (filter to vapor separator) g. Vapor separator
10. Fuel hose (vapor separator to fuel rail) h. Fuel rail
11. Fuel hose (pressure regulator to fuel k. Pressure regulator
cooler) m. Fuel cooler
6-1
Hose routing
Air hose, pressure regulator hose, and vapor gas hose
g
C 0
7 3
B
A
1
12
8
8
3
1 k 2
f
b 2
a
c
A
3
m
4
7
10
d
5 5
4
6
m 6
b 4
7
3
7
3
2 1
e
8
6 5
B C h 9 d 11
1. Vapor gas hose (vapor separator to joint) 9. Vapor gas hose (canister atmospheric
9
2. Vapor gas hose (vapor separator to joint) port to filter)
3. Vapor gas hose (joint to filter) 10. Vapor gas hose (filter to joint)
4. Vapor gas hose (filter to canister tank
port)
11. Vapor gas hose (joint to bottom cowling)
12. Pressure regulator hose (intake manifold
10
5. Vapor gas hose (canister purge port to to pressure regulator)
vapor shut-off valve)
6. Vapor gas hose (vapor shut-off valve to a. Vapor separator
joint) b. Joint
7. Vapor gas hose (joint to joint) c. Filter
d. Canister
8. Air hose (joint to intake manifold)
e. Vapor shut-off valve A
6-2
Hose routing
C
g
7 3
B
A
12
8
8
3
1 k
f
b 2
a
c
A
7
10
d
5
4
6
m
b 4
3
7
2 1
3 e
6 5
B C h 9 d 11
f. Joint
g. Joint
h. Filter
k. Joint
m. Pressure regulator
6-3
Hose routing
Blowby hose and cooling water hose
0
1 1
2
3
5 4
5
3
6
2
7
a
8
4
b
1. Blowby hose (cylinder head cover to a. Fuel cooler

9
intake silencer) b. Cooling water pilot hole (on the bottom
2. Blowby hose (cylinder head cover to cyl- cowling)
inder block)
3. Cooling water hose (exhaust cover to fuel
10
cooler)
4. Cooling water pilot hose (fuel cooler to
cooling water pilot hole)
5. Flushing hose (flushing hose adapter to
exhaust cover)
A
6-4
Fuel system
Fuel system
Reducing the fuel pressure
1
Before servicing the high-pressure fuel
line or vapor separator, make sure to 2
reduce the fuel pressure in the fuel line.
Otherwise, pressurized fuel could spray
out. a 2
Fuel pressure gauge “2”:

90890-06753
2. Cover the pressure check valve “a” of the 4. Turn the engine start switch to ON, and
fuel rail using a rag, and then push the then measure the fuel pressure within 3
pressure check valve “a” inward using a seconds.
flathead screwdriver to release the fuel
pressure.
TIP:
The fuel pressure will decrease 3 seconds
after the engine start switch is turned to ON.
1
Fuel pressure (reference data):
300.0 kPa (3.00 kgf/cm2, 43.5 psi)
5. Start the engine and warm it up until the

a engine idle speed stabilizes at
650–750 r/min.
3. Install the cap. 6. Measure the fuel pressure.

Fuel pressure (reference data):
Measuring the fuel pressure 260.0 kPa (2.60 kgf/cm2, 37.7 psi)
1. Reduce the fuel pressure. See “Reducing at engine idle speed
the fuel pressure” (6-5).
3. Connect the special service tool “2” to then install the cap.
the pressure check valve “a”.
Before disconnecting the special service

To prevent fuel from leaking out, screw in tools, cover the end of the hose using a
the gauge gently until it is connected clean and dry rag.
firmly.
Checking the pressure regulator
1. Reduce the fuel pressure. See “Reducing
2. Connect the special service tool. See

steps 2 and 3 in “Measuring the fuel
pressure” (6-5).
6-5
Fuel system
3. Disconnect the pressure regulator hose
“1”, and then connect the special service
tool “2” to the pressure regulator “3”.
4. Block the end of the pressure regulator

hose “1” using a rubber plug “4”.
0
1
2 1
4 3
2 2
3
4
90890-06945
5. Start the engine and let it idle.

5
6. Check that the fuel pressure is reduced
when negative pressure is applied to the
pressure regulator.
6

7
then connect the pressure regulator
hose.
8
9. Disconnect the special service tools. See
steps 7 and 8 in “Measuring the fuel
pressure” (6-5).
9
10
A
6-6
Fuel filter
Fuel filter
6
7
8
5 9
2
12
13
2
15
1 16
10
2 2
1
3 14 11
5 N·m (0.5 kgf·m, 3.7 ft·lb)

1 Joint 2
2 Plastic tie 5
3 Hose 1 Joint to joint
4 Hose 1 Joint to fuel filter assembly
5 Bolt 2 M6 × 30 mm
6 Bolt 2 M6 × 14 mm
7 Collar 2
8 Grommet 2
9 Bracket 1
10 Hose 1 Fuel filter assembly to joint
11 Fuel filter assembly 1
12 O-ring 1 Not reusable
13 Fuel filter element 1
14 Fuel cup assembly 1
15 Clip 1
16 Float 1
6-7
Fuel filter
Removing the fuel filter assembly
Cover the fuel components using a rag to
prevent fuel from spilling out.
1. Disconnect the fuel hoses “1” and “2”. 0

2. Disconnect the water detection switch 2
coupler “a”.
3
1 1
2
Checking the fuel filter assembly
1. Connect the special service tool “1” to
the fuel inlet “a”.
2
2. Block the fuel outlet “b” using a rubber
a
plug “2”, and then apply the specified
positive pressure. Replace the O-ring,
3
1
fuel cup assembly, or fuel filter assembly
3. Remove the fuel filter assembly “1”.

if the specified pressure cannot be main-
tained for 15 seconds or more. 4
5
2
6
1
2
1
5. Remove the retaining plate “1”, and then

b a
7
remove the fuel hose “2”.
2 Leakage tester “1”:

8
90890-06840
Specified positive pressure:

200.0 kPa (2.00 kgf/cm2, 29.0 psi)
9
1 the fuel outlet “a”. 10
6. Remove the fuel hose “1” from the hold- 4. Block the fuel inlet “b” using a rubber
ers “2” and “3”. plug “2”, and then apply the specified
negative pressure. Replace the O-ring,
7. Disconnect the fuel hose “1”. fuel cup assembly, or fuel filter assembly
if the specified pressure cannot be main-
tained for 15 seconds or more.
A
6-8
Fuel filter
When cleaning the fuel cup assembly, do

not remove the clip and float.
1
2. Check the water detection switch. See
“Checking the water detection switch” (5-
2
16).
Checking the primer pump

a b 1. Connect the special service tool “1” to
the primer pump inlet “a”.
6P3 6P3
2. Block the fuel outlet “b” using a rubber

plug “2”.
90890-06945
3. Apply the specified positive pressure.
Replace the primer pump if the specified
pressure cannot be maintained for 30
80.0 kPa (0.80 kgf/cm2, 11.6 psi)
seconds or more.
Disassembling the fuel filter
assembly
1. Remove the fuel cup assembly “1”, O-
2 b a
ring “2”, and fuel filter element “3”.
2 1
Leakage tester “1”: 90890-06840
3
1 Specified positive pressure:
166.7 kPa (1.67 kgf/cm2, 24.2 psi)
Assembling the fuel filter assembly

1. Install the fuel filter element “1”, a new
O-ring “2”, and the fuel cup assembly “3”,
and then tighten the fuel cup assembly
Checking the fuel filter element “3” to the specified torque.
1. Check the fuel filter element. Replace if
there is dirt or residue.
Checking the fuel cup assembly

1. Check the fuel cup assembly. Clean
using straight gasoline if there is foreign
material or replace if cracked.
6-9
Fuel filter
2 0
1
3 a
3 1
1
8. Install the fuel hose “1” to the holders “2”
and “3”. 2
9. Connect the fuel hose “1”, and then fas-
Fuel cup assembly “3”: ten it using the plastic tie “4”.
5 N·m (0.5 kgf·m, 3.7 ft·lb) 3
Installing the fuel filter assembly
4
1. Install the bracket “1”.
4
2. Install the fuel filter assembly “2”.
2
3
1 5
1
6
2
7
3. Route the fuel hose “1” through the bot-
tom cowling.
4. Route the fuel hose “2” through the 8

proper holes in the rigging grommet. See
“Rigging grommet mounting” (3-9).
5. Install the retaining plate. See steps 4–6 9

in “Installing the rigging grommet” (3-13).
6. Connect the fuel hoses “1” and “2”, and

then fasten them using the plastic ties
10
“3”.
7. Connect the water detection switch cou-

pler “a”.
A
6-10
Fuel pump
Fuel pump
10 N·m (1.0 kgf·m, 7.4 ft·lb)
12 14
13
16
14 7 9
14
18
10
11 5 8
7
4
3 6
4 N·m (0.4 kgf·m, 3.0 ft·lb)
14
1 16
15 14 2
7 8 18
16 6
10 19
9
5 7 14
4
13
14
11
17
1
3 14
1 2
4 N·m (0.4 kgf·m, 3.0 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb)
20

1 Screw 6 M6 × 35 mm
2 Cover 2
3 Fuel pump body 2 2
4 Diaphragm 2
5 Spring 2
6 Fuel pump body 1 2
7 Nut 6
8 Spring 2
9 Plunger 2
10 Pin 2
11 Fuel pump assembly 2
12 Hose 1 Fuel pump to joint
13 Joint 2
14 Plastic tie 10
15 Hose 1 Fuel pump to joint
16 Bolt 3 M6 × 30 mm
17 Bolt 1 M6 × 42 mm
6-11
Fuel pump
10 N·m (1.0 kgf·m, 7.4 ft·lb)
12 14 0
13
16
14
14 7 9
18
1
10
11 5 8
7
3
4
6
2
4 N·m (0.4 kgf·m, 3.0 ft·lb)
14
1 16
3
15 14 2
7 8 18
16 6
9
10 19 4
5 7 14
4
13
11
14 5
17
1
1 2
3 14 6
20

19 Hose 1 Joint to fuel pump
20 Hose 1 Joint to fuel pump 8
9
10
A
6-12
Fuel pump
Removing the fuel pump assembly
2 b
1. Disconnect the fuel hoses “1”, “2”, “3”,

“4”, and “5”.
1
a
4
3 5
90890-06945

50.0 kPa (0.50 kgf/cm2, 7.3 psi)
2 3. Apply the specified negative pressure,

1
and then check that there is no air leak-
age.
2. Remove the fuel pump assemblies “1”.

30.0 kPa (0.30 kgf/cm2, 4.4 psi)

the fuel pump outlet “a”.
5. Block the fuel pump inlet “b” using a rub-

Checking the fuel pump assembly ber plug “2”.
the fuel pump inlet “a”. 6. Apply the specified positive pressure,
and then check that there is no air leak-
2. Block the fuel pump outlet “b” using a age.
rubber plug “2”, and then apply the speci-
fied positive pressure. Check that there is 2 b
no air leakage.
a 1
6-13
Fuel pump

50.0 kPa (0.50 kgf/cm2, 7.3 psi)
Disassembling the fuel pump

assembly 0
1. Remove the cover “1”, diaphragm “2”,
and fuel pump body 2 “3”. 1
2
1
3
5. Remove the diaphragm “1”, plunger “2”,
and springs “3” and “4”. 2
1
2
3
1 3
2. Hold fuel pump body 1 “1”.
1 4
2 4
Checking the diaphragm and valve

1. Check the diaphragm “1”. Replace if torn.
5
2 2. Check the valve “2”. Replace fuel pump
1
body 2 “3” if deformed or worn. 6
Small end bearing installer “2”: 3
90890-06528
1
7
3. While holding fuel pump body 1 “1” in
place, insert a flathead screwdriver into
the hole “a” in the plunger “2” and turn it
90°.
8
2
90
1
a 2 Assembling the fuel pump assembly 9
a Before assembling the fuel pump assembly,
clean the parts and soak the valves and dia-
phragm in gasoline to obtain prompt opera-
tion of the fuel pump assembly. 10
2 1. Install the springs “1” and “2”, plunger
1
“3”, and diaphragm “4”.
4. Remove the pin “1”.
A
6-14
Fuel pump
5. While holding fuel pump body 1 “1” in
place, insert a flathead screwdriver into
1 the hole “a” in the plunger “2” and turn it
3 4 90° until the tab “b” on the diaphragm is
aligned with the slot “c” in fuel pump body
1 “1”.
2 90°
2 1
1 2
2. Hold fuel pump body 1 “1”.
1 b c a
2 b
a
6. Install fuel pump body 2 “1”, diaphragm

“2”, and cover “3”, and then tighten the
2 1 fuel pump screws “4” to the specified
torque.
Small end bearing installer “2”: TIP:

90890-06528 Make sure to align the protrusions “a”, “b”,
and “c”.
3. Align the hole “a” in the plunger “1” with
the hole “b” in the diaphragm “2”. 3 4
2
1 2 1 1
c 4
a b c
b
b a
a
4. Install the pin “1”.
Fuel pump screw “4”:

4 N·m (0.4 kgf·m, 3.0 ft·lb)
Installing the fuel pump assembly

1. Install new O-rings “1” and the fuel pump
1 assemblies “2”, and then tighten the fuel
pump bolts “3” to the specified torque.
6-15
Fuel pump
1 0
2 3
1 1
3
2
Fuel pump bolt “3”:
10 N·m (1.0 kgf·m, 7.4 ft·lb) 3
2. Connect the fuel hoses “1”, “2”, “3”, “4”,
and “5”, and then fasten them using the
plastic ties “6”. 4
6
2
5
3 1
6 6
6
5 4
7
6
8
9
10
A
6-16
Canister and vapor shut-off valve
1
10
11
3
3
4
2
3
9 12
5 8
3 3
6 3
3
13
14
7 15
3 16

1 Nut 1
2 Hose 1 Filter to joint
3 Plastic tie 8
4 Joint 1
5 Hose 1 Joint to bottom cowling
6 Clamp 1
7 Filter 1
8 Vapor shut-off valve 1
9 Hose 1 Canister to filter
10 Canister 1
11 Bolt 1 M6 × 16 mm
12 Bracket 1
13 Hose 1 Vapor shut-off valve to joint
14 Hose 1 Canister to vapor shut-off valve
15 Holder 1
16 Holder 1
6-17
Removing the canister
1. Disconnect the vapor gas hoses “1” and
“2”.
2. Remove the spark plug wires from the

holders.
0
3. Remove the vapor gas hose “3” from the
holders “4”.
a
2 1
1
4
3. Remove the vapor shut-of valve “1”.
2
1 3
1 4
3 2
4. Disconnect the vapor gas hoses “1”.
4. Disconnect the vapor gas hoses “1” and 1

5
“2”.
5. Remove the bracket “3” and canister “4”.

6
1
4 2
7
3 Checking the canister
1. Check the canister. Replace if cracked. 8
the atmospheric port “a” and block the
Removing the vapor shut-off valve
1. Disconnect the vapor shut-of valve cou-
other ports using rubber plugs “b”. 9
pler “a”. 3. Apply the specified positive pressure and
check that there is no air leakage.
2. Disconnect the vapor gas hoses “1” and
“2”.
Replace the canister if there is air leak- 10
age.
A
6-18
3 1
a 4
b Dimension “a”: 100.0 mm (3.93 in)

a
3. Connect the vapor gas hoses “1” and “2”,
and then fasten them using the plastic
Vacuum/pressure pump gauge set “1”: ties “3”.
90890-06945
Specified pressure: TIP:

19.6 kPa (0.20 kgf/cm2, 2.8 psi) Connect the vapor gas hose “1” that has a
white paint mark “a” to the upper port of the
Checking the vapor shut-off valve vapor shut-off valve.
1. Check the vapor shut-off valve exterior.
Replace if cracked. 4. Connect the vapor shut-off valve coupler
“b”.
2. Check the electrical performance of the
vapor shut-off valve. See “Checking the
vapor shut-off valve” (5-18).
b
Installing the vapor shut-off valve
1. Install the vapor shut-off valve “1”. a
3
2 1
5. Connect the vapor gas hose “1”, and

then install the vapor gas hose “1” to the
holders “2”.
1 1
2. Install the holders “1” and “2” to the vapor

gas hoses “3” and “4”. 2
Installing the canister

1. Install the bracket “1” and canister “2”.
6-19
2. Connect the vapor gas hoses “3” and “4”, 6
and then fasten them using the plastic
ties “5”.
3. Install the vapor gas hose “4” to the

holder “6”.
0
2 3
6 1
4
3
1
5
5 1
2 4 2
1
4. Connect the vapor gas hoses “1”, “2”,

3
plastic ties “4”.
4
4
5
1 2
6
3
4
7
then fasten it using the plastic tie “2”.
8
then fasten it using the clamp “4”.
9
holder “6”.
8. Install the spark plug wires to the hold-

10
ers.
A
6-20
Intake silencer
Intake silencer
6 N·m (0.6 kgf·m, 4.4 ft·lb)
4 4
5 6 6 5
6
3 7
2
3
1
5
8
2 3
3
2 3 5
8
6
6
6
6 N·m (0.6 kgf·m, 4.4 ft·lb)

1 Intake silencer assembly 1
3 Collar 6
4 Collar 2
5 Grommet 4
6 Bolt 6 M6 × 20 mm
7 Clamp 1
8 Bolt 2 M6 × 45 mm
6-21
Throttle link
Throttle link
0
1
2
3
8 9 3
6 9
7 5
10 9
4
3
3 7 11
6 5
1 12
2
4
6

1 Bolt 1 M6 × 35 mm
2 Collar 1
3
4
Wave washer
Throttle cam
3
1
8
5 Roller 1
M6 × 25 mm
6
7
Bolt
Collar
2
2 9
8 Throttle lever 1 1
9 Washer 3
10
11
Spring
Throttle link rod
1
1
10
12 Throttle lever 2 1
A
6-22
Throttle link
Removing the throttle link
1. Remove the clip “1” and throttle cable 4
2
joint “2”. 1
1
2
3 5
5. Disconnect the throttle link joint assembly

“1”.
2. Remove the throttle link rod “1” from the

throttle cam “2”.
6. Remove the collar “1”, wave washer “2”,

2
throttle lever 1 “3”, washer “4”, and roller
“5”.
throttle cam “3”, spring “4”, and washer
“5”. 3
2
5
3 4 1
4
2
5
1 Checking the throttle link

1. Check throttle lever 1, roller, and throttle
cam. Replace if cracked or worn.
throttle lever 2 “3”, washer “4”, and throt- 2. Check throttle lever 2 and throttle link
tle link rod “5”. rod. Replace if cracked or worn.
3. Check the spring. Replace if deformed or

fatigued.
Installing the throttle link

1. Install the roller “1”, washer “2”, wave
washer “3”, and collar “4” onto throttle
lever 1 “5”.
6-23
Throttle link
2. Install throttle lever 1 “5” to cylinder block.
2
3
4
5
3
0
4
2
5 1
1
1
7. Install the throttle link rod “1” to the throt-
3. Install the spring “1” so that the spring
end “a” fits into the groove “b” in the throt-
tle cam “2”. 2
tle cam “2”, and then install the washer 1
“3”, wave washer “4”, and collar “5”.
a
3
b
3
4
1
2
4
5
2
8. Check that throttle lever 1 throttle cam
and throttle control lever 2 move
5
smoothly.
4. Hook the end “a” of the spring “1” under
the protrusion “b” on the cylinder block,
and then install the throttle cam “2” to the
6
cylinder block.
1
7
b
8
b a
2
2 9
5. Install the throttle link rod “1”, washer “2”,
wave washer “3”, and collar “4” onto the
throttle lever 2 “5”. 10
6. Install throttle lever 2 “5” to the cylinder
block.
A
6-24
Throttle body
Throttle body
9 9
10 1
2
11 3
7
4
5
6
14
12 14
13
15 17
14 7
UP 17 17
4 7
14
13
17 5
6
12 14 8
16
7
A 13 N·m (1.3 kgf·m, 9.6 ft·lb)

1 Throttle link joint 1 1
2 Nut 1
3 Throttle link joint 2 1
4 Bracket 2
5 Bolt 4 M6 × 16 mm
6 Bolt 2 M8 × 20 mm
7 Bolt 6 M8 × 70 mm
8 Throttle body assembly 1
9 Screw 2 M4× 12 mm
10 TPS 1
12 Synchronizing screw 1
13 Throttle stop screw 1
14 Spring 3
15 Nut 2
16 Spring washer 1
17 Screw 8 M6 × 16 mm
6-25
Throttle body
Removing the throttle body
assembly 1
1. Disconnect the TPS coupler “a”.
0
1
2. Install new gaskets “1”.
a 3. Install the throttle body assembly “2”, and

2
2. Remove the brackets “1”. then tighten the throttle body assembly
bolts “3” to the specified torque.
3
1
3
4
1
1
3
5
3. Remove the throttle body assembly “1”.
2 3
6
Throttle body assembly bolt “3”:
13 N·m (1.3 kgf·m, 9.6 ft·lb) 7
4. Install the brackets “1”.
8
1
1 9
1
Checking the TPS
1. Check the TPS exterior. Replace if
cracked.
10
5. Connect the TPS coupler “a”.
TPS. See “Checking the TPS” (5-15).
Installing the throttle body assembly

1. Install the throttle link joint assembly “1”.
A
6-26
Throttle body and throttle link adjustment
4. Tighten the locknut “1”.
1
a
Throttle body and throttle link

adjustment Adjusting the throttle valve reference
Adjusting the throttle link opening angle
1. Turn throttle lever 2 “1” until it contacts If there is dirt in the passages in the throttle
the stopper “a” of the cylinder block. body, it may affect the intake air pressure and
correct adjustments of the throttle valve refer-
2. Adjust the specified clearance “b” so that ence opening angle cannot be obtained.
the mark “c” on the throttle cam “2” and Clean the passages in the throttle body
the roller “3” are aligned. before adjusting the throttle valve reference
opening angle.
2 1. Connect the YDIS to display “TPS volt-
age”.
2. Loosen the synchronizing screw “1” until

it is no longer pushing the plate “2”, and
c the plate “2” stops.
3 b
1
2
a
1
Roller clearance “b”: 0.50 mm (0.02 in)
1
3. Adjust the throttle link rod length so that
its end “a” fits onto the protrusion “b” on
throttle lever 1, and then install the throt- 3. Loosen the throttle stop screw “1” until it
tle link rod to the throttle lever. is no longer pushing the stopper “2”.
1
a
1
2
6-27
4. Loosen the TPS screws “1” and adjust
the position of the TPS “2” to get the TIP:
specified output voltage. Warm up the engine so that the engine tem-
perature displayed on the YDIS screen is
TIP:
51 °C (123.8 °F) or more. 0
• To increase the output voltage, turn the
TPS “2” in direction “a”. 10. Perform the “Active test” using the YDIS
• To decrease the output voltage, turn the
TPS “2” in direction “b”.
to fix the ISC valve.
1
11. Adjust the throttle stop screw “1” so that
the engine speed is 850 r/min.
TIP:
2
b • To increase the engine speed, turn the
throttle stop screw “1” in direction “a”.
1
• To decrease the engine speed, turn the
throttle stop screw “1” in direction “b”.
3
• Set the Y axis “2” minimum range to 700
2 a and the maximum range to 900 on the
TPS output voltage:

graph to make the adjustment process eas- 4
ier.
0.66 V
5. Tighten the TPS screws. 5

6. Operate the throttle valves several times
and check that the TPS output voltage is
within specification. 6
7. Tighten the synchronizing screw “1”
slowly until the TPS output voltage
begins to change. 7
8. Tighten the throttle stop screw “2” slowly a b
until the TPS output voltage is within
specification.
1 8
9
2 1
2 10
TPS output voltage: 12. Stop the engine.
0.70 ± 0.02 V
13. Loosen the TPS screws “1” and adjust
9. Start the engine and warm it up. the position of the TPS “2” to get the
specified output voltage.
A
6-28
TIP:
• To increase the output voltage, turn the
TPS “2” in direction “a”.
• To decrease the output voltage, turn the 2 1
TPS “2” in direction “b”.
2 a Vacuum gauge “2”: 90890-03159
TPS output voltage: 3

0.70–0.72 V
1
14. Tighten the TPS screws.
15. Start the engine and move the shift lever

from the N position to the F position, and 4
then return it to the N position.
16. Check the engine speed.

Engine idle speed: 650–750 r/min
Checking the synchronization of the

throttle valve
Do not adjust the throttle valves when they Vacuum gauge “3” and “4”:
are operating properly. (commercially available)
1. Remove the caps “1”, and then connect 2. Start the engine and warm it up for 5 min-
the special service tool “2” to the intake utes.
manifold.
3. Check the vacuum pressure of all cylin-
ders.
TIP:
Use a commercially available vacuum gauge 4. Check that the difference of the vacuum
“3” or “4” with 4 adapters. pressure between cylinders #1 or #2 and
#3 or #4 is less than 2.0 kPa
(15.0 mmHg). If the difference is more
than 2.0 kPa (15.0 mmHg), adjust the
throttle valve reference opening angle.
See “Adjusting the throttle valve refer-
ence opening angle” (6-27).
6-29
Fuel injector
Fuel injector
0
13 N·m (1.3 kgf·m, 9.6 ft·lb)
7 8
6
5
1
5 8
2
3 7
8 3
4
7
9 5 4
8 10 mm
1
2 10
9
(0.39 in)
5
7 11
3 5
5 N·m (0.5 kgf·m, 3.7 ft·lb)
13 N·m (1.3 kgf·m, 9.6 ft·lb)

11
12 mm
(0.47 in) 6

1 Holder 1
2 Cap 1
3
4
Bolt
Fuel rail
2
1
M8 × 18 mm 8
5 Clamp 3
6
7
O-ring set
Fuel injector
1
4
Not reusable
9
8 Rubber seal 4 Not reusable
9 Bolt 2 M6 × 25 mm
10
11
Fuel cooler
Clamp
1
1
10
A
6-30
Fuel injector
Removing the fuel injector

the fuel pressure” (6-4). 1
2. Disconnect the fuel injector couplers “a”

and fuel pump coupler “b”. a 1
3. Remove the holder “1”.

7. Remove the fuel injectors “1”.
4. Disconnect the fuel hose “2”.
1
2
a
1
b
1
a 1
1
Removing the fuel cooler
5. Remove the holders “1” from the fuel rail Cover the fuel components using a rag to
“2”. prevent fuel from spilling out.
1. Drain the fuel. See “Draining the fuel” (6-

1 37).
1
2. Disconnect the fuel hoses “1” and “2”.
3. Disconnect the cooling water hoses “3”

and “4”.
1 2
1
6. Remove the fuel pump coupler “a” from

the fuel rail “1”, and then remove the fuel 3
rail “1”.
4
2
6-31
Fuel injector
4. Remove the fuel cooler “1”.
Fuel injection volume:
132–152 cm3 (132–152 cc)/30 sec
Test fuel:
Dry sorbent (viscosity: 1.2 ± 0.02 mm2/s,
specific gravity: 0.774 [15 °C])
0
Test fuel temperature:
21 ± 1 °C (room temperature and test
fuel temperature should be the same)
Test fuel pressure: 300 ± 4.8 kPa
1
Measuring cylinder internal pressure (stan-
dard atmosphere pressure):
960–1060 hpa 2
1 Installing the fuel cooler
1. Install the fuel cooler “1”.
Checking the fuel rail and fuel 3
injector
1. Check the fuel rail. Replace if cracked or
deformed.
4
2. Check the electric performance of the
fuel injector. See “Checking the fuel
injector” (5-17). 5
3. Measure the volume injected by the
injector. See the “Fuel Injection Meter
Operation Manual”.
1
6
Do not use gasoline when measuring the
fuel injection volume. Otherwise, the cyl-
2. Connect the fuel hoses “1” and “2”, and
then fasten them using the clamps “3”.
7
inder could be damaged, which can cause
a gasoline leakage. Make sure to follow 3. Connect the cooling water hoses “4” and
the instructions for operation of the fuel
injection meter.
“5”, and then fasten the cooling water
hose “5” using the clamp “6”.
8
1
TIP:
• When measuring, obtain a result from the
3 9
average of 4 measurements. 4
• It is not possible to obtain correct measure-
ments under disparate test conditions.
Make sure to fully charge the battery.
6
10
• The cylinder is graduated in increments of 3
2.5 cm3 (2.5 cc).
5
• Make sure to comply with the laws and reg- 2
ulations of the region when disposing of the
used test fuel. 5
Fuel injection meter: FIM20000ME A

6-32
Fuel injector
Installing the fuel injector Fuel rail bolt “2”:
1. Install a new O-ring “1” and a new rubber 13 N·m (1.3 kgf·m, 9.6 ft·lb)
seal “2” to the fuel injector “3”.
5. Install the fuel pump coupler “a” to the
3 fuel rail.
2
1
a
2. Install the fuel injectors “1” onto the fuel
rail “2”.
6. Route the wiring harness “1”, and then
install the holders “2” to the fuel rail “3”.
2
1
2
1
7. Connect the fuel injector couplers “a” and

fuel pump coupler “b”.
3. Install the fuel rail “1” onto the intake
manifold. 8. Connect the fuel hose “1”, and then fas-
ten it using the clamp “2”.
4. Tighten the fuel rail bolts “2” equally and
gradually to the specified torque. 9. Install the holder “3”.
1
2
a
1 2 3
6-33
Intake manifold and vapor separator
5 17
4
18
3
6
7
5 11
5 N·m (0.5 kgf·m, 3.7 ft·lb)
0
13 11
19
9
20 8
16
11
5 N·m (0.5 kgf·m, 3.7 ft·lb) 1
11 12
7 14 26
21
10
22
27
28
2
15 23 29
30
24
11
29 25 3
31
1
2
36 11
29
4
37 34 32
1
35
28
29
5
2
32 33
33 32
6
30

1 Dowel 2
3
4
Hose with filter
Holder
1
1
Hose to joint 8
5 Plastic tie 2
6
7
Hose
Joint
1
2
Joint to joint
9
8 Hose 1 Vapor separator to fuel rail
9 Holder 1
10
11
Hose
Clamp
1
6
Intake manifold to pressure regulator
10
12 Joint 1
13 Hose 1 Vapor separator to joint
14 Hose 1 Vapor separator to joint
15 Vapor separator 1
16 Hose 1 Joint to filter
17 Hose 1 Joint to intake manifold
A
6-34
5 17
4
18
7
6 5 11
3 11
5 N·m (0.5 kgf·m, 3.7 ft·lb)
13 19
9
20 8 11
16 5 N·m (0.5 kgf·m, 3.7 ft·lb)
11 12
7 14 26
21
10 27
22 28
15 23 29
30
24
29 25
11
31
1
36 11
2 29
37 34 32
1 28
2 35 29
33 32
32 33
30

18 Filter 1
19 Hose 1 Filter to vapor separator
20 Wiring harness 1
21 Screw 2 M5 × 15 mm
22 Air pressure sensor 1
23 Filter 1
24 Cap 1
26 Screw 3 M4 × 15 mm
27 ISC valve 1
28 Grommet 3
29 Collar 6
30 Bolt 3 M6 × 35 mm
32 Bolt 5 M8 × 40 mm
33 Cap 4
34 Drain hose 1
6-35
5 17
4
18
3
6
7
5 11
5 N·m (0.5 kgf·m, 3.7 ft·lb)
0
13 11
19
9
20 8
16
11
5 N·m (0.5 kgf·m, 3.7 ft·lb) 1
11 12
7 14 26
21
10
22
27
28
2
15 23 29
30
24
11
29 25 3
31
1
2
36 11
29
4
37 34 32
1
35
28
29
5
2
32 33
33 32
6
30

35 Intake manifold 1
36 Hose 1 Fuel cooler to vapor separator
37 Hose 1 Pressure regulator to fuel cooler 8
9
10
A
6-36
Draining the fuel
1. Loosen the vapor separator drain screw
1
“1”, and then remove the cap “2”.
2
2. Push the air valve “3” inward.
3
2
4. Remove the intake manifold “1” and dow-

els “2”.
1
1 2
3. Tighten the vapor separator drain screw

2
Vapor separator drain screw:
2 N·m (0.2 kgf·m, 1.5 ft·lb) Removing the vapor separator
1. Remove the drain hose “1” from the
Removing the intake manifold intake manifold.
1. Disconnect the ISC valve coupler “a” and
air pressure sensor coupler “b”. 2. Remove the vapor separator bolts “2”.
2. Remove the holder “1” from the intake

manifold.
a
2
1
b
3. Remove the plastic ties “1”.

1
1
4. Disconnect the pressure regulator hose
3. Remove the vapor gas hose with filter “1” “2” from the intake manifold.
from the holder “2”.
5. Remove the vapor separator “3”.
TIP:
Remove the fuel hose and fuel pump coupler
in this order from the intake manifold.
6-37
2
a
0
1
3
1
6. Remove the drain hose “1” and fuel hose 10. Disconnect the vapor gas hose with filter
“2”. “1” and vapor gas hoses “2” and “3”. 2
3 3
2
1
2
1
4
7. Disconnect the fuel hoses “1”, “2”, and
“3”, and remove the fuel filter “4”.
Checking the fuel filter
1. Check the fuel filter. Replace the fuel fil-
5
4 ter if there is dirt, residue, or external
damage.
3
6
Checking the intake manifold
2
1. Check the intake manifold. Replace if
cracked or deformed.
7
1 Checking the air pressure sensor
1. Check the air pressure sensor exterior.
8. Remove the fuel hose “1” and pressure

Replace if cracked.
8
regulator hose “2”. 2. Check the electrical performance of the
air pressure sensor. See “Checking the
air pressure sensor” (5-24). 9
Checking the ISC valve
1
1. Check the ISC valve exterior. Replace if
2
cracked. 10
ISC valve. See “Checking the ISC valve”
(5-15).
9. Disconnect the fuel pump coupler “a”.
A
6-38
Installing the vapor separator 7. Connect the fuel hose “6”, and then fas-
1. Connect the vapor gas hoses “1” and “2” ten it using the clamp “7”.
and vapor gas hose with filter “3” to the
joint “4”. 3
4
2. Connect the vapor gas hoses “1” and “2”
to the vapor separator. 1
4 3
2 5
6 7
3 1 1 2
2
8. Install the drain hose “1” and fuel hose
“2”, and then fasten the fuel hose “2”
using the clamp “3”.
4
3. Connect the fuel pump coupler “a”.
a 1
2
9. Install the grommets “1” and collars “2”.
10. Connect the air hose “3” and vapor gas

4. Connect the fuel hose “1” and pressure hose “4” to the joint “5”.
regulator hose “2”, and then fasten the
fuel hose “1” using the clamp “3”. 11. Connect the air hose “3” to the intake
manifold.
3 2
1 4
2
5
2 1 2
3
5. Connect the fuel hoses “1” and “2” to the
fuel filter “3”, and then fasten them using 1
the clamps “4”. 2
6. Connect the fuel hose “1” to the vapor

separator, and then fasten it using the 12. Pass the fuel pump coupler “a” and the
clamp “5”. fuel hose “1” in this order through the gap
“b” in the intake manifold.
6-39
13. Route the fuel hose “2” through the gap 19. Fasten the fuel filter “1”, vapor gas hose
“c” in the intake manifold. with filter “2”, and air hose “3” using the
plastic ties “4”.
a
3 0
1
2
1 4
1
2
2
b
Installing the intake manifold
c 1. Install new gaskets “1” onto the intake
manifold. 3
14. Fit the fuel hose “1” into the groove “a” in
the intake manifold. 2. Install the holders “2” and “3” to the vapor
15. Fit the vapor gas hose with filter “2” into
gas hoses.
4
the groove “b” in the intake manifold.
16. Connect the pressure regulator hose “3”.

3
1
2 5
2
1
2 6
3
1
1
b
a 1
3 7
17. Tighten the vapor separator bolts “1” to
3. Install the dowels “1” and intake manifold
“2”.
8
18. Install the drain hose “2” to the intake
2
manifold. 1 9
10
1
2 1

holder “2”.
Vapor separator bolt “1”:

5 N·m (0.5 kgf·m, 3.7 ft·lb)
A
6-40
5. Connect the ISC valve coupler “a” and air

pressure sensor coupler “b”.
6. Install the holder “1” to the intake mani-

fold.
1
1
6-41
Vapor separator and high-pressure fuel pump
2 N·m (0.2 kgf·m, 1.5 ft·lb)
5 N·m (0.5 kgf·m, 3.7 ft·lb)

3 4 0
2
6 1
5
8
7 9
2
1
12
11
10 3
4
13
14 2 N·m (0.2 kgf·m, 1.5 ft·lb)
11
15
5
16
17 6
2 N·m (0.2 kgf·m, 1.5 ft·lb)

2 Pressure regulator 1
3
4
Screw
Cover assembly
7
1
M4 × 16 mm 8
6
7
Pin
Cap
1
1 9
8 Grommet 1
9 Plate 1
10
11
Plate
Screw
1
3 M4 × 8 mm
10
12 Needle valve assembly 1
13 Float 1
14 High-pressure fuel pump 1
15 Filter 1
16 Filter holder 1
17 Drain screw 1
A
6-42
Disassembling the vapor separator
1. Remove the pressure regulator “1”.
1
2
5. Disconnect the lead coupler “a”.
2. Remove the cover “1”, gasket “2”, and fil- 6. Remove the needle valve assembly “1”.
ter holder “3”.
1
1
a
2
7. Remove the plates “1” and “2”.

3
1
3. Disconnect the lead coupler “a”, and then
remove the high-pressure fuel pump “1”, 2
filter “2”, and grommet “3”.
2
a
pump
1
high-pressure fuel pump. See “Checking
a the high-pressure fuel pump” (5-18).
3
Checking the vapor separator
4. Remove the pin “1” in the direction of the 1. Check the needle valve. Replace the
arrow, and then remove the float “2”. needle valve assembly if bent or worn.
6-43
Float chamber plate screw “3”:

2 N·m (0.2 kgf·m, 1.5 ft·lb)
2. Connect the lead coupler “a”.

0
3. Install the needle valve assembly “1”, and
then tighten the needle valve screw “2” to
2
1
2. Check the float. Replace if deteriorated.
3. Check the filter. Clean if there is dirt or

1
2
residue.
4. Place the cover assembly upside down,

and then measure the float height “a”.
a
3
TIP:
When measuring the float height, the float
Needle valve screw “2”:
2 N·m (0.2 kgf·m, 1.5 ft·lb) 4
should be resting on the needle valve. Do not
press the float. 4. Install the float “1”.
5. Insert the float pin “2” in the direction of 5

the arrow.
a
6
7
2
Float height “a”: 55.0–61.0 mm (2.2–2.4 in) 1
Assembling the vapor separator

8
6. Install the filter “1” to the high-pressure
1. Install the plates “1” and “2”, and then fuel pump “2”.
tighten the float chamber plate screws “3”
to the specified torque. 7. Install the grommet “3”, and then install 9
the high-pressure fuel pump “2”.
3
1 Make sure to install the grommet to the

10
float chamber cover before installing the
2 high-pressure fuel pump. Otherwise, the
grommet could be damaged.
8. Connect the lead coupler “a”.

