(6S1)

(6S2)

(6FJ)

(6FK)

6FJ-28197-5W-11

6FJ-28197-5W-11
Feb. 2017 !
(E)

6FJ-28197-5W-11_cover.indd 1 2017/02/13 10:35:31

 Preface
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained me-
chanics when performing maintenance procedures and repairs to Yamaha equipment. It has been writ-
ten 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. Au-
thorized Yamaha dealers are notified periodically of modifications and significant changes in specifica-
tions 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:

:This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey
all safety messages that follow this symbol to avoid possible injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could result in death or se-
rious injury.

A NOTICE indicates special precautions that must be taken to avoid damage to the outboard
motor or other property.

A TIP provides key information to make procedures easier or clearer.

F200B, FL200B, F250H, FL250H

SERVICE MANUAL
©2017 by Yamaha Motor Co., Ltd.
1st Edition, February 2017
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
6FJ-28197-5W-11

6FJ-28197-5W-11_cover.indd 2 2017/02/13 10:35:32

 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

Appendix A
 General information

Important safety and service information........................ 0-1

Rotating parts ............................................................................. 0-1 0
Hot parts..................................................................................... 0-1
Electric shock ............................................................................. 0-1
Propeller ..................................................................................... 0-1
Handling of gasoline................................................................... 0-1
1
Ventilation................................................................................... 0-1
Self-protection ............................................................................ 0-2
Lifting outboard motors............................................................... 0-2
Handling of gas torch ................................................................. 0-2
2
Parts, lubricants, and sealants ................................................... 0-2
Handling of lubricants and sealants ........................................... 0-3
Special service tools................................................................... 0-3
Tightening torque ....................................................................... 0-3
3
Non-reusable parts..................................................................... 0-3

4
Disassembly and assembly........................................................ 0-3
Disposal of used components and chemicals ............................ 0-3

How to use this manual ..................................................... 0-4

Manual format ............................................................................ 0-4 5
Conditions when testing and adjusting....................................... 0-5
Abbreviation ............................................................................... 0-5
Color code .................................................................................. 0-6
6
Symbol ................................................................................ 0-7
Symbol ....................................................................................... 0-7
Lubricant, sealant, and thread locking agent.............................. 0-7
7
Special service tool............................................................ 0-9 8
9
10

A
 Important safety and service information

Important safety and service in- Handling of gasoline

formation • Gasoline is highly flammable. Keep gasoline
To prevent an accident or injury and to provide and all flammable products away from heat,
quality service, observe the following informa- sparks, and open flames.
tion. • Gasoline is poisonous and can cause injury
or death. Handle gasoline with care. Never
Rotating parts siphon gasoline by mouth. If you swallow
• Hands, feet, hair, jewelry, clothing, personal some gasoline, inhale a lot of gasoline vapor,
flotation device straps, and so on, can be- or get some gasoline in your eyes, see your
come entangled with internal rotating parts of doctor immediately. If gasoline spills on your
the engine, resulting in serious injury or skin, wash with soap and water. If gasoline
death. spills on your clothing, change your clothes.
• Keep the top cowling installed whenever
possible. Do not remove or install the top
cowling when the engine is running.
• Only operate the engine with the top cowling
removed according to the specific instruc-
tions in the manual. Keep hands, feet, hair,
jewelry, clothing, personal flotation device
straps, and so on, away from any exposed
moving parts.

Hot parts Ventilation

During and after operation, engine parts are • Gasoline vapor and exhaust gases are
hot enough to cause burns. Do not touch any heavier than air and extremely poisonous. If
parts under the top cowling until the engine has gasoline vapor or exhaust gases are inhaled
cooled. in large quantities, it may cause loss of con-
sciousness and death within a short time.
Electric shock • When test running an engine indoors (for ex-
Do not touch any electrical parts while starting ample, in a water tank) make sure to do so
or operating the engine. Otherwise, shock or where adequate ventilation can be main-
electrocution could result. tained.

Propeller
Do not hold the propeller with your hands when
loosening or tightening the propeller nut. Sharp
propeller edges can cause injury. Place a
wood block between gear case and propeller
to hold the propeller for removal and installa-
tion.

0-1
 Important safety and service information

Self-protection Handling of gas torch

• Protect your eyes by wearing safety glasses • Improper handling of a gas torch may result
or safety goggles during all operations involv- in burns. For information on the proper han-
ing drilling and grinding, or when using an air dling of the gas torch, see the operation man-
compressor. ual issued by the manufacturer.
• Protect your hands and feet by wearing pro- • When using a gas torch, keep it away from
tective gloves and safety shoes when neces- gasoline and oil to prevent a fire.
sary. • Components become hot enough to cause
burns. Do not touch any hot components di-
rectly.

Lifting outboard motors

• Outboard motors weighing 18 kg (40 lb) and
over must be carried by a crane or equiva- Parts, lubricants, and sealants
lent. Use only genuine Yamaha parts, lubricants,
• Use a wire cable lifting harness of adequate and sealants, or those recommended by
strength to lift up the outboard motor in a sta- Yamaha, when servicing or repairing the out-
ble manner. board motor. Failures caused by the use of
• Lift and suspend the outboard motor in a sta- parts, lubricants, or sealants that are not equiv-
ble manner using the designated lifting at- alent in design and quality to genuine Yamaha
tachment points. parts, lubricants, or sealants will not be cov-
• Do not work on or under an outboard motor ered by warranty.
while it is suspended from a lifting device. Se-
curely mount the motor on a suitable work
stand or place it on a stable work surface as
soon as possible.

0-2
 Important safety and service information

Handling of lubricants and sealants

• Follow all instructions and safety precautions
provided on the product label and the materi-
al safety data sheet (MSDS/SDS) for lubri-
cants, sealants, and other shop chemicals.
• Wear impervious gloves, eye protection, or
other protective apparel when required.
• Wash skin thoroughly after contact with lubri-
cants, sealants, and other shop chemicals,
and change clothing if contaminated with
them. Disassembly and assembly
• Use compressed air to remove dust and dirt
during disassembly.
• Apply engine oil to the contact surfaces of
moving parts before assembly.

Special service tools

For safety and to help protect parts from dam-
age, use the recommended special service
tools.
• During disassembly, cover all openings,
such as intake and exhaust ports, to prevent
foreign materials from entering the engine.
Foreign materials could cause severe inter-
nal damage when the engine is started.
• Install bearings so that the bearing identifica-
tion mark is facing in the direction indicated in
the installation procedure. In addition, make
sure to lubricate the bearings liberally.
• Apply a thin coat of water resistant grease to
the lip and periphery of an oil seal before in-
Tightening torque stallation.
When tightening nuts, bolts, and screws, follow • Check that moving parts operate normally af-
the tightening instructions provided throughout ter assembly.
the manual. If the tightening order is not speci- • When starting the engine after reassembly,
fied, tighten the large sizes first, and then tight- check for fuel and water leaks from hoses
en the small sizes, starting from the center and and pipes that were disconnected or re-
moving outward. moved while servicing.

Non-reusable parts Disposal of used components and

Always use new gaskets, seals, O-rings, cotter
chemicals
pins, and so on, when installing or assembling
Obey all federal, state and local regulations
parts.
when disposing of used components and/or
chemicals such as crate frames, replaced
parts, gaskets, oil, and so on.
0-3
 How to use this manual

How to use this manual

Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the following information as a guide for effective and quality service.

• Parts are shown and detailed in an exploded diagram and are listed in the component list (see “1” in
the following figure for an example page).
• The component list consists of part names and quantities, as well as bolt and screw dimensions (see
“2” in the following figure).
• Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
the lubrication points (see “3” in the following figure).
• Tightening torque specifications are provided in the exploded diagrams (see “4” in the following fig-
ure), and in the related detailed instructions. Some torque specifications are listed in stages as torque
values or angles in degrees.
• Separate procedures and illustrations are used to explain the details of removal, checking, and instal-
lation where necessary (see “5” in the following figure for an example page).

For troubleshooting procedures, see Chapter 4, “Troubleshooting”.

3 4

1
Lower unit (regular rotation model)

Lower unit (regular rotation model)

42 Nm (4.2 kgf·m, 31.0 ft·lb) 6
7 54 Nm (5.4 kgf·m, 39.8 ft·lb)

15
9 Nm (0.9 kgf·m, 6.6 ft·lb) 13
10
5
14 Drive shaft and lower case (regular rotation model)
8 3. Install a new oil seal “1” in the drive shaft Assembling the lower case
3 5
2 4 12 housing at the specified installation depth
11 “a”.
9 A • Use heat-resistant gloves. Otherwise,
1
burns could result.
a • To prevent fires, remove any flammable
16
substances, such as gasoline and oil,
3
around the working area.
2 • Keep good ventilation while working.

17
20 1 1. Install the original forward gear shims “1”.

2. Heat the area of the lower case where

B the tapered roller bearing outer race is to
4
20 19 a be installed using a gas torch, and then
18 install a new tapered roller bearing outer
9 Nm (0.9 kgf·m, 6.6 ft·lb) 47 Nm (4.7 kgf·m, 34.7 ft·lb) 5
race “2”.
47 Nm (4.7 kgf·m, 34.7 ft·lb) 4

No. Par t name Q’ty Remarks

When heating the lower case, heat the
1 entire installation area evenly. Otherwise,
1 Hose nipple 1
the paint on the lower case could be
2 O-ring 1 Not reusable
burned.
3 Oil level plug 1 M8 8 mm A. Worldwide
4 Gasket 2 Not reusable B. USA and Canada
5 Dowel pin 2 TIP:
6 Grommet 1
Bearing outer race attachment “2” Do not reuse a shim if deformed or
90890-06628 scratched.
7 Bolt 1 M10 45 mm
Driver rod LS “3”
8 Lower unit 1
90890-06606
9 Spacer 1 2
10 Propeller 1
Bearing cup installer “4”
1
YB-06167
Not reusable, Shift Dampener System (SDS) pro-
11 Damper 1 Driver handle (large) “5”
peller
12 Spacer 1 Shift Dampener System (SDS) propeller YB-06071
13 Washer 1
Installation depth
14 Propeller nut 1 M18
0.25–0.75 mm (0.010–0.030 in)
15 Cotter pin 1 Not reusable
16 Spacer 1 Except Shift Dampener System (SDS) propeller 4. Install a new O-ring “1”.
17 Trim tab 1
1
8-1

3. While holding the special service tool “1”,

strike the tool to check that the tapered
roller bearing outer race is installed prop-
erly.

2
5 8-26

0-4
 How to use this manual

Conditions when testing and adjusting

Conditions can affect specifications when checking, measuring and making certain adjustments. Ser-
vice data in this manual was determined under the following conditions:
• Electrical resistance for components such as ignition coils and sensors was measured at 20 C (68
F).
• Engine compression was measured at:
• Sea level
• 20 C (68 F)
• All spark plugs removed
• Throttle valve at WOT (depending on model specification)
• Trim/tilt angles shown are when the transom angle is 12 degrees.

Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
ABYC American Boat and Yacht Council
ANZ Australia and New Zealand
APS Accelerator Position Sensor
ASSY Assembly
DEC Digital Electronic Control
ECM Electronic Control Module
EN European Norm (European standard)
EPA Environmental Protection Agency
ETV Electronic Throttle Valve
ISC Idle Speed Control
LPS Lever Position Sensor
NOA North America
OCV Oil Control Valve
OP Option
PCV Pressure Control Valve
PT Power Tilt
PTT Power Trim and Tilt
SPS Shift Position Sensor
TPS Throttle Position Sensor
VCT Variable Camshaft Timing
VST Vapor Separator Tank
VSV Vapor Shut-off Valve
Y-COP Yamaha Customer Outboard Protection
YDIS Yamaha Diagnostic System

0-5
 How to use this manual

Color code
The following color codes are used in this service manual.
Color code Color
B Black
Br Brown
G Green
Gy Gray
L Blue
Lg Light green
Or Orange
P Pink
Pu Purple
R Red
Sb Sky blue
W White
Y Yellow

For example, “R/Y” stands for a Red with Yellow tracer stripe wire.

0-6
 Symbol

Symbol
Symbol
Illustrated symbols are used to identify the specifications which appear.
Symbol Definition Symbol Definition

Filling fluid Lubricant

Special tool Tightening torque

T.
R.
Wear limit, clearance Engine speed

Electrical data

Lubricant, sealant, and thread locking agent

Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication points.
Symbol Name Application

YAMALUBE 4 or YAMALUBE 4M FC-W Lubricant

YAMALUBE outboard gear oil or Yamalube

Lubricant
Marine Gearcase Lube

Water resistant grease

Lubricant
(Yamaha grease A or Yamalube Marine Grease)
Molybdenum disulfide grease
Lubricant
(Yamalube Molybdenum Disulfide grease)
Corrosion resistant grease
Lubricant
(Yamaha grease D or Yamalube Marine Grease)
Low temperature resistant grease
(Yamaha grease C or Yamalube Molybdenum Lubricant
Disulfide grease)

YAMAHA WR-No.2 grease Lubricant

ThreeBond 1901 Lubricant

0-7
 Symbol
Symbols in an exploded diagram or illustration indicate the type of sealant or thread locking agent and
the application points.
Symbol Name Application
YAMAHA Gasket Maker Sealant

ThreeBond 1104J Sealant

ThreeBond 1207B Sealant

ThreeBond 1280B
Sealant
(Yamabond 4 Marine)

ThreeBond 1322 Thread locking agent

ThreeBond 1386B Sealant

ThreeBond 1377B Thread locking agent

ThreeBond 1324 Thread locking agent

ThreeBond 1401 Thread locking agent

ThreeBond 1303N Thread locking agent

ThreeBond 1530D Sealant

ThreeBond 1303 Thread locking agent

LOCTITE 271 (red) Thread locking agent

LOCTITE 242 (blue) Thread locking agent

LOCTITE 572 (white) Sealant

Silicone sealant Sealant

LOCTITE 648 (green) Thread locking agent

LOCTITE 210 (red) Thread locking agent

0-8
 Special service tool

Special service tool

Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division.
Some of the special service tools are only available from the Marine Service Division.

Reference
Tool name/Tool No. Illustration
pages
Drilling plate 3-6
90890-06783

YDIS2 Hardware Kit 4-1, 5-22

90890-06884

Digital circuit tester 5-22, 5-23,

90890-03243 9-34

Peak voltage adapter B 5-22

90890-03172

Test harness FWY–6 5-24

90890-06872

Test harness (3 pins) 5-31, 5-40,

90890-06869 5-53, 5-54

Vacuum/pressure pump gauge set 5-34, 5-40, 6-4,

90890-06945 6-7, 6-8, 6-19,
6-24, 6-35

Ignition checker (Spark gap tester) 5-37

90890-06754

0-9
 Special service tool

Reference
Tool name/Tool No. Illustration
pages
Test harness (2 pins) 5-38, 5-55
90890-06867

Fuel pressure gauge adapter 6-3, 6-4

90890-06946

Fuel pressure gauge 6-3, 6-4

90890-06753

Fuel injection meter 6-40

FIM20000ME

Compression gauge 7-1

90890-03160

Compression gauge extension 7-1

90890-06563

Flywheel holder 7-18, 7-20

90890-06522

Flywheel stopper 7-18, 7-20

90890-06598

Flywheel puller 7-18

90890-06521

0-10
 Special service tool

Reference
Tool name/Tool No. Illustration
pages
Sheave holder 7-52, 7-60
90890-01701

Valve spring compressor 7-67, 7-73

90890-04019

Valve spring compressor 7-67, 7-73

90890-06689

Valve spring compressor attachment 7-67, 7-73

90890-06320

Valve guide remover/installer 7-69, 7-70

90890-06801

Valve guide installer 7-70

90890-06810

Valve guide reamer 7-70

90890-06804

Valve lapper 7-70, 7-73

90890-04101

Valve seat cutter holder 7-71

90890-06316

0-11
 Special service tool

Reference
Tool name/Tool No. Illustration
pages
Valve seat cutter 30 7-71
90890-06817

Valve seat cutter 45 7-71

90890-06816

Valve seat cutter 30 7-71

90890-06326

Valve seat cutter 45 7-71

90890-06325

Valve seat cutter 60 7-71

90890-06324

Oil filter wrench 7-82, 7-86,

90890-06874 10-13

Driver rod L3 7-84, 8-3, 8-13,

90890-06652 8-19, 8-23,
8-66, 8-67,
9-20

Needle bearing attachment 7-84

90890-06613

Needle bearing attachment 7-84

90890-06607

0-12
 Special service tool

Reference
Tool name/Tool No. Illustration
pages
Piston slider 94 mm 7-103
90890-06683

Needle bearing attachment 8-3, 8-4, 8-22,

90890-06653 8-67, 9-20

Shift rod socket 8-8, 8-27, 8-32,

90890-06681 8-73

Bearing housing puller claw L 8-12, 8-32,

90890-06502 8-73

Stopper guide plate 8-12, 8-13,

90890-06501 8-20, 8-32,
8-65, 8-73,
9-20

Center bolt 8-12, 8-32,

90890-06504 8-73

Bearing separator 8-13, 8-19,

90890-06534 8-20, 8-57,
8-58

Stopper guide stand 8-13, 8-20,

90890-06538 8-65, 9-20

Bearing puller assembly 8-13, 8-20,

90890-06535 8-65, 9-20

0-13
 Special service tool

Reference
Tool name/Tool No. Illustration
pages
Slide hammer handle 8-13, 8-56
90890-06531

Bearing outer race puller assembly 8-13, 8-22

90890-06523

Needle bearing attachment 8-13

90890-06611

Driver rod SS 8-15, 8-22,

90890-06604 8-67

Needle bearing attachment 8-15, 8-19,

90890-06610 8-23

Bearing depth plate 8-15

90890-06603

Bearing inner race attachment 8-15

90890-06640

Needle bearing attachment 8-15, 8-66,

90890-06654 8-67

Drive shaft holder 6 8-19, 8-24,

90890-06520 8-39

0-14
 Special service tool

Reference
Tool name/Tool No. Illustration
pages
Pinion nut holder 8-19, 8-24
90890-06715

Bearing puller claw 1 8-20, 8-65

90890-06536

Ball bearing attachment 8-20, 8-22

90890-06655

Driver rod LL 8-20, 8-22

90890-06605

Bearing inner race attachment 8-22

90890-06658

Bearing inner race attachment 8-22

90890-06659

Leakage tester 8-27

90890-06840

Backlash indicator 8-33, 8-74

90890-06706

Magnet base plate 8-33, 8-74

90890-07003

0-15
 Special service tool

Reference
Tool name/Tool No. Illustration
pages
Dial gauge set 8-33, 8-41,
90890-03238 8-74, 8-79

Magnet base B 8-33, 8-41,

90890-06844 8-74, 8-79

Pinion height gauge 8-38

90890-06672

Puller head 8-56

90890-06514

Ring nut wrench 8-57, 8-60,

90890-06578 8-61, 8-62

Housing nut wrench 8-58, 8-62

90890-06876

PTT oil pressure gauge assembly 9-38, 9-39

90890-06580

Cylinder end screw wrench 9-59, 9-63,

90890-06591 9-64

PTT piston vice attachment 9-60, 9-61

90890-06572

0-16
 Special service tool

Reference
Tool name/Tool No. Illustration
pages
Tilt rod wrench 9-60, 9-61
90890-06569

0-17
 Specification

Model feature ...................................................................... 1-1

General feature .......................................................................... 1-1 0
Model name designation ............................................................ 1-2
Serial number ............................................................................. 1-3
1
Model data .......................................................................... 1-4

Electrical system technical data ....................................... 1-6 2

Ignition timing control system ..................................................... 1-6
Fuel injection control system ...................................................... 1-7
Engine speed control system ..................................................... 1-7
VCT system................................................................................ 1-8
3
PTT system ................................................................................ 1-8
Charging system ........................................................................ 1-8
Starting system........................................................................... 1-8 4
Gauge/sensor............................................................................. 1-9

Fuel system technical data.............................................. 1-10 5

Fuel system .............................................................................. 1-10

Power unit technical data ................................................ 1-11 6

Power unit ................................................................................ 1-11
Cylinder head assembly ........................................................... 1-11
Crankcase assembly ................................................................ 1-12 7
Lower unit technical data ................................................ 1-14
Lower unit assembly (regular rotation model) .......................... 1-14 8
Lower unit assembly (counter rotation model) ......................... 1-14

Bracket unit technical data.............................................. 1-16 9

PTT system .............................................................................. 1-16

External dimensions ........................................................ 1-17

10
Clamp bracket dimensions.............................................. 1-18

Specified tightening torque............................................. 1-19

General tightening torque......................................................... 1-19 A
 Model feature

Model feature
General feature
• Electronic fuel injected, 4-stroke, V6, DOHC, 24-valve, 3352 cm³ (204.5 cu. in) engine
• Hard surface coating for lower components for durability.

a. Power unit e. Lower unit

• Shimless valve lifters • Hard chromeplated water pump (outer plate
• VCT (IN) cartridge and insert cartridge)
• Blowby gas reburning system • Anodized lower case and propeller shaft
• Vapor gas treatment system housing (F250H, FL250H)
• Single electronic throttle body • Drive shaft spring (F250H, FL250H)
• Long intake manifolds • Propeller damper cooling system (F250H,
• Large diameter intake valve heads FL250H)
• In-bank exhaust system • Patented shift damper system (Shift Damp-
ener System [SDS] propeller)
b. Electrical • Forward gear and reverse gear hardness im-
• New fuse box and relays proved (F250H, FL250H)
• Electronic fuel injection control • Thicker gear tooth: Pinion gear 15  13
• Digital ignition control teeth F/R gear 30  26 teeth (F250H,
• ETV control FL250H)
• VCT control (IN)
• Knock control a
• Over-revolution control
b
• Fail-safe control
• Self-diagnosis system with YDIS (2.22 and
later versions)
• Water-cooled rectifier/regulator
• High generator output (maximum 46 A)
• Compatible with digital network gauges
c
(6Y8/6YC) Meter, and conventional gauges d
(6Y5/6Y7)
• Speed sensor and water pressure sensor
(optional)

c. Bracket unit
• Long span mount e

d. Upper case
• Anodized exhaust passages

1-1
 Model feature

Model name designation

F 250 H E T X
1 2 3 4 5

None: 2-stroke
E: Enduro
F: 4-stroke
L: Counter rotating propeller
1 Model category
T: High thrust (4-stroke)
D: Twin rotating propeller
K: Kerosene
Z: HPDI
2 Output horsepower Example: 6/9.9/75/150/250/300
3 Model generation A/B/C/D/F/G/H/J/L/N/P/Q/R/S/T/U/V/X/Y (Repeat from A)
Level 1: Starting method
M: Manual start
E: Electric start
W: Electric start with manual start

Level 2: Control method

None: Remote control without tiller handle
H: Tiller handle
C: Remote control with tiller handle
4 Model variation
Level 3: Trim and tilt method
None: Manual tilt
D: Hydraulic tilt
P: PT (Power tilt)
T: PT/T (Power trim and tilt)

Level 4: Lubrication system (2-stroke model)

None: Premixed fuel with oil model
O: Oil injection model
S (15 in)
L (20 in)
Transom height (Drive
5 Y (22 in)
shaft length)
X (25 in)
U (30 in)

1-2
 Model feature

Serial number
The outboard motor serial number is indicated
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. Motor transom height
4. Serial number

Approved Starting
Model name
model code serial No.
F200BET 6S1 1006301–
FL200BET 6S2 1002029–
F250HET 6DX 1004982–
FL250HET 6DY 1002299–

1-3
 Model data

Model data
Dimension and weight

0
Overall length 868 mm (34.2 in)
Overall width 634 mm (25.0 in)
Overall height X 1829 mm (72.0 in)
Overall height U 1956 mm (77.0 in)
Motor transom height X
Motor transom height U
643 mm (25.3 in)
770 mm (30.3 in) 1
Dry weight (SUS) X 283 kg (624 lb)
Dry weight (SUS) U 289 kg (637 lb)
* Dry weight: With SUS (stainless steel) propeller
Performance
2
Rated power 147.1 kW (200 HP) (F200BET, FL200BET)

Full throttle operating range

183.9 kW (250 HP) (F250HET, FL250HET)
5000–6000 r/min 3
Maximum fuel consumption (reference data) 73.7 L/h at 5500 r/min (19.5 US gal/h at 5500 r/min,
16.2 Imp.gal/h at 5500 r/min) (F200BET,
FL200BET)
75.6 L/h at 5500 r/min (20.0 US gal/h at 5500 r/min,
4
16.6 Imp.gal/h at 5500 r/min) (F250HET,

5
FL250HET)
Idle speed (in neutral) 600–700 r/min
Power unit
Type 4-stroke DOHC V6 24 valves
Total displacement
Bore  stroke
3352 cm³ (204.5 c.i.)
94.0  80.5 mm (3.70  3.17 in)
6
Compression ratio 9.9 : 1

7
Minimum (reference data) 595 kPa (5.95 kgf/cm², 86.3 psi)
Throttle & shift control system Remote control
Starting system Electric starter
Fuel system Fuel injection
Starting carburetion system
Ignition system
Fuel injection
TCI 8
Advance type Microcomputer
Maximum generator output 46 A
Maximum charging capacity 28 A (F200BET, FL200BET)
27 A (F250HET, FL250HET)
9
Spark plug (NGK) LFR6A-11
Firing order 1-2-3-4-5-6
Steering system
Exhaust system
Remote steering
Through propeller boss
10
Cooling system Water
Lubrication system Wet sump
Remote propulsion system Mechanical control
Lower unit

A
Gear shift positions Forward-neutral-reverse

1-4
 Model data
Gear ratio 2.00 (30/15) (F200BET, FL200BET)
2.00 (26/13) (F250HET, FL250HET)
Gear type Spiral bevel gear
Clutch type Dog clutch
Propeller fitting mechanism Spline
Propeller direction (rear view) Clockwise (F200BET, F250HET)
Counter clockwise (FL200BET, FL250HET)
Propeller mark M/T (F200BET, F250HET)
ML/TL (FL200BET, FL250HET)
Bracket unit
Trim angle -3 to +16
Full Tilt-up angle 70
Tilt support angle 67
Steering angle 32 +32
Trim and tilt system Power trim and tilt

Fuel and oil

Recommended fuel Regular unleaded gasoline
Min. research octane number (RON) 84 (F200BET, FL200BET)
90 (F250HET, FL250HET)
Recommended engine oil YAMALUBE 4 or 4-stroke outboard motor oil
Recommended engine oil grade 1 SAE 10W-30/10W-40/5W-30
API SE/SF/SG/SH/SJ/SL
Recommended engine oil grade 2 SAE 15W-40/20W-40/20W-50
API SH/SJ/SL
Engine oil quantity (total amount) 5.6 L (5.92 US qt, 4.93 Imp.qt)
Engine oil quantity (without oil filter replace- 4.5 L (4.76 US qt, 3.96 Imp.qt)
ment)
Engine oil quantity (with oil filter replacement)
4.7 L (4.97 US qt, 4.14 Imp.qt)
Recommended gear oil YAMALUBE outboard gear oil or Hypoid gear oil
Recommended gear oil grade SAE 90 API GL-4 / SAE 80W API GL-5 / SAE 90
API GL-5
Gear oil quantity 1.150 L (1.216 US qt, 1.012 Imp.qt)
(F200BET, F250HET)
1.000 L (1.057 US qt, 0.880 Imp.qt)
(FL200BET, FL250HET)
* Recommended engine oil and gear oil grade: Meeting both API and SAE requirements.
Battery requirement
Battery rating (CCA/EN) 510–1080 A
Battery rating (20HR/IEC) 80 Ah

1-5
 Electrical system technical data

Electrical system technical data

Ignition timing control system

0
Spark plug
Spark plug gap 1.0–1.1 mm (0.039–0.043 in)

Cam position sensor

1
Input voltage (R/Y–B) 12 V
Input voltage (STBD IN: W/B–B, PORT IN: 4.75–5.25 V
W/G–B, PORT EX: W/L–B)

Ignition coil
Input voltage 12 V 2
Pulser coil
Air gap 1.40–1.60 mm (0.055–0.063 in)
Output peak voltage at cranking (unloaded)
(reference data)
3.0 V
3
Output peak voltage at cranking (loaded) (ref- 2.7 V
erence data)
Output peak voltage at 1500 r/min (loaded)
(reference data)
14.5 V 4
Output peak voltage at 3500 r/min (loaded) 17.8 V
(reference data)
Resistance 396.0–594.0  5
Intake air pressure sensor

6
Input voltage 4.75–5.25 V
Output voltage at -20.0 kPa (-0.20 kgf/cm², 0.79 V
-2.9 psi)
Output voltage at -46.7 kPa (-0.467 kgf/cm², 1.84 V
-6.8 psi)

Intake air temperature sensor

7
Resistance at 20 C (68 F) 2.210–2.690 k
Resistance at 80 C (176 F)
Engine temperature sensor
0.322 k
8
Input voltage 4.75–5.25 V
Resistance at 5 C (41 F) (reference data)
9
128.00 k
Resistance at 20 C (68 F) (reference data) 54.20–69.00 k
Resistance at 100 C (212 F) (reference data) 3.12–3.48 k
Thermo switch
Input voltage
Switch ON temperature
12 V
84–90 C (183–194 F)
10
Switch OFF temperature 68–82 C (154–180 F)

Shift cut-off switch

Input voltage (reference data) 5V
Free position resistance 4.465–4.935 k
0
A
Pushed position resistance

1-6
 Electrical system technical data

Shift position switch

Input voltage (reference data) 5V
Knock sensor
Resistance 504–616 k

Fuel injection control system

Water detection switch
Input voltage 4.75–5.25 V
Fuel injector
Input voltage 12 V
Resistance (reference data) 12.00 

Low-pressure fuel pump

Input voltage 12 V
Resistance (reference data) 0.5–4.0 

High-pressure fuel pump

Input voltage 12 V
Resistance (reference data) 0.3–10.0 
Vapor shut-off valve
Input voltage 12 V
Resistance 30.0–34.0 

Engine speed control system

TPS
Input voltage 4.75–5.25 V
TPS 1 output voltage at throttle valve fully 0.723 V
closed (reference data)
TPS 2 output voltage at throttle valve fully 2.279 V
closed (reference data)
TPS 1 output voltage at throttle valve fully 4.311 V
open (reference data)
TPS 2 output voltage at throttle valve fully 4.639 V
open (reference data)
APS
Input voltage 4.75–5.25 V
APS 1 output voltage at throttle valve fully 0.644 V
closed (reference data)
APS 2 output voltage at throttle valve fully 0.688 V
closed (reference data)
APS 1 output voltage at throttle valve fully 4.014 V
open (reference data)
APS 2 output voltage at throttle valve fully 4.043 V
open (reference data)

1-7
 Electrical system technical data
Resistance at throttle valve fully open (refer- 0.8 k
ence data)
Resistance at throttle valve fully closed (refer- 5.3 k
ence data)

Oil pressure sensor

0
Input voltage 4.75–5.25 V

1
Output voltage at 392 kPa (3.92 kgf/cm², 56.8 2.5 V
psi)
Output voltage at 784 kPa (7.84 kgf/cm², 113.7 4.5 V
psi)

VCT system
2
OCV
Input voltage
Resistance
12 V
6.7–7.7 
3
PTT system 4
Trim sensor
Free position resistance 248–388 
Setting resistance 9–11 
5
Charging system
Lighting coil 6
Output peak voltage at cranking (unloaded) 8.3 V
(reference data)
Output peak voltage at 1500 r/min (unloaded)
(reference data)
44.7 V
7
Output peak voltage at 3500 r/min (unloaded) 97.7 V
(reference data)
Resistance (reference data) 0.1144–0.1716 
8
Rectifier/Regulator
Output voltage at 1500 r/min (loaded) (refer- 13 V
ence data)
Output voltage at 3500 r/min (loaded) (refer- 13 V
9
ence data)

Starting system 10
Starter motor
Type Sliding gear
Output 1.40 kW
Cranking time limit 30 sec
Standard brush length 15.5 mm (0.61 in)
Wear limit
Standard commutator diameter
9.5 mm (0.37 in)
29.0 mm (1.14 in)
A
1-8
 Electrical system technical data
Wear limit 28.0 mm (1.10 in)
Standard commutator undercut 0.8 mm (0.03 in)
Wear limit 0.2 mm (0.01 in)

Gauge/sensor
Water pressure sensor
Input voltage 4.75–5.25 V
Output voltage at 392 kPa (3.92 kgf/cm², 56.8 2.5 V
psi) (reference data)
Output voltage at 784 kPa (7.84 kgf/cm², 113.7 4.5 V
psi) (reference data)

Speed sensor
Input voltage 4.75–5.25 V
Output voltage at 392 kPa (3.92 kgf/cm², 56.8 2.5 V
psi) (reference data)
Output voltage at 784 kPa (7.84 kgf/cm², 113.7 4.5 V
psi) (reference data)

1-9
 Fuel system technical data

Fuel system technical data

Fuel system

0
Fuel line
Fuel pressure at engine start switch to “ON” 290.0 kPa (2.90 kgf/cm², 42.1 psi)
within 5 seconds
Fuel pressure at engine idle speed 260.0 kPa (2.60 kgf/cm², 37.7 psi)

Fuel filter assembly

Fuel inlet holding pressure (positive pressure) 200 kPa (2.0 kgf/cm², 29.0 psi)
1
Fuel outlet holding pressure (negative pres- 80 kPa (0.8 kgf/cm², 11.6 psi)
sure)
Primer pump
2
Positive pressure 166.7 kPa (1.67 kgf/cm², 24.2 psi)
Vapor separator tank
Float height 65.0–70.0 mm (2.56–2.76 in)
3
Canister
Holding pressure (positive pressure) 19.6 kPa (0.20 kgf/cm², 2.8 psi)
4
5
6
7
8
9
10

A
1-10
 Power unit technical data

Power unit technical data

Power unit
Compression pressure
Minimum (reference data) 595 kPa (5.95 kgf/cm², 86.3 psi)

Engine oil
Engine oil pressure at idle speed (reference 507.3 kPa (5.073 kgf/cm², 73.6 psi)
data)
Engine oil pressure at 3000 r/min (reference 700.6 kPa (7.006 kgf/cm², 101.6 psi)
data)
* For the checking method, see “Checking the oil pressure” (7-1). The figures are for reference only.
Thermostat
Valve opening temperature 58–62 C (136–144 F)
Fully open temperature 70 C (158 F)
Fully open stroke 4.3 mm (0.17 in)

Timing belt
Installation height 2.0 mm (0.08 in)

Cylinder head assembly

Cylinder head
Warpage limit 0.10 mm (0.0039 in)
Journal inside diameter 25.000–25.021 mm (0.9843–0.9851 in)
Camshaft journal oil clearance 0.020–0.061 mm (0.0008–0.0024 in)
Limit 0.080 mm (0.0032 in)

Camshaft
Cam lobe height IN 46.311–46.411 mm (1.8233–1.8272 in)
Limit 46.261 mm (1.8213 in)
Cam lobe height EX 45.360–45.460 mm (1.7858–1.7898 in)
Limit 45.310 mm (1.7839 in)
Journal diameter 24.960–24.980 mm (0.9827–0.9835 in)
Runout 0.030 mm (0.0012 in)

Valve clearance
Valve clearance IN (cold engine) 0.17–0.24 mm (0.0067–0.0094 in)
Valve clearance EX (cold engine) 0.31–0.38 mm (0.0122–0.0150 in)

Valve
Margin thickness IN 0.50–0.90 mm (0.0197–0.0354 in)
Margin thickness EX 0.90–1.30 mm (0.0354–0.0512 in)
Seat contact width IN 1.10–1.40 mm (0.0433–0.0551 in)
Limit 1.850 mm (0.0728 in)
Seat contact width EX 1.40–1.70 mm (0.0551–0.0669 in)
Limit 2.150 mm (0.0846 in)

Valve lifter
Outside diameter 30.970–30.980 mm (1.2193–1.2197 in)
Clearance IN (reference data) 0.020–0.055 mm (0.0008–0.0022 in)
Clearance EX (reference data) 0.020–0.055 mm (0.0008–0.0022 in)

1-11
 Power unit technical data

Valve stem
Diameter IN 5.477–5.492 mm (0.2156–0.2162 in)
Limit 5.447 mm (0.2144 in)
Diameter EX
Limit
5.464–5.479 mm (0.2151–0.2157 in)
5.434 mm (0.2139 in)
0
Runout limit IN 0.01 mm (0.0004 in)

1
Runout limit EX 0.01 mm (0.0004 in)

Valve guide
Inside diameter IN 5.504–5.522 mm (0.2167–0.2174 in)
Clearance IN 0.012–0.045 mm (0.0005–0.0018 in)
Limit
Inside diameter EX
0.070 mm (0.0028 in)
5.504–5.522 mm (0.2167–0.2174 in)
2
Clearance EX 0.025–0.058 mm (0.0010–0.0023 in)
Limit
Installation height
0.080 mm (0.0032 in)
11.30–11.70 mm (0.4449–0.4606 in) 3
Valve spring

4
Free length IN 48.08 mm (1.89 in)
Limit 45.68 mm (1.80 in)
Tilt limit IN 1.7 mm (0.07 in)
Free length EX 48.08 mm (1.89 in)
Limit
Tilt limit EX
45.68 mm (1.80 in)
1.7 mm (0.07 in) 5
Crankcase assembly
Cylinder
6
Bore 94.000–94.017 mm (3.7008–3.7014 in)

7
Limit 94.071 mm (3.7036 in)

Piston
Diameter 93.921–93.941 mm (3.6977–3.6985 in)
Limit 93.881 mm (3.6961 in)
Measuring point
Piston clearance
13.5 mm (0.53 in)
0.075–0.080 mm (0.0030–0.0032 in)
8
Limit 0.190 mm (0.0075 in)
Ring groove (Top)
Ring groove (2nd)
1.22–1.25 mm (0.0480–0.0492 in)
1.22–1.24 mm (0.0480–0.0488 in) 9
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)
Limit
Pin outside diameter
21.051 mm (0.8288 in)
21.008–21.017 mm (0.8271–0.8274 in) 10
Limit 20.998 mm (0.8267 in)

Piston ring (Top)

Type Barrel
Height (B) 1.170–1.190 mm (0.0461–0.0469 in)
Width (T) 2.800–3.000 mm (0.1102–0.1181 in)
End gap
Limit
0.20–0.30 mm (0.0079–0.0118 in)
0.470 mm (0.0185 in)
A
1-12
 Power unit technical data
Side clearance 0.03–0.08 mm (0.0012–0.0032 in)
Limit 0.130 mm (0.0051 in)

Piston ring (2nd)

Type Taper
Height (B) 1.170–1.190 mm (0.0461–0.0469 in)
Width (T) 3.600–3.800 mm (0.1417–0.1496 in)
End gap 0.35–0.50 mm (0.0138–0.0197 in)
Limit 0.650 mm (0.0256 in)
Side clearance 0.03–0.07 mm (0.0012–0.0028 in)
Limit 0.110 mm (0.0043 in)

Piston ring (Oil)

Height (B) 2.400–2.470 mm (0.0945–0.0972 in)
Width (T) 2.300–2.700 mm (0.0906–0.1063 in)
End gap 0.15–0.60 mm (0.0059–0.0236 in)
Side clearance 0.04–0.13 mm (0.0016–0.0051 in)

Connecting rod
Small end inside diameter 21.022–21.037 mm (0.8276–0.8282 in)
Big end inside diameter 53.015–53.035 mm (2.0872–2.0880 in)
Big end side clearance 0.150–0.300 mm (0.0059–0.0118 in)
Limit 0.35 mm (0.0138 in)
Big end oil clearance 0.028–0.066 mm (0.0011–0.0026 in)
Limit 0.096 mm (0.0038 in)

Crankshaft
Journal diameter 62.968–62.992 mm (2.4791–2.4800 in)
Crankshaft pin diameter 49.976–50.000 mm (1.9676–1.9685 in)
Runout 0.03 mm (0.0012 in)
Limit 0.04 mm (0.0016 in)
Crankshaft pin width 21.50–21.55 mm (0.8465–0.8484 in)
Journal oil clearance 0.035–0.050 mm (0.0014–0.0020 in)
Limit 0.070 mm (0.0028 in)

1-13
 Lower unit technical data

Lower unit technical data

Lower unit assembly (regular rotation model)

0
Lower unit
Holding pressure 68.6 kPa (0.69 kgf/cm², 9.9 psi) (F200BET,
F250HET)
Gear backlash
Forward gear backlash 0.29–0.67 mm (0.0114–0.0264 in) (F200BET)
0.18–0.90 mm (0.0071–0.0354 in) (F250HET)
1
Reverse gear backlash 0.25–0.88 mm (0.0098–0.0346 in) (F200BET)
0.63–1.44 mm (0.0248–0.0567 in) (F250HET)
* Figures obtained using the special service tools. 2
Available shim thicknesses

3
Pinion shims 0.10/0.12/0.15/0.18/0.30/0.40/0.50 mm (F200BET,
F250HET)
Forward shims 0.10/0.12/0.15/0.18/0.30/0.40/0.50 mm (F200BET,
F250HET)
Reverse shims 0.10/0.12/0.15/0.18/0.30/0.40/0.50 mm (F200BET,
F250HET) 4
Propeller shaft shims 1.80/1.90/2.00/2.10/2.20 mm (F250HET)

Propeller shaft
Propeller shaft free play 0.20–0.50 mm (0.0079–0.0197 in) (F250HET) 5
Runout 0.02 mm (0.0008 in) (F200BET, F250HET)

6
Drive shaft
Runout 0.2 mm (0.008 in) (F200BET, F250HET)

Lower unit assembly (counter rotation model)

Lower unit
7
Holding pressure 68.6 kPa (0.69 kgf/cm², 9.95 psi) (FL200BET,
FL250HET)
Gear backlash 8
Forward gear backlash 0.49–0.84 mm (0.0193–0.0331 in) (FL200BET)
0.15–0.88 mm (0.0059–0.0346 in) (FL250HET)
Reverse gear backlash 0.45–0.97 mm (0.0177–0.0382 in) (FL200BET)
0.60–1.37 mm (0.0236–0.0539 in) (FL250HET)
9
* Figures obtained using the special service tools.

Available shim thicknesses

Pinion shims 0.10/0.12/0.15/0.18/0.30/0.40/0.50 mm 10
(FL200BET, FL250HET)
Forward shims 0.10/0.12/0.15/0.18/0.30/0.40/0.50 mm
(FL200BET, FL250HET)
Reverse shims 0.10/0.12/0.15/0.18/0.30/0.40/0.50 mm
(FL200BET, FL250HET)

A
Propeller shaft shims 0.10/0.12/0.15/0.18/0.30/0.40/0.50 mm
(FL200BET, FL250HET)

1-14
 Lower unit technical data

Propeller shaft
Propeller shaft free play 0.25–0.35 mm (0.0098–0.0138 in) (FL200BET,
FL250HET)
Runout 0.02 mm (0.0008 in) (FL200BET, FL250HET)

Drive shaft
Runout 0.2 mm (0.008 in) (FL200BET, FL250HET)

1-15
 Bracket unit technical data

Bracket unit technical data

PTT system

0
Hydraulic pressure
Down 7.70 Mpa (77.0 kgf/cm², 1116.5 psi)
Up 14.00 Mpa (140.0 kgf/cm², 2030.0 psi)
Motor
Standard commutator diameter
Wear limit
23.00 mm (0.9055 in)
22.00 mm (0.8661 in)
1
Standard commutator undercut 1.40 mm (0.0551 in)
Wear limit
Standard brush length
0.90 mm (0.0354 in)
11.50 mm (0.4528 in) 2
Wear limit 4.5 mm (0.18 in)

3
PTT fluid requirement
Recommended fluid ATF Dexron II

4
5
6
7
8
9
10

A
1-16
 External dimensions

External dimensions

The dimension values may include reference values.

mm (in)

453 (17.8)

723.9 (28.5)
T1*1
32°
317 (12.5)

X: 1155 (45.5)
619 (24.4) U: 1272 (50.1)
219 (8.6) 651 (25.6)
75 (3.0)
902 (35.5)

752 (29.6)
39 (1.5) 387 (15.2)
45 (1.8)
U: 770 (30.3)
X: 643 (25.3)

230 (9.1)
U: 1205 (47.4)
X: 1078 (42.4)

H*2

59 (2
U: 924 (36.4)
X: 847 (33.3)

.3)
216 (8.5)

3
°*
70

12°

X: 52 (2.0)
(1.0)

U: 59 (2.3) –3° 673 (26.5)

25

*1. Minimum distance between the outboard motors in twin or triple engine application
*2. Motor transom height
*3. Fully tilt-up angle (Not tilt support angle)

1-17
 Clamp bracket dimensions

Clamp bracket dimensions

The dimension values may include reference values.

0
mm (in)

1
2
180 (7.1) 180 (7.1)
3
163.5 (6.4) 163.5 (6.4)
4
50.8 (2.0)

5
6
79 (3.1)
254 (10.0)

13 (0.5) 20 (0.8)
18.5 (0.7)
411 (16.2)

13 (0.5) 7
55.5 (2.2)

8
9
102 (4.0) 102 (4.0)
52 (2.0)

10
125.4 (4.9) 125.4 (4.9)

A
1-18
 Specified tightening torque

Specified tightening torque

Specified tightening torques are provided for
specific nuts, bolts, and screws. Specified
tightening torque specifications are provided in
the exploded diagrams and in the related work-
ing instructions. When tightening these fasten-
ers, follow the tightening torque specifications
and procedures indicated throughout the man-
ual to meet the design aims of the outboard
motor.

General tightening torque

This chart indicates the tightening torques for
standard fasteners with a standard ISO thread
pitch.

Width General torque speci-

Thread fications
across
size (B)
flats (A) Nm kgf·m ft·lb
8 mm M5 5 0.5 3.7
10 mm M6 8 0.8 5.9
12 mm M8 18 1.8 13
14 mm M10 36 3.6 27
17 mm M12 52 5.2 38

1-19
 Technical feature and description

Electronic control system ................................................. 2-1

Electrical components ................................................................ 2-3 0
Fail-safe...................................................................................... 2-5

Fuse box and relay ............................................................. 2-7 1

Fuse box..................................................................................... 2-7

2
Relays and fuel pump fuse......................................................... 2-8

Lower unit ........................................................................... 2-9

Forward gear and reverse gear (F250H, FL250H)..................... 2-9
Shift Dampener System (SDS)................................................. 2-10 3
Fuel system ...................................................................... 2-11
Fuel diagram ............................................................................ 2-11
4
Lubrication system .......................................................... 2-13
Lubrication diagram.................................................................. 2-13
5
Cooling system ................................................................ 2-15 6
Cooling diagram ....................................................................... 2-15

Intake and exhaust system.............................................. 2-17 7

Intake and exhaust diagram ..................................................... 2-17

Hose routing ..................................................................... 2-18

8
Fuel hose and blowby hose...................................................... 2-18
Pressure regulator hose, vapor gas hose, and intake air
pressure sensor hose............................................................... 2-19 9
Cooling water hose................................................................... 2-20

10

A
 Electronic control system

Electronic control system

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

17. High-pressure fuel pump

22. Fuel injector 18. Low-pressure fuel pump
23. OCV 19. Vapor shut-off valve

24. Ignition
coil

21. ETV

24. Ignition
20. TPS
coil
23. OCV
22. Fuel injector

1. Cam position sensor (IN)

25. ETV control 2. Cam position sensor (EX)
3. Pulser coil
26. Digital ignition control 4. Intake air pressure sensor
5. Oil pressure sensor
27. Valve control 6. Engine temperature sensor
28. Fuel injection control 33. Engine 7. Intake air temperature sensor
ECM 8. Knock sensor
9. APS
29. YDIS 10. Shift cut-off switch
11. Shift position switch
30. 6Y8 Multifunction Meters 12. Thermo switch
13. Engine shut-off switch
31. Multi-hub 14. Water detection switch
15. Water pressure sensor *1
16. Speed sensor *2
32. Battery

2-1
 Electronic control system

1. Cam position sensor (IN) 18. Low-pressure fuel pump

2. Cam position sensor (EX) 19. Vapor shut-off valve
3. Pulser coil 20. TPS
4. Intake air pressure sensor 21. ETV
5. Oil pressure sensor 22. Fuel injector
6. Engine temperature sensor 23. OCV
7. Intake air temperature sensor 24. Ignition coil
8. Knock sensor 25. ETV control
9. APS 26. Digital ignition control
10. Shift cut-off switch 27. Valve control
11. Shift position switch 28. Fuel injection control
12. Thermo switch 29. YDIS
13. Engine shut-off switch 30. 6Y8 Multifunction Meters
14. Water detection switch 31. Multi-hub
15. Water pressure sensor *1 32. Battery
16. Speed sensor *2 33. Engine ECM
17. High-pressure fuel pump

*1. Standard for Caribbean and China market and optional for other markets. (F250H)
Standard for Caribbean market and optional for other markets. (FL250H)
Optional. (F200B, FL200B)
*2. Standard for Caribbean and China market and optional for other markets. (F250H)
Optional. (F200B, FL200B, FL250H)

2-2
 Electronic control system

Electrical components

1
12
2

11
3

13
4 14
5
10 15
16
9
26
8 17
7 6

25
24
18

23

22

19
21 20

2-3
 Electronic control system

Part name Function

Advances or retards the intake camshaft timing by switching
the oil passages through which the engine oil is sent into the
1 OCV (STBD)
advance chamber or the retard chamber in the rotor vane
housing.
2 Thermo switch (STBD) Detects engine overheating.
Detects the throttle lever operation. APS 2 is the main sensor
3 APS (APS 1 and APS 2) and APS 1 is the sub sensor. APS 1 and APS 2 mutually mon-
itor each other for malfunctions.
4 Shift position switch Detects the neutral position.
5 Shift cut-off switch Detects the shift-out condition for the forward gearshift.
6 Fuel injector (STBD) Injects fuel.
Cam position sensor (STBD
7 Detects the advance angle on the intake camshaft.
IN)
8 Ignition coil (STBD) Produces high voltage to ignite a spark plug.
9 Knock sensor Detects engine knocking.
Determines the engine operating conditions according to the
input signals from the sensors and switches which are installed
10 Engine ECM
at various locations on the engine, and sends output signals to
operate the actuators to perform the various control functions.
11 Ignition coil (PORT) Produces high voltage to ignite a spark plug.
Determines the stroke of each cylinder according to the signals
Cam position sensor (PORT
12 from both the pulser coil and the cam position sensor (PORT
EX)
EX).
Detects the engine speed.
Detects the crankshaft angle and piston positions.
13 Pulser coil
Determines each group of cylinders (#1 and #4, #2 and #5,
and #3 and #6).
14 Engine temperature sensor Detects the engine temperature.
15 Thermo switch (PORT) Detects engine overheating.
Advances or retards the intake camshaft timing by switching
the oil passages through which the engine oil is sent into the
16 OCV (PORT)
advance chamber or the retard chamber in the rotor vane
housing.
Cam position sensor (PORT
17 Detects the advance angle on the intake camshaft.
IN)
18 Fuel injector (PORT) Injects fuel.
19 High-pressure fuel pump Pressurizes the fuel and sends the fuel to the fuel rail.
20 Low-pressure fuel pump Sends the fuel from the fuel tank to the vapor separator.
Detects the throttle valve opening angle. TPS 1 is the main
21 TPS (TPS 1 and TPS 2) sensor and TPS 2 is the sub sensor. TPS 1 and TPS 2 mutu-
ally monitor each other for malfunctions.

2-4
 Electronic control system

Part name Function

22 Oil pressure sensor Detects the oil pressure.
23 ETV Opens and closes the throttle valve using an electric motor.
24 Intake air pressure sensor Detects the intake air pressure.
Controls the amount of vapor gas to be sent from the vapor
25 Vapor shut-off valve
separator to the intake system.
Intake air temperature sen-
26 Detects the intake air temperature.
sor

Fail-safe
In the fail-safe control, the engine ECM enters the fail-safe control mode when an electrical component
malfunctions.
The fail-safe control system records the trouble codes according to the engine trouble conditions.
Item Trouble conditions to be detected Controls performed by ECM
Use cam position sensor (PORT
There is a signal from cam position EX) signal.
Pulser coil sensor (PORT EX) but no signal Ignition timing is limited to BTDC
from pulser coil. 10.
Set VCT in full retard position.
Switch to group fuel injection mode.
No signal from cam position sensor
Cam position sensor Ignition timing advance angle is lim-
(PORT EX) during 2 rotations of the
(PORT EX) ited to BTDC 10.
crankshaft.
Set VCT in full retard position.
No signal from cam position sensor
Cam position sensor
(STBD IN) during 2 rotations of the Set VCT in full retard position.
(STBD IN)
crankshaft.
No signal from cam position sensor
Cam position sensor
(PORT IN) during 2 rotations of the Set VCT in full retard position.
(PORT IN)
crankshaft.
TPS 1 output voltage is 0.35 V or
Set to intake air pressure.
less or 4.80 V or more. TPS 2 output
Throttle valve is set at specified
voltage is 2.25 V or less or 4.80 V or
TPS opening angle.
more. Difference between TPS 1
High engine idle speed.
and TPS 2 voltages is 1.7 V or less
Set VCT in full retard position.
or 2.30 V or more.
Output voltage of APS 1 or APS 2 is
0.293 V or less, or one of them is
less than 4.004 V and the other is Throttle valve is set at specified
APS
4.805 V or more. Difference opening angle.
between APS 1 and APS 2 voltages
is 0.996 V or more.
Intake air pressure Output voltage is less than 0.20 V or Set to TPS value.
sensor more than 4.50 V. High engine idle speed.

2-5
 Electronic control system

Item Trouble conditions to be detected Controls performed by ECM

Set to intake air temperature when
Engine temperature Output voltage is less than 0.18 V or starting.
sensor more than 4.90 V. Set to 40 C (104 F) when running.
High engine idle speed.
Intake air tempera- Output voltage is less than 0.10 V or Set to 40 C (104 F).
ture sensor more than 4.60 V. High engine idle speed.
Output voltage is less than 0.30 V,
more than 4.80 V for 260 seconds,
Oil pressure sensor High engine idle speed.
or more than 4.80 V when engine is
stopped.
Output voltage is less than 0.90 V or
Knock sensor High engine idle speed.
more than 4.00 V.
Output voltage is more than 4.50 V,
the shift cut-off switch is ON for 328
Shift cut-off switch is always recog-
seconds when engine is starting, or
Shift cut-off switch nized as OFF.
both the shift position switch and
High engine idle speed.
shift cut-off switch are ON for 5 sec-
onds or more.
Thermo switch ON when the engine
Thermo switch is always recognized
temperature is less than 40 C (104
Thermo switch as OFF.
F) or OFF when the engine temper-
High engine idle speed.
ature is more than 120 C (248 F).
Shift position switch is OFF when Shift position switch is always recog-
Shift position switch
the engine is starting. nized as OFF.
Set VCT in full retard position.
OCV Open or short circuit.
High engine idle speed.

2-6
 Fuse box and relay

Fuse box and relay

Fuse box
The fuse box has been changed to a new one in the current model. The fuse type has also been
changed and the new fuse is not interchangeable with the previous one. (High pressure fuel pump fuse
and low pressure fuel pump fuse are the same as the previous types.)
A B

1 2
2
3 3

1. Relay
2. Fuse (60 A)
3. Fuse (5 A–30 A)
A. Previous fuse box
B. New fuse box

2-7
 Fuse box and relay

Relays and fuel pump fuse

Together with the change in the fuse box, the high pressure fuel pump fuse and low pressure fuel pump
fuse are now fitted on the outside to improve serviceability.
In addition, serviceability has been improved by fitting the various relays on the outside which used to
be integrated with the fuse box in previous models.

The parts used for the relays (from the main relay 1 “1” to the starter relay “5”) are the same.

5 4 3 1

1. Main relay 1 (Ignition and fuel injection

system)
2. Main relay 2 (Fuel pump system)
3. ETV relay
4. Fuel pump relay
5. Starter relay
6. High-pressure fuel pump fuse
7. Low-pressure fuel pump fuse

2-8
 Lower unit

Lower unit
Forward gear and reverse gear (F250H, FL250H)
A gear with a new design is adopted in the current model. Heat treatment has been given on the gear
surface for better resistance against abrasion and the gear teeth has been changed from 15/30 to 13/26
to improve the durability and extend the maintenance period.
Forward gear (F250H)
The plain metal bearing which used to be integrated in the previous gear has been changed to a needle
bearing, allowing only the needle bearing to be replaced. In addition, frictional loss is reduced by em-
ploying a needle bearing.
Propeller housing ring nut (FL250H)
The propeller housing ring nut has also been changed together with the gear change.

The removal procedure has been changed together with the change in the propeller housing
ring nut. To be noted as the previous removal procedure may result in damage to the parts.

See “Disassembling the propeller shaft housing assembly (FL250H)” (8-57)

4
3 a
7
2
1
6

A 5

1. Circlip (F250H)
2. Needle bearing (F250H)
3. Forward gear (F250H)
4. Pinion gear
5. Forward gear (FL250H)
6. Propeller housing ring nut (FL250H)
7. Propeller shaft housing (FL250H)
a. Identification mark “6FJ00” (F250H)
b. Identification mark “6FK00” (FL250H)

2-9
 Lower unit

Shift Dampener System (SDS)

The Shift Dampener System (SDS) uses a damper “1” to reduce the shock when the outboard motor
is shifted into gear.
The damper “1” is replaceable.
When shifting gears, the damper compresses to absorb shock, and the protrusions “a” on the dedicated
spacer “2” transmit the rotational force of the propeller shaft directly to the propeller “3”.

1
2

A B

A. Neutral
B. Shift in

2-10
 Fuel system

Fuel system
Fuel diagram

11. Fuel rail 9. Pressure regulator

(STBD)

13. Fuel
injector
12. Fuel rail (PORT)

13. Fuel injector

3. Fuel filter

8. High-pressure fuel pump

5. Vapor separator

4. Low-pressure fuel pump

2. Primer pump

17. Canister

2-11
 Fuel system

4. Low-pressure fuel pump 3. Fuel filter 2. Primer pump 1. Fuel tank

17. Canister 22. Atmosphere

10. Check
(cowl inside)
valve

23. Charcoal 20. Check valve

21. Atmosphere (cowl outside)
6. Filter
18. Vapor shut-off valve 19. Surge tank

7. Float chamber
8. High-pressure 9. Pressure regulator
fuel pump 294 kPa
(2.94 kgf/cm2, 42.6 psi)
5. Vapor separator

12. Fuel rail (PORT) 11. Fuel rail (STBD)

13. 13. 13. 13. 13. 13.

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

15. Intake port (PORT) 14. Intake port (STBD)

16. 16. 16. 16. 16. 16.

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

A
B
C
D

1. Fuel tank 16. Combustion chamber

2. Primer pump 17. Canister
3. Fuel filter 18. Vapor shut-off valve
4. Low-pressure fuel pump 19. Surge tank
5. Vapor separator 20. Check valve
6. Filter 21. Atmosphere (cowl outside)
7. Float chamber 22. Atmosphere (cowl inside)
8. High-pressure fuel pump 23. Charcoal
9. Pressure regulator
A. Fuel flow
10. Check valve
B. Vapor gas flow
11. Fuel rail (STBD)
C. Air flow
12. Fuel rail (PORT)
D. Purified gas flow
13. Fuel injector
14. Intake port (STBD)
15. Intake port (PORT)

2-12
 Lubrication system

Lubrication system
Lubrication diagram

14. VCT assembly

14. VCT assembly

12. OCV

12. OCV
5. Oil pressure sensor

4. Oil filter 2. Oil strainer

3. Oil pump

1. Oil pan

12. OCV 13. Camshaft oil 14. VCT

11. Piston passage assembly
10. Crankshaft pin
7. Cylinder head oil passage 8. Camshaft journal
9. Crankshaft
main journal
6. Cylinder block main gallery 15.Valve and related parts

5. Oil pressure sensor

4. Oil filter
16. Relief valve
441 kPa
3. Oil pump (4.41 kgf/cm2, 63.9 psi)

2. Oil strainer

1. Oil pan

2-13
 Lubrication system

1. Oil pan
2. Oil strainer
3. Oil pump
4. Oil filter
5. Oil pressure sensor
6. Cylinder block main gallery
7. Cylinder head oil passage
8. Camshaft journal
9. Crankshaft main journal
10. Crankshaft pin
11. Piston
12. OCV
13. Camshaft oil passage
14. VCT assembly
15. Valve and related parts
16. Relief valve
A. Engine oil flow

2-14
 Cooling system

Cooling system
Cooling diagram

13. Thermostat (STBD)

10. Thermostat (PORT)

18. PCV

6. Upper exhaust guide

4. Oil pan

A B

3. Water pump 3. Water pump

2. Water inlet 2. Water inlet 2. Water inlet 2. Water inlet

2-15
 Cooling system

10. Thermostat (PORT) 13. Thermostat (STBD)

7. Cylinder block

9. Exhaust cover (PORT) 12. Exhaust cover (STBD)

8. Cylinder head (PORT) 11. Cylinder head (STBD)

7. Cylinder block
D
14. Flushing device
6. Upper Exhaust
guide

18. PCV
19. Muffler
15. Fuel cooler 16. Rectifier/
5. Lower Exhaust
regulator
guide
20. Upper case

4. Oil pan
21. Lower case E
23. Water inlet 3. Water pump
(Trim tab)
17. Cooling water
22. Propeller boss 2. Water inlet pilot hole

1. Water
C

1. Water 17. Cooling water pilot hole

2. Water inlet 18. PCV
3. Water pump 19. Muffler
4. Oil pan 20. Upper case
5. Lower exhaust guide 21. Lower case
6. Upper exhaust guide 22. Propeller boss
7. Cylinder block 23. Water inlet (Trim tab)
8. Cylinder head (PORT)
A. F250H, FL250H
9. Exhaust cover (PORT)
B. F200B, FL200B
10. Thermostat (PORT)
C. Cooling water flow
11. Cylinder head (STBD)
D. When flushing the cooling water pas-
12. Exhaust cover (STBD)
sages
13. Thermostat (STBD)
E. Dynamic water pressure while cruising
14. Flushing device
for cooling propeller damper (F250H,
15. Fuel cooler
FL250H)
16. Rectifier/regulator

2-16
 Intake and exhaust system

Intake and exhaust system

Intake and exhaust diagram

2.Surge tank
3.Intake manifold
1.ETV

4.Exhaust cover

3.Intake manifold

5.Exhaust guide 4.Exhaust cover

6.Exhaust manifold

7.Muffler

8.Propeller

A
B

1. ETV 7. Muffler
2. Surge tank 8. Propeller
3. Intake manifold
A. Intake air flow
4. Exhaust cover
B. Exhaust gas flow
5. Exhaust guide
6. Exhaust manifold

2-17
 Hose routing

Hose routing
Fuel hose and blowby hose
7

8
4

1 2

1. Primer pump to fuel filter assembly

2. Fuel filter assembly to joint
3. Joint to low-pressure fuel pump
4. Vapor separator to joint
5. Low-pressure fuel pump to vapor separa-
tor
6. Vapor separator to fuel rail (PORT)
7. Vapor separator to fuel rail (STBD)
8. Cylinder head cover (STBD) to intake
silencer
9. Cylinder block to joint

2-18
 Hose routing

Pressure regulator hose, vapor gas hose, and intake air pressure sensor hose

A D
1
11

8
12 13
11
11
7 C
B 2
14
6
A
E F
4
E
10
3
9
C 8
7
10 6
D
6 F STBD
5

13 5
1
4 2
3 B

1. Vapor separator to joint 14. Joint to check valve

2. Canister atmospheric port to joint
3. Joint to canister tank port
4. Canister purge port to joint
5. Joint to vapor shut-off valve
6. Vapor shut-off valve to surge tank
7. Surge tank to joint
8. Joint to intake air pressure sensor
9. Check valve to joint
10. Intake silencer to check valve
11. Joint to pressure regulator
12. Joint to joint
13. Check valve to bottom cowling

2-19
 Hose routing

Cooling water hose

5
6
4
3 7
2

1
8

19 9
10

11 14
7
12
13
14
15
5
16 8
18 17
4
9

17
12

1
11
18
10
2
19 6
13 16 15

1. Rectifier/regulator to joint 13. Joint to joint

2. Joint to rectifier/regulator 14. Joint to fuel cooler
3. Joint to joint 15. Fuel cooler to joint
4. Joint to joint 16. Cylinder head (STBD) to adapter (water
5. Thermostat cover (STBD) to joint pressure sensor)
6. Joint to cylinder block 17. Joint to joint
7. Joint to joint 18. Joint to cooling water pilot hole
8. Thermostat cover (PORT) to cylinder 19. Joint to joint
block
9. Joint to joint
10. Joint to cooling water passage cover
11. Flushing hose adapter to joint
12. Cylinder block to joint

2-20
 Rigging information

Important reminder on rigging.......................................... 3-1

Outboard motor mounting instructions ....................................... 3-1

Crate handling .................................................................... 3-2

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

Uncrating ............................................................................ 3-3

Uncrating procedure................................................................... 3-3

Outboard motor mounting................................................. 3-4

Installing the outboard motor...................................................... 3-4
Outboard motor mounting height................................................ 3-7
Adjusting the twin engine positions ............................................ 3-7

Rigging grommet mounting .............................................. 3-8

Rigging grommet description...................................................... 3-8
Installing the battery cable.......................................................... 3-8
Installing the shift cable .............................................................. 3-9
Installing the throttle cable........................................................ 3-10
Installing the main wire harness ............................................... 3-10
Installing the 6Y8/6YC multifunction meter harness
(pigtail bus wire) ....................................................................... 3-10
Installing the conventional gauge (6Y5/6Y7) harness .............. 3-11
Installing the rigging grommet .................................................. 3-11

Optional equipment ......................................................... 3-12

Installing the isolator lead......................................................... 3-12
Installing the water pressure sensor
(6Y8/6YC Multifunction Meters) ............................................... 3-12
Installing the speed sensor (6Y8/6YC Multifunction Meters).... 3-12
Installing the twin engine tie-bar with steering cable ................ 3-12

Battery installation........................................................... 3-13

Battery wiring without house battery ........................................ 3-13
Battery wiring with house battery ............................................. 3-16

System diagram................................................................ 3-21

Single engine application (6Y8 Multifunction Meters) .............. 3-21
Twin engine application (6YC Multifunction Meter) .................. 3-23
Single engine application (conventional gauge)....................... 3-25
 Rigging information

Rigging recommendation ................................................ 3-27

Battery cable length.................................................................. 3-27 0
Extension length recommendation for battery cable ................ 3-28

Propeller selection ........................................................... 3-29 1

Propeller size............................................................................ 3-29

2
Selection................................................................................... 3-29

3
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 outboard motor
and other equipment.

Before mounting the outboard motor, consult the manufacturer of the engine jack plates or
brackets. Excessive loads could damage the engine jack plates, brackets, boat transom, steer-
ing 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.

6 7

9 8
2

3 4
IMPORTANT
This unit delivered to carrier in a good condition.
For protection against loss due to damage, inspect thoroughly.
If damage is noted, make note on freight bill.
Shipper assumes no further liability to the transportation company.
Your claim should be filed against carrier for damage of any nature.

1. WARNING 3. IMPORTANT
Wear suitable protective gear such as This unit delivered to carrier in a good
gloves and eye protection when handling condition.
and opening crate. For protection against loss due to dam-
2. NOTICE age, inspect thoroughly.
• Use forklifts with forks that are at least If damage is noted, make note on freight
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 the transportation company.
corners fit securely on unit below it). Your claim should be filed against carrier
• Stack Limit - 2 units (at handling). for damage of any nature.
4. Lifting fork insert position
5. Balance point
6. Stack limit: Maximum 4 units for storage
7. Upward indication
8. Care handling indication
9. Water avoidance indication

3-2
 Uncrating

Uncrating 1
Uncrating procedure 2 2

Wear gloves to avoid injury from sharp

steel edges while uncrating.

1. Check the crate for shipping damage. If

any damage is found, consult your
Yamaha agency.
9. Lift up the outboard motor carefully along
2. Cut the strap, and then remove the top with the bottom frame “1”.
cover.

3. Remove all of the bolts from the bottom Make sure that the lifting harnesses do not
plate, and then remove the frame. damage any parts of the outboard motor.

Be careful not to damage the outboard mo-

tor.

4. Remove the wrapping, and then check the

outboard motor for concealed damage. If
any damage is found, consult your
Yamaha agency.
1
5. Remove the top cowling.

6. Remove the bolts “1”, and then remove the

flywheel magneto cover “2”.
1 1 10. Remove the skeg holder “1”.
2

1
7. Install the lifting harness “1” to the engine
hangers “2”.

8. Apply tension to the lifting harness.

3-3
 Outboard motor mounting
11. Remove the bolts “1”. Outboard motor mounting
Installing the outboard motor
Proper mounting of the outboard motor pro-
vides better performance, maximum reliability,
and the highest customer satisfaction. This
1 chapter contains the specifications necessary
to mount the outboard motor, and may vary
slightly depending on the applications. When
mounting the outboard motor, make sure that
there is sufficient clearance for the outboard
motor to fully tilt up, and to fully move to port
12. Remove the steering retainer, and then in- and starboard. See “External dimensions”
stall a hydraulic steering cylinder or steer- (1-17).
ing cable following the recommendation of
the manufacturer. 1. For single engine application, place the
outboard motor on the vertical centerline of
13. For the procedure of outboard motor the boat transom.
mounting on boat, see “Installing the out-
board motor” (3-4).
Make sure that distance “a” is equal to distance
14. Remove the lifting harness, and then in- “b”, and distance “c” is equal to distance “d”.
stall the flywheel magneto cover and top
cowling. A C/L

R a b R

c d
B C/L

a b
c d

A. Hull without strakes

B. Hull with strakes
C/L: Centerline of the transom
R: Radius
For twin engine application, place the out-
board motors so that the distance from the
C/L of each outboard motor to the C/L of
the boat transom are equal on both sides.

3-4
 Outboard motor mounting

A
• Make sure that distance “e” is equal to dis-
tance “f”.
• For the distance (T1), see “External dimen-
sions” (1-17). 1

C/L
e f
B

1 1

T1

A. Single engine application

C/L: Centerline of the transom B. Twin engine application

2. Adjust the position of the outboard motor 3. Install the special service tool “1”.
so that the height of the anti-cavitation
plate “1” is equal to or slightly above the 4. Adjust the height of the scale “2” to the
bottom of the boat transom. transom height (H), and place it on the
special service tool “1”. Secure the special
service tool “1” to the boat transom using
This mounting height information is for refer- screws or vises.
ence only. It is impossible to provide complete
instructions for every possible boat and out-
board motor combination. For the transom height (H), see “External di-
mensions” (1-17).

3-5
 Outboard motor mounting
5. When the outboard motor mounting posi-
tion has been determined, mark the best
1
suited 4 symmetrical mounting holes on 2
3 2
the boat transom “3”. Drill the mounting 4
holes perpendicular to the surface of the
boat transom using a 13.0 mm (0.5 in) “a” 1
drill bit. 2
3 4
2 1 2

D 1
2
3 2
4

H Boat transom thick-

Mounting bolt
ness (D)
a 65–75 mm M12  130 mm
2 (2.56–2.95 in) (5.12 in)
75–95 mm M12  150 mm
C/L (2.95–3.74 in) (5.91 in)
C/L: Centerline of the transom
7. Install the mounting bolts, and then tighten
Drilling plate “1” the nuts firmly.
90890-06783

6. Apply sealant to the mounting holes, and Make sure that the clamp brackets do not
then secure the outboard motor using the bite into the boat transom.
included mounting bolts “1”, small washers
“2”, large washers “3”, and nuts “4”. 8. Tighten the locknuts firmly.

Make sure that there is no clearance be-

tween the surfaces of the boat transom and
the clamp brackets. Otherwise, the clamp
brackets or boat transom may be damaged.

The second hole from the top of each clamp

bracket is recommended for the upper mount-
ing bolt.

3-6
 Outboard motor mounting

Outboard motor mounting height

If the water line is too close to the power head,
poor engine performance could result, and wa-
ter could enter the cylinders and damage the
engine.
When mounting a 4-stroke outboard motor to a
boat, make sure that the mounting height be-
tween the water surface and the clamp bracket
seating point is not less than the specified min-
imum mounting height “a”. Measure the
mounting height when the boat is moored and b
carrying the maximum load.

a
a
Adjustment: “b” – “a” = Within 25 mm (1 in)

For best result, the toe-out distance should be

set so that the twin engines wake meets ap-
proximately 7.5–15.0 m (24.6–49.2 ft) past the
Minimum mounting height stern of the boat.
100 mm (3.9 in)

Adjusting the twin engine positions

Set the engines in the toe-out position, and
measure the distances between the two en-
gines at the center point of the rear “a” and
front “b” of the lower case. The difference be-
tween measurement “a” and measurement “b” 7.5–15.0 m (24.6–49.2 ft)
should not exceed 25 mm (1 in).

3-7
 Rigging grommet mounting

Rigging grommet mounting

Rigging grommet description
Pass all the control components through the
proper holes in the rigging grommet.

2 3
4
1

1 2
10
Installing the battery cable
5 1. Route the battery cable through the bottom
9
6 cowling.
8 7

1. Throttle cable 2. Connect the positive battery cable “1”.

2. Main wire harness
3. Water temperature sensor harness The positive battery cable is marked with red
(optional) or water pressure sensor hose tape.
(optional)
4. Isolator lead (optional)
5. Battery cable 3. Connect the negative battery cable “2”,
6. Conventional gauge lead (optional) or and then tighten the negative battery cable
6Y8/6YC multifunction meter harness nut “3” to the specified torque.
(optional) 3
7. Fuel hose
8. Speedometer hose
9. Shift cable
10. Flushing hose

1. Remove the rubber seal “1” from the re-

taining plate “2”.
2 1

Negative battery cable nut “3”

13 Nm (1.3 kgf·m, 9.6 ft·lb)
T.
R.

4. Install the rubber cap “1”.

1
2

2. Remove the retaining plate “1”.

3. Remove the rigging grommet “2”.

3-8
 Rigging grommet mounting

Installing the shift cable 1

a
Always perform the cable adjustment in ad-
vance, following the procedures in the re-
mote control operation manual.

1. Remove the cable holder “1”. b

2
1
6. Adjust the shift cable joint “1”, and then in-
stall it to the pin “2”.

The shift cable joint must be screwed in 8.0

mm (0.31 in) or more.

2
1
2. Fully screw in the shift cable joint “1” to the
shift cable “2”.

1 a

2
1 Dimension “a”
8.0 mm (0.31 in) or more

3. Move the remote control lever to the N po- 7. Install the clip “1”, and then tighten the shift
sition. cable locknut “2” to the specified torque.

4. Fit the cable holder “1” into the groove “a”

in the shift cable “2”, and then install the
cable holder “1” along with the shift cable
“2”. 2

a
1
1

Shift cable locknut “2”

2 5 Nm (0.5 kgf·m, 3.7 ft·lb)
T.
R.

2
8. Check the shift cable for proper operation.

5. Align the mark “a” on the bushing “1” with

the mark “b” on the shift bracket “2”.