A
6-44
1
a
a
3
9. Install a new gasket “1”, the filter holder

“2”, and the cover “3”, and then tighten
the float chamber cover screws “4” to the
specified torque.
4 3
Float chamber cover screw “4”:

2 N·m (0.2 kgf·m, 1.5 ft·lb)
10. Install the pressure regulator “1”, and

then tighten the pressure regulator screw
“2” to the specified torque.
Pressure regulator screw “2”:

5 N·m (0.5 kgf·m, 3.7 ft·lb)
6-45
Power unit 7
Power unit (check and adjustment) ................................. 7-1

Checking the compression pressure ......................................... 7-1 0
Checking the oil pressure .......................................................... 7-1
Checking the valve clearance ................................................... 7-1
Adjusting the valve clearance .................................................... 7-3 1
Power unit assembly ........................................................ 7-5
Removing the power unit ........................................................... 7-7
Installing the power unit ............................................................. 7-9
2
Flywheel magnet ............................................................. 7-12
Removing the flywheel magnet ............................................... 7-13
3
Removing the stator assembly ................................................ 7-13
Installing the stator assembly .................................................. 7-14
Installing the flywheel magnet ................................................. 7-15 4
Timing belt ....................................................................... 7-16
Removing the timing belt ......................................................... 7-17 5
Removing the drive sprocket ................................................... 7-17
Checking the timing belt .......................................................... 7-17
Installing the drive sprocket ..................................................... 7-17
Installing the timing belt ........................................................... 7-18
6
Starter motor ................................................................... 7-20
Removing the starter motor ..................................................... 7-21
7
Installing the starter motor ....................................................... 7-21
Rectifier Regulator and ignition coil .............................. 7-23

8
Removing the Rectifier Regulator ........................................... 7-25
Removing the ignition coil ....................................................... 7-25
Checking the spark plug .......................................................... 7-25 9
Installing the ignition coil ......................................................... 7-26
Installing the Rectifier Regulator ............................................. 7-26
10
Fuse box .......................................................................... 7-27
Wiring harness ................................................................ 7-28

Removing the wiring harness .................................................. 7-30
Installing the wiring harness .................................................... 7-31
A
Power unit
Camshaft .......................................................................... 7-33

Removing the driven sprocket and camshaft .......................... 7-35
Checking the driven sprocket .................................................. 7-35
Checking the camshaft ............................................................ 7-35
Installing the driven sprocket and camshaft ............................ 7-36
Cylinder head .................................................................. 7-38

Removing the cylinder head .................................................... 7-40
Disassembling the cylinder head ............................................. 7-40
Checking the valve lifter .......................................................... 7-40
Checking the cylinder head ..................................................... 7-41
Checking the valve spring ....................................................... 7-41
Checking the valve .................................................................. 7-41
Checking the valve guide ........................................................ 7-42
Replacing the valve guide ....................................................... 7-42
Checking the valve seat .......................................................... 7-43
Refacing the valve seat ........................................................... 7-43
Checking the cylinder head and cylinder block anode ............ 7-45
Assembling the cylinder head ................................................. 7-45
Installing the cylinder head ...................................................... 7-46
Exhaust cover .................................................................. 7-48

Removing the exhaust cover ................................................... 7-50
Checking the PCV ................................................................... 7-50
Checking the thermostat ......................................................... 7-50
Checking the exhaust cover anode ......................................... 7-50
Installing the exhaust cover ..................................................... 7-51
Cylinder block (F150A, FL150A) .................................... 7-52

Removing the oil pump assembly ........................................... 7-54
Removing the oil filter bracket ................................................. 7-54
Removing the balancer assembly ........................................... 7-54
Disassembling the oil pump .................................................... 7-54
Checking the oil pump ............................................................. 7-54
Assembling the oil pump ......................................................... 7-54
Installing the oil pump assembly ............................................. 7-55
Installing the balancer assembly ............................................. 7-55
Installing the oil filter bracket ................................................... 7-56
Cylinder block (F150B, FL150B) .................................... 7-58

Removing the oil pump assembly ........................................... 7-60
Power unit
Removing the oil filter bracket ................................................. 7-60

Removing the crankcase cover ............................................... 7-60
Disassembling the oil pump .................................................... 7-60
0
Checking the oil pump ............................................................. 7-60
Assembling the oil pump ......................................................... 7-60
Installing the oil pump assembly ............................................. 7-60
1
Installing the crankcase cover ................................................. 7-60
Installing the oil filter bracket ................................................... 7-60
2
Crankcase ........................................................................ 7-61
Disassembling the cylinder block ............................................ 7-63
Checking the piston diameter .................................................. 7-64 3
Checking the cylinder bore ...................................................... 7-64
Checking the piston ring .......................................................... 7-64
Checking the piston ring end gap ............................................ 7-65
Checking the piston ring groove .............................................. 7-65
4
Checking the piston ring side clearance .................................. 7-65
Checking the piston pin boss inside diameter ......................... 7-65
Checking the piston pin diameter ............................................ 7-66 5
Checking the connecting rod small end inside diameter and
big end inside diameter ........................................................... 7-66
Checking the connecting rod big end side clearance .............. 7-66
Checking the crankshaft .......................................................... 7-66
6
Checking the big end oil clearance ......................................... 7-67
Selecting the crankpin bearing ................................................ 7-68
Crankpin bearing selection table ............................................. 7-70
7
Checking the journal oil clearance .......................................... 7-71
Selecting the crankshaft journal bearing ................................. 7-72
Crankshaft journal bearing selection table .............................. 7-74 8
Assembling the cylinder block ................................................. 7-75
9
10
A
Power unit (check and adjustment)
Power unit (check and Checking the oil pressure
adjustment) 1. Connect the YDIS to display “Oil pres-
sure”.
Checking the compression pressure
1. Start the engine, warm it up for 5 min-
utes, and then stop it.
2. Start the engine and warm it up until the
engine idle speed stabilizes at
0
650–750 r/min.
2. Remove the clip from the engine shut-off
switch.
3. Measure the oil pressure. 1
3. Disconnect the spark plug wires. Oil pressure (reference data):
320.0 kPa (3.20 kgf/cm2, 46.4 psi)
4. Remove all of the spark plugs, and then
install the special service tools “1” and
at 60 °C (140 °F) with SL 10W-30
engine oil and at 700 r/min
2
“2” into the spark plug hole. 500.0 kPa (5.00 kgf/cm2, 72.5 psi)
at 62 °C (144 °F) with SL 10W-30
2
engine oil and at 3000 r/min 3
Checking the valve clearance
1 • Measure the valve clearances when the
engine is cold. 4
• Cover the fuel components using a rag to
5
Compression gauge “1”: 90890-03160 Do not turn the flywheel magnet counter-
Compression gauge extension “2”: clockwise. Otherwise, the water pump
90890-06563 impeller could be damaged. 6
5. Fully open the throttle.
6. Crank the engine until the reading on the
compression gauge stabilizes, and then
7
2. Disconnect the fuel hoses “1” and “2”.
measure the compression pressure.
Minimum compression pressure
(reference data): 1
8
880.0 kPa (8.80 kgf/cm2, 127.6 psi)
at 20 °C (68 °F)
7. Remove the special service tools “1” and

9
“2”.
8. Install all of the spark plugs, and then

tighten the spark plugs to the specified
10
torque. 2
Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb)
9. Connect the spark plug wires.

3. Remove the fuel pump assemblies. See
“Removing the fuel pump assembly” (6-
13). A
7-1
4. Remove the canister. See “Removing the
EX IN
canister” (6-18).
5. Disconnect the spark plug wires “1”, and #1

then remove the blowby hoses “2” and
“3”, all of the spark plugs, and cylinder
#2
head cover “4”.
#3
2
3 #4
a b
6. Turn the flywheel magnet clockwise to

align the “TDC” mark “a” on the flywheel
magnet with the pointer “b”. Check that
the “I” marks “c” and “d” on the driven
sprockets are aligned.
c d
Valve clearance:
Intake “a”:
0.17–0.24 mm (0.0067–0.0094 in)
Exhaust “b”:
0.31–0.38 mm (0.0122–0.0150 in)
8. Measure the intake and exhaust valve

clearances of the specified cylinders.
Adjust if out of specification.
#1 #2 #3 #4
IN ✔ ✔ — —
a EX ✔ — ✔ —
—: Not applicable
b ✔: Specified cylinder
9. Turn the flywheel magnet clockwise 360°

7. Measure the valve clearances “a” and “b” to align the “TDC” mark on the flywheel
according to steps 8–10. magnet with the pointer.
TIP:
Write down the measurement data.
7-2
10. Measure the intake and exhaust valve 15. Install the canister. See “Installing the
clearances of the specified cylinders. canister” (6-19).
Adjust if out of specification. See “Adjust-
ing the valve clearance” (7-3). 16. Install the fuel pump assemblies. See
#1 #2 #3 #4
“Installing the fuel pump assembly” (6-
15).
0
IN — — ✔ ✔
EX — ✔ — ✔ 17. Connect the fuel hoses “1” and “2”, and
—: Not applicable then fasten the fuel hoses “1” and “2”
using the plastic ties “3”.
1
✔: Specified cylinder
11. Install a new gasket “1” and the cylinder

head cover “2”.
2 2
3
2
3
3
4
1
5
1 Adjusting the valve clearance
Adjust the valve clearances when the engine
12. Install all of the spark plugs, and then

is cold. 6
tighten them to the specified torque.
• Do not turn the flywheel magnet coun-
Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb)
terclockwise. Otherwise, the water pump 7
13. Install the blowby hoses “1” and “2”, and impeller could be damaged.
then fasten the blowby hose “2” using the • Do not turn the flywheel magnet or the
clamp “3”. driven sprockets when the timing belt is
not installed. Otherwise, the pistons and 8
14. Connect the spark plug wires “4”. valves, or intake and exhaust valves will
collide with each other and be damaged.
1
• Do not remove the ignition timing
pointer.
9
3
2 1. Remove the flywheel magnet. See
“Removing the flywheel magnet” (7-13). 10
2. Remove the stator assembly. See
4 “Removing the stator assembly” (7-13).
3. Remove the timing belt. See “Removing

the timing belt” (7-17).
A
7-3
4. Remove the driven sprockets, camshaft 12. Install the flywheel magnet. See “Install-
caps, and camshafts. See “Removing the ing the flywheel magnet” (7-15).
driven sprocket and camshaft” (7-35).
5. Remove the valve lifters. See step 1 in

“Removing the cylinder head” (7-40).
6. Measure the valve lifter thickness “a”,

and then write down the measurement
data.
7. Select the necessary valve lifter by calcu-

lating its thickness using the following for-
mula.
Calculation formula:
Necessary valve lifter thickness = Removed
valve lifter thickness + Measured valve clear-
ance – Specified valve clearance
Example:
Removed valve lifter thickness = 3.000 mm
Measured valve clearance = 0.30 mm
Specified valve clearance = 0.20 mm
Necessary valve lifter thickness
= 3.000 mm + 0.30 mm – 0.20 mm
= 3.100 mm
8. Install the selected valve lifter into the

cylinder head. See step 5 in “Installing
the cylinder head” (7-46).
9. Install the camshafts, camshaft caps, and

driven sprockets. See “Installing the
driven sprocket and camshaft” (7-36).
10. Install the timing belt. See “Installing the

timing belt” (7-18).
11. Install the stator assembly. See “Install-

ing the stator assembly” (7-14).
7-4
Power unit assembly
Power unit assembly
1
19
2 0
1
20
3
1
18
17
2
16
14
15 10 3
10 15 10
13 4
12
11
7 4
5
6
5
42 N·m (4.2 kgf·m, 31.0 ft·lb)

8
4 N·m (0.4 kgf·m, 3.0 ft·lb)
20 N·m (2.0 kgf·m, 14.8 ft·lb) 6
8 42 N·m (4.2 kgf·m, 31.0 ft·lb)
9

1 Grommet 3
2 Cover 1
3
4
Cover
Apron
1
1
8
5 Nut 2
M6 × 40 mm
6
7
Screw
Bolt
2
3 M8 × 35 mm 9
8 Bolt 8 M10 × 140 mm
9 Bolt 4 M10 × 35 mm
10
11
Bolt
Rigging grommet
4
1
M6 × 16 mm
10
12 Plastic tie 1
13 Retaining plate 1
14 Bolt 2 M6 × 30 mm
15 Dowel 2
A
7-5
Power unit assembly
2
19
1
20
3
18
17
16
14
15 10
10 15 10
13
11 4
12 7
6
5
4 N·m (0.4 kgf·m, 3.0 ft·lb)
8 20 N·m (2.0 kgf·m, 14.8 ft·lb)
42 N·m (4.2 kgf·m, 31.0 ft·lb) 8
9 42 N·m (4.2 kgf·m, 31.0 ft·lb)

18 Dipstick guide 1
19 Bolt 1 M6 × 16 mm
20 Dipstick 1
7-6
Power unit assembly
Removing the power unit
1. Remove the clip “1” and throttle cable “2”.
1
a
0
2
1
6. Disconnect the fuel hose “1”.
2. Disconnect the battery cables “1”.

2
3. Remove the junction box cover “2”. 1
3
2
4
7. Disconnect the vapor gas hose “1”.
5
1
6
4. Disconnect the PTT motor leads “1”.
1
7
1 8. Remove the dipstick guide “1”.
8
1 9
5. Disconnect the 10-pin coupler “a”.
1
10
9. Disconnect the PTT switch coupler “a”
and trim sensor coupler “b”.
A
7-7
Power unit assembly
12. Disconnect the shift cut-off switch cou-
a pler “a” and shift position switch coupler
“b”.
10. Remove the 6Y8 Multifunction Meter har-

a
ness coupler “a” and gauge harness cou-
pler “b” from the bracket “1”.
13. Disconnect the cooling water pilot hose
1 “1”.
a 1
11. Disconnect the 6Y8 Multifunction Meter

harness coupler “a” or gauge coupler “b”.
14. Disconnect the flushing hose “1”.
A
B
15. Remove the apron “1”.
b
A. 6Y8 Multifunction Meter

B. Conventional gauge
7-8
Power unit assembly
4 4
4
5
4
5 0
1
2
1
1
3
2
3
16. Install the lifting harnesses to the engine
hangers “1”. 3
5 4
17. Suspend the power unit.
18. Remove the power unit mounting bolts

Power unit mounting bolt (M8) “3”:
20 N·m (2.0 kgf·m, 14.8 ft·lb) 4
“2”, “3”, and “4”, and then remove the Power unit mounting bolts (M10) “4” and
power unit. “5”: 42 N·m (4.2 kgf·m, 31.0 ft·lb)
2 1 1 3. Install the apron “1”, and then tighten the 5
3 3 apron screw “2” to the specified torque.
3 3
4 4 6
7
1
2
8
2
4 3
2
9
Apron screw “2”:
Installing the power unit
1. Clean the power unit mating surface, and
4 N·m (0.4 kgf·m, 3.0 ft·lb)
4. Connect the flushing hose “1”, and then

10
then install the dowels “1” and a new gas-
ket “2”. fasten it using the plastic tie “2”.
2. Install the power unit, and then tighten

the power unit mounting bolts “3”, “4”,
and “5” to the specified torque.
A
7-9
Power unit assembly
2
1
5. Connect the cooling water pilot hose “1”. A. 6Y8 Multifunction Meter
B. Conventional gauge harness
1 8. Install the 6Y8 Multifunction Meter har-

ness coupler “a” and gauge harness cou-
pler “b” to the bracket “1”.
6. Connect the shift cut-off switch coupler

“a” and shift position switch coupler “b”.
b
b 9. Connect the PTT switch coupler “a” and

trim sensor coupler “b”.
7. Connect the 6Y8 Multifunction Meter har-

ness coupler “a” or gauge coupler “b”.
A
b
a
10. Install the dipstick guide “1”.
7-10
Power unit assembly
PTT motor lead bolt “2”:
then fasten it using the clamp “2”.
4 N·m (0.4 kgf·m, 3.0 ft·lb)
15. Install the junction box cover “1”.

0
16. Connect the battery cables “2”, and then
tighten the battery cable nut “3” to the
specified torque.
1
17. Install the rubber cap “4”.
1 2
12. Connect the fuel hose “1”, and then fas-

2
1
ten it using the plastic tie “2”. 3
2
4
3
1
4
2
5
13. Connect the 10-pin coupler “a”. Battery cable nut “3”:
9 N·m (0.9 kgf·m, 6.6 ft·lb)
18. Install the throttle cable. See “Installing

6
the throttle cable” (3-11).
a 7
8
14. Connect the PTT motor leads “1”, and
then tighten the PTT motor lead bolts “2”
to the specified torque. 9
1
10
2
A
7-11
Flywheel magnet
Flywheel magnet
9 4
270 N·m (27.0 kgf·m, 199.1 ft·lb) 5
8 4
1 9
2
10
9
8 3
9
14
6 7 15
11 11
13
12
16

1 Nut 1 Width across flats: 36 mm
2 Washer 1 Apply oil on both sides of the washer.
3 Base assembly 1
5 Stator assembly 1
6 Pulser coil 1
7 Holder 1
8 Bracket 2
9 Bolt 4 M6 × 35 mm
10 Holder 1
11 Dowel 2
12 Flywheel magnet 1
13 Woodruff key 1
14 Bolt 1 M6 × 16 mm
15 Bracket 1
16 Blowby hose 1
7-12
Flywheel magnet
Removing the flywheel magnet A 1
1. Loosen the flywheel magnet nut.
Apply force in the direction of the arrow to 0

prevent the flywheel holder “1” from slip-
ping off easily.
A 1
B 4 a
1 2 b
3
2
2
3
3
B
4
A. Conventional special service tool
B. New special service tool
2
Flywheel puller “1”: 90890-06521
Hydro puller kit “4”: 90890-06593
5
Removing the stator assembly
1. Remove the pulser coil coupler “a” from
the junction box “1”, and then disconnect
6
B. New special service tool the pulser coil coupler “a”.
Flywheel holder “1”: 90890-06522

Flywheel stopper “2”: 90890-06598
7
a
2. Remove the flywheel magnet and Woo-
druff key. 8
To prevent damage to the engine or tools,
screw in the flywheel puller set bolts 1 9
evenly and completely so that the fly-
2. Disconnect the lighting coil coupler “a”.
wheel puller “1” is parallel to the flywheel
magnet. 10
TIP: a
Fit the protrusion “a” on the hydro puller
spacer “2” into the hole “b” in the hydro
pusher “3”.
A
7-13
Flywheel magnet
3. Remove the holders “1” and “2” and
blowby hose “3”.
3
1 2
1
2
1
4. Remove the wiring harness “1” from the

holders “2”.
2. Install the wiring harness “1” to the hold-
2
ers “2”.
2
1
2 1
5. Remove the stator assembly “1” and

pulser coil “2”.
1 3. Install the blowby hose “1” and holders
“2” and “3”.
2 3
4. Connect the lighting coil coupler “a”.
Installing the stator assembly

1. Install the dowels “1”, pulser coil “2”, and
stator assembly “3”. a
7-14
Flywheel magnet
5. Connect the pulser coil coupler “a”, and
A
then install the pulser coil coupler “a” to 2
the bracket “1”.
0
1
a
1
B
1
1
2
Installing the flywheel magnet
1. Install the Woodruff key “1”, and then
install the flywheel magnet “2” and fly-
3
3
wheel magnet nut “3”.
TIP:
Make sure to clean the tapered portions of
4
the crankshaft “a” and flywheel magnet “b”.
B. New special service tool
3
Flywheel holder “2”: 90890-06522
Flywheel stopper “3”: 90890-06598
5
Flywheel magnet nut “1”:
2
270 N·m (27.0 kgf·m, 199.1 ft·lb) 6
7
2
1 a
b 8
9
2. Tighten the flywheel magnet nut “1” to
the specified torque. 10
Apply force in the direction of the arrow to
prevent the flywheel holder “2” from slip-
ping off easily.
A
7-15
Timing belt
Timing belt
39 N·m (3.9 kgf·m, 28.8 ft·lb)
7 N·m (0.7 kgf·m, 5.2 ft·lb)
8 2
1
5
4

1 Timing belt 1
2 Timing belt tensioner 1
3 Plate 1
4 Dowel 1
6 Plate 1
7 Drive sprocket 1
8 Bolt 4 M5 × 40 mm
7-16
Timing belt
Removing the timing belt 3. Remove the timing belt “1” from the
driven sprocket side.
When the timing belt is not installed, do

not turn the crankshaft or driven sprocket. 1 0
Otherwise, the pistons and valves could
1. Turn the crankshaft clockwise to align the

1
mark “a” in the drive sprocket and the
protrusion “b” on the cylinder block.
Check that the “I” marks “c” and “d” on
Removing the drive sprocket
2
the driven sprockets are aligned.
1. Remove the drive sprocket “1”, plate “2”,
c d and dowel “3”.
3
3 1
4
b
a 5
2
6
2. Turn the timing belt tensioner gradually
clockwise using a hexagon wrench, and
then insert a 5.0 mm (0.2 in) diameter pin
“1” into the hole “a”.
Checking the timing belt
1. Check the interior and exterior of the tim-
7
ing belt. Replace if cracked, damaged, or
TIP: worn.
• When turning the timing belt tensioner,
Installing the drive sprocket
8
apply a force of 15 N·m (1.5 kgf·m,
11.1 ft·lb) or less. 1. Install the dowel “1”, plate “2”, and drive
sprocket “3”, and then tighten the drive
• Leave the pin “1” inserted into the hole “a”
of the timing belt tensioner until the timing sprocket bolts “4” to the specified torque. 9
belt is installed again.
10
1 a
A
7-17
Timing belt
4 4
Do not apply grease or oil to the timing
1 3 belt.
Drive sprocket bolt “4”: 3. Adjust the timing belt to the specified
7 N·m (0.7 kgf·m, 5.2 ft·lb) installation height “a”.
Installing the timing belt

a

not turn the crankshaft or driven sprocket.
Otherwise, the pistons and valves could
1. Check that the mark “a” in the drive

sprocket and the protrusion “b” on the Timing belt installation height “a”:
cylinder block are aligned. Check that the 2.0 mm (0.08 in)
“I” marks “c” and “d” on the driven
sprockets are aligned. 4. Turn the timing belt tensioner gradually
clockwise using a hexagon wrench, and
c d then remove the pin “1”.
TIP:
When turning the timing belt tensioner, apply
a force of 15 N·m (1.5 kgf·m, 11.1 ft·lb) or
less.
b
1
2. Install a new timing belt with its part num-
ber in the proper orientation, from the
drive sprocket side to the port and star-
board driven sprockets, in the counter-
clockwise direction.
7-18
Timing belt
5. Turn the crankshaft clockwise 2 full turns,
and then check that the mark “a” in the
drive sprocket and the protrusion “b” on
the cylinder block are aligned. Also,
check that the “I” marks “c” and “d” on the
driven sprockets are aligned.
0
c d
1
2
b
a
3
4
5
6
7
8
9
10
A
7-19
Starter motor
Starter motor
30 N·m (3.0 kgf·m, 22.1 ft·lb)
4 N·m (0.4 kgf·m, 3.0 ft·lb)
9 N·m (0.9 kgf·m, 6.6 ft·lb)
6 9
7
3
2
1 8 10 11
9 N·m (0.9 kgf·m, 6.6 ft·lb)

1 Cap 1
2 Nut 1
3 Terminal 1
4 Starter motor 1
5 Bolt 3 M8 × 45 mm
6 Cap 1
7 Bolt 1 M6 × 10 mm
8 Battery cable 1
9 Bolt 1 M8 × 16 mm
10 Spring washer 1
11 Nut 1
7-20
Starter motor
Removing the starter motor
1. Remove the cap “1” and terminal “2”, and 1
then disconnect the positive lead “3”. 2
0
2
3
2 1
Starter motor mounting bolt “2”:
1 30 N·m (3.0 kgf·m, 22.1 ft·lb) 2
2. Remove the starter motor lead “1” from 2. Connect the starter motor lead “1”, and
the holder “2”. then tighten the starter motor lead bolt
3. Disconnect the starter motor lead “1”.

“2” to the specified torque. 3
3. Install the cap “3”.
1 4. Install the starter motor lead “1” to the

holder “4”.
4
1
1 5
3 1
2 2
4. Remove the starter motor “1”.

6
1 2 4 4
Starter motor lead bolt “2”:

7
4 N·m (0.4 kgf·m, 3.0 ft·lb)
5. Install the positive lead “1” and terminal

“2”, and then tighten the terminal nut “3”
8
6. Install the cap “4”. 9

Installing the starter motor
1. Install the starter motor “1”, and then
tighten the starter motor mounting bolts
“2” to the specified torque. 10
1
2
3
4
A
7-21
Starter motor
Terminal nut “3”:

9 N·m (0.9 kgf·m, 6.6 ft·lb)
7-22
Rectifier Regulator and ignition coil
25 N·m (2.5 kgf·m, 18.4 ft·lb)

0
4
18 1
2
19
1
3
5
2
3
19
6 3
16
3 9
15
12
7 4
14 10
17
16
11
8
5
15 19 13
14 12
10 11
9
6
7 N·m (0.7 kgf·m, 5.2 ft·lb)
17

1 Rectifier Regulator 1
3
4
Bolt
Bolt
6
1
M6 × 30 mm
M6 × 16 mm
8
5 Spark plug wire #1 1
6
7
Spark plug wire #2
Spark plug wire #3
1
1 9
8 Spark plug wire #4 1
9 Holder 2
10
11
Holder
Bolt
2
2 M6 × 10 mm
10
12 Holder 2
13 Holder 1
14 Ignition coil 2
15 Bracket 2
16 Holder 2
17 Bolt 4 M6 × 25 mm
A
7-23
25 N·m (2.5 kgf·m, 18.4 ft·lb)
4
18
2
19
1
3
5
19
3 6
16
3 9
15 7
12
14 10
11
17
16
8
15 19 13
14 12
10 11
7 N·m (0.7 kgf·m, 5.2 ft·lb) 9
17

18 Hose 1 Exhaust cover to fuel cooler
19 Spark plug 4
7-24
Removing the Rectifier Regulator 3. Remove the ignition coils “3”.
1. Disconnect the Rectifier Regulator cou-
pler “a”, and then remove the ground a
lead “1”.
0
1
1 3
2
1
a
a
2
3
2. Remove the Rectifier Regulator “1”.
Checking the spark plug 3
1 1. Clean the electrodes “a” using a spark
plug cleaner.
a
4
5
Removing the ignition coil
1. Remove the spark plug wires “1”, “2”, “3”, 6
and “4”.
2. Check the spark plug. Replace if the
1
electrodes are eroded, or there is carbon
or other deposits.
7
3. Check the spark plug gap “a”. Replace if
out of specification.
8
a
9
2
10
3
Specified spark plug: LFR5A-11 (NGK)
4
Spark plug gap “a”:
2. Disconnect the ignition coil couplers “a”, 1.0–1.1 mm (0.039–0.043 in)
and then remove the wiring harness “1”
from the holders “2”. A
7-25
Installing the ignition coil
1
1. Install the ignition coils “1”, and then 2
tighten the ignition coil bolts “2” to the
specified torque.
2. Install the wiring harness “3” to the hold-

ers “4”, and then connect the ignition coil
couplers “a”.
a 2
2. Connect the Rectifier Regulator coupler
“a”, and then install the ground lead “1”.
3 1 1
2 a
a 1
Ignition coil bolt “2”:

7 N·m (0.7 kgf·m, 5.2 ft·lb)
3. Install the spark plug wires “1”, “2”, “3”,

holders “5”, “6”, and “7”.
5
3
6
4
5 7
Installing the Rectifier Regulator

1. Install a new gasket “1” and the Rectifier
Regulator “2”.
7-26
Fuse box
Fuse box
7 0
2
1
1
3
2
3
2
10 3
4 9
5
8
4
12 11 6
4
2
4
7 5
11
5
12
6 6

1 Fuse box assembly 1
2 Fuse 2 50 A
3
4
Screw
Fuse
4
2
M5 × 10 mm
20 A
8
5 Relay 1
6
7
Fuse
Screw
1
3
30 A
M5 × 20 mm 9
8 Cover 1
9 Gasket 1
10
11
Fuse puller
Fuse
1
1 20 A, Spare
10
12 Fuse 1 30 A, Spare
A
7-27
Wiring harness
Wiring harness
3
4
5
21
19 22 20
18 6
17
23 19 18
18 19
24 26
17 4 N·m (0.4 kgf·m, 3.0 ft·lb)
25
7
17 8
27 15 16
14
28
13 8
12 10
4 N·m (0.4 kgf·m, 3.0 ft·lb) 11 9 4 N·m (0.4 kgf·m, 3.0 ft·lb)

1 Wiring harness 1
2 Cover 1
3 Screw 3 ø6 × 19 mm
4 Wiring harness 1
5 Bolt 4 M6 × 16 mm
6 Plastic tie 2
7 Bolt 2 M6 × 20 mm
8 Bolt 2 M6 × 10 mm
9 PTT relay 1
10 Cap 1
11 Bolt 1 M6 × 10 mm
12 Screw 1 ø6 × 19 mm
13 Bracket 1
14 Starter relay 1
15 Holder 1
16 Bolt 1 M6 × 12 mm
17 Bolt 3 M6 × 35 mm
7-28
Wiring harness
2
0
3
1
1
3
4
2
5
19 22
21
20 3
18 6
23 19
18
17
18 19
4
24 26
17 4 N·m (0.4 kgf·m, 3.0 ft·lb)
25
17
7
8 5
27 15 16
14
28
13
12 10
8 6

18 Grommet 3
19 Collar 3
20
21
Grommet
Junction box
1
1
8
22 Bolt 1 M6 × 16 mm
ø6 × 19 mm
23
24
Screw
Holder
1
1 9
25 Screw 1 ø6 × 19 mm
26 Bracket 1
27
28
Grommet
Air temperature sensor
1
1
10
A
7-29
Wiring harness
Removing the wiring harness 6. Remove the 10-pin wiring harness cou-
1. Disconnect the thermoswitch connectors pler “a” from the holder “1”.
“a”.
7. Remove the joint connectors “b”.
a
1
b a
8. Remove the junction box “1” along with
the wiring harness.
3. Disconnect the oil pressure sensor cou-

pler “a”.
4. Remove the ground leads “1”.
1 a
9. Disconnect the engine ECM coupler “a”,
and then remove the engine ECM “1”.
1
a
5. Disconnect the engine temperature sen-

sor coupler “a”.
10. Disconnect the starter relay lead connec-

tor “a” and PTT relay coupler “b”.
11. Remove the PTT relay leads “1” and “2”,

ground lead “3”, and starter relay lead
a “4”.
7-30
Wiring harness
12. Disconnect the air temperature sensor
coupler “c”, and then remove the YDIS
coupler “d”.
7
13. Remove the holder “5” and plastic ties “6”
and “7”.
0
5
a
5
b
1
8 1
3
2
6
d
4 9 2
1 c
c 6
3
2
d
3
4 7
a PTT relay lead nut “5”:
4 N·m (0.4 kgf·m, 3.0 ft·lb) 4
Starter relay lead bolt “6”:
b 4 N·m (0.4 kgf·m, 3.0 ft·lb)
5. Install the engine ECM “1”, and then con- 5

Installing the wiring harness nect the engine ECM coupler “a”.
See “Electrical component and wiring har-
ness routing” (5-1). 6
1
1. Install the YDIS coupler “a”, and then
connect the air temperature sensor cou- a
pler “b”. 7
2. Install the PTT relay leads “1” and “2”,
ground lead “3”, and starter relay lead
“4”, and then tighten the PTT relay lead 8
nuts “5” and starter relay lead bolt “6” to 6. Install the junction box “1” along with the
the specified torque. wiring harness.
3. Connect the starter relay lead connector 9

“c” and PTT relay coupler “d”.
4. Install the holder “7” to the junction box,

and then fasten the wiring harnesses
10
using the plastic ties “8” and “9”.
A
7-31
Wiring harness
1 a
12. Install the bracket “1”.
7. Install the joint connectors “a”.
8. Install the 10-pin wiring harness coupler

“b” to the holder “1”.
13. Connect the thermoswitch connectors

“a”.
1
a b
9. Connect the engine temperature sensor a

coupler “a”.
10. Install the ground leads “1”.
11. Connect the oil pressure sensor coupler

“a”.
7-32
Camshaft
Camshaft
2 N·m (0.2 kgf·m, 1.5 ft·lb)

0
8 25
9
8 10
23
60 N·m (6.0 kgf·m, 44.3 ft·lb)
1
5 22 23 24
22
2
8 24
11
8
19 20
19
3
7
20
7 24
5
6
12
17
18
4
6 21
3
4 5 16
3 13 5
15
4
3 14 12
1
2
a 9 N·m (0.9 kgf·m, 6.6 ft·lb)
6
b 17 N·m (1.7 kgf·m, 12.5 ft·lb)

1 Bolt 2 M6 × 42 mm
2 Bracket 1
3
4
Grommet
Collar
3
3
8
5 Bolt 13 M6 × 30 mm
6
7
Holder
Bracket
2
2 9
8 Grommet 5
9 Cylinder head cover 1
10
11
Screw
Plate
8
1
M4 × 8 mm
10
12 Clamp 2
13 Hose 1 Cylinder head cover to cylinder block
14 Bolt 16 M7 × 37 mm
15 Camshaft cap 8
16 Bolt 4 M7 × 48 mm
17 Camshaft cap 2
A
7-33
Camshaft
2 N·m (0.2 kgf·m, 1.5 ft·lb)
8 25
60 N·m (6.0 kgf·m, 44.3 ft·lb)
8 10
9 23
5 22 23 24
22
8 24
11
8 20
19
7 19
20
7 24
18
12
5 17
6 6
3 21
4 5 16
3 13
15
4
3 14 12
2
1 a 9 N·m (0.9 kgf·m, 6.6 ft·lb)
b 17 N·m (1.7 kgf·m, 12.5 ft·lb)

18 Camshaft 1 EX
19 Oil seal 2 Not reusable
20 Dowel 2
21 Camshaft 1 IN
22 Driven sprocket 2
23 Bolt 2 M10 × 35 mm
24 Dowel 4
7-34
Camshaft
Removing the driven sprocket and Checking the driven sprocket
camshaft 1. Check the driven sprockets. Replace if
cracked, damaged, or worn.
When the timing belt is not installed, do Checking the camshaft 0

not turn the crankshaft or driven sprock- 1. Measure the cam lobe height “a” and
ets. Otherwise, the pistons and valves width “b”.
could collide with each other and be dam-
aged.
1
a
1. Remove the cylinder head cover.
2. Secure the camshaft using a wrench,

2
and then remove the driven sprockets
“1”.
b 3
1 Cam lobe height “a”:
1
Intake:
45.310–45.410 mm 4
(1.7839–1.7878 in)
Exhaust:
44.360–44.460 mm
(1.7465–1.7504 in)
5
Cam lobe width “b”:
Intake and exhaust:
35.950–36.050 mm
(1.4154–1.4193 in)
6
2. Measure the camshaft runout.
3. Remove the camshaft caps “1” and “2”,
camshafts “3” and “4”, and oil seals “5”.
7
2 8
2
2
2
2 1
9
2 3 5
2
Camshaft runout:
2 1 0.03 mm (0.0012 in) 10
4 5
3. Measure the camshaft journal diameter
“a” and cylinder head journal inside
diameter “b”.
A
7-35
Camshaft
3
b
63P EX
a 2
4
63P IN
b 2
1
1
Camshaft journal diameter “a”:
24.960–24.980 mm
(0.9827–0.9835 in)
Cylinder head journal inside diameter “b”:
25.000–25.021 mm IN EX
2
(0.9843–0.9851 in)
Installing the driven sprocket and

camshaft

not turn the crankshaft or driven sprock-
ets. Otherwise, the pistons and valves
could collide with each other and be dam- 3. Apply a thin, even coat of sealant to the
aged. mating surface of the camshaft caps “1”.
1. Install new oil seals “1” and the dowels UP

“2” onto the camshafts “3” and “4”.
2. Install the camshafts so that the dowels

“2” are facing inward and that they are 1
aligned with the mating surface of the cyl-
inder head.
TIP:
Make sure that pistons #1 and #4 are posi- 4. Install the dowels “1”, camshaft caps “2”
tioned at the TDC. and “3”, and camshaft cap bolts “4” and
“5”.
TIP:
Install the camshaft caps “2” and “3” in the
proper positions so that the stamped num-
bers are upside down.
7-36
Camshaft
6. Install the driven sprockets “1”.
5 3
4 7. Secure the camshaft using a wrench,
3
3 3 and then tighten the driven sprocket bolts
3
3
3 2 “2” to the specified torque. 0
3 2
2
1
1
1
2
2
6
EX
3
IN
1 3
7 2
#1
8
#2
3 Driven sprocket bolt “2”: 4
60 N·m (6.0 kgf·m, 44.3 ft·lb)
9 4
#3 8. Install the cylinder head cover. See step
11 in “Checking the valve clearance” (7- 5
10 5 1).
#4
6
5. Tighten the camshaft cap bolts “1” and
“2” gradually to the specified torques in 2
stages and in the order [1], [2], and so
on.
7
EX 1 IN
2 8
[5] [5]
#1
[1] [1]
#2 9
[4] [4]
#3
[2] [2] 10
#4
[3] [3]
Camshaft cap bolts “1” and “2”:

1st: 9 N·m (0.9 kgf·m, 6.6 ft·lb)
2nd: 17 N·m (1.7 kgf·m, 12.5 ft·lb)
A
7-37
Cylinder head
Cylinder head
a 14 N·m (1.4 kgf·m, 10.3 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb)
b 28 N·m (2.8 kgf·m, 20.7 ft·lb)
21
19 20
18 9
5 7
6
8
1 4
2 3 22 24
23
11 14
17 13
12 16
15 25
10 11 14
7 26
13 23
12 6
16
15 5
4
3 27
10 23
2 25
a 28 N·m (2.8 kgf·m, 20.7 ft·lb) 1
b 56 N·m (5.6 kgf·m, 41.3 ft·lb)
c 90°

1 Valve lifter 16
2 Valve cotter 32
3 Valve spring retainer 16
4 Valve spring 16
5 Valve spring seat 16
6 Valve seal 16 Not reusable
7 Valve guide 16 Not reusable
8 Intake valve 8
9 Exhaust valve 8
10 Anode assembly 2
11 Bolt 2 M8 × 40 mm
12 Bolt 2 M6 × 20 mm
14 Cover 2
15 Grommet 2
16 Anode 2
17 Bolt 10 M10 × 120 mm
7-38
Cylinder head
a 14 N·m (1.4 kgf·m, 10.3 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb)
b 28 N·m (2.8 kgf·m, 20.7 ft·lb)
21 0
19 20
18 9
1
5 7
6
1
8 2
4 22 24
2 3 23
17
11
13
14
3
12 16
15 25
10 11 14
4
7 26
13 23
12 6
15
16
4
5 5
3 27
10 23
2 25
a 28 N·m (2.8 kgf·m, 20.7 ft·lb) 1
b 56 N·m (5.6 kgf·m, 41.3 ft·lb) 6
c 90°

18 Bolt 10 M8 × 55 mm
19 Plug 1
20
21
Gasket
Cylinder head
1
1
Not reusable 8
M6 × 16 mm
23
24
Screw
Anode
3
1 9
25 Dowel 2
26 Anode 1
27 Anode 1
10
A
7-39
Cylinder head
Removing the cylinder head
1. Remove the valve lifters “1”. TIP:
Make sure to keep the parts in the order of
removal.
TIP:
removal.
2
1
1
2. Remove the cylinder head “1”.
Valve spring compressor “1”: 90890-04019
Valve spring compressor attachment “2”:
Do not scratch or damage the mating sur- 90890-06320
faces of the cylinder head and cylinder
block. Checking the valve lifter
1. Check the valve lifters. Replace if dam-
aged, scratched, or worn.
2. Measure the valve lifter outside diameter

“a”.
Valve lifter outside diameter “a”:

30.970–30.980 mm
(1.2193–1.2197 in)
Disassembling the cylinder head
1. Remove the intake and exhaust valves.
7-40
Cylinder head
Checking the cylinder head
a
1. Remove carbon deposits from the com-
bustion chambers, and then check the
cylinder head for damage and scratches.
2. Check the cylinder head warpage using a

0
straightedge “1” and a thickness gauge
“2” in 7 directions. Replace the cylinder
head if above specification. 1
1 2 Valve spring tilt limit “a”:
1.7 mm (0.07 in) 2
Checking the valve
1. Check the valve face. Replace if pitted or
worn. 3
2. Measure the valve margin thickness “a”.
a
4
5
Cylinder head warpage limit:

6
0.10 mm (0.0039 in) Valve margin thickness “a”:
Checking the valve spring

Intake:
0.40–0.80 mm (0.0157–0.0315 in) 7
1. Measure the valve spring free length “a”. Exhaust:
0.80–1.20 mm (0.0315–0.0472 in)
3. Measure the valve stem diameter “a”. 8

a
9
a
10
Valve spring free length “a”:
48.08 mm (1.8929 in)
2. Measure the valve spring tilt “a”. Replace

if above specification.
A
7-41
Cylinder head
Valve stem diameter “a”: Replacing the valve guide

Intake: After replacing a valve guide, check the valve
5.477–5.492 mm (0.2156–0.2162 in) seat contact area.
Exhaust:
1. Remove the valve guide “1” from the
5.464–5.479 mm (0.2151–0.2157 in)
combustion chamber side.
4. Measure the valve stem runout.
Valve guide remover/installer “2”:

Valve stem runout: 90890-06801
Intake and exhaust: 0.01 mm (0.0004 in)
2. Install a new valve guide “1” from the
Checking the valve guide camshaft side to the specified installation
Before checking the valve guides, make sure height “a”.
that the valve stem diameter is within specifi-
cation.
2
1. Measure the valve guide inside diameter
“a”. a
3
Valve guide remover/installer “2”:

a 90890-06801
Valve guide installer “3”: 90890-06810
Installation height “a”:

Valve guide inside diameter “a”: 11.3–11.7 mm (0.44–0.46 in)
Intake and exhaust:
3. Insert the special service tool “1” into the
5.504–5.522 mm (0.2167–0.2174 in)
valve guide “2”, and then ream the valve
2. Calculate the valve guide clearance. guide.
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)
7-42
Cylinder head
4. Measure the valve seat contact width “a”
TIP: where the blueing dye is adhered to the
• To ream the valve guide, turn the valve valve face. Reface the valve seat if the
guide reamer clockwise. valve is not seated properly or if the valve
• When removing the valve guide reamer, do
not turn it counterclockwise.
seat contact width is out of specification.
Check the valve guide if the valve seat
0
• After reaming the valve guide, make sure to contact width is uneven.
clean it.
1
1
a
2
2
3
Valve guide reamer “1”: 90890-06804
4
4. Measure the valve guide inside diameter.
Valve guide inside diameter:
Intake and exhaust:
5.504–5.522 mm (0.2167–0.2174 in)
5
Checking the valve seat
1. Remove carbon deposits from the valve. 6
2. Apply a thin, even layer of Mechanic’s
blueing dye (Dykem) onto the valve seat.
7
3. Push the valve lightly against the valve Valve seat contact width “a”:
seat using the special service tool “1”. Intake:
1
1.10–1.40 mm (0.0433–0.0551 in)
Exhaust:
8
1.40–1.70 mm (0.0551–0.0669 in)
Refacing the valve seat

9
After every lapping procedure, make sure
to clean off any remaining lapping com-
pound from the cylinder head and valves.
10
Valve lapper “1”: 90890-04101
1. Reface the valve seat using the valve
seat cutters.
A
7-43
Cylinder head
a. Slag or rough surface
3. Adjust the top edge of the valve seat con-

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

Intake:
Valve seat cutter 30°: 90890-06327
Valve seat cutter 60°: 90890-06324 a. Previous contact width
Exhaust:
Valve seat cutter 30°: 90890-06326 4. Adjust the bottom edge of the valve seat
Valve seat cutter 45°: 90890-06325 contact width using a 60° cutter.
2. Cut the surface of the valve seat using a a