3-9
 Rigging grommet mounting

Installing the throttle cable

1. Fully screw in the throttle cable joint “1” to Dimension “a”
the throttle cable “2”. 8.0 mm (0.31 in) or more

6. Install the clip “1”, and then tighten the

throttle cable locknut “2” to the specified
torque.

2
1

2. Fasten the throttle cable “1” using the ca-

ble holder “2” so that the cable holder “2” is
fitted into the groove “a” in the throttle ca- 1 2
ble “1”.

a Throttle cable locknut “2”

5 Nm (0.5 kgf·m, 3.7 ft·lb)
2
T.
R.

7. Check the throttle cable for proper opera-

tion.

1 Installing the main wire harness

1. Connect the main wire harness coupler
1 “a”, and then fasten it using the holders “1”
and “2” on the bracket.
3. Move the throttle lever “1” so that it con-
tacts the stopper “2”.

4. Pull the inner cable “3” using the force of 2

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

5. Adjust the throttle cable joint “4”, and then

install it to the pin “5” of the throttle lever.
a

The throttle cable joint must be screwed in Installing the 6Y8/6YC multifunction
8.0 mm (0.31 in) or more. meter harness (pigtail bus wire)
1. Remove the cap “1”.

2 2. Route the 6Y8/6YC multifunction meter

harness.
1
5

a 3
4 4

3-10
 Rigging grommet mounting
3. Connect the 6Y8/6YC multifunction meter
harness coupler “a”.
1

a
1

a 3. Install the retaining plate “1” and rubber

seal “2”.
4. Remove the yellow tape “1” and caps “2”
2
and “3”.

5. Connect the trim sensor coupler “a”.

3 1 2

a
4. Install the rigging tube retainer “1”, and
then fasten it using the plastic tie “2”.

Installing the conventional gauge

(6Y5/6Y7) harness
1. Remove the cap “1”.

2. Connect the gauge harness coupler “a”.

2
1
1

Installing the rigging grommet

1. Route each harness through the proper
hole in the rigging grommet. See “Rigging
grommet description” (3-8).

2. Align the white tape “a” on the battery ca-

ble “1” with the outer end of the rigging
grommet.

3-11
 Optional equipment

Optional equipment 2. Adjust the twin engine tie-bar. See “Adjust-

Installing the isolator lead ing the twin engine positions” (3-7).
1. Remove the cap “1”.

2. Route the isolator lead “2” through the bot-

tom cowling.

3. Connect the isolator coupler “a”.

1
a

Installing the water pressure sensor

(6Y8/6YC Multifunction Meters)
See “Speed sensor/cooling water pressure
sensor installation manual” (6Y5-2819K-**) for
details of the components.

Installing the speed sensor (6Y8/6YC

Multifunction Meters)
See “Speed sensor/cooling water pressure
sensor installation manual” (6Y5-2819K-**) for
details of the components.

Installing the twin engine tie-bar with

steering cable
1. Install the tie-bars “1” and “2” and steering
guide “3”.

3-12
 Battery installation

Battery installation

• Make sure to connect the battery properly and select the proper cable sizes. Otherwise, a fire
could result.
• If optional isolator lead is installed and connected to a house battery, overcurrent protection
in compliance with ABYC (E-11) or equivalent must be provided.

Do not reverse the battery connections. Otherwise, the charging system could be damaged.

Battery wiring without house battery

When using a dual battery installation, a negative battery cable must be installed between both
engine batteries. This cable must be sized equivalent to the engine battery cables or larger AWG
cable size in accordance with ABYC specifications.

1. Outboard motor

2. Red
3. Black

1. Outboard motor
2. Red
3. Black

3-13
 Battery installation

STBD PORT
1. Outboard motor 1. Outboard motor

2. Red 2. Red

3. Black 3. Black

3. Black

1. Outboard motor 3. Black

2. Red

1. Outboard motor

3. Red

4. Black
2. Battery switch
ON/OFF

1. Outboard motor
2. Battery switch
3. Red
4. Black

3-14
 Battery installation

STBD PORT

1. Outboard motor 1. Outboard motor

3. Red 3. Red

4. Black 4. Black

ON/OFF ON/OFF
2. Battery switch

2. Battery switch
4. Black

1. Outboard motor 3. Red

2. Battery switch 4. Black

STBD PORT
1. Outboard motor 1. Outboard motor

2. Battery switch
2. Battery switch 3. Navigation system 4. Boat system

5. Black 5. Black
ON/OFF ON/OFF

6. Red
6. Red
6. Red 6. Red

5. Black 5. Black 5. Black

1. Outboard motor
2. Battery switch
3. Navigation system
4. Boat system
5. Black
6. Red

3-15
 Battery installation

Battery wiring with house battery

• When only one battery is used for one engine, connect the positive battery cable and isolator
lead to the positive battery terminal. If the isolator lead is left unconnected, accidental contact
of the isolator lead with the negative terminal of the battery can cause a short circuit, which
may result in a fire.
• This cable must be sized equivalent to the engine battery cables or larger, such as larger AWG
cables 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
3. Battery switch ON/OFF
4. Red
7. Fuse (60 A)
1 2
5. Black
4. Red
6. House battery

1. Outboard motor
2. Isolator lead
3. Battery switch
4. Red
5. Black
6. House battery
7. Fuse (60 A)

3-16
 Battery installation

1. Outboard motor

2. Isolator lead

3. Red 6. Fuse (60 A)

4. Black
4. Black

5. House battery

1. Outboard motor 4. Black

2. Isolator lead 5. House battery
3. Red 6. Fuse (60 A)

1. Outboard motor

2. Isolator lead

3. Black

4. Red 7. Fuse (60 A)

5. Battery switch

1 2
3. Black
4. Red
6. House battery

1. Outboard motor
2. Isolator lead
3. Black
4. Red
5. Battery switch
6. House battery
7. Fuse (60 A)

3-17
 Battery installation

STBD 1. Outboard motor PORT

5. Isolator lead

2. Black 7. Fuse (60A)

3. Battery switch 4. Red 4. Red 2. Black

3. Battery switch

ON/OFF
1 2 2. Black ON/OFF

6. House battery
2. Black
1. Outboard motor 5. Isolator lead
2. Black 6. House battery
3. Battery switch 7. Fuse (60 A)
4. Red

STBD 1. Outboard motor PORT

5. Isolator lead

7. Fuse (60A)
2. Black

3. Battery switch 4. Red 4. Red 2. Black

ON/OFF
3. Battery switch
1 2 1 2

2. Black
3. Battery switch
6. House battery
2. Black
1. Outboard motor
2. Black
3. Battery switch
4. Red
5. Isolator lead
6. House battery
7. Fuse (60 A)

3-18
 Battery installation

STBD 1. Outboard motor PORT

5. Isolator lead

7. Fuse (60A)
2. Black
4. Red 4. Red 2. Black

3. Battery switch
3. Battery switch
1 2 1 2

6. House battery

2. Black 2. Black

1. Outboard motor
2. Black
3. Battery switch
4. Red
5. Isolator lead
6. House battery
7. Fuse (60 A)

3-19
 Battery installation

1. Outboard motor
STBD PORT

6. Isolator lead

5. Battery switch
7. Fuse (60A)

5. Battery switch
ON/OFF 2. Black
5. Battery switch
ON/OFF
4. Red
4. Red
ON/OFF
2. Black
2. Black

2. Black 2. Black

3. House battery 3. House battery

1. Outboard motor
2. Black
3. House battery
4. Red
5. Battery switch
6. Isolator lead
7. Fuse (60 A)

3-20
 System diagram

System diagram
Single engine application (6Y8 Multifunction Meters)

12 13

10 7
b 11 7
c
c
c 14 5
*1 R
b *1 G
a 6
B B
Y Y Y

7
4

1
2

P P 3

3-21
 System diagram

Ref.
Part name Part No. Remarks
No.
1 Engine ECM —
2 Speed sensor kit 60V-8A4L1-14
3 Trim sensor —
4 Main wire harness (10 pins) —
5 Remote control box 703-48205-B1 For additional trim switch
6 Power supply wire 6Y8-83553-01 w/ 10 A fuse, 2.4 m (8 ft)
6Y8-82521-01 0.3 m (1 ft)
6Y8-82521-11 0.6 m (2 ft)
6Y8-82521-21 0.9 m (3 ft)
7 Pigtail bus wire
6Y8-82521-31 1.8 m (6 ft)
6Y8-82521-41 2.7 m (9 ft)
6Y8-82521-51 3.6 m (12 ft)
8 Single hub 6Y8-81920-11 w/ resistor, 4-6P, White
6Y8-82553-01 0.3 m (1 ft)
6Y8-82553-50 3.0 m (10 ft)
6Y8-82553-11 4.6 m (15 ft)
9 Main bus wire
6Y8-82553-21 6.1 m (20 ft)
6Y8-82553-31 7.6 m (25 ft)
6Y8-82553-41 9.1 m (30 ft)
10 Multi-hub 6Y8-81920-01 w/ resistor cap, Black
11 Resistor cap 6Y8-85371-01 6P, Gray
12 Tachometer 6Y8-8350T-20 Round
13 Speedometer 6Y8-83500-20 Round
14 Water proof cap 6Y8-82581-11 4P, White

a. Power port
b. Bus port
c. Device port

*1. Attach the waterproof cap to the open terminal.

3-22
 System diagram

Twin engine application (6YC Multifunction Meter)

15
18

B P B P/B

L W

A B
11
16 16
17

7
b 10
c 14 6
c 14
8 c
b Y B
a 9
12 Y B
b
c
11 Y
c
8 11
c
11
b 10
a
13
5

19

2
1 1

3 3
P P 4 P P 4

3-23
 System diagram

Ref.
Part name Part No. Remarks
No.
1 Engine ECM —
2 Speed sensor kit 60V-8A4L1-14
3 Water pressure sensor kit 63P-8A4L0-03
4 Trim sensor —
688-8258A-50 5 m (16 ft)
688-8258A-60 6 m (20 ft)
5 Main wire harness 688-8258A-70 7 m (23 ft)
6K1-8258A-40 8 m (26 ft)
61B-8258A-01 9.5 m (31 ft)
6 Remote control box 704-48207-R0
7 Main switch 6Y8-82570-04
8 Multi-hub 6Y8-81920-01 w/ resistor cap, Black
9 Waterproof cap 6Y8-82582-01 2P, Red
10 Resistor cap 6Y8-85371-01 6P, Gray
6Y8-82521-01 0.3 m (1 ft)
6Y8-82521-11 0.6 m (2 ft)
6Y8-82521-21 0.9 m (3 ft)
11 Pigtail bus wire
6Y8-82521-31 1.8 m (6 ft)
6Y8-82521-41 2.7 m (9 ft)
6Y8-82521-51 3.6 m (12 ft)
6Y8-82553-01 0.3 m (1 ft)
6Y8-82553-50 3.0 m (10 ft)
6Y8-82553-11 4.6 m (15 ft)
12 Main bus wire
6Y8-82553-21 6.1 m (20 ft)
6Y8-82553-31 7.6 m (25 ft)
6Y8-82553-41 9.1 m (30 ft)
13 Power supply wire 6Y8-83553-01 w/ 10 A fuse, 2.4 m (8 ft)
14 Waterproof cap 6Y8-82582-11 4P, White
15 Multifunction Meter 6YC-83701-00 w/ screen cover
16 Fuel tank (fuel level sensor) —
17 GPS — NMEA0183
18 Fuel tank/GPS wire 6Y8-8356N-01
19 Transom multi-sensor 6Y8-83688-01
a. Power port A. PORT
b. Bus port B. STBD
c. Device port

3-24
 System diagram

Single engine application (conventional gauge)

*1 7

W(+) 14

W
R R
15
W
W B
B W B R
2 3 4
W/R

G/W
Pu/W B
Gy G/W
Or

Or Pu
Or/B P G/R
Pu
R Y L B G P G/R
Pu/W Or
B W/R Gy G
1
B

W 12
16 G
13 L Y R R R B Y
5
Or

Y Y
L Y 9 8 *1
Pu

B
IN

6
Or

10
UP
OUT

11

Gy G
P G/R
P P/W
P/B P/B

3-25
 System diagram

Ref.
Part name Part No. Remarks
No.
1 Remote control box 703-48205-B1 For additional trim switch
2 Fuel management gauge 6Y5-83500-F2
3 Speedometer 6Y5-83570-S6
4 Tachometer 6Y5-8350T-91
5 Fuel tank (fuel level sensor) —
6 Fuel flow sensor 6Y5-85752-02
7 GPS — NMEA0183
8 Speedometer hose 688-83557-00 6 m (20 ft)
6Y5-83653-00 5 m (16 ft)
6Y5-83653-10 6 m (20 ft)
6Y5-83653-20 7 m (23 ft)
9 Conventional gauge harness
6Y5-83653-30 8 m (26 ft)
6Y5-83653-40 9 m (30 ft)
6Y5-83653-50 10.5 m (34 ft)
10 Main wire harness —
11 Fuel hose —
12 Lamp switch 688-82520-00 0.1 m (0.33 ft)
13 Fuel management gauge harness 6Y5-83553-F1 8.0 m (26 ft)
14 GPS wire 6Y5-85721-F0 NMEA0183
15 Wire lead for speedometer 6Y5-87122-S0
16 Wire lead for digital meter 6Y5-83553-M0 2.5 m (8 ft)

*1. When a GPS (NMEA0183) is used, a speedometer hose is not required.

3-26
 Rigging recommendation

Rigging recommendation
Battery cable length
The table below shows the battery cable length from the negative terminal of the battery cable to the
rigging grommet.
The positive battery cable is 100 mm (3.9 in) longer than the negative battery cable.
Length (L)
3.50 m (11.5 ft)

(L)
100 mm
(3.9 in)

3-27
 Rigging recommendation

Extension length recommendation for battery cable

Do not exceed the recommended extension length for the battery cable. Otherwise, the electri-
cal system could be damaged or operate improperly.

To extend the length of battery cables, follow the requirements in the tables for battery capacity, cable
size, and ambient temperature.
The maximum total extension length is the total combined length of the positive and negative battery
cables.
Select an extension battery cable and terminal that meet ABYC requirements or the equivalent.
Select the battery stud that is best-suited to the terminal size.
Solder the cable and terminal connections to prevent them from corroding.
Ambient temperature is 0 C (32 F) and above
Battery requirements Cable specifications
Maximum total extension length
Unit Rating (Positive battery cable + Negative battery cable)
AWG4 (20 mm²) AWG2 (30 mm²) AWG1/0 (50 mm²)
CCA/EN 711 Amps 5.4 m 9.2 m 14.2 m
20HR/IEC 100 Ah (17.7 ft) (30.2 ft) (46.6 ft)

Ambient temperature is below 0 C (32 F)

Battery requirements Cable specifications
Maximum total extension length
Unit Rating (Positive battery cable + Negative battery cable)
AWG4 (20 mm²) AWG2 (30 mm²) AWG1/0 (50 mm²)
CCA/EN 711 Amps 3.5 m 6.0 m 9.2 m
20HR/IEC 83 Ah (11.5 ft) (19.7 ft) (30.2 ft)

1. Extension battery cable 2. Battery switch

ON/OFF

3. Battery 4. Original battery cable

1. Extension battery cable 3. Battery

2. Battery switch 4. Original battery cable

3-28
 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 dam-
age the engine seriously.
Use the following information as a guide for selecting a propeller that meets the operating conditions of
the boat and outboard motor.

Propeller size
The size of the propeller is indicated on the propeller boss end, or on the side of the propeller boss.

a b c b
a
c

a. Propeller diameter (in inches) c. Propeller type (propeller mark)

b. Propeller pitch (in inches)

Selection
With the engine speed at full throttle operating range and under a maximum boat load, the engine
speed should be within the upper half of the full throttle operating speed range.

Full throttle operating range

5000–6000 r/min

Regular rotation model

Blade Dia. (in) Pitch (in) Mark Material Part number Remarks
3 15 3/4 13 M Aluminum 6G5-45932-00 *5
3 14 5/8 16 M Aluminum 6G5-45952-00 *5
3 14 1/2 17 M Aluminum 6G5-45947-01 *5
3 14 19 M Aluminum 6G5-45945-01 *5
3 13 3/4 21 M Aluminum 6G5-45943-01 *5
3 13 1/2 23 M Aluminum 6G5-45949-00 *5
3 15 3/4 13 M Stainless steel 6G5-45932-00
3 15 1/4 15 M Stainless steel 6G5-45970-02
3 13 3/4 17 M2 Stainless steel 6G5-45978-03
3 13 3/4 19 M2 Stainless steel 6G5-45974-03
3 13 3/4 21 M Stainless steel 6G5-45972-02
3 13 3/8 23 M Stainless steel 6G5-45976-01

3-29
 Propeller selection

Blade Dia. (in) Pitch (in) Mark Material Part number Remarks
3 13 3/8 25 M Stainless steel 6G5-45930-00
3 14 1/4 17 M Stainless steel 68F-45972-00 *2
3 14 1/4 18 M Stainless steel 68F-45978-00 *2
3 13 3/4 19 M Stainless steel 68F-45974-00 *2
3 13 3/4 21 M Stainless steel 68F-45974-00 *2
3 14 1/2 13 M Stainless steel 68F-45932-10 *1, *2
3 14 1/2 14 M Stainless steel 68F-45930-10 *1, *2
3 14 1/2 15 M Stainless steel 68F-45970-10 *1, *2
3 14 1/4 17 M Stainless steel 68F-45972-10 *1, *2
3 14 1/4 18 M Stainless steel 68F-45978-10 *1, *2
3 13 3/4 19 M Stainless steel 68F-45974-10 *1, *2
3 13 3/4 21 M Stainless steel 68F-45976-10 *1, *2
3 15 17 T Stainless steel 61A-45978-00
3 14 1/2 19 T Stainless steel 61A-45974-00
3 14 1/2 21 T Stainless steel 61A-45972-00
3 15 1/4 15 M Stainless steel 6R4-45976-A0 *2
3 15 1/4 17 M Stainless steel 6R4-45978-A0 *2
3 15 1/4 19 M Stainless steel 6R4-45970-A1 *2
3 14 7/8 21 M Stainless steel 6R4-45972-A0 *2
3 14 1/2 23 M Stainless steel 6R4-45974-A0 *2
3 15 3/4 15 T Stainless steel 6D0-45976-00 *3
3 15 1/2 17 T Stainless steel 6D0-45978-00 *3
3 15 1/4 19 T Stainless steel 6D0-45970-00 *3
3 15 21 T Stainless steel 6D0-45972-00 *3
4 15 21 T Stainless steel 6BR-45B70-00 *4
4 15 22 T Stainless steel 6BR-45B72-00 *4
4 15 23 T Stainless steel 6BR-45B74-00 *4
4 15 21 T Stainless steel 6CE-45B70-00 *1, *4
4 15 22 T Stainless steel 6CE-45B72-00 *1, *4
4 15 23 T Stainless steel 6CE-45B74-00 *1, *4

*1. Shift Dampener System (SDS) propellers

*2. Reliance series propellers
*3. Saltwater series II propellers
*4. Saltwater series HS4 propellers
*5. F200B only

3-30
 Propeller selection
Counter rotation model
Blade Dia. (in) Pitch (in) Mark Material Part number Remarks
3 14 1/2 17 ML Aluminum 6K1-45947-00 *6
3 14 19 ML Aluminum 6K1-45945-00 *6
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 13 3/4 21 ML Stainless steel 6K1-45972-01
3 13 3/8 23 ML Stainless steel 6K1-45976-00
3 14 1/4 17 ML Stainless steel 68G-45972-00 *2
3 14 1/4 18 ML Stainless steel 68G-45978-00 *2
3 13 3/4 19 ML Stainless steel 68G-45974-00 *2
3 13 3/4 21 ML Stainless steel 68G-45976-00 *2
3 14 1/2 14 ML Stainless steel 68G-45930-10 *1, *2
3 14 1/2 15 ML Stainless steel 68G-45970-10 *1, *2
3 14 1/4 17 ML Stainless steel 68G-45972-10 *1, *2
3 14 1/4 18 ML Stainless steel 68G-45978-10 *1, *2
3 13 3/4 19 ML Stainless steel 68G-45974-10 *1, *2
3 13 3/4 21 ML Stainless steel 68G-45976-10 *1, *2
3 15 17 TL Stainless steel 61B-45978-00
3 14 1/2 19 TL Stainless steel 61B-45974-00
3 14 1/2 21 TL Stainless steel 61B-45972-00
3 15 1/4 15 ML Stainless steel 6R1-45976-A0 *3
3 15 1/4 17 ML Stainless steel 6R1-45978-A0 *3
3 15 1/4 19 ML Stainless steel 6R1-45970-A1 *3
3 14 7/8 21 ML Stainless steel 6R1-45972-A0 *3
3 14 1/2 23 ML Stainless steel 6R1-45974-A0 *3
3 15 3/4 15 TL Stainless steel 6D1-45976-00 *4
3 15 1/2 17 TL Stainless steel 6D1-45978-00 *4
3 15 1/4 19 TL Stainless steel 6D1-45970-10 *4
3 15 21 TL Stainless steel 6D1-45972-10 *4
4 15 21 TL Stainless steel 6BS-45B70-00 *5
4 15 22 TL Stainless steel 6BS-45B72-00 *5
4 15 23 TL Stainless steel 6BS-45B74-00 *5
3 15 3/4 13 TL Stainless steel 6CF-45930-00 *1, *4
3 15 3/4 15 TL Stainless steel 6CF-45976-00 *1, *4
3 15 1/2 17 TL Stainless steel 6CF-45978-00 *1, *4
3 15 1/4 18 TL Stainless steel 6CF-45934-00 *1, *4
3 15 1/4 19 TL Stainless steel 6CF-45970-10 *1, *4

3-31
 Propeller selection

Blade Dia. (in) Pitch (in) Mark Material Part number Remarks
3 15 20 TL Stainless steel 6CF-45932-00 *1, *4
3 15 21 TL Stainless steel 6CF-45972-10 *1, *4
3 14 3/4 22 TL Stainless steel 6CF-45936-00 *1, *4
3 14 3/4 23 TL Stainless steel 6CF-45974-00 *1, *4
4 15 21 TL Stainless steel 6CF-45B70-00 *1, *5
4 15 22 TL Stainless steel 6CF-45B72-00 *1, *5
4 15 23 TL Stainless steel 6CF-45B74-00 *1, *5

*1. Shift Dampener System (SDS) propellers

*2. Reliance series propellers
*3. Saltwater series propellers
*4. Saltwater series II propellers
*5. Saltwater series HS4 propellers
*6. FL200B only

3-32
 Propeller selection

— MEMO —

3-33
 Troubleshooting

YDIS ..................................................................................... 4-1

Basic components ...................................................................... 4-1 0
Function...................................................................................... 4-2
Connecting the communication cable ........................................ 4-6
1
Outboard motor troubleshooting...................................... 4-8

2
Troubleshooting procedure ........................................................ 4-8
Troubleshooting the power unit using the YDIS ......................... 4-8
Trouble code and checking step .............................................. 4-10
Troubleshooting the power unit (trouble code not detected) .... 4-18
Troubleshooting the PTT unit ................................................... 4-23
Troubleshooting the lower unit ................................................. 4-25 3
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 re-
spond to new models and technologies, maintaining compatibility with regulations. This manual con-
tains the model-specific information. See YDIS (Ver. 2.22 or later) instruction manual for detailed
information.

Basic components

YDIS2 Hardware Kit

90890-06884

The software is available through YMAN (Yamaha Marine Associate Network).

1 2 4
3

5 6

9 10
8

No. Part name Q’ty Remarks

1 Adapter interface 1
2 USB cable 1 5 m (16.4 ft)
3 Adapter cap 1
4 AD harness 1 For external input
5 CAN-Line harness 1
6 K-Line harness 1
7 Power supply harness 1
8 Trigger switch harness 1
9 Trigger switch extension harness 1
10 Reprogramming harness 1

4-1
 YDIS

Function
YDIS version 2.22 comprises the following items.

1. Start 2. Engine 3. Diagnosis 4. Diagnosis

5. Diagnosis Record

6. Engine Record

7. Engine operating
hours by RPM

8. Engine Monitor 9. Digital Display

10. Graph Display

11. Input Setting

12. Component Test 13. Stationary Test

14. Active Test

15. Data Logger 16. Logger Graph

17. ECM Rec Graph

19. Record of engine 18. Logging

oil change

20. Boat System 21. Boat Setting 22. Gauge Test

23. Gauge Custom

30. Update
24. Outboard Motor
25. Tilt Limiter
Setting
31. Setting
26. R/C System Reset
32. Off Line 28. Maintenance 29. Check Engine
27. Rotor Reset
33. Special Function 34. Engine 35. ONLINE

36. OFFLINE

37. History
39. Communication
38. CAN Information
List

40. Bus Statistics

41. 6X6 RC Checker 42. Virtual Engine

43. Virtual Remote

Control

4-2
 YDIS

1. Start 23. Gauge Custom

2. Engine 24. Outboard Motor Setting
3. Diagnosis 25. Tilt Limiter
4. Diagnosis 26. R/C System Reset
5. Diagnosis Record 27. Rotor Reset
6. Engine Record 28. Maintenance
7. Engine operating hours by RPM 29. Check Engine
8. Engine Monitor 30. Update
9. Digital Display 31. Setting
10. Graph Display 32. Off Line
11. Input Setting 33. Special Function
12. Component Test 34. Engine
13. Stationary Test 35. ONLINE
14. Active Test 36. OFFLINE
15. Data Logger 37. History
16. Logger Graph 38. CAN Information
17. ECM Rec Graph 39. Communication List
18. Logging 40. Bus Statistics
19. Record of engine oil change 41. 6X6 RC Checker
20. Boat System 42. Virtual Engine
21. Boat Setting 43. Virtual Remote Control
22. Gauge Test

4. Diagnosis
Displays diagnosis codes recorded in the engine ECM, item names, and current item conditions.
This can identify components and/or systems with problems. The trouble codes displayed are the same
as those described in this chapter. See “Trouble code and checking step” (4-10).

5. Diagnosis Record
Displays diagnosis codes recorded in the engine ECM, item names, and when problems are detected.
The fault diagnosis history can be erased. The trouble codes displayed are the same as those de-
scribed in this chapter. See “Trouble code and checking step” (4-10).

6. Engine Record
Data recorded on the engine ECM related to various controls for engine speed (max.) and engine
speed, and the time and the number of times the controls occurred is displayed as a list.

7. Engine operating hours by RPM

Displays both operating hours and total operating hours for different engine speeds.

4-3
 YDIS
8. Engine Monitor
Displays engine ECM conditions (sensor information) in real time. “9. Digital Display” displays these in
digital form, and “10. Graph Display” displays these in graph form. Additionally, connecting a commer-
cially available external device, and configuring “11. Input Setting”, enables the Engine Monitor to dis-
play values of the external sensor.
Engine speed Ignition timing Multi-engine system
Intake air pressure Engine temperature Shift cut-off switch
TPS 1 Intake air temperature Thermo switch
Throttle valve opening angle Oil pressure Main switch
TPS 2 Intake cam timing (S bank) Main relay
APS 1 Intake cam timing (P bank) ETV relay
APS 2 Cooling water pressure Engine start switch
Atmospheric pressure Speed Fuel pump relay
Battery voltage Engine shut-off switch Trim level
Fuel injection duration Shift position switch Fuel flow

13. Stationary Test

When the engine is stopped and the shift is in the N position, certain engine components can be oper-
ated to check the component operation and component circuits.
Activate ignition coil (#1–#6) Activate OCV Activate electric fuel pump *1
Activate low-pressure fuel
Activate injector (#1–#6)
pump

*1. Activate high-pressure fuel pump

14. Active test

When the engine is running and the shift is in the N position, certain components can be operated to
check the component operation, the component circuits and/or the engine condition.

16. Logger Graph

Displays in graph form engine operation data stored in the ECM for the last 13 minutes in 1-minute in-
tervals.
Engine speed TPS Intake air pressure
Battery voltage Engine temperature Oil pressure

4-4
 YDIS
17. ECM Rec Graph
When a problem occurs in the electronic throttle system, the data for 2 seconds before and after the
problem is recorded on the ECM, for a total of 4 seconds. The recorded data is displayed in graph form.
Engine speed Ref. TPS voltage *2 ETV relay
APS 1 Ref. APS voltage *3 Overheat alert
APS 2 Target TPS voltage for ISC *4 Low oil pressure
TPS 1 Engine stop mode Engine operating hours
TPS 2 Engine start mode Trigger
SW-activated engine stop
Intake air pressure
mode
Battery voltage Engine shut-off switch
Target TPS voltage *1 Main relay

*1. This item shows the target output voltage of the TPS. This value is the control voltage that the
engine ECM requires to set the target opening angle of the throttle valve.
*2. “Ref. TPS voltage” is a recorded value of the TPS voltage when the throttle valve is fully
closed.
*3. “Ref. APS voltage” is a recorded value of the APS voltage when the APS is fully closed.
*4. “Target TPS voltage for ISC” is a voltage required for the engine ECM to set the throttle valve
opening angle to the opening angle of the idle speed.

18. Logging
While the computer and the outboard motor are not connected, records “Engine Monitor” data using
the adapter.

19. Record of engine oil change

It is possible to maintain oil change records using this function.

22. Gauge Test

It is possible to check if the 6Y8 Multifunction Meters function properly using this function.

23. Gauge Custom

It is possible to customize the screen settings of the 6Y8 Multifunction Meters using this function.

30. Update
It is possible to update the database when update information is provided.

31. Setting
Switches the language to use in the YDIS.
It is possible to select units when connected via the CAN-Line.

32. Off Line

Displays saved graph data in the Engine Monitor (Graph Display) and Logging menus when the com-
puter is not connected to the outboard motor.
Record settings for logging, deleting data, and data playback are possible even when the computer is
not connected to the outboard motor.

4-5
 YDIS
39. Communication List
By connecting the YDIS to a multi-hub via a CAN-Line, displays the name of Yamaha genuine parts
connected to the Digital Network. This enables to check that the connections are correct.

40. Bus Statistics

By connecting the YDIS to a multi-hub via a CAN-Line, displays the bus load connected to the Digital
Network. If the bus load is higher than 40%, then check the connection status.

Connecting the communication cable

CAN-Line

3. Adapter interface
2. Adapter cap
4. USB cable

1. CAN-Line harness

5. Multi-hub

1. CAN-Line harness
2. Adapter cap
3. Adapter interface
4. USB cable
5. Multi-hub

4-6
 YDIS
K-Line

a. YDIS coupler

2. Adapter cap

1. Adapter interface

3. USB cable 4. K-Line harness

1. Adapter interface
2. Adapter cap
3. USB cable
4. K-Line harness
a. YDIS coupler (gray)

4-7
 Outboard motor troubleshooting

Outboard motor troubleshooting

Troubleshooting procedure
1. Before troubleshooting the outboard motor, check that fresh fuel of the specified type has been
used.

2. Check that all electrical connections are secure and free from corrosion, and that the battery is fully
charged.

3. Check the trouble code using the YDIS first, and then check the electronic control system following
the trouble code chart.

4. When a trouble code is detected, check the data logger of the engine ECM record graph as well.

5. If a trouble code is not detected, check the power unit according to “Troubleshooting the power unit
(trouble code not detected)” (4-18).

6. Before using the YDIS to check the power unit, check the engine ECM circuit. See “Checking the
engine ECM circuit” (5-24).

• When deleting the diagnosis record on the YDIS, make sure to check the time that the trouble codes
were detected.
• When checking the input voltage of a part, the coupler or connector must be disconnected. As a result,
the engine ECM determines that the part is disconnected and a trouble code is detected.
Therefore, make sure to delete the diagnosis record after checking the input voltage.
• Since the main relay comes on for approximately 10 seconds after the engine start switch is turned to
OFF, the power of the engine ECM cannot be turned off. Therefore, if the engine start switch is turned
to ON within 10 seconds after it was turned to OFF, the trouble codes cannot be deleted.

Troubleshooting the power unit using the YDIS

1. Use the trouble codes, displayed by the YDIS, to check each part according to the table of “Trouble
code and checking step” (4-10).

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.

4-8
 Outboard motor troubleshooting
Trouble code table
: Indicated
—: Not indicated
YDIS diagnosis
Code No. Item YDIS diagnosis
record
13 Pulser coil  
15 Engine temperature sensor  
17 Knock sensor  
19 Battery voltage  
23 Intake air temperature sensor  
24 Cam position sensor (EX)  
27 Water in fuel filter — —
28 Shift position switch  
29 Intake air pressure sensor  
37 Intake air passage  
39 Oil pressure sensor  
44 Engine shut-off switch  —
45 Shift cut-off switch  
46 Thermo switch  
56 Main power supply  
57 Starter magnet power supply  
58 HP fuel pump PWR supply  
59 Memory data — 
68 VCT (S bank)  
69 VCT (P bank)  
71 Cam position sensor (S bank in)  
72 Cam position sensor (P bank in)  
73 OCV (P bank)  
74 OCV (S bank)  
112, 113,
114, 115,
116, 117,
118, 119,
121, 122,
ETV  
129, 136,
137, 138,
139, 141,
142, 143,
144, 145
123 ETV power supply  

4-9
 Outboard motor troubleshooting

YDIS diagnosis
Code No. Item YDIS diagnosis
record
124, 125,
126, 127, TPS  
128
131, 132,
133, 134, APS  
135

Trouble code and checking step

—: Not applicable
Trouble See
Item (Condition) Symptom Checking steps
code page
Measure the pulser coil air
7-2
gap.
Measure the pulser coil output
5-38
peak voltage.
Pulser coil “Check Engine” is displayed. Measure the pulser coil resis-
5-38
13 (Irregular sig- Engine stops suddenly. tance.
nal) Engine does not restart. Check for wiring continuity
between the pulser coil and A-6
the engine ECM.
Check the protrusions on the
7-17
flywheel magneto for damage.
Measure the engine tempera-
5-41
ture sensor input voltage.
“Check Engine” is displayed.
Engine temper- Measure the engine tempera-
Degraded acceleration perfor- 5-41
ature sensor ture sensor resistance.
15 mance.
(Out of specifi- Check for wiring continuity
Declining maximum engine
cation) between the engine tempera-
speed. A-6
ture sensor and the engine
ECM.
Measure the knock sensor
5-42
Knock sensor resistance.
“Check Engine” is displayed.
17 (Irregular sig- Check for wiring continuity
High engine idle speed.
nal) between the knock sensor and A-6
the engine ECM.

4-10
 Outboard motor troubleshooting

Trouble See
Item (Condition) Symptom Checking steps
code page
Check the battery cable and
terminals for proper connec- 10-4
tion.
Battery voltage and battery Measure the lighting coil out-
alert are displayed. 5-35
Battery voltage put peak voltage.
Engine operates normally.
19 (Below speci- Measure the lighting coil resis-
Engine does not restart 5-35
fied voltage) tance.
(depends on battery condi-
tion). Measure the rectifier/regula-
5-36
tor output voltage.
Check the rectifier/regulator
5-36
for continuity.
Check the intake air tempera-
5-39
ture using the YDIS.
Measure the intake air tem-
5-39
Intake air tem- perature sensor input voltage.
perature sensor “Check Engine” is displayed. Measure the intake air tem-
23 5-39
(Out of specifi- High engine idle speed. perature sensor resistance.
cation)
Check for wiring continuity
between the intake air temper-
A-6
ature sensor and the engine
ECM.
Measure the cam position
5-27
sensor input voltage.
“Check Engine” is displayed. Measure the cam position
Cam position High engine idle speed. 5-27
sensor output voltage.
sensor (EX) Degraded acceleration perfor-
24 Check for wiring continuity
(Irregular sig- mance.
nal) Declining maximum engine between the cam position sen- A-4
speed. sor and the engine ECM.
Check the brim of the cam-
7-54
shaft.
Check the fuel filter for water. —
Measure the water detection
5-31
switch input voltage.
Water in fuel fil- “Water in fuel” is displayed.
27 ter (Water in Alert buzzer comes on while Check the water detection
5-31
fuel filter) the shift is in the N position. switch for continuity.
Check for wiring continuity
between the water detection A-5
switch and the engine ECM.

4-11
 Outboard motor troubleshooting

Trouble See
Item (Condition) Symptom Checking steps
code page
Check the gear shift opera-
10-6
tion.
Measure the shift position
5-43
Shift position switch input voltage.
“Check Engine” is displayed.
28 switch (Irregu- Check the shift position switch
Engine operates normally. 5-43
lar signal) for continuity.
Check for wiring continuity
between the shift position A-6
switch and the engine ECM.
Measure the intake air pres-
5-39
sure sensor input voltage.
Intake air pres- “Check Engine” is displayed. Measure the intake air pres-
5-39
sure sensor High engine idle speed. sure sensor output voltage.
29
(Out of specifi- Declining maximum engine Check for wiring continuity
cation) speed. between the intake air pres-
A-6
sure sensor and the engine
ECM.
Check the gaskets of the 6-10
intake manifolds, surge tank, 6-16
and ETV. 6-21
“Check Engine” is displayed.
High engine idle speed. Check the hose between the
Impossible to shift-in (when vapor shut-off valve and the 2-19
Intake air pas- surge tank.
37 the engine speed is more than
sage (Air leak)
1500 r/min). Check the hose between the
Declining maximum engine intake air pressure sensor and 2-19
speed. the surge tank.
Check the pressure regulator
2-19
hose.
Check the oil pressure using
7-1
the YDIS.
Measure the oil pressure sen-
“Check Engine” is displayed. 5-30
Oil pressure sor input voltage.
High engine idle speed.
39 sensor (Out of Measure the oil pressure sen-
Declining maximum engine 5-30
specification) sor output voltage.
speed.
Check for wiring continuity
between the oil pressure sen- A-4
sor and the engine ECM.

4-12
 Outboard motor troubleshooting

Trouble See
Item (Condition) Symptom Checking steps
code page
Measure the shift cut-off
5-42
switch input voltage.
Shift cut-off Measure the shift cut-off
“Check Engine” is displayed. 5-42
45 switch (Irregu- switch resistance.
Higher idle speed.
lar signal) Check for wiring continuity
between the shift cut-off A-6
switch and the engine ECM.
Measure the thermo switch
5-41
input voltage.
Thermo switch Measure the thermo switch
“Check Engine” is displayed. 5-41
46 (Out of specifi- continuity.
Higher idle speed.
cation) Check for wiring continuity
between the thermo switch A-6
and the engine ECM.
Memory data
“Check Engine” is displayed.
59 (Irregular sig- Replace the engine ECM. 7-38
Engine stalls.
nal)
Measure the cam position
5-27
sensor input voltage.
“Check Engine” is displayed. Measure the cam position
Cam position High engine idle speed. 5-27
sensor output voltage.
sensor (STBD Degraded acceleration perfor-
71 Check for wiring continuity
IN) (Irregular mance.
signal) Declining maximum engine between the cam position sen- A-4
speed. sor and the engine ECM.
Check the brim of the cam-
7-54
shaft.
Measure the cam position
5-27
sensor input voltage.
“Check Engine” is displayed. Measure the cam position
Cam position High engine idle speed. 5-27
sensor output voltage.
sensor (PORT Degraded acceleration perfor-
72 Check for wiring continuity
IN) (Irregular mance.
signal) Declining maximum engine between the cam position sen- A-4
speed. sor and the engine ECM.
Check the brim of the cam-
7-54
shaft.

4-13
 Outboard motor troubleshooting

Trouble See
Item (Condition) Symptom Checking steps
code page
Check the OCV operation
5-29
using the YDIS.
Measure the OCV input volt-
5-29
age.
“Check Engine” is displayed.
High engine idle speed. Measure the OCV resistance. 5-29
OCV (STBD)
Degraded acceleration perfor- Check for wiring continuity
73 (Irregular load
mance. between the OCV and the A-4
current value)
Declining maximum engine main relay.
speed.
Check for wiring continuity
between the OCV and the A-4
engine ECM.
Check the OCV filter. 10-15
Check the OCV operation
5-29
using the YDIS.
Measure the OCV input volt-
5-29
age.
“Check Engine” is displayed.
High engine idle speed. Measure the OCV resistance. 5-29
OCV (PORT)
Degraded acceleration perfor- Check for wiring continuity
74 (Irregular load
mance. between the OCV and the A-4
current value)
Declining maximum engine main relay.
speed.
Check for wiring continuity
between the OCV and the A-4
engine ECM.
Check the OCV filter. 10-15
“Check Engine” is displayed.
ETV system
High engine idle speed.
(Engine ECM
112 Throttle does not operate. Replace the engine ECM. 7-38
internal circuit
Engine speed is set at approx-
malfunction)
imately 1500 r/min.
Measure the TPS output volt-
“Check Engine” is displayed. 5-25
age using the YDIS.
ETV system High engine idle speed.
113 (Throttle valve Throttle does not operate. Check the ETV circuit. A-4
malfunction) Engine speed is set at approx- Check the fuse. 5-3
imately 1500 r/min.
Check the ETV motor relay. 5-26
ETV system
(Engine ECM
114 Engine will not start. Replace the engine ECM. 7-38
internal circuit
malfunction)

4-14
 Outboard motor troubleshooting

Trouble See
Item (Condition) Symptom Checking steps
code page
“Check Engine” is displayed. Check the ETV circuit. A-4
ETV system High engine idle speed.
115
(Throttle valve Throttle does not operate.
116
malfunction) Engine speed is set at approx- Check the ETV. 6-23
imately 1500 r/min.
“Check Engine” is displayed. Check the ETV circuit. A-4
ETV system High engine idle speed. Check the fuse. 5-3
117
(Throttle valve Throttle does not operate.
118 Check the ETV motor relay. 5-26
malfunction) Engine speed is set at approx-
imately 1500 r/min. Check the ETV. 6-23
“Check Engine” is displayed.
ETV system High engine idle speed.
119 (Throttle valve Throttle does not operate. Check the ETV circuit. A-4
malfunction) Engine speed is set at approx-
imately 1500 r/min.
“Check Engine” is displayed.
ETV system High engine idle speed.
121 (Throttle valve Throttle does not operate. Replace the engine ECM. 7-38
malfunction) Engine speed is set at approx-
imately 1500 r/min.
“Check Engine” is displayed. Check the throttle valve opera-
6-23
ETV system High engine idle speed. tion.
122 (Throttle valve Throttle does not operate.
malfunction) Engine speed is set at approx- Replace the ETV. 6-21
imately 1500 r/min.
“Check Engine” is displayed. Check the ETV circuit. A-4
ETV power High engine idle speed. Check the fuse. 5-3
123 supply (Out of Throttle does not operate.
specification) Engine speed is set at approx- Check the ETV motor relay. 5-26
imately 1500 r/min.
“Check Engine” is displayed. Measure the TPS output volt-
5-25
High engine idle speed. age using the YDIS.
124 TPS (Out of Degraded acceleration perfor-
125 specification) mance.
Declining maximum engine Check the ETV circuit. A-4
speed.

“Check Engine” is displayed. Measure the TPS output volt-

5-25
High engine idle speed. age using the YDIS.
TPS (Out of
126 Throttle does not operate. Measure the TPS input volt-
specification) 5-25
Engine speed is set at approx- age.
imately 1500 r/min. Check the ETV circuit. A-4

4-15
 Outboard motor troubleshooting

Trouble See
Item (Condition) Symptom Checking steps
code page
“Check Engine” is displayed. Measure the TPS output volt-
5-25
Degraded acceleration perfor- age using the YDIS.
127 TPS (Out of
mance.
128 specification)
Declining maximum engine Check the ETV circuit. A-4
speed.
“Check Engine” is displayed.
ETV system
Degraded acceleration perfor-
(Engine ECM
129 mance. Replace the engine ECM. 7-38
internal circuit
Declining maximum engine
malfunction)
speed.
Measure the APS output volt-
“Check Engine” is displayed. 5-26
age using the YDIS.
High engine idle speed.
131 APS (Out of Degraded acceleration perfor- Measure the APS input volt-
5-26
132 specification) mance. age.
Declining maximum engine Measure the APS resistance. 5-26
speed.
Check the APS circuit. A-4
Measure the APS output volt-
“Check Engine” is displayed. 5-26
age using the YDIS.
High engine idle speed.
133 APS (Out of Degraded acceleration perfor- Measure the APS input volt-
5-26
134 specification) mance. age.
Declining maximum engine Measure the APS resistance. 5-26
speed.
Check the APS circuit. A-4
Measure the APS output volt-
5-26
“Check Engine” is displayed. age using the YDIS.
High engine idle speed. Measure the APS input volt-
APS (Out of 5-26
135 Throttle does not operate. age.
specification)
Engine speed is set at approx-
imately 1500 r/min. Measure the APS resistance. 5-26
Check the APS circuit. A-4
“Check Engine” is displayed.
ETV system
High engine idle speed.
136 (Engine ECM
Throttle does not operate. Replace the engine ECM. 7-38
137 internal circuit
Engine speed is set at approx-
malfunction)
imately 1500 r/min.
“Check Engine” is displayed.
ETV system
High engine idle speed.
138 (Engine ECM
Throttle does not operate. Replace the engine ECM. 7-38
139 internal circuit
Engine speed is set at approx-
malfunction)
imately 1500 r/min.

4-16
 Outboard motor troubleshooting

Trouble See
Item (Condition) Symptom Checking steps
code page
“Check Engine” is displayed.
ETV system High engine idle speed.
141 (Throttle valve Throttle does not operate. Check the ETV circuit. A-4
malfunction) Engine speed is set at approx-
imately 1500 r/min.
ETV system “Check Engine” is displayed. Check the throttle valve opera-
6-23
142 (Throttle valve Declining maximum engine tion.
malfunction) speed. Replace the ETV. 6-21
“Check Engine” is displayed.
ETV system
High engine idle speed.
(Engine ECM
143 Throttle does not operate. Replace the engine ECM. 7-38
internal circuit
Engine speed is set at approx-
malfunction)
imately 1500 r/min.
Check the battery cable and
terminals for proper connec- 10-4
tion.
Check the fuse. 5-3
“Check Engine” is displayed. Measure the lighting coil out-
ETV system High engine idle speed. 5-35
put peak voltage.
144 (Throttle valve Throttle does not operate.
malfunction) Engine speed is set at approx- Measure the lighting coil resis-
5-35
imately 1500 r/min. tance.
Measure the rectifier/regula-
5-36
tor output peak voltage.
Check the rectifier/regulator
5-36
for continuity.
Check that other trouble
ETV system codes (112–144) are 4-8
145 (Throttle valve High engine idle speed. detected.
malfunction) Check the throttle valve opera-
6-23
tion.

4-17
 Outboard motor troubleshooting

Troubleshooting the power unit (trouble code not detected)

Troubleshooting consists of the following 3 items:
Symptom 1: Specific trouble conditions
Symptom 2: Trouble conditions of an area or individual part
Cause: Trouble causes of symptom 2
—: Not applicable

Symptom 1: Engine does not crank.

See
Symptom 2 Cause Checking steps
page
Gear shift not in the N posi-
Set the gear shift to the N position. 10-6
tion
Blown fuse Check the fuse. 5-3
Engine start switch mal-
Check the engine start switch. 5-45
function
Starter motor does
not operate Neutral switch malfunction Check the neutral switch. —
Short, open, or loose con-
Check the wire harness for continu-
nection in starter motor cir- A-7
ity.
cuit
Disassemble and check the starter
Starter motor malfunction 5-48
motor.
Disassemble and check the power
Stuck piston or crankshaft 7-87
Starter motor oper- unit.
ates, but the engine Check the drive shaft bushing. 9-20
does not crank Stuck drive shaft Disassemble and check the lower 8-17
unit. 8-63

Symptom 1: Engine will not start (engine cranks).

See
Symptom 2 Cause Checking steps
page
Blown fuse Check the fuse. 5-3
Main relay malfunction Check the main relay 5-23

Engine ECM does Check for wire harness continuity

not operate Short, open, or loose con- between the main relay and the A-4
nection in the engine ECM engine ECM.
circuit Check for continuity between the
5-24
engine ECM and ground.

4-18
 Outboard motor troubleshooting

See
Symptom 2 Cause Checking steps
page
— Measure the fuel pressure. 6-2
Pinched or kinked fuel hose Check the fuel hose. 2-18
Fuel leakage Check the fuel line for leakage. 2-18
Check the fuel filter element for dirt
Clogged fuel filter element 6-8
and obstructions.
Blown fuse Check the fuse. 5-3
Check the high-pressure fuel pump
5-26
High-pressure fuel pump operation using the YDIS.
malfunction Measure the high-pressure fuel
5-26
pump resistance.
Check the high-pressure fuel pump
5-26
input voltage.
Check for wiring continuity between
Short, open, or loose con-
Fuel not supplied (all the high-pressure fuel pump and the A-5
nection in high-pressure
cylinders) engine ECM.
fuel pump circuit
Check for wiring continuity between
the high-pressure fuel pump and the A-5
fuse box.
Check the low-pressure fuel pump
5-26
input voltage.
Check for wiring continuity between
Short, open, or loose con-
the low-pressure fuel pump and the A-5
nection in low-pressure fuel
engine ECM.
pump circuit
Check for wiring continuity between
the low-pressure fuel pump and the A-5
fuse box.
Low-pressure fuel pump Check the low-pressure fuel pump
5-26
malfunction resistance.
Open check valve Check the check valve. 6-35
— Measure the compression pressure. 7-1
Check the valve timing. 7-46
Improper valve timing
Check the timing belt. 7-46
Compression pres- Check the valve for bends and stick-
sure is low 7-68
ing.
Compression leakage Check the piston and piston rings for
7-87
damage.
Check the cylinder for scratches. 7-92

4-19
 Outboard motor troubleshooting
Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited engine
speed.
See
Symptom 2 Cause Checking steps
page
Check the ignition spark. 5-37
Spark plug malfunction
Check the spark plug. 7-42
Measure the ignition coil input volt-
5-37
age.
Short, open, or loose con- Check for wiring continuity between
Spark plug does not nection in ignition coil cir- the ignition coil and the engine A-6
produce a spark cuit ECM.
(some cylinders) Check for wiring continuity between
A-6
the ignition coil and the fuse box.
Exchange the ignition coil with a dif-
Ignition coil malfunction ferent one, and then check the igni- 5-37
tion spark.
Engine ECM malfunction Replace the engine ECM. 7-38
— Measure the fuel pressure. 6-2
Fuel leakage Check for fuel leakage. 2-18
Pressure regulator mal-
Check the pressure regulator. 6-4
function
Fuel pressure is low Check the fuel filter for dirt and
Clogged fuel filter 2-18
obstructions.
High-pressure fuel pump Measure the high-pressure fuel
6-4
malfunction pump resistance.
Open check valve Check the check valve. 6-35
Check the fuel injector operation
5-32
Fuel injector malfunction using the YDIS.
Measure the fuel injector resistance. 5-32
Measure the fuel injector input volt-
5-32
age.
Fuel not supplied Short, open, or loose con- Check for wiring continuity between
A-5
(some cylinders) nection in fuel injector cir- the fuel injector and the fuse box.
cuit Check for wiring continuity between
the fuel injector and the engine A-5
ECM.
Clogged fuel injector Replace the fuel injector. 6-38
Engine ECM malfunction Replace the engine ECM. 7-38

4-20
 Outboard motor troubleshooting

See
Symptom 2 Cause Checking steps
page
— Measure the compression pressure. 7-1
Check the valve timing. 7-46
Improper valve timing
Check the timing belt. 7-46
Compression pres- Check the valve for bends and stick-
sure is low 7-68
ing.
Compression leakage Check the piston and piston rings for
7-87
damage.
Check the cylinder for scratches. 7-92
Symptom 1: High engine idle speed.
See
Symptom 2 Cause Checking steps
page
6-10
Air leakage (ETV–cylinder Check the gaskets of the intake
— 6-16
head) manifolds, surge tank, and ETV.
6-21

Symptom 1: Engine stalls, unstable engine idle speed, or poor acceleration.

See
Symptom 2 Cause Checking steps
page
Check the OCV valve operation
5-29
Stuck OCV plunger using the YDIS.

Improper intake cam Check the OCV plunger. 5-29

timing Clogged OCV filter Replace the OCV filter. 10-15
Clogged oil passage Check the oil passage. 2-13
Stuck VCT Replace the VCT assembly. 7-50

4-21
 Outboard motor troubleshooting
Symptom 1: Limited engine speed (below 2000–3000 r/min).
See
Symptom 2 Cause Checking steps
page
Measure the thermo switch input
5-41
voltage.
Check the thermo switch for continu-
Thermo switch malfunction 5-41
ity.
Check for continuity between the
A-6
thermo switch and the engine ECM.
Clogged cooling water inlet Check the cooling water inlet. 10-9
8-9
Check the impeller.
8-52
Buzzer comes on.
8-9
Overheat alert indica- Check the impeller key.
8-52
tor comes on.
8-9
Water pump malfunction Check the water pump housing.
8-52
8-9
Check the insert cartridge.
8-52
8-9
Check the outer plate cartridge.
8-52
Clogged cooling water pas-
Check the cooling water passage. 2-15
sage
Thermostat malfunction Check the thermostat. 7-91
Check the engine oil level. 10-4
Check for engine oil leakage. 2-13
Insufficient engine oil Check the valve stem seals and
7-70
valves.
Check the piston rings. 7-92
Buzzer comes on. — Measure the oil pressure. 5-30
Oil pressure alert
indicator comes on. Check the oil pump. 7-83
Check the oil strainer. 9-24
Engine oil pressure Check the relief valve. 7-87
decrease Check the oil passage (power unit
2-13
and oil pump).
Replace the oil filter. 10-12

4-22
 Outboard motor troubleshooting
Symptom 1: Discharged battery.
See
Symptom 2 Cause Checking steps
page
Check the battery capacity and spe-
10-4
Battery performance cific gravity.
decrease Check the proper connection of bat-
—
tery cables and terminals.
Short, open, or loose con- Check the proper connection of the
A-7
Low voltage indicator nection in charging circuit charging circuit and for damage.
activates on the Measure the lighting coil output
Stator assembly malfunc- 5-35
gauge peak voltage.
tion
Measure the lighting coil resistance. 5-35
Measure the rectifier/regulator out-
5-36
Rectifier/regulator malfunc- put voltage.
tion Check the rectifier/regulator for con-
5-36
tinuity.

Troubleshooting the PTT unit

Troubleshooting consists of the following 3 items:
Symptom 1: Specific trouble conditions
Symptom 2: Trouble conditions of an area or individual part
Cause: Trouble causes of symptom 2
—: Not applicable

Symptom 1: PTT unit does not operate.

See
Symptom 2 Cause Checking steps
page
Blown fuse Check the fuse. 5-3
PTT switch malfunction Check the PTT switch. 5-56
PTT relay malfunction Check the PTT relay. 5-55
Measure the PTT switch input volt-
5-56
age.
PTT relay does not
operate Measure the PTT relay input volt-
5-55
Short, open, or loose con- age.
nection of the wire harness Check for continuity between the
A-7
PTT switch and the PTT relay.
Check for wiring continuity between
A-7
the PTT switch and the fuse.

4-23
 Outboard motor troubleshooting

See
Symptom 2 Cause Checking steps
page
PTT motor malfunction Check the PTT motor. 9-43
Short, open, or loose con- Check for wiring continuity between
nection of the PTT motor the PTT motor and the PTT relay A-7
PTT motor does not lead terminal.
operate
Bent tilt ram or trim ram Check the tilt ram and trim ram. 9-57
Disassemble and check the PTT
Stuck tilt ram or trim ram 9-57
unit.
— Measure the PTT fluid pressure. 9-38
Open manual valve Check the manual valve. 9-40
Insufficient PTT fluid Add sufficient PTT fluid. 10-17
PTT fluid leakage Check for PTT fluid leakage. 10-17
Disassemble and check the PTT 9-51
unit. 9-55
PTT fluid pressure
does not increase Check the filter for dirt and obstruc- 9-47
Clogged fluid passage tions. 9-55
Check the valves for damage. 9-54
Check the fluid passages for 9-51
obstructions. 9-57
PTT motor malfunction Check the PTT motor. 9-43
Gear pump malfunction Check the gear pump assembly. 9-54
Symptom 1: PTT unit does not hold the outboard motor up.
See
Symptom 2 Cause Checking steps
page
Open manual valve Check the manual valve. 9-40
Insufficient PTT fluid Add sufficient PTT fluid. 10-17
Decrease in PTT fluid PTT fluid leakage Check for PTT fluid leakage. 10-17
pressure in lower Disassemble and check the PTT 9-51
chamber of PTT cyl- unit. 9-57
inders Clogged or open fluid pas-
Check the valves for damage. 9-54
sage
Check the fluid passages for 9-51
obstructions. 9-57

4-24
 Outboard motor troubleshooting

Troubleshooting the lower unit

Troubleshooting consists of the following 3 items:
Symptom 1: Specific trouble conditions
Symptom 2: Trouble conditions of an area or individual part
Cause: Trouble causes of symptom 2
—: Not applicable

Symptom 1: Shift mechanism of the forward gear and reverse gear does not operate properly.
See
Symptom 2 Cause Checking steps
page
Shift cable is not adjusted
Adjust the shift cable. 10-7
properly
Check the shift lever operation. 10-6
Shift rod does not operate
properly 8-9
Check the shift rod for wear.
8-52
8-27
Check the shift rod connection.
— 8-69
Check the dog clutch and related 8-14
parts. 8-59
Shift mechanism malfunc-
tion (in lower unit) 8-21
Check the forward gear, reverse 8-66
gear, and pinion for damage and 8-59
wear. 8-14
8-66

4-25
 Outboard motor troubleshooting

— MEMO —

4-26
 Electrical system

Electrical component ......................................................... 5-1

Port............................................................................................. 5-1
Starboard.................................................................................... 5-2
Fuse holder ................................................................................ 5-3
Rear............................................................................................ 5-4
Top ............................................................................................. 5-5
Bottom cowling ........................................................................... 5-6

Wiring harness routing ...................................................... 5-7

Port............................................................................................. 5-7
Starboard.................................................................................... 5-9
Rear.......................................................................................... 5-11
Top ........................................................................................... 5-13
Bottom cowling ......................................................................... 5-15

ECM circuit diagram......................................................... 5-17

ECM coupler layout.......................................................... 5-20

Checking the electrical component................................ 5-22

Using the YDIS......................................................................... 5-22
Measuring the peak voltage ..................................................... 5-22
Using the digital tester.............................................................. 5-23

Engine control unit and component............................... 5-23

Checking the main relay 1 and main relay 2 ............................ 5-23
Checking the engine ECM circuit ............................................. 5-24
Checking the ETV and TPS ..................................................... 5-25
Checking the ETV motor relay ................................................. 5-26
Checking the APS .................................................................... 5-26
Checking the cam position sensor ........................................... 5-27
Checking the OCV.................................................................... 5-29
Checking the oil pressure sensor ............................................. 5-30

Fuel control unit and component ................................... 5-31

Checking the water detection switch ........................................ 5-31
Checking the fuel injector ......................................................... 5-32
Checking the low-pressure fuel pump and high-pressure fuel
pump ........................................................................................ 5-32
Checking the high-pressure fuel pump relay............................ 5-33
Checking the vapor shut-off valve ............................................ 5-34
 Electrical system

Charging unit and component ........................................ 5-35

Checking the lighting coil (stator assembly) ............................. 5-35 0
Checking the rectifier/regulator ................................................ 5-36

Ignition unit and component ........................................... 5-37 1

Checking the ignition spark ...................................................... 5-37

2
Checking the ignition coil.......................................................... 5-37
Checking the pulser coil ........................................................... 5-38
Checking the intake air temperature sensor............................. 5-39
Checking the intake air pressure sensor .................................. 5-39
Checking the engine temperature sensor ................................ 5-41
Checking the thermo switch ..................................................... 5-41
Checking the knock sensor ...................................................... 5-42
3
Checking the shift cut-off switch............................................... 5-42
Checking the shift position switch ............................................ 5-43
Checking the engine shut-off switch......................................... 5-43 4
Starting unit and component .......................................... 5-44
Checking the starter relay ........................................................ 5-44
5
Checking the engine start switch.............................................. 5-45

Starter motor .................................................................... 5-46 6

Removing the starter motor...................................................... 5-48
Disassembling the starter motor............................................... 5-48
Checking the starter motor pinion ............................................ 5-49
Checking the armature (starter motor) ..................................... 5-50
7
Checking the brush holder ....................................................... 5-50
Assembling the starter motor ................................................... 5-51
Installing the starter motor........................................................ 5-52 8
6Y8/6YC Multifunction Meters sensor ............................ 5-53
Checking the water pressure sensor........................................ 5-53
9
Checking the speed sensor...................................................... 5-54

PTT system ....................................................................... 5-55 10

Checking the PTT relay............................................................ 5-55
Checking the PTT switch (on bottom cowling) ......................... 5-56
Checking the trim sensor.......................................................... 5-56

A
 Electrical component

Electrical component
Port

1 2 3 4

10

7 6

1. Intake air temperature sensor 8. Water detection switch (in fuel cup
2. Fuse box (low-pressure fuel pump) assembly)
3. Fuse box (high-pressure fuel pump) 9. Intake air pressure sensor
4. YDIS coupler 10. ETV (TPS)
5. Fuel injector
6. High-pressure fuel pump
7. Low-pressure fuel pump

5-1
 Electrical component

Starboard

1 2

4
8

7 6 5

1. PTT relay
2. Fuse box
3. Starter motor
4. Diode (connect to the PTT relay)
5. Oil pressure sensor
6. APS
7. Rectifier/regulator
8. Fuel injector

5-2
 Electrical component

Fuse holder

1 2 3 4
20
10

30
30

60 60

6 5

1. Fuse (20 A) (main switch and PTT

switch)
2. Fuse (10 A) (ETV)
3. Fuse (30 A) (starter relay)
4. Fuse (30 A) (ignition coil, VCT, fuel injec-
tor, and engine ECM)
5. Fuse (60 A) (isolator)
6. Fuse (60 A) (battery)

5-3
 Electrical component

Rear

2 3

14

4 4

13

12

11 10 9 8 7 6

1. Cam position sensor (PORT IN) 10. Starter relay

2. Cam position sensor (PORT EX) 11. Knock sensor coupler
3. Engine ECM 12. Water pressure sensor coupler
4. Ignition coil 13. Condenser (connect to the cam position
5. Cam position sensor (STBD IN) sensor [PORT EX])
6. Main relay 2 14. Knock sensor
7. Main relay 1
8. ETV relay
9. Fuel pump relay

5-4
 Electrical component

Top

1. Thermo switch (STBD)

2. OCV (STBD)
3. Joint coupler 1
4. OCV (PORT)
5. Thermo switch (PORT)
6. Engine temperature sensor
7. Pulser coil
8. Vapor shut-off valve
9. Stator assembly

5-5
 Electrical component

Bottom cowling
A

8 7 6
B
3

7 6

1. Shift cut-off switch 9. PTT switch wire harness extension cou-

2. Shift position switch pler
3. PTT switch
A. Regular rotation model
4. Trim sensor coupler
B. Counter rotation model
5. Main wire harness coupler (10 pin)
6. 6Y8/6YC Multifunction meter communi-
cation coupler
7. Gauge harness coupler
8. PTT switch coupler

5-6
 Wiring harness routing

Wiring harness routing

Port

O
A B C D E F

R R
P

Q S
G
K

J H

T T

2 1 1 3 4
L M
M
3
2 N
1
O P Q R-R S T-T

5-7
 Wiring harness routing

1. Fuel hose
2. Low-pressure fuel pump lead
3. Wire harness
4. Thermo switch lead connector
A. Install the low-pressure fuel pump cou-
pler onto the wire harness guide.
B. Install the engine temperature sensor
lead and thermo switch lead on the hook
of the wire harness guide.
C. Install the engine temperature sensor
coupler onto the wire harness guide.
D. Fasten the wire harness using the holder
on the fuel rail cover.
E. Fasten the wire harness to the fuel rail
using the plastic tie. Make sure that there
is no slack in the wire harness.
F. Fasten the wire harness (to fuel injector
[#2]) and wire harness (to fuel injector
[#4 and #6]) using the holder in the order
listed.
G. Fasten the wire harness (to fuel injector
[#6]) using the holder.
H. Fasten the wire harness (to fuel injector
[#6]) using the plastic tie at the white
tape.
I. Fasten the wire harness in the order H,
G, and F.
J. Fasten the wire harness at the white tape
using the holder. Make sure that there is
no slack in the wire harness.
K. Install the holder with its end against the
protection tube of the fuel hose.
L. Before installing the intake silencer, fas-
ten the wire harness (to intake air tem-
perature sensor) at the white tape using
the holder on the oil filler neck.
M. Make sure that the catch of the holder is
facing forward.
N. Make sure that the end of the plastic tie is
pointing rearward.

5-8
 Wiring harness routing

Starboard

6 7
1
1
R 2

3
2
6 7 6 7 6 7
S-S 1 T 1 U-U 1 V-V 1
3 4 4
2 2
5 4 3 5 2 3 5
2 2 3
W-W Q X-X Y-Y Z-Z
P

S B
S
O C
U U

L
N T V V
W W

X X D
Y Y
Z
E F
M Z G

K J I

5-9
 Wiring harness routing

1. Wire harness
2. Stator assembly lead
3. Rectifier/regulator lead
4. Starter motor lead
5. PTT motor lead
6. Ground lead
7. Isolator lead
A. Fit the stator assembly lead into the
groove in the junction box.
B. Fasten the PTT motor lead and wire har-
ness ground lead using the holder.
C. Connect the starter motor lead and
brown lead of the wire harness together.
D. Fasten the starter motor lead and junc-
tion box wire harness extension using the
holder.
E. Route the PTT motor lead to the outside
of the other leads.
F. Fasten the starter motor lead, wire har-
ness, and PTT motor lead using the
holder.
G. Route the wire harnesses and PTT motor
lead through the guide on the terminal.
H. Fasten the wire harnesses and PTT
motor lead using the holder.
I. Route the battery cable along the bottom
cowling.
J. Install the wire harness ground lead ter-
minal so that it contacts the stopper.
K. Install the junction box wire harness
extension ground lead terminal so that it
contacts the stopper.
L. Fasten the wire harness in the order M,
N, O, and P.
M. Fasten the wire harness (to fuel injector
[#5]) to the holder at the white tape.
N. Fasten the wire harness (to fuel injector
[#3 and #5]) to the holder.
O. Fasten the wire harness (to fuel injector
[#1]) and wire harness (to fuel injector
[#3 and #5]) using the holder in the order
listed.
P. Fasten the wire harness using the plastic
tie so that there is no slack in the wire
harness.
Q. Fasten the wire harness using the holder.
R. Install the plastic tie as shown in the illus-
tration.

5-10
 Wiring harness routing

Rear

1 Q
Q Q
1 R
2 3 1 S
1

T-T A U-U B V-V W-W X-X Y-Y

C
Z
X
P
X Y
O

W W
D

V V
N
E
M T F

U
L T
K G
U
J H

5-11
 Wiring harness routing

1. Wire harness
2. Condenser
3. Cam position sensor (PORT IN) lead
A. Fasten the wire harness using the holder.
B. Route the wire harness to the inside of
the blowby hose.
C. Install the holder and fasten the plastic
ties in the order B, P, and Z.
D. Pass the wire harness through the
holder.
E. Fasten the wire harness at the white tape
using the holder.
F. Fasten the yellow wire harness with the
plastic tie.
G. Yellow tape.
H. White tape.
I. Fasten the knock sensor lead using the
holder. Make sure that the end of the cor-
rugated tube is positioned 30 mm (1.2 in)
from the holder.
J. Route the knock sensor lead to the inside
of the wire harness.
K. Attach the wire harness so that it does
not interfere with the knock sensor.
L. Fit the protrusion on the knock sensor
coupler into the hole in the engine ECM
bracket. Make sure that the protrusions
on the sides of the coupler are positioned
under the stoppers on the engine ECM
bracket.
M. Install the speed sensor coupler to the
relay holder.
N. Install the wire harness so that it does
not interfere with the relay holder.
O. Route the condenser on the inside of the
ignition coil lead #2.
P. Fit the protrusion on the plastic tie into
the hole in the engine ECM bracket.
Q. Install the plastic tie as shown in the illus-
tration.
R. Install the plastic tie as shown in the illus-
tration so that it does not interfere with
the blowby hose.
S. Install the wire harness by pushing it
against to the ECM bracket.

5-12
 Wiring harness routing

Top

F
K
L L
E

N
K
M
C
M

J
N

J
D

1 5 I
2 H 7
3
G
4 6
4
J-J K-K L-L M-M N-N

5-13
 Wiring harness routing

1. Stator assembly lead

2. Fuel hose
3. Thermo switch connector
4. Wire harness
5. High-pressure fuel hose
6. Vapor gas hose
7. Engine temperature sensor lead
A. Fit the protrusion on the plastic tie into
the hole in the wire harness guide.
B. Make sure that the protrusion on the
holder contacts the rib on the bracket.
C. Route the wire harness under the high-
pressure fuel hose and blowby hose.
D. Install the pulser coil coupler to the
bracket.
E. Fasten the wire harness and vapor gas
hose using the holder.
F. Fasten the wire harness and quick con-
nector using the holder.
G. Fasten the thermo switch connector with
the plastic tie. Install the plastic tie with
its buckle facing in the direction shown in
the illustration.
H. Make sure that the wire harness does not
rise above the rib area of the wire har-
ness guide.
I. Fold the engine temperature sensor lead.

5-14
 Wiring harness routing

Bottom cowling
A

C D E

M M

K
G

I H
B

M-M J

1
N F
3 L
4 O
O
2

G
N O-O H

5-15
 Wiring harness routing

1. Water detection switch coupler

2. Isolator coupler
3. Wire harness
4. PTT switch wire harness extension
A. Regular rotation model
B. Counter rotation model
C. Fasten the flushing hose, cooling water
hose, and trim sensor lead using the
plate.
D. Fasten the flushing hose, cooling water
hose, trim sensor lead, and speedometer
hose using the plate. Make sure to route
the speedometer hose over the flushing
hose and trim sensor lead.
E. Fasten the flushing hose, cooling water
hose, and trim sensor lead using the
holder.
F. If the 6Y8/6YC Multifunction meter is
selected, remove the caps and connect
the coupler.
G. Do not route the wire harness over the
bolt.
H. If conventional meters are selected, con-
nect the gauge harness coupler, and
then install the coupler in the location
shown in the illustration.
I. Fasten the meter lead and extension wire
harness using the holder.
J. Fasten the flushing hose, cooling water
hose, trim sensor lead, and PTT switch
lead using the holder.
K. Make sure that the white paint mark on
the flushing hose and the white tape on
the PTT motor lead are aligned with the
edge of the grommet.
L. Fasten the PTT switch wire harness
extension at the white tape using the
holder.

5-16
 ECM circuit diagram

ECM circuit diagram

, , a, b, c, d: Indicate a connection between the symbols.
The circled numbers in the illustration indicate the engine ECM terminal numbers.
< INPUT > < OUTPUT >
12. Fuel injector #1
1. Pulser coil 59
16 13. Fuel injector #2
60
14. Fuel injector #3
15 58
15. Fuel injector #4
57
2. Cam position sensor 16. Fuel injector #5
(PORT EX) 3 56
17. Fuel injector #6
55
3. Cam position sensor
(PORT IN)
2 18. Ignition coil #1

4. Cam position sensor

(STBD IN)
1 71
19. Ignition coil #2
5V
51
70
5. TPS 1 45
6. TPS 2 50
26. Ground 20. Ignition coil #3
47 63
21. Ignition coil #4
5V 11. Engine
49
ECM
7. APS 1 31 62
26. Ground 22. Ignition coil #5
41
5V
44
54
8. APS 2 38
26. Ground
40 23. Ignition coil #6
53
5V
48
79 24. ETV relay
9. Intake air pressure sensor 36
80
10 A
66
10. Oil pressure sensor 37 83 25. ETV
81 motor

75
84

a b c d

5-17
 ECM circuit diagram
, , a, b, c, d: Indicate a connection between the symbols.
The circled numbers in the illustration indicate the engine ECM terminal numbers.
a < INPUT > b < OUTPUT > c d

42. OCV (STBD)

27. Water pressure sensor 42 86
43. OCV (PORT)
77
28. Speed sensor 43

29. Intake air temperature sensor

23 44. High-pressure 45. High-pressure
fuel pump relay fuel pump
30. Engine temperature sensor
15 A
17 P
65
31. Trim sensor 19

52
32. Thermo switch
46. Low-pressure fuel pump
33. Water detection switch 61 P
5
34. Shift cut-off switch
47. Vapor shut-off valve
6 85
35. Shift position switch
12

26. Ground
18 48. Low oil pressure alert indicator
72
36. Knock sensor 11. Engine
8 ECM 49. Overheat alert indicator
73
37. Engine shut-off switch
78
50. Alert buzzer
67 BZ

51. Tachometer
64 T

20 52. 6Y8
21 Network
27
30 A
34
28 53. YDIS
40. Rectifier/ 7
regulator
38. Main relay 46
20 A
13
60 A 39. Main switch 68
69
76

41. Battery

5-18
 ECM circuit diagram

1. Pulser coil 50. Alert buzzer

2. Cam position sensor (PORT EX) 51. Tachometer
3. Cam position sensor (PORT IN) 52. 6Y8 Network
4. Cam position sensor (STBD IN) 53. YDIS
5. TPS 1
6. TPS 2
7. APS 1
8. APS 2
9. Intake air pressure sensor
10. Oil pressure sensor
11. Engine ECM
12. Fuel injector #1
13. Fuel injector #2
14. Fuel injector #3
15. Fuel injector #4
16. Fuel injector #5
17. Fuel injector #6
18. Ignition coil #1
19. Ignition coil #2
20. Ignition coil #3
21. Ignition coil #4
22. Ignition coil #5
23. Ignition coil #6
24. ETV relay
25. ETV motor
26. Ground
27. Water pressure sensor
28. Speed sensor
29. Intake air temperature sensor
30. Engine temperature sensor
31. Trim sensor
32. Thermo switch
33. Water detection switch
34. Shift cut-off switch
35. Shift position switch
36. Knock sensor
37. Engine shut-off switch
38. Main relay
39. Main switch
40. Rectifier/regulator
41. Battery
42. OCV (STBD)
43. OCV (PORT)
44. High-pressure fuel pump relay
45. High-pressure fuel pump
46. Low-pressure fuel pump
47. Vapor shut-off valve
48. Low oil pressure alert indicator
49. Overheat alert indicator

5-19
 ECM coupler layout

ECM coupler layout

1 2 3 4 5 6 7 27 28 29 30 31 32 33 53 54 55 56 57 58 59 60 61
8 9 10 11 12 13 34 35 36 37 38 39 62 63 64 65 66 67 68 69
14 15 16 17 18 19 40 41 42 43 44 45 70 71 72 73 74 75 76 77
20 21 22 23 24 25 26
46 47 48 49 50 51 52 78 79 80 81 82 83 84 85 86

No. Connecting part Color No. Connecting part Color

Cam position sensor 21 6Y8 Network Blue
1 White/Black
(STBD IN) 22 — —
Cam position sensor Intake air tempera-
2 White/Green 23 Black/Yellow
(PORT IN) ture sensor
Cam position sensor 24 — —
3 White/Blue
(PORT EX)
25 — —
4 — —
26 — —
Water detection
5 Blue/White 27 Battery power source Red/Yellow
switch
28 YDIS White/Black
6 Shift cut-off switch Blue/Yellow
29 — —
7 Main relay Yellow/Green
30 — —
8 Knock sensor Green
31 APS 1 Pink/White
9 — —
32 — —
10 — —
33 — —
11 — —
34 Battery power source Red/Yellow
12 Shift position switch Blue/Green
35 — —
13 Main switch Yellow
Intake air pressure
14 — — 36 Pink/Green
sensor
15 Pulser coil ground Black
37 Oil pressure sensor Pink/White
16 Pulser coil White/Black
38 APS 2 Pink
Engine temperature
17 Black/Yellow 39 — —
sensor
40 APS 2 ground Black
18 Sensor ground Black
41 APS 1 ground Black
19 Trim sensor Pink
Water pressure sen-
20 6Y8 Network White 42 Blue/Black
sor

5-20
 ECM coupler layout

No. Connecting part Color No. Connecting part Color

43 Speed sensor Blue 77 OCV (PORT) Purple
44 APS 2 power source Orange Engine shut-off
78 White
45 TPS 1 Pink switch
46 Ground Black 79 ETV power source Red/Green
47 TPS ground Black 80 ETV power source Red/Green
48 Sensor power source Orange 81 ETV motor (close) Green/Black
49 APS 1 power source Orange 82 — —

50 TPS 2 Pink/White 83 ETV motor (open) Green/Red

51 TPS power source Orange 84 ETV ground Black

52 Thermo switch Pink 85 Vapor shut-off valve Green/Black

53 Ignition coil #6 Black/Brown 86 OCV (STBD) Purple

54 Ignition coil #5 Black/Blue

55 Fuel injector #6 Purple/White
56 Fuel injector #5 Purple/Blue
57 Fuel injector #4 Purple/Green
58 Fuel injector #3 Purple/Yellow
59 Fuel injector #1 Purple/Red
60 Fuel injector #2 Purple/Black
Low-pressure fuel
61 Blue/White
pump
62 Ignition coil #4 Black/Green
63 Ignition coil #3 Black/Yellow
64 Tachometer Green
High-pressure fuel
65 Blue/Red
pump relay
66 ETV relay Yellow
67 Alert buzzer Pink
68 Ground Black
69 Ground Black
70 Ignition coil #2 Black/White
71 Ignition coil #1 Black/Orange
Oil pressure alert
72 Pink/White
indicator
Overheat alert indica-
73 Pink/Black
tor
74 — —
75 ETV ground Black
76 Ground Black

5-21
 Checking the electrical component

Checking the electrical compo- To check the electrical components or mea-

nent sure the peak voltage, use the special service
tools.
Using the YDIS
A malfunctioning electrical component can be
When checking the ETV, TPS, APS, OCV, ig-
checked easily by measuring the peak voltage.
nition spark, high-pressure fuel pump, fuel in-
The specified engine speed when measuring
jector, and related sensors, use the YDIS.
the peak voltage is affected by many factors,
such as fouled spark plugs or a weak battery.
• When deleting the diagnosis record in the If one of these factors is present, the peak volt-
YDIS, make sure to check the time that the age cannot be measured properly.
trouble codes were detected.
• When checking the input voltage of a part, the
• Before measuring the peak voltage, check all
coupler or connector must be disconnected.
of the wire harnesses for corrosion. Also,
As a result, the engine ECM determines that
make sure that the wire harnesses are con-
the part is disconnected and a trouble code is
nected properly and that the battery is fully
detected. Therefore, make sure to delete the
charged.
diagnosis record after checking the input volt-
• Use peak voltage adapter with the recom-
age.
mended digital circuit tester.
• To connect and operate the YDIS, see the
• Connect the positive pin of peak voltage
YDIS (Ver. 2.22 or later) instruction manual.
adapter to the positive terminal of the digital
• The software is available through YMAN
tester, and the negative pin to the negative
(Yamaha Marine Associate Network).
terminal.
• When measuring the peak voltage, set the
YDIS2 Hardware Kit digital circuit tester to the DC voltage mode.
90890-06884

Measuring the peak voltage

DC V
When measuring the peak voltage, do not
touch any of the connections of the digital
tester probes.