45° cutter by turning the cutter clockwise
until the valve seat face has become
smooth.
60˚
Do not overcut the valve seat. To prevent
chatter marks, make sure to turn the cut-
ter evenly using a downward force of a. Previous contact width
40–50 N (4.0–5.0 kgf, 8.8–11.0 lbf).
5. Adjust the valve seat contact width to
specification using a 45° cutter.
a
b
45˚
45˚
a a. Previous contact width
b. Specified contact width
6. Check the valve seat contact area of the

valve. See “Checking the valve seat” (7-
43).
7-44
Cylinder head
Example: a. Previous contact width
• If the valve seat contact area is too wide
and situated in the center of the valve face, 7. After refacing the valve seat to the speci-
cut the top edge of the valve seat using a fied contact width, apply a thin, even
30° cutter. Cut the bottom edge using a 60°
cutter to center the area and set its width.
layer of lapping compound onto the valve
seat, and then lap the valve using the
0
30
a 1
Do not get the lapping compound on the
valve stem and valve guide.
2
1
60
a. Previous contact width

3
• If the valve seat contact area is too narrow
and situated near the top edge of the valve 4
face, cut the top edge of the valve seat
using a 30° cutter to center the area. Set its
Valve lapper “1”: 90890-04101
width using a 45° cutter.
8. Recheck the valve seat contact area of
5
30 the valve. See “Checking the valve seat”
a
(7-43).
Checking the cylinder head and

6
cylinder block anode
1. Check the anodes. Clean if there is
grease, oil, or scales. 7
a. Previous contact width Do not apply grease, oil, or paint to the
anodes.
8
• If the valve seat contact area is too narrow
and situated near the bottom edge of the
valve face, cut the bottom edge of the valve
seat using a 60° cutter. Set its width using a
Assembling the cylinder head
1. Install a new valve seal “1” onto the valve 9
guide “2”.
45° cutter.
2 1 10
a
60
A
7-45
Cylinder head
2. Install the valve “1”, valve spring seat “2”,
valve spring “3”, and valve spring retainer
“4” in this order, and then install the spe-
cial service tools “5” and “6”.
4
3
2
6 1 1
Installing the cylinder head

1 5 1. Install the dowels “1”, a new gasket “2”,
the cylinder head “3”, and the cylinder
head bolts “4” and “5”.
Valve spring compressor “5”: 90890-04019
Valve spring compressor attachment “6”: 5
90890-06320
4
3. Compress the valve spring, and then
install the valve cotters “1”.
1
3
1
2
4. Tap the valve spring retainer lightly using

a plastic hammer to seat the valve cot-
ters “1” securely.
2. Tighten the cylinder head bolts “1” to the
specified torques in 2 stages and in the
order [1], [2], and so on.
3. Mark the M10 bolts and cylinder head

with paint marks “a”, and then tighten the
M10 bolts 90° from the marks on the cyl-
inder head.
7-46
Cylinder head
4. Tighten the cylinder head bolts “2” to the
specified torques in 2 stages and in the
order [11], [12], and so on.
2
[9] 1
0
[17] [10]
[15] a 90q
[13]
[5]
[1]
[6]
1
[11] [2]
[12]
[14]
[4] [3] 2
[16] [7]
[8]
[20] [19] [18] 3
Cylinder head bolt “1” [1]–[10] (M10):
1st: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
2nd: 56 N·m (5.6 kgf·m, 41.3 ft·lb) 4
3rd: 90°
Cylinder head bolt “2” [11]–[20] (M8):
4th: 14 N·m (1.4 kgf·m, 10.3 ft·lb)
5th: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
5
5. Install the valve lifters “1”.
6
1
7
8
9
10
A
7-47
Exhaust cover
Exhaust cover
6 N·m (0.6 kgf·m, 4.4 ft·lb) 8
12 N·m (1.2 kgf·m, 8.9 ft·lb)
5 30
4 31
7
6
3
2
1 14
13
12
11
10
9
15
21 32
33
20
19
17 18
27
26 29
22 28
23 N·m (2.3 kgf·m, 17.0 ft·lb)
22
16 6 N·m (0.6 kgf·m, 4.4 ft·lb)
23
12 N·m (1.2 kgf·m, 8.9 ft·lb)
24 25
56 N·m (5.6 kgf·m, 41.3 ft·lb)

1 Bolt 1 M6 × 16 mm
2 Holder 1
3 Thermoswitch 1
4 Bolt 3 M6 × 30 mm
5 Cover 1
7 Thermostat 1
9 Anode assembly 1
10 Bolt 1 M6 × 20 mm
12 Cover 1
13 Grommet 1
14 Anode 1
15 Bolt 1 M8 × 40 mm
16 Bolt 3 M6 × 20 mm
17 Cover 1
7-48
Exhaust cover
6 N·m (0.6 kgf·m, 4.4 ft·lb) 8

12 N·m (1.2 kgf·m, 8.9 ft·lb)
5 30
0
4 31
7
3
6
1
2
1 14
13
10
11
12
2
9
15 3
21 32
33
19
20
4
17 18
27
26 22 28
29
5
23 N·m (2.3 kgf·m, 17.0 ft·lb)
22
6 N·m (0.6 kgf·m, 4.4 ft·lb)
16 23
24 25 12 N·m (1.2 kgf·m, 8.9 ft·lb) 6
56 N·m (5.6 kgf·m, 41.3 ft·lb)

18 Spring 1
19 PCV 1
20
21
Grommet
Gasket
1
1 Not reusable
8
22 Bolt 19 M6 × 30 mm
23
24
Bracket
Plug
1
1 M18 × 17 mm 9
26 Bolt 1 M6 × 12 mm
27
28
Holder
Plug
1
1 M14 × 12 mm
10
30 Exhaust cover 1
32 Screw 7 M5 × 27 mm
33 Anode 7
A
7-49
Exhaust cover
Removing the exhaust cover
1. Remove the thermoswitch “1”, thermo-
stat “2”, and PCV “3”.
1
1 2 3
Checking the thermostat

1. Suspend the thermostat in a container of
3
water.
2. Place a thermometer in the water, and

then heat the water slowly.
2. Remove the exhaust cover “1”.
3. Measure the thermostat valve opening

“a” at the specified water temperatures.
Checking the PCV

1. Check the PCV “1”. Replace if damaged
or worn.
2. Check the grommet “2”. Replace if

deformed.
3. Check the spring “3”. Replace if Water

deformed or fatigued. Valve opening “a”
temperature
58–62 °C
Starts opening
(136–144 °F)
above 70 °C
4.3 mm (0.17 in) or above
(158 °F)
Checking the exhaust cover anode

1. Check the anodes. Clean if there is
grease, oil, or scales.
7-50
Exhaust cover
4. Install the thermoswitch “6”.
Do not apply grease, oil, or paint to the 5. Install the grommet “7”, the PCV “8”, the
anodes. spring “9”, a new gasket “10”, and the
cover “11”. 0
Installing the exhaust cover
1. Install a new gasket “1” and the exhaust
cover “2”, and then tighten the exhaust
cover bolts “3” to the specified torques in 5
1
2 stages and in the order [1], [2], and so 6 3
2
on. 1
2 1
4
10 2
7
8
11 9
3
Thermostat cover bolt “5”: 4
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
3
3
3
5
3
[19]
[15]
6
[14]
[9] [10]
[4]
[5] 7
[2] [1]
[3]
[7]
[8]
[6]
8
[13] [11]
[18] [12]
[17] [16]
9
Exhaust cover bolt “3”:
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb) 10
2. Install a new gasket “1” to the thermostat
“2”.
3. Install the thermostat “2”, a new gasket

“3”, and the thermostat cover “4”, and
then tighten the thermostat cover bolts
“5” to the specified torques in 2 stages. A
7-51
Cylinder block (F150A, FL150A)
12 N·m (1.2 kgf·m, 8.9 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb)
34 33
18 19 33
17 7
16
12 13 15
14
11 10
7 9 21
4 20 32
8
22
31
6 30
5
3
23
24
2
24 29
28
1
18 N·m (1.8 kgf·m, 13.3 ft·lb)
18 N·m (1.8 kgf·m, 13.3 ft·lb)
31 N·m (3.1 kgf·m, 22.9 ft·lb) 26 34 N·m (3.4 kgf·m, 25.1 ft·lb)
25 27
7 N·m (0.7 kgf·m, 5.2 ft·lb)

1 Bolt 10 M8 × 55 mm
2 Bolt 2 M6 × 40 mm
3 Balancer assembly 1
4 Seal 2 Not reusable
5 Bracket 1
6 Engine hanger 1
7 Bolt 5 M6 × 20 mm
8 Bolt 2 M6 × 45 mm
9 Oil filler neck 1
12 Oil filler cap 1
13 Engine temperature sensor 1
14 Washer 1
15 Screw 1 M5 × 12 mm
16 Anode 1
7-52
15 N·m (1.5 kgf·m, 11.1 ft·lb)

18
17
12 N·m (1.2 kgf·m, 8.9 ft·lb)
19 7
33
34 33 0
16
12 13 15
14
1
11 10
2
7 9 21
4 20 32
8
22
31 3
6 30
5
3
23 4
24
2
1
24 29
28 5
18 N·m (1.8 kgf·m, 13.3 ft·lb)
18 N·m (1.8 kgf·m, 13.3 ft·lb)
26 34 N·m (3.4 kgf·m, 25.1 ft·lb)
31 N·m (3.1 kgf·m, 22.9 ft·lb)
7 N·m (0.7 kgf·m, 5.2 ft·lb)
25 27
6

18 Plug 1 M14 × 12 mm
19 Engine hanger 1
20
21
Oil pressure sensor
O-ring
1
1 Not reusable
8
22 Oil filter 1
23
24
Union bolt
O-ring
1
2 Not reusable 9
25 Relief valve 1
26 Oil filter bracket 1
27
28
Bolt
Bolt
4
4
M6 × 40 mm
M6 × 40 mm
10
29 Oil pump assembly 1
A
7-53
Removing the oil pump assembly
1. Remove the oil pump assembly “1”. 1
Disassembling the oil pump

1. Remove the oil pump cover “1”, gasket
Removing the oil filter bracket “2”, outer rotor “3”, inner rotor “4”, and oil
1. Remove the oil filter “1”. seals “5” and “6”.
1
1 3
4
2
5
6
Oil filter wrench “2”: 90890-06830
2. Remove the oil filter bracket “1”.
Checking the oil pump

1. Check the inner surface of the oil pump
1 housing. Replace the oil pump assembly
if scratched.
2. Check the gear teeth of the inner rotor

and outer rotor. Replace the oil pump
assembly if the gear teeth are cracked or
worn.
Removing the balancer assembly
1. Remove the balancer assembly “1”. Assembling the oil pump
1. Install new oil seals “1” into the oil pump
housing “2”.
TIP:
Install an oil seal halfway into the oil pump
housing, and then install the other oil seal.
7-54
Oil pump cover screw “5”:

1 4 N·m (0.4 kgf·m, 3.0 ft·lb)
3 2 Installing the oil pump assembly
1. Fill the oil pump assembly with engine oil 0
through the oil passage.
4
1
Driver rod L3 “3”: 90890-06652
Needle bearing attachment “4”:
90890-06611
2
2. Install a new oil seal “1” into the oil pump
housing “2”. 3
1 a 2. Install new O-rings “1” and the oil pump
assembly “2” by aligning the oil pump
3 2
gear with the crankshaft.
4
5
1
1
General pipe “3”:
a = 45 mm (1.77 in)
6
3. Install the outer rotor “1”, the inner rotor
“2”, a new gasket “3”, and the oil pump
cover “4”, and then tighten the oil pump
2 7
cover screws “5” to the specified torque.
4. Install a new oil seal “6” so that it is facing

in the proper direction.
Installing the balancer assembly
1. Align the keyway “a” in the crankshaft
8
with the cylinder block and crankcase
6 mating surfaces (STBD) “b”.
9
5 a
4 2 b
10
1
3
A
7-55
2. Apply a thin, even layer of sealant onto
[12] 3
the mating surface of the balancer 2
assembly. [9] [10]
[5] [6]
[1] [2]
[4] [3]
[8] [7]
[11]
3. Align the marks “a” on the balancer

shafts with the marks “b”. Balancer assembly bolt “2”:
b 1st: 18 N·m (1.8 kgf·m, 13.3 ft·lb)
2nd: 31 N·m (3.1 kgf·m, 22.9 ft·lb)
Balancer assembly bolt “3”:
1st: 7 N·m (0.7 kgf·m, 5.2 ft·lb)
2nd: 13 N·m (1.3 kgf·m, 9.6 ft·lb)
5. Install new seals “1”.

1
a
4. Install the balancer assembly “1”, and

then tighten the balancer assembly bolts
“2” and “3” to the specified torque in 2
stages and in the order [1], [2], and so
on.
1
Installing the oil filter bracket
1. Install new O-rings “1” and the oil filter
bracket “2”.
1
2
3 1
2. Install the oil filter “1”, and then tighten it

7-56
1
0
1
1
Oil filter wrench “2”: 90890-06830
Oil filter “1”: 18 N·m (1.8 kgf·m, 13.3 ft·lb)

2
3
4
5
6
7
8
9
10
A
7-57
Cylinder block (F150B, FL150B)
33 32
17 18 32
16 6
15
11 12 14
13
10 9
6 8 20 31
7 19
21
30
5 29
4
3 22
23
2
23 28
27
1
18 N·m (1.8 kgf·m, 13.3 ft·lb)
18 N·m (1.8 kgf·m, 13.3 ft·lb)
31 N·m (3.1 kgf·m, 22.9 ft·lb) 25 34 N·m (3.4 kgf·m, 25.1 ft·lb)
24 26
7 N·m (0.7 kgf·m, 5.2 ft·lb)

1 Bolt 10 M8 × 35 mm
2 Bolt 2 M6 × 25 mm
3 Crankcase cover 1
4 Bracket 1
5 Engine hanger 1
6 Bolt 5 M6 × 20 mm
7 Bolt 2 M6 × 45 mm
8 Oil filler neck 1
11 Oil filler cap 1
12 Engine temperature sensor 1
13 Washer 1
14 Screw 1 M5 × 12 mm
15 Anode 1
17 Plug 1 M14 × 12 mm
7-58
15 N·m (1.5 kgf·m, 11.1 ft·lb)

17
16
12 N·m (1.2 kgf·m, 8.9 ft·lb)
18 6
32
33 32 0
15
11 12 14
13
1
10 9
2
6 8 20 31
7 19
21
30 3
5 29
4
3 22 4
23
2
1
23 28
27 5
18 N·m (1.8 kgf·m, 13.3 ft·lb)
18 N·m (1.8 kgf·m, 13.3 ft·lb)
25 34 N·m (3.4 kgf·m, 25.1 ft·lb)
31 N·m (3.1 kgf·m, 22.9 ft·lb)
7 N·m (0.7 kgf·m, 5.2 ft·lb)
24 26
6

18 Engine hanger 1
19 Oil pressure sensor 1
20
21
O-ring
Oil filter
1
1
Not reusable 8
22 Joint 1
23
24
O-ring
Relief valve
2
1
Not reusable
9
25 Oil filter bracket 1
26 Bolt 4 M6 × 40 mm
27
28
Bolt
Oil pump assembly
4
1
M6 × 40 mm
10
A
7-59
Removing the oil pump assembly 2. Install the crankcase cover “1”, and then
See “Removing the oil pump assembly” (7- tighten the crankcase cover bolts “2” and
54). “3” to the specified torque in 2 stages and
in the order [1], [2], and so on.
Removing the oil filter bracket
See “Removing the oil filter bracket” (7-54). 1
Removing the crankcase cover

1. Remove the crankcase cover “1”.
[12] 3
2
[9] [10]
[5] [6]
[1] [2]
Disassembling the oil pump [4] [3]
See “Disassembling the oil pump” (7-54).
[8] [7]
Checking the oil pump [11]
See “Checking the oil pump” (7-54).
Assembling the oil pump

See “Assembling the oil pump” (7-54).
Installing the oil pump assembly Crankcase cover bolt “2”:

See “Installing the oil pump assembly” (7-55). 1st: 18 N·m (1.8 kgf·m, 13.3 ft·lb)
2nd: 31 N·m (3.1 kgf·m, 22.9 ft·lb)
Installing the crankcase cover Crankcase cover bolt “3”:
1. Apply a thin, even layer of sealant onto 1st: 7 N·m (0.7 kgf·m, 5.2 ft·lb)
the mating surface of the crankcase 2nd: 13 N·m (1.3 kgf·m, 9.6 ft·lb)
cover.
Installing the oil filter bracket
See “Installing the oil filter bracket” (7-56).
7-60
Crankcase
Crankcase
a 30 N·m (3.0 kgf·m, 22.1 ft·lb)

b 90q
a 14 N·m (1.4 kgf·m, 10.3 ft·lb)
0
b 28 N·m (2.8 kgf·m, 20.7 ft·lb)
9
a 30 N·m (3.0 kgf·m, 22.1 ft·lb)
b 90q
7
8 1
6 10
2
5 11
3 2 6
9
12
3
6 6
17
4
6
2 4 13 18 19
14
14
5
16 17
1
16
a 13 N·m (1.3 kgf·m, 9.6 ft·lb)
b 23 N·m (2.3 kgf·m, 17.0 ft·lb)
20 6
15 c 90°

1 Crankcase 1
2 Bolt 10 M10 × 85 mm
3
4
Bolt
Main bearing cap
10
1
M8 × 55 mm 8
5 Dowel 10
6
7
Crankshaft journal bearing
Oil seal
5
1 Not reusable 9
8 Crankshaft 1
9 Crankshaft journal bearing 4
10
11
Thrust bearing
O-ring
1
1 Not reusable
10
12 Cylinder block 1
13 Collar 1 Not reusable
14 Crankpin bearing 8
15 Connecting rod assembly 4
16 Connecting rod bolt 8 Not reusable, M9 × 44 mm
17 Clip 8 Not reusable
A
7-61
Crankcase
a 30 N·m (3.0 kgf·m, 22.1 ft·lb)

b 90q
a 14 N·m (1.4 kgf·m, 10.3 ft·lb)
b 28 N·m (2.8 kgf·m, 20.7 ft·lb)
9
a 30 N·m (3.0 kgf·m, 22.1 ft·lb) 7
b 90q 8
5 6 10 11
2 6
3 9
12
6 6
17
6
2 4 13 18 19
14
14
16 17
a 13 N·m (1.3 kgf·m, 9.6 ft·lb) 20
16 b 23 N·m (2.3 kgf·m, 17.0 ft·lb)
1 15 c 90°

18 Piston pin 4
19 Piston 4
20 Piston ring set 4
7-62
Crankcase
Disassembling the cylinder block
1. Remove the crankcase “1”. 1
2
0
1
1
2
3
3
2. Remove the main bearing cap “1”. a
4. Remove the crankshaft “1”, crankshaft

journal bearings “2”, thrust bearing “3”, 4
and oil seal “4”.
2
1
2
5
2
2
6
1
3
2 7
3. Remove the connecting rod bolts “1” and 4
connecting rod caps “2”, and then
remove the piston and connecting rod
assemblies “3”.
8
5. Remove the collar “1”.
TIP:
• To prevent mixing the piston and connect- 2 a
9
ing rod assemblies “3” and connecting rod 4
caps “2”, mark each with an identification
number “a” of the corresponding cylinder.
• Make sure to keep the parts in the order of
1
b
10
removal.
3
4
A
7-63
Crankcase
Bearing separator “2”: 90890-06534 Checking the cylinder bore

Gear puller “3”: 90890-06540 1. Measure the cylinder bore (D1–D6) at
General cylindrical tool “4”: measuring points “a”, “b”, and “c”, and in
a = 19.9 mm (0.78 in) directions “d” (D1, D3, D5) and “e” (D2, D4,
b = 90.0 mm (3.54 in) D6).
6. Remove the clips “1” and piston pin “2”,

and then remove the connecting rod “3”. a
b D2 D1
c d
TIP: D4 D3 e
removal. D6 D5
a. 10.0 mm (0.39 in)

2 b. 50.0 mm (1.97 in)
c. 85.0 mm (3.35 in)
d. Parallel to the crankshaft
e. At a right angle to the crankshaft
Cylinder bore (D1–D6):
94.000–94.017 mm
(3.7008–3.7014 in)
1 Checking the piston ring
3
1. Measure piston ring dimensions B and T.
Checking the piston diameter a b
1. Measure the piston outside diameter “a”
B B
at the specified measuring point “b”.
T T
c B
b T
a
Piston ring dimensions:
Top ring “a”:
B: 1.170–1.185 mm (0.0461–0.0467 in)
T: 2.800–3.000 mm (0.1102–0.1181 in)
Piston diameter “a”:
2nd ring “b”:
93.921–93.941 mm
B: 1.170–1.190 mm (0.0461–0.0469 in)
(3.6977–3.6985 in)
T: 3.700–3.900 mm (0.1457–0.1535 in)
Measuring point “b”:
Oil ring “c”:
13.5 mm (0.53 in) above the bottom of
B: 2.400–2.470 mm (0.0945–0.0972 in)
the piston skirt
T: 2.300–2.700 mm (0.0906–0.1063 in)
7-64
Crankcase
Checking the piston ring end gap Checking the piston ring side
1. Level the piston ring “1” in the cylinder clearance
using a piston crown at the specified 1. Measure the piston ring side clearance.
measuring point “a”.
2. Measure the piston ring end gap “b”. a

0
b
1
c
a
2
1
Piston ring side clearance:
b Top ring “a”:
0.04–0.08 mm (0.0016–0.0031 in) 3
2nd ring “b”:
0.03–0.07 mm (0.0012–0.0028 in)
Oil ring “c”:
0.04–0.13 mm (0.0016–0.0051 in)
4
Measuring point “a”: 10.0 mm (0.39 in)
Piston ring end gap “b” (reference data): Checking the piston pin boss inside
Top ring:
0.20–0.30 mm (0.0079–0.0118 in)
diameter
1. Measure the piston pin boss inside diam-
5
2nd ring: eter “a”.
0.30–0.45 mm (0.0118–0.0177 in)
Oil ring:
0.15–0.60 mm (0.0059–0.0236 in)
TIP: 6
When measuring the piston pin boss inside
diameter, do not measure it at the ring groove
Checking the piston ring groove
1. Measure the piston ring grooves.
“b” or oil groove “c”.
7
b
a
a 8
b
c c
c 9
Piston ring groove:
Top ring “a”:
10
1.23–1.25 mm (0.0484–0.0492 in)
2nd ring “b”:
1.22–1.24 mm (0.0480–0.0488 in) Piston pin boss inside diameter “a”:
Oil ring “c”: 21.021–21.031 mm
2.51–2.53 mm (0.0988–0.0996 in) (0.8276–0.8280 in)
A
7-65
Crankcase
Checking the piston pin diameter Connecting rod small end inside diameter
1. Measure the piston pin diameter “a”. “b”:
21.022–21.037 mm
a (0.8276–0.8282 in)
Connecting rod big end inside diameter
“c”:
53.025–53.045 mm
(2.0876–2.0884 in)
Checking the connecting rod big end

side clearance
1. Measure the connecting rod big end side
Piston pin outside diameter “a”: clearance “a”.
21.008–21.017 mm
(0.8271–0.8274 in)
Checking the connecting rod small

end inside diameter and big end
inside diameter a
1. Tighten the connecting rod bolts “1” to
the specified torques in 3 stages.
a
TIP:
• When checking the big end inside diameter, Connecting rod big end side clearance “a”:
reuse the removed connecting rod bolt. 0.14–0.31 mm (0.006–0.012 in)
• In the third tightening stage for the connect-
ing rod bolts “1”, mark the connecting rod Checking the crankshaft
bolts and the connecting rod cap with iden- 1. Measure the crankshaft journal diame-
tification marks “a”, and then tighten the ters “a”, crankpin diameters “b”, and
bolts 90° from the marks on the connecting crankpin widths “c”.
rod cap.
2. Measure the connecting rod small end a

inside diameter “b” and big end inside
diameter “c”.
a b
90˚
c
b
1
c
Connecting rod bolt “1”:
1st: 13 N·m (1.3 kgf·m, 9.6 ft·lb)
2nd: 23 N·m (2.3 kgf·m, 17.0 ft·lb)
3rd: 90°
7-66
Crankcase
Crankshaft journal diameter “a”: TIP:

51.980–52.000 mm Do not place the Plastigauge (PG-1) over the
(2.0465–2.0472 in) oil hole in the crankpin of the crankshaft.
Crankpin diameter “b”:
49.980–50.000 mm
0
(1.9677–1.9685 in)
Crankpin width “c”:
22.000–22.100 mm
(0.8661–0.8701 in)
1
2. Measure the crankshaft runout.
2
4. Install the connecting rod “1” and con-
necting rod cap “2” onto the crankpin. 3
TIP:
• When checking the oil clearance, reuse the
removed connecting rod bolts.
4
• Make sure that the marks “a” on the con-
Crankshaft runout: 0.03 mm (0.0012 in) necting rod “1” and connecting rod cap “2”
Checking the big end oil clearance

face toward the flywheel magnet end of the
crankshaft.
5
1. Clean the crankpin bearings, connecting • Do not turn the connecting rod until the big
rod, connecting rod cap, and crankpin. end oil clearance measurement has been
2. Install the crankpin bearings “1” into the

completed. 6
connecting rod “2” and connecting rod
cap “3”. 2
1
7
TIP:
Install the crankpin bearings in the original
positions.
a
a
8
2
1
3 9
10
3. Place a piece of Plastigauge (PG-1) on
the crankpin, parallel to the crankshaft. 5. Tighten the connecting rod bolts “1” to
the specified torques in 3 stages.
A
7-67
Crankcase
TIP:
In the third tightening stage for the connect-
ing rod bolts “1”, mark the connecting rod
bolts and the connecting rod cap with identifi-
cation marks “a”, and then tighten the bolts
90° from the marks on the connecting rod a
cap.
1 a 90˚
Connecting rod big end inside diameter
“a”:
53.025–53.045 mm
(2.0876–2.0884 in)
Example:
Connecting rod big
end inside diameter Number in table
“a”
53.035 mm 35
2. Check the crankpin mark “a” on the

crankshaft.
1st: 13 N·m (1.3 kgf·m, 9.6 ft·lb) P1 P4
2nd: 23 N·m (2.3 kgf·m, 17.0 ft·lb)
3rd: 90°
6. Remove the connecting rod cap, and

then measure the width of the com-
pressed Plastigauge (PG-1) on the
crankpin. P2 P3
P2 P3
P1 P4
a
J
P
Big end oil clearance: 3. Select the suitable colors “1” for the
0.030–0.057 mm (0.0012–0.0022 in) crankpin bearing from the “Crankpin
bearing selection table”.
Selecting the crankpin bearing
When replacing the crankpin bearing, select
the bearing as follows:
1. Measure the connecting rod big end

inside diameter “a”.
7-68
Crankcase
0
1
1
Upper bearing Lower bearing
“a”
color
Green
color
Green
2
“b” Green Blue
“c”
“d’
Blue
Blue
Blue
Red
3
“e” Red Red
Example:
If the connecting rod big end inside diameter 4
is “35” and the crankpin mark is “81”, select
the bearing colors in “d”. The upper bearing
color is blue and the lower bearing color is
red.
5
6
25 26 34 35 36 37
80
81
7
d
82
8
9
10
A
7-69
Crankcase
Crankpin bearing selection table
A
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
80
81 e
82
83
84
d
85
86
87
88
89 c
B 90
91
92
93
94
b
95
96
97
98
a
99
00
A. Connecting rod big end inside diameter

B. Crankpin mark
7-70
Crankcase
Checking the journal oil clearance 6. Install the main bearing cap “1”, and then
1. Clean the crankshaft journal bearings, tighten the main bearing cap bolts “2” to
crankshaft journals, and bearing portions the specified torques in 2 stages and in
of the crankcase and cylinder block. the order [1], [2], and so on.
2. Place the cylinder block upside down.

0
TIP:
• Do not turn the crankshaft until the journal
3. Install the crankshaft journal bearings “1”
and crankshaft “2” into the cylinder block
oil clearance measurement has been com-
pleted.
1
“3”. • In the second tightening stage for the main
bearing cap bolts “2”, mark the main bear-
TIP:
Install the crankshaft journal bearings “1” in
ing cap bolts and the main bearing cap with
identification marks “a”, and then tighten
2
the original positions. the bolts 90° from the marks on the main
bearing cap.
3
2
2 1
3
4
1
5
4. Place a piece of Plastigauge (PG-1) on
each crankshaft journal, parallel to the
crankshaft. 6
TIP:
Do not place the Plastigauge (PG-1) over the
oil hole in each crankshaft journal. 90q
7
a 2
[5] [6]
8
[1] [2]
[4] [3]
9
5. Install the crankshaft journal bearings

10
into the main bearing cap and crankcase. Main bearing cap bolts “2”:
1st: 30 N·m (3.0 kgf·m, 22.1 ft·lb)
TIP: 2nd: 90°
Install the crankshaft journal bearings in the
original positions.
A
7-71
Crankcase
7. Install the crankcase “1”, and then tighten 8. Remove the crankcase, and then mea-
the crankcase bolts “2” and “3” to the sure the width of the compressed Plasti-
specified torques in 2 stages and in the gauge (PG-1) on each crankshaft
order [1], [2], and so on. journal.
TIP:
• Do not turn the crankshaft until the journal
oil clearance measurement has been com-
pleted.
• In the second tightening stage for the M10
bolts “2”, mark the M10 bolts and the crank-
case with identification marks “a”, and then
tighten the bolts 90° from the marks on the
crankcase.
Journal oil clearance:
2 0.021–0.046 mm (0.0008–0.0018 in)
Selecting the crankshaft journal

bearing
3
1 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.
J1 J2 J3 J4 J5
[3] [4] 2 3
a 90q
[13] [14]
[9] [10]
[5] [6]
J2 J3
[8] [7] J1 J4
J5
[12] [11]
a
J
P
[2] [1]
Crankcase bolts “2” [1]–[4] (M10):

1st: 30 N·m (3.0 kgf·m, 22.1 ft·lb)
2nd: 90°
1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb)
2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
7-72
Crankcase
J5 J4 J3 J2 J1 b
20 21 29 30 31 32 33
80
0
81
82
e
1
2. Select the suitable colors “1” for the
crankshaft journal bearing from the
“Crankshaft journal bearing selection
2
table”.
1 3
4
1
5
J1/J2/ Upper bearing Lower bearing
J4/J5 color color
“a” Green Green 6
“b” Green Red
“c” Red Red
“d’
“e”
Red
Yellow
Yellow
Yellow
7
“f” Yellow Blue
J3
Upper bearing Lower bearing 8
color color
“a” Green Brown
“b”
“c”
Green
Red
Green
Green
9
“d’ Red Red
“e”
“f”
Yellow
Yellow
Red
Yellow 10
Example:
If the crankshaft journal mark is “81” and the
cylinder block mark is “30”, select the bearing
colors in “e”.
A
7-73
Crankcase
Crankshaft journal bearing selection table
A
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
80
81
82
f
83
84
85
e
86
87
88
d
89
B 90
91
c
92
93
94
b
95
96
97
98 a
99
00
A. Cylinder block mark

B. Crankshaft journal mark
7-74
Crankcase
Assembling the cylinder block
1. Install a new collar “1” by striking it using TIP:
a plastic hammer. • Make sure that the “2R” mark “a” on the
2nd ring “2” and “R” mark “b” on the top ring
“3” are facing up.
• Make sure that the piston rings move
0
1 smoothly.
1 a
1
#5 #4
#3 2
3
2
2. Assemble the piston “1”, the connecting #2
rod “2”, the piston pin “3”, and new clips #1
“4”. #5
45˚ 45˚
#2 3
TIP: b
• Face the mark “a” on the connecting rod “2”
in the same direction as the mark “b” on the
#1
#4 #3
4
piston crown.
• Do not align the clip “4” end with the groove 5. Install the crankpin bearings “1” into the
“c” in the piston pin boss. connecting rod “2” and connecting rod
cap “3”.
5
4 4
TIP:
c
3
b
Install the crankpin bearings in the original 6
positions.
1
1 7
3
1 8
2 4 2
a
3. Install the oil rings “1”, 2nd ring “2”, and

9
top ring “3”. 6. Apply engine oil to the side of the piston,
piston rings, and cylinder wall, and then
Do not scratch the pistons or break the

install the piston so that the mark “a” on
the piston crown is facing toward the fly-
10
piston rings. wheel magnet end of the crankshaft.
4. Offset the piston ring end gaps.
A
7-75
Crankcase
a 3
1
1 3 2
Piston ring compressor “1”: 90890-05158

2
and thrust bearing “2” into the cylinder
block “3”. 9. Install the connecting rod caps “1” to the
piston and connecting rod assemblies,
TIP: and then tighten new connecting rod
• Install the crankshaft journal bearings “1” in bolts “2” to the specified torques in 3
the original positions. stages.
• Install the thrust bearing “2” at the position
“a”. TIP:
• Make sure that the protrusions “a” on the
1 piston and connecting rod assemblies and
2 connecting rod caps “1” are facing toward
1 the flywheel magnet end of the crankshaft.
• In the third tightening stage for the connect-
3
ing rod bolts “2”, mark the connecting rod
a bolts and connecting rod cap with paint
marks “b”, and then tighten the connecting
rod bolts 90° from the marks on the con-
necting rod cap.
• After tightening the connecting rod bolts
“2”, make sure that the crankshaft turns
smoothly.
2
8. Install new oil seal “1” onto the crankshaft b 90˚
“2”, and then install the crankshaft onto
the cylinder block “3”.
7-76
Crankcase

1st: 13 N·m (1.3 kgf·m, 9.6 ft·lb) 90q
a 2
2nd: 23 N·m (2.3 kgf·m, 17.0 ft·lb)
3rd: 90°
[5] [6] 0
into the main bearing cap. [1] [2]
[4] [3]
1
1
2
1 1
Main bearing cap bolts “2”:
1st: 30 N·m (3.0 kgf·m, 22.1 ft·lb) 3
2nd: 90°
11. Install the main bearing cap “1”, and then
tighten the main bearing cap bolts “2” to
the specified torques in 2 stages and in into the crankcase. 4
the order [1], [2], and so on.
13. Apply a thin, even layer of sealant onto
TIP:
In the second tightening stage for the main
the mating surface of the crankcase.
5
TIP:
bearing cap bolts “2”, mark the main bearing
• Install the crankshaft journal bearings “1” in
cap bolts and the main bearing cap with iden-
tification marks “a”, and then tighten the bolts
the original positions.
• Do not apply any sealant to the crankshaft
6
90° from the marks on the main bearing cap.
journal bearings “1”.
2
7
1
1 1
8
9
14. Install a new O-ring “1” and the crank-
case “2”, and then tighten the crankcase
bolts “3” and “4” to the specified torques 10
in 2 stages and in the order [1], [2], and
so on.
A
7-77
Crankcase
TIP:
In the second tightening stage for the M10
bolts “3”, mark the M10 bolts and the crank-
case with identification marks “a”, and then
tighten the bolts 90° from the marks on the
crankcase.
2 4
1
[3] [4] 3 4
a 90q
[13] [14]
[9] [10]
[5] [6]
[8] [7]
[12] [11]
[2] [1]

1st: 30 N·m (3.0 kgf·m, 22.1 ft·lb)
2nd: 90°
1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb)
2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
7-78
Lower unit 8
Lower unit
(regular rotation model, L-transom model) ..................... 8-1
Removing the lower unit ............................................................ 8-3
Disassembling the propeller (SDS propeller) ............................ 8-3
Checking the propeller .............................................................. 8-3
Checking the lower unit anode .................................................. 8-3
Assembling the propeller (SDS propeller) ................................. 8-4
Lower unit
(regular rotation model, X-transom model) .................... 8-6
Removing the lower unit ............................................................ 8-8
Disassembling the propeller (SDS propeller) ............................ 8-8
Checking the propeller .............................................................. 8-8
Checking the lower unit anode .................................................. 8-8
Assembling the propeller (SDS 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 ................................... 8-11
Assembling the water pump housing ...................................... 8-12
Propeller shaft housing (regular rotation model) ......... 8-13

Removing the propeller shaft housing assembly ..................... 8-15
Disassembling the propeller shaft assembly ........................... 8-15
Disassembling the propeller shaft housing assembly ............. 8-16
Checking the propeller shaft .................................................... 8-16
Checking the dog clutch .......................................................... 8-16
Checking the propeller shaft housing ...................................... 8-16
Checking the reverse gear ...................................................... 8-16
Assembling the propeller shaft assembly ................................ 8-17
Assembling the propeller shaft housing assembly .................. 8-17
Drive shaft and lower case

(regular rotation model) .................................................. 8-19
Removing the drive shaft ......................................................... 8-21
Disassembling the drive shaft housing .................................... 8-21
Disassembling the forward gear .............................................. 8-21
Disassembling the lower case ................................................. 8-22
Checking the pinion ................................................................. 8-22
Checking the forward gear ...................................................... 8-22
Lower unit
Checking the drive shaft .......................................................... 8-22

Checking the lower case ......................................................... 8-23
Assembling the forward gear ................................................... 8-23
0
Assembling the drive shaft housing ......................................... 8-23
Assembling the lower case ...................................................... 8-24
Installing the drive shaft ........................................................... 8-25
1
Installing the propeller shaft housing assembly ....................... 8-26
Installing the shift rod .............................................................. 8-27
Installing the water pump ........................................................ 8-27 2
Checking the lower unit for air leakage ................................... 8-28
Installing the lower unit (L-transom model) ............................. 8-29
Installing the lower unit (X-transom model) ............................. 8-30 3
Shimming (regular rotation model) ............................... 8-32
Shimming workflow ................................................................. 8-32
Shimming check sheet ............................................................ 8-33
4
Measuring the forward gear backlash and
reverse gear backlash before disassembly ............................. 8-35
Shimming procedure ............................................................... 8-38 5
Shim location ........................................................................... 8-38
Selecting the pinion shim (T3) ................................................. 8-39
Measuring the forward gear backlash ..................................... 8-41
Adjusting the forward gear shim thickness (T1) ...................... 8-41
6
Measuring the reverse gear backlash ..................................... 8-43
Adjusting the reverse gear shim thickness (T2) ...................... 8-43
7
Lower unit
(counter rotation model, L-transom model) .................. 8-45
Removing the lower unit .......................................................... 8-47
8
Disassembling the propeller (SDS propeller) .......................... 8-47
Checking the propeller ............................................................ 8-47
Checking the lower unit anode ................................................ 8-47 9
Assembling the propeller (SDS propeller) ............................... 8-47
Lower unit 10
(counter rotation model, X-transom model) ................. 8-48
Removing the lower unit .......................................................... 8-50
Disassembling the propeller (SDS propeller) .......................... 8-50
Checking the propeller ............................................................ 8-50
Checking the lower unit anode ................................................ 8-50
Assembling the propeller (SDS propeller) ............................... 8-50
A
Lower unit
Water pump and shift rod

(counter rotation model) ................................................. 8-51
Removing the water pump and shift rod .................................. 8-53
Disassembling the water pump housing .................................. 8-53
Checking the water pump and shift rod ................................... 8-53
Assembling the water pump housing ...................................... 8-53
Propeller shaft housing (counter rotation model) ........ 8-54

Removing the propeller shaft housing assembly ..................... 8-56
Disassembling the propeller shaft housing assembly ............. 8-56
Disassembling the forward gear .............................................. 8-56
Checking the propeller shaft .................................................... 8-57
Checking the dog clutch .......................................................... 8-57
Checking the propeller shaft housing ...................................... 8-57
Checking the forward gear ...................................................... 8-57
Assembling the propeller shaft housing assembly and
forward gear ............................................................................ 8-57
Drive shaft and lower case

(counter rotation model) ................................................. 8-60
Removing the drive shaft ......................................................... 8-62
Removing the reverse gear ..................................................... 8-62
Disassembling the drive shaft housing .................................... 8-62
Disassembling the reverse gear .............................................. 8-62
Disassembling the lower case ................................................. 8-62
Checking the pinion ................................................................. 8-63
Checking the reverse gear ...................................................... 8-63
Checking the drive shaft .......................................................... 8-63
Checking the lower case ......................................................... 8-63
Assembling the reverse gear ................................................... 8-63
Assembling the lower case ...................................................... 8-63
Assembling the drive shaft housing ......................................... 8-64
Installing the reverse gear ....................................................... 8-64
Installing the drive shaft ........................................................... 8-64
Installing the propeller shaft housing assembly ....................... 8-64
Installing the shift rod .............................................................. 8-64
Installing the water pump ........................................................ 8-64
Checking the lower unit for air leakage ................................... 8-65
Installing the lower unit (L-transom model) ............................. 8-65
Installing the lower unit (X-transom model) ............................. 8-65
Lower unit
Shimming (counter rotation model) .............................. 8-66

Shimming workflow ................................................................. 8-66
Shimming check sheet ............................................................ 8-67
0
reverse gear backlash before disassembly ............................. 8-69
Shimming procedure ............................................................... 8-72
1
Shim location ........................................................................... 8-72
Selecting the pinion shim (T3) ................................................. 8-73
Selecting the propeller shaft shim (T4) .................................... 8-73 2
Measuring the forward gear backlash ..................................... 8-74
Adjusting the forward gear shim thickness (T2) ...................... 8-74
Measuring the reverse gear backlash ..................................... 8-76
Adjusting the reverse gear shim thickness (T1) ...................... 8-76
3
4
5
6
7
8
9
10
A
Lower unit (regular rotation model, L-transom model)
43 N·m (4.3 kgf·m, 31.7 ft·lb) 6
7 55 N·m (5.5 kgf·m, 40.6 ft·lb)
13
9 N·m (0.9 kgf·m, 6.6 ft·lb)
12
10
5 11
14
3 5 8
2 4
9
1
15
16
17
20
4
20 19 18
48 N·m (4.8 kgf·m, 35.4 ft·lb)

1 Hose nipple 1
3 Check screw 1
5 Dowel 2
6 Grommet 1
7 Bolt 1 M10 × 45 mm
8 Lower unit 1
9 Spacer 1
10 Propeller 1
12 Washer 1
13 Cotter pin 1 Not reusable
14 Propeller nut 1
15 Spacer 1 SDS propeller
16 Damper 1 SDS propeller
17 Trim tab 1
8-1
43 N·m (4.3 kgf·m, 31.7 ft·lb) 6

7 55 N·m (5.5 kgf·m, 40.6 ft·lb)
0
13
9 N·m (0.9 kgf·m, 6.6 ft·lb)
12
5
10
11
1
14
8
2
3
4
5
2
9
1
15 3
16
4
17
20
5
4
20 19
9 N·m (0.9 kgf·m, 6.6 ft·lb)
18
48 N·m (4.8 kgf·m, 35.4 ft·lb) 6
48 N·m (4.8 kgf·m, 35.4 ft·lb)

18 Bolt 1 M10 × 70 mm
19 Drain screw 1
20 Bolt 6 M10 × 45 mm 8
9
10
A
8-2
Removing the lower unit
TIP:
When disassembling the lower unit, measure
the backlash before disassembly. See “Mea-
• Make sure to disconnect the battery
suring the forward gear backlash and reverse
cables from the battery, and remove the
gear backlash before disassembly” (8-35).
clip from the engine shut-off switch.
• When removing the lower unit with the
1
power unit installed, make sure to sus-
pend the outboard motor. Otherwise, the
outboard motor could fall suddenly and
result in severe injuries.
• When loosening or tightening the pro-
5
peller nut, do not hold the propeller
using your hands.
1. Drain the gear oil.