When measuring the peak voltage between

the terminals of an electrical component Digital circuit tester
using the digital tester, make sure that the 90890-03243
leads do not contact any metal parts. Other- Peak voltage adapter B
wise, the electrical component may short- 90890-03172
circuit and be damaged.

5-22
 Engine control unit and component

Using the digital tester Engine control unit and compo-

The electrical technical data applies to the nent
measurements taken using the Yamaha rec- Checking the main relay 1 and main
ommended tester.
relay 2
The resistance values shown are the values
1. Remove the engine ECM cover.
taken before the engine is started. The actual
resistance may vary depending on the environ-
2. Remove the main relay 1 “1” and main re-
mental conditions and ambient temperature.
lay 2 “2”.
The input voltage changes depending on the
battery voltage. Check the battery and wire 3. Disconnect the main relay coupler “a”.
harness if the input voltage is less than the
specified value. Check the components be-
tween the battery and the input voltage mea-
suring point if there is no problem with the
battery and wire harness.
If the tester probe cannot be inserted into the
coupler, prepare a test lead suitable for the
measurement.

2 1 a

4. Measure the input voltage between the ter-

minal and ground.

1 2

3 2
4

Digital circuit tester

90890-03243
Test lead
Terminal, male “1”
(commercially available)
Input voltage
Terminal, female “2”
12 V (battery voltage)
(commercially available)
Terminal 2–Ground
Terminal 3–Ground
Terminal 4–Ground

5-23
 Engine control unit and component
5. Turn the engine start switch to ON, and
Relay terminals continuity
then measure the input voltage between
the terminal and ground. “c” “d”

9. Disconnect the special service tool.

10. Install the main relay 1 and main relay 2,

2
4
and then connect the main relay 1 and
main relay 2 coupler.

11. Install the engine ECM cover.

Checking the engine ECM circuit

Input voltage 1. Remove the engine ECM cover.
12 V (battery voltage)
Terminal 2–Ground 2. Remove the engine ECM. See “Removing
Terminal 4–Ground the engine ECM” (7-39).

6. Turn the engine start switch to OFF. 3. Disconnect the engine ECM couplers “a”,
“b”, and “c”.
7. Connect the special service tool “2” to the
fuel pump relay “1”.

8. Connect the positive battery lead to the

connector “a”, and the negative battery a
lead to the connector “b”, and then check
for continuity between the connectors “c” b
and “d”. Replace the relay if out of specifi- c
cation.

4. Check the wire harness for continuity.

Do not reverse the battery leads.

b
1

46
123 4 56 2
b d
W/R W/Br
c
W/B W/L
a W/G c
W/Y
69 68
76

Test harness FWY–6 “2”

90890-06872

5-24
 Engine control unit and component
1. Connect the YDIS to display “TPS 1” and
Wire harness continuity “TPS 2”.
Terminal 46–Ground
Terminal 68–Ground 2. Start the engine, warm it up for 5–10 min-
Terminal 69–Ground utes, and then stop it.
Terminal 76–Ground
3. Turn the engine start switch to ON, and
5. Turn the engine start switch to ON, and then measure the TPS output voltages
then measure the input voltage between when the remote control lever is at the fully
the engine ECM coupler “a” terminal 7 and closed position.
ground. TPS output voltage (reference data)
Item Fully closed Fully open
a
TPS 1 0.723 4.331
7 TPS 2 2.729 4.639

4. Turn the engine start switch to OFF.

5. Remove the intake silencer, and then dis-

connect the ETV coupler “a”. See “Remov-
ing the intake silencer” (6-12).

Input voltage 6. Turn the engine start switch to ON, and

12 V then measure the TPS input voltage at the
Terminal 7–Ground ETV coupler.

6. Turn the engine start switch to OFF.

7. Connect the engine ECM couplers.

8. Installing the engine ECM. See “Installing

the engine ECM” (7-39).
Or B
Checking the ETV and TPS
TPS 1 and TPS 2 are components of the ETV, a
which cannot be disassembled.

Do not loosen the throttle stop screw nut or

turn the throttle stop screw.
Input voltage
4.75–5.25 V
Orange (Or)–Black (B)

7. Turn the engine start switch to OFF.

8. Connect the ETV coupler, and then install

the intake silencer. See “Installing the in-
take silencer” (6-14).

5-25
 Engine control unit and component

Checking the ETV motor relay

1. Remove the engine ECM cover. Input voltage
12 V (battery voltage)
2. Remove the ETV motor relay “1”. Terminal 2–Ground
Terminal 4–Ground
3. Disconnect the ETV motor relay coupler
“a”. 6. Turn the engine start switch to OFF.

7. Check the ETV motor relay. See “Check-

ing the main relay 1 and main relay 2”
(5-23).

8. Install the ETV motor relay, and then con-

nect the ETV motor relay coupler.

Checking the APS

1 a APS 1 and APS 2 are a single unit, which can-
not be disassembled.
4. Measure the input voltage between the ter-
minal and ground. 1. Connect the YDIS to display “APS 1” and
“APS 2”.

2. Check that the accelerator lever “1” con-

tacts the stopper “2” when the remote con-
trol lever is in the N position.
4

Input voltage
12 V (battery voltage)
Terminal 4–Ground

5. Turn the engine start switch to ON, and

3. Turn the engine start switch to ON, and
then measure the input voltage between
then measure the APS output voltage
the terminal and ground.
when the remote control lever is at the fully
closed position and fully open position.
APS output voltage (reference data)
Item Fully closed Fully open
2 APS 1 0.664 V 4.014 V
4
APS 2 0.688 V 4.043 V

4. Check that the output voltages of APS 1

and APS 2 change continuously when the
remote control lever is operated.

5. Turn the engine start switch to OFF.

5-26
 Engine control unit and component
6. Remove the intake manifold (STBD). See
APS resistance (reference data)
“Removing the intake manifold” (6-12).
Fully Fully
Item Terminal
7. Disconnect the throttle cable joint from the closed open
APS. APS 1 “c”–“d”
0.8 k 5.3 k
8. Disconnect the APS coupler “a”. APS 2 “a”–“b”

9. Turn the engine start switch to ON, and 12. Connect the APS coupler.
then measure the input voltage at the APS
13. Connect the throttle cable joint to the APS.
coupler.
Or B Or B 14. Install the intake manifold (STBD). See “In-
stalling the intake manifold” (6-13).

Checking the cam position sensor

1. Remove the engine ECM cover.

2. Disconnect the cam position sensor cou-

a plers “a”, “b”, and “c”.

3. Turn the engine start switch to ON, and

then measure the input voltage at the cam
position sensor coupler.
STBD IN
W/B R/Y a
Input voltage B
4.75–5.25 V
Orange (Or)–Black (B)

10. Turn the engine start switch to OFF.

11. Measure the APS resistance when the ac-

celerator lever “1” is at the fully closed po- b
PORT IN R/Y W/G B
sition “A” and fully open position “B”.
A B

1 1

d c a b

5-27
 Engine control unit and component

PORT EX c
B W/L R/Y Test lead
Terminal, male “1”
9E212-10303
Terminal, female “2”
9E212-11303
Terminal, female “3”
(commercially available)
“a” = 100 mm (3.94 in)
“b” = 50 mm (1.97 in)
“c” = Cutout area
Input voltage (R/Y–B)
12 V 6. Remove the cam position sensors “1”.
Red/Yellow (R/Y)–Black (B)
Input voltage 7. Connect the test leads to the cam position
4.75–5.25 V sensor “1” and cam position sensor cou-
White/Black (W/B)–Black (B) pler.
(STBD IN)
White/Green (W/G)–Black (B)
(PORT IN) Make sure that the test leads do not contact
White/Blue (W/L)–Black (B) each other and cause a short circuit. Other-
(PORT EX) wise, the fuse could blow when the engine
start switch is turned to ON.
4. Turn the engine start switch to OFF.
8. Connect the tester probes to the test
5. Make 3 test leads.
leads.
2 STBD IN
PORT EX 1
3

b
a

1
1
c B

R/Y W/B
W/L

5-28
 Engine control unit and component

PORT IN Cam position sensor output voltage

W/G
1 White/Black (W/B)–Black (B)
R/Y (STBD IN)
White/Blue (W/L)–Black (B)
B (PORT EX)
Position Voltage
“a”, “c” More than 4.8
“b” Less than 1.0
White/Green (W/G)–Black (B)
(PORT IN)
Position Voltage
“a”, “c” Less than 1.0
9. Turn the engine start switch to ON, and “b” More than 4.8
then measure the output voltage when
moving a screwdriver close to the cam po- 10. Turn the engine start switch to OFF.
sition sensor “1”. Replace if out of specifi-
cation. 11. Disconnect the test leads, and then install
the cam position sensors.

Make sure to remove the high-pressure fuel 12. Connect the cam position sensor couplers.
pump fuse.
13. Install the engine ECM cover.

Checking the OCV

Using an analog circuit tester is recommended.
1. Check the operation of the OCV using the
YDIS “Stationary Test” and check the op-
1 erating sound.

2. Disconnect the OCV couplers “a” and “b”.

3. Turn the engine start switch to ON, and

a b c then measure the input voltage between
the OCV coupler and ground.

PORT
R/Y
a

5-29
 Engine control unit and component
9. Install the OCV, and then connect the OCV
R/Y STBD couplers. See “Installing the cylinder head”
b (7-74).

Checking the oil pressure sensor

1. Disconnect the oil pressure sensor coupler
“a”.
a
B Or

Input voltage
12 V
Red/Yellow (R/Y)–Ground

4. Turn the engine start switch to OFF.

5. Remove the OCVs. 2. Turn the engine start switch to ON, and
then measure the input voltage at the oil
6. Measure the OCV resistance. Replace if
pressure sensor coupler.
out of specification.
Input voltage
4.75–5.25 V
Orange (Or)–Black (B)

3. Remove the oil pressure sensor, and then

connect the pressure pump “1” and special
service tool “2”.

4. Apply positive pressure to the oil pressure

sensor slowly, and then measure the out-
Resistance put voltage at the specified pressures.
6.7–7.7  P/W
B
Or
7. Connect the battery leads to the terminals G/W B G
and check the operation of the spool valve.
Replace the OCV if the spool valve does 2
not operate.

1 2

8. Disconnect the battery leads.

5-30
 Fuel control unit and component

Fuel control unit and component

Pressure pump “1” Checking the water detection switch
(commercially available) 1. Disconnect the water detection switch
Test harness (3 pins) “2” coupler “a”.
90890-06869
2. Turn the engine start switch to ON, and
then measure the input voltage at the wa-
Output voltage at 392 kPa (3.92
ter detection switch coupler.
kgf/cm², 56.8 psi)
2.5 V
Output voltage at 784 kPa (7.84 B L/W
kgf/cm², 113.7 psi)
4.5 V
Pink/White (P/W)–Black (B)

5. Turn the engine start switch to OFF, and

then disconnect the special service tool
a
and pressure pump.

6. Connect the oil pressure sensor coupler.

Input volatage
4.75–5.25 V
Blue/White (L/W)–Black (B)

3. Turn the engine start switch to OFF, and

then remove the filter cup assembly.

4. Check that the float “1” moves smoothly.

Do not remove the clip and float.

5. Check the water detection switch for conti-

nuity when the float “1” is in positions “A”
and “B”. Replace the fuel cup assembly if
out of specification.
A

5-31
 Fuel control unit and component

B STBD

R/Y
1
a

Water detection switch continuity

Float position Terminal Input voltage
“A” 12 V
Red/Yellow (R/Y)–Ground
“B”

6. Install the filter cup assembly. See “Fuel fil- 4. Turn the engine start switch to OFF.
ter” (6-6).
5. Measure the fuel injector resistance. Re-
7. Connect the water detection switch cou- place if out of specification.
pler.

Checking the fuel injector

1. Check the operation of the fuel injector us-
ing the YDIS “Stationary Test” and check
the operating sound.

2. Disconnect the fuel injector couplers “a”.

3. Turn the engine start switch to ON, and

then measure the input voltage between
the fuel injector coupler terminal and Resistance (reference data)
ground. 12.00 

PORT 6. Connect the fuel injector couplers.

R/Y
Checking the low-pressure fuel pump
and high-pressure fuel pump
a 1. Check the operation of the low-pressure
fuel pump and high-pressure fuel pump
using the YDIS “Stationary Test” and
check the operating sound.

2. Remove the intake silencer. See “Remov-

ing the intake manifold” (6-12).

3. Disconnect the low-pressure fuel pump

coupler “a”.

5-32
 Fuel control unit and component
4. Turn the engine start switch to ON, and
then measure the input voltage between R B R B
the low-pressure fuel pump coupler termi-
nal and ground.
A B
a

R/Y

A. Low-pressure fuel pump

Low-pressure fuel pump B. High-pressure fuel pump
Input voltage
12 V
Low-pressure fuel pump
Red/Yellow (R/Y)–Ground
Resistance (reference data)
5. Turn the engine start switch to OFF. 0.5–4.0 
High-pressure fuel pump
6. Disconnect the vapor separator wire har- Resistance (reference data)
ness extension coupler “a”. 0.3–10.0 

7. Connect the tester probes to the terminals 9. Connect the low-pressure fuel pump cou-
of the vapor separator wire harness exten- pler and vapor separator wire harness ex-
sion coupler “a”, and then measure the in- tension coupler.
put voltage within 5 seconds after turning
the engine start switch to ON. 10. Install the intake silencer. See “Installing
the intake silencer” (6-14).

a Checking the high-pressure fuel

B R pump relay
1. Remove the engine ECM cover.

2. Remove the high-pressure fuel pump relay

“1”.

3. Disconnect the high-pressure fuel pump

relay coupler “a”.
High pressure fuel pump
Input voltage
12 V
Red (R)–Black (B)

8. Measure the resistance of the fuel pump

motors. Replace if out of specification.

1 a

5-33
 Fuel control unit and component
4. Turn the engine start switch to ON, and
then measure the input voltage between R/Y
the terminal and ground.

2
4 a

Input voltage
12 V
Red/Yellow (R/Y)–Ground
Input voltage
12 V (battery voltage) 4. Turn the engine start switch to OFF.
Terminal 2–Ground
Terminal 4–Ground 5. Remove the intake manifold (STBD). See
“Removing the intake manifold” (6-12).
5. Turn the engine start switch to OFF.
6. Remove the intake manifold (PORT). See
6. Check the high-pressure fuel pump relay. “Removing the intake manifold” (6-12).
See “Checking the main relay 1 and main
relay 2” (5-23). 7. Remove the throttle body assembly. See
“Removing the throttle body assembly”
7. Install the high-pressure fuel pump relay, (6-18).
and then connect the high-pressure fuel
pump relay coupler. 8. Remove the vapor shut-off valve from the
throttle body assembly.
8. Install the engine ECM cover.
9. Connect the special service tool “1” to the
Checking the vapor shut-off valve vapor shut-off valve.
1. Remove the intake silencer. See “Remov-
ing the intake silencer” (6-12). Vacuum/pressure pump gauge set
“1”
2. Disconnect the throttle body assembly 90890-06945
wire harness extension coupler “a”.
10. Apply the specified negative pressure to
3. Turn the engine start switch to ON, and the vapor shut-off valve.
then measure the input voltage between
the throttle body assembly wire harness
extension coupler terminal and ground. Do not connect the battery leads to the va-
por shut-off valve terminals for more than a
few seconds.

Specified negative pressure

67.0 kPa (0.67 kgf/cm², 9.7 psi)

5-34
 Charging unit and component
11. Check that the vapor shut-off valve opens Charging unit and component
and the negative pressure is released Checking the lighting coil (stator as-
when the battery leads are connected to sembly)
the vapor shut-off valve terminals.
1. Remove the intake manifold (STBD). See
“Installing the intake manifold” (6-13).
1
2. Remove the lighting coil leads from the
plastic ties “1”, and then disconnect the
lighting coil couplers “a”.

12. Remove the special service tool. a 1

13. Measure the resistance between the vapor

shut-off valve terminals. Replace if out of
specification.
3. Move the lighting coil leads away from the
Resistance area covered by the intake manifold, and
30.0–34.0  then install the intake manifold (STBD).
See “Removing the intake manifold”
14. Install the vapor shut-off valve to the throt- (6-12).
tle body assembly.
4. Remove the clip from the engine shut-off
15. Install the throttle body assembly. See “In- switch.
stalling the throttle body assembly” (6-19).
5. While cranking the engine, measure the
16. Install the intake manifolds. See “Installing peak voltage.
the intake manifold” (6-13).
6. Insert the clip into the engine shut-off
17. Install the intake silencer. See “Installing switch.
the intake silencer” (6-14).
7. Start the engine, and then measure the
peak voltage at the specified engine
speed.

5-35
 Charging unit and component
8. Measure the lighting coil output peak volt-
age between all combinations of the termi-
nals. Replace the stator assembly if below Do not use peak voltage adapter when mea-
specification. suring the rectifier/regulator output voltage.

STBD

G
G G

Rectifier/regulator output peak voltage

(reference data)
Positive battery terminal–Ground
Loaded
Lighting coil output peak voltage r/min
(reference data) 1500 3500
Green (G)–Green (G) DC V 13 13
Unloaded
r/min 2. Remove the intake manifold (STBD). See
Cranking 1500 3500 “Removing the intake manifold” (6-12).
DC V 8.3 44.7 97.7
3. Remove the rectifier/regulator.
9. Measure the lighting coil resistance.
4. Set the digital circuit tester to the diode
Resistance (reference data) mode, and then check the rectifier/regula-
0.1144–0.1716  tor for continuity.
Green (G)–Green (G)
a
10. Remove the intake manifold (STBD). b

11. Connect the stator assembly couplers, c

and then fasten the stator assembly leads d
using the plastic ties. e

12. Install the intake manifold (STBD). See “In- f

stalling the intake manifold” (6-13).
a R
Checking the rectifier/regulator b R

Do not connect the battery cables in re- c G

verse. Otherwise, the rectifier/regulator d G
e G
could be damaged.

1. Measure the rectifier/regulator output volt- f B

age.
5-36
 Ignition unit and component

Rectifier/regulator continuity Ignition unit and component

(testing diode mode) Checking the ignition spark
1. Remove the engine ECM cover.
Tester probe Display value
(+) (–) (reference data) 2. Remove the ignition coils.
b
3. Connect the special service tool “1” to the
c
ignition coil.
a d OL
e
Repeat steps 3–5 for each ignition coil.
f
a
4. Check the ignition spark using the YDIS
c “Stationary Test”.
b d OL
e
Do not touch any of the connections of the
f special service tool.
a 0.4–0.5 V
b 0.4–0.5 V OK

c d
e OL
f
a 0.4–0.5 V
b 0.4–0.5 V
1 0 5
d c
e OL
f Ignition checker (Spark gap tester)
“1”
a 0.4–0.5 V 90890-06754
b 0.4–0.5 V
e c 5. Disconnect the special service tool.
d OL 6. Install the ignition coils.
f
a 0.7–0.8 V 7. Install the engine ECM cover.

b 0.7–0.8 V Checking the ignition coil

f c 0.4–0.5 V 1. Disconnect the ignition coil couplers “a”.
d 0.4–0.5 V
e 0.4–0.5 V

OL: Indicates an overload

5. Install the rectifier/regulator.

6. Install the intake manifold (STBD). See “In-

stalling the intake manifold” (6-13).

5-37
 Ignition unit and component
2. Turn the engine start switch to ON, and
then measure the input voltage at the igni- W/B W/R
tion coil coupler. B B
G G/W
1

R/Y B
a
a

W/R B
1
Input voltage
6. Connect the special service tool “1” to the
12 V
pulser coil coupler “a” (wire harness end).
Red/Yellow (R/Y)–Black (B)
7. While cranking the engine, measure the
3. Turn the engine start switch to OFF. peak voltage under loaded condition.
4. Connect the ignition coil couplers. 8. Insert the clip into the engine shut-off
switch.
Checking the pulser coil
1. Remove the flywheel magneto cover. 9. Start the engine, and then measure the
peak voltage at the specified engine
2. Disconnect the pulser coil coupler “a”.
speed.

Check that the wiring harness does not in-

terfere with the flywheel magneto.

W/B W/R
B B
G G/W
a
a 1
3. Connect the special service tool “1” to the
pulser coil coupler (pulser coil end).

4. Remove the clip from the engine shut-off

switch.

5. While cranking the engine, measure the W/R B

peak voltage under unloaded condition.
a 1

Check that the wiring harness does not in- Test harness (2 pins) “1”
terfere with the flywheel magneto. 90890-06867

5-38
 Ignition unit and component

Pulser coil output peak voltage

(reference data)
White/Red (W/R)–Black (B)
Unload B B/Y
Loaded
r/min -ed
Cranking 1500 3500
DC V 3.0 2.7 14.5 17.8 a

10. Disconnect the special service tool.

11. Measure the pulser coil resistance. Re- Input voltage

place if out of specification. 4.75–5.25 V
Black/Yellow (B/Y)–Black (B)
Resistance
396.0–594.0  7. Turn the engine start switch to OFF.
White/Red (W/R)–Black (B)
8. Remove the intake air temperature sen-
sor.
12. Connect the pulser coil coupler.
9. Place the intake air temperature sensor in
13. Install the flywheel magneto cover.
a container of water and heat the water
Checking the intake air temperature slowly.
sensor
1. Measure the ambient temperature.

2. Connect the YDIS to display “Intake air

temperature”.

3. Check that the difference between the am-

bient temperature and the displayed intake
air temperature is within ± 5 C (± 9 F).

10. Measure the intake air temperature sensor

• Check the intake air temperature sensor resistance.
when the engine is cold.
• When checking the intake air temperature Resistance at 20 C (68 F)
sensor, remove the top cowling and do not 2.210–2.690 k
start the engine. Resistance at 80 C (176 F)
0.322 k
4. Remove the flywheel magneto cover.
11. Install the intake air temperature sensor
5. Disconnect the intake air temperature sen- and connect the coupler.
sor coupler “a”.
12. Install the flywheel magneto cover.
6. Turn the engine start switch to ON, and
then measure the input voltage at the in- Checking the intake air pressure sen-
take air temperature sensor coupler. sor
1. Remove the intake silencer. See “Remov-
ing the intake silencer” (6-12).

5-39
 Ignition unit and component
2. Disconnect the intake air pressure sensor
coupler “a”. 1
2
3. Turn the engine start switch to ON, and
then measure the input voltage at the in-
take air pressure sensor coupler.

P/G
B
Or
B
B Or G/W G
2
a

Input voltage
4.75–5.25 V
Orange (Or)–Black (B) Vacuum/pressure pump gauge set
“1”
4. Turn the engine start switch to OFF. 90890-06945
Test harness (3 pins) “2”
5. Remove the intake manifolds. See “Re- 90890-06869
moving the intake manifold” (6-12).
10. Turn the engine start switch to ON.
6. Remove the throttle body assembly. See
“Removing the throttle body assembly” 11. Apply negative pressure to the intake air
(6-18). pressure sensor slowly, and then measure
the output voltage at the specified pres-
7. Remove the air pressure sensor from the sure.
throttle body assembly.
Output voltage at -20.0 kPa (-0.20
8. Remove the intake air pressure sensor.
kgf/cm², -2.9 psi)
9. Connect the special service tools “1” and 0.79 V
“2”. Output voltage at -46.7 kPa (-0.467
kgf/cm², -6.8 psi)
1.84 V
Pink/Green (P/G)–Black (B)

12. Turn the engine start switch to OFF.

13. Disconnect the special service tools.

14. Install the intake air pressure sensor to the

throttle body assembly.

15. Install the throttle body assembly. See “In-

stalling the intake manifold” (6-13).

5-40
 Ignition unit and component
16. Install the intake manifolds. See “Installing 8. Measure the engine temperature sensor
the intake silencer” (6-14). resistance.

17. Install the intake silencer. See “Installing Resistance at 5 C (41 F) (refer-
the intake silencer” (6-14). ence data)
128.00 k
Checking the engine temperature sen- Resistance at 20 C (68 F) (refer-
sor ence data)
1. Remove the flywheel magneto cover. 54.20–69.00 k
Resistance at 100 C (212 F) (ref-
2. Disconnect the engine temperature sensor erence data)
coupler “a”. 3.12–3.48 k

3. Turn the engine start switch to ON, and 9. Install the engine temperature sensor and
then measure the input voltage at the en- connect the coupler. See “Installing the fly-
gine temperature sensor coupler. wheel magneto” (7-19).
PORT a
10. Install the flywheel magneto. See “Install-
ing the flywheel magneto” (7-19).
B B/Y
11. Install the flywheel magneto cover.

Checking the thermo switch

1. Remove the flywheel magneto cover.

2. Disconnect the thermo switch connectors

“a”.
Input voltage
4.75–5.25 V 3. Turn the engine start switch to ON, and
Black/Yellow (B/Y)–Black (B) then measure the input voltage at the ther-
mo switch connector.
4. Turn the engine start switch to OFF.
PORT
5. Remove the flywheel magneto. See P B
“Crankcase” (7-80).
aa
6. Remove the engine temperature sensor.

7. Place the engine temperature sensor in a

container of water and heat the water
slowly.

STBD
P B
a

5-41
 Ignition unit and component
10. Install the flywheel magneto cover.
Input voltage
12 V Checking the knock sensor
Pink (P)–Black (B) 1. Remove the engine ECM cover.

4. Turn the engine start switch to OFF. 2. Disconnect the knock sensor coupler “a”.

5. Remove the thermo switch.

6. Place the thermo switch in a container of

a
water and heat the water slowly.

P B
3. Measure the knock sensor resistance. Re-
place if out of specification.

7. Check the thermo switch for continuity at

the specified temperatures. Replace if out
of specification.

d
d d
e
a
f Resistance
c
c 504–616 k

4. Connect the knock sensor coupler.

b
a. Temperature 5. Install the engine ECM cover.
b. Time
c. No continuity Checking the shift cut-off switch
d. Continuity 1. Disconnect the shift cut-off switch coupler
e. Switch ON temperature “a”.
f. Switch OFF temperature

Switch ON temperature
84–90 C (183–194 F)
Switch OFF temperature
68–82 C (154–180 F)

8. Install the thermo switch.

9. Connect the thermo switch connectors.

5-42
 Ignition unit and component
2. Turn the engine start switch to ON, and 2. Turn the engine start switch to ON, and
then measure the input voltage at the shift then measure the input voltage at the shift
cut-off switch coupler. position switch coupler.

STBD B L/Y STBD B L/G

Input voltage (reference data) Input voltage (reference data)

5V 5V
Blue/Yellow (L/Y)–Black (B) Blue/Green (L/G)–Black (B)

3. Turn the engine start switch to OFF. 3. Turn the engine start switch to OFF.

4. Remove the shift cut-off switch. 4. Remove the shift position switch.

5. Measure the shift cut-off switch resistance. 5. Check the shift position switch for continu-
Replace if out of specification. ity. Replace if out of specification.
a a
b b

a. Free position Shift position Lead color

b. Pushed position switch conti-
nuity L/G B
Free position resistance “a”
4.465–4.935 k
“b”
Pushed position resistance
0 6. Install the shift position switch. See “Shift
rod and shift bracket” (9-1).
6. Install the shift cut-off switch. See “Shift
rod and shift bracket” (9-1). 7. Connect the shift position switch coupler.
7. Connect the shift cut-off switch coupler.
Checking the engine shut-off switch
1. Disconnect the main wire harness coupler
Checking the shift position switch
or engine start switch coupler.
1. Disconnect the shift position switch cou-
pler “a”.

5-43
 Starting unit and component
2. Turn the engine start switch to ON, and Starting unit and component
then check the engine shut-off switch for Checking the starter relay
continuity. Replace if out of specification. 1. Remove the engine ECM cover.
2. ON
A 2. Remove the starter relay “1”.
1. OFF 3. START b

a 3. Disconnect the starter relay coupler “a”.

4. Check the wire harness for continuity.

B
5

a
b

1. OFF a
1
2. ON
3. START
Wire harness continuity
A. Switch panel (704 remote control) Terminal 5–Ground
B. 703 side mount remote control
5. Measure the input voltage between the ter-
Engine shut- Terminal
minal and ground.
off switch
continuity “a” “b”

Clip removed
Clip installed

3. Turn the engine start switch to OFF. 4

4. Connect the main wire harness coupler or

engine start switch coupler.

Input voltage
12 V (battery voltage)
Terminal 4–Ground

5-44
 Starting unit and component
6. Turn the engine start switch to START, 1. OFF
and then measure the input voltage be- 2. ON
tween the terminal and ground. 3. START
A. Switch panel (704 remote control)
B. 703 side mount remote control

Switch Terminal
2
position “a” “b” “c” “d” “e”
OFF
ON
START

Input voltage 3. Connect the main wire harness coupler or

12 V (battery voltage) engine start switch coupler.
Terminal 2–Ground

7. Turn the engine start switch to OFF.

8. Check the starter relay. See “Checking the

main relay 1 and main relay 2” (5-23).

9. Install the starter relay, and then connect

the starter relay coupler.

10. Install the engine ECM cover.

Checking the engine start switch

1. Disconnect the main wire harness coupler
or engine start switch coupler.

2. Check the engine start switch for continu-

ity. Replace if out of specification.

A
d b

a
2. ON e
1. OFF 3. START c

B
c
d
a
b e

5-45
 Starter motor

Starter motor
11

1 22 23

12

24
2

13

4 7

3 14
5 15
7
6
16 25
17 6
8 26
18
19
27
28
9
20
10 21

No. Part name Q’ty Remarks

1 Stator 1
2 Armature 1
3 Brush holder assembly 1
4 Brush spring 4
5 Brush assembly 1
6 Starting motor gear assembly 1
7 Washer set 1
8 Bracket 1
9 Screw 2 M4  15 mm
10 Bolt 2 M6  117 mm
11 Bolt 2 M6  35 mm
12 Cover assembly 1
13 Clutch assembly 1
14 Bracket 1
15 Bearing 1
16 Outer gear 1
17 Gasket 1 Not reusable

5-46
 Starter motor

11

1 22 23

12

24
2

13

4 7

3 14
5 15
7
6
16 25
17 6
8 26
18
19
27
28
9
20
10 21

No. Part name Q’ty Remarks

18 Washer 1
19 Pinion shaft 1
20 Planetary gear 3
21 Plate 1
22 Starter motor pinion 1
23 Pinion stopper set 1
24 Lever assembly 1
25 Seal set 1 Not reusable
26 Magnet switch 1
27 Washer 1
28 Nut 1

5-47
 Starter motor

Removing the starter motor

Pipe “3”
(commercially available)
Before removing the starter motor, make “a”: 26 mm (1.02 in)
sure to disconnect the negative battery ter- “b”: 24 mm (0.94 in)
minal.
3. Remove the pinion stopper “1”, pinion “2”,
and spring “3”.
1. Remove the intake silencer. See “Remov-
ing the intake silencer” (6-12).

2. Remove the intake manifold (STBD). See

“Removing the intake manifold” (6-12). 1
2
3. Remove the starter motor from the power
unit. See “Removing the starter motor” 3
(7-35).

Disassembling the starter motor

1. Remove the magnet switch “1” and spring
“2”.

4. Remove the stator assembly “1”, plate “2”,

planetary gears “3”, and outer gear “4”.

3 3
4
1
2

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

then remove the clip “2”.
a
b 3

1
2 1

5-48
 Starter motor
5. Remove the rubber seal “1”, lever “2”, and
pinion shaft assembly “3”.
2
2
1

3
1
2
3
1

9. Remove the E-clip “1”.

6. Remove the stator “1”. 10. Push the clutch assembly “2” completely
down onto the pinion shaft “3” in direction
7. Remove the armature “2” along with the “a”, and turn it one spline in direction “b”,
brush holder assembly “3” from the brack- and then remove it in direction “c”.
et “4”.
11. Remove the clutch assembly “2” from the
pinion shaft “3”.
Do not disassemble the stator. Do not re-
move the magnets “5” from it.
c 2
1 5 2
c
2

3 1 a b
3

3 a b

8. Remove the plate “1”, and then remove the

armature “2” from the brush holder assem-
2
bly “3”.

Checking the starter motor pinion

1. Check the pinion teeth. Replace the pinion
if cracked or worn.
5-49
 Starter motor
2. Turn the pinion counterclockwise to check
that it operates smoothly and turn it clock- Standard commutator undercut
wise to check that it locks in place. 0.8 mm (0.03 in)
Wear limit
Checking the armature (starter motor) 0.2 mm (0.01 in)
1. Check the commutator. Clean using 600-
grit sandpaper and compressed air if dirty. 4. Check the armature for continuity. Re-
place if out of specification.

a
b c d

2. Measure the commutator diameter “a”.

Replace the armature if out of specifica- Armature continuity
tion. “a” “b” “c” “d”

Checking the brush holder

1. Check the brush holder assembly for con-
tinuity. Replace if out of specification.

e
a
a

c b
Standard commutator diameter
29.0 mm (1.14 in)
d
Wear limit
28.0 mm (1.10 in) c a

3. Measure the commutator undercut “a”. e

Replace the armature if out of specifica-
tion. d b

Brush holder assembly continuity

a
“a” “b” “c” “d” “e”

5-50
 Starter motor
2. Measure the length “a” of each brush. Re-
place the brush assembly if out of specifi-
cation. Align the holes “a” and “b” in the plate “c” with
the holes “d” and “e” in the bracket “3”.
a
b
4

1
a. Standard brush length b
2 c
b. Wear limit
3
Standard brush length d
15.5 mm (0.61 in)
Wear limit e
3
9.5 mm (0.37 in)

Assembling the starter motor

4. Install the bracket “1”, a new gasket “2”,
and the clutch assembly “3” onto the pinion
Do not apply grease or oil to the commuta- shaft “4”.
tor of the armature.