2
2. Remove the cotter pin.
3. Set the gear shift to the N position. a

4
4. Place a block of wood between the anti- 3
cavitation plate and the propeller to pre-
vent the propeller from turning, and then
remove the propeller nut and propeller. Disassembling the propeller (SDS
propeller)
1. Remove the damper “1”.
2 3 3 1
5. Remove the grommet “1”.
6. Mark the trim tab “2” and lower case with

an identification mark “a”, and then Driver rod L3 “2”: 90890-06652
remove the trim tab “2”. Needle bearing attachment “3”:
90890-06653
7. Remove the lower case mounting bolts
“3” and “4”, and then remove the lower Checking the propeller
unit “5”. 1. Check the propeller blades and damper
rubber splines. Replace the propeller if
cracked, damaged, or worn.
Checking the lower unit anode

1. Check the trim tab. Clean if there is
grease, oil, or scales.
8-3
Do not apply grease, oil, or paint to the 3

trim tab.
0
Assembling the propeller (SDS
propeller)
1. Place a new damper “1” in the propeller
“2”. 3 1
3
2 a
TIP:
Align the mark “a” on the damper “1” with the
mark “b” on the propeller “2”.
2
1
1 a 2 b
3
90890-06653 4
Installation height “a” (reference data):
4.0 mm (0.158 in)
5
2. Install the damper “1” using the special 3. Check the installation depth “a” of the
service tool “2” and spacer “3” to the damper “1”.
specified height “a”.
TIP:
6
The damper “1” will be in the proper position
Be careful not to install the spacer in the (the damper “1” is in contact with the spacer
opposite direction. “2”) after the propeller nut “3” has been tight- 7
ened to the specified torque. Therefore, when
installing the propeller to the outboard motor,
TIP:
When installing the damper “1”, make sure
that the spacer “3” does not contact the pro-
make sure to tighten the propeller nut “3” to
the specified torque. See step 4 in “Installing 8
the lower unit (X-transom model)” (8-30).
peller boss.
a 9
1
1
10
A
8-4
3
2
1
B 1
3
2
A. Before tightening the propeller nut “3” to

B. After tightening the propeller nut “3” to
Installation depth “a” (reference data):
9.4 mm (0.37 in)
8-5
43 N·m (4.3 kgf·m, 31.7 ft·lb)
10 8 12
2
1 9 9
7 13 0
8
7
1
55 N·m (5.5 kgf·m, 40.6 ft·lb)
6 19
9 N·m (0.9 kgf·m, 6.6 ft·lb)
11
5 7
16
17
18
2
7 14 20
5
48 N·m (4.8 kgf·m, 35.4 ft·lb)
4
15
3
3
2
21
1
22 4
23
5
5
5 4
48 N·m (4.8 kgf·m, 35.4 ft·lb)
25 24
6

1 Hose nipple 2
3
4
Check screw
Gasket
1
2 Not reusable
8
5 Bolt 12 M10 × 45 mm
6
7
Extension
Dowel
1
4 9
8 Cover 2
9 Seal 2
10
11
Water pipe
Water pipe
1
1
10
12 Grommet 1
13 Bolt 1 M10 × 45 mm
14 Lower unit 1
15 Spacer 1
16 Propeller 1
A
8-6
43 N·m (4.3 kgf·m, 31.7 ft·lb)

10 8 12
2 7 13
1 9 9
8
55 N·m (5.5 kgf·m, 40.6 ft·lb)

6 19
18
9 N·m (0.9 kgf·m, 6.6 ft·lb) 16
5 7 17
11
7 14 20
5 4
48 N·m (4.8 kgf·m, 35.4 ft·lb) 15
3
2
1 21
22
23
5
48 N·m (4.8 kgf·m, 35.4 ft·lb) 5 4 24

25

18 Washer 1
20 Propeller nut 1
23 Trim tab 1
24 Bolt 1 M10 × 200 mm
25 Drain screw 1
8-7
Removing the lower unit Disassembling the propeller (SDS
propeller)
See “Disassembling the propeller (SDS pro-
peller)” (8-3).
0
clip from the engine shut-off switch. Checking the propeller
• When removing the lower unit with the See “Checking the propeller” (8-3).
pend the outboard motor. Otherwise, the Checking the lower unit anode 1
outboard motor could fall suddenly and See “Checking the lower unit anode” (8-3).
propeller)
2
using your hands. See “Assembling the propeller (SDS propel-
ler)” (8-4).
1. Drain the gear oil. 3
2. Remove the propeller and trim tab. See
steps 2–6 in “Removing the lower unit”
(8-3).
4
3. Remove the lower case mounting bolts
“1” and “2”, and then remove the lower
unit “3” and extension “4”.
5
TIP:
When disassembling the lower unit, measure 6
7
4 8
3
9
1
10
1 2
A
8-8
Water pump and shift rod (regular rotation model)
6 22 24
7
8 23
9 22
5 10 22
9
5
11
5 20 21
12
4
19
3 13
18
2
14 17
16
1 15
15

1 Shift rod 1
2 E-clip 1
4 Plate 1
5 Bolt 3 M6 × 20 mm
7 Collar 1
8 Spacer 1
9 Washer 2
10 Wave washer 1
11 Impeller 1
12 Outer plate cartridge 1
14 Woodruff key 1
15 Dowel 2
16 Plate 1
17 Rubber seal 1
8-9
6 22 24
7
8 23
0
9 22
5 10 22
5
9
11
1
5 20 21
4
12 2
19
3 13
18 3
2
14 17
1 15
16 4
15
5
6

19 Insert cartridge 1
20
21
O-ring
Water pump housing
1
1
Not reusable 8
22 Bolt 4 M8 × 45 mm
23
24
Seal
Cover
1
1 9
10
A
8-10
Removing the water pump and shift
rod
1. Remove the water pump housing “1”,
O-ring “2”, dowels “3”, collar “4”, spacer
“5”, washers “6”, wave washer “7”, and
impeller “8”.
1
2. Remove the Woodruff key “9”, outer plate
cartridge “10”, and gasket “11”.
10
1 9 Disassembling the water pump

11 housing
3
4 2 1. Remove the insert cartridge “1” and
5 3 O-ring “2”.
6
7 1
6
3. Remove the rubber seal “1” and plate “2”.

2
1
2
2. Remove the cover “1” and seal “2”.
4. Set the gear shift to the N position.

2
Checking the water pump and shift

rod
R 1 1. Check the water pump housing. Replace
N if deformed.
F
Shift rod socket “1”: 90890-06681
5. Remove the shift rod “1”.
8-11
TIP:
If the engine overheats, the inside of the
water pump housing may be deformed.
Therefore, make sure to remove the insert
cartridge when checking the water pump
0
housing.
2. Check the impeller, insert cartridge, and 1

outer plate cartridge. Replace if cracked
or worn.
3. Check the Woodruff key and the keyway 2

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

3
cracked, or worn.
Assembling the water pump housing

1. Install the seal “1” and cover “2”.
4
5
2
1 6
2. Install a new O-ring “1” and the insert

7
cartridge “2”.
TIP: 8
Fit the protrusions “a” on the insert cartridge
“2” into the slots “b” in the water pump hous-
ing “3”.
9
2
3
a 10
b
A
8-12
Propeller shaft housing (regular rotation model)
38 10
1 2 4 4
8
2 5
10 3 9
6
4 9
3
2 22
7
5
3
1 2
17 21
20
16
19
15
14
18
11 12
145 N·m (14.5 kgf·m, 106.9 ft·lb)
13

1 Slider 1
2 Ball 2 5.54 mm (0.22 in) (reference data)
5 Spring 1
6 Dog clutch 1 F150A: Six teeth
7 Dog clutch 1 F150B: Ten teeth
8 Cross pin 1
9 Spring 1
10 Propeller shaft 1
11 Reverse gear shim (T2) —
12 Washer 1
13 Reverse gear 1
14 Thrust washer 1
15 Ball bearing 1 Not reusable
17 Propeller shaft housing 1
8-13
38 10
1 2 4 4
0
8
2 5
10
6
3 9
1
4 9
3
2
5
7
22
2
3
1 2 3
17 21
20
15
16
19 4
14
18
5
11 12
145 N·m (14.5 kgf·m, 106.9 ft·lb)
13
6

18 Key 1
19 Needle bearing 1 Not reusable
20
21
Oil seal
Claw washer
2
1
Not reusable 8
22 Ring nut 1
9
10
A
8-14
Removing the propeller shaft
housing assembly
1. Straighten the bent tab “1” on the claw 3 2
washer.
1
1
1
Bearing housing puller claw L “1”:

90890-06502
Stopper guide plate “2”: 90890-06501
Center bolt “3”: 90890-06504
2. Loosen the ring nut.
5. Remove the washer “1”, propeller shaft
assembly “2”, and reverse gear shims
“3”.
1
1
3
2 2
Ring nut wrench extension “1”:

90890-06513
Ring nut wrench 4 “2”: 90890-06512
Disassembling the propeller shaft
3. Remove the ring nut “1” and claw washer assembly
“2”. 1. Remove the spring “1”, and then remove
the cross pin “2”, dog clutch “3”, slider
1 “4”, balls “5”, “6”, and “7”, and spring “8”.
2 TIP:
When removing the slider “4”, make sure that
the balls do not fall out of position.
4. Remove the propeller shaft housing

assembly and key.
8-15
3. Remove the oil seals “1” along with the
1 needle bearing “2”.
6 8
5
4
6 7
0
3
2 4 3
1
5
4
3 2 2
1

housing assembly 3
1. Remove the reverse gear “1” and thrust Driver rod L3 “3”: 90890-06652
washer “2”. Needle bearing attachment “4”:
4
90890-06653
4
Checking the propeller shaft
1
1. Check the propeller shaft. Replace if
5
damaged or worn.
5
2 2. Measure the propeller shaft runout.
6 3 6
Bearing separator “3”: 90890-06534
Stopper guide stand “5”: 90890-06538
7
Bearing puller assembly “6”: 90890-06535
2. Remove the ball bearing “1”.

8
Propeller shaft runout:
2 0.02 mm (0.0008 in)
1 Checking the dog clutch

9
3 1. Check the dog clutch, cross pin, spring,
4 balls, and slider. Replace if cracked or
1 worn. 10
Checking the propeller shaft housing
1. Check the propeller shaft housing.
Replace if cracked or damaged.
Bearing puller assembly “4”: 90890-06535 Checking the reverse gear
1. Check the teeth and dogs of the reverse
gear. Replace if cracked or worn. A
8-16
Assembling the propeller shaft
assembly 1
1. Install the spring “1”, balls “2”, “3”, and
“4”, and slider “5”.
2
TIP:
When installing the slider “5”, make sure that
the balls do not fall out of position.
2
5 3 1 4
3 2 4 Assembling the propeller shaft

housing assembly
4 1 1. Install a new needle bearing “1” in the
3 propeller shaft housing at the specified
5 2 installation depth “a”.
4
TIP:
3
• Face the bearing identification mark “b” on
2. Install the dog clutch “1” so that the hole the needle bearing toward the propeller.
“a” in the dog clutch “1” and the hole “b” • When using the driver rod, do not strike the
in the propeller shaft are aligned with the special service tool in a manner that will
hole “c” in the slider “2”. force the stopper “5” out of place.
b
TIP:
2
Face the “F” mark “d” on the dog clutch “1”
3 5
toward the slider “2”.
4
a a
b
d
1
1 a
Driver rod SS “2”: 90890-06604
1 Needle bearing attachment “3”:
90890-06610
Bearing depth plate “4”: 90890-06603
2
b c 24.75–25.25 mm (0.974–0.994 in)
2. Install new oil seals “1” in the propeller

3. Install the cross pin “1”, and then install shaft housing at the specified installation
the spring “2”. depth “a”.
8-17
TIP: 1 2 1 2
Install an oil seal halfway into the propeller
shaft housing, and then install the other oil
seal. 0
2
a
1
1
90890-06654 2
5. Check that the reverse gear turns
smoothly.
Bearing inner race attachment “2”:
6. Install a new O-ring “1”.
3
90890-06640

4.75–5.25 mm (0.187–0.207 in)
1
4
3. Install the thrust washer “1” and a new
ball bearing “2” onto the reverse gear “3”.
5
TIP:
Face the bearing identification mark “a” on
the ball bearing toward the propeller. 6
a
4
4
2
7
2
1
3
1
8
3
Needle bearing attachment “4”: 9

90890-06654
4. Install the reverse gear assembly “1”.

10
A
8-18
8 9
10
13
7
15
6
6
5 14
3 17
11
20 16
16
1 18
19
12
21
95 N·m (9.5 kgf·m, 70.1 ft·lb)
22 1 N·m (0.1 kgf·m, 0.7 ft·lb)

1 Thrust bearing 1
2 Pinion shim (T3) —
5 Drive shaft housing 1
6 Bolt 4 M8 × 25 mm
8 Cover 1
9 Self-locking nut 1
10 Water inlet cover (STBD) 1
11 Drive shaft 1
12 Sleeve 1
13 Lower case 1
14 Forward gear shim (T1) —
15 Taper roller bearing 2 Not reusable
17 Forward gear 1
8-19
8 9
10
13
0
7
15
6
6 1
5 14
2
4
3 17 3
11
2 4
20 16
16
1 18
5
19
12
95 N·m (9.5 kgf·m, 70.1 ft·lb)
21 6
22 1 N·m (0.1 kgf·m, 0.7 ft·lb)

18 Water inlet cover (PORT) 1
19 Screw 1 M5 × 45 mm
20
21
Needle bearing
Pinion
1
1
Not reusable 8
22 Pinion nut 1
9
10
A
8-20
Removing the drive shaft
1. Remove the cover “1”, drive shaft hous- 1
ing “2”, pinion shims “3”, and thrust bear-
ing “4”.
1
2 4
3
2. Remove the oil seals “1”.
1
2. Loosen the pinion nut, and then remove
the pinion “1”, drive shaft “2”, and sleeve.
3. Remove the needle bearing “1”.
4
2 3
3 3
2
1
2
Drive shaft holder 6 “3”: 90890-06520
Pinion nut holder “4”: 90890-06715
3. Remove the forward gear assembly “1”. 90890-06610
Driver rod L3 “3”: 90890-06652
1 Disassembling the forward gear

1. Remove the taper roller bearing inner
race “1”.
2
1 3 1
2
3
Disassembling the drive shaft

housing
1. Remove the O-ring “1”.
8-21

90890-06608
2. Remove the needle bearings from the 0

forward gear.
Disassembling the lower case

1
• Use heat-resistant gloves. Otherwise, 2
burns could result.
1 2
3. Remove the needle bearing “1”.
around the working area.
• Keep good ventilation while working. 3
3 3
1. Remove the water inlet covers “1” and 2
“2”. 4
1 2
5
1 Ball bearing attachment “2”:
2
90890-06636 6
Driver rod LL “3”: 90890-06605
Checking the pinion

2. Heat the area of the lower case where
the taper roller bearing outer race is to be
1. Check the teeth of the pinion. Replace if 7
cracked or worn.
installed using a gas torch, and then
remove the taper roller bearing outer
race “1” and forward gear shims “2”.
Checking the forward gear
1. Check the teeth and dogs of the forward
8
gear. Replace if cracked or worn.
When heating the lower case, heat the

entire installation area evenly. Otherwise,
Checking the drive shaft
1. Check the drive shaft. Replace if dam-
9
the paint on the lower case could be aged or worn.
burned.
2. Measure the drive shaft runout. 10
A
8-22
2
2
1 1
Drive shaft runout: 1.0 mm (0.039 in) Needle bearing attachment “2”:
90890-06654
Checking the lower case
1. Check the lower case. Replace if cracked Assembling the drive shaft housing
or damaged. 1. Install a new needle bearing “1” in the
drive shaft housing at the specified instal-
Assembling the forward gear lation depth “a”.
1. Install new needle bearings “1” and “2” at
the specified installation depth “a” and TIP:
“b”. When using the driver rod, do not strike the
special service tool in a manner that will force
TIP: the stopper “2” out of place.
• Face the bearing identification mark “c” on
the needle bearing up. 4
• When using the driver rod, do not strike the 2
special service tool in a manner that will 5 3
force the stopper “3” out of place.
a
c
5 1
5
6 4 3 4
a 2 b
1 Needle bearing attachment “3”:
90890-06610
Driver rod SS “4”: 90890-06604
Bearing depth plate “5”: 90890-06603
Needle bearing attachment “4”: Installation depth “a”:

90890-06612 5.75–6.25 mm (0.226–0.246 in)
Driver rod SS “5”: 90890-06604
Bearing depth plate “6”: 90890-06603 2. Install new oil seals “1” in the drive shaft
housing at the specified installation depth
Installation depth “a”: “a”.
20.95–21.45 mm (0.825–0.844 in)
Installation depth “b”: TIP:
4.45–4.95 mm (0.175–0.195 in) Install an oil seal halfway into the drive shaft
housing, and then install the other oil seal.
2. Install a new taper roller bearing inner
race “1”.
8-23
a When heating the lower case, heat the

3 the paint on the lower case could be
burned.
0
2
1
TIP:
1
scratched.
Bearing outer race attachment “2”:
90890-06628
Driver rod LS “3”: 90890-06606
2
1
2
0.25–0.75 mm (0.010–0.030 in) 3
1 4
5
3. While holding the special service tool “1”,
strike the tool to check that the taper
roller bearing outer race is installed prop-
6
Assembling the lower case erly.
TIP:
7
• Use heat-resistant gloves. Otherwise,
burns could result. when the special service tool is struck, the
outer race is installed properly.
8
• Keep good ventilation while working.
1
9

the taper roller bearing outer race is to be 1 10
installed using a gas torch, and then 2
install a new taper roller bearing outer
race “2”.
A
8-24
Driver rod LL “1”: 90890-06605 Installing the drive shaft

Bearing outer race attachment “2”: 1. Install the forward gear assembly “1”.
90890-06619
4. Install a new needle bearing “1” in the 1

lower case.
TIP:
• Make sure to face the bearing identification
mark “a” on the needle bearing toward the
pinion.
• The needle bearing contains 18 rollers.
2. Install the sleeve “1”, drive shaft “2”,
3 thrust bearing “3”, and original pinion
shims “4”.
TIP:
1 Make sure that the protrusion “a” on the
sleeve “1” is aligned with the slot “b” in the
lower case.
2
a
Ball bearing attachment “2”: 90890-06633 4

1
Bearing outer race puller assembly “3”: a
90890-06523 3
b
5. Install the water inlet covers “1” and “2”,
nut “3”, and water inlet cover screw “4”,
2
and then tighten the water inlet cover
screw “4” to the specified torque.
3. Install the pinion and pinion nut tempo-
TIP: rarily.
After installing the water inlet covers, make
sure that there is no rattling. TIP:
When installing the pinion, lift up the drive
shaft slightly and align the splines on the
3 drive shaft with the splines on the pinion.
4. Install the drive shaft housing “1” and

cover “2” into the lower case.
1
2
4 TIP:
Make sure to face the cutout “a” in the drive
shaft housing “1” forward.
Water inlet cover screw “4”:
1 N·m (0.1 kgf·m, 0.7 ft·lb)
8-25
2. Install the original reverse gear shims “1”,
2 propeller shaft housing assembly “2”, and
key “3”.
a
0
1 3 1
2
1
5. Tighten the pinion nut “1” to the specified
torque. 2
1
3
3 3. Install the claw washer “1”.
TIP:
4
Make sure to fit the protrusion “a” on the pro-
peller shaft housing into the slot “b” in the
2
claw washer “1”. 5
b

a
6
Pinion nut holder “3”: 90890-06715 1
Pinion nut “1”:

95 N·m (9.5 kgf·m, 70.1 ft·lb) 7
6. Check that the drive shaft turns smoothly.
Installing the propeller shaft housing 4. Install the ring nut “1”, and then tighten it 8
assembly to the specified torque.
1. Install the washer “1” and propeller shaft
housing assembly “2”.
2
9
3
2
10
1
1
Ring nut wrench extension “2”:

90890-06513
Ring nut wrench 4 “3”: 90890-06512
A
8-26
Ring nut “1”:

145 N·m (14.5 kgf·m, 106.9 ft·lb)
5. Bend one of the 4 tabs on the claw

washer outward, and then bend the other
3 tabs inward.
1
4. Check that the shift rod operates

smoothly.
Installing the shift rod
1. Install a new O-ring “1” and a new oil seal Installing the water pump
“2” to the plate “3”. 1. Install the plate “1” and rubber seal “2”.
2
2 1
2. Install the E-clip “1” and plate “2” to the 2. Install the dowels “1”, a new gasket “2”,
shift rod “3”. and the outer plate cartridge “3”.
2
3
2
1
1 1
3
3. Install the shift rod “1”.
TIP:
Make sure to install the shift rod “1” in the
3. Install the Woodruff key “1”.
proper orientation. Installation orientation is
different between the counter rotation model
and the regular rotation model.
8-27
4. Align the slot “a” in the impeller “2” with
the Woodruff key “1”, and then install the TIP:
impeller “2”. While turning the drive shaft clockwise, push
the water pump housing down to install it.
0
a
2 1
1
1
2
5. Install the washers “1”, wave washer “2”,
spacer “3”, and collar “4”.
3
TIP:
The spacer “3” and collar “4” should fit
together firmly. Checking the lower unit for air
leakage
4
4 1. Remove the check screw “1”, and then
install the special service tool “2”.
3 5
1
2 6
1
2
6. Install a new O-ring “1”. 1 7
Leakage tester “2”: 90890-06840
1
2. Apply the specified pressure. Check that
8
the pressure is maintained in the lower
unit for 10 seconds or more.
9
Do not overpressurize the lower unit. Oth-
7. Install the water pump housing “1”.
erwise, the oil seals could be damaged.
10
Lower unit holding pressure:
69.0 kPa (0.69 kgf/cm2, 10.0 psi)
Do not turn the drive shaft counterclock-
wise. Otherwise, the water pump impeller
could be damaged.
A
8-28
Installing the lower unit (L-transom 5. Install the lower unit “3”, and then tighten
model) the lower case mounting bolts “5” and “6”
6. Install the trim tab “7” to its original posi-

tion “a”, and then tighten the trim tab bolt
• When installing the lower unit with the 7. Install the grommet “9”.
pend the outboard motor. Otherwise, the 9
outboard motor could fall suddenly and 8
• When loosening or tightening the pro- 1
peller nut, do not hold the propeller 2 4
using your hands. 3
1. Check that the mark “a” on the bushing

“1” is aligned with the mark “b” on the 4
plate “2”.
7
5
a
1 6
a
b Lower case mounting bolts “5” and “6”:
2 48 N·m (4.8 kgf·m, 35.4 ft·lb)
Trim tab bolt “8”:
2. Set the gear shift to the N position. 43 N·m (4.3 kgf·m, 31.7 ft·lb)
8. Install the spacer “1”, propeller “2”,

spacer “3”, washers “4”, and propeller nut
“5”.
A 3
R 1
4 5
N B 3
F

1
3. Install a new O-ring “1” to the hose nipple 2
“2”, and then install the hose nipple “2” to
the lower unit “3”. A. Except SDS propeller
B. SDS propeller
4. Install the dowels “4”.
8-29
9. Place a block of wood between the anti- Installing the lower unit (X-transom
cavitation plate and the propeller to pre- model)
vent the propeller from turning, and then
tighten the propeller nut to the specified
torque. • Make sure to disconnect the battery 0
• When installing the lower unit with the
1
pend the outboard motor. Otherwise, the
outboard motor could fall suddenly and
2
Propeller nut:
55 N·m (5.5 kgf·m, 40.6 ft·lb)
using your hands.
3
1. Check that the shift rod is in the N posi-
10. Install a new cotter pin “1”. tion. See steps 1 and 2 in “Installing the
lower unit (L-transom model)” (8-29). 4
TIP: 2. Install new O-rings “1” to the hose nip-
If the slots in the propeller nut “2” are not ples “2”, and then install the hose nipples
aligned with the cotter pin hole, tighten the
propeller nut until they are aligned.
“2” to the lower unit “3” and extension “4”. 5
3. Install the dowels “5” into the lower unit
“3” and extension “4”.
4. Install the water pipe “6” to the water

6
1 pump.
5. Install the seals “7” and covers “8” to the

water pipe “9”.
7
2 6. Install the water pipe “9”, extension “4”,
11. Fill the lower unit with gear oil up to the

and lower unit “3”, and then tighten the 8
lower case mounting bolts “10” and “11”
proper level. See steps 5–9 in “Changing to the specified torque.
the gear oil” (10-11).
9
10
A
8-30
1 8
9 7
2
7
5
8 4
5
6 3
5
5
1 10
2
10 11
Lower case mounting bolts “10” and “11”:

48 N·m (4.8 kgf·m, 35.4 ft·lb)
7. Install the trim tab and propeller. See

steps 6–9 in “Installing the lower unit (L-
transom model)” (8-29).

proper level. See steps 5–9 in “Changing
8-31
Shimming (regular rotation model)
Shimming workflow
1. Remove the water pump

0
assembly.
2. Measure the backlash before 1

disassembly.
3. Within specification?
4. YES
5. Shimming is not required.
2
6. NO
7. Disassemble the lower unit. 3
8. Select the pinion shims (T3).
4
9. Assemble the lower unit.
10. Measure the backlash.

5
6. NO 11. Adjust the forward gear shim
3. Within specification? thickness (T1) and reverse gear
shim thickness (T2).
6
4. YES
12. Install the water pump
assembly. 7
1. Remove the water pump assembly. 8. Select the pinion shims (T3). 8
2. Measure the backlash before disassem- 9. Assemble the lower unit.
bly. 10. Measure the backlash.
4. YES
11. Adjust the forward gear shim thickness
(T1) and reverse gear shim thickness 9
5. Shimming is not required. (T2).
6. NO 12. Install the water pump assembly.
7. Disassemble the lower unit. 10
TIP:
• Make sure to drain the gear oil before measuring the backlash.
• If the backlash is within specification, shimming is not required.
• When assembling the original inner parts and a new lower case, shimming is required.
• When replacing the pinion, forward gear, reverse gear, bearings, drive shaft, or propeller shaft
housing, shimming is required.
A
8-32
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
8-33
Forward gear shim (T1) thickness adjustment in 2 places (mm)
Number of shim(s) Subtotal
0.10
0.12
0.15
0
0.18
0.30
0.40 1
0.50
Total
2
Reverse gear shim (T2) thickness adjustment in 2 places (mm)
0.10 3
0.12
0.15
0.18
0.30
4
0.40
0.50
Total 5
6
7
8
9
10
A
8-34
Measuring the forward gear backlash
and reverse gear backlash before
disassembly
1. Install the lower unit onto a repair stand. 1
2. Remove the water pump assembly.
Center bolt “1” (shimming):

5 N·m (0.5 kgf·m, 3.7 ft·lb)
8. Place the lower unit in an upright

1 position.
R
N 9. Remove the cover “1”, and then install
F the outer plate cartridge “2”.
1
4. Set up the special service tools “1”, “2”,
and “3”, and then tighten the center bolt
“3” temporarily.
1 2
1 2

90890-06502
Center bolt “3”: 90890-06504
5. Turn the lower unit so that the propeller 10. Set the spring “1” on the outer plate
shaft is pointing down. cartridge, and then install the handle
holder “2” so that the spring is
6. Turn the drive shaft 10 turns or more to compressed to the specified setting
seat the taper roller bearing. height “a”.
7. While holding the drive shaft to prevent it

from turning, tighten the center bolt “1” to
8-35
TIP: TIP:
• After installing the handle holder, pull the • The resistance of the spring increases the
drive shaft upward to remove any free play. force required to turn the drive shaft. There-
• Do not press the spring more than 5.0 mm
(0.197 in). Otherwise, too much torque will
fore, to obtain correct measurements, con-
sider the spring resistance force when
0
be required to turn the drive shaft, making it turning the drive shaft.
difficult to obtain correct measurements. • Do not turn the drive shaft using too much
force. Otherwise, the forward gear will turn,
leading to incorrect measurements.
1
2 • When turning the drive shaft, hold it using a
a
1
little force. A knocking sound may be heard
when the drive shaft is rotated, but this is 2
the sound of the pinion contacting the
reverse gear and does not affect the back-
lash measurement.
3
Spring “1”: 90501-450A2
Handle holder “2”: EU0-23814-30 4
Setting height “a”:
3.0–5.0 mm (0.118–0.197 in)
5
11. Install the special service tool “1” onto
the drive shaft at the lowest possible
position where the shaft diameter is
22.4 mm (0.881 in), and then set up the
13. Turn the drive shaft 180° clockwise, and
then measure the backlash again.
6
special service tools “2”, “3”, and “4”.
1
4
2 TIP:
• Measure the backlash at 4 points: “a”, “b”, 7
“c”, and “d”, turning the drive shaft 180°
clockwise after each measurement.
3
• Write down the measurement data in the
shimming check sheet.
8
9
Backlash indicator “1”: 90890-06706 a
Magnet base plate “2”: 90890-07003
Dial gauge set “3”: 90890-01252
Magnet base B “4”: 90890-06844 b
10
d
12. Turn the drive shaft slowly clockwise and
counterclockwise, and then measure the
backlash between where the drive shaft
stops in each direction.
c
A
8-36
14. Determine the backlash average, and 19. Repeat steps 12–14 to measure the
then round down the average to 2 reverse gear backlash.
decimal places.
Example: 20. Check that the reverse gear backlash
average is within specification.
(mm)
Measurement point “a” 0.30
TIP:
Measurement point “b” 0.36 Adjust the shim thicknesses if the reverse
Measurement point “d” 0.34 gear backlash is out of specification.
Measurement point “e” 0.33
Average 0.3325 Reverse gear backlash (F150A):
Round-down average 0.33 0.33–0.67 mm (0.0130–0.0264 in)
Reverse gear backlash (F150B):
15. Check that the forward gear backlash 0.33–0.74 mm (0.0130–0.0291 in)
average is within specification.
21. Remove the special service tools, and
then install the water pump assembly.
TIP:
Adjust the shim thicknesses if the forward
gear backlash is out of specification.
Forward gear backlash (F150A):

0.15–0.61 mm (0.0059–0.0240 in)
Forward gear backlash (F150B):
0.15–0.68 mm (0.0059–0.0268 in)
16. Remove the special service tools from

the propeller shaft.
17. Apply a load to the reverse gear by

installing the propeller “1”, spacer “2”
(without installing the spacer “3”), and
washer “4”.
18. Tighten the propeller nut “5” to the

specified torque.
1 A 3
2
4 5
B
A. Except SDS propeller

B. SDS propeller
Propeller nut “5” (shimming):
10 N·m (1.0 kgf·m, 7.4 ft·lb)
8-37
Shimming procedure
• Before selecting the forward gear shim (T1) and reverse gear shims (T2), make sure to select the
pinion shims (T3).
• When assembling the lower unit to measure the backlash after selecting the pinion shims (T3), do
not apply gear oil, grease, or sealant to the parts. 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
T3
F R
2
P
3
4
5
6
7
8
9
10
T1
T2
A
8-38
Selecting the pinion shim (T3) Pinion height gauge “1”: 90890-06671
• Spray anti-rust lubricant on the bearing
before installation. Do not apply gear oil to 2. Tighten the drive shaft housing bolts “1”.
the parts. Otherwise, correct measure-
ments cannot be obtained.
• Keep the parts free of foreign material,
such as dirt and lint.
1
Be careful not to damage the measure-
ment plane surface of the special service
tool. Otherwise, correct measurements
cannot be obtained.
1. Hold the special service tool “1”, and

then install the drive shaft “2”, thrust
bearing “3”, and drive shaft housing
assembly to the special service tool. 3. Install the pinion “1” and pinion nut “2”,
and then tighten the pinion nut “2”
TIP: temporarily.
• Do not install the pinion shims (T3) and
O-ring. Make sure that the pinion shims
(T3) are not affixed to the thrust bearing When tightening the pinion nut, check
outer race. that the drive shaft turns smoothly.
• Make sure to install the thrust bearing outer
race so that it is facing the same direction 4. Check that there is a gap “a” between the
as when it was removed. pinion “1” and the special service tool “3”.
• Make sure that the cutout “a” in the drive
shaft housing assembly is facing the oppo-
site direction of the plate “4” of the special If there is no gap and the drive shaft does
service tool. not turn, the special service tool could be
damaged.
TIP:
a If there is no gap, the thrust bearing outer
race “4” may not have been installed. If the
3 gap is 1.0 mm (0.039 in) or more, the pinion
4 shims (T3) “5” may not have been removed.
1
2
1 2
a a
8-39
5 0
4
1
1
5. Install the special service tool “1” to the
drive shaft spline and hold the special
service tool “1”.
2
6. Tighten the pinion nut “2” to the specified 8. Turn the drive shaft 10 turns or more to
torque. seat the thrust bearing. 3
9. Push down on the pinion “1” so that it
does not pop up, and then measure the
distance between the pinion “1” and the 4
2 special service tool “2”.
1
TIP:
• When measuring the distance, insert the
5
end of the thickness gauge straight into the
gap at the measurement point. Do not
insert the thickness gauge at an angle.
• Measure the distance at 4 points: “a”, “b”,
6
“c”, and “d”.

shimming check sheet. 7
Pinion nut “2”: a
95 N·m (9.5 kgf·m, 70.1 ft·lb)
b 8
7. Hold the special service tool “1” so that 1 d
the pinion is facing up.
2
c
9
10. Determine the distance average, and

10
then round down the average to 2
decimal places.
A
8-40
Example: 12. Remove the special service tools, and
then install the determined pinion shims
(mm)
(T3).
Measurement point “b” 0.24 Measuring the forward gear backlash
Measurement point “c” 0.25 • Spray anti-rust lubricant on the gear and
Measurement point “d” 0.25 bearings before installation. Do not apply
Average 0.2450 gear oil to the parts. Otherwise, correct
Round-down average (M) 0.24 measurements cannot be obtained.
• Keep the parts free of foreign material,
11. Determine the pinion shim (T3) thickness such as dirt and lint.
adjustment using the “Pinion shim (T3) • When measuring the forward gear or
selection table” according to the rounded reverse gear backlash, use the original
average (M) and the deviation (P) bearings and shims.
stamped on the lower case. See “Pinion
shim (T3) selection table” (A-12). 1. Install the original forward gear shims
(T1) and taper roller bearing outer race.
TIP:
The (P) mark “a” is stamped on the trim tab TIP:
mounting surface of the lower case in • If the original forward gear shims (T1) are
0.01 mm units. If the (P) mark is unreadable, missing, install new shims with a combined
replace the lower case. thickness of 0.55 mm.
• Do not reuse a shim if deformed or
Available shim thicknesses: scratched.
0.10, 0.12, 0.15, 0.18, 0.30, 0.40,
0.50 mm
2. Install the forward gear assembly, drive
Example: shaft, and pinion. See “Installing the drive
(M) = 0.24 shaft” (8-25).
(P) = –3
F +2 R +4 4. Install the propeller shaft housing

P –3 assembly. See “Installing the propeller
a shaft housing assembly” (8-26).
6. Measure the forward gear backlash. See

steps 3–15 in “Measuring the forward
(T3) = 0.95 mm from the “Pinion shim (T3) gear backlash and reverse gear backlash
selection table”. before disassembly” (8-35).
Pinion height Forward gear backlash (F150A):

measurement (M) 0.15–0.61 mm (0.0059–0.0240 in)
Forward gear backlash (F150B):
0.23 0.24 0.25
0.15–0.68 mm (0.0059–0.0268 in)
Stamped –2 Y
value on the –3 G 0.95 Adjusting the forward gear shim
lower case (P) –4 thickness (T1)
1. Remove the taper roller bearing outer
race and forward gear shims (T1).
8-41
2. Measure the thickness of original forward
B (mm)
gear shim (T1) in 2 places. 0.30
0.20
0.10
TIP:
Do not reuse a shim if deformed or b 0 0
scratched. –0.10
–0.20
3. Determine the forward gear shim (T1)
thickness adjustment using the “Forward
–0.30
0 5 10 15 20 25 30 35 1
a A (1/100 mm)
gear shim (T1) selection chart” according
to the backlash measurement (BL1) from
“Measuring the forward gear backlash”.
See “Forward gear shim (T1) selection
A 0 5 10 15 20 25 30 35
B –0.26 –0.22 –0.19 –0.16 –0.12 –0.09 –0.06 –0.02
2
chart (F150A)” (A-13) or “Forward gear
A. Backlash measurement (BL1)
shim (T1) selection chart (F150B)” (A-
14). B. Shim thickness adjustment 3
4. Calculate the new forward gear shim (T1)
TIP:
• If the shim thickness adjustment value is
positive, increase the current shim thick-
thickness.
4
ness by that amount and, if the value is TIP:
negative, decrease the current shim thick- • Use the lowest number of shims to obtain
ness by that amount.
• The gray-colored area on the selection
the required shim thickness.
• If the calculated shim thickness cannot be
5
chart indicates the range of the specified obtained with a combination of the available
shims, increase or decrease the shim thick-
backlash. Shimming is not required if the
measured backlash is within the gray-col- ness by 0.01 mm. 6
ored area.
• The values for the shim thickness adjust- Calculation formula:
ments specified in the selection chart are
intended to obtain the median value within
New forward gear shim (T1) thickness =
Current forward gear shim thickness + shim
7
the range for the specified forward gear or thickness adjustment
reverse gear backlash.
• The table that follows the selection chart
shows the shim thickness adjustments for
Example:
Use the following formula when the shim
8
the points marked on the chart. thickness adjustment value is positive.
Current forward gear shim thickness =
Example: 0.55 mm 9
Backlash measurement (BL1) = 0.10 mm “a” Shim thickness adjustment = 0.18 mm
Forward gear shim (T1) thickness adjustment New forward gear shim (T1) thickness =
= –0.19 mm “b”
The current shim thickness must be
0.55 mm + 0.18 mm
= 0.73 mm 10
decreased by 0.19 mm. Use the following formula when the shim
thickness adjustment value is negative.
Current forward gear shim thickness =
0.55 mm
Shim thickness adjustment = –0.19 mm
New forward gear shim (T1) thickness =
0.55 mm + (–0.19 mm) = 0.36 mm A
8-42
Available shim thicknesses: TIP:

0.10, 0.12, 0.15, 0.18, 0.30, 0.40, Do not reuse a shim if deformed or
0.50 mm scratched.
5. Install the determined forward gear shims
(T1) and taper roller bearing outer race. 3. Determine the reverse gear shim (T2)
thickness adjustment using the “Reverse
Measuring the reverse gear backlash gear shim (T2) selection chart” according
• Spray anti-rust lubricant on the gears and to the backlash measurement (BL2) from
bearings before installation. Do not apply “Measuring the reverse gear backlash”.
gear oil to the parts. Otherwise, correct See “Forward gear shim (T1) selection
measurements cannot be obtained. chart (F150A)” (A-13) or “Reverse gear
• Keep the parts free of foreign material, shim (T2) selection chart (F150B)” (A-
such as dirt and lint. 14).
• When measuring the forward gear or
reverse gear backlash, use the original TIP:
bearings and shims. • If the shim thickness adjustment value is
1. Install the original reverse gear shims ness by that amount and, if the value is
(T2) and propeller shaft housing assem- negative, decrease the current shim thick-
bly. See “Installing the propeller shaft ness by that amount.
housing assembly” (8-26). • The gray-colored area on the selection
chart indicates the range of the specified
TIP: backlash. Shimming is not required if the
• If the original reverse gear shims (T2) are measured backlash is within the gray-col-
missing, install new shims with a combined ored area.
thickness of 0.62 mm. • The values for the shim thickness adjust-
• Do not reuse a shim if deformed or ments specified in the selection chart are
scratched. intended to obtain the median value within
the range for the specified forward gear or
2. Measure the reverse gear backlash. See reverse gear backlash.
steps 17–20 in “Measuring the forward • The table that follows the selection chart
gear backlash and reverse gear backlash shows the shim thickness adjustments for
before disassembly” (8-35). the points marked on the chart.
Reverse gear backlash (F150A):

0.33–0.67 mm (0.0130–0.0264 in) Example:
Reverse gear backlash (F150B): Backlash measurement (BL2) = 0.80 mm “a”
0.33–0.74 mm (0.0130–0.0291 in) Reverse gear shim (T2) thickness adjustment
= –0.21 mm “b”
Adjusting the reverse gear shim The current shim thickness must be
thickness (T2) decreased by 0.21 mm.
assembly and reverse gear shims (T2).
2. Measure the thickness of original reverse

gear shim (T2) in 2 places.
8-43
Available shim thicknesses:

B (mm)
0.10 0.10, 0.12, 0.15, 0.18, 0.30, 0.40,

0 0.50 mm
–0.10
–0.20 5. Install the determined reverse gear shims 0
–0.30 (T2) and propeller shaft housing assem-
b –0.40 bly.
0 5 10 65 70 75 80 85
a
1
A (1/100 mm)
A 0 5 10 65 70 75 80 85
B 0.34 0.30 0.27 0.10 –0.14 –0.17 –0.21 –0.24
2
B. Shim thickness adjustment 3
4. Calculate the new reverse gear shim (T2)
thickness.
4
TIP:
• Use the lowest number of shims to obtain
5
obtained with a combination of the available
ness by 0.01 mm. 6
New reverse gear shim (T2) thickness =
Current reverse gear shim thickness + shim
7
thickness adjustment
Example:
8
thickness adjustment value is positive.
Current reverse gear shim thickness =
0.62 mm 9
Shim thickness adjustment = 0.14 mm
0.62 mm + 0.14 mm
= 0.76 mm 10
Current reverse gear shim thickness =
0.62 mm
0.62 mm + (–0.21 mm) = 0.41 mm A
8-44
Lower unit (counter rotation model, L-transom model)
43 N·m (4.3 kgf·m, 31.7 ft·lb) 6
55 N·m (5.5 kgf·m, 40.6 ft·lb)
7
13
9 N·m (0.9 kgf·m, 6.6 ft·lb) 12
11
5
14
10
3 5 8
2 4
9
1
15
16
17
20
4
20 19 18
48 N·m (4.8 kgf·m, 35.4 ft·lb)

1 Hose nipple 1
3 Check screw 1
5 Dowel 2
6 Grommet 1
7 Bolt 1 M10 × 45 mm
8 Lower unit 1
9 Spacer 1
10 Propeller 1
12 Washer 1
14 Propeller nut 1
17 Trim tab 1
8-45
43 N·m (4.3 kgf·m, 31.7 ft·lb) 6

55 N·m (5.5 kgf·m, 40.6 ft·lb)
7
0
13
9 N·m (0.9 kgf·m, 6.6 ft·lb) 12
5
11 1
14
10
8
2
3
4
5
2
9
1
15 3
16
4
17
20
5
4
20 19
9 N·m (0.9 kgf·m, 6.6 ft·lb)
18
48 N·m (4.8 kgf·m, 35.4 ft·lb) 6
48 N·m (4.8 kgf·m, 35.4 ft·lb)

18 Bolt 1 M10 × 70 mm
19 Drain screw 1
20 Bolt 6 M10 × 45 mm 8
9
10
A
8-46
2. Remove the propeller, trim tab, and lower

unit. See steps 2–7 in “Removing the
lower unit” (8-3).
TIP:
Disassembling the propeller (SDS

propeller)
See “Assembling the propeller (SDS propel-
ler)” (8-4).
Checking the propeller

See “Checking the propeller” (8-3).