1. Push the brushes “1” into the holders, and

then install the armature “2” to the brush
holder assembly “3”. 3
2. Install the plate “4”.
1
2 2
2 4

5. Push the clutch assembly “1” completely

4
down onto the pinion shaft “2” in direction
“a”, turn it one spline in direction “b”, and
3 then slide it in direction “c”.

1
4

3 1

3. Install the armature “1”, along with the

brush holder assembly “2”, to the bracket
“3”, and then install the stator “4”.

5-51
 Starter motor
6. Install the E-clip “3”.
2
1
Make sure that the clutch assembly “1” does
not come out from the pinion shaft “2”.

1 2 1

1 b a
c
c
3 b a
2
2 a 9. Install the spring “1”, pinion “2”, pinion
b
stopper “3”, and clip “4”.
3 3
2 4
2
7. Install the pinion shaft assembly “1”, the le-
ver “2”, a new rubber seal “3”, the plane- 1
tary gears “4”, the outer gear “5”, and the
plate “6”.

10. Install a new gasket “1”, the spring “2”, and

1
the magnet switch “3”.
2
2

1 3
2
3
2

1
4
5

6 3

8. Install the stator assembly “1”, and then Installing the starter motor
align the protrusion “a” on the stator as- 1. Install the starter motor to the power unit.
sembly “1” with the slot “b” in the cover as- See “Installing the starter motor” (7-35).
sembly “2”.
2. Install the intake manifold (STBD). See “In-
stalling the intake manifold” (6-13).

5-52
 6Y8/6YC Multifunction Meters sensor
3. Install the intake silencer. See “Installing 6Y8/6YC Multifunction Meters
the intake silencer” (6-14). sensor
Checking the water pressure sensor
1. Disconnect the water pressure sensor
coupler “a”.

2. Turn the engine start switch to ON, and

then measure the input voltage at the wa-
ter pressure sensor coupler.

a
B Or

Input voltage
4.75–5.25 V
Orange (Or)–Black (B)

3. Remove the water pressure sensor, and

then connect the pressure pump “1” and
special service tool “2”.

4. Apply positive pressure to the water pres-

sure sensor slowly, and then measure the
output voltage.

L/B
B Or
G B G/W
2

1
2

Pressure pump “1”

(commercially available)
Test harness (3 pins) “2”
90890-06869

5-53
 6Y8/6YC Multifunction Meters sensor

Output voltage at 392 kPa (3.92 B

L
kgf/cm², 56.8 psi) (reference data) Or
G B G/W
2.5 V
Output voltage at 784 kPa (7.84 2
kgf/cm², 113.7 psi) (reference data)
4.5 V
Blue/Black (L/B)–Black (B)
2
5. Turn the engine start switch to OFF, and
then disconnect the special service tool
and pressure pump. 1

Checking the speed sensor

1. Disconnect the speed sensor coupler “a”.
Pressure pump “1”
2. Turn the engine start switch to ON, and (commercially available)
then measure the input voltage at the Test harness (3 pins) “2”
speed sensor coupler. 90890-06869

Output voltage at 392 kPa (3.92

B Or kgf/cm², 56.8 psi) (reference data)
2.5 V
Output voltage at 784 kPa (7.84
kgf/cm², 113.7 psi) (reference data)
4.5 V
a
Blue (L)–Black (B)

5. Turn the engine start switch to OFF, and

Input voltage then disconnect the special service tool
4.75–5.25 V and pressure pump.
Orange (Or)–Black (B)

3. Remove the speed sensor, and then con-

nect the pressure pump “1” and special
service tool “2”.

4. Apply positive pressure to the speed sen-

sor slowly, and then measure the output
voltage.

5-54
 PTT system

PTT system
Checking the PTT relay
1. Remove the intake manifold (STBD). See Lg
“Removing the intake manifold” (6-12). Sb
G/W G 1
e c
2. Measure the input voltage between the f b
PTT relay terminal “a” and terminal “b”.
a

PTT relay continuity

b “a” “b” “c” “d” “e” “f”

Input voltage
12 V
Terminal “a”–Terminal “b”

3. Disconnect the battery power source,

7. Connect the positive battery lead to the
ground lead, PTT motor leads, and PTT
terminal “a”, and the negative battery lead
relay coupler.
to the terminal “b”, and then check the PTT
4. Remove the PTT relay. relay for continuity. Replace the PTT relay
if out of specification.

Before disconnecting the PTT relay termi- Lg

nals, make sure to disconnect the battery Sb
G/W G
negative terminal.
a d
b
5. Connect the special service tool “1”. c

Test harness (2 pins) “1”

90890-06867
e
6. Check the PTT relay for continuity. Re-
place if out of specification.

PTT relay continuity

“b” “c” “d” “e”

5-55
 PTT system
8. Connect the positive battery lead to the
B
terminal “a”, and the negative battery lead
to the terminal “b”, and then check the PTT
R a
relay for continuity. Replace the PTT relay
if out of specification.

Lg
Sb
G/W G
a d
b
A. F200B, F250H
c B. FL200B, FL250H

Input voltage
12 V
e Red (R)–Ground

3. Check the PTT switch for continuity. Re-

place the PTT switch if out of specification.
PTT relay continuity
“b” “c” “d” “e”

c a
b
9. Disconnect the special service tool. Sb
R
10. Install the PTT relay. Lg

11. Connect the PTT relay coupler, battery

power source, ground lead, and PTT mo- PTT switch continu- Terminal
tor leads. ity “a” “b” “c”
Switch position UP
Checking the PTT switch (on bottom
cowling) Switch position DN
1. Disconnect the PTT switch coupler “a”.
4. Connect the PTT switch coupler.
2. Measure the input voltage between the
PTT switch coupler terminal and ground. Checking the trim sensor
1. Disconnect the trim sensor coupler “a”,
A and then remove the trim sensor.

R a

5-56
 PTT system
2. Measure the trim sensor resistance.

3. Turn the trim sensor lever “1” from the free

position “a” to the setting position “b”, and
then measure the resistance as it gradual-
ly changes.
b

Free position resistance

248–388 
Setting resistance
9–11 

4. Install the trim sensor, and then connect

the trim sensor coupler.

5-57
 PTT system

— MEMO —

5-58
 Fuel system

Fuel system ........................................................................ 6-1

Reducing the fuel pressure ........................................................ 6-1
Disconnecting the quick connector............................................. 6-1
Connecting the quick connector ................................................. 6-2
Measuring the fuel pressure....................................................... 6-2
Checking the pressure regulator ................................................ 6-4

Fuel filter ............................................................................. 6-6

Removing the fuel filter assembly .............................................. 6-7
Checking the fuel filter assembly................................................ 6-7
Disassembling the fuel filter assembly ....................................... 6-8
Checking the fuel filter element .................................................. 6-8
Checking the fuel cup assembly................................................. 6-8
Checking the primer pump ......................................................... 6-8
Assembling the fuel filter assembly ............................................ 6-8
Installing the fuel filter assembly ................................................ 6-9

Intake manifold ................................................................. 6-10

Removing the intake silencer ................................................... 6-12
Removing the intake manifold .................................................. 6-12
Checking the intake manifold ................................................... 6-13
Checking the intake air temperature sensor............................. 6-13
Installing the intake manifold .................................................... 6-13
Installing the intake silencer ..................................................... 6-14

Throttle body .................................................................... 6-16

Removing the throttle body assembly ...................................... 6-18
Checking the canister check valve ........................................... 6-18
Checking the vacuum hose ...................................................... 6-19
Installing the throttle body assembly ........................................ 6-19

ETV .................................................................................... 6-21

Removing the canister, ETV, and surge tank........................... 6-23
Checking the ETV .................................................................... 6-23
Checking the intake air pressure sensor .................................. 6-23
Checking the vapor shut-off valve ............................................ 6-24
Checking the canister............................................................... 6-24
Installing the canister, ETV, and surge tank............................. 6-24

Low-pressure fuel pump.................................................. 6-26

Removing the low-pressure fuel pump..................................... 6-27
Checking the low-pressure fuel pump ...................................... 6-27
 Fuel system

Installing the low-pressure fuel pump....................................... 6-27

0
Vapor separator ................................................................ 6-29
Draining the fuel ....................................................................... 6-30
Removing the vapor separator ................................................. 6-30 1
Installing the vapor separator ................................................... 6-30

Vapor separator and high-pressure fuel pump ............. 6-32 2

Disassembling the vapor separator.......................................... 6-34
Checking the high-pressure fuel pump..................................... 6-35
Checking the vapor separator .................................................. 6-35
Checking the check valve......................................................... 6-35
3
Assembling the vapor separator............................................... 6-36

Fuel injector ...................................................................... 6-38

4
Removing the fuel injector........................................................ 6-39
Checking the fuel rail and fuel injector ..................................... 6-39
Checking the quick connector .................................................. 6-40 5
Installing the fuel injector.......................................................... 6-40

6
7
8
9
10

A
 Fuel system

Fuel system 3. Wrap a rag around the quick connector “1”.

Reducing the fuel pressure
4. Spread apart the ends of the locking slider
“2”, and then move the locking slider to the
Before servicing the high-pressure fuel line unlock position.
or vapor separator, make sure to reduce PORT
the fuel pressure in the fuel line. Otherwise,
pressurized fuel could spray out.

1. Start the engine. 1

2. Remove the fuse box cover “1”.

3. Remove the fuel pump fuse (15 A) “2” to

stop the operation of the high-pressure
fuel pump.
1
After removing the fuse, wait until the engine
stalls. STBD

1
1
2

4. After the engine stalls, crank the engine 2

or 3 times.

5. Turn the engine start switch to OFF.

6. Install the fuel pump fuse (15 A), and then

install the fuse box cover.

Disconnecting the quick connector

2
Before disconnecting the quick connector,
reduce the fuel pressure. Otherwise, pres-
surized fuel could spray out.

1. Reduce the fuel pressure. See “Reducing

the fuel pressure” (6-1).

2. Remove the flywheel magneto cover.

6-1
 Fuel system
5. Disconnect the quick connector “1” from
the fuel rail or vapor separator.
2
Cover the quick connector, fuel rail, and vapor
separator using a plastic bag “2” to prevent
damage and to protect them from dirt.

1 1

Measuring the fuel pressure

1. Reduce the fuel pressure. See “Reducing
the fuel pressure” (6-1).

2. Disconnect the quick connector from the

fuel rail (PORT). See steps 2–5 in “Reduc-
ing the fuel pressure” (6-1).

2 3. Remove the fuel rail cover (PORT) “1”, and

then disconnect the OCV coupler (PORT)
“a”.

4. Remove the holder “2”.

Connecting the quick connector

1. Connect the quick connector “1” to the fuel
rail or vapor separator, and then move the 2
locking slider “2” to the lock position.
1

• If the quick connector “1” is not installed com-

pletely onto the fuel rail or vapor separator,
the locking slider “2” cannot be moved to the
lock position.
• Confirm that the quick connector is installed
properly by making sure there is a small
amount of free play when the quick connector
is pulled and pushed.
• If there is no free play in the quick connector,
disconnect the fuel hose and check the O-
ring for damage and proper installation. See
“Checking the quick connector” (6-40).

6-2
 Fuel system
5. Connect the special service tool “1” be-
tween the quick connector and the fuel rail
(PORT).

Position the special service tool “1” under the

wire harness “2”. Otherwise, the OCV coupler
(PORT) cannot be connected to the OCV
(PORT).

Fuel pressure gauge “1”

90890-06753
1
8. Turn the engine start switch to ON, and
then measure the fuel pressure within 5
2
seconds.

• The fuel pressure decreases 5 seconds after

the engine start switch is turned to ON.
• The high-pressure fuel pump does not oper-
1
ate when the engine start switch is turned to
ON again within 10 seconds after turning the
engine start switch to OFF.
Fuel pressure gauge adapter “1”
90890-06946
Fuel pressure at engine start switch
6. Connect the special service tool “1”. to “ON” within 5 seconds
290.0 kPa (2.90 kgf/cm², 42.1 psi)

To prevent fuel from leaking out, screw in 9. Start the engine and warm it up until the
the gauge gently until it is connected firmly. engine idle speed stabilizes at the speci-
fied engine idle speed range.
7. Connect the OCV coupler (PORT).
Idle speed (in neutral)
600–700 r/min

10. Measure the fuel pressure.

Fuel pressure at engine idle speed

260 kPa (2.60 kgf/cm², 37.7 psi)

11. Turn the engine start switch to OFF.

12. Reduce the fuel pressure. See “Discon-

necting the quick connector” (6-1).
6-3
 Fuel system
13. Disconnect the OCV coupler (PORT).

14. Disconnect the special service tools.

1

Before disconnecting the special service

tools, cover the end of the hose using a
clean and dry rag.

15. Fasten the wire harness and thermo

switch connectors (PORT) using the hold-
er. 2
5 3
4
16. Connect the OCV coupler (PORT), and
then install the fuel rail cover (PORT).

17. Connect the quick connector to the fuel rail

(PORT). See “Connecting the quick con-
nector” (6-2).
Fuel pressure gauge adapter “1”
Checking the pressure regulator 90890-06946
1. Reduce the fuel pressure. See “Reducing Fuel pressure gauge “2”
the fuel pressure” (6-1). 90890-06753
Vacuum/pressure pump gauge set
2. Disconnect the quick connector from the “4”
fuel rail (PORT). See steps 2–5 in “Discon- 90890-06945
necting the quick connector” (6-1).
5. Block the end of the pressure regulator
3. Connect the special service tools “1” and hose “1” using a rubber plug “2”.
“2” to the fuel rail (PORT). See steps 3–7
in “Measuring the fuel pressure” (6-2). 6. Start the engine and let it idle.

4. Disconnect the pressure regulator hose 7. Check that the fuel pressure is reduced
“3”, and then connect the special service when vacuum pressure is applied to the
tool “4” to the pressure regulator “5”. pressure regulator. If the fuel pressure is
not reduced, replace the pressure regula-
tor.

8. Turn the engine start switch to OFF.

9. Remove the rubber plug “2”.

10. Reduce the fuel pressure. See “Reducing

the fuel pressure” (6-1).

6-4
 Fuel system
11. Disconnect the special service tool “3”,
and then connect the pressure regulator
hose “1” to the pressure regulator “4”.

2 1
4
3

12. Disconnect the special service tools from

the fuel rail (PORT). See steps 13–16 in
“Measuring the fuel pressure” (6-2).

13. Connect the quick connector to the fuel rail

(PORT). See “Connecting the quick con-
nector” (6-2).

6-5
 Fuel filter

Fuel filter

1 2
5
3
2 6
9

10 7
8 11
12

13 14

5 Nm (0.5 kgf･m, 3.7 ft･lb)

15 12 mm
(0.47 in)
15 18
2
2 18
16
2 2
17 16
12 mm 12 mm 9 mm
(0.47 in) (0.47 in) (0.35 in)

No. Part name Q’ty Remarks

1 Hose 1 Fuel filter assembly to joint
2 Plastic tie 6
3 Bracket 1
4 Bolt 2 M6  25 mm
5 Grommet 2
6 Collar 2
7 Bolt 2 M6  14 mm
8 Fuel filter assembly 1
9 O-ring 1 Not reusable
10 Fuel filter element 1
11 Clip 1
12 Float 1
13 Fuel cup assembly 1
14 Hose 1 Joint to fuel filter assembly
15 Holder 1
16 Joint 2
17 Hose 1
18 Holder 1

6-6
 Fuel filter

Removing the fuel filter assembly

Cover the fuel components using a rag to pre-
vent fuel from spilling out.
1
1. Remove the intake manifold (PORT).
See “Removing the intake manifold”
(6-12).
2
2. Disconnect the water detection switch
coupler “a”.

3. Disconnect the fuel hoses “1” and “2”.

4. Remove the fuel filter assembly “3”. a b

a Vacuum/pressure pump gauge set

3 “1”
90890-06945
2

Fuel inlet holding pressure (positive

1 pressure)
200 kPa (2.0 kgf/cm², 29.0 psi)

3. Connect the special service tool “1” to the

a fuel outlet “a”.

4. Block the fuel inlet “b” using a rubber plug

Checking the fuel filter assembly “2”, and then apply the specified negative
pressure. Replace the O-ring, fuel cup as-
1. Connect the special service tool “1” to the
sembly, or fuel filter assembly if the speci-
fuel inlet “a”.
fied pressure cannot be maintained for 15
2. Block the fuel outlet “b” using a rubber plug seconds or more.
“2”, and then apply the specified positive
pressure. Replace the O-ring, fuel cup as-
sembly, or fuel filter assembly if the speci-
fied pressure cannot be maintained for 15
1
seconds or more.

b a

6-7
 Fuel filter
2. Block the fuel outlet “b” using a rubber plug
Vacuum/pressure pump gauge set “2”.
“1”
90890-06945 3. Apply the specified positive pressure. Re-
place the primer pump if the specified
pressure cannot be maintained for 30 sec-
Fuel outlet holding pressure (nega- onds or more.
tive pressure)
80 kPa (0.8 kgf/cm², 11.6 psi)

Disassembling the fuel filter assembly 2 b a

1. Remove the fuel cup assembly “1”, O-ring
“2”, and fuel filter element “3”.

2
1
3
1
Vacuum/pressure pump gauge set
“1”
90890-06945

Positive pressure
Checking the fuel filter element 166.7 kPa (1.67 kgf/cm², 24.2 psi)
1. Check the fuel filter element. Replace if
there is dirt or residue. Assembling the fuel filter assembly
1. Install the fuel filter element “1”, a new O-
Checking the fuel cup assembly ring “2”, and the fuel cup assembly “3”, and
1. Check the fuel cup assembly. Clean using then tighten the fuel cup assembly “3” to
straight gasoline if there is foreign material the specified torque.
or replace if cracked.

When cleaning the fuel cup assembly, do

not remove the clip and float.
2

2. Check the water detection switch. See

“Checking the water detection switch” 1
3
(5-31).

Checking the primer pump

1. Connect the special service tool “1” to the
primer pump inlet “a”.

6-8
 Fuel filter

Fuel cup assembly “3”

5 Nm (0.5 kgf·m, 3.7 ft·lb)
T.
R.

Installing the fuel filter assembly

1. Install the fuel filter assembly “1”.

2. Connect the fuel hoses “2” and “3”, and

then fasten them using the plastic ties “4”.

3. Fasten the fuel hoses “2” and “3” using the

holders “5” and “6”.

4. Connect the water detection switch cou-

pler “a”.

a
4

1 2

5 6 4

5. Install the intake manifold (PORT). See

“Installing the intake manifold” (6-13).

6-9
 Intake manifold

Intake manifold
1 7 Nm (0.7 kgf･m, 5.2 ft･lb) 8
1 4 7
3 1 6
2 7 8

17
5
9 5
5

15
14 10
11
15 12

20 13

17
19
16 17

18
10 Nm (1.0 kgf･m, 7.4 ft･lb) 18

No. Part name Q’ty Remarks

1 Bolt 4 M6  25 mm
2 Intake silencer 1
3 Grommet 1
4 Intake air temperature sensor 1
5 Grommet 4
6 Flywheel magneto cover 1
7 Grommet 2
8 Bolt 2 M6  18 mm
9 Plastic tie 1
10 Hose 1 Cylinder head cover to intake silencer
11 Plastic tie 1
12 Hose 1 Cylinder block to joint
13 Holder 1
14 Intake manifold assembly (PORT) 1
15 Gasket 6 Not reusable
16 Gasket 1 Not reusable
17 Bolt 8 M8  40 mm

6-10
 Intake manifold

1 7 Nm (0.7 kgf･m, 5.2 ft･lb) 8

1 4 7
3 1 6
2 7 8

17
5
9 5
5

15
14 10
11
15 12

20 13

17
19
16 17

18
10 Nm (1.0 kgf･m, 7.4 ft･lb) 18

No. Part name Q’ty Remarks

18 Bolt 7 M6  40 mm
19 Intake manifold assembly (STBD) 1
20 Gasket 1 Not reusable

6-11
 Intake manifold

Removing the intake silencer

1. Remove the flywheel magneto cover.

2. Disconnect the intake air temperature sen-

sor coupler “a”, and then remove the in-
take air temperature sensor “1”. 2

a
1

Removing the intake manifold

1. Remove the fuel drain hose “1” from the in-
take manifold (PORT) “2”.

PORT

3. Remove the blowby hose “1”.

2
1

4. Disconnect the vapor gas hose “1”, and

then remove the intake silencer “2”.

6-12
 Intake manifold
2. Remove the intake manifolds “1” and “2”. 2. Check the electrical performance of the in-
take air temperature sensor. See “Check-
ing the intake air temperature sensor”
(5-39).

Installing the intake manifold

2
1. Connect the blowby hose “1” with the paint
mark “a” facing outward, and then fasten it
using the holder “2”.

1 2

3. Remove the blowby hose “1”.

1 2. Install new gaskets “1” and “2” onto the in-

take manifolds. Check that the tabs on the
gaskets “1” and “2” are properly and firmly
fitted into the grooves “a” and “b” in the in-
take manifold.

Checking the intake manifold a

1. Check the intake manifolds. Replace if
cracked or deformed. STBD PORT

2. Check the intake silencer. Replace if

cracked or deformed.

3. Check the blowby hoses. Replace if 2 2

cracked or damaged.

Checking the intake air temperature

b b
sensor
1. Check the intake air temperature sensor
exterior. Replace if cracked.

6-13
 Intake manifold
3. Install the intake manifolds “1” and “2” tem-
porarily. PORT

[7]
When the protrusions on the gaskets contact 2
the fuel rail cover, make sure that the gaskets [4] [5]
“a” remain installed properly. [1] 1
[2]
[6]
[3] 1 2
[8]

2
3

STBD

[6]
2 1
[4]
[1]
[2]
1 [5]
2 1 [3]

[7]

Intake manifold bolt “1”

10 Nm (1.0 kgf·m, 7.4 ft·lb)
T.
R.

Installing the intake silencer

1. Install the intake silencer “1”, and then
tighten the intake silencer bolts “2” to the
specified torque.
4. Tighten the intake manifold bolts “1” to the
specified torque, and then tighten the in-
take manifold bolts “2” in the order [1], [2],
and so on.

5. Fasten the fuel drain hose “3” to the holder

on the intake manifold (PORT).

6-14
 Intake manifold
2. Connect the vapor gas hose “3” to the in- 7. Install the intake air temperature sensor
take silencer. lead “2” at the white tape “3” to the holder
2 “4” on the oil filler neck.
2
2 2
4

1
a
3
3
1

Intake silencer bolt “2” 8. Install the flywheel magneto cover.

7 Nm (0.7 kgf·m, 5.2 ft·lb)
T.
R.

3. Connect the blowby hose “4” into the in-

take silencer “1” and cylinder head cover
(STBD), and then connect the blowby
hose “5” into the joint “6”.

4. Fasten the blowby hose “5” using the plas-

tic tie “7”.

5. Fasten the blowby hose “4” using the plas-

tic tie “8”.

8
1 6 4

4 7
5
1
8

6. Install the intake air temperature sensor

“1”, and then connect the intake air tem-
perature sensor coupler “a”.

6-15
 Throttle body

Throttle body

18
1 14

24
20
2 23 19
22

21 19
16
17

4 28 14
25
27
26 15
12
13 11

3
5 10 10
6
8 9
3 5 8

No. Part name Q’ty Remarks

1 Joint 1
2 Plastic tie 1
3 Bolt 4 M8  40 mm
4 Throttle body assembly 1
5 Bolt 2 M6  16 mm
6 Holder 2
7 Hose 1 Joint to canister tank port
8 Holder 2
9 Hose 1 Canister purge port to joint
10 Joint 2 ø5 mm
11 Hose 1 Canister atmospheric port to joint
12 Holder 2
13 Hose 1 Joint to vapor shut-off valve
14 Holder 3
15 Hose 1 Vapor shut-off valve to surge tank
16 Hose 1 Joint to pressure regulator
17 Hose 1 Joint to joint

6-16
 Throttle body

18
1 14

24
20
2 23 19
22

21 19
16
17

4 28 14
25
27
26 15
12
13 11

3
5 10 10
6
8 9
3 5 8

No. Part name Q’ty Remarks

18 Joint 1 ø3 mm
19 Dowel 2
20 Holder 1
21 Joint 1
22 Hose 1 Joint to joint
23 Check valve 1
24 Hose 1 Intake silencer to check valve
25 Hose 1 Joint to intake air pressure sensor
26 Hose 1 Surge tank to joint
27 Joint 1
28 Hose 1 Vapor shut-off valve to surge tank

6-17
 Throttle body

Removing the throttle body assembly 5. Remove the plastic tie “1”, and then re-
1. Disconnect the throttle body assembly move the joint “2”.
wire harness extension coupler “a” and
ETV coupler “b”. 6. Remove the throttle body assembly “3”.

2
a
1

b 3

2. Remove the wire harness “1”.

7. Remove the hoses and check valve “1”.

3. Remove the vacuum hose “1” from the

holder “2”, and then disconnect the vacu-
um hose “1”.

4. Disconnect the vapor gas hoses “3” and

“4”.

1
4 Checking the canister check valve
1. Connect the special service tool “1” to the
2 canister check valve port.

3
1

6-18
 Throttle body
2. Apply positive pressure and check that air Installing the throttle body assembly
comes out of the opposite end of the can- 1. Install the hoses, joint, and check valve
ister check valve. Replace the canister “1”, and then install the holders.
check valve if no air comes out.
1

Vacuum/pressure pump gauge set

“1”
90890-06945

3. Connect the special service tool “1” to the

opposite canister check valve port.

4. Apply positive pressure and check that no 2. Install the dowels “1” and throttle body as-
air comes out of the opposite end of the sembly “2”.
canister check valve. Replace the canister
3. Install the joint “3”, and then fasten it using
check valve if air comes out.
the plastic tie “4”.
1
1
3

Checking the vacuum hose

1. Check the hoses “1”, “2”, and “3”. Replace
any hose that is cracked or damaged.

4. Connect the vapor gas hoses “1” and “2”.

3
2

6-19
 Throttle body
5. Connect the vacuum hose “3”, and then
fasten it using the holder “4”.

1 3

2
3

6. Fasten the wire harness “1” using the hold-

ers.

7. Connect the throttle body assembly wire

harness extension coupler “a” and ETV
coupler “b”.

6-20
 ETV

ETV
13 Nm (1.3 kgf㺃m, 9.6 ft㺃lb) 5 Nm (0.5 kgf㺃m, 3.7 ft㺃lb)
1 3
24
2 23 20
1 19
3 22
13 Nm (1.3 kgf㺃m, 9.6 ft㺃lb)
23
5 21
4 2
1 A
1

A
22 21
20
6
5 Nm (0.5 kgf㺃m, 3.7 ft㺃lb)
5 18
9 7 5 Nm (0.5 kgf㺃m, 3.7 ft㺃lb) 19
10

11 17

16

14
13 14
13 15
12
12
5 Nm (0.5 kgf㺃m, 3.7 ft㺃lb)

No. Part name Q’ty Remarks

1 Nut 4
2 Washer 2
3 ETV 1
4 Gasket 1 Not reusable
5 Bolt 4 M8  18 mm
6 Throttle damper plate 1
7 Gasket 1 Not reusable
8 Surge tank 1
9 Bolt 1 M6  10 mm
10 Holder 1
11 Canister 1
12 Bolt 2 M6  28 mm
13 Collar 2
14 Grommet 2
15 Bracket 1
16 Intake air pressure sensor 1
17 Washer 1

6-21
 ETV

13 Nm (1.3 kgf㺃m, 9.6 ft㺃lb) 5 Nm (0.5 kgf㺃m, 3.7 ft㺃lb)

1 3
24
2 23 20
1 19
3 22
13 Nm (1.3 kgf㺃m, 9.6 ft㺃lb)
23
5 21
4 2
1 A
1

A
22 21
20
6
5 Nm (0.5 kgf㺃m, 3.7 ft㺃lb)
5 18
9 7 5 Nm (0.5 kgf㺃m, 3.7 ft㺃lb) 19
10

11 17

16

14
13 14
13 15
12
12
5 Nm (0.5 kgf㺃m, 3.7 ft㺃lb)

No. Part name Q’ty Remarks

18 Bolt 1 M6  20 mm
Throttle body assembly wire harness
19 1
extension
20 Plastic tie 1
21 Vapor shut-off valve 1
22 Bracket 1
23 Holder 1
24 Nut 1

6-22
 ETV

Removing the canister, ETV, and

surge tank 1
1. Remove the holder “1” and canister “2”.

3
2

1
6. Remove the intake air pressure sensor “1”.
2

2. Remove the bracket “1”.

1
Checking the ETV
1. Check the ETV exterior. Replace if
cracked.
3. Disconnect the intake air pressure sensor
coupler “a” and vapor shut-off valve cou- 2. Turn the throttle valve manually and check
pler “b”, and then remove the throttle body that it moves smoothly. Replace if it does
assembly wire harness extension “1”. not move smoothly.

4. Remove the holder “2” and vapor shut-off

valve “3”.

3
2
1

b
3. Check the electrical performance of the
a TPS. See “Checking the ETV and TPS”
(5-25).
5. Remove the bracket “1” and ETV “2”, and
then remove the throttle damper plate “3”. Checking the intake air pressure sen-
sor
1. Check the intake air pressure sensor exte-
rior. Replace if cracked.

6-23
 ETV
2. Check the electrical performance of the in-
take air pressure sensor. See “Checking 2
the intake air pressure sensor” (5-39).

Checking the vapor shut-off valve 1

1. Check the vapor shut-off valve. See
“Checking the vapor shut-off valve” (5-34).

Checking the canister

1. Check the canister. Replace if cracked.

2. Connect the special service tool “1” to the Intake air pressure sensor bolt “2”
atmospheric port “a” and block the other 5 Nm (0.5 kgf·m, 3.7 ft·lb)

T.
R.
ports using rubber plugs “2”.
2. Install a new gasket “1” and the throttle
3. Apply the specified positive pressure and damper plate “2”, and then tighten the
check that there is no air leakage. Replace throttle damper plate bolts “3” to the spec-
the canister if there is air leakage. ified torque.

3. Install a new gasket “4”, the ETV “5” and

the bracket “6”, and then tighten the ETV
1 nuts “7” to the specified torque.
3 7
6

2
5
3
1 7
a 2
4

Vacuum/pressure pump gauge set Throttle damper plate bolt “3”

“1” 13 Nm (1.3 kgf·m, 9.6 ft·lb)
T.
R.

90890-06945 ETV nut “7”

13 Nm (1.3 kgf·m, 9.6 ft·lb)

Holding pressure (positive pres- 4. Install the holder “1” and vapor shut-off
sure) valve “2”, and then tighten the vapor shut-
19.6 kPa (0.20 kgf/cm², 2.8 psi) off valve nut “3” to the specified torque.

Installing the canister, ETV, and surge 5. Install the throttle body assembly wire har-
tank ness extension coupler “a” to the holder “4”
1. Install the intake air pressure sensor “1”, on the bracket “5”.
and then tighten the intake air pressure
sensor bolt “2” to the specified torque. 6. Fasten the throttle body assembly wire
harness extension “6” and holder “1” using
the plastic tie “7”.

6-24
 ETV
7. Connect the intake air pressure sensor
coupler “b” and vapor shut-off valve cou- 3
pler “c”.
7
3 1 2
4 5
6 2
1
a
c
Canister holder bolt “3”
b
5 Nm (0.5 kgf·m, 3.7 ft·lb)

T.
R.
Vapor shut-off valve nut “3”
5 Nm (0.5 kgf·m, 3.7 ft·lb)
T.
R.

8. Install the grommets “1” and collars “2” to

the bracket “3”.

1
1 2
2

9. Install the bracket “1”, and then tighten the

canister bracket bolts “2” to the specified
torque.

1
2

Canister bracket bolt “2”

5 Nm (0.5 kgf·m, 3.7 ft·lb)
T.
R.

10. Secure the canister “1” using the holder

“2”, and then tighten the canister holder
bolt “3” to the specified torque.

6-25
 Low-pressure fuel pump

Low-pressure fuel pump

8
5 Nm (0.5 kgf･m, 3.7 ft･lb)

7 8

9
6

3 10

5 4

3 3 2

No. Part name Q’ty Remarks

1 Hose 1 Joint to low-pressure fuel pump
2 Clamp 3
3 Clamp 2
4 Joint 1
5 Bushing 2
6 Low-pressure fuel pump 1
7 Hose 1 Low-pressure fuel pump to vapor separator
8 Holder 2
9 Cover 1
10 Bolt 2 M6  15 mm

6-26
 Low-pressure fuel pump

Removing the low-pressure fuel pump

Cover the fuel components using a rag to pre-
vent fuel from spilling out.

1. Disconnect the low-pressure fuel pump

coupler “a”.

2. Remove the holders “1” from the fuel hose

1
“2”, and then disconnect the fuel hose “2”. 2

Checking the low-pressure fuel pump

2
1 1. Drain the fuel from the vapor separator
and check the condition of the fuel. See
“Draining the fuel” (6-30). If the fuel is dirty,
check and clean the fuel lines.

2. Check the electrical performance of the

low-pressure fuel pump. See “Checking
the low-pressure fuel pump and high-pres-
3. Remove the fuel hose “1” and joint “2”. sure fuel pump” (5-32).

Installing the low-pressure fuel pump

1. Install the low-pressure fuel pump “1” and
cover “2”, and then tighten the low-pres-
sure fuel pump cover bolts “3” to the spec-
ified torque.

2
1

2
1
4. Remove the cover “1” and low-pressure 3
fuel pump “2”.

Low-pressure fuel pump cover bolt

“3”
T.
R.

5 Nm (0.5 kgf·m, 3.7 ft·lb)

6-27
 Low-pressure fuel pump
2. Install the joint “1” to the fuel hose “2”, and
then fasten the fuel hose using the clamp
“3”.

3. Connect the fuel hose “4” to the low-pres-

sure fuel pump and joint “1”, and then fas-
ten the fuel hose using the clamps “5” and
“6”.

6 2
3
4 1
5

4. Connect the fuel hose “1”, and then fasten

it using the clamps “2”.

5. Install the fuel hose “1” to the holders “3”.

6. Connect the low-pressure fuel pump cou-

pler “a”.

1
3

6-28
 Vapor separator

Vapor separator

3 10
8 5
3 7

3 6
5 5
7
5 4
7 11
3
5
11 13
4
5
7
12

11 5
2 4
14
13 15
1 5
4

No. Part name Q’ty Remarks

1 Hose 1 Vapor separator to joint
2 Clamp 1
3 Bolt 4 M6  16 mm
4 Bolt 4 M6  35 mm
5 Collar 8
6 Vapor separator assembly 1
7 Grommet 4
8 Bracket 1
9 Bracket 1
10 Vapor separator wire harness extension 1
11 Plastic tie 3
12 Hose 1 Joint to fuel cooler
13 Clamp 2
14 Hose 1 Fuel cooler to joint
15 Joint 1

6-29
 Vapor separator

Draining the fuel 2. Remove the vapor separator wire harness

Cover the fuel components using a rag to pre- extension “1”.
vent fuel from spilling out.

1. Remove the flywheel magneto cover.

2. Remove the intake silencer. See “Remov-

ing the intake silencer” (6-12).

3. Disconnect the fuel hose “1” from the va-

por separator assembly.

4. Loosen the vapor separator drain screw

“2” to drain the fuel into a drain pan.
1
1
1
3. Remove the vapor separator assembly
“1”, and then remove the cooling water
hoses “2” and “3” and joint “4”.

2
2
5. Tighten the vapor separator drain screw
2
“2” to the specified torque.

Vapor separator drain screw “2”

2 Nm (0.2 kgf·m, 1.5 ft·lb)
T.

3
R.

6. Connect the fuel hose to the vapor separa- 3

tor assembly. 4

7. Install the intake silencer. See “Installing

the intake silencer” (6-14). Installing the vapor separator
1. Install the joint “1” to the cooling water
8. Install the flywheel magneto cover. hose “2”, and then fasten the cooling water
hose using the clamp “3”.
Removing the vapor separator
Cover the fuel components using a rag to pre- 2. Install the cooling water hose “4”, and then
vent fuel from spilling out. fasten it using the plastic ties “5”.

1. Disconnect the quick connector. See steps 3. Install the cooling water hose “6”, and then
3–5 in “Disconnecting the quick connector” fasten it using the clamp “7” and plastic tie
(6-1). “8”.

6-30
 Vapor separator
4. Install the vapor separator assembly “9”.

2 6
7

8 7 5
8

6
5
4
5
1 4
3

5. Connect the vapor separator wire harness

extension “1”.

6. Connect the quick connector. See “Con-

necting the quick connector” (6-2).

6-31
 Vapor separator and high-pressure fuel pump

Vapor separator and high-pressure fuel pump

2 Nm (0.2 kgf·m, 1.5 ft·lb) 5 2 Nm (0.2 kgf·m, 1.5 ft·lb)
4 5 14
2 6 10 12
7
3
11
1 8

9
3.5 Nm (0.35 kgf·m, 2.58 ft·lb) 13
28

29 3.5 Nm (0.35 kgf·m, 2.58 ft·lb) 16

17
20

15
30 31 18
25 24
32

27 26
23 19
2 Nm (0.2 kgf·m, 1.5 ft·lb)
33 21
2 Nm (0.2 kgf·m, 1.5 ft·lb)
2 Nm (0.2 kgf·m, 1.5 ft·lb) 22
34

No. Part name Q’ty Remarks

1 Vapor separator cover assembly 1
2 Screw 1 M5  12 mm
3 Holder 1
4 Pressure regulator 1
5 Bolt 3 M4  12 mm
6 Cover 1
7 Gasket 1 Not reusable
8 Filter 1
9 Check valve 1
10 Screw 1 M4  14 mm
11 Joint pipe 1
12 Hose 1 Vapor separator cover assembly to joint pipe
13 Hose 1 Vapor separator cover assembly to joint pipe
14 Screw 6 M4  16 mm
15 Gasket 1 Not reusable
16 Grommet 1
17 Joint 1

6-32
 Vapor separator and high-pressure fuel pump

2 Nm (0.2 kgf·m, 1.5 ft·lb) 5 2 Nm (0.2 kgf·m, 1.5 ft·lb)

4 5 14
2 6 10 12
7
3
11
1 8

9
3.5 Nm (0.35 kgf·m, 2.58 ft·lb) 13
28

29 3.5 Nm (0.35 kgf·m, 2.58 ft·lb) 16

17
20

15
30 31 18
25 24
32

27 26
23 19
2 Nm (0.2 kgf·m, 1.5 ft·lb)
33 21
2 Nm (0.2 kgf·m, 1.5 ft·lb)
2 Nm (0.2 kgf·m, 1.5 ft·lb) 22
34

No. Part name Q’ty Remarks

18 Damper 1
19 High-pressure fuel pump 1
20 Lead 1
21 Filter 1
22 Holder 1
23 Needle valve assembly 1
24 Screw 1 M4  8 mm
25 Pin 1
26 Float 1
27 Screw 1 M4  8 mm
28 Float chamber assembly 1
29 Screw 3 M5  6 mm
30 Cover 1
31 Gasket 1 Not reusable
32 Gasket 1 Not reusable
33 Drain screw 1
34 Drain hose 1

6-33
 Vapor separator and high-pressure fuel pump

Disassembling the vapor separator 5. Remove the cover “1”, gasket “2”, filter “3”,
1. Remove the drain screw “1” and drain and check valve “4”.
hose “2”.
3
1

4 2
1

2. Remove the vapor gas hoses “1” and “2”

and joint pipe “3”.

1 6. Remove the vapor separator cover “1”,

gasket “2”, high-pressure fuel pump “3”,
and grommet “4”.
3

2
2
3

4
3. Remove the fuel cooler cover “1” and gas-
kets “2” and “3”.

4. Remove the holder “4”, and then remove

the pressure regulator “5”. 7. Remove the screw “1”, and then remove
the pin “2”, float “3”, and needle valve as-
sembly “4”.
4 1

1 2
5 2 4

6-34
 Vapor separator and high-pressure fuel pump
8. Remove the lead “1” and filter holder “2”,
and then remove the filter “3”, joint “4”, and
damper “5”. a

4 1

Float height
65.0–70.0 mm (2.56–2.76 in)

2
5 Checking the check valve
1. Connect the special service tool “1” to the
check valve port “a”.
Checking the high-pressure fuel
2. Apply positive pressure and check that air
pump comes out of the opposite end “b” of the
1. Check the electrical performance of the check valve. Replace the check valve if no
high-pressure fuel pump. See “Checking air comes out.
the low-pressure fuel pump and high-pres-
sure fuel pump” (5-32).
b a 1
Checking the vapor separator
1. Check the needle valve. Replace the nee-
dle valve assembly if bent or worn.

Vacuum/pressure pump gauge set

“1”
90890-06945

3. Connect the special service tool “1” to the

2. Check the float. Replace if deteriorated. opposite check valve port “a”.

3. Check the filter. Clean if there is dirt or res-

idue.

4. Place the cover assembly upside down,

and then measure the float height “a”.

When measuring the float height, the float

should be resting on the needle valve. Do not
press the float.

6-35
 Vapor separator and high-pressure fuel pump
4. Apply positive pressure and check that no
air comes out of the opposite end “b” of the 2 5
check valve. Replace the check valve if air 3
comes out.

b a 1

4
1

Assembling the vapor separator 4. Install the grommet “1” and high-pressure
1. Install the needle valve assembly “1”, and fuel pump “2”, and then connect the high-
then tighten the needle valve assembly pressure fuel pump coupler “a”.
screw “2” to the specified torque.

2. Install the float “3” and pin “4”, and then

tighten the float pin screw “5” to the speci- 2
fied torque.

2
5 4 1 a

5. Install a new gasket “1” and the vapor sep-

arator cover “2”, and then tighten the float
chamber cover screws “3” to the specified
torque.
3 3

Needle valve assembly screw “2” 1

2 Nm (0.2 kgf·m, 1.5 ft·lb)
T.
R.

Float pin screw “5”

2 Nm (0.2 kgf·m, 1.5 ft·lb)

3. Install the damper “1”, joint “2”, filter “3”, fil-

ter holder “4”, and lead “5”.

Float chamber cover screw “3”

2 Nm (0.2 kgf·m, 1.5 ft·lb)
T.
R.

6-36
 Vapor separator and high-pressure fuel pump
6. Install the check valve “1”, the filter “2”, a 9. Install the joint pipe “1” and vapor gas hos-
new gasket “3”, and the cover “4”, and then es “2” and “3”, and then tighten the joint
tighten the cover bolts “5” to the specified pipe screw “4” to the specified torque.
torque.
4 2
5
2
4
1
1 3

Joint pipe screw “4”

Cover bolt “5” 2 Nm (0.2 kgf·m, 1.5 ft·lb)
T.
R.

2 Nm (0.2 kgf·m, 1.5 ft·lb)

T.
R.

10. Install the drain hose “1” and drain screw

7. Install the pressure regulator “1” and hold- “2”, and then tighten the drain screw “2” to
er “2”, and then tighten the pressure regu- the specified torque.
lator screw “3” to the specified torque.

8. Install new gaskets “4” and “5” and the fuel

cooler cover “6”, and then tighten the fuel
cooler cover screws “7” to the specified 2
torque.

3 7

2 6 1

1 5 Drain screw “2”

2 Nm (0.2 kgf·m, 1.5 ft·lb)
T.

4
R.

Pressure regulator screw “3”

3.5 Nm (0.35 kgf·m, 2.58 ft·lb)
T.
R.

Fuel cooler cover screw “7”

3.5 Nm (0.35 kgf·m, 2.58 ft·lb)

6-37
 Fuel injector

Fuel injector
3 4
STBD
1
6
5

3 9
8 7
2

8
7
7
14 13
8 10

4 PORT
17 13 9
14
12
14 3
8 9
7
15 4 1
16 9
8
7
3
8 11
7

No. Part name Q’ty Remarks

1 Bolt 4 M6  20 mm
2 Cover (STBD) 1
3 Bolt 4 M6  35 mm
4 Plastic tie 3
5 Fuel rail assembly (STBD) 1
6 Fuel rail (STBD) 1
7 Fuel injector 6
8 O-ring set 6 Not reusable
9 Holder 6
10 Fuel rail assembly (PORT) 1
11 Fuel rail (PORT) 1
12 Cover (PORT) 1
13 Quick connector 2
14 Clamp 4
15 Hose 1
16 Quick connector 1
17 Hose 1

6-38
 Fuel injector

Removing the fuel injector

Cover the fuel components using a rag to pre- STBD
1 a
vent fuel from spilling out.

1. Disconnect the quick connectors. See

steps 3–5 in “Disconnecting the quick con- a
nector” (6-1).
a
2. Remove the fuel hoses “1” and “2”.

PORT
4. Remove the fuel rails “1”.

PORT 1

1
STBD
1
STBD

5. Remove the holders “1”, and then remove

the fuel injectors “2” and O-rings “3” and
“4”.
3 4

3. Remove the fuel rail covers “1”, and then

disconnect the fuel injector couplers “a”. 1
2
PORT
a
1

a
Checking the fuel rail and fuel injector
1. Check the fuel rails. Replace if cracked or
a deformed.

6-39
 Fuel injector
2. Check the electrical performance of the Checking the quick connector
fuel injectors. See “Checking the fuel injec- 1. Check the quick connector “1”. Replace if
tor” (5-32). cracked or damaged.

3. Measure the volume injected by the injec- 2. Check the O-rings “2” in the quick connec-
tors. See the “Fuel Injection Meter Opera- tor “1”. Replace the quick connector if an
tion Manual” (90894-62982-**). O-ring is cracked or damaged.

Do not use gasoline when measuring the 1

fuel injection volume. Otherwise, the cylin- 1
der could be damaged, which can cause a
gasoline leakage. Make sure to follow the
2
instructions for operation of the fuel injec-
tion meter.

• When measuring, obtain a result from the av- Installing the fuel injector
erage of 4 measurements. 1. Install new O-rings “1” and “2” to the fuel
• It is not possible to obtain correct measure- injector “3”.
ments under disparate test conditions.
• Make sure to fully charge the battery.
• The cylinder is graduated in increments of 2.5
1
cm³ (2.5 cc).
• Make sure to comply with the laws and regu-
lations of the region when disposing of the
used test fuel.
3
Fuel injection meter 2
FIM20000ME
2. Install the fuel injectors “1” onto the fuel
rails “2”, and then install the holders “3”.
Fuel injection volume
PORT 2 3
130–150 cm³/30 sec
Test fuel
1
Dry sorbent (viscosity: 1.2 ± 0.03
3
mm²/s, specific gravity: 0.774 [15
C]) 1
Test fuel temperature 3
22–24 C (room temperature and
test fuel temperature should be 1
the same)
Test fuel pressure
300 ± 1.5 kPa
Measuring cylinder internal pres-
sure (standard atmosphere pres-
sure)
960–1060 hPa

6-40
 Fuel injector

STBD PORT STBD

2 1 3 2

3
1
3
1 1

1
a
3. Install the fuel rails “1” onto the cylinder a
heads.

4. Tighten the bolts “2” equally and gradually.

PORT 1 2
2

7. Install the fuel rail covers “1”.

2 PORT

STBD
1
2

STBD
2 1

5. Connect the fuel injector couplers “a”.

6. Fasten the wire harness using the holders

“1”, and then fasten the wire harness using
the plastic ties “2”. See “Wiring harness
routing” (5-7). 8. Connect the quick connectors. See “Con-
necting the quick connector” (6-2).

6-41
 Fuel injector
9. Fasten the fuel hoses “1” and “2” using the
holders “3”, “4”, and “5”.

PORT

4
3

STBD

6-42
 Fuel injector

— MEMO —

6-43
 Power unit

Power unit (check and adjustment) .................................. 7-1

Checking the compression pressure .......................................... 7-1 0
Checking the oil pressure........................................................... 7-1
Checking the pulser coil air gap ................................................. 7-2
Checking the valve clearance .................................................... 7-2
Adjusting the valve clearance..................................................... 7-4
1
Power unit assembly.......................................................... 7-7
Removing the power unit............................................................ 7-9
2
Installing the power unit............................................................ 7-13

Flywheel magneto ............................................................ 7-17

3
Removing the flywheel magneto .............................................. 7-18
Checking the pulser coil ........................................................... 7-19
Installing the flywheel magneto ................................................ 7-19 4
Wire harness..................................................................... 7-21
Removing the wire harness...................................................... 7-22
5
Installing the wire harness........................................................ 7-25

Fuse box............................................................................ 7-29

6
Junction box ..................................................................... 7-30 7
Removing the rectifier/regulator ............................................... 7-32
Checking the rectifier/regulator anode ..................................... 7-32
Removing the junction box ....................................................... 7-32
Installing the junction box ......................................................... 7-32 8
Installing the rectifier/regulator ................................................. 7-33

Starter motor and APS..................................................... 7-34 9

Removing the starter motor...................................................... 7-35
Removing the APS ................................................................... 7-35
Checking the APS .................................................................... 7-35
Installing the APS ..................................................................... 7-35
10
Installing the starter motor........................................................ 7-35

Relay.................................................................................. 7-37

A
 Power unit

Engine ECM ...................................................................... 7-38

Removing the engine ECM ...................................................... 7-39
Installing the engine ECM ........................................................ 7-39

Cylinder head cover ......................................................... 7-40

Removing the cylinder head cover ........................................... 7-42
Checking the spark plug........................................................... 7-42
Installing the cylinder head cover ............................................. 7-42

Timing belt ........................................................................ 7-44

Removing the timing belt.......................................................... 7-45
Checking the timing belt ........................................................... 7-46
Installing the timing belt............................................................ 7-46

Camshaft ........................................................................... 7-50

Removing the driven sprocket and camshaft ........................... 7-52
Checking the sprocket.............................................................. 7-53
Checking the valve lifter ........................................................... 7-53
Checking the camshaft............................................................. 7-54
Checking the camshaft journal oil clearance............................ 7-54
Checking the camshaft journal outside diameter and
camshaft journal inside diameter.............................................. 7-56
Installing the camshaft and driven sprocket ............................. 7-56

Exhaust cover................................................................... 7-61

Removing the exhaust cover.................................................... 7-62
Checking the exhaust cover anode .......................................... 7-62
Installing the exhaust cover...................................................... 7-62

Cylinder head ................................................................... 7-63

Removing the cylinder head..................................................... 7-66
Disassembling the cylinder head.............................................. 7-66
Checking the cylinder head ...................................................... 7-67
Checking the valve spring ........................................................ 7-68
Checking the valve ................................................................... 7-68
Checking the valve guide ......................................................... 7-69
Replacing the valve guide ........................................................ 7-69
Checking the valve seat ........................................................... 7-70
Refacing the valve seat ............................................................ 7-71
Checking the cylinder head anode ........................................... 7-73
Assembling the cylinder head .................................................. 7-73
Installing the cylinder head....................................................... 7-74
 Power unit

Cooling water passage cover.......................................... 7-76

Removing the cooling water passage cover............................. 7-78 0
Checking the cooling water passage cover anode................... 7-78
Checking the knock sensor ...................................................... 7-78
Installing the cooling water passage cover............................... 7-78
1
Crankcase ......................................................................... 7-80
Removing the oil filter bracket .................................................. 7-82
Removing the oil pump............................................................. 7-82
2
Removing the crankcase cover ................................................ 7-82
Disassembling the oil pump ..................................................... 7-83
Checking the oil pump.............................................................. 7-83
Assembling the oil pump .......................................................... 7-84
3
Installing the crankcase cover .................................................. 7-84
Installing the oil pump............................................................... 7-85
Installing the oil filter bracket .................................................... 7-85 4
Cylinder block................................................................... 7-87
Disassembling the cylinder block ............................................. 7-90
5
Checking the thermostat .......................................................... 7-91
Checking the piston diameter................................................... 7-92
Checking the cylinder bore....................................................... 7-92
Checking the piston clearance ................................................. 7-92
6
Checking the piston ring........................................................... 7-92
Checking the piston ring end gap............................................. 7-93
Checking the piston ring groove............................................... 7-93
Checking the piston ring side clearance................................... 7-94
7
Checking the piston pin boss inside diameter .......................... 7-94

8
Checking the piston pin diameter ............................................. 7-94
Checking the connecting rod small end inside diameter and
big end inside diameter ............................................................ 7-95
Checking the connecting rod big end side clearance............... 7-95
Checking the crankshaft........................................................... 7-95
Checking the crankcase bolt .................................................... 7-96 9
Checking the big end oil clearance .......................................... 7-96
Selecting the crankshaft pin bearing ........................................ 7-98
Checking the journal oil clearance ........................................... 7-98
Selecting the crankshaft journal bearing ................................ 7-100 10
Crankshaft journal bearing selection table ............................. 7-101
Checking the cylinder block anode......................................... 7-102
Assembling the cylinder block ................................................ 7-102

A
 Power unit (check and adjustment)

Power unit (check and adjust-

ment) Compression pressure
Minimum (reference data)
Checking the compression pressure
595 kPa (5.95 kgf/cm², 86.3 psi)
1. Start the engine, warm it up for 5–10 min-
utes, and then stop it.
9. Turn the engine start switch to OFF.
2. Remove the clip from the engine shut-off
10. Remove the special tools.
switch.
11. Install the spark plugs, and then tighten
3. Remove the fuel rail covers (PORT and
them to the specified torque.
STBD), and then disconnect fuel injector
couplers.
Spark plug
4. Remove the engine ECM cover, ignition 25 Nm (2.5 kgf·m, 18.4 ft·lb)

T.
R.
coils, and spark plugs.
12. Install the ignition coils, and then tighten
the ignition coil bolts to the specified
Before removing the spark plugs, remove torque.
any dirt or dust in the spark plug wells that
could fall into the cylinders. Ignition coil bolt
7 Nm (0.7 kgf·m, 5.2 ft·lb)
T.
R.

5. Install the special service tools “1” and “2”

13. Connect the fuel injector couplers, and
into the spark plug hole.
then install the fuel rail covers (PORT and
STBD) and engine ECM cover.

Checking the oil pressure

1
1. Connect the YDIS to display “Oil pres-
sure”.

2. Start the engine and warm it up until the

engine idle speed stabilizes at the speci-
2 fied engine idle speed range.

Idle speed (in neutral)

Compression gauge “1”
600–700 r/min
90890-03160
Compression gauge extension “2”
3. Measure the oil pressure. Check the en-
90890-06563
gine internal parts if the oil pressure is be-
6. Turn the engine start switch to ON. low specification.

7. Fully open the throttle. Engine oil pressure at idle speed

(reference data)
8. Crank the engine until the reading on the 507.3 kPa (5.073 kgf/cm², 73.6
compression gauge stabilizes, and then psi) / SL 10W-30 engine oil
measure the compression pressure. Engine oil pressure at 3000 r/min
Check the engine internal parts if the com- (reference data)
pression pressure is below specification. 700.6 kPa (7.006 kgf/cm², 101.6
psi) / SL 10W-30 engine oil

7-1
 Power unit (check and adjustment)

Checking the pulser coil air gap 7. Install the flywheel magneto cover.

Checking the valve clearance

Do not turn the flywheel magneto counter- Measure the valve clearances when the en-
clockwise. Otherwise, the water pump im- gine is cold.
peller could be damaged.

Do not turn the flywheel magneto counter-

1. Remove the flywheel magneto cover, and
clockwise. Otherwise, the water pump im-
then remove the wire harness guide bolts
peller could be damaged.
and lift up the wire harness guide.

1. Reduce the fuel pressure. See “Reducing

To completely remove the wire harness guide the fuel pressure” (6-1).
when checking the air gap, see “Reducing the
fuel pressure” (6-1) and “Removing the wire
harness” (7-22). When measuring or adjusting the valve clear-
ances, the fuel line must be disconnected, so
make sure to reduce the fuel pressure before
2. Turn the flywheel magneto clockwise to
performing the disassembly procedure.
align the protrusion “a” on the flywheel
magneto with the protrusion “b” on the
pulser coil. 2. Remove the flywheel magneto cover and
engine ECM cover.
3. Measure the pulser coil air gap “c”. Adjust
if out of specification. 3. Remove the blowby hose. See “Removing
the intake silencer” (6-12).
Air gap
1.40–1.60 mm (0.055–0.063 in) 4. Remove the relays and relay holder. See
“Relay” (7-37).
4. Loosen the pulser coil screws “1” and ad-
5. Remove the speed sensor coupler from
just the pulser coil air gap.
the bracket. See step 16 in “Removing the
power unit” (7-9).
a
c 6. Remove the wire harness from the engine
ECM bracket and holder. See steps 4–13
in “Removing the wire harness” (7-22).

7. Remove the ignition coils and spark plugs.

b
1 8. Disconnect the cooling water hose “1”.

5. Tighten the pulser coil screws, and then 9. Remove the knock sensor lead “a” from
check the pulser coil air gap. the engine ECM bracket “2”.

Pulser coil screw

4 Nm (0.4 kgf·m, 3.0 ft·lb)
T.
R.

6. Install the wire harness guide and wire har-

ness guide bolts. See “Installing the wire
harness” (7-25).

7-2
 Power unit (check and adjustment)
10. Remove the engine ECM bracket “2”.

2 IN EX EX IN
1

#1
#2

#3
a #4

11. Turn the flywheel magneto clockwise and #5

align the “1TDC” mark “a” on the flywheel #6
magneto with the pointer “b”.
PORT STBD
12. Check that the “II” marks “c” on the VCT
assembly (PORT) and driven sprocket
(PORT) are aligned, and check that the “I”
marks “d” on the VCT assembly (STBD)
and driven sprocket (STBD) are aligned.

a a

b b
PORT STBD

d c Valve clearance IN (cold engine)

0.17–0.24 mm (0.0067–0.0094
in)
Valve clearance EX (cold engine)
a 0.31–0.38 mm (0.0122–0.0150
in)
b
15. Measure the intake and exhaust valve
clearances of the specified cylinders. Ad-
just if out of specification. See “Adjusting
13. Remove the cylinder head covers. the valve clearance” (7-4).

14. Measure the valve clearances “a” and “b” #1 #2 #3 #4 #5 #6

according to steps 15–17. IN —    — —
EX — — —   
Write down the measurement data. —: Not applicable
: Specified cylinder

16. Turn the flywheel magneto an additional

360° clockwise and align the “1TDC” mark
on the flywheel magneto with the pointer.

7-3
 Power unit (check and adjustment)
17. Measure the intake and exhaust valve 25. Install the speed sensor to the bracket.
clearances of the specified cylinders. Ad- See step 17 in “Installing the power unit”
just if out of specification. See “Adjusting (7-13).
the valve clearance” (7-4).
26. Install the relays and relay holder. See
#1 #2 #3 #4 #5 #6 “Relay” (7-37).
IN  — — —  
EX    — — — 27. Install the blowby hose. See “Installing the
intake silencer” (6-14).
—: Not applicable
: Specified cylinder 28. Install the engine ECM cover and flywheel
magneto cover.
18. Install the cylinder head covers. See “In-
stalling the cylinder head cover” (7-42). Adjusting the valve clearance
Adjust the valve clearances when the engine is
19. Connect the water cooling hose “1”. cold.

20. Install the engine ECM bracket “2”.

• Do not turn the flywheel magneto counter-
21. Fasten the knock sensor lead “a” using the clockwise. Otherwise, the water pump im-
holder “3” on the engine ECM bracket. peller could be damaged.
• Do not turn the flywheel magneto, VCT as-
sembly or driven sprocket when the tim-
2 ing belt is not installed. Otherwise, the
1 pistons and valves, or intake and exhaust
valves will collide with each other and be
damaged.

a
1. Check that the “1TDC” mark “a” on the fly-
3 wheel magneto and the pointer “b” are
aligned.
22. Install the spark plugs, and then tighten
them to the specified torque.

Spark plug
25 Nm (2.5 kgf·m, 18.4 ft·lb)
T.
R.

23. Install the ignition coils, and then tighten

the ignition coil bolts to the specified
torque.

Ignition coil bolt

7 Nm (0.7 kgf·m, 5.2 ft·lb)
T.
R.

24. Install the wire harness to the engine ECM

bracket. See steps 24–29 in “Installing the
wire harness” (7-25).

7-4
 Power unit (check and adjustment)
2. Check that the “II” marks “c” on the VCT
assembly (PORT) and driven sprocket
(PORT) are aligned, and check that the “I” Make sure to keep the parts in the order as
marks “d” on the VCT assembly (STBD) they were removed.
and driven sprocket (STBD) are aligned.
10. Measure the valve lifter thickness “a”, and
then write down the measurement data.

d c

11. Select the necessary valve lifter by calcu-

a
lating its thickness using the following for-
mula.
b
Calculation formula:
Necessary valve lifter thickness = Re-
3. Remove the intake manifolds. See “Re- moved valve lifter thickness + Measured
moving the intake manifold” (6-12). valve clearance – Specified valve clear-
ance
4. Disconnect the quick connectors. See
steps 3–5 in “Disconnecting the quick con- Example:
nector” (6-1). Removed valve lifter thickness = 3.000
mm
5. Remove the fuel hoses and fuel rail cov- Measured valve clearance = 0.255 mm
ers. Specified valve clearance = 0.205 mm
Necessary valve lifter thickness
6. Remove the flywheel magneto and stator
= 3.000 mm + 0.255 mm – 0.205 mm
assembly. See “Removing the flywheel
= 3.050 mm
magneto” (7-18).

7. Remove the wire harness and wire har-

ness guide. See steps 14–25 in “Remov-
ing the wire harness” (7-22).

8. Remove the timing belt. See steps 9–11 in

“Removing the timing belt” (7-45).

9. Remove the VCT assemblies, driven

sprockets, and camshafts. See “Removing
the driven sprocket and camshaft” (7-52).

7-5
 Power unit (check and adjustment)
12. Install the necessary valve lifter into the
cylinder head.

3-digit mark “a” is stamped as shown to easily

know new valve lifter thickness.

A A

13. Install the camshafts, driven sprockets,

and VCT assemblies. See “Installing the
camshaft and driven sprocket” (7-56).

14. Install the timing belt. See steps 1–10 in

“Installing the timing belt” (7-46).

15. Install the stator assembly and flywheel

magneto. See steps 1–7 in “Installing the
flywheel magneto” (7-19).

16. Measure the valve clearances. See steps

13–17 in “Checking the valve clearance”
(7-2).

17. Install the intake manifolds. See in “Install-

ing the intake manifold” (6-13).

18. Check the pulser coil air gap. See steps 2–

5 in “Checking the pulser coil air gap” (7-2).

19. Install the wire harness guide and wire har-

ness. See steps 12 and 13 in “Installing the
wire harness” (7-25).

20. Install the fuel hoses and fuel rail covers.

21. Connect the quick connectors. See “Con-

necting the quick connector” (6-2).

7-6
 Power unit assembly

Power unit assembly

4 Nm (0.4 kgf㺃m, 3.0 ft㺃lb) 27 28
1
28

11
12
25 12
3
24
25
21 12 3
26
23 11 11
22
16 14
4
2
3 5
19 3
20
17 16

18
6

16 7
17

13 8
9
16 11 11 10
15 12 42 Nm (4.2 kgf㺃m, 31.0 ft㺃lb)

No. Part name Q’ty Remarks

1 Power unit 1
2 Gasket 1 Not reusable
3 Dowel 2
4 Bolt 2 M6  20 mm
5 Cable holder 1
6 Bolt 2 M6  30 mm
7 Retaining plate 1
8 Rigging tube retainer 1
9 Plastic tie 1
10 Rigging grommet 1
11 Bolt 7 M10  35 mm
12 Bolt 6 M10  140 mm
13 Nut 2
14 Apron (PORT) 1
15 Bolt 1 M6  30 mm
16 Bolt 7 M6  14 mm
17 Grommet 6

7-7
 Power unit assembly

4 Nm (0.4 kgf㺃m, 3.0 ft㺃lb) 27 28

1
28

11
12
25 12
3
24
25
21 12 3
26
23 11 11
22
16 14
4
2
3 5
19 3
20
17 16

18
6

16 7
17

13 8
9
16 11 11 10
15 12 42 Nm (4.2 kgf㺃m, 31.0 ft㺃lb)

No. Part name Q’ty Remarks

18 Apron (STBD) 1
19 Cover 1
20 O-ring 1 Not reusable
21 Bolt 1 M6  16 mm
22 Dipstick guide 1
23 Dipstick 1
24 Holder 3
25 Bolt 2 M6  10 mm
26 Cap 2
27 Engine ECM cover 1
28 Bolt 4 M6  20 mm

7-8
 Power unit assembly

Removing the power unit 1

Make sure to reduce the fuel pressure before
removing the power unit. See “Reducing the
fuel pressure” (6-1).
It is recommended to loosen the flywheel mag-
neto nut before removing the power unit to im-
prove working efficiency. See “Removing the 2
flywheel magneto” (7-18).
3
1. Remove the flywheel magneto cover.
6. Remove the cable holder “1”, and then dis-
2. Remove the plastic tie “1”, and then re- connect the shift cable “2”.
move the rigging tube retainer “2”.

2
2

1
7. Disconnect the fuel hose “1” from the fuel
3. Remove the retaining plate “1” and rigging filter.
grommet “2”.

1 1

8. Remove the PTT switch coupler “a” from

the bracket “1”, and then disconnect the
PTT switch coupler.
2

4. Disconnect the battery cables “1”.

5. Remove the throttle cable “2” from the

holder “3”, and then disconnect the throttle
cable.

7-9
 Power unit assembly
9. Remove the water detection switch cou-
pler “b” and isolator coupler “c” from the
bracket “1”. 2
b 1

b
a b

c a

15. Disconnect the cooling water hose “1”.

1 a

10. Remove the main wire harness coupler

(10-pin) “a” from the holders on the bracket
“1”, and then disconnect the main wire har-
ness coupler (10-pin).

11. Remove the 6Y8/6YC Multifunction meter

coupler “b” from the tab on the bracket,
and then disconnect the 6Y8/6YC Multi-
function meter coupler.

1
16. Remove the engine ECM cover “1”, and
then remove the speed sensor coupler “a”
from the bracket “2”.

17. Disconnect the flushing hose “3”.

b a

12. Remove the gauge harness coupler “a”

a
from the bracket.
2 1
13. Remove the trim sensor coupler “b” from
3
the tab on the bracket, and then discon-
nect the trim sensor coupler.

14. Remove the wire harness “1” from the

holders on the bracket “2”.

7-10
 Power unit assembly
18. Disconnect the vapor gas hose “1” from
4 3 3 4 1
the housing (STBD).

STBD 1
2

19. Remove the intake manifold (STBD). See

“Removing the intake manifold” (6-12).
25. Remove the aprons “1” and cover “2”.
20. Remove the dipstick “1”, and then remove
the dipstick guide “2”.
1
21. Disconnect the shift cut-off switch coupler
“a”, and then remove the wire harness and
shift position switch lead from the holders
“3” and “4”.
2
22. Remove the shift position switch coupler
“b”, and then disconnect the shift position
switch coupler from the bracket “5”.

23. Remove the cooling water hose “6” from 1

the holder “7”, and then disconnect the
cooling water hose.
1 2
3
a
4

b
5
7
6

24. Remove the holders “1”, plastic tie “2”, and

caps “3”, and then disconnect the PTT re-
lay terminals “4”.

7-11
 Power unit assembly
26. Retract the cowling lock levers “1” (PORT
1 1 3
and STBD).
4
Make sure that the cowling lock levers “1”
are retracted and the engine stoppers “2” 4
are installed before removing the power
unit. Otherwise, the fuel rails could be dam- 3 3
2
aged.
5

STBD PORT 6 6

3
3
3
4

2 2

1 1

27. Hook a lifting harnesses to the engine

hangers “1”, and then suspend the power
unit “2”.

28. Remove the power unit mounting bolts “3”

and “4”, and then remove the power unit
“2”, gasket “5”, and dowels “6”.

7-12
 Power unit assembly

Installing the power unit

5 3 3
Before installing the power unit, make sure to 3
install the shift rod and shift bracket onto the 6
bottom cowling. See “Shift rod and shift brack-
et” (9-1).
6
1. Retract the cowling lock levers “1” (PORT 5 5
and STBD).

Make sure that the cowling lock levers “1” 1

are retracted and the engine stoppers “2” 2
4
are installed before removing the power
unit. Otherwise, the fuel rails could be dam-
aged.

5 5
STBD PORT 6 5

Power unit mounting bolt “5” and “6”

42 Nm (4.2 kgf·m, 31.0 ft·lb)
T.
R.

5. Install the cover “1” and aprons “2”.

2 2 Make sure that the ground lead “3” is routed

through the gap between the aprons and is not
pinched.

2
1 1

2. Clean the power unit mating surface, and

then the install the dowels “1” and a new
gasket “2”. 1

3. Hook a lifting harness to the engine hang-

ers “3”, and then suspend the power unit
“4”.
2
4. Install the power unit “4”, and then tighten
the power unit mounting bolts “5” and “6” to
the specified torque. 3

6. Connect the PTT relay terminals “1”, and

then tighten the PTT relay terminal bolts to
the specified torque.

7-13
 Power unit assembly
7. Install the caps “2”, and then fasten the
8 7
PTT motor lead “3” using the plastic tie “4” 6
and holders “5”. b 5

To fasten the PTT motor lead, see “Wiring har-

ness routing” (5-7).
a
4
1 2 2 1 5 3
1 2

14. Install the intake manifold (STBD). See “In-

4 stalling the intake manifold” (6-13).

3 15. Connect the vapor gas hose “1” to the

5 housing (STBD), and then fasten it using
the plastic tie “2”.

STBD
1

PTT relay terminal bolt

4 Nm (0.4 kgf·m, 3.0 ft·lb)
T.
R.

8. Connect the cooling water hose “1”, and

then fasten it using the clamp “2”. 16. Connect the flushing hose “1”, and then
fasten it using the plastic tie “2”.
9. Fasten the cooling water hose “1” using
the holder “3”. 17. Install the speed sensor coupler “a” to the
bracket “3”, and then install the engine
10. Connect the shift position switch coupler
ECM cover “4”.
“a”, and then install the shift position switch
coupler to the bracket “4”.

11. Connect the shift cut-off switch coupler “b”. a

3 4
12. Fasten the shift position switch lead and 2
wire harness using the holder “5” and “6”. 1

13. Install a new O-ring and the dipstick guide

“7”, and then install the dipstick “8”.

7-14
 Power unit assembly
18. Connect the cooling water hose “1”, and
then fasten it using the clamp “2”.

a b

2 24. Install the water detection switch coupler

“a” and isolator coupler “b” to the bracket
“1”.
1 25. Connect the PTT switch coupler “c”, and
then install the PTT switch coupler to the
19. Install the wire harness “1” to the holders bracket “1”.
on the bracket “2”.

20. Connect the trim sensor coupler “a”, and To install the water detection switch coupler
then install the trim sensor coupler to the and isolator coupler, see “Wiring harness rout-
tab on the bracket. ing” (5-7).

21. Install the gauge harness coupler “b” to the

bracket. a c a

2
a 1 b

1 c

26. Connect the fuel hose “1” to the fuel filter,

b and then fasten it using the plastic tie “2”.

22. Connect the 6Y8/6YC Multifunction meter 27. Fasten the fuel hose “1” using the holder
coupler “a”, and then install the 6Y8/6YC “3”.
Multifunction meter coupler to the tab on
the bracket. 2

23. Connect the main wire harness coupler 1

(10-pin) “b”, and then fasten the main wire
harness coupler (10-pin) to the holders on 3
the bracket “1”.

7-15
 Power unit assembly
28. Connect the shift cable, and then install
the cable holder. See steps 4–7 in “Install-
ing the shift cable” (3-9).

29. Connect the throttle cable. See steps 2–6

in “Installing the throttle cable” (3-10).

30. Connect the battery cables “1”, and then 1

tighten the negative battery cable nut to
the specified torque. 2

1 33. Install the flywheel magneto cover.

Negative battery cable nut

13 Nm (1.3 kgf·m, 9.6 ft·lb)
T.
R.

31. Install the rigging grommet “1” and retain-

ing plate “2”.

Route each harness through the proper hole in

the rigging grommet. See “Rigging grommet
description” (3-8) for the detailed description of
the rigging grommet.

32. Install the rigging tube retainer “1”, and

then fasten it using the plastic tie “2”.

7-16
 Flywheel magneto

Flywheel magneto
240 Nm (24.0 kgf･m, 177.0 ft･lb)
1
2

5
5
5 8
7
13

5
11
10 6
9
6
12

4 Nm (0.4 kgf･m, 3.0 ft･lb)

No. Part name Q’ty Remarks

1 Nut 1 Width across flats: 36 mm
2 Washer 1
3 Flywheel magneto 1
4 Stator assembly 1
5 Bolt 4 M6  35 mm
6 Dowel 2
7 Holder 1
8 Holder 1
9 Bracket 1
10 Holder 1
11 Pulser coil 1
12 Screw 2 M5  20 mm
13 Woodruff key 1

7-17
 Flywheel magneto

Removing the flywheel magneto

To prevent damage to the engine or tools,

Do not turn the flywheel magneto counter- screw in the puller set bolts evenly and
clockwise. Otherwise, the water pump im- completely so that the flywheel puller is
peller could be damaged. parallel to the flywheel magneto.

1. Loosen the flywheel magneto nut. 1

Apply force in the direction of the arrow to

prevent the special service tool from slip-
ping off easily.

A 1

Flywheel puller “1”

90890-06521

3. Remove the plastic ties “1”, and then dis-

connect the stator assembly couplers “a”.

a 1

4. Disconnect the pulser coil coupler “a”.

a
A. Conventional tool
B. New special service tool

Flywheel holder “1”

90890-06522
Flywheel stopper “2”
90890-06598

2. Remove the flywheel magneto using the

special service tool “1”, and then remove
the Woodruff key.

7-18
 Flywheel magneto
5. Remove the vapor gas hose “1” from the
holder “2”. 5
6

1 2

1
4
7
2 4
3

Pulser coil screw “3”

6. Remove the stator assembly “1”, and then 4 Nm (0.4 kgf·m, 3.0 ft·lb)

T.
R.
remove the pulser coil “2”.
3. Fasten the vapor gas hose “1” using the
holder “2”.

1 1

2
2

Checking the pulser coil

1. Check the pulser coil. See step 6 in
4. Connect the pulser coil coupler “a”, and
“Checking the pulser coil” (5-38).
then fasten the pulser coil lead using the
holder “1”.
Installing the flywheel magneto

Do not turn the flywheel magneto counter-

1
clockwise. Otherwise, the water pump im- a
peller could be damaged.

1. Install the pulser coil “1” to the stator as-

sembly “2”, and then tighten the pulser coil
screws “3” to the specified torque.

2. Install the dowels “4” and stator assembly

“2”, and then install the holders “5” and “6”
and bracket “7”.

7-19
 Flywheel magneto
5. Connect the stator assembly couplers “a”,
and then fasten the stator assembly lead
using the plastic ties “1”. Apply force in the direction of the arrow to
prevent the special service tool from slip-
ping off easily.
To fasten the stator assembly lead, “Wiring
harness routing” (5-7). A

a 1
1

6. Install the Woodruff key “1”, and then in-

stall the flywheel magneto “2”.