See “Checking the lower unit anode” (8-3).

propeller)
See “Assembling the propeller (SDS propel-
ler)” (8-4).
8-47
Lower unit (counter rotation model, X-transom model)
43 N·m (4.3 kgf·m, 31.7 ft·lb)
8 12
2
1
10
9
7 13 0
9
8
7 1
55 N·m (5.5 kgf·m, 40.6 ft·lb)
6 19
9 N·m (0.9 kgf·m, 6.6 ft·lb)
5 7 16
18 2
11 17
7 14 20
5 4
15
3
48 N·m (4.8 kgf·m, 35.4 ft·lb) 3
2
1
22
21
4
23
5 5
48 N·m (4.8 kgf·m, 35.4 ft·lb) 5
25
4 24
6

1 Hose nipple 2
3
4
Check screw
Gasket
1
2 Not reusable
8
5 Bolt 12 M10 × 45 mm
6
7
Extension
Dowel
1
4 9
8 Cover 2
9 Seal 2
10
11
Water pipe
Water pipe
1
1
10
12 Grommet 1
13 Bolt 1 M10 × 45 mm
14 Lower unit 1
15 Spacer 1
16 Propeller 1
A
8-48
43 N·m (4.3 kgf·m, 31.7 ft·lb)

10 8 12
2 7 13
1 9 9
8
55 N·m (5.5 kgf·m, 40.6 ft·lb)

6 19
9 N·m (0.9 kgf·m, 6.6 ft·lb)
18
5 7 16
11 17
7 14 20
5 4
48 N·m (4.8 kgf·m, 35.4 ft·lb) 15
3
2
1 21
22
23
5
48 N·m (4.8 kgf·m, 35.4 ft·lb) 5 4 24

25

18 Washer 1
20 Propeller nut 1
23 Trim tab 1
24 Bolt 1 M10 × 200 mm
25 Drain screw 1
8-49
2. Remove the propeller and trim tab. See

steps 2–6 in “Removing the lower unit”
(8-3).
0
3. Remove the lower unit and extension.
See step 3 in “Removing the lower unit” 1
(8-8).
TIP:
2
gear backlash before disassembly” (8-69). 3
Disassembling the propeller (SDS
propeller)
See “Disassembling the propeller (SDS pro-
4
peller)” (8-3).
Checking the propeller

See “Checking the propeller” (8-3).
5
See “Checking the lower unit anode” (8-3). 6
propeller)
See “Assembling the propeller (SDS propel- 7
ler)” (8-4).
8
9
10
A
8-50
Water pump and shift rod (counter rotation model)
6 22 24
7
8 23
9 22
5 10 22
9
5
11
5 20 21
12
4
19
3 13
18
2
14 17
16
1 15
15

1 Shift rod 1
2 E-clip 1
4 Plate 1
5 Bolt 3 M6 × 20 mm
7 Collar 1
8 Spacer 1
9 Washer 2
10 Wave washer 1
11 Impeller 1
12 Outer plate cartridge 1
14 Woodruff key 1
15 Dowel 2
16 Plate 1
17 Rubber seal 1
8-51
6 22 24
7
8 23
0
9 22
5 10 22
5
9
11
1
5 20 21
4
12 2
19
3 13
18 3
2
14 17
1 15
16 4
15
5
6

19 Insert cartridge 1
20
21
O-ring
Water pump housing
1
1
Not reusable 8
22 Bolt 4 M8 × 45 mm
23
24
Seal
Cover
1
1 9
10
A
8-52
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).
2. Remove the shift rod “1”.
Disassembling the water pump

housing
See “Disassembling the water pump hous-
ing” (8-11).
Checking the water pump and shift

rod
See “Checking the water pump and shift rod”
(8-11).
Assembling the water pump housing

See “Assembling the water pump housing”
(8-12).
8-53
Propeller shaft housing (counter rotation model)
12 8
1 2 4 3 15
10
0
8
2 5
3 9
6
11
1
4 9
3
2
5
7 2
17
3
1 2 16
3
23
4
14
18
21
15
20
22
5
19
6
13 145 N·m (14.5 kgf·m, 106.9 ft·lb)

1 Slider 1
3
4
Ball
Ball
2
2
4.74 mm (0.19 in) (reference data)
8.72 mm (0.34 in) (reference data)
8
5 Spring 1
6
7
Dog clutch
Dog clutch
1
1
FL150A: Six teeth
FL150B: Ten teeth 9
8 Cross pin 1
9 Spring 1
10
11
Forward gear shim (T2)
Forward gear
—
1
10
12 Thrust washer 1
13 Taper roller bearing 1 Not reusable
15 Propeller shaft 1
16 Thrust bearing 1
17 Propeller shaft shim (T4) —
A
8-54
12 8
1 2 4 3 15
10
8
2 5
3 9
11
6
4 9
3
2
7
5
17
3
1 2 16
23
14
18
15 21 22
20
19
13 145 N·m (14.5 kgf·m, 106.9 ft·lb)

18 Propeller shaft housing 1
19 Key 1
22 Claw washer 1
23 Ring nut 1
8-55
Removing the propeller shaft 3. Heat the area of the propeller shaft
housing assembly housing “1” where the taper roller bearing
1. Remove the ring nut and claw washer. outer race is to be installed using a gas
torch, and then remove the forward gear
See steps 1–3 in “Removing the propel-
ler shaft housing assembly” (8-15). assembly “2”. 0
assembly, key, and forward gear shims. When heating the propeller shaft housing,
heat the entire installation area evenly.
1
Otherwise, the propeller shaft housing
could be damaged.
2
2
1 3
1
Slide hammer handle “1”: 90890-06531

Puller head “2”: 90890-06514 4
housing assembly 2
5
burns could result.
4. Remove the propeller shaft “1”, thrust
bearing “2”, and propeller shaft shims “3”.
6
substances, such as gasoline and oil, 3
• Keep good ventilation while working. 2
7
1. Remove the dog clutch. See “Disassem-
bling the propeller shaft assembly” (8-
15). 1
8
2. Remove the O-ring “1”.
5. Remove the oil seals and needle
9
bearing. See step 3 in “Disassembling
1
the propeller shaft housing assembly” (8-
16) 10
Disassembling the forward gear
1. Remove the taper roller bearing “1” and
thrust washer “2”.
A
8-56
3 4
1 housing assembly and forward gear
3
1
2
burns could result.
4 around the working area.
90890-06607
1. Install the needle bearing and oil seals.
See steps 1 and 2 in “Assembling the
propeller shaft housing assembly” (8-17).
Checking the propeller shaft
1. Check the propeller shaft. Replace if 2. Install the original propeller shaft shims
damaged or worn. “1” and thrust bearing “2”.
2. Measure the propeller shaft runout. 2
3. Install the propeller shaft “1” and taper

roller bearing inner race “2”.
Propeller shaft runout:
0.02 mm (0.0008 in)
2
Checking the dog clutch
See “Checking the dog clutch” (8-16).
Checking the propeller shaft housing 1

See “Checking the propeller shaft housing”
(8-16).
Checking the forward gear

1. Check the teeth and dogs of the forward
gear. Replace if cracked or worn.
4. Heat the area of the propeller shaft hous-

ing where the taper roller bearing outer
race “1” is to be installed using a gas
torch, and then install the taper roller
bearing outer race “1”.
8-57
When heating the propeller shaft housing,

heat the entire installation area evenly. a
Otherwise, the propeller shaft housing
could be damaged.
0
4
3
4 2
1
1
1 3
2
1 2
Ring nut wrench “4”: 90890-06578
7. Install the spring “1”, balls “2”, “3”, and

3
“4”, and slider “5”.
TIP: 4
5. While holding the special service tool “1”, When installing the slider “5”, make sure that
strike the tool to check that the taper the balls do not fall out of position.
roller bearing “2” is installed properly.
5 4 1 3
5
TIP:
when the special service tool is struck, the 6
taper roller bearing outer race is installed 4 2 3
properly.
4
3 1
7
1 5 2
1
2
4
3
8
8. Install the dog clutch “1” so that the hole
“a” in the dog clutch “1” and the hole “b” 9
in the propeller shaft are aligned with the
Ring nut wrench “1”: 90890-06578 hole “c” in the slider “2”.
6. Install the thrust washer “1” and forward TIP:

10
gear “2” using the dog clutch “3” and Face the “F” mark “d” on the dog clutch “1”
special service tool “4”. toward the forward gear.
TIP:
Face the “F” mark “a” on the dog clutch “3”
toward the forward gear.
A
8-58
d b
1 a
b c
9. Install the cross pin “1”, and then install

the spring “2”.
8-59
Drive shaft and lower case (counter rotation model)
8 9
10
13
0
7
6
6
15
1
5 16
14
2
4
3 18
3
11
2 4
21
1
17
17
5
12
95 N·m (9.5 kgf·m, 70.1 ft·lb)
22 19 20 6
23 1 N·m (0.1 kgf·m, 0.7 ft·lb)

1 Thrust bearing 1
2 Pinion shim (T3) —
3
4
O-ring
Needle bearing
1
1
Not reusable
Not reusable
8
5 Drive shaft housing 1
M8 × 25 mm
6
7
Bolt
Oil seal
4
2 Not reusable 9
8 Cover 1
10
11
Water inlet cover (STBD)
Drive shaft
1
1
10
12 Sleeve 1
13 Lower case 1
14 Reverse gear shim (T1) —
15 Roller bearing 1 Not reusable
16 Thrust bearing 1
A
8-60
8 9
10
13
7
6
6
15
5 14 16
3 18
11
21
17
1
17
12
22 19 20
95 N·m (9.5 kgf·m, 70.1 ft·lb)
23 1 N·m (0.1 kgf·m, 0.7 ft·lb)

18 Reverse gear 1
19 Water inlet cover (PORT) 1
20 Screw 1 M5 × 45 mm
22 Pinion 1
23 Pinion nut 1
8-61
Removing the drive shaft Disassembling the lower case
See steps 1 and 2 in “Removing the drive
shaft” (8-21).
Removing the reverse gear

burns could result. 0
1. Remove the reverse gear “1” and thrust • To prevent fires, remove any flammable
bearing “2”. substances, such as gasoline and oil,
1
1
2
1. Remove the water inlet covers “1” and
“2”. 2
3
2
1
4
housing
See “Disassembling the drive shaft housing”
2. Heat the area of the lower case where 5
the roller bearing outer race is to be
(8-21). installed using a gas torch, and then
Disassembling the reverse gear

remove the roller bearing outer race “1”
and reverse gear shims “2”. 6
1. Remove the roller bearing inner race “1”.
2 3 2 1
When heating the lower case, heat the
7
3 the paint on the lower case could be
burned.
8
1
9
90890-06608
10
2. Remove the needle bearings from the
reverse gear.
2
A
8-62
3. Remove the needle bearing. See step 3
in “Disassembling the lower case” (8-22). TIP:
Checking the pinion scratched.
See “Checking the pinion” (8-22).
Checking the reverse gear the roller bearing outer race is to be
1. Check the teeth and dogs of the reverse installed using a gas torch, and then
gear. Replace if cracked or worn. install the roller bearing outer race “2”.
Checking the drive shaft

See “Checking the drive shaft” (8-22). When heating the lower case, heat the
Checking the lower case the paint on the lower case could be
See “Checking the lower case” (8-23). burned.
Assembling the reverse gear

1. Install new needle bearings. See step 1 2
in “Assembling the forward gear” (8-23).
2. Install a new roller bearing inner race “1”. 1
TIP:
Face the bearing identification mark “a” on
the roller bearing inner race “1” up.
a
2
2 1
3. While holding the special service tool “1”,

strike the tool to check that the roller
bearing outer race is installed properly.
1
TIP:
Bearing inner race attachment “2”:
when the special service tool is struck, the
90890-06660
outer race is installed properly
Assembling the lower case

burns could result.
8-63
Installing the propeller shaft housing
assembly
1. Install the original forward gear shims “1”,
1
propeller shaft housing “2”, and key “3”.
0
1 3
2 2
1
1
2
2
Driver rod LL “1”: 90890-06605
Ball bearing attachment “2”: 90890-06629 3
4. Install the needle bearing and water inlet
covers. See steps 4 and 5 in “Assembling
the lower case” (8-24).
2. Install the claw washer and ring nut. See
steps 3–5 in “Installing the propeller shaft
4
housing assembly” (8-26).
Assembling the drive shaft housing
See “Assembling the drive shaft housing” (8-
23).
Installing the shift rod
1. Install the plate to the shift rod. See steps
5
1 and 2 in “Installing the shift rod” (8-27).
Installing the reverse gear
1. Install the thrust bearing “1” and reverse
gear “2”.
2. Install the shift rod “1”. 6
TIP:
2
1
Make sure to install the shift rod “1” in the
proper orientation. Installation orientation is 7
different between the counter rotation model
and the regular rotation model.
8
9
Installing the drive shaft

1
10
See steps 2–6 in “Installing the drive shaft”
(8-25).
Installing the water pump

See “Installing the water pump” (8-27).
A
8-64
Checking the lower unit for air
leakage
See “Checking the lower unit for air leakage”
(8-28).
Installing the lower unit (L-transom

model)
1. Install the lower unit, trim tab, and propel-
ler. See steps 1–9 in “Installing the lower
unit (L-transom model)” (8-29).

Installing the lower unit (X-transom

model)
1. Check that the shift rod is in the N posi-
tion. See steps 1 and 2 in “Installing the
lower unit (L-transom model)” (8-29).
2. Install the extension and lower unit. See

steps 2–6 in “Installing the lower unit (X-
3. Install the trim tab and propeller. See

steps 6–9 in “Installing the lower unit (L-

8-65
Shimming (counter rotation model)
Shimming workflow
1. Remove the water pump

assembly.
0
2. Measure the backlash before
disassembly.
1
4. YES
5. Shimming is not required. 2
6. NO
7. Disassemble the lower unit.
3
8. Select the pinion shims (T3)
and propeller shaft shims (T4).
4
9. Assemble the lower unit.

5
6. NO 11. Adjust the forward gear shim
thickness (T2) and reverse gear 6
shim thickness (T1).
4. YES
12. Install the water pump
assembly.
7
1. Remove the water pump assembly. 8. Select the pinion shims (T3) and propel- 8
2. Measure the backlash before disassem- ler shaft shims (T4).
bly. 9. Assemble the lower unit.
4. YES
11. Adjust the forward gear shim thickness 9
5. Shimming is not required. (T2) and reverse gear shim thickness
6. NO (T1).
7. Disassemble the lower unit. 12. Install the water pump assembly. 10
TIP:
• Make sure to drain the gear oil before measuring the backlash.
• If the backlash is within specification, shimming is not required.
• When assembling the original inner parts and a new lower case, shimming is required.
• When replacing the pinion, forward gear, reverse gear, bearings, drive shaft, or propeller shaft
housing, shimming is required.
A
8-66
Shimming check sheet
Lower case deviation
Serial number P F R Remarks
Pinion height (mm)

Measurements
Measuring point #1
Measuring point #2
Measuring point #3
Measuring point #4
Average
Round-down average
(M)
Forward gear backlash (mm)

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

Measurements
Measuring point #1
Measuring point #2
Measuring point #3
Measuring point #4
Average
Round-down average
8-67
Forward gear shim (T2) thickness adjustment in 2 places (mm)
0.10
0.12
0.15
0
0.18
0.30
0.40 1
0.50
Total
2
Reverse gear shim (T1) thickness adjustment in 2 places (mm)
0.10 3
0.12
0.15
0.18
0.30
4
0.40
0.50
Total 5
6
7
8
9
10
A
8-68
Measuring the forward gear backlash
and reverse gear backlash before 1
disassembly
Two washers (90201-26M00) are required for
the reverse gear backlash measurement in
the counter rotation model. Prepare the
washers before starting the shimming proce-
dure.
1. Install the lower unit onto a repair stand.
2. Remove the water pump assembly.

Center bolt “1” (shimming):
20 N·m (2.0 kgf·m, 14.8 ft·lb)
7. Place the lower unit in an upright

position.
1 8. Remove the cover “1”, and then install

R
the outer plate cartridge “2”.
N
F
1
4. Set up the special service tools “1”, “2”,

and “3”, and then tighten the center bolt
“3” temporarily.
1 2
2
1

90890-06502
Center bolt “3”: 90890-06504 9. Set the spring “1” on the outer plate
cartridge, and then install the handle
5. Turn the drive shaft 10 turns or more. holder “2” so that the spring is
compressed to the specified setting
6. While holding the drive shaft to prevent it height “a”.
from turning, tighten the center bolt “1” to
8-69
TIP: TIP:
• After installing the handle holder, pull the • The resistance of the spring increases the
drive shaft upward to remove any free play. force required to turn the drive shaft. There-
• Do not press the spring more than 5.0 mm
(0.197 in). Otherwise, too much torque will
fore, to obtain correct measurements, con-
sider the spring resistance force when
0
be required to turn the drive shaft, making it turning the drive shaft.
difficult to obtain correct measurements. • Do not turn the drive shaft using too much
force. Otherwise, the forward gear will turn,
leading to incorrect measurements.
1
2 • When turning the drive shaft, hold it using a
a
1
little force. A knocking sound may be heard
when the drive shaft is rotated, but this is 2
the sound of the pinion contacting the
reverse gear and does not affect the back-
lash measurement.
3
Spring “1”: 90501-450A2
Handle holder “2”: EU0-23814-30 4
Setting height “a”:
3.0–5.0 mm (0.118–0.197 in)
5
10. Install the special service tool “1” onto
the drive shaft at the lowest possible
position where the shaft diameter is
22.4 mm (0.881 in), and then set up the
12. Turn the drive shaft 180° clockwise, and
then measure the backlash again.
6
special service tools “2”, “3”, and “4”.
1
4
2 TIP:
• Measure the backlash at 4 points: “a”, “b”, 7
“c”, and “d”, turning the drive shaft 180°
clockwise after each measurement.
3
shimming check sheet.
8
9
Backlash indicator “1”: 90890-06706 a
Magnet base plate “2”: 90890-07003
Dial gauge set “3”: 90890-01252
Magnet base B “4”: 90890-06844 b
10
d
11. Turn the drive shaft slowly clockwise and
counterclockwise, and then measure the
backlash between where the drive shaft
stops in each direction.
c
A
8-70
13. Determine the backlash average, and
then round down the average to 2
3
decimal places.
Example: 2 1
(mm)
Measurement point “b” 0.36
Measurement point “c” 0.34
Measurement point “d” 0.33 Washer “1”: 90201-26M00
Average 0.3325
Round-down average 0.33 18. Install the original forward gear shims
(T2) and propeller shaft housing
14. Check that the forward gear backlash assembly, and then tighten the ring nut to
average is within specification. the specified torque.
Ring nut (shimming):
TIP: 70 N·m (7.0 kgf·m, 51.6 ft·lb)
Adjust the shim thicknesses if the forward
gear backlash is out of specification. 19. Repeat steps 11–13 to measure the
Forward gear backlash (FL150A):
0.15–0.42 mm (0.0059–0.0165 in) 20. Check that the reverse gear backlash
Forward gear backlash (FL150B): average is within specification.
0.15–0.49 mm (0.0059–0.0193 in)
15. Remove the special service tools from TIP:

Adjust the shim thicknesses if the reverse
the propeller shaft.
gear backlash is out of specification.
16. Remove the shift rod and propeller shaft
Reverse gear backlash (FL150A):
housing assembly.
0.24–0.58 mm (0.0094–0.0228 in)
17. Install the washers “1” between the Reverse gear backlash (FL150B):
reverse gear “2” and the propeller shaft 0.24–0.65 mm (0.0094–0.0256 in)
“3”.
21. Remove the special service tools and
washers, and then install the propeller
1 shaft housing assembly, shift rod, and
water pump assembly.
8-71
Shimming procedure
• Before selecting the forward gear shims (T2) and reverse gear shims (T1), make sure to select the
pinion shims (T3).
• When assembling the lower unit to measure the backlash after selecting the pinion shims (T3), do
not apply gear oil, grease, or sealant to the parts. 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
T3
F R 2
P
3
4
5
6
7
8
9
10
T1 T2 T4
A
8-72
Selecting the pinion shim (T3)
See “Selecting the pinion shim (T3)” (8-39). TIP:
In the “Propeller shaft shim (T4) selection
Selecting the propeller shaft shim table”, use the rounded measurement value
for the free play measurement.
(T4)
1. Install the original propeller shaft shims
(T4). 7. Determine the value of propeller shaft
shim (T4) thickness adjustment using the
“Propeller shaft shim (T4) selection table”
TIP:
• If the original shims are missing, measure according to the free play measurement.
the free play without any shims. See “Propeller shaft shim (T4) selection
• Do not reuse a shim if deformed or table” (A-15).
scratched.
TIP:
2. Install the propeller shaft housing
positive, the current shim thickness must be
assembly. See “Installing the propeller
increased by that amount and, if the value
shaft housing assembly” (8-64).
is negative, the current shim thickness must
3. Turn the propeller shaft 10 turns or more. be decreased by that amount.
• The gray-colored cell on the selection table
4. Set up the special service tools “1” and indicates the specified propeller shaft free
“2”. play. Shimming is not required if the mea-
sured propeller shaft free play is 0.25–0.35
5. Measure the propeller shaft free play. mm.
• The values for the shim thickness adjust-
2 ments specified in the selection table are
intended to obtain the specified propeller
shaft free play of 0.3 mm.
1 Example:
Free play measurement = 1.1 mm “a”
Propeller shaft shim (T4) thickness adjust-
ment = 0.8 mm “b”
increased by 0.8 mm.
a
(mm)
Dial gauge set “1”: 90890-01252
Magnetic base B “2”: 90890-06844 A 1.0 1.1
Propeller shaft free play: B +0.7 +0.8

0.25–0.35 mm (0.0098–0.0138 in)
b
6. Round the measurement value to the
1/10 place if out of specification.
A. Free play measurement
B. Shim thickness adjustment
8-73
8. Calculate the new propeller shaft shim Measuring the forward gear backlash
(T4) thickness. • Spray anti-rust lubricant on the gears and
bearings before installation. Do not apply
gear oil to the parts. Otherwise, correct
TIP:
Use up to 3 shims to obtain the required shim measurements cannot be obtained. 0
thickness. • Keep the parts free of foreign material,
New propeller shaft shim (T4) thickness =
reverse gear backlash, use the original 1
bearings and shims.
Current propeller shaft shim thickness +
Shim thickness adjustment
1. Install the original forward gear shims
(T2) and propeller shaft housing assem-
2
Example:
bly. See “Installing the propeller shaft
housing assembly” (8-64).
Current propeller shaft shim thickness
TIP:
3
= 0.8 mm
• If the original forward gear shims (T2) are
New propeller shaft shim (T4) thickness
= 0.8 mm + 0.2 mm
missing, install new shims with a combined
thickness of 0.52 mm. 4
= 1.0 mm
scratched.
Current propeller shaft shim thickness 2. Measure the forward gear backlash. See
5
= 0.8 mm steps 3–13 in “Measuring the forward
gear backlash and reverse gear backlash
New propeller shaft shim (T4) thickness before disassembly” (8-69). 6
= 0.8 mm + (–0.1) mm Forward gear backlash (FL150A):
= 0.7 mm 0.15–0.42 mm (0.0059–0.0165 in)
0.10, 0.12, 0.15, 0.18, 0.30, 0.40,
Forward gear backlash (FL150B):
0.15–0.49 mm (0.0059–0.0193 in)
7
0.50 mm
Adjusting the forward gear shim
9. Remove the special service tools, and
then install the determined propeller
thickness (T2)
8
shaft shims. assembly and forward gear shims (T2).
2. Measure the thickness of original forward 9

gear shim (T2) in 2 places.
TIP:
10
scratched.
A
8-74
3. Determine the forward gear shim (T2) A. Backlash measurement (BL2)
thickness adjustment using the “Forward B. Shim thickness adjustment
gear shim (T2) selection chart” according
to the backlash measurement (BL2) from 4. Calculate new forward gear shim (T2)
“Measuring the forward gear backlash”. thickness.
See “Reverse gear shim (T1) selection
chart (FL150A)” (A-16) or See “Forward TIP:
gear shim (T2) selection chart (FL150B)” • Use the lowest number of shims to obtain
(A-17). the required shim thickness.
TIP: obtained with a combination of the available
• If the shim thickness adjustment value is shims, increase or decrease the shim thick-
positive, increase the current shim thickness by 0.01 mm.
ness by that amount and, if the value is
negative, decrease the current shim thick- Calculation formula:
ness by that amount. New forward gear shim (T2) thickness =
• The gray-colored area on the selection Current forward gear shim thickness + shim
chart indicates the range of the specified thickness adjustment
measured backlash is within the gray-col- Example:
ored area. Use the following formula when the shim
• The values for the shim thickness adjust- thickness adjustment value is positive.
ments specified in the selection chart are Current forward gear shim thickness
intended to obtain the median value within = 0.52 mm
the range for the specified forward gear or Shim thickness adjustment = 0.12 mm
reverse gear backlash. New forward gear shim (T2) thickness
• The table that follows the selection chart = 0.52 mm + 0.12 mm
shows the shim thickness adjustments for = 0.64 mm
the points marked on the chart. Use the following formula when the shim
Example: Current forward gear shim thickness
Backlash measurement (BL2) = 0.10 mm “a” = 0.52 mm
Forward gear shim (T2) thickness adjustment Shim thickness adjustment = –0.15 mm
= 0.12 mm “b” New forward gear shim (T2) thickness
The current shim thickness must be = 0.52 mm + (–0.15 mm)
increased by 0.12 mm. = 0.37 mm
0.30
B (mm)
0.10, 0.12, 0.15, 0.18, 0.30, 0.40,

0.20
0.50 mm
0.10
0 5. Install the determined forward gear shims
b –0.10
(T2) and propeller shaft housing assem-
–0.20 bly.
–0.30
0 5 10 15 20 25 30 35
a A (1/100 mm)
A 0 5 10 15 20 25 30 35
B 0.19 0.16 0.12 0.09 0.06 0.02 –0.01 –0.05
8-75
Measuring the reverse gear backlash 2. Measure the thickness of original reverse
• Spray anti-rust lubricant on the gear and gear shim (T1) in 2 places.
bearings before installation. Do not apply
gear oil to the parts. Otherwise, correct
measurements cannot be obtained.
TIP:
Do not reuse a shim if deformed or 0
• Keep the parts free of foreign material, scratched.
reverse gear backlash, use the original
3. Determine the reverse gear shim (T1)
thickness adjustment using the “Reverse
1
bearings and shims. gear shim (T1) selection chart” according
to the backlash measurement (BL1) from
1. Install the original reverse gear shims
(T1) and roller bearing outer race.
“Measuring the reverse gear backlash”.
See “Forward gear shim (T2) selection
2
chart (FL150A)” (A-16) or See “Forward
TIP:
• If the original reverse gear shims (T1) are
missing, install new shims with a combined
gear shim (T2) selection chart (FL150B)”
(A-17). 3
thickness of 1.00 mm.
TIP:
scratched.
4
ness by that amount and, if the value is
2. Install the reverse gear assembly, drive negative, decrease the current shim thick-
shaft, and pinion. See “Installing the drive
shaft” (8-25).
ness by that amount.
• The gray-colored area on the selection
5
chart indicates the range of the specified
4. Install the thrust bearing, pinion shims

measured backlash is within the gray-col- 6
ored area.
(T3), and drive shaft housing.
• The values for the shim thickness adjust-
5. Install the propeller shaft housing
assembly. See “Installing the propeller
ments specified in the selection chart are
intended to obtain the median value within
7
shaft housing assembly” (8-64). the range for the specified forward gear or
6. Check that the drive shaft turns smoothly. • The table that follows the selection chart
shows the shim thickness adjustments for
8
7. Measure the reverse gear backlash. See the points marked on the chart.
steps 16–19 in “Measuring the forward
gear backlash and reverse gear backlash Example: 9
before disassembly” (8-69). Backlash measurement (BL1) = 0.20 mm “a”
Reverse gear backlash (FL150A): Reverse gear shim (T1) thickness adjustment
0.24–0.58 mm (0.0094–0.0228 in)
Reverse gear backlash (FL150B):
= –0.14 mm “b”
10
0.24–0.65 mm (0.0094–0.0256 in) decreased by 0.14 mm.
Adjusting the reverse gear shim

thickness (T1)
1. Remove the roller bearing outer race and
reverse gear shims (T1).
A
8-76
= 0.86 mm
B (mm)
0.30 Available shim thicknesses:

0.20 0.10, 0.12, 0.15, 0.18, 0.30, 0.40,
0.10 0.50 mm
b 0
–0.10 5. Install the determined reverse gear shims
–0.20 (T1) and roller bearing outer race.
–0.30
0 5 10 15 20 25 30 35
a A (1/100 mm)
A 0 5 10 15 20 25 30 35
B –0.28 –0.24 –0.21 –0.18 –0.14 –0.11 –0.08 –0.04

4. Calculate the new reverse gear shim (T1)

thickness.
TIP:
• Use the lowest number of shims to obtain
obtained with a combination of the available
ness by 0.01 mm.
Current reverse gear shim thickness + shim
thickness adjustment
Example:
Current reverse gear shim thickness
= 1.00 mm
New reverse gear shim (T1) thickness
= 1.00 mm + 0.22 mm
= 1.22 mm
Current reverse gear shim thickness
= 1.00 mm
New reverse gear shim (T1) thickness
= 1.00 mm + (–0.14 mm)
8-77
— MEMO —
0
1
2
3
4
5
6
7
8
9
10
A
8-78
Bracket unit 9
Shift rod and shift bracket ................................................ 9-1

Removing the shift rod and shift bracket ................................... 9-3
Disassembling the shift bracket ................................................. 9-3
Assembling the shift bracket ..................................................... 9-3
Installing the shift rod and shift bracket ..................................... 9-4
PTT switch and cowling lock lever .................................. 9-6

Removing the PTT switch ......................................................... 9-8
Removing the cowling lock lever ............................................... 9-8
Removing the flushing hose ...................................................... 9-8
Installing the flushing hose ........................................................ 9-8
Installing the cowling lock lever ................................................. 9-9
Installing the PTT switch ........................................................... 9-9
Bottom cowling ............................................................... 9-11
Upper case and mounts ................................................. 9-13

Removing the upper case ....................................................... 9-15
Installing the upper case ......................................................... 9-15
Upper case ....................................................................... 9-17

Disassembling the upper case ................................................ 9-18
Checking the drive shaft bushing ............................................ 9-18
Assembling the upper case ..................................................... 9-18
Oil pan and exhaust manifold ........................................ 9-20

Disassembling the oil pan and exhaust manifold .................... 9-22
Checking the oil pan and exhaust manifold ............................. 9-22
Checking the oil strainer .......................................................... 9-22
Assembling the oil pan and exhaust manifold ......................... 9-22
Steering arm .................................................................... 9-24

Removing the steering arm ..................................................... 9-25
Installing the steering arm ....................................................... 9-25
Clamp bracket and swivel bracket ................................ 9-27

Removing the clamp bracket ................................................... 9-30
Checking the clamp bracket anode ......................................... 9-30
Installing the clamp bracket ..................................................... 9-30
Adjusting the trim sensor cam ................................................. 9-32
Bracket unit
PTT unit ............................................................................ 9-33

Removing the PTT unit ............................................................ 9-34
Checking the hydraulic pressure ............................................. 9-35
0
Bleeding the PTT unit .............................................................. 9-37
Installing the PTT unit .............................................................. 9-39
1
PTT cylinder ..................................................................... 9-41
Removing the tilt ram and trim ram ......................................... 9-43
Disassembling the tilt ram ....................................................... 9-44
2
Disassembling the trim ram ..................................................... 9-44
Checking the tilt cylinder and trim cylinder .............................. 9-44
Checking the absorber valve ................................................... 9-44 3
Assembling the tilt ram ............................................................ 9-44
Assembling the trim ram .......................................................... 9-45
Installing the trim ram .............................................................. 9-46
Installing the tilt ram ................................................................ 9-46
4
PTT motor ........................................................................ 9-48
Removing the reservoir ........................................................... 9-50
5
Removing the PTT motor ........................................................ 9-50
Disassembling the PTT motor ................................................. 9-50
Checking the armature (PTT motor) ........................................ 9-51 6
Checking the brush ................................................................. 9-51
Checking the reservoir ............................................................ 9-52
Assembling the PTT motor ...................................................... 9-52
Installing the PTT motor .......................................................... 9-53
7
Installing the reservoir ............................................................. 9-53
PTT gear pump ................................................................ 9-54

8
Removing the gear pump assembly ........................................ 9-57
Disassembling the gear pump housing ................................... 9-57
Disassembling the gear pump ................................................. 9-57 9
Checking the gear pump ......................................................... 9-58
Checking the gear pump housing ............................................ 9-58
Checking the valve seal .......................................................... 9-58 10
Checking the filter .................................................................... 9-58
Assembling the gear pump ...................................................... 9-59
Assembling the gear pump housing ........................................ 9-60
Installing the gear pump assembly .......................................... 9-61
A
Shift rod and shift bracket
7
2 2.5 N·m (0.25 kgf·m, 1.84 ft·lb)
4 2 3
1 5
2.5 N·m (0.25 kgf·m, 1.84 ft·lb)
8
6
12
1 N·m (0.1 kgf·m, 0.7 ft·lb)
29 10 2
2 3
4 11
9
28 13
14
11
15
26
18 19 N·m (1.9 kgf·m, 14.0 ft·lb)
25 27
24
19
23
20 18
21 17
22 16
18 N·m (1.8 kgf·m, 13.3 ft·lb)

1 Shift position switch 1
3 Plate 2
4 Clip 2
5 Bushing 1
6 Bracket 1
7 Washer 1
8 Shift lever 1
9 Shift cut-off switch 1
10 Spring 1
11 Bushing 2
12 Bolt 2 M6 × 50 mm
13 Bracket 1
14 Grease nipple 1
15 Bolt 1
16 Grommet 1
17 Circlip 1
9-1
7
2 2.5 N·m (0.25 kgf·m, 1.84 ft·lb)
4 2
1
3
5 0
2.5 N·m (0.25 kgf·m, 1.84 ft·lb)
8
6 1
12
1 N·m (0.1 kgf·m, 0.7 ft·lb)
29 10
2
2
3 2
4 11
9
28 14
11
13
3
15
26
18
25
19 N·m (1.9 kgf·m, 14.0 ft·lb)
27
4
24
19
23
20 18 5
21 17
16
22
6
18 N·m (1.8 kgf·m, 13.3 ft·lb)

18 Washer 2
19 Bracket 1
20
21
Ball
Spring
1
1
6.34 mm (0.25 in) (reference data) 8
22 Shift rod detent bolt 1
23
24
Dowel
Grease nipple
1
1 9
25 Bushing 1
27
28
Bolt
Shift rod
1
1
M6 × 35 mm
10
29 Bushing 1
A
9-2
Removing the shift rod and shift
bracket
1. Remove the shift bracket assembly “1”.
1
1
2. Remove the shift position switch “1”.
2. Remove the shift lever “1” and shift rod 1

assembly “2”.
2
1
3. Remove the shift cut-off switch “1”.
1
3. Remove the shift rod detent bolt “1”,
spring “2”, and ball “3”.
4. Remove the circlip “4” and bushing “5”.
Assembling the shift bracket

1. Install the shift cut-off switch “1” and plate
5 3 “2”, and then tighten the shift cut-off
2 switch screws “3” to the specified torque.
4
1
3
2
Disassembling the shift bracket
1. Remove the bolt “1”, and then disassem- 1
ble the shift bracket assembly.
Shift cut-off switch screw “3”:

2.5 N·m (0.25 kgf·m, 1.84 ft·lb)
9-3
2. Install the shift position switch “1” and
plate “2”, and then tighten the shift posi-
tion switch screws “3” to the specified 1
torque.
3
0
a 1
2
1
b 1
2
3 c
2
Shift position switch screw “3”: Shift bracket bolt “3”:
2.5 N·m (0.25 kgf·m, 1.84 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) 3
3. Install the bushing “1” to the bracket “2”. 7. Install the grease nipple “1”, and then
tighten it to the specified torque.
4. Fit the spring end “a” into the cutout “b” in
the bracket “2” and the spring end “c” into
4
TIP:
the cutout “d” in the bracket “3”. Make sure that the installation angle of the
c d
grease nipple “1” is within the range “a”.
5
3 8. Inject grease into the grease nipple until
grease comes out of the bushings “b”.
c
6
3
a
1
30°
7
b a
2 b a
2
b 1
8
5. Turn the bracket “1” to the position “a”,
Shift bracket grease nipple “1”:
push it down, and then install the bushing
“2” and shift bracket bolt “3” temporarily.
1 N·m (0.1 kgf·m, 0.7 ft·lb) 9
Installing the shift rod and shift
Move the shift cut-off switch lever “b” in

direction “c” when pushing the shift
bracket
1. Install the bushing “1” and washers “2”, 10
and then install the circlip “3”.
bracket “1” down. Otherwise the lever
may be damaged. 2. Install the ball “4”, spring “5”, and shift
rod detent bolt “6”, and then tighten the
6. Tighten the shift bracket bolt “3” to the shift rod detent bolt “6” to the specified
specified torque. torque.
A
9-4
2 3
2
4
1 1
2 5 5
6
3
Shift rod detent bolt “6”:

18 N·m (1.8 kgf·m, 13.3 ft·lb)
3. Install a new O-ring “1” to the shift rod

assembly “2”.
4. Install the grommet “3” to the upper case.
5. Install the shift lever “4” to the set pin “a”

of the shift rod assembly “2”.
6. Install the dowel “5” and shift rod assem-

bly “2”, and then align the center of the
set pin “a” with the mark “b” on the bot-
tom cowling.
a
4 2
5
1
b
a
7. Install the washer “1” and shift bracket

assembly “2”, and then install the bush-
ing “3” and clip “4” to the shift lever “5”.
9-5
PTT switch and cowling lock lever
13 9
9 9
15
14 11
8 12
13 17
18 16
0
12 8
3 16 8 10
4
17
8
14 16
1
1 2 15
17
18 27 18
2
6
30 29
3
30
3
28 4
4
7 26
21 19
5
21 5
5 N·m (0.5 kgf·m, 3.7 ft·lb)
25
24 23
1 6
22 21 20

1 Gasket 2 Regular rotation model
2 PTT switch 1 Regular rotation model
3
4
Bolt
Holder
4
2
M6 × 20 mm 8
5 Cover 1 Regular rotation model
6
7
Cowling lock lever (rear)
Cowling lock lever (front)
1
1 9
8 Bushing 4
9 Bolt 4 M6 × 30 mm
10
11
Housing
Housing
1
1
10
12 Wave washer 2
13 Lever 2
14 Washer 2
15 Bolt 2 M6 × 20 mm
16 Spring 2
17 Bolt 2 M6 × 20 mm
A
9-6
13 9
9 9
15 8 12 18 16
14 11 13 17
12 8
3 16 8 10
17
8
4 14 16
1 2 15
17
18 27 18
6
30 29
30
28
3
4
7 26
21 19
21 5
5 N·m (0.5 kgf·m, 3.7 ft·lb)
1
25
24 23
22 21 20

18 Hook 2
19 Grommet 1
20 Hose 1 Hose joint to exhaust cover
21 Plastic tie 3
22 Hose joint 1
23 Hose joint 1
24 Gasket 1
25 Adapter 1
26 Screw 2 ø6 × 19 mm
27 Clamp 1
28 PTT switch 1 Counter rotation model
29 Cover 1 Counter rotation model
30 Gasket 2 Counter rotation model
9-7
Removing the PTT switch
1. Remove the holder “1”, and then remove
the PTT switch “2”.
A 0
STBD 1
1 1
2
2 2
B
1 Removing the flushing hose
PORT
1. Remove the adapter “1” and hose joints 3
“2”, and “3”.
2
4
1

2 5
B. Counter rotation model 3
Removing the cowling lock lever

1. Remove the spring “1”.
6
1
7
2. Remove the flushing hose “1”, PTT motor
leads “a”, trim sensor lead “b”, and grom-
met “2”. 8
2
2. Remove the lever “1” and cowling lock

9
lever “2”.
b
a 1 10
Installing the flushing hose
1. Install the grommet “1” to the bottom
cowling.
A
9-8
2. Pass the flushing hose “2”, trim sensor
Flushing hose adapter screw “2”:
lead “3”, and PTT motor leads “4”
5 N·m (0.5 kgf·m, 3.7 ft·lb)
through the grommet “1”, and then fasten
them using the plastic ties “5” around the Installing the cowling lock lever
grommet “1”. 1. Install the cowling lock lever “1” and lever
“2”.
TIP:
Align the white paint mark “a” on the flushing
hose “2” with the outer end of the grommet
“1”.
4 2 1
3 5
5
5 1 3 2. Install the spring “1”.
5 2 1
a 4
3. Install the flushing hose adapter “1”, and

then tighten the flushing hose adapter
screws “2” to the specified torque.
4. Route the flushing hose through the hose

joint “3”, install it to the hose joint “4”, and
then fasten the flushing hose “5” using
the plastic tie “6”. 3. Inject grease into the housing “1” until
grease comes out from the cowling lock
5. Install the hose joint to the adapter “1” lever bushing.
along with the gasket “7”.
2 1
1
7
4
3
6
Installing the PTT switch

5 1. Install the gasket “1”, PTT switch “2”, and
holder “3”.
9-9
A
1 3
STBD
0
2 1
B
3 2
PORT 1
2 3
4
B. Counter rotation model
5
6
7
8
9
10
A
9-10
Bottom cowling
Bottom cowling
1
1
14
8
14 15
1
9 14
4 5 3 15
2 14
10 11 15
15
3
2
18
1
15 12
16
6 7 13
13
15 15
17
15 16 16
19
16

1 Bolt 5 M6 × 20 mm
2 Pin 2
3 Holder 2
4 Bracket 1
5 Bracket 1
6 Bracket 1
7 Clamp 1
8 Holder 1
9 Grommet 4
10 Collar 4
11 Rubber seal 1
12 Water outlet 1
13 Grommet 2
14 Bolt 4 M8 × 35 mm
15 Grommet 8
16 Collar 4
17 Rubber seal 1
9-11
Bottom cowling
1
1
8
14
0
14 15
1
9 14
4 5
2
3 14
15
10 11 15
1
15
2
3 2
18 3
1
15 12
6 7
16 4
13
13 5
15 15
17
19
15
16
16 16
6

18 Bottom cowling 1
19 Grommet 1
8
9
10
A
9-12
Upper case and mounts
18 55 N·m (5.5 kgf·m, 40.6 ft·lb)
7 9 11 13 13 20
17
12
11 15
10 19 20
8 10 12 9 16
8 15 14 16 15
7 14
15
19
16 15 19 20
15
14
72 N·m (7.2 kgf·m, 53.1 ft·lb)
5
4
23 10 13
22 12
1 3 24 11
9
6
3 23 7 8
26 4
25
21 21
26
2 3
72 N·m (7.2 kgf·m, 53.1 ft·lb)

2 Nut 2
3 Washer 4
4 Bolt 4 M10 × 40 mm
5 Cover 1
6 Cover 1
7 Washer 2
8 Lower mount 2
9 Washer 2
10 Washer 2
11 Washer 2
12 Bolt 2 M14 × 225 mm
13 Cap 2
14 Collar 2
15 Washer 4
16 Upper mount 2
17 Bracket 1
9-13
18 55 N·m (5.5 kgf·m, 40.6 ft·lb)

7 9 11 13 13
12
17
20
0
11 15
10 19 20
8 10 12 9 16
7
8
14
15
15
14 16 15
1
19
16 15 19 20
15
14
2
72 N·m (7.2 kgf·m, 53.1 ft·lb)
5
4 3
3
23 10
12
13 4
22
1 3 24 11
9
6
5
3 23 7 8
26 4
25
3
26
21 21 6
2 72 N·m (7.2 kgf·m, 53.1 ft·lb)

18 Bolt 3 M10 × 45 mm
19 Washer 2
20
21
Bolt
Bolt
2
1
M14 × 203 mm
M6 × 10 mm
8
22 Nipple 1
23
24
Plastic tie
Speedometer hose
2
1 Adapter to nipple 9
25 Adapter 1
26 Bolt 1 M6 × 20 mm
10
A
9-14
Removing the upper case Installing the upper case
1. Drain the remaining engine oil. 1. Install the washers “1” and “2”, upper
mounts “3”, washer “4”, and collar “5” to
2. Disconnect the ground lead “1”. the upper mount bolts “6”.
3. Remove the adapter “2”, and then dis- 2. Install the upper mounts “3” and upper
connect the speedometer hose “3”. mount bracket “7”, and then tighten the
upper mount bracket bolts “8” tempo-
4. Loosen the upper mount bracket bolts “4” rarily.
and lower mount cover bolts (PORT and
STBD) “5”. 3
5 4 2 16
4
8
6
1
7
2
4 3
5
5
32
5 4
1 3
3. Install the caps “1”, washers “2”, “3”, and
1 “4”, lower mounts “5”, and washers “6” to
the lower mount bolts “7”.
2
2 3
4. Install the lower mounts “5” and lower
mount covers “8”, and then tighten the
5. Remove the upper mounting nuts “1” and lower mount cover bolts “9” temporarily.
lower mounting nuts “2”, and then
remove the upper case assembly “3”. 5 4 3 27 1
6
1 3 2 1
4 7
3 6 5 9
2 5. Install the upper and lower mounting

bolts into the bracket assembly “1” simul-
taneously.
9-15
6. Install the ground lead (STBD) “2”, wash-
Upper mount bolt “1”:
ers “3”, upper mounting nuts “4”, and
55 N·m (5.5 kgf·m, 40.6 ft·lb)
lower mounting nuts “5”, and then tighten
the upper mounting nuts “4” and lower
mounting nuts “5” to the specified torque.
9. Connect the ground lead “1”.
0
10. Pass the speedometer hose “2” through
TIP: the steering arm “3”.
Fit the ground lead “2” into the groove “a” in
the steering yoke. 11. Connect the speedometer hose “2” to the 1
adapter “4”, and then fasten it using the
a 4 3 plastic tie “5”.
2
12. Install the adapter “4” to the upper case. 2
3
4
1 3
3
2
3
4
5 3
5
2 5
Upper mounting nut “4”: 1 4
72 N·m (7.2 kgf·m, 53.1 ft·lb) 1
Lower mounting nut “5”:
72 N·m (7.2 kgf·m, 53.1 ft·lb)
6
7. Tighten the upper mount bolts “1” to the 2
4
5
specified torque in the order [1], [2], and
so on.
7
8. Tighten the lower mount bolts (PORT
and STBD) “2”.
8
[2]
[1]
1
[3]
9
10
A
9-16
Upper case
Upper case
8 4 N·m (0.4 kgf·m, 3.0 ft·lb)
6
4 7
10
10
11
1
13 12
14
15
28 N·m (2.8 kgf·m, 20.7 ft·lb) 3

2

1 Upper case 1
2 Circlip 1
3 Bushing 1
4 Rubber seal 1
5 Dowel 2
7 Baffle plate 1
8 Bolt 2 M8 × 30 mm
9 Bolt 4 M10 × 45 mm
10 Grommet 2
12 Drain bolt 1
13 Damper 1
14 Rubber seal 1
15 Rubber seal 1 Not reusable
9-17
Upper case
Disassembling the upper case Checking the drive shaft bushing
1. Remove the drain bolt “1”. 1. Check the bushing. Replace if cracked or
worn.
Assembling the upper case 0

1. Install the bushing “1”, and then install
1
the circlip “2”.
1 2 1
4
2. Remove the upper case bolts “1” and “2”,

3 3
2
and then remove the oil pan assembly
“3”.
2 2 2
1 3
1
90890-06653
Driver rod L3 “4”: 90890-06652 4
2. Install the dowels “1”.
3
1
3. Install the baffle plate “2”, and then 5
tighten the baffle plate screws “3” to the
specified torque.
4. Install the rubber seal “4” to the joint hole 6

“a” in the upper case.
5. Install a new rubber seal “5”, the rubber

seal “6”, and the damper “7”, and then
7
install the oil pan assembly “8”.
3. Remove the circlip “1”, and then remove

the bushing “2”.
TIP:
Make sure to fit the tip of the cooling water
8
pipe “9” into the joint hole “a” in the upper
1
4 5
case.
9
2 6. Install the oil pan bolts “10” and “11”, and
then tighten them to the specified
torques. 10
3 4
Bearing puller assembly “3”: 90890-06535

A
9-18
Upper case
10 11
2
8
4
7 1
9
6
5
9
4
a
Baffle plate screw “3”:

4 N·m (0.4 kgf·m, 3.0 ft·lb)
Oil pan assembly bolt (M8) “10”:
20 N·m (2.0 kgf·m, 14.8 ft·lb)
Oil pan assembly bolt (M10) “11”:
42 N·m (4.2 kgf·m, 31.0 ft·lb)
7. Install a new gasket “1” and the drain bolt

“2”, and then tighten the drain bolt “2” to
1
2
Drain bolt “2”: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
9-19
Oil pan and exhaust manifold
0
7
7 14 1
2
8
9 15 2
16
3 11 14
3
4 20 N·m (2.0 kgf·m, 14.8 ft·lb)
5
12
17 18
4
19
10 13
5
6
20
20 N·m (2.0 kgf·m, 14.8 ft·lb)
6

1 Exhaust guide 1
3
4
Gasket
Collar
1
3
Not reusable 8
5 Oil strainer 1
M6 × 25 mm
6
7
Bolt
Dowel
3
2 9
8 Oil pan 1
9 Bolt 10 M8 × 35 mm
10
11
Bolt
Gasket
4
1
M8 × 60 mm
Not reusable
10
12 Exhaust manifold 1
13 Rubber seal 1
15 Plate 1
16 Water pipe 1
17 Rubber seal 1
A
9-20
7
7 14
2
8
9 15
16
3 11 14
4 20 N·m (2.0 kgf·m, 14.8 ft·lb)
17 18
5
12
19
10 13
6
20 N·m (2.0 kgf·m, 14.8 ft·lb) 20

18 Dowel 2
19 Muffler 1
20 Bolt 8 M8 × 35 mm
9-21
Disassembling the oil pan and 3. Check the oil pan. Replace if corroded or
exhaust manifold cracked.
1. Remove the muffler “1”, plate “2”, and
Checking the oil strainer
exhaust manifold “3”.
1
1. Check the oil strainer. Clean if there is
dirt or residue.
0
Assembling the oil pan and exhaust
3
manifold 1
1. Install the collars “1”, a new gasket “2”,
and the oil strainer “3”, and then tighten
the oil strainer bolts “4” to the specified
torque.
2
4
2 1
3
4
4
1
3
1
2 4
2. Remove the oil pan “1” and oil strainer
“2”.
5
1
Oil strainer bolt “4”:

6
2 12 N·m (1.2 kgf·m, 8.9 ft·lb)
2. Install the dowels “1”, a new gasket “2”,

and the oil pan “3”, and then tighten the
7
oil pan bolts “4” temporarily.
8
9
10
Checking the oil pan and exhaust
manifold
1. Clean the removed parts.
2. Check the exhaust guide, exhaust mani-

fold, and muffler. Replace if corroded or
cracked. A
9-22
3 Exhaust manifold bolt:

20 N·m (2.0 kgf·m, 14.8 ft·lb)
4 Oil pan bolt:
4
20 N·m (2.0 kgf·m, 14.8 ft·lb)
5. Install the rubber seal “1” and water pipe

4 “2”.
4
6. Install the dowels “3”, new gaskets “4”,
1 the plate “5”, and the muffler “6”.
7. Tighten the muffler bolts “7” to the speci-

fied torque.
2
7 7
3. Install a new gasket “1”, the exhaust 5

manifold “2”, the rubber seal “3”, and 6
then tighten the exhaust manifold bolts 1
“4” temporarily. 4
3
3 2
TIP:
Make sure that the sealant “a” side of the
gasket “1” is facing toward the exhaust mani-
fold.
2
4 Muffler bolt “7”:
4 20 N·m (2.0 kgf·m, 14.8 ft·lb)
1 a
4. Tighten the exhaust manifold bolts first,

and then tighten the oil pan bolts to the
specified torques.
9-23
Steering arm
Steering arm
0
1
1
2 2
3
3
3
4
4
5
2
8
5
6
7
6

1 Steering arm 1
2 Washer 2
3
4
Bushing
O-ring
2
1 Not reusable
8
5 Bushing 1
6
7
Steering yoke
Circlip
1
1 9
8 Grommet 1
10
A
9-24
Steering arm
Removing the steering arm
1. Remove the circlip “1”, and then remove 3
the steering yoke “2” by striking it using a
copper hammer.
1
2. Install the bushing “1”, a new O-ring “2”,

the bushing “3”, and the washer “4”.
2 1
1
2. Remove the washer “1”, bushing “2”,

O-ring “3”, and bushing “4”.
1
2
3
4
4
3
2
1 3. Install the steering yoke “1” so that it
faces the same direction as the steering
arm “2” (aligning “a” with “b”).
3. Remove the steering arm from the swivel

bracket.
Installing the steering arm

1. Install the washer “1” and bushing “2”
onto the steering arm “3”, and then install
the steering arm “3”.
9-25
Steering arm
a 1
0
1
2
a
2
1
a
3
4. Hold the steering arm “1”, and then strike
the steering yoke “2” using a copper 4
hammer until the groove “a” for installing
the circlip is visible.
5. Install the circlip “3”.

5
1
6
7
a
3 8
2 3
6. Inject grease into the grease nipple “1”

9
until grease comes out from both the
upper and lower bushings “a”.
10
A
9-26
Clamp bracket and swivel bracket
3 N·m (0.3 kgf·m, 2.2 ft·lb)
15 N·m (1.5 kgf·m, 11.1 ft·lb)
1
7
8 33 8
32
9
3 5
4 3
3
2 48 N·m (4.8 kgf·m, 35.4 ft·lb)
11
10
3 19
13
18
10
26 11
26 3 34
27 3 6 12
28 25 14
27
24 16
36
35 17
29
4 N·m (0.4 kgf·m, 3.0 ft·lb) 20
30 27 28 27 15
31 26 26 21
21 23
22 22

2 Clamp bracket (STBD) 1
3 Grease nipple 6
4 Ground lead 1
6 Ground lead 1
7 Tilt stop lever 1
8 Bushing 2
9 Tilt stop lever 1
10 Bushing 2
11 Washer 2
12 Clamp bracket (PORT) 1
13 Through tube 1
14 Bolt 1 M8 × 20 mm
15 Plastic tie 1
16 Swivel bracket 1
17 Trim stopper 2
9-27
3 N·m (0.3 kgf·m, 2.2 ft·lb)

15 N·m (1.5 kgf·m, 11.1 ft·lb)
1
7
8 33 8
0
32
9
3
4
5
3
1
3
2 48 N·m (4.8 kgf·m, 35.4 ft·lb)
11
10 2
3 19
13
18
10
26
26 3 34
11
3
27 3 6 12
28 25 14
27
24 16
4
36
35 17
29
30
4 N·m (0.4 kgf·m, 3.0 ft·lb) 20 5
31 27 28 27 15
26 26 21
21 23 6
22 22

18 Washer 2
19 Nut 2
20
21
Anode
Plate
1
2
8
22 Bolt 4 M6 × 30 mm
23
24
Ground lead
Bushing
1
2 9
25 Collar 1
26 Pin 2
27
28
Distance collar
Pin
2
1
10
29 Spring 1
30 Hook 1
31 Bolt 1 M6 × 10 mm
32 Screw 1 M5 × 35 mm
33 Trim sensor cam 1
34 Clamp 1
A
9-28
3 N·m (0.3 kgf·m, 2.2 ft·lb)

15 N·m (1.5 kgf·m, 11.1 ft·lb)
1
7
8 33 8
32
9
3 5
4 3
3
2 48 N·m (4.8 kgf·m, 35.4 ft·lb)
11
10
3 19
13
18
10
26 11
26 3 34
27 3 6 12
28 25 14
27
24 16
36
35 17
29
4 N·m (0.4 kgf·m, 3.0 ft·lb) 20
30 27 28 27 15
31 26 26 21
21 23
22 22

35 Screw 2 M6 × 15 mm
36 Trim sensor 1
9-29
Removing the clamp bracket
1. Remove the PTT unit. See “Removing
the PTT unit” (9-34).
2. Remove the plastic tie “1”. 1 0

1
9. Remove the spring “1”, hook “2”, and
1
pins “3”. 2
3. Remove the anode “1” and ground lead
“2”. 3 3
3
1
2
4. Remove the trim sensor cam “3”.
5. Remove the ground leads “4” and “5”.

4
6. Remove the bolt “6” and self-locking nut
“7”. 10. Remove the tilt stop levers “1” and “2”,
distance collar assembly “3”, collar “4”,
5
7. Remove the through tube “8”, and then and bushings “5” and “6”.
disassemble the clamp brackets “9” and
“10”.
1
6
6
4
3
6
7
7 2
5 5
4
5 8
3
9
6 Checking the clamp bracket anode
1
9 1. Check the anode. Replace if eroded.
Clean if there is grease, oil, or scales.
10
8
10
2
Do not apply grease, oil, or paint to the
8. Remove the trim sensor “1”. anode.
Installing the clamp bracket

1. Assemble the distance collar assembly.
A
9-30
4. Install the trim sensor “1”, and then
tighten the trim sensor screw “2” to the
specified torque.
a
Distance “a”: 2
30.3–30.6 mm (1.19–1.20 in)
2. Install the bushings “1” and “2”, collar “3”, Trim sensor screw “2”:
distance collar assembly “4”, and tilt stop 4 N·m (0.4 kgf·m, 3.0 ft·lb)
levers “5” and “6”.
5. Install the bushing “1”, through tube “2”
and temporarily tighten the self-locking
nut “3”.
5 6. Install the anode “4” and ground lead “5”.
2
4 7. Tighten the self-locking nut “3” to the
1 3 2
specified torque.
6
1
8. Install the ground leads “6” and “7”.
9. Install the trim sensor cam “8”.
10. Install the grease nipples “9”, and then

tighten them to the specified torque.
3. Install the pins “1”, hook “2”, and spring
“3”. 9
9 6
1 1 1
9
a 3
7
9 1
8 9
9
3
1
4
2 2
Distance “a”: 3.0 mm (0.12 in) 5
9-31
Self-locking nut “3”:

15 N·m (1.5 kgf·m, 11.1 ft·lb)
Grease nipple “9”: c d
3 N·m (0.3 kgf·m, 2.2 ft·lb)
a
d
0
11. Inject grease into the grease nipples until
grease comes out from the bushings “a”.
1 b
c
1
Digital circuit tester: 90890-03189
Trim sensor setting resistance:

2
9.0–11.0 Ω
4. Tighten the trim sensor cam screw.

3
a
5. Check that the trim sensor setting resis-
tance is within specification. 4
5
12. Install the PTT unit. See “Installing the
PTT unit” (9-39). 6
Adjusting the trim sensor cam
1. Fully tilt the swivel bracket down.
7
2. Loosen the trim sensor cam screw “1”.
3. Measure the trim sensor setting resis-

tance. Adjust if out of specification. 8
TIP:
• To decrease the resistance, turn the trim
sensor cam in direction “a”.
9
• To increase the resistance, turn the trim
sensor cam in direction “b”.
10
A
9-32
PTT unit
PTT unit
2
10 3
7
1
4
8
9
3
8
3
7
5
6
39 N·m (3.9 kgf·m, 28.8 ft·lb)

1 Upper mounting shaft 1
2 Circlip 1
3 Bushing 6
4 PTT unit 1
5 Ground lead 1
6 Bolt 1 M6 × 10 mm
7 Bolt 2 M10 × 30 mm
8 Washer 2
9 Lower mounting shaft 1
10 Plastic tie 3
9-33
PTT unit
Removing the PTT unit
1
When removing the PTT unit with the

power unit installed, make sure to sus- 0
pend the outboard motor.
2
1. Fully tilt the swivel bracket up, and then
support it using the tilt stop lever “1”.
1
5. Connect the battery jumper leads to the
PTT motor lead “1” to fully retract the
PTT rams.
2
1
1
G L 3
2. Remove the plastic ties “1”, and then pull

4
out the PTT motor lead from the clamp
bracket (PORT).
Ram PTT motor lead Battery

5
1 Green (G) (+)
Retract
Blue (L) (–)
6
6. Remove the lower mounting shaft “1”,
and then remove the PTT unit “2”.
1 1 7
3. Disconnect the ground lead “1”.
8
9
1 2 10
1
4. Remove the circlip “1” and upper mount-

ing shaft “2”.
A
9-34
PTT unit
Checking the hydraulic pressure 4. If the fluid is below the proper level, add
Check the hydraulic pressure. Check the the recommended fluid.
internal parts if out of specification. Recommended PTT fluid: ATF Dexron II
1. Place the PTT unit in an upright position. 5. Install the reservoir cap, and then tighten
it to the specified torque.
PTT motor lead “1” to fully extend the Reservoir cap:
PTT rams. 7 N·m (0.7 kgf·m, 5.2 ft·lb)
6. Remove the main valve “1”.

1
L G
Be careful when removing the main valve.

Fluid could be expelled forcefully from the
PTT unit due to internal pressure.

Blue (L) (+)
Extend 1
Green (G) (–)
3. Remove the reservoir cap “1”, and then

check the fluid level in the reservoir.
7. Install the special service tools “1” and

Before removing the reservoir cap “1”, “2”.
make sure that the PTT rams are fully
extended. Otherwise, fluid could be TIP:
expelled forcefully from the PTT unit due Install the special service tools quickly before
to internal pressure. any fluid flows out of the hole.
TIP:
If the fluid is at the proper level, a small
amount of fluid should flow out of the filler 1 2
hole.
PTT hydraulic gauge adapter “1”:

90890-06863
1 Hydraulic pressure gauge “2”:
90890-06776/06800
9-35
PTT unit
8. Connect the battery jumper leads to the 11. Install the main valve “1”, and then
PTT motor lead “1” to fully retract the tighten it to the specified torque.
PTT rams.
G L
1
TIP:
Install the main valve “1” quickly before any 0
fluid flows out of the hole.
1
1 2
Retract
Green (G)
Blue (L)
(+)
(–)
3
Main valve “1”:
9. Reverse the connection between battery 11 N·m (1.1 kgf·m, 8.1 ft·lb)
jumper leads and the PTT motor lead “1”
to fully extend the PTT rams, and then 12. Remove the main valve “1” from the
4
measure the hydraulic pressure when the opposite side.
reading on the pressure gauge stabilizes.
Be careful when removing the main valve.

5
1
L G Fluid could be expelled forcefully from the
PTT unit due to internal pressure.
6
7
1
Hydraulic pressure (up):
11.20–13.20 MPa
(112.0–132.0 kgf/cm2,
8
1624.0–1914.0 psi)
Ram PTT motor lead Battery 13. Install the special service tools “1” and
“2”.
9
Blue (L) (+)
Extend
Green (G) (–)
TIP:
10. Remove the special service tools.
Install the special service tools quickly before 10
any fluid flows out of the hole.
Be careful when removing the special ser-

vice tool. Fluid could be expelled force-
fully from the PTT unit due to internal
pressure.
A
9-36
PTT unit
1
L G
2 1
PTT hydraulic gauge adapter “1”: Ram PTT motor lead Battery
90890-06863 Blue (L) (+)
Hydraulic pressure gauge “2”: Extend
Green (G) (–)
90890-06776/06800
17. Remove the special service tools.
14. Repeat steps 2–4 to check the fluid level.

PTT motor lead “1” to fully retract the Be careful when removing the special ser-
PTT rams, and then measure the hydrau- vice tool. Fluid could be expelled force-
lic pressure when the reading on the fully from the PTT unit due to internal
pressure gauge stabilizes. pressure.
18. Install the main valve “1”, and then

1
G L tighten it to the specified torque.
TIP:
Install the main valve “1” quickly before any
fluid flows out of the hole.
Hydraulic pressure (down):

5.85–8.85 MPa
(58.5–88.5 kgf/cm2, 1
848.3–1283.3 psi)

Green (G) (+)
Retract
Blue (L) (–) Main valve “1”:
11 N·m (1.1 kgf·m, 8.1 ft·lb)
16. Reverse the connection between battery
jumper leads and the PTT motor lead “1” 19. Repeat steps 2–4 to check the fluid level.
to fully extend the PTT rams.
Bleeding the PTT unit
1. Place the PTT unit in an upright position.
2. Turn the manual valve “1” clockwise to

close it.
9-37
PTT unit
1
L G
1
0
1
Manual valve “1”: Ram PTT motor lead Battery
3 N·m (0.3 kgf·m, 2.2 ft·lb)
Extend
Blue (L) (+) 2
3. Check the fluid level. See steps 2–4 in Green (G) (–)
“Checking the hydraulic pressure” (9-35).

6. Repeat steps 4 and 5 to fully extend and
retract the PTT rams 4 or 5 times. 3
PTT motor lead “1” to fully retract the
7. Fully extend the tilt ram.
PTT rams.
8. Remove the reservoir cap, and then 4
TIP: check the fluid level in the reservoir.
If the PTT rams do not move down easily,
push on the PTT rams to assist operation.
Before removing the reservoir cap, make
5
sure that the PTT rams are fully extended.
1
G L Otherwise, fluid could be expelled force-
fully from the PTT unit due to internal
pressure.
6
TIP:
If the fluid is below the proper level, add the
7
recommended PTT fluid. Repeat steps 3–7
until the fluid remains at the proper level.
Ram PTT motor lead
Green (G)
Battery
(+)
8
Retract 9. Install a new O-ring and the reservoir
Blue (L) (–) cap, and then tighten the reservoir cap to
5. Reverse the connection between battery

Reservoir cap:
9
jumper leads and the PTT motor lead “1”
to fully extend the PTT rams. 7 N·m (0.7 kgf·m, 5.2 ft·lb)
TIP:
10
If the PTT rams do not move down easily, pull
on the PTT rams to assist operation.
A
9-38
PTT unit
Installing the PTT unit
• After tilting the swivel bracket up, make

sure to support it using the tilt stop
lever.
• When installing the PTT unit with the 4
pend the outboard motor.
1 1
PTT motor lead “1” to retract the PTT 3 2
rams. 4
1 1
G L
1
Lower mounting shaft bolt “4”:
39 N·m (3.9 kgf·m, 28.8 ft·lb)
4. Pass the PTT motor lead “1” through the

hole “a” in the clamp bracket (PORT).
Ram PTT motor lead Battery 5. Connect the battery jumper leads to the
Green (G) (+) PTT motor lead “1” to extend the PTT
Retract rams until the end of the tilt ram is
Blue (L) (–)
aligned with the mounting position hole.
2. Fully tilt the swivel bracket up, and then
support it using the tilt stop lever “1”. L 1
G

Blue (L) (+)
3. Install the bushings “1”, PTT unit “2”, and Extend
Green (G) (–)
lower mounting shaft “3”, and then
tighten the lower mounting shaft bolts “4” 6. Install the upper mounting shaft “1” and
to the specified torque. circlip “2”.
9-39
PTT unit
0
1
1
7. Install the ground lead “1”.
2
3
1
4
8. Fasten the PTT motor lead and trim sen-
sor lead using the plastic ties “1”. 5
1
6
1 1
7
8
9
10
A
9-40
PTT cylinder
PTT cylinder
160 N·m (16.0 kgf·m, 118.0 ft·lb)
150 N·m (15.0 kgf·m, 110.6 ft·lb) 19
65 N·m (6.5 kgf·m, 47.9 ft·lb) 18
160 N·m (16.0 kgf·m, 118.0 ft·lb)

1 19
18 17
16
2
3
17
4 16
13 14
5 15
6
7 12 14
8 13
15
8
8
8
9
11
10 20
21
7 N·m (0.7 kgf·m, 5.2 ft·lb)

1 Tilt ram 1
2 Dust seal 1 Not reusable
4 Tilt cylinder end screw 1
7 Pin 1
9 Washer 1
11 Tilt piston assembly 1
12 Tilt ram assembly 1
13 Trim ram assembly 2
14 Backup ring 2
17 Trim cylinder end screw 2
9-41
PTT cylinder
160 N·m (16.0 kgf·m, 118.0 ft·lb)

150 N·m (15.0 kgf·m, 110.6 ft·lb) 19
65 N·m (6.5 kgf·m, 47.9 ft·lb) 18
0
160 N·m (16.0 kgf·m, 118.0 ft·lb)
1 19
18 17
16
1
2
3
4
17
16
2
13 14
6
5 15
3
7 12 14
8 13
8
8
15
4
8
9
11
10 20 5
21
7 N·m (0.7 kgf·m, 5.2 ft·lb)

6

18 Dust seal 2 Not reusable
19 Circlip 2
20
21
Free piston
O-ring
1
1 Not reusable
8
9
10
A
9-42
PTT cylinder
Removing the tilt ram and trim ram Cylinder end screw wrench “2”:
90890-06591
Before removing the tilt cylinder end 4. Tighten the manual valve “1” to the spec-
screw, make sure that the PTT rams are ified torque.
fully extended. Otherwise, fluid could be
expelled forcefully from the PTT unit due
to internal pressure.
1
PTT motor lead “1” to fully extend the
PTT rams.
1
L G
Manual valve “1”:
3 N·m (0.3 kgf·m, 2.2 ft·lb)

PTT motor lead “1”, and then remove the
free piston “2”.

When removing the free piston, never
Blue (L) (+) look into the tilt cylinder opening. Other-
Extend
Green (G) (–) wise, fluid could be expelled forcefully
from the PTT unit due to internal pres-
2. Open the manual valve “1”. sure.
1 2
L G
1
3. Loosen the tilt cylinder end screw “1”,

and then remove the tilt ram assembly. PTT motor lead Battery
Blue (L) (+)
2 Green (G) (–)
6. Loosen the trim cylinder end screws “1”,

and then remove the trim ram assem-
blies.
9-43
PTT cylinder
Disassembling the trim ram
1. Remove the O-ring “1” and backup ring
“2”.
2 0
1
1
1
2
Trim & tilt wrench “2”: 90890-06587
Disassembling the tilt ram

2
1. Remove the tilt piston absorber valves Checking the tilt cylinder and trim
“1” and O-ring “2”.
1 1
cylinder
1. Check the PTT body. Replace if corroded 3
or cracked.
1
2 2. Check the inner surface of the PTT body.
Replace if scratched.
4
3. Check the outer surfaces of the tilt piston,
1
trim pistons, and free piston. Replace if
scratched.
5
4. Check the backup rings. Replace if dam-
aged or worn. 6
5. Check the trim rams and tilt ram. Clean
using 400–600-grit sandpaper if there is
2. Remove the tilt piston “1”.
rust or replace if bent or corroded. 7
Checking the absorber valve
2 1. Check the tilt piston absorber valves.
Clean if there is dirt or residue. 8
Assembling the tilt ram
1 9
When assembling the PTT unit, do not use
a rag. Otherwise, dust and particles could
3 get on the PTT unit components, causing
poor performance.
10
Power tilt wrench “2”: 90890-06560 1. Install a new dust seal “1” and new
PTT piston vice attachment “3”: O-rings “2” and “3” to the tilt cylinder end
90890-06572 screw “4”.
A
9-44
PTT cylinder
6. Install the plate “3”, washer “4”, and tilt
piston screw “5”, and then tighten the tilt
1 1 4 piston screw “5” to the specified torque.
2
5 2 2
3 2 4
1
3 2
4
3
2. Install the tilt cylinder end screw “1” and

tilt piston “2”. 2
Tilt piston screw “5”:

2 7 N·m (0.7 kgf·m, 5.2 ft·lb)
Assembling the trim ram
3. Tighten the tilt ram “1” to the specified

torque. When assembling the PTT unit, do not use
get on the PTT unit components, causing
poor performance.
1 1. Install the backup ring “1” and a new

2 O-ring “2” to the trim piston “3”.
1
3 2
1 3
3
Power tilt wrench “2”: 90890-06560
PTT piston vice attachment “3”:
90890-06572 2. Install a new dust seal “1”, the circlip “2”,
and a new O-ring “3” to the trim cylinder
Tilt ram “1”: end screw “4”, and then install the trim
65 N·m (6.5 kgf·m, 47.9 ft·lb) cylinder end screw “4” onto the trim ram
“5”.
5. Install the absorber valves “2”.
9-45
PTT cylinder
4. Install the trim ram assemblies, and then
2
4 tighten the trim cylinder end screws “1” to
1 2
5 4
1
3 0
2
3 1
Installing the trim ram
1. Install a new O-ring “1” to the free piston
“2”.
1 2
Trim & tilt wrench “2”: 90890-06587
1 Trim cylinder end screw “1”:

160 N·m (16.0 kgf·m, 118.0 ft·lb)
3
Installing the tilt ram
2 1. Place the tilt cylinder end screw “1” at the 4
bottom of the tilt ram.
2. Install the free piston “1” and push it

2. Fill the tilt cylinder and PTT body with the
recommended fluid up to the proper level 5
“a”.
down until it bottoms out.
1 1 6
1 a
7
8
3. Fill the trim cylinders with the recom- a
mended fluid up to the proper level “a”.
9
a
10
Recommended PTT fluid: ATF Dexron II
3. Install the tilt ram assembly, and then

tighten the tilt cylinder end screw “1” to
A
9-46
PTT cylinder
Cylinder end screw wrench “2”:

90890-06591
Tilt cylinder end screw “1”:

150 N·m (15.0 kgf·m, 110.6 ft·lb)
9-47
PTT motor
PTT motor
5
3 8 7 N·m (0.7 kgf·m, 5.2 ft·lb)
3 5
6
7 N·m (0.7 kgf·m, 5.2 ft·lb) 0
4
4
9
7
4 1
2 10 4
4
15
2
1 16
11
17
3
12
18
13 19
20
4
4
14
5
6

1 Armature 1
2 Stator 1
3
4
Screw
Bolt
3
6
M5 × 20 mm
M6 × 25 mm
8
6
7
Circuit breaker
Brush holder
1
1 9
8 Brush 1
9 Spring 2
10
11
O-ring
Motor base assembly
1
1
Not reusable
10
14 Joint 1
16 Reservoir cap 1
A
9-48
PTT motor
5
3 8 7 N·m (0.7 kgf·m, 5.2 ft·lb)
3 5
7 N·m (0.7 kgf·m, 5.2 ft·lb)
6 4
7 4
9 4
2 10 4
4
15
1 16
11
17
12
18
13 19
20
14
4

18 Circlip 1
19 Filter 1
9-49
PTT motor
Removing the reservoir
1. Remove the reservoir “1” and O-ring “2”.
Secure the end of the armature shaft
using a pair of pliers, and then remove the
TIP:
Place a container under the PTT unit to catch
armature along with the motor base
assembly. Otherwise, the armature could
0
the fluid.
separate from the motor base assembly
due to the magnetic force of the stator
1 and damage the brushes. 1
2. Remove the armature “2”.
1
2
3
2
2
4
2. Remove the circlip “1”, filter “2”, and 3. Remove the screws “1”, and then remove
O-ring “3”.
1
the brush “2”, plate “3”, circuit breaker
“4”, and springs “5”.
5
2
3 4 1
1
2 6
5 3
5
7
Removing the PTT motor
1. Remove the PTT motor assembly “1”, 8
O-ring “2”, and joint “3”.
4. Remove the oil seal “1”.

9
2
3
10
Disassembling the PTT motor

1. Remove the stator “1”. 1
A
9-50
PTT motor
Checking the armature (PTT motor)
1. Check the commutator. Clean using 600-
grit sandpaper and compressed air if
dirty. a
b d
c
Armature continuity:
Continuity:
“a”–“b”
No continuity:
2. Measure the commutator diameter “a”. “a”–“c”
Replace the armature if below specifica- “a”–“d”
tion.
Checking the brush
1. Measure the length of each brush.
Replace if below specification.
a b
a
Motor commutator standard diameter “a”:

22.0 mm (0.8661 in)
Motor brush standard length “a”:
3. Measure the commutator undercut “a”. 10.00 mm (0.3937 in)
Replace the armature if below specifica- Wear limit “b”: 3.5 mm (0.14 in)
tion.
2. Check the brush and circuit breaker for
continuity. Replace if there is no continu-
ity.
a
Do not damage the bimetal “1”. Other-

wise, the operation of the circuit breaker
could be affected.
Motor commutator standard undercut (ref-

erence data) “a”: 1.50 mm (0.0591 in)
4. Check the armature for continuity.

9-51
PTT motor
3
6 1
1
4
2
0
2
1
3. Check the PTT motor base. Replace the
PTT motor assembly if the base is
cracked or damaged.
5
2
Checking the reservoir 4. Push the brushes “1” and “2” into the
1. Check the reservoir. Replace if cracked
or damaged.
holders, and then install the armature “3”. 3
1 3
Assembling the PTT motor
4
Do not apply grease or oil to the commu-
tator of the armature. 5
2
1. Install a new oil seal “1”.
5. Install the stator “1”. 6

1
Secure the end of the armature shaft
using a pair of pliers, and then install the
7
armature along with the motor base
assembly. Otherwise, the armature could
1 separate from the motor base assembly
due to the magnetic force of the stator
8
2. Install a new O-ring “1”, the spring “2”, and damage the brushes.
and the circuit breaker “3”.
3. Install the plate “4” under the PTT motor 1

9
lead “5”, and then install the brush “6”.
10
A
9-52
PTT motor
Installing the PTT motor 3
2
1
poor performance.
1. Install the joint “1”.
2. Install a new O-ring “1” and the reservoir

“2”, and then tighten the reservoir mount-
Make sure that the deeper end of the
ing bolts “3” to the specified torque.
groove “a” is facing the PTT motor when
installing the joint “1”. 3. Install a new O-ring “4” to the reservoir
cap “5”, and then install the reservoir cap
1 “5”.
a 4. Tighten the reservoir cap “5” to the speci-

fied torque.
2
3
3
2. Install a new O-ring “1” and the PTT

motor assembly “2”, and then tighten the
PTT motor mounting bolts “3” to the
specified torque. 4
5
1
TIP:
Align the protrusion “a” on the armature shaft
with the slot “b” in the joint.
2 3 Reservoir mounting bolt “3”:

3 a 7 N·m (0.7 kgf·m, 5.2 ft·lb)
Reservoir cap “5”:
1 7 N·m (0.7 kgf·m, 5.2 ft·lb)
b
PTT motor mounting bolt “3”:

7 N·m (0.7 kgf·m, 5.2 ft·lb)
Installing the reservoir

1. Install a new O-ring “1”, the filter “2”, and
the circlip “3”.
9-53
PTT gear pump
PTT gear pump
7 N·m (0.7 kgf·m, 5.2 ft·lb)
3
1 1 4 4
1
9 5
4 N·m (0.4 kgf·m, 3.0 ft·lb)
0
10
6 13
11 12
7 22
8
28 28
1
14 21
2
30
20 15
26
21 44 2
15 29
19
18 16
19 17
27
33
34
35
3
4
22
37
23
21 44
33
32
31 36 38
39 5
34 36
35 40 41
7 N·m (0.7 kgf·m, 5.2 ft·lb)
4 N·m (0.4 kgf·m, 3.0 ft·lb)
25 24 11 N·m (1.1 kgf·m, 8.1 ft·lb)
42
6
3 N·m (0.3 kgf·m, 2.2 ft·lb) 43

1 Bolt 4 M5 × 25 mm
2 Plate 1
3
4
Wave washer
Valve lock screw
1
2
8
5 Spring 1
6
7
Valve support pin
O-ring
1
1 Not reusable 9
9 Spring 1
10
11
Valve pin
Valve seal
1
1 Not reusable
10
12 Pin 2
13 Filter 1
14 Backup ring 1
16 Valve seat 1
A
9-54
PTT gear pump
7 N·m (0.7 kgf·m, 5.2 ft·lb)

3
1 1 4 4
9 5
1 4 N·m (0.4 kgf·m, 3.0 ft·lb)
10
6 13
11 12
7 22
8
28 28
14 21
2
26 30
20 15 21 44
15 29
18 27 35
19 16 34
33
19 17
22
31 37
21 44 36 38
23 32 39
33 36
34
35 40 41
4 N·m (0.4 kgf·m, 3.0 ft·lb) 42
3 N·m (0.3 kgf·m, 2.2 ft·lb) 43

18 Spring 1
20 Spring 1
23 Bracket 1
24 Bolt 1 M4 × 25 mm
25 Bolt 1 M5 × 25 mm
26 Plug 1
28 Port plug 2
29 Spacer 1
30 Spacer 1
32 Shuttle piston 1
9-55
PTT gear pump
7 N·m (0.7 kgf·m, 5.2 ft·lb)

3
1 1 4 4
1
9 5
4 N·m (0.4 kgf·m, 3.0 ft·lb)
0
10
6 13
11 12
7 22
8
28 28
1
14 21
2
30
20 15
26
21 44 2
15 29
19
18 16
19 17
27
33
34
35
3
4
22
37
23
21 44
33
32
31 36 38
39 5
34 36
35 40 41
7 N·m (0.7 kgf·m, 5.2 ft·lb)
4 N·m (0.4 kgf·m, 3.0 ft·lb)
25 24 11 N·m (1.1 kgf·m, 8.1 ft·lb)
42
6
3 N·m (0.3 kgf·m, 2.2 ft·lb) 43

36 Manual valve seat 2
37
38
Spring
Adapter
1
1
8
39 Spring 1
40
41
O-ring
O-ring
1
1
Not reusable
Not reusable 9
42 Manual valve 1
43 Circlip 1
44 Main valve 2
10
A
9-56
PTT gear pump
Removing the gear pump assembly
1. Remove the plate “1”, filter “2”, backup
4
ring “3”, wave washer “4”, protection 3
valves “5” and “6”, and gear pump 2
assembly “7”. 1
1
6 9
8
2 5 7
6
3 5
4
4. Remove the main valves “1” and shuttle
piston “2”, and then remove the O-rings
7 “3”, “4”, “5”, and “6”.
Disassembling the gear pump

housing 3
4
1. Remove the O-rings “1” and “2”, spacers 5
“3” and “4”, and port plugs “5”.
2 1
1
1 3 5
5
4
6 1
2
4 3
Disassembling the gear pump

1. Remove the valve lock screws “1” and
2. Remove the plug “1” and ball “2”. “2”, and then remove the spring “3”, valve
support pin “4”, ball “5”, spring “6”, valve
1 pin “7”, and valve seal “8”.
2
TIP:
Before removing the valve lock screws “1”
and “2”, measure and write down the screw
height “a” and screw depth “b”.
3. Remove the circlip “1”, manual valve “2”,

O-rings “3” and “4”, manual valve seat
“5”, spring “6”, adapter “7”, spring “8”,
and manual valve seat “9”.
9-57
PTT gear pump
1 2
3 6
7 1
4
5 8 4 0
5
3
5 1
A B 2
a
b 2
1 4. Remove the valve seat “1” and O-ring “2”.
2
1
3
2
A. Up-relief valve
B. Down-relief valve 4
2. Remove the bracket “1” and O-rings “2”
and “3”.
5
Checking the gear pump
1. Check the drive gear and driven gear. 6
1 Replace the gear pump assembly if dam-
2 aged or worn.
3
2. Check the up-relief valve and down-relief 7
valve. Clean if there is dirt or residue.
Checking the gear pump housing

1. Check the PTT body. Replace if corroded
8
or cracked.
3. Remove the gear housing “1”, and then

remove the drive gear “2”, driven gear
Checking the valve seal
1. Check the main valves and the shuttle
9
“3”, balls “4”, and pins “5”. piston. Replace if damaged.
2. Check the manual valve, manual valve

seat, adapter, and springs. Replace if
10
damaged.
Checking the filter

1. Check the filters. Clean if there is dirt or
residue.
A
9-58
PTT gear pump
Assembling the gear pump
Lubricate the parts using ATF Dexron II dur- 4 5
ing assembly.
3
2 1
poor performance.
1. Install a new O-ring “1” and the valve

seat “2”.
2
1 Pump bracket bolt (M5) “4”:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
Pump bracket bolt (M4) “5”:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
4. Install a new valve seal “1”, the valve pin

“2”, and the spring “3”, and then install
the valve lock screw “4”.
2. Install the drive gear “1”, driven gear “2”, 5. Install a new O-ring “5” to the valve sup-
balls “3”, and pins “4”, and then install the port pin “6”.
gear housing “5”.
6. Install the ball “7”, valve support pin “6”,
and spring “8”, and then install the valve
lock screw “9”.
5
3 TIP:
• Install the valve lock screw “4” and valve
4 lock screw “9” to the height “a” and depth
2 “b” that were measured before removing
4
them.
• If installing new parts, install them accord-
1 ing to the preceding reference data.
3. Install new O-rings “1” and “2” and the

bracket “3”, and then tighten the pump
bracket bolts “4” and “5” to the specified
torque.
9-59
PTT gear pump
9 4
8 3
4
6 2
5 1 0
7
1
2 3
1
A B 4
5
a
b 6 2
3 2 1
9 Main valve “4”:

4
11 N·m (1.1 kgf·m, 8.1 ft·lb) 3
4. Install the manual valve seat “1”, spring
“2”, adapter “3”, spring “4”, and manual
A. Up-relief valve
B. Down-relief valve valve seat “5”. 4
Installation height “a” (reference data): 5. Install a new O-ring “6” to the manual
1.63–1.83 mm (0.064–0.072 in)
Installation depth “b” (reference data):
valve “7”, and then install a new O-ring
“8”, manual valve “7”, and circlip “9”. 5
1.77–2.27 mm (0.070–0.089 in)
6. Tighten the manual valve “7” to the spec-
Assembling the gear pump housing
Lubricate the parts using ATF Dexron II dur-
ified torque.
6
ing assembly.
8
6
When assembling the PTT unit, do not use 9

7 7
poor performance.
4
3
2
1
8
5
1. Install new O-rings “1”, “2”, and “3” to the
main valves “4”.
9
2. Install a new O-ring “5” to the shuttle pis-
ton “6”.
3. Install the shuttle piston “6” and main

Manual valve “7”:
3 N·m (0.3 kgf·m, 2.2 ft·lb)
10
valves “4”, and then tighten the main
valves “4” to the specified torque. 7. Install the ball “1” and plug “2”, and then
tighten the plug “2” to the specified
torque.
A
9-60
PTT gear pump
2 8
1 8
7
3
6 2
5
4
Plug “2”: 4 N·m (0.4 kgf·m, 3.0 ft·lb)

1
8. Install the spacers “1” and “2”, the port
plugs “3”, and new O-rings “4” and “5”.
5 Gear pump bolt “8”:
4
7 N·m (0.7 kgf·m, 5.2 ft·lb)
4 2 3
1
Installing the gear pump assembly

Lubricate the parts using ATF Dexron II dur-
ing assembly.

poor performance.
1. Install the gear pump assembly “1”, pro-

tection valves “2” and “3”, wave washer
“4”, backup ring “5”, filter “6”, and plate
“7”, and then tighten the gear pump bolt
9-61
PTT gear pump
— MEMO —
0
1
2
3
4
5
6
7
8
9
10
A
9-62
Maintenance 10
Outline .............................................................................. 10-1

Maintenance interval chart 1 ................................................... 10-1
Maintenance interval chart 2 ................................................... 10-3
Predelivery check ............................................................ 10-4

Checking the battery ............................................................... 10-4
Checking the cooling water pilot hole ...................................... 10-5
Checking the engine oil level ................................................... 10-5
Checking the main switch/stop switch/choke switch ............... 10-5
Checking the fuel line .............................................................. 10-6
Checking the gear oil level ...................................................... 10-6
Checking the shift link/shift cable and throttle link/
throttle cable/throttle pick-up timing ......................................... 10-6
Checking the outboard motor mounting height ....................... 10-6
Checking the power trim and tilt unit ....................................... 10-7
Checking the steering system ................................................. 10-7
Checking the throttle cable and shift cable .............................. 10-7
Test run ................................................................................... 10-7
Break-in ................................................................................... 10-8
After test run ............................................................................ 10-8
General periodic maintenance ....................................... 10-8

Checking the anode ................................................................ 10-8
Checking the battery ............................................................... 10-8
Checking the cooling water inlet .............................................. 10-8
Checking the cooling water pilot hole ...................................... 10-9
Checking the engine idle speed/noise ..................................... 10-9
Changing the engine oil ........................................................... 10-9
Checking the engine oil level ................................................. 10-10
Replacing the oil filter ............................................................ 10-10
Checking the exhaust guide/exhaust manifold ...................... 10-11
Checking the main switch/stop switch/choke switch ............. 10-11
Checking the fuel filter ........................................................... 10-11
Checking the fuel pump ......................................................... 10-11
Checking for fuel leakage/oil leakage .................................... 10-11
Changing the gear oil ............................................................ 10-11
Checking the gear oil level .................................................... 10-12
Greasing points ..................................................................... 10-12
Checking the PCV ................................................................. 10-14
Checking the propeller/propeller nut/cotter pin ...................... 10-14
Checking the PTT fluid level .................................................. 10-14
Checking the power trim and tilt unit operation ..................... 10-14
Maintenance
Adjusting the shift link/shift cable .......................................... 10-15

Checking the spark plug ........................................................ 10-15
Checking the timing belt ........................................................ 10-15
0
Replacing the timing belt ....................................................... 10-15
Checking the thermostat ....................................................... 10-15
Adjusting the throttle link/throttle cable/
1
throttle pick-up timing ............................................................ 10-15
Checking the cowling lock lever ............................................ 10-15
Checking the valve clearance ............................................... 10-15 2
Checking the impeller/water pump housing .......................... 10-15
3
4
5
6
7
8
9
10
A
Outline
Outline
• To obtain long product life, Yamaha strongly recommends that the specified periodic checks and
maintenance be performed according to the maintenance interval charts.
• If replacement parts are necessary, use only genuine Yamaha parts of equivalent design and 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

The “F” symbol indicates the check-ups which the owners or operators may carry out themselves.
The “U” symbol indicates work to be carried out by a Yamaha dealer.
Initial Every
Item Actions 20 hours 100 hours 300 hours 500 hours
(3 months) (1 year) (3 years) (5 years)
Anode(s) (external) Inspection or replacement
F/U
as necessary
Anode(s) (cylinder head, Inspection or replacement
U
thermostat cover) as necessary
Anodes (exhaust cover, Replacement
cooling water passage
U
cover, Rectifier Regulator
cover)
Battery (electrolyte level, Inspection
F/U F/U
terminal)
Battery (electrolyte level,Fill, charging or replacing
U
terminal) as necessary
Cooling water leakage Inspection or replacement
U U
as necessary
Cowling lock lever Inspection F/U
Engine starting condition/ Inspection
F/U F/U
noise
Engine idle speed/noise Inspection F/U F/U
10-1
Outline
Initial Every
Engine oil
Engine oil filter (cartridge)
Replacement
Replacement
F/U F/U
F/U 0
Fuel filter (can be Inspection or replacement
F/U F/U
disassembled) as necessary
Fuel line (High pressure)
Fuel line (High pressure)
Inspection
Inspection or replacement
F F 1
U U
as necessary
Fuel line (Low pressure)
Fuel line (Low pressure)
Inspection
F
U
F
U
2
as necessary
Fuel pump Inspection or replacement
Fuel/engine oil leakage

as necessary
Inspection U U
U
3
Gear oil Replacement F/U F/U
Greasing points
Impeller/water pump
Greasing
F/U F/U
4
U
housing as necessary
Impeller/water pump Replacement
housing
U
5
Power trim and tilt unit Inspection F/U F/U
Propeller/propeller nut/ Inspection or replacement
F/U F/U
cotter pin
PCV (Pressure Control
as necessary
6
U
Valve) as necessary
Shift link/shift cable Inspection, adjustment or
replacement as
necessary
U U 7
Spark plug(s) Inspection or replacement
F/U
Spark plug caps/spark

as necessary
U U
8
plug wires as necessary
Water from the cooling Inspection
water pilot hole
Throttle link/throttle cable/ Inspection, adjustment or
F/U F/U
9
throttle pick-up timing replacement as U U
Thermostat
necessary
U
10
as necessary
Timing belt Inspection or replacement
U
as necessary
Valve clearance Inspection and
U
replacement
F/U F/U
Cooling water inlet Inspection
A
10-2
Outline
Initial Every
Main switch/stop switch/ Inspection or replacement
U U
choke switch as necessary
Wire harness Inspection or replacement
connections/wire coupler as necessary U U
connections
(Yamaha) Meter/gauge Inspection U U
Maintenance interval chart 2

Every
Item Actions
1000 hours
Exhaust guide/exhaust Inspection or replacement
U
manifold as necessary
Timing belt Replacement U
10-3
Predelivery check
Predelivery check
To make the delivery process smooth and
efficient, complete the predelivery checks as
a
explained in the following procedures.
0
Checking the battery
Battery electrolyte is dangerous; it con-

1
tains sulfuric acid, which is poisonous
and highly caustic. Always follow these 2. Check the specific gravity of the electro-
preventive measures:
• Avoid bodily contact with electrolyte as
lyte. Fully charge the battery if below
specification.
2
it can cause severe burns or permanent
eye injury.
• Wear protective eye gear when handling
TIP:
• Batteries vary depending on the manufac- 3
or working near batteries. turer. The procedures mentioned in this
Antidote (EXTERNAL): manual may not always apply. Therefore,
• SKIN - Wash with water.
• EYES - Flush with water for 15 minutes
see the instruction manual of the battery.
• Disconnect the negative battery cable first,
4
and get immediate medical attention. and then disconnect the positive battery
Antidote (INTERNAL): cable.
• Drink large quantities of water or milk
followed with milk of magnesia, beaten Representative examples:
5
egg, or vegetable oil. Get immediate Recommended battery capacity:
medical attention. CCA/EN: 711.0 Amps
Batteries generate explosive, hydrogen
gas. Always follow these preventive mea-
20HR/IEC: 100.0 Ah
Electrolyte specific gravity:
6
sures: 1.280 at 20 °C (68 °F)
• Charge batteries in a well-ventilated
area. 7
• Keep batteries away from fire, sparks, or
open flames (for example, welding
equipment and lighted cigarettes).
• DO NOT SMOKE when charging or han-
8
dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN. 9
1. Check the battery electrolyte level. If the
level is at or below the minimum level
mark “a”, add distilled water until the level 10
is between the maximum and minimum
level marks.
A
10-4
Predelivery check
Checking the cooling water pilot hole
1. Start the engine, and then check that
cooling water is discharged from the 1
cooling water pilot hole.
a
Checking the main switch/stop

switch/choke switch
1. Check that the engine starts when the
engine start switch is turned to START.
Checking the engine oil level
1. Place the outboard motor in an upright 2. Check that the engine stops when the
position. engine start switch is turned to OFF.
A 2. ON
1. OFF 3. START
If the outboard motor is not level, the oil
level indicated on the dipstick may not be
correct.
2. Start the engine and warm it up for 5–10

minutes.
3. Stop the engine and leave it off for 5–10

minutes. B 2. ON
1. OFF 3. START
4. Remove the top cowling.
5. Remove the dipstick “1” and wipe it

clean.
6. Insert the dipstick “1” completely for a

correct measurement and remove it
again.
1. OFF
7. Check that the oil level indicated on the 2. ON
dipstick “1” is between the upper mark “a” 3. START
and the lower mark “b”. If the engine oil is
not at the proper level, add or extract A. 703 remote control model
engine oil. B. 704 remote control model
3. Check that the engine stops when the

clip is removed from the engine shut-off
switch.
10-5
Predelivery check
A
2
1
0
1
B 3. Install a new gasket and the check screw,
and then tighten the check screw to the
specified torque.
2
Check screw:
9 N·m (0.9 kgf·m, 6.6 ft·lb)
3
Checking the shift link/shift cable
and throttle link/throttle cable/
throttle pick-up timing 4
A. 703 remote control model
B. 704 remote control model
Checking the fuel line

Do not overtighten the friction adjuster. If
there is too much resistance, it could be 5
1. Check that the fuel hoses are connected difficult to operate the remote control
securely. See “Fuel hose” (6-1). lever, which could result in an accident.
1. Check that the gear shift operates

6
This outboard motor is equipped with a 4- smoothly when the remote control lever
stroke engine. Never use premixed fuel or is moved from the N position to the F or R
2-stroke outboard motor oil. position. 7
2. Check that the throttle operates smoothly
Checking the gear oil level
1. Place the outboard motor in an upright
position.
when the remote control lever is moved
from the F or R position to the fully open 8
position.
2. Remove the check screw “1” and gasket
“2”, and then check the gear oil level. Checking the outboard motor
mounting height
9
1. Check that the anti-cavitation plate “1” is
TIP:
aligned with the bottom of the boat “2”. If
If the oil is at the proper level, a small amount
of oil should flow out of the check hole. the mounting height is too high, cavita-
tion will occur and propulsion will
10
decrease. Besides, the engine speed will
increase abnormally and cause the
engine to overheat. If the mounting
height is too low, water resistance will
increase, which will decrease engine effi-
ciency and performance.
A
10-6
Predelivery check
2. Check that the mark “a” on the bushing
TIP: “1” and the mark “b” on the plate “2” are
The appropriate mounting height depends on aligned.
the combination of the boat and outboard
motor. To determine the appropriate mount-
ing height, test run the outboard motor at dif-
ferent heights.
1
a
b
2
1
3. Check that the throttle lever 2 “1” con-
tacts the stopper “2” on the cylinder
2 block.
2. Check that the clamp brackets are

secured using the clamp bolts.
Checking the power trim and tilt unit

1. Check that the outboard motor tilts up 1
and down smoothly when the PTT switch
is pushed.
2
2. Check that there is no abnormal noise
produced when the outboard motor is Test run
tilted up or down. 1. Start the engine, and then check that the
gear shift operates smoothly.
3. Check that there is no interference with
cables, hoses, leads, or the boat when 2. Warm up the engine, and then check the
the tilted-up outboard motor is steered. engine idle speed.
4. Check that the trim meter points down 3. Operate the boat at trolling speed.
when the outboard motor is fully tilted
down. 4. Operate the outboard motor according to
the break-in procedure.
Checking the steering system
1. Check that the steering operates 5. Check that the outboard motor does not
smoothly. tilt up when the remote control lever is
moved to the R position and that water
2. Check that there is no interference with does not flow in over the transom.
cables, hoses, or lead when the outboard
motor is steered. 6. Check that the PTT operates smoothly
while the outboard motor is running.
Checking the throttle cable and shift
cable TIP:
1. Move the remote control lever to the N The test run is part of the break-in operation.
position and turn the throttle lever to the
fully closed position.
10-7
General periodic maintenance
Break-in
Operate the engine under load (in gear with a
propeller installed) for 10 hours as follows: When flushing the cooling water pas-
sages, do not start the engine. Otherwise,
1. For the first hour “a” of operation:
Operate the engine at varying speeds up
the water pump could be damaged and
the engine could be severely damaged
0
to 2000 r/min or approximately 1/2 throt- due to overheating.
tle.
TIP:
1
2. For the second hour “b” of operation:
When using the flushing device (flushing
Increase the engine speed until the boat
hose joint adapter), flush the cooling water
is on plane (but do not fully open the
throttle), and then back off on the throttle
passages without starting the engine. 2
while keeping the boat at a planing
speed. General periodic maintenance
3. For the remaining 8 hours “c” of opera-

Checking the anode 3
tion:
Operate the engine at any engine speed. Do not apply grease, oil, or paint to the
However, do not operate the engine at
full throttle for more than 5 minutes at a
anodes or the trim tab. 4
time.
1. Check the anodes and trim tab. See
4. After the first 10 hours of operation:
Operate the engine normally.
“Checking the cylinder head and cylinder
block anode” (7-45), “Checking the
5
exhaust cover anode” (7-50), “Checking
the lower unit anode” (8-3), and “Check-
ing the clamp bracket anode” (9-30). 6
a b c
TIP:
A 0 1 2 10
Replace the anodes or trim tab if eroded.
Also, check the ground lead. 7
Checking the battery
A. Hour
1. Check the battery. See “Checking the
battery” (10-4).
8
After test run Checking the cooling water inlet
1. Check for water in the gear oil. 1. Remove the water inlet covers “1” and 9
“2”.
2. Check all the fuel lines for leakage.
3. Flush the cooling water passages using

2. Mark the trim tab “3” with an identification
mark “a”, and then remove the trim tab 10
fresh water. “3”.
3. Check the water inlet covers and water

inlets. Clean if clogged.
A
10-8
Checking the engine idle speed/

noise
1. Start the engine and warm it up for 5–10
minutes.
a 3
2. Check the engine idle speed using the
Yamaha genuine tachometer (on-board
meter) or the YDIS. See the YDIS (Ver.
2.00 or later) instruction manual.
4. Install the water inlet covers and trim tab, Changing the engine oil
and then tighten the water inlet cover The engine oil should be extracted using an
screw and trim tab bolt to the specified oil changer.
torque.
TIP: Change the engine oil after the first 20

After installing the water inlet covers, make hours of operation or 3 months, and every
sure that there is no rattling. 100 hours or at 1-year intervals thereafter.
Water inlet cover screw: 1. Place the outboard motor in an upright

1 N·m (0.1 kgf·m, 0.7 ft·lb) position.
Trim tab bolt:
43 N·m (4.3 kgf·m, 31.7 ft·lb)
Checking the cooling water pilot hole If the outboard motor is not level, the oil
1. Place the lower unit in water, and then level indicated on the dipstick may not be
start the engine. correct.
2. Check that cooling water is discharged 2. Start the engine and warm it up for 5–10
from the cooling water pilot hole. If there minutes.
is no water flow, check the cooling water
passages inside the outboard motor. 3. Stop the engine and leave it off for 5–10
minutes.
4. Remove the oil filler cap “1”.
10-9
8. Remove the dipstick “1” and wipe it
clean.
1 9. Insert the dipstick “1” completely for a

correct measurement and remove it
again.
0
10. Check that the oil level indicated on the
dipstick “1” is between the upper mark “a”
and the lower mark “b”.
1
5. Remove the dipstick “1” and extract the
engine oil using the oil changer “2”.
1 2
1 a
3
b
11. Start the engine and check that the oil

4
pressure alert indicator does not come
2 on. Also, check that there is no oil leak-
age. 5
6. Fill the engine with the specified amount If the oil pressure alert indicator comes
on or if there is oil leakage, stop the
6
of the recommended engine oil through
the oil filler hole. Install the oil filler cap engine and find the cause. Continued
operation with a problem could cause
and dipstick.
severe engine damage. 7
Do not overfill the engine with engine oil. Checking the engine oil level
Otherwise, the engine could be damaged
or oil could leak. If the engine oil is above
1. Check the oil level. See “Checking the
engine oil level” (10-5).
8
the upper level, extract the excess engine
oil until the oil is at the proper level. Replacing the oil filter
Recommended engine oil:

1. Extract the engine oil using an oil
changer. See steps 1–5 in “Changing the
9
4-stroke motor oil with combination of the engine oil” (10-9).
following SAE and API oil classifications:
API: SE, SF, SG, SH, SJ, SL 2. Place a rag under the oil filter, and then
remove the oil filter.
10
SAE: 5W-30, 10W-30, 10W-40
Replacement engine oil quantity:
Without oil filter replacement: TIP:
4.3 L (4.55 US qt, 3.78 lmp qt) Make sure to clean up any oil spills.
7. Leave the outboard motor off for 5–10

minutes.
A
10-10
Checking the exhaust guide/exhaust
manifold
1 1. Check the exhaust guide and exhaust
manifold. See “Checking the oil pan and
exhaust manifold” (9-22).
Checking the main switch/stop

switch/choke switch
1. Check the engine start switch and engine
shut-off switch. See “Checking the main
Oil filter wrench “1”: 90890-06830 switch/stop switch/choke switch” (10-5).
3. Install a new oil filter “1”, and then tighten Checking the fuel filter
it to the specified torque. 1. Check the fuel filter. See “Checking the
fuel filter assembly” (6-8), “Checking the
fuel filter element” (6-9), and “Checking
the fuel cup assembly” (6-9).
Checking the fuel pump

1. Check the fuel pump. See “Checking the
fuel pump assembly” (6-13).
1 Checking for fuel leakage/oil leakage

1. Check the fuel joint and fuel hose con-
Oil filter “1”: nections. See “Fuel hose” (6-1).
18 N·m (1.8 kgf·m, 13.3 ft·lb)
2. Check for oil leakage.
4. Fill the engine with the specified amount
of the recommended engine oil through Changing the gear oil
the oil filler hole.
Recommended engine oil:
4-stroke motor oil with combination of the Never get under the lower unit while it is
following SAE and API oil classifications: tilted.
API: SE, SF, SG, SH, SJ, SL
SAE: 5W-30, 10W-30, 10W-40 1. Tilt the outboard motor so that the drain
Replacement engine oil quantity: screw is at the lowest point.
With oil filter replacement:
4.5 L (4.76 US qt, 3.96 lmp qt) 2. Place a drain pan “1” under the gear oil
drain hole.
5. Install the oil filler cap and dipstick, and
then start the engine and warm it up for 3. Remove the drain screw “2” and gasket
5–10 minutes. “3”.
6. Stop the engine, and then leave if off for

5–10 minutes. If there is a significant amount of metal
particles on the magnetic drain screw, the
7. Check the oil level.
lower unit may have a problem.
10-11
4. Remove the check screw “4” and gasket
Recommended gear oil:
“5” and let the oil drain completely.
Hypoid gear oil
API: GL-4
After the gear oil has been drained, check

SAE: 90
Oil quantity:
0
the used oil. If the oil is milky, water is get- Regular rotation model:
ting into the lower case, which can cause 0.980 L (1.036 US qt, 0.862 lmp qt)
gear damage. Counter rotation model:
0.870 L (0.920 US qt, 0.766 lmp qt)
1
8. Remove the gear oil pump, and then
5
4
install a new gasket “1” and the drain
screw “2”.
2
3
2
TIP:
Before installing the magnetic drain screw, 3
make sure to remove all metal particles.
1
9. Tighten the check screw “3” and drain
screw “2” to the specified torque.
4
5. Place the outboard motor in an upright
3
5
position.
1 2
6. Insert the gear oil pump into the drain
hole, and then fill the lower unit slowly 6
with gear oil until oil flows out of the
check hole and no air bubbles are visible.
7. Install a new gasket “1” and the check Drain screw “2”:
7
screw “2”. 9 N·m (0.9 kgf·m, 6.6 ft·lb)
1 Check screw “3”:
2
9 N·m (0.9 kgf·m, 6.6 ft·lb) 8
Checking the gear oil level
1. Check the gear oil level. See “Checking
the gear oil level” (10-6). 9
Greasing points
1. Apply water resistant grease to the spec-
ified lubrication points. 10
A
10-12
TIP:
Make sure to set the gear shift to the R posi-
tion before injecting grease into the grease
nipple on the shift rod.
A
A
2. Apply low temperature resistant grease

to the specified lubrication point.
3. Apply corrosion resistant grease to the

specified lubrication point.
10-13
Before removing the reservoir cap, make

sure that the PTT ram is fully extended.
Otherwise, fluid could be expelled force-
fully from the unit due to internal pres-
0
sure.
TIP:
1
If the fluid is at the proper level, a small
Checking the PCV amount of fluid should flow out of the filler
1. Check the PCV. See “Checking the PCV”
(7-50).
hole when the reservoir cap is removed. 2
Checking the propeller/propeller nut/
cotter pin 3
1. Check the propeller. See “Checking the
propeller” (8-3).
2. Check the propeller nut and cotter pin. 2 1

4
See “Installing the lower unit (L-transom
model)” (8-29).
Checking the PTT fluid level 3. If the fluid is below the proper level, add 5
the recommended fluid.
Never get under the outboard motor while
it is tilted. 4. Install a new O-ring and the reservoir
6
cap, and then tighten the reservoir cap to
1. Fully tilt the outboard motor up, and then
support it using the tilt stop lever “1”. Reservoir cap: 7
7 N·m (0.7 kgf·m, 5.2 ft·lb)
Checking the power trim and tilt unit

operation
8
1. Fully tilt the outboard motor up and down
1
a few times and check that the outboard
motor tilts up and down smoothly. Check
the PTT fluid level if the tilt operation is
9
not smooth.
2. Remove the reservoir cap “1” and O-ring TIP: 10

“2”, and then check the fluid level in the Make sure that the PTT motor makes a wind-
reservoir. ing sound when it is operating smoothly.
2. Fully tilt the outboard motor up, and then

support it using the tilt stop lever “1”.
Check that the tilt stop lever locks in
place properly. A
10-14
3. Check the PTT unit for fluid leakage. 2. Loosen the bolts “1”.
Adjusting the shift link/shift cable 3. Move the hook “2” up or down slightly to
1. Disconnect the shift cable, and then adjust its position.
adjust it. See “Installing the shift cable”
(3-9). TIP:
• To loosen the fitting, move the hook in
Checking the spark plug direction “a”.
1. Check the spark plugs. See “Checking • To tighten the fitting, move the hook in
the spark plug” (7-25). direction “b”.
Checking the timing belt

1. Check the timing belt. See “Checking the a
timing belt” (7-17).
Replacing the timing belt

1. Replace the timing belt. See “Timing belt” 2 1
(7-16).
Checking the thermostat b

1. Check the thermostat. See “Checking the
thermostat” (7-50). 4. Tighten the bolts.
Adjusting the throttle link/throttle 5. Recheck the fitting. Replace the cowling
seal if the free play cannot be adjusted.
cable/throttle pick-up timing
1. Adjust the throttle link rod. See “Adjusting
Checking the valve clearance
the throttle link” (6-27).
1. Check the valve clearance. See “Check-
2. Install the throttle cable. See “Installing ing the valve clearance” (7-1).
the throttle cable” (3-11).
Checking the impeller/water pump
Checking the cowling lock lever housing
1. Check the fitting by pushing the top cowl- 1. Check the water pump housing and
ing. Adjust if there is free play. impeller. See “Checking the water pump
and shift rod” (8-11).
10-15
Index i
Index
A. B.
Abbreviation ................................................0-5 Basic components ...................................... 4-1
Adjusting the forward gear shim Battery installation .................................... 3-22
thickness (T1) .........................................8-41 Battery wiring with house (accessory)
Adjusting the forward gear shim battery..................................................... 3-25
thickness (T2) .........................................8-74 Battery wiring without house (accessory)
Adjusting the reverse gear shim battery..................................................... 3-22
thickness (T1) .........................................8-76 Bleeding the PTT unit ............................... 9-37
Adjusting the reverse gear shim Blowby hose and cooling water hose ......... 6-4
thickness (T2) .........................................8-43 Bottom cowling .................................. 5-7, 9-11
Adjusting the shift link/shift cable ............10-15 Bracket unit............................................... 1-19
Adjusting the throttle link...........................6-27 Bracket unit technical data ....................... 1-16
Adjusting the throttle link/throttle cable/throttle Break-in .................................................... 10-8
pick-up timing........................................10-15
Adjusting the throttle valve reference opening C.
angle .......................................................6-27
Camshaft .................................................. 7-33
Adjusting the trim sensor cam...................9-32
Canister .................................................... 6-17
Adjusting the valve clearance .....................7-3
Changing the engine oil............................ 10-9
After test run .............................................10-8
Changing the gear oil ............................. 10-11
Air hose, pressure regulator hose, and vapor
Charging unit and component .................. 5-19
gas hose ...................................................6-2
Charging unit and starting unit (F150A, FL150A
Assembling the cylinder block...................7-75
[except for European and Oceanian markets]
Assembling the cylinder head ...................7-45
and F150B, FL150B) ................................A-8
Assembling the drive shaft
housing ..........................................8-23, 8-64
for European and Oceanian markets) ......A-6
Assembling the forward gear ....................8-23
Checking for fuel leakage/oil leakage..... 10-11
Assembling the fuel filter assembly.............6-9
Checking the absorber valve .................... 9-44
Assembling the fuel pump assembly ........6-14
Checking the air pressure sensor.... 5-24, 6-38
Assembling the gear pump .......................9-59
Checking the air temperature sensor ....... 5-23
Assembling the gear pump housing..........9-60
Checking the anode.................................. 10-8
Assembling the lower case ..............8-24, 8-63
Checking the armature (PTT motor)......... 9-51
Assembling the oil pan and
Checking the armature (starter motor) ..... 5-37
exhaust manifold.....................................9-22
Checking the battery........................ 10-4, 10-8
Assembling the oil pump..................7-54, 7-60
Checking the big end oil clearance........... 7-67
Assembling the propeller
Checking the brush................................... 9-51
(SDS propeller) ............... 8-4, 8-8, 8-47, 8-50
Checking the brush holder........................ 5-37
Checking the button cell battery ............... 5-31
assembly.................................................8-17
Checking the buzzer................................. 5-30
Assembling the propeller shaft housing
Checking the camshaft ............................. 7-35
assembly.................................................8-17
Checking the canister ............................... 6-18
Assembling the propeller shaft housing
Checking the clamp bracket anode .......... 9-30
assembly and forward gear.....................8-57
Checking the compression pressure .......... 7-1
Assembling the PTT motor .......................9-52
Checking the connecting rod big end side
Assembling the reverse gear ....................8-63
clearance ................................................ 7-66
Assembling the shift bracket .......................9-3
Checking the connecting rod small end inside
Assembling the starter motor ....................5-38
diameter and big end inside diameter .... 7-66
Assembling the tilt ram..............................9-44
Checking the cooling water inlet ............... 10-8
Assembling the trim ram ...........................9-45
Checking the cooling water pilot
Assembling the upper case.......................9-18
hole................................................ 10-5, 10-9
Assembling the vapor separator ...............6-44
Checking the cowling lock lever ............. 10-15
Assembling the water pump housing ........8-12
Checking the crankshaft ........................... 7-66
Assembling the water pump
Checking the cylinder bore ....................... 7-64
housing ...................................................8-53
i-1
Index
Checking the cylinder head.......................7-41 Checking the oil pan and
Checking the cylinder head and cylinder block exhaust manifold .................................... 9-22
anode ......................................................7-45 Checking the oil pressure ........................... 7-1
Checking the diaphragm and valve...........6-14 Checking the oil pressure sensor ............. 5-16
Checking the dog clutch...................8-16, 8-57
Checking the drive shaft ..................8-22, 8-63
Checking the oil pump ..................... 7-54, 7-60
Checking the oil strainer ........................... 9-22
0
Checking the drive shaft bushing..............9-18 Checking the outboard motor mounting
Checking the driven sprocket....................7-35 height...................................................... 10-6
Checking the electrical component ...........5-12
Checking the engine ECM circuit..............5-14
Checking the PCV ......................... 7-50, 10-14
Checking the pinion ......................... 8-22, 8-63
1
Checking the engine idle speed/noise ......10-9 Checking the piston diameter ................... 7-64
Checking the engine oil level .........10-5, 10-10 Checking the piston pin boss inside
Checking the engine shut-off switch .........5-27
Checking the engine start switch ..............5-28
diameter.................................................. 7-65
Checking the piston pin diameter ............. 7-66
2
Checking the engine temperature Checking the piston ring ........................... 7-64
sensor .....................................................5-24 Checking the piston ring end gap ............. 7-65
Checking the exhaust cover anode...........7-50
Checking the exhaust guide/
Checking the piston ring groove ............... 7-65
Checking the piston ring side clearance... 7-65
3
exhaust manifold...................................10-11 Checking the power trim and tilt unit ........ 10-7
Checking the filter .....................................9-58 Checking the power trim and
Checking the forward gear...............8-22, 8-57
Checking the fuel cup assembly .................6-9
tilt unit operation ................................... 10-14
Checking the pressure regulator ................ 6-5
5
Checking the fuel filter ............................10-11 Checking the primer pump ......................... 6-9
Checking the fuel filter assembly ................6-8 Checking the propeller.......8-3, 8-8, 8-47, 8-50
Checking the fuel filter element...................6-9
Checking the fuel injector..........................5-17
Checking the propeller shaft............ 8-16, 8-57
Checking the propeller shaft housing ....... 8-16
6
Checking the fuel line................................10-6 Checking the propeller shaft
Checking the fuel pump ..........................10-11 housing ................................................... 8-57
Checking the fuel pump assembly ............6-13
Checking the fuel rail and fuel injector ......6-32
Checking the propeller/propeller nut/
cotter pin............................................... 10-14
7
Checking the gear oil level.............10-6, 10-12 Checking the PTT fluid level................... 10-14
Checking the gear pump...........................9-58 Checking the PTT relay ............................ 5-41
Checking the gear pump housing .............9-58
Checking the PTT switch
(on bottom cowling) ................................ 5-42
8
pump ..............................................5-18, 6-43 Checking the pulser coil ........................... 5-22
Checking the hydraulic pressure...............9-35 Checking the Rectifier Regulator .............. 5-19
Checking the ignition coil ..........................5-21
Checking the ignition spark.......................5-21
Checking the reservoir.............................. 9-52
Checking the reverse gear .............. 8-16, 8-63
9
Checking the impeller/ Checking the shift cut-off switch ............... 5-26
water pump housing..............................10-15 Checking the shift link/shift cable and
Checking the intake manifold....................6-38
Checking the ISC valve.............................5-15
throttle link/throttle cable/
throttle pick-up timing ............................. 10-6
10
Checking the journal oil clearance ............7-71 Checking the shift position switch............. 5-26
Checking the lighting coil Checking the spark plug ................ 7-25, 10-15
(stator assembly) ....................................5-19
Checking the lower case..................8-23, 8-63
Checking the spark plug wire ................... 5-21
Checking the speed sensor (optional) ...... 5-40
10
Checking the lower unit Checking the starter motor pinion............. 5-35
anode .............................. 8-3, 8-8, 8-47, 8-50 Checking the starter relay......................... 5-27
Checking the lower unit for air Checking the steering system .................. 10-7
leakage ..........................................8-28, 8-65 Checking the synchronization of the throttle
Checking the main relay ...........................5-13 valve ....................................................... 6-29
Checking the main switch/stop switch/choke Checking the thermostat................ 7-50, 10-15
switch ...........................................10-5, 10-11 Checking the thermoswitch ...................... 5-25
A
i-2
Index
Checking the throttle cable and Disassembling the gear pump .................. 9-57
shift cable................................................10-7 Disassembling the gear pump housing .... 9-57
Checking the throttle link...........................6-23 Disassembling the lower case ......... 8-22, 8-62
Checking the tilt cylinder and Disassembling the oil pan and exhaust
trim cylinder.............................................9-44 manifold .................................................. 9-22
Checking the tilt limiter (optional)..............5-43 Disassembling the oil pump............. 7-54, 7-60
Checking the timing belt.................7-17, 10-15 Disassembling the propeller
Checking the TPS ............................5-15, 6-26 (SDS propeller)................8-3, 8-8, 8-47, 8-50
Checking the trim sensor ..........................5-42 Disassembling the propeller shaft
Checking the valve....................................7-41 assembly ................................................ 8-15
Checking the valve clearance ..........7-1, 10-15 Disassembling the propeller shaft housing
Checking the valve guide..........................7-42 assembly ....................................... 8-16, 8-56
Checking the valve lifter............................7-40 Disassembling the PTT motor .................. 9-50
Checking the valve seal ............................9-58 Disassembling the reverse gear ............... 8-62
Checking the valve seat............................7-43 Disassembling the shift bracket.................. 9-3
Checking the valve spring.........................7-41 Disassembling the starter motor ............... 5-35
Checking the vapor separator...................6-43 Disassembling the tilt ram ........................ 9-44
Checking the vapor shut-off valve.............5-18 Disassembling the trim ram ...................... 9-44
Checking the vapor Disassembling the upper case ................. 9-18
shut-off valve...........................................6-19 Disassembling the vapor separator .......... 6-43
Checking the water detection switch.........5-16 Disassembling the water pump housing... 8-11
Checking the water pressure sensor Disassembling the water pump
(optional) .................................................5-40 housing ................................................... 8-53
Checking the water pump and Disassembly and assembly ........................ 0-3
shift rod ..........................................8-11, 8-53 Draining the fuel ....................................... 6-37
Checking the Y-COP main wiring Drive shaft and lower case (counter rotation
harness ...................................................5-30 model)..................................................... 8-60
Checking Y-COP.......................................5-30 Drive shaft and lower case (regular rotation
Circuit diagram............................................5-9 model)..................................................... 8-19
Clamp bracket.............................................3-6
Clamp bracket and swivel bracket ............9-27 E.
Connecting the communication cable .........4-5
ECM circuit ................................................. 5-9
Control unit............................................... A-10
ECM coupler layout .................................. 5-11
Cooling diagram........................................2-16
Electric shock ............................................. 0-1
Cooling system .........................................2-16
Electrical component and wiring harness
Crankcase.................................................7-61
routing....................................................... 5-1
Crankpin bearing selection table...............7-70
Electrical system....................................... 1-17
Crankshaft journal bearing selection
Electrical technical data .............................. 1-7
table ........................................................7-74
Electronic control system............................ 2-1
Crate handling.............................................3-2
Engine control unit and component .......... 5-13
Crate top cover pictograph description .......3-2
Engine control unit and fuel unit .................A-2
Cylinder block (F150A, FL150A)...............7-52
Engine ECM component............................. 2-3
Cylinder block (F150B, FL150B)...............7-58
Engine speed control.................................. 2-5
Cylinder head............................................7-38
Exhaust cover........................................... 7-48
Extension length recommendation for battery
D. cable ....................................................... 3-37
Deactivating the tilt limiter .........................3-20 External dimensions ................................... 3-5
Disassembling the cylinder block..............7-63
Disassembling the cylinder head ..............7-40 F.
Fail-safe control .......................................... 2-6
housing ..........................................8-21, 8-62
Flywheel magnet ...................................... 7-12
Disassembling the forward gear ......8-21, 8-56
Forward gear shim (T1) selection chart
Disassembling the fuel pump assembly....6-14
(F150A)...................................................A-13
i-3
Index
Forward gear shim (T1) selection chart Installing the fuel injector .......................... 6-33
(F150B) .................................................. A-14 Installing the fuel pump assembly ............ 6-15
Forward gear shim (T2) selection chart Installing the gear pump assembly ........... 9-61
(FL150A) ................................................ A-16 Installing the ignition coil........................... 7-26
Forward gear shim (T2) selection chart
(FL150B) ................................................ A-17
Installing the intake manifold .................... 6-40
Installing the isolator lead ......................... 3-14
0
Fuel control unit and component...............5-16 Installing the lower unit
Fuel diagram .............................................2-13 (L-transom model) ......................... 8-29, 8-65
Fuel filter .....................................................6-7
Fuel hose and blowby hose ........................6-1
Installing the lower unit
(X-transom model)......................... 8-30, 8-65
1
Fuel injector ..............................................6-30 Installing the main wiring harness ............ 3-13
Fuel pump .................................................6-11 Installing the oil filter bracket ........... 7-56, 7-60
Fuel system.............................. 1-17, 2-13, 6-5
Fuel system technical data .......................1-11
Installing the oil pump assembly...... 7-55, 7-60
Installing the outboard motor ...................... 3-7
2
Function ......................................................4-2 Installing the power unit.............................. 7-9
Fuse box ...................................................7-27 Installing the propeller shaft housing
F150A, FL150A, F150B, FL150B................3-5 assembly ....................................... 8-26, 8-64
Installing the PTT motor ........................... 9-53
3
G. Installing the PTT switch............................. 9-9
Installing the PTT unit............................... 9-39
General feature ...........................................1-1
General periodic maintenance ..................10-8
Installing the Rectifier Regulator............... 7-26
Installing the reservoir .............................. 9-53
5
General tightening torque .........................1-20
Installing the reverse gear ........................ 8-64
Greasing points.......................................10-12
Installing the rigging grommet .................. 3-13
H.
Installing the shift cable .............................. 3-9
Installing the shift rod....................... 8-27, 8-64
6
Handling of gas torch ..................................0-2 Installing the shift rod and shift bracket ...... 9-4
Handling of gasoline ...................................0-1 Installing the speed sensor....................... 3-15
Handling of sealant .....................................0-3
Hose routing................................................6-1
Installing the starter motor ............... 5-39, 7-21
Installing the stator assembly ................... 7-14
7
Hot part .......................................................0-1 Installing the steering arm ........................ 9-25
How to use the wiring diagram................... A-1 Installing the throttle body assembly ........ 6-26
How to use this manual...............................0-4 Installing the throttle cable........................ 3-11
Installing the throttle link ........................... 6-23
8
I. Installing the tilt limiter .............................. 3-16
Installing the tilt ram.................................. 9-46
Ignition unit................................................. A-4
Ignition unit and component......................5-21
Installing the timing belt ............................ 7-18
Installing the trim ram ............................... 9-46
9
Important reminder on rigging.....................3-1 Installing the upper case........................... 9-15
Installing the balancer assembly...............7-55 Installing the vapor separator ................... 6-39
Installing the canister ................................6-19
Installing the clamp bracket ......................9-30
Installing the vapor shut-off valve ............. 6-19
Installing the water pressure sensor......... 3-14
10
Installing the conventional gauge harness 3-12 Installing the water pump................. 8-27, 8-64
Installing the cowling lock lever...................9-9 Installing the wiring harness ..................... 7-31
Installing the crankcase cover...................7-60
Installing the cylinder head .......................7-46
Installing the 6Y8 Multifunction Meter
harness................................................... 3-12
10
Installing the drive shaft ...................8-25, 8-64 Installing Y-COP ....................................... 3-20
Installing the drive sprocket ......................7-17 Intake and exhaust diagram ..................... 2-17
Installing the driven sprocket and Intake and exhaust system....................... 2-17
camshaft .................................................7-36 Intake manifold and vapor separator ........ 6-34
Installing the exhaust cover ......................7-51 Intake silencer .......................................... 6-21
Installing the flushing hose..........................9-8
Installing the flywheel magnet...................7-15
Installing the fuel filter assembly ...............6-10 A
i-4
Index
J. O.
Junction box assembly................................5-3 Oil pan and exhaust manifold ................... 9-20
Optional equipment .................................. 3-14
L. Outboard motor mounting........................... 3-7
Outboard motor mounting instructions ....... 3-1
Logging .....................................................2-11
Outboard motor troubleshooting ................. 4-6
Lower unit .................................................2-18
Outline ...................................................... 10-1
Lower unit
Overview..................................................... 2-9
(counter rotation model)..........................1-19
Lower unit (counter rotation model, L-transom
model) .....................................................8-45 P.
Lower unit (counter rotation model, X-transom Part, lubricant, and sealant......................... 0-2
model) .....................................................8-48 Pinion shim (T3) selection table ...............A-12
Lower unit Port ............................................................. 5-1
(regular rotation model)...........................1-19 Power unit................................................. 1-18
Lower unit (regular rotation model, L-transom Power unit (check and adjustment) ............ 7-1
model) .......................................................8-1 Power unit assembly .................................. 7-5
Lower unit (regular rotation model, X-transom Power unit system .................................... 2-12
model) .......................................................8-6 Power unit technical data ......................... 1-12
Lower unit technical data ..........................1-15 Predelivery check ..................................... 10-4
Lubricant, sealant, and thread locking Propeller ..................................................... 0-1
agent .........................................................0-6 Propeller (SDS) ........................................ 2-18
Lubrication diagram ..................................2-15 Propeller selection .................................... 3-38
Lubrication system ....................................2-15 Propeller shaft housing
(counter rotation model) ......................... 8-54
M. Propeller shaft housing
(regular rotation model) .......................... 8-13
Maintenance interval chart 1.....................10-1
Propeller shaft shim (T4) selection
Maintenance interval chart 2.....................10-3
table........................................................A-15
Manual format .............................................0-4
Propeller size............................................ 3-38
Measuring the forward and
PTT cylinder ............................................. 9-41
reverse gear backlash
PTT gear pump......................................... 9-54
before disassembly .................................8-69
PTT motor................................................. 9-48
Measuring the forward gear backlash.......8-74
PTT switch and cowling lock lever.............. 9-6
Measuring the forward gear
PTT system .............................................. 5-41
backlash..................................................8-41
PTT unit ..................................1-20, 2-19, 9-33
reverse gear backlash before
disassembly ............................................8-35 R.
Measuring the fuel pressure .......................6-5 Rear............................................................ 5-5
Measuring the peak voltage......................5-12 Rectifier Regulator and ignition coil .......... 7-23
Measuring the reverse gear backlash.......8-76 Reducing the fuel pressure......................... 6-5
Measuring the reverse gear Refacing the valve seat ............................ 7-43
backlash..................................................8-43 Registering the receiver ID to the
Model data ..................................................1-4 ECM........................................................ 3-20
Model features ............................................1-1 Removing the balancer assembly ............ 7-54
Model name designation.............................1-2 Removing the clamp bracket .................... 9-30
Removing the cowling lock lever ................ 9-8
N. Removing the crankcase cover ................ 7-60
Removing the cylinder head ..................... 7-40
New functions ...........................................2-10
Removing the drive shaft................. 8-21, 8-62
Non-reusable part .......................................0-3
Removing the drive sprocket .................... 7-17
Removing the driven sprocket and
camshaft ................................................. 7-35
i-5
Index
Removing the exhaust cover ....................7-50 S.
Removing the flushing hose........................9-8
Safety while working................................... 0-1
Removing the flywheel magnet.................7-13
Removing the fuel filter assembly ...............6-8 Selecting the crankpin bearing ................. 7-68
Removing the fuel injector and vapor shut-off
valve........................................................6-18
Selecting the crankshaft journal bearing .. 7-72
Selecting the pinion shim (T3) ......... 8-39, 8-73 0
Removing the fuel pump assembly...........6-13 Selecting the propeller shaft
Removing the gear pump assembly .........9-57 shim (T4) ................................................ 8-73
Removing the ignition coil .........................7-25
Removing the intake manifold...................6-37
Selection................................................... 3-38
Self-protection ............................................ 0-2 1
Removing the lower unit ... 8-3, 8-8, 8-47, 8-50 Serial number ............................................. 1-3
Setting the tilt limiter ................................. 3-18
Removing the oil filter bracket..........7-54, 7-60
Removing the oil pump assembly ....7-54, 7-60
Removing the power unit ............................7-7
Shift rod and shift bracket........................... 9-1
Shim location ................................... 8-38, 8-72 2
Shim selection table and chart (counter rotation
Removing the propeller shaft housing
assembly........................................8-15, 8-56 model).....................................................A-15
Removing the PTT motor..........................9-50
Removing the PTT switch ...........................9-8
Shim selection table and chart (regular rotation
model).....................................................A-12 3
Removing the PTT unit .............................9-34 Shimless valve lifter .................................. 2-12
Removing the Rectifier Regulator .............7-25 Shimming (counter rotation model) .......... 8-66
Removing the reservoir.............................9-50
Removing the reverse gear.......................8-62
Shimming (regular rotation model) ........... 8-32
Shimming check sheet .................... 8-33, 8-67 5
Removing the shift rod and shift bracket.....9-3 Shimming procedure ....................... 8-38, 8-72
Removing the starter motor .............5-35, 7-21 Shimming workflow.......................... 8-32, 8-66
Removing the stator assembly..................7-13
Removing the steering arm.......................9-25
Shock-absorbing function ......................... 2-22
Single outboard motor application 6
Removing the throttle body assembly.......6-26 (conventional gauge) .............................. 3-31
Single outboard motor application (6Y8
Removing the throttle link .........................6-23
Removing the tilt ram and trim ram...........9-43
Removing the timing belt ..........................7-17
Multifunction Meter) ................................ 3-29
Special service tool.............................. 0-3, 0-8 7
Specified tightening torque ....................... 1-17
Removing the upper case .........................9-15
Removing the vapor separator..................6-37 Starter motor.................................... 5-33, 7-20
Removing the water pump and shift rod ...8-11
Removing the water pump and
Starting unit and component..................... 5-27
Stationary condition .................................. 2-22 8
shift rod ...................................................8-53 Steering arm ............................................. 9-24
Removing the wiring harness....................7-30 Symbol........................................................ 0-6
Replacing the oil filter..............................10-10
Replacing the timing belt.........................10-15
System diagram........................................ 3-29
9
Replacing the valve guide.........................7-42 T.
Reverse gear shim (T1) selection chart Test run .................................................... 10-7
(FL150A) ................................................ A-16
Reverse gear shim (T1) selection chart
Throttle body............................................. 6-25
Throttle body and throttle link adjustment. 6-27
10
(FL150B) ................................................ A-17 Throttle link ............................................... 6-22
Reverse gear shim (T2) selection chart Tightening torque........................................ 0-3
(F150A) .................................................. A-13
Reverse gear shim (T2) selection chart
Tilt limiter (F150A, FL150A [optional for
European and Oceanian markets])........... 2-8
10
(F150B) .................................................. A-14 Timing belt ................................................ 7-16
Rigging grommet description ......................3-9 Top ............................................................. 5-6
Rigging grommet mounting.........................3-9 Trim-down and tilt-down function.............. 2-20
Rigging information ...................................1-17 Trim-up and tilt-up function....................... 2-19
Rigging recommendation ..........................3-37 Trouble code and checking step................. 4-8
Rotating part ...............................................0-1 Troubleshooting procedure......................... 4-6
A
i-6
Index
Troubleshooting the power unit (trouble code
not detected) ...........................................4-11
Troubleshooting the power unit using the
diagnostic flash indicator.........................4-10
Troubleshooting the power unit using
the YDIS....................................................4-6
Troubleshooting the PTT unit...........4-16, 4-17
Twin outboard motor application (conventional
gauge).....................................................3-35
Twin outboard motor application (6Y8
Multifunction Meter) ................................3-33
U.
Uncrating.....................................................3-3
Uncrating procedure ...................................3-3
Upper case................................................9-17
Upper case and mounts............................9-13
Using the digital tester ..............................5-12
Using the YDIS .........................................5-12
V.
Vapor gas diagram....................................2-14
6-42
Ventilation ...................................................0-1
W.
Water pump and shift rod (counter rotation
model) .....................................................8-51
Water pump and shift rod (regular rotation
model) .......................................................8-9
Wiring diagram........................................... A-1
Wiring harness ..........................................7-28
Working with crane .....................................0-2
Y.
Y-COP (standard for European market
and optional for
Oceanian market) .................. 2-7, 3-20, 5-29
YDIS.....................................................2-9, 4-1
6.
6Y8 Multifunction Meter sensor ................5-40
i-7
Index
— MEMO —
0
1
2
3
5
6
7
8
9
10
10
A
i-8
Jan. 2013 ABE
(E_3)
Appendix A Wiring diagram
How to use the wiring diagram
Composition of the wiring diagrams
Wiring diagram ..................................................................A-1 The wiring diagram consists of four categories. The engine control unit and fuel unit, ignition unit,
How to use the wiring diagram .................................................. A-1 charging unit and starting unit, and control unit.
Engine control unit and fuel unit ................................................ A-2 Legend symbols in the wiring diagrams
Ignition unit ................................................................................ A-4
Charging unit and starting unit 1 2 3 4 5
(F150A, FL150A for European and Oceanian markets) ............ A-6
BZ
[except for European and Oceanian markets] and
F150B, FL150B) ........................................................................ A-8 1. Double colors wire
Control unit .............................................................................. A-10 2. No wire connector
3. A wire is not included in the selected wiring unit.
4. Alert buzzer
Shim selection table and chart 5. Optional parts
(regular rotation model) ..................................................A-12 Color Code
Pinion shim (T3) selection table .............................................. A-12 P : Pink
B : Black
Forward gear shim (T1) selection chart (F150A) ..................... A-13 P/B : Pink/Black
B/O : Black/Orange
Reverse gear shim (T2) selection chart (F150A) .................... A-13 P/G : Pink/Green
B/W : Black/White
Forward gear shim (T1) selection chart (F150B) ..................... A-14 P/W : Pink/White
B/Y : Black/Yellow
Reverse gear shim (T2) selection chart (F150B) .................... A-14 Pu/B : Purple/Black
Br : Brown
Br/W : Brown/White Pu/G : Purple/Green
Shim selection table and chart G : Green Pu/R : Purple/Red
(counter rotation model) .................................................A-15 G/B : Green/Black Pu/Y : Purple/Yellow
Pinion shim (T3) selection table .............................................. A-15 G/R : Green/Red R : Red
Propeller shaft shim (T4) selection table ................................. A-15 G/Y : Green/Yellow R/Y : Red/Yellow
Forward gear shim (T2) selection chart (FL150A) ................... A-16 Gy : Gray Sb : Sky blue
Reverse gear shim (T1) selection chart (FL150A) .................. A-16 L : Blue W : White
Forward gear shim (T2) selection chart (FL150B) ................... A-17 L/G : Blue/Green W/B : White/Black
Reverse gear shim (T1) selection chart (FL150B) .................. A-17 L/W : Blue/White W/R : White/Red
L/Y : Blue/Yellow Y : Yellow
Lg : Light green Y/G : Yellow/Green
O : Orange
A-1
Engine control unit and fuel unit
1. Engine ECM
3. ISC valve
4. Speed sensor
7. Fuel injector
10. Joint connector 1
12. Fuse box
13. Battery
14. Starter motor
15. PTT relay
a. Fuse (50A) (engine battery)

b. Fuse (50A) (house [accessory] battery)
c. Fuse (20A) (engine ECM, ISC valve, fuel injector, high-pressure fuel pump, ignition coil)
d. Fuse (20A) (engine start switch, PTT switch)
e. Fuse (30A) (starter relay)
f. Main relay
A. To remote control
*1. Depending on the outboard motor, the locations of terminals 7 and 12–17 may vary.
A-2
Engine control unit and fuel unit
a 12. Fuse box

A 14. Starter motor c d e
b
R
f
R
W
R
Y
P
B
15. PTT relay
*1
12
13
14
15
16
17
19
20
7
1
8
13. Battery *1
R
B R
R
R
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
Y/G
R/Y
R 10 1
23 11
B
1 13
2 G
3 P
4 W R/Y 9
5 L/W R/Y 10
6 G/B R/Y 11
R/Y 12
8 B
1 23 10 O
11 L/W
12 L O 17
13 Y O 18
O 19
O 20 12 24
16 Y/G
17 Pu/G
18 G/B
19 G
20 G/R
21 G/Y 11. Joint connector 2
B 1
B 5 1 13
29 P/W
30 R/Y
32 B
B 11
B 12
22 44 B 13
B 14
B 15
39 Pu/B
1. Engine ECM 40 Pu/R
41 Pu/Y
42 B 12 24
43 L
R 22
R 23
R 24
G/R
G/Y
R/Y
G/B
R/Y
R/Y

G
L/W
O
B
L
Pu/R
Pu/G
Pu/B
Pu/Y
B
R/Y
R/Y
R/Y
R/Y
P/W
O
B
L/W
O
B
#1 #2 #3 #4
G/B
R/Y
3. ISC valve 7. Fuel injector
4. Speed sensor 6. High-pressure fuel pump
2. Oil pressure sensor 5. Water pressure sensor 8. Vapor shut-off valve
A-3
Ignition unit
1. Engine ECM
2. Pulser coil
3. Thermoswitch
4. Ignition coil
6. TPS
13. Fuse box
14. Battery
15. Starter motor
16. PTT relay

f. Main relay
*1. Depending on the outboard motor, the locations of terminals 6, 7, 18 may vary.
A-4
Ignition unit
15. Starter motor a 13. Fuse box

A
c d e
b
R f
R
W
R
Y
P
B
16. PTT relay
*1
18
19
20
1
6
7
8
R
R
B 14. Battery *1
R
R
R/Y
R/Y
R/Y
Y/G
R
10 1 1 13
23 11
2 G
3 P
4 W
7 B/Y
8 B
9 L/Y
1 23 10 O
O 19
13 Y 12 24
14 W/R O 21
15 W/B O 22
16 Y/G
B 1
22 B/O B 2
B 3
B 4
B 5 1 13
B 6
B 7
B 8
B 9
30 R/Y B 10
31 L/G
32 B
33 P/G B 13
34 P
22 44 35 B/Y
37 P
1. Engine ECM 12 24
42 B R 22
R 23
44 B/W R 24
P
B
O
P
B
B/W
B/O
R/Y
R/Y
B/Y
P/G
B
L/G
O
B
B
W/R
W/B
B/Y
B
3. Thermoswitch
L/Y
#1, #4 #2, #3
B
6. TPS
8. Shift position switch 10. Air temperature sensor
2. Pulser coil
4. Ignition coil
7. Engine temperature sensor 9. Shift cut-off switch
A-5
Charging unit and starting unit (F150A, FL150A for European and Oceanian
markets)
1. Engine ECM
2. PTT relay
3. PTT motor
4. Starter relay
5. Starter motor
6. PTT switch
7. Trim sensor
8. Tilt limiter
11. Fuse box
12. Stator assembly
14. Battery
15. House (accessory) battery

f. Main relay
B. To hub
D. To diagnostic flash indicator
E. To YDIS
F. To alert indicator
G. If the outboard motor is not fitted with a tilt limiter (optional), connect the coupler.
H. If the 6Y8 Multifunction Meter is selected, connect the coupler.
*1. Depending on the outboard motor, the locations of terminals 7 and 11 may vary.
A-6
Charging unit and starting unit
13. Rectifier Regulator 12. Stator assembly
(F150A, FL150A for European and Oceanian markets)
R
R
R
2
1
a 11. Fuse box
A 15. House (accessory)
battery AC 1 G c d e
AC 1 G
AC 1 G
b
+1 R f
+2 R
14. Battery B
W
Sb
Lg
Br
R
Y
P
B
*1
*1
19
20
21
11
1
2
7
8
1
R 10 1
23 11
R
R
R
R
R
R
R/Y
Y/G
R/Y
1 W
2 G
3 P Lg 1
4 W Lg 2
Lg 3
Lg 4
1 13
8 B L 6
L 7
1 23 L 8
13 Y
Sb 13
16 Y/G Sb 14
Sb 15
Lg
L
g
12 24
23 L
24 P/W
26 W/B
27 L/W
28 P/B 10. Joint connector 2
30 R/Y B 1
32 B
B 5 1 13
22 44
36 P
Br
Lg
L
1. Engine ECM
R
Sb
Lg
R
R
R
R
42 B Br B 13
B
Lg
P/B 16
Sb Br/W P/B 17
4. Starter relay P/B 18
P 19
W
12 24
L
P 20
P 21
P
B
L/W
2. PTT relay
P/W
R 22
P/B
P/B
R 23
P
R 24
Sb
B
L
B 5. Starter motor
P
D G
B
B
B
B
B
G
W/B
R/Y
6. PTT switch
B
F
H
E 3. PTT motor
7. Trim sensor 8. Tilt limiter
A-7
Charging unit and starting unit (F150A, FL150A [except for European and
Oceanian markets] and F150B, FL150B)
1. Engine ECM
2. PTT relay
3. PTT motor
4. Starter relay
5. Starter motor
6. PTT switch
7. Trim sensor
10. Fuse box
11. Stator assembly
13. Battery
14. House (accessory) battery

f. Main relay
g. Diode
B. To hub
D. To diagnostic flash indicator
E. To YDIS
F. To alert indicator
G. If the 6Y8 Multifunction Meter is selected, connect the coupler.
*1. Depending on the outboard motor, the locations of terminals 7 and 11 may vary.
A-8
Charging unit and starting unit (F150A, FL150A [except for
European and Oceanian markets] and F150B, FL150B) 11. Stator assembly
R
R
R
2
1
14. House (accessory) a 10. Fuse box
A battery c
AC 1 G d e
AC 1 G
AC 1 G
b
+1 R f
13. Battery +2 R
B
W
Sb
Lg
Br
R
Y
P
B
*1
R *1
11
19
20
21
1
2
7
8
1
10 1
23 11
R
R
R
R
R
R
R/Y
Y/G
R/Y
1 W
2 G
3 P Lg 1
4 W Lg 2
Lg 3
Lg 4
Sb 5 1 13
8 B Sb 6
Sb 7
1 23 Sb 8
13 Y
16 Y/G
Sb
Lg
g 12 24
23 L
24 P/W
26 W/B
27 L/W
28 P/B 9. Joint connector 2
30 R/Y B 1
32 B
B 5 1 13
Br
22 44
36 P
Sb
Lg
1. Engine ECM
R
Sb
Lg
R
R
R
42 B Br R B 13
B
Lg
P/B 16
Sb Br/W P/B 17
4. Starter relay P/B 18
P 19
W
12 24
L
P 20
P 21
P
B
L/W
P/W
R 22
P/B
P/B
2. PTT relay
R 23
P
R 24
B
P
D 5. Starter motor 8. Joint connector 1
B
B
B
B
B
G
W/B
R/Y
6. PTT switch
B
F
G
3. PTT motor
E
7. Trim sensor
A-9
Control unit
1. 703 remote control

3. Engine shut-off switch
4. PTT switch
5. ON
6. OFF
7. START
8. Clip removed
9. Clip installed
10. UP
11. Free
12. DN
13. Neutral switch
14. Switch panel (6R5-82570-05)
15. 704 remote control
17. Twin switch panel (61B-82570-03)
18. Engine start switch (PORT)
19. Engine start switch (STBD)
20. Control unit
21. 704 remote control (twin)
22. PTT switch (twin)
23. PTT switch (PORT)
24. PTT switch (STBD)
25. Relay (Left)
26. Relay (Right)
27. Neutral switch (PORT)
28. Neutral switch (STBD)
A. To power unit
B. To gauge
D. To power unit (PORT)
E. To power unit (STBD)
F. To switch panel (PORT)
G. To switch panel (STBD)
H. To main wiring harness (PORT)
J. To main wiring harness (STBD)
A-10
Control unit 14. Switch panel (6R5-82570-05)
W B R Y Br 3. Engine shut-off switch
5. ON W B
1. 703 remote control 8. Clip removed
6. OFF
2. Engine start switch 4. PTT switch 7. START 9. Clip installed
W B R Y Br 3. Engine shut-off switch Sb R Lg 16. Main wiring harness
5. ON 10. UP
Y
Br
W B
B
B
W
6. OFF 8. Clip removed 11. Free R A
Y Y
7. START 9. Clip installed 12. DN B G
BZ W W
W
W
R
Lg
Br
B
Sb
P
R
Br P
Y L
L
B R R
Lg
Sb
R
G G B
Br
W
B
B
R R R 15. 704 remote control
Y 4. PTT switch
B G G
W Sb R Lg
B Sb 10. UP
P P A
Y Lg 11. Free
Br Y L L 12. DN
B B
Br Br
Lg
Sb
R
Sb
R Lg
13. Neutral switch Lg R
Y P Sb Br
Br Br Br
BZ Br Br B
13. Neutral switch

21. 704 remote control (twin) 17. Twin switch panel (61B-82570-03)
22. PTT switch (twin) 23. PTT switch (PORT) 24. PTT switch (STBD) 18. Engine start switch (PORT) 19. Engine start switch (STBD)
Sb R Lg Sb R Lg Sb R Lg W B R Y Br 3. Engine shut-off switch W B R Y Br
10. UP 10. UP 10. UP 5. ON W B W B 5. ON
11. Free 11. Free 11. Free 6. OFF 8. Clip removed 6. OFF
12. DN 12. DN 12. DN 7. START 9. Clip installed 7. START
Lg
Lg
Lg
Sb
Sb
Sb
Br
R
W
W
R
B
B
Br
W
R
B
B
Y
Lg
Lg
Lg
Sb
Sb
Sb
R
W
B 16. Main wiring harness
R
Y Y R D
B Y R Y
B G
G W
G
W
P P
L L
L
G
Lg Lg Y B
Y Br B
R B Br
Lg BZ
Sb Sb
Br H Lg
Br P Gy R
B B F
P
B Br
Y Br
B
R L 16. Main wiring harness
Y
Lg Y Y R E
Sb J R R Y
B
Sb
Sb
Lg
Lg
Br B G G
R
R
B
Br G W W
Br
Br
Br
Br
P P
L
B L
Br B
BZ Br
P Gy Sb
Sb
Sb
Lg
Lg
Lg
Gy
Gy
28. Neutral switch (STBD)

Br
Br
G
G
Y
Y
P
B
B
P
R
G Br
27. Neutral switch (PORT) Br
R R B
20. Control unit
B B
25. Relay (left) 26. Relay (right)
A-11
Shim selection table and chart (regular rotation model)
Pinion shim (T3) selection table
(mm)
A
0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.20 0.21 0.22 0.23 0.24 0.25 0.26 0.27 0.28 0.29 0.30
13 1.32 1.32 1.32 1.30 1.30 1.28 1.28 1.25 1.25 1.25 1.22 1.22 1.22 1.20 1.20 1.18 1.18 1.15 1.15 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05
12 1.32 1.32 1.30 1.30 1.28 1.28 1.25 1.25 1.25 1.22 1.22 1.22 1.20 1.20 1.18 1.18 1.15 1.15 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02
11 1.32 1.30 1.30 1.28 1.28 1.25 1.25 1.25 1.22 1.22 1.22 1.20 1.20 1.18 1.18 1.15 1.15 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02
10 1.30 1.30 1.28 1.28 1.25 1.25 1.25 1.22 1.22 1.22 1.20 1.20 1.18 1.18 1.15 1.15 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02
9 1.30 1.28 1.28 1.25 1.25 1.25 1.22 1.22 1.22 1.20 1.20 1.18 1.18 1.15 1.15 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00
8 1.28 1.28 1.25 1.25 1.25 1.22 1.22 1.22 1.20 1.20 1.18 1.18 1.15 1.15 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00
7 1.28 1.25 1.25 1.25 1.22 1.22 1.22 1.20 1.20 1.18 1.18 1.15 1.15 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98
6 1.25 1.25 1.25 1.22 1.22 1.22 1.20 1.20 1.18 1.18 1.15 1.15 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98
5 1.25 1.25 1.22 1.22 1.22 1.20 1.20 1.18 1.18 1.15 1.15 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95
4 1.25 1.22 1.22 1.22 1.20 1.20 1.18 1.18 1.15 1.15 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95
3 1.22 1.22 1.22 1.20 1.20 1.18 1.18 1.15 1.15 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95
2 1.22 1.22 1.20 1.20 1.18 1.18 1.15 1.15 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92
1 1.22 1.20 1.20 1.18 1.18 1.15 1.15 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92
B 0 1.20 1.20 1.18 1.18 1.15 1.15 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92
–1 1.20 1.18 1.18 1.15 1.15 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90
–2 1.18 1.18 1.15 1.15 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90
–3 1.18 1.15 1.15 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88
–4 1.15 1.15 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88
–5 1.15 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85
–6 1.15 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85
–7 1.12 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85
–8 1.12 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82
–9 1.12 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82
–10 1.10 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82
–11 1.10 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80
–12 1.08 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80
–13 1.08 1.05 1.05 1.05 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78
A
0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 0.39 0.40 0.41 0.42 0.43 0.44 0.45 0.46 0.47 0.48 0.49 0.50 0.51 0.52 0.53 0.54 0.55 0.56 0.57 0.58 0.59 0.60
13 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75
12 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72
11 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72
10 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72
9 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70
8 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70
7 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68
6 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68
5 0.95 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68 0.65
4 0.95 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68 0.65 0.65
3 0.92 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68 0.65 0.65 0.62
2 0.92 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68 0.65 0.65 0.62 0.62
1 0.92 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68 0.65 0.65 0.62 0.62 0.62
B 0 0.90 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68 0.65 0.65 0.62 0.62 0.62 0.60
–1 0.90 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68 0.65 0.65 0.62 0.62 0.62 0.60 0.60
–2 0.88 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68 0.65 0.65 0.62 0.62 0.62 0.60 0.60 0.58
–3 0.88 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68 0.65 0.65 0.62 0.62 0.62 0.60 0.60 0.58 0.58
–4 0.85 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68 0.65 0.65 0.62 0.62 0.62 0.60 0.60 0.58 0.58 0.55
–5 0.85 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68 0.65 0.65 0.62 0.62 0.62 0.60 0.60 0.58 0.58 0.55 0.55
–6 0.85 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68 0.65 0.65 0.62 0.62 0.62 0.60 0.60 0.58 0.58 0.55 0.55 0.55
–7 0.82 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68 0.65 0.65 0.62 0.62 0.62 0.60 0.60 0.58 0.58 0.55 0.55 0.55 0.52
–8 0.82 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68 0.65 0.65 0.62 0.62 0.62 0.60 0.60 0.58 0.58 0.55 0.55 0.55 0.52 0.52
–9 0.82 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68 0.65 0.65 0.62 0.62 0.62 0.60 0.60 0.58 0.58 0.55 0.55 0.55 0.52 0.52 0.52
–10 0.80 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68 0.65 0.65 0.62 0.62 0.62 0.60 0.60 0.58 0.58 0.55 0.55 0.55 0.52 0.52 0.52 0.50
–11 0.80 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68 0.65 0.65 0.62 0.62 0.62 0.60 0.60 0.58 0.58 0.55 0.55 0.55 0.52 0.52 0.52 0.50 0.50
–12 0.78 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68 0.65 0.65 0.62 0.62 0.62 0.60 0.60 0.58 0.58 0.55 0.55 0.55 0.52 0.52 0.52 0.50 0.50 0.48
–13 0.78 0.75 0.75 0.75 0.72 0.72 0.72 0.70 0.70 0.68 0.68 0.65 0.65 0.62 0.62 0.62 0.60 0.60 0.58 0.58 0.55 0.55 0.55 0.52 0.52 0.52 0.50 0.50 0.48 0.48
A. Pinion height measurement (M)

B. Stamped value on the lower case (P)
A-12
Forward gear shim (T1) selection chart (F150A)
1.20
1.10
1.00
0.90
0.80
0.70
0.60
B (mm)
0.50
0.40
0.30
0.20
0.10
0
–0.10
–0.20
–0.30
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
A (1/100 mm)
A 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
B –0.26 –0.22 –0.19 –0.16 –0.12 –0.09 –0.06 –0.02 0.02 0.05 0.08 0.12 0.15 0.18 0.22 0.25 0.29 0.32 0.35 0.39 0.42 0.45 0.49 0.52 0.56 0.59 0.62 0.66 0.69 0.73 0.76 0.79 0.83 0.86 0.89 0.93 0.96 1.00 1.03 1.06 1.10

Reverse gear shim (T2) selection chart (F150A)

0.40
0.30
0.20
0.10
0
–0.10
B (mm)
–0.20
–0.30
–0.40
–0.50
–0.60
–0.70
–0.80
–0.90
–1.00
–1.10
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
A (1/100 mm)
A 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
B 0.34 0.30 0.27 0.24 0.20 0.17 0.14 0.10 0.07 0.03 0.00 –0.04 –0.07 –0.10 –0.14 –0.17 –0.21 –0.24 –0.27 –0.31 –0.34 –0.37 –0.41 –0.44 –0.48 –0.51 –0.54 –0.58 –0.61 –0.65 –0.68 –0.71 –0.75 –0.78 –0.81 –0.85 –0.88 –0.92 –0.95 –0.98 –1.02

A-13
Forward gear shim (T1) selection chart (F150B)
1.20
1.10
1.00
0.90
0.80
0.70
B (mm)
0.60
0.50
0.40
0.30
0.20
0.10
0
–0.10
–0.20
–0.30
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
A (1/100 mm)
A 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
B –0.28 –0.25 –0.21 –0.18 –0.15 –0.11 –0.08 –0.04 –0.01 0.02 0.06 0.09 0.13 0.16 0.19 0.23 0.26 0.29 0.33 0.36 0.40 0.43 0.46 0.50 0.53 0.57 0.60 0.63 0.67 0.70 0.73 0.77 0.80 0.84 0.87 0.90 0.94 0.97 1.00 1.04 1.07

Reverse gear shim (T2) selection chart (F150B)

0.40
0.30
0.20
0.10
0
–0.10
B (mm)
–0.20
–0.30
–0.40
–0.50
–0.60
–0.70
–0.80
–0.90
–1.00
–1.10
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
A (1/100 mm)
A 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
B 0.36 0.33 0.29 0.26 0.23 0.19 0.16 0.12 0.09 0.06 0.02 –0.01 –0.05 –0.08 –0.11 –0.15 –0.18 –0.21 –0.25 –0.28 –0.32 –0.35 –0.38 –0.42 –0.45 –0.49 –0.52 –0.55 –0.59 –0.62 –0.65 –0.69 –0.72 –0.76 –0.79 –0.82 –0.86 –0.89 –0.92 –0.96 –0.99

A-14
Shim selection table and chart (counter rotation model)
Pinion shim (T3) selection table
See “Pinion shim (T3) selection table” (A-12)
Propeller shaft shim (T4) selection table

The shim thickness does not have to be adjusted for the gray-colored cell.
(mm)
A 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9
B –0.3 –0.2 –0.1 +0.1 +0.2 +0.3 +0.4 +0.5 +0.6 +0.7 +0.8 +0.9 +1.0 +1.1 +1.2 +1.3 +1.4 +1.5 +1.6 +1.7 +1.8 +1.9 +2.0 +2.1 +2.2 +2.3 +2.4 +2.5 +2.6
A. Free play measurement

A-15
Forward gear shim (T2) selection chart (FL150A)
0.30
0.20
0.10
0
B (mm)
–0.10
–0.20
–0.30
–0.40
–0.50
–0.60
–0.70
–0.80
–0.90
–1.00
–1.10
–1.20
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
A (1/100 mm)
A 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
B 0.19 0.16 0.12 0.09 0.06 0.02 –0.01 –0.05 –0.08 –0.11 –0.15 –0.18 –0.22 –0.25 –0.28 –0.32 –0.35 –0.38 –0.42 –0.45 –0.49 –0.52 –0.55 –0.59 –0.62 –0.66 –0.69 –0.72 –0.76 –0.79 –0.82 –0.86 –0.89 –0.93 –0.96 –0.99 –1.03 –1.06 –1.09 –1.13 –1.16

Reverse gear shim (T1) selection chart (FL150A)

1.20
1.10
1.00
0.90
0.80
0.70
B (mm)
0.60
0.50
0.40
0.30
0.20
0.10
0
–0.10
–0.20
–0.30
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
A (1/100 mm)
A 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
B –0.28 –0.24 –0.21 –0.18 –0.14 –0.11 –0.08 –0.04 –0.01 0.03 0.06 0.35 0.13 0.16 0.20 0.23 0.27 0.30 0.33 0.37 0.40 0.43 0.47 0.50 0.54 0.57 0.60 0.64 0.67 0.71 0.74 0.77 0.81 0.84 0.87 0.91 0.94 0.98 1.01 1.04 1.08

A-16
Forward gear shim (T2) selection chart (FL150B)
0.30
0.20
0.10
0
–0.10
–0.20
–0.30
B (mm)
–0.40
–0.50
–0.60
–0.70
–0.80
–0.90
–1.00
–1.10
–1.20
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
A (1/100 mm)
A 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
B 0.22 0.18 0.15 0.12 0.08 0.05 0.02 –0.02 –0.06 –0.09 –0.12 –0.16 –0.19 –0.22 –0.26 –0.29 –0.33 –0.36 –0.39 –0.43 –0.46 –0.49 –0.53 –0.56 –0.60 –0.63 –0.67 –0.70 –0.73 –0.77 –0.80 –0.83 –0.87 –0.90 –0.93 –0.97 –1.00 –1.04 –1.07 –1.10 –1.14

Reverse gear shim (T1) selection chart (FL150B)

1.20
1.10
1.00
0.90
0.80
0.70
B (mm)
0.60
0.50
0.40
0.30
0.20
0.10
0
–0.10
–0.20
–0.30
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
A (1/100 mm)
A 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
B –0.30 –0.27 –0.23 –0.20 –0.17 –0.13 –0.10 –0.06 –0.03 0.00 0.04 0.35 0.11 0.14 0.17 0.21 0.24 0.27 0.31 0.34 0.38 0.41 0.44 0.48 0.51 0.55 0.58 0.61 0.65 0.68 0.71 0.75 0.78 0.82 0.85 0.88 0.92 0.95 0.98 1.02 1.05

A-17

F150a, B, F

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F150a, B, F

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Available Formats

F150A

F150A, FL150A, F150B, FL150B

Safety while working .................................................... 0-1

Lubricant, sealant, and thread locking agent ................. 0-6 6

Special service tool ........................................................... 0-8 7

Disassembly and assembly

• Install bearings so that the bearing identifi-

Low temperature resistant grease

Corrosion resistant grease

ThreeBond 1303N Thread locking agent

ThreeBond 1386B Sealant

Symbol Name Application

ThreeBond 1401 Thread locking agent

ThreeBond 1530D Sealant

LOCTITE 271 (red) Thread locking agent

LOCTITE 242 (blue) Thread locking agent

LOCTITE 572 (white) Sealant

Silicone sealant Sealant

YDIS 2 starter kit Test harness (3 pins)

Ignition tester (spark gap tester) Leakage tester

Test harness (2 pins) Small end bearing installer

Test harness (3 pins) Vacuum gauge

Test harness (2 pins) Fuel injection meter

Flywheel stopper Valve guide remover/installer

Valve lapper Valve seat cutter 30°

Valve seat cutter holder Oil filter wrench

Valve seat cutter 30° Driver rod L3

Valve seat cutter 45° Needle bearing attachment

Needle bearing attachment Stopper guide plate

Bearing puller assembly Needle bearing attachment

Driver rod SS Drive shaft holder 6

Needle bearing attachment Pinion nut holder

Bearing depth plate Needle bearing attachment

Bearing outer race attachment Backlash indicator

Magnet base B Ring nut wrench

Pinion height gauge Bearing inner race attachment

Slide hammer handle Ball bearing attachment

Puller head PTT hydraulic gauge adapter

Power tilt wrench

Model feature ..................................................................... 1-1

Model data ......................................................................... 1-4

Electrical technical data ................................................... 1-7

Fuel system technical data ............................................ 1-11

Power unit technical data ............................................... 1-12

Lower unit technical data ............................................... 1-15

Bracket unit technical data ............................................ 1-16

Specified tightening torque ............................................ 1-17

Level 2: Control method

Level 4: Lubrication system (2-stroke model) 8

*1.With SUS (stainless steel) propeller

Engine idle speed

Air temperature sensor

Air pressure sensor

Engine temperature sensor

Shift cut-off switch

Shift position switch

Fuel injection control system 0

High-pressure fuel pump

Vapor shut-off valve

Oil pressure sensor

Button cell battery - CR2016

Fuel filter assembly

Vapor separator tank