• Make sure to remove any grease from the ta-

pered portion “a” of the crankshaft and the in- 2
ner surface “b” of the flywheel magneto.
• Apply engine oil to the threads “c” of the fly-
wheel magneto nut and upper and lower sur-
faces “d” of the washer before installation.

c
2 A. Conventional tool
d B. New special service tool

Flywheel holder “1”

d
90890-06522
Flywheel stopper “2”
90890-06598
2
1 Flywheel magneto nut
b
240 Nm (24.0 kgf·m, 177.0 ft·lb)
T.
R.

8. Check the pulser coil air gap. See “Check-

ing the pulser coil air gap” (7-2).
a

7. Tighten the flywheel magneto nut to the

specified torque.

7-20
 Wire harness

Wire harness
2 2
2

7 2

5
4
3

8
10

No. Part name Q’ty Remarks

1 Wire harness guide 1
2 Plastic tie 6
3 Damper 2
4 Bolt 5 M6  35 mm
5 Holder 4
6 Wire harness 1
7 Bolt 3 M6  16 mm
8 Cover 2
9 Fuse 2 15 A, spare is included
10 Fuse 2 10 A, spare is included

7-21
 Wire harness

Removing the wire harness e

When removing the wire harness and wire har- b
ness guide, the fuel line must be disconnected.
Therefore, make sure to reduce the fuel pres-
sure before performing the disassembly proce- b c
dure.
a
1. Disconnect the intake air temperature sen- c
c
sor coupler, and then remove the blowby 1
hose and intake silencer. See “Removing c
the intake silencer” (6-12). c
d
2. Remove the intake manifold (PORT). See b
“Removing the intake manifold” (6-12). c

3. Disconnect the quick connectors. See 10. Remove the cam position sensor lead
steps 3–5 in “Disconnecting the quick con- (PORT IN) from the holder “1”.
nector” (6-1).
11. Remove the plastic ties “2”.
4. Remove the fuel hoses and fuel rail cov-
12. Remove the holders “3” on the wire har-
ers. See steps 2 and 3 in “Removing the
ness from the engine ECM bracket.
fuel injector” (6-39).
13. Remove the wire harness “4” from the
5. Remove the relays and relay holder. See
holders “5” and “6” on the engine ECM
“Relay” (7-37).
bracket.
6. Remove the engine ECM “1”, and then dis- 2 4 5
connect the engine ECM couplers “a”. 1
3
7. Disconnect the cam position sensor cou-
pler “b”, and ignition coil couplers “c”. 2 6
3
8. Remove the knock sensor coupler “d” from
the engine ECM bracket, and then discon- 2 6
nect the knock sensor coupler.

9. Remove joint coupler 1 “e” from the wire 3

harness guide.

2 2

14. Remove the low-pressure fuel pump cou-

pler “a” from the wire harness guide, and
then disconnect the low-pressure fuel
pump coupler.

15. Remove the YDIS coupler “b” and fuse

box “c” from the bracket.

7-22
 Wire harness
16. Remove the holder “1”, and then discon-
STBD
nect the vapor separator wire harness ex-
tension coupler “d” and thermo switch
1
connectors (PORT) “e”.
a
b
17. Remove the engine temperature sensor
coupler “f” from the wire harness guide,
and then disconnect the engine tempera- 1
ture sensor coupler. 3 c

18. Disconnect the OCV coupler (PORT) “g” 2

and fuel injector couplers (PORT) “h”.

19. Remove the plastic ties “2”, and then re-

move the fuel injector lead from the hold-
ers “3”. 23. Remove the fuse box “1” and then discon-
nect the fuse box couplers “a”, “b”, “c” and
PORT f e “d”.
1 a
b g
h 1
c

d
a 3
d c b

h
2 24. Remove the plastic tie “1”, and then re-
move the holders “2” on the wire harness
20. Remove the plastic tie “1”, and then dis- from the wire harness guide.
connect the thermo switch connectors
2
(STBD) “a”.

21. Disconnect the OCV coupler (STBD) “b”

and fuel injector couplers (STBD) “c”.

22. Remove the fuel injector lead from the

holders “2” and “3”.

2 2

7-23
 Wire harness
25. Remove the thermo switch lead and en- 30. Disconnect the ground lead terminals “1”
gine temperature sensor lead from the and “2” and brown lead of the wire harness
holder “1” on the wire harness guide, and “3”, and then remove the cap “4”.
then remove the wire harness guide “2”.
31. Remove the plastic ties “5”.

32. Remove the rectifier/regulator protector

“6”, and then remove the holder “7” on the
wire harness from the junction box.
1
33. Disconnect the APS coupler “a”.

2
5

3
4
26. Remove the intake air temperature sensor 1
lead from the holder “1”. 5

27. Disconnect the throttle body assembly 6

wire harness extension coupler “a” and
ETV coupler “b”.

28. Remove the wire harness “2” from the

holders “3”. 7 a 2

a 1
34. Disconnect the oil pressure sensor coupler
“a” and water detection switch coupler “b”.
2
35. Remove the plastic tie “1”, and then re-
3
move the wire harness from the holder “2”.

29. Disconnect the PTT relay coupler “1”.

1
a
1
2
b

36. Remove the wire harness.

7-24
 Wire harness

Installing the wire harness

To install all of the wire harness, see “Wiring
harness routing” (5-7).

1. Connect the oil pressure sensor coupler 7

“a” and water detection switch coupler “b”.
4
2. Install the wire harness at the white tape 3
“c” to the holder “1”, and then fasten the 6
wire harness using the plastic tie “2”. 7
2

2
a
2

1 1 a 5

c 1
8. Connect the PTT relay coupler “1”.

1
b

3. Connect the APS coupler “a”.

4. Install the holder “1” on the wire harness to

the junction box, and then install the recti-
fier/regulator protector “2”.

5. Install the cap “3” to the starter motor lead 9. Fasten the wire harness “1” using the hold-
and brown lead of the wire harness “4”, ers “2”.
and then connect them together.
10. Connect the throttle body assembly wire
6. Connect the ground lead terminals “5” and harness extension coupler “a” and ETV
“6”. coupler “b”.

7. Fasten the rectifier/regulator lead and wire 11. Fasten the intake air temperature sensor
harness using the plastic ties “7”. lead using the holder “3”.

a 3

1
2

7-25
 Wire harness
12. Install the wire harness guide “1”, and then 1 a
install the thermo switch lead and engine
temperature sensor lead to the holder “2”
on the wire harness guide.

Fold the engine temperature sensor lead “3”

and route it through the hole “4” in the wire har-
ness guide. d c b

3 15. Connect the fuel injector couplers (STBD)

“a” and OCV coupler (STBD) “b”.
4
16. Fasten the fuel injector lead to the holders
1 “1” and “2”, and then fasten the fuel injector
lead using the plastic tie “3”.

17. Connect the thermo switch connectors

(STBD) “c”, and then fasten the thermo
switch connectors and wire harness using
the plastic tie “4”.

2 STBD

13. Install the holders “a” on the wire harness 4

to the wire harness guide in the order [1], c
[2], and so on, and then fasten the wire b
harness using the plastic tie “1”.
3
a
2 a

[1] 1

18. Connect the fuel injector couplers (PORT)

[2] “a” and OCV coupler (PORT) “b”.
[3]
a
19. Install the fuel injector lead to the holder
a “1”, and then fasten the fuel injector lead
1 using the plastic ties “2”.

14. Connect the fuse box couplers “a”, “b”, “c” 20. Connect the engine temperature sensor
and “d”, and then install the fuse box “1”. coupler “c”, and then install the engine
temperature sensor coupler to the wire
harness guide.

7-26
 Wire harness
21. Connect the thermo switch connectors 5 [1] 1 2
(PORT) “d” and vapor separator wire har- 6
ness extension coupler “e”, and then fas-
[3] 4
ten the thermo switch connectors, vapor
separator wire harness extension, and 5 3
wire harness using the holder “3”. [2]
4
22. Install the fuse box “f” and YDIS coupler “g” 3
5
to the bracket.

23. Connect the low-pressure fuel pump cou- 4

pler “h”, and then install the low-pressure
fuel pump coupler to the wire harness
guide. 5 5

PORT c d 27. Connect the cam position sensor coupler

“a” and ignition coil couplers “b”.
g
b
a 3 28. Install joint coupler 1 “c” to the wire har-
f ness guide.

2 29. Connect the knock sensor coupler “d”, and

then install the knock sensor coupler to the
e engine ECM bracket.
h 1
30. Connect the engine ECM couplers “e”.
a
2 31. Install the engine ECM “1”, and then tight-
en the engine ECM bolts “2” to the speci-
24. Fasten the wire harness “1” using the hold- fied torque.
ers “2” and “3” on the engine ECM bracket. c 2
25. Install the holders “4” on the wire harness
to the engine ECM bracket and fasten the
wire harness using the plastic ties “5”. b
a
26. Install the cam position sensor lead (PORT e
IN) to the holder “6”. b
b
1
b b
Make sure to install the holder “4” and plastic
ties “5” in the order [1], [2], and so on.
b
a
d 2

Engine ECM bolt “2”

7 Nm (0.7 kgf·m, 5.2 ft·lb)
T.
R.

32. Install the relays and relay holder. See

“Relay” (7-37).

7-27
 Wire harness
33. Install the fuel hoses and fuel rail covers.
See steps 7 and 9 in “Installing the fuel in-
jector” (6-40).

34. Connect the quick connectors. See “Con-

necting the quick connector” (6-2).

35. Install the intake manifold (PORT). See

“Installing the intake manifold” (6-13).

36. Install the intake silencer, and then con-

nect the air temperature sensor coupler
and blowby hose. See “Installing the intake
silencer” (6-14).

7-28
 Fuse box

Fuse box

2 Nm (0.2 kgf·m, 1.5 ft·lb)

9
9

1 2 5
A
7
4
8

4 5

6
7
3
A

No. Part name Q’ty Remarks

1 Fuse box assembly 1
2 Cover 1
3 Fuse puller 1
4 Fuse 3 60 A, spare is included.
5 Fuse 2 10 A, spare is included.
6 Fuse 2 20 A, spare is included.
7 Fuse 3 30 A, spare is included.
8 Screw 5 M3  10 mm
9 Screw 4 M5  19 mm

7-29
 Junction box

Junction box

4 Nm (0.4 kgf·m, 3.0 ft·lb)

1
3
3
4
2 22
24 5
25 23 6
5 6

18 10
6
17 11
23 5
25 24 22 12
26 8
19
13 7
20 3 4
22
9
16 6 Nm (0.6 kgf·m, 4.4 ft·lb)
21 14
15 13 12 Nm (1.2 kgf·m, 8.9 ft·lb)
3 Nm (0.3 kgf·m, 2.2 ft·lb)

20 6 Nm (0.6 kgf·m, 4.4 ft·lb)

3 12 Nm (1.2 kgf·m, 8.9 ft·lb)

No. Part name Q’ty Remarks

1 Junction box 1
2 PTT relay 1
3 Bolt 6 M6  30 mm
4 Plastic tie 4
5 Grommet 6
6 Collar 6
7 Plastic tie 2
8 Bolt 4 M6  25 mm
9 Holder 1
10 Cover 1
11 Anode 1
12 Screw 1 M4  12 mm
13 Clip 3
14 Plastic tie 1
15 Hose 1 Joint to rectifier/regulator
16 Hose 1 Rectifier/regulator to join
17 Gasket 1 Not reusable

7-30
 Junction box

4 Nm (0.4 kgf·m, 3.0 ft·lb)

1
3
3
4
2 22
24 5
25 23 6
5 6

18 10
6
17 11
23 5
25 24 22 12
26 8
19
13 7
20 3 4
22
9
16 6 Nm (0.6 kgf·m, 4.4 ft·lb)
21 14
15 13 12 Nm (1.2 kgf·m, 8.9 ft·lb)
3 Nm (0.3 kgf·m, 2.2 ft·lb)

20 6 Nm (0.6 kgf·m, 4.4 ft·lb)

3 12 Nm (1.2 kgf·m, 8.9 ft·lb)

No. Part name Q’ty Remarks

18 Bolt 2 M6  25 mm
19 Rectifier/regulator 1
20 Bolt 2 M6  35 mm
21 Protector 1
22 Bolt 3 M6  16 mm
23 Washer 2
24 Nut 2
25 Cap 2
26 Ground lead 1

7-31
 Junction box

Removing the rectifier/regulator

1. Remove the rectifier/regulator protector
“1”. Do not apply grease, oil, or paint to the an-
odes.
2. Disconnect the cooling water hoses “2”
and “3”.
Removing the junction box
1. Remove the caps “1”, and then disconnect
3. Disconnect the rectifier/regulator ground
the PTT relay terminals “2”.
lead “4”.
2. Disconnect the PTT relay coupler “a”.
4. Remove the plastic ties “5”, and then re-
move the rectifier/regulator leads.
3. Remove the PTT relay “3”.
5. Remove the rectifier/regulator couplers “a”
4. Disconnect the junction box wire harness
from the junction box.
extension terminal “4” and ground lead ter-
minal “5”.
6. Remove the rectifier/regulator “6”.
5. Remove the plastic ties “6”.

6. Remove the holder “7” on the wire harness

4 from the junction box “8”.
5
a 7. Remove the junction box “8”.
1
2 a
6 5
3 6
1
2
2
3 8
7
7. Remove the cover “1” and gasket “2” from
the rectifier/regulator.
4
4 5
8. Remove the anode “3” from the cover.
5
3
2
Installing the junction box
1. Install the junction box “1”.
1 2. Install the holder “2” on the wire harness to
the junction box “1”.

3. Fasten the wire harness using the plastic

ties “3”.
Checking the rectifier/regulator anode
1. Check the anode. Replace if eroded. 4. Install the ground lead terminal “4” and
Clean if there is grease, oil, or scales. junction box wire harness extension termi-
nal “5”.

7-32
 Junction box
5. Install the PTT relay “6”.
Anode screw “3”
6. Connect the PTT relay coupler “7”. 3 Nm (0.3 kgf·m, 2.2 ft·lb)

T.
R.
Rectifier/regulator cover bolt “5”
7. Connect the PTT relay terminals “8”, and 1st: 6 Nm (0.6 kgf·m, 4.4 ft·lb)
then tighten the PTT relay terminal nuts “9” 2nd: 12 Nm (1.2 kgf·m, 8.9 ft·lb)
to the specified torque.
3. Install the rectifier/regulator “1”, and then
8. Install the caps “10”. tighten the rectifier/regulator bolts “2” to
9
6 8 7 the specified torques in 2 stages.
8

8 4. Install the rectifier/regulator couplers “a” to

10 3
the junction box.
9

10 5. Connect the rectifier/regulator ground lead

“3”.
1
2 6. Fasten the rectifier/regulator leads using
the plastic tie “4”.
4
4
5 7. Connect the cooling water hoses “5” and
5 “6”.

8. Install the rectifier/regulator protector “7”.

PTT relay terminal nut “9”
4 Nm (0.4 kgf·m, 3.0 ft·lb)
To fasten the rectifier/regulator leads, see “Wir-
T.
R.

ing harness routing” (5-7).

Installing the rectifier/regulator
1. Install the anode “1” to the cover “2”, and
then tighten the anode screw “3” to the
specified torque. 2
3
2. Install the gasket “4” and cover “2” to the 4
rectifier/regulator, and then tighten the rec- a
tifier/regulator cover bolts “5” to the speci-
1
fied torques in 2 stages. 4
7
1
3
4 5
6

5 2
2

Rectifier/regulator bolt “2”

1st: 6 Nm (0.6 kgf·m, 4.4 ft·lb)
T.
R.

2nd: 12 Nm (1.2 kgf·m, 8.9 ft·lb)

7-33
 Starter motor and APS

Starter motor and APS

14

3 4

11 9 6
12

5
8 7
10
13
26 Nm (2.6 kgf·m, 19.2 ft·lb)

No. Part name Q’ty Remarks

1 Starter motor 1
2 Bolt 3 M8  45 mm
3 Nut 1
4 Holder 2
5 Plastic tie 2
6 Bolt 1 M8  16 mm
7 Terminal 1
8 Bolt 1 M8  20 mm
9 Terminal stud bolt 1
10 APS 1
11 Collar 3
12 Grommet 3
13 Bolt 3 M6  35 mm
14 Bolt 1 M6  16 mm

7-34
 Starter motor and APS

Removing the starter motor

1. Disconnect the starter motor lead “1”, and
then remove the plastic ties “2” and hold-
ers “3”.

3 1

Checking the APS

2
1. Check the APS exterior. Replace if
cracked.

2. Remove the junction box wire harness ex- 2. Check the electrical performance of the
tension terminal “1”, and then remove the APS. See “Checking the APS” (5-26).
starter motor “2”.
Installing the APS
3. Remove the junction box wire harness ex- 1. Install the APS “1”.
tension terminal “3”, terminal “4”, and ter-
minal stud bolt “5”.

1
3
5 4 Installing the starter motor
1. Install the terminal “1”, junction box wire
Removing the APS harness extension terminal “2”, and termi-
1. Remove the APS “1”. nal stud bolt “3”, and then tighten the termi-
nal stud bolt to the specified torque.

7-35
 Starter motor and APS
2. Install the starter motor “4”, and then install
the junction box wire harness extension
terminal “5”.

2
3 1

Terminal stud bolt “3”

26 Nm (2.6 kgf·m, 19.2 ft·lb)
T.
R.

3. Connect the starter motor lead “1” and

brown lead of the wire harness, and then
fasten the starter motor lead using the
holders “2” and plastic ties “3”.

To fasten the starter motor lead, see “Wiring

harness routing” (5-7).

7-36
 Relay

Relay

1
9 10

1
6

7 8 1
10
7

5 7
1
4
1 2

1
3

No. Part name Q’ty Remarks

1 Screw 7 M6  19 mm
2 Main relay 2 1
3 Main relay 1 1
4 ETV relay 1
5 Fuel pump relay 1
6 Starter relay 1
7 Bolt 3 M6  20 mm
8 Bracket 1
9 Holder 1
10 Bracket 2

7-37
 Engine ECM

Engine ECM

5
3

6
7

4
6
7
12
7 Nm (0.7 kgf･m, 5.2 ft･lb)
11 7
1 8

6
7
9

10 11 8 9
2 8 11

No. Part name Q’ty Remarks

1 Engine ECM 1
2 Bolt 4 M6  20 mm
3 Plastic tie 2
4 Holder 1
5 Bracket 1
6 Collar 4
7 Grommet 4
8 Bolt 4 M6  28 mm
9 Holder 2
10 Holder 1
11 Holder 3
12 Holder 1

7-38
 Engine ECM

Removing the engine ECM

1. Remove the engine ECM “1”.

2. Remove the knock sensor lead “2” from

the holder “3”.

2 3

Installing the engine ECM

1. Fasten the knock sensor lead “1” using the
holder “2”.

2. Install the engine ECM “3”, and then tight-

en the engine ECM bolts “4” to the speci-
fied torque.

4
1 2

Engine ECM bolt “4”

7 Nm (0.7 kgf·m, 5.2 ft·lb)
T.
R.

7-39
 Cylinder head cover

Cylinder head cover

2 Nm (0.2 kgf㺃m, 1.5 ft㺃lb)
5

6
2 4
1
4
13
3

1 7
11 12 8 9
10 15
12 8 Nm (0.8 kgf·m, 5.9 ft·lb) 14
11
10 8 Nm (0.8 kgf·m, 5.9 ft·lb)

11 12
10

12
25 Nm (2.5 kgf㺃m, 18.4 ft㺃lb) 11
12
7 Nm (0.7 kgf㺃m, 5.2 ft㺃lb) 10 11 7
12 17
10 4 16
11
2
20 18
10
19 1
23 Nm (2.3 kgf㺃m, 17.0 ft㺃lb)

No. Part name Q’ty Remarks

1 Bolt 3 M6  20 mm
Cam position sensor (PORT EX/STBD
2 2
IN)
3 Cam position sensor (PORT IN) 1
4 O-ring 3 Not reusable
5 Bolt 1 M6  12 mm
6 Holder 1
7 Bolt 28 M6  30 mm
8 Cylinder head cover (PORT) 1
9 Gasket 1 Not reusable
10 Bolt 12 M6  20 mm
11 Ignition coil 6
12 Spark plug 6
13 Screw 8 M4  8 mm
14 Plate 1
15 Gasket 1 Not reusable
16 Cylinder head cover (STBD) 1

7-40
 Cylinder head cover

2 Nm (0.2 kgf㺃m, 1.5 ft㺃lb)

5

6
2 4
1
4
13
3

1 7
11 12 8 9
10 15
12 8 Nm (0.8 kgf·m, 5.9 ft·lb) 14
11
10 8 Nm (0.8 kgf·m, 5.9 ft·lb)

11 12
10

12
25 Nm (2.5 kgf㺃m, 18.4 ft㺃lb) 11
12
7 Nm (0.7 kgf㺃m, 5.2 ft㺃lb) 10 11 7
12 17
10 4 16
11
2
20 18
10
19 1
23 Nm (2.3 kgf㺃m, 17.0 ft㺃lb)

No. Part name Q’ty Remarks

17 Adapter 1
18 Gasket 1 Not reusable
19 Plug 1 M14  12 mm
20 Bolt 2 M6  30 mm

7-41
 Cylinder head cover

Removing the cylinder head cover

1. Remove the ignition coils “1”, spark plugs
a
“2”, cam position sensors “3” and “4”, and
adapter “5”, and then remove the cylinder
head covers “6” and “7”.

4 6
2. Check the spark plug. Replace if the elec-
1 trodes are eroded, edges of electrodes are
2 rounded, insulator is damaged, or there is
1
carbon or other deposits.
1
3. Check the spark plug gap “a”. Adjust if out
of specification.
2
5
1 7 a

2. Remove the cylinder head cover plate “1”

from the cylinder head cover (STBD) “2”.

Spark plug (NGK)

LFR6A-11
Spark plug gap
1.0–1.1 mm (0.039–0.043 in)
1
Installing the cylinder head cover
2
When the timing belt is not installed, do not
turn the crankshaft, driven sprocket or VCT
assembly. Otherwise, the pistons and
valves could collide with each other and be
Checking the spark plug damaged.
1. Clean the electrodes “a” using a spark plug
cleaner.

7-42
 Cylinder head cover
1. Install the cylinder head cover plate “1” to
the cylinder head cover (STBD) “2”, and Cylinder head cover bolt “5”
then tighten the cylinder head cover plate 1st: 8 Nm (0.8 kgf·m, 5.9 ft·lb)

T.
R.
screws “3” to the specified torque. 2nd: 8 Nm (0.8 kgf·m, 5.9 ft·lb)
3
4. Install the adapter “1”.

5. Install a new gasket “2” and the adapter

plug “3”, and tighten the adapter plug to
the specified torque.

6. Connect the cooling water hose “4”, and

then fasten it using the clamp “5”.

7. Install new O-rings “6” and the cam posi-

1
tion sensors “7” and “8”.
2 6
7

6
Cylinder head cover plate screw “3”
2 Nm (0.2 kgf·m, 1.5 ft·lb)
T.
R.

8
2. Install new gaskets “1” and “2” to the cylin-
der head covers “3” and “4”.
4 5 1
3. Tighten the cylinder head cover bolts “5”
twice to the general tightening torque. 6
2 7
3

Adapter plug “3”

23 Nm (2.3 kgf·m, 17.0 ft·lb)
T.
R.

8. Install the spark plugs, and then tighten

them to the specified torque.

Spark plug
25 Nm (2.5 kgf·m, 18.4 ft·lb)
T.
R.

1280B
1280B 9. Install the ignition coils, and then tighten
the ignition coil bolts to the specified
torque.

Ignition coil bolt

7 Nm (0.7 kgf·m, 5.2 ft·lb)
T.
R.

5 2 5
1
4 3

7-43
 Timing belt

Timing belt

39 Nm (3.9 kgf·m, 28.8 ft·lb)

39 Nm (3.9 kgf·m, 28.8 ft·lb)
1

2 3
7
9 7
4

5
8 3

6
4

No. Part name Q’ty Remarks

1 Timing belt 1
2 Timing belt tensioner 1
3 Bolt 2 M10  55 mm
4 Washer 2
5 Pulley 2
6 Collar 2
7 Bolt 4 M6  14 mm
8 Guide (PORT) 1
9 Guide (STBD) 1

7-44
 Timing belt

Removing the timing belt

When the timing belt is not installed, do not

turn the crankshaft, driven sprocket or VCT
assembly. Otherwise, the pistons and
valves could collide with each other and be
damaged.

d
1. Disconnect the intake air temperature sen- c
sor coupler, and then remove the blowby
hose and intake silencer. See “Removing b
the intake silencer” (6-12). a

2. Remove the intake manifold (PORT). See

“Removing the intake manifold” (6-12).

3. Disconnect the quick connectors. See

steps 3–5 in “Disconnecting the quick con- 8. Remove the timing belt guides “1”.
nector” (6-1).
1 1
4. Remove the fuel hoses and fuel rail cov-
ers. See steps 2 and 3 in “Removing the
fuel injector” (6-39).

5. Remove the wire harness guide. See

steps 6–25 in “Removing the wire har-
ness” (7-22).

6. Align the “” mark “a” on the drive sprock-

et with the “” mark “b” on the cylinder 9. Hold the timing belt tensioner, applying a
block. torque of 15 Nm (1.5 kgf·m, 11.1 ft·lb) or
less clockwise, using a hexagon wrench
7. Check that the “II” marks “c” on the VCT for 20 seconds, and then insert a 5.0 mm
assembly (PORT) and driven sprocket (0.2 in) diameter pin “1” into the hole “a”.
(PORT) are aligned, and check that the “I”
marks “d” on the VCT assembly (STBD)
and driven sprocket (STBD) are aligned. Do not turn the timing belt tensioner by ap-
plying a torque higher than 15 Nm (1.5
kgf·m, 11.1 ft·lb). Otherwise, the timing belt
tensioner could be damaged.

7-45
 Timing belt

Installing the timing belt

Leave the pin “1” inserted into the hole “a” of
the timing belt tensioner until the timing belt is When the timing belt is not installed, do not
installed again. turn the crankshaft, driven sprocket or VCT
assembly. Otherwise, the pistons and
valves could collide with each other and be
damaged.

1
1. Install the timing belt tensioner “1”, collar
“2”, and pulley “3”, and then tighten the tim-
ing belt tensioner bolt “4” and pulley bolt
“5” to the specified torque.
a
4 5

10. Remove the timing belt “1” from the driven

sprocket (PORT) or driven sprocket
1 3
(STBD), and then remove it from the
crankshaft.
2
1

Timing belt tensioner bolt “4”

11. Remove the timing belt tensioner “1” and 39 Nm (3.9 kgf·m, 28.8 ft·lb)
T.
R.

pulleys “2” and “3”. Pulley bolt “5”

39 Nm (3.9 kgf·m, 28.8 ft·lb)

2. Install the timing belt “1” onto the crank-

shaft so that part number “a” is in the up-
1 right position and the belt position mark “b”
is aligned with the “ ” mark “c” on the
3
crankshaft.
2

Do not apply grease or oil to the timing belt.

Checking the timing belt

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

7-46
 Timing belt

Before installing the timing belt, make sure that d c b a

the marks on the crankshaft and cylinder block
are aligned. Also, make sure that the marks on 6P2-462**-**
the VCT assemblies and driven sprockets are
aligned. See steps 6 and 7 in “Removing the
timing belt” (7-45). 0123 60 88 133 160 A

1
A. Belt teeth number

4. Install the collar “1”, push the timing belt in-

a
ward using the pulley “2”, and then install
the pulley.

Make sure that the pulley “2” is installed

properly onto the collar “1”.

5. Install the washer, and then tighten the

c pulley bolt “3” to the specified torque.

b
When installing the pulley, make sure to keep
the belt position marks and the “” marks
aligned as specified in step 3.
3. Install the timing belt onto the VCT assem-
blies and driven sprockets by aligning belt 3
position marks “a”, “b”, “c”, and “d” with the
“” marks in the order listed.
2

b c

Pulley bolt “3”

39 Nm (3.9 kgf·m, 28.8 ft·lb)
T.
R.

a d

7-47
 Timing belt
6. Adjust the timing belt installation height “a”
1 1
to specification.

6P2-462**-**

10. Turn the crankshaft clockwise 2 full turns

until the marks “a” and “b” are aligned, and
then check that the marks “c” and “d” on
Timing belt installation height “a” the VCT assemblies and driven sprockets
2.0 mm (0.08 in) are aligned.

7. While holding the timing belt tensioner ap-

plying a torque of 15 Nm (1.5 kgf·m, 11.1
ft·lb) or less clockwise using a hexagon
wrench, remove the pin “1”.

Do not turn the timing belt tensioner by ap-

plying a torque higher than 15 Nm (1.5
kgf·m, 11.1 ft·lb). Otherwise, the timing belt
d
tensioner could be damaged. c
b

Make sure that the belt position marks are a

aligned with the marks. See steps 2 and 3.

8. Turn the timing belt tensioner gradually

counterclockwise until the timing belt is
taut.

9. Install the timing belt guides “1”.

7-48
 Timing belt
11. Adjust the timing belt guide clearance “a”.

Timing belt guide clearance “a”

0.5–1.5 mm (0.02–0.06 in)

12. Install the wire harness guide. See steps

12–30 in “Installing the wire harness”
(7-25).

13. Install the fuel hoses and fuel rail covers.

See steps 7 and 9 in “Installing the fuel in-
jector” (6-40).

14. Connect the quick connectors. See “Con-

necting the quick connector” (6-2).

15. Install the intake manifold (PORT). See

“Installing the intake manifold” (6-13).

16. Install the intake silencer, and then con-

nect the air temperature sensor coupler
and blowby hose. See “Installing the intake
silencer” (6-14).

7-49
 Camshaft

Camshaft
7 32 Nm (3.2 kgf㺃m, 23.6 ft㺃lb)
8
8 Nm (0.8 kgf·m, 5.9 ft·lb) 9 10
17 Nm (1.7 kgf·m, 12.5 ft·lb)

11 14
12 15
2 17
4
1 4 17
12
11
3
13 17
6 60 Nm (6.0 kgf㺃m, 44.3 ft㺃lb)
10 7
5
14 8 17
16
6 15 9 60 Nm (6.0 kgf㺃m, 44.3 ft㺃lb)
11
4 12 10

8 Nm (0.8 kgf·m, 5.9 ft·lb)

11
19 12
17 Nm (1.7 kgf·m, 12.5 ft·lb)
20
21 18
21
8 Nm (0.8 kgf·m, 5.9 ft·lb) 22
17 Nm (1.7 kgf·m, 12.5 ft·lb) 6

6
5 5

No. Part name Q’ty Remarks

1 Bolt 6 M7  48 mm
2 Camshaft cap 1
3 Camshaft cap 1
4 Dowel 6
5 Bolt 26 M7  37 mm
6 Camshaft cap 13
7 Cap 2
8 Gasket 2 Not reusable
9 VCT bolt 2 M12  35 mm
10 VCT assembly 2
11 Oil seal 4 Not reusable
12 Dowel 4
13 Camshaft (PORT IN) 1
14 Bolt 2 M10  35 mm
15 Driven sprocket 2
16 Camshaft (PORT EX) 1
17 Valve lifter 24

7-50
 Camshaft

7 32 Nm (3.2 kgf㺃m, 23.6 ft㺃lb)

8
8 Nm (0.8 kgf·m, 5.9 ft·lb) 9 10
17 Nm (1.7 kgf·m, 12.5 ft·lb)

11 14
12 15
2 17
4
1 4 17
12
11
3
13 17
6 60 Nm (6.0 kgf㺃m, 44.3 ft㺃lb)
10 7
5
14 8 17
16
6 15 9 60 Nm (6.0 kgf㺃m, 44.3 ft㺃lb)
11
4 12 10

8 Nm (0.8 kgf·m, 5.9 ft·lb)

11
19 12
17 Nm (1.7 kgf·m, 12.5 ft·lb)
20
21 18
21
8 Nm (0.8 kgf·m, 5.9 ft·lb) 22
17 Nm (1.7 kgf·m, 12.5 ft·lb) 6

6
5 5

No. Part name Q’ty Remarks

18 Camshaft (STBD IN) 1
19 Camshaft (STBD EX) 1
20 Camshaft cap 1
21 Bolt with seal washer 4 Not reusable M7  48 mm
22 Bolt 1 M6  30 mm

7-51
 Camshaft

Removing the driven sprocket and

camshaft POR
PORT

When the timing belt is not installed, do not

turn the crankshaft or camshafts. Other-
wise, the intake and exhaust valves could
collide with each other or with the pistons
and be damaged. a

1. Align the “” mark “a” on the drive sprock- 3. Secure the VCT assembly using the spe-
et with the mating surface of the crankcase cial service tool “1”, and then remove the
and cylinder block by turning the crank- VCT caps “2”.
shaft counterclockwise 60 gradually.

• When removing the VCT cap, do not se-

Do not turn the crankshaft counterclock- cure the camshaft. Otherwise, the VCT as-
wise more than 60. Otherwise, the pistons sembly could be damaged.
and valves could collide with each other • When removing the VCT cap, do not turn
and be damaged. the VCT assembly. Otherwise, the intake
and exhaust valves could collide with
each other and be damaged.
STBD PORT

2
2

2. Check that the “I” marks “a” on the VCT as-

sembly (PORT) and driven sprocket
(PORT) are aligned.
Sheave holder “1”
90890-01701
Be careful when turning the VCT assemblies
and driven sprockets. Depending on the posi- 4. Remove the special service tool.
tion of the camshafts, the force of the valve
springs may cause the VCT assemblies and
driven sprockets to be rotated too far.

7-52
 Camshaft
5. Secure the intake camshaft using a
PORT STBD
wrench, and then remove the VCT assem-
1 2 3 [1]
blies “1”.
[1] [1]
[3] [4]
• When removing the VCT bolt, do not se- [3] [3]
cure the VCT assembly. Otherwise, the
[2] [3]
VCT assembly could be damaged. [2] [2]
• When removing the VCT assembly, do not
turn the intake camshaft. Otherwise, the [4] [5]
intake and exhaust valves could collide [4] [4]
with each other and be damaged. 4 [2]

4
1
1 8. Remove the camshafts “1”, “2”, “3”, and “4”
and oil seals “5”, and then remove the
valve lifters “6”.

Make sure to keep the parts in the order as

they were removed.

6. Secure the exhaust camshaft using a 5

wrench, and then remove the driven
sprockets “1”. 6

When removing the driven sprocket, do not 4

turn the exhaust camshaft. Otherwise, the
intake and exhaust valves could collide 5
with each other and be damaged.
3
2
1 1 1

Checking the sprocket

1. Check the VCT assemblies and driven
7. Loosen the camshaft cap bolts gradually in sprockets. Replace the VCT assembly or
several stages and in the order [1], [2], and driven sprocket if cracked, damaged, or
so on, and then remove the camshaft caps worn.
“1”, “2”, “3”, and “4”. Take precaution not to
tilt the camshafts.
Checking the valve lifter
1. Check the valve lifters. Replace if dam-
aged, scratched, or worn.

7-53
 Camshaft
2. Measure the valve lifter outside diameter
“a”.

a
Cam lobe height IN
46.311–46.411 mm (1.8233–
Outside diameter 1.8272 in)
30.970–30.980 mm (1.2193– Limit
1.2197 in) 46.261 mm (1.8213 in)
Cam lobe height EX
Checking the camshaft 45.360–45.460 mm (1.7858–
1. Check the edges and faces of the flanges 1.7898 in)
on the camshafts (PORT) and intake cam- Limit
shaft (STBD) is used for detection by the 45.310 mm (1.7839 in)
cam position sensor. Replace the cam-
shaft if damaged, rough, or scratched. 3. Measure the camshaft runout. Replace if
above specification.

• Be careful not to scratch or damage the face

of the flange.
• If there is a scratch that is more than 0.2 mm
(0.008 in) deep or more than 0.5 mm (0.020
in) wide on the surface of the flange, an error
may occur in the cam position sensor signal.

Camshaft runout
0.030 mm (0.0012 in)

Checking the camshaft journal oil

clearance
1. Place the camshafts on the cylinder head.

2. Measure the cam lobe height “a”.

7-54
 Camshaft
2. Place a piece of Plastigauge (PG-1) “1” on
each camshaft journal, parallel to the cam- 5 PORT 4 STBD 2
shaft. 5P
6S 1S
1P
7S 2S
Do not place the Plastigauge (PG-1) over
2P 6P
the oil hole in each camshaft journal. 8S 3S
3P 7P

1 9S 4S
4P 8P
5S
3
3

5. Tighten the camshaft cap bolts “1”, “2” and

“3” to the specified torques in 2 stages and
in the order [1], [2], and so on.
3. Install the collars “1” and camshaft caps
6. Tighten the camshaft cap bolt “4” to the
“2”, “3”, “4” and “5” in their proper positions
general tightening torque.
so that the stamped numbers are upside
down.
Do not turn the camshafts when measuring the
4. Install the camshaft cap bolts “6”, “7”, “8” camshaft journal oil clearance using the Plasti-
and “9”. gauge.
5
1 PORT [4] STBD [5]
[4] [4]
8 4
4
3 2
1
9 3 [2] [2]
[2] [2] 2
2 1
[3] [3]
[3] [3]
7 [1]
7 [1]
6 [1] [1]

9 3 9 3 3 [4]

Camshaft cap bolts “1”, “2” and “3”

1st: 8 Nm (0.8 kgf·m, 5.9 ft·lb)
T.
R.

2nd: 17 Nm (1.7 kgf·m, 12.5 ft·lb)

7-55
 Camshaft
7. Remove the camshaft caps, and then 2. Install the camshaft caps “1”. See steps 3–
measure the width of the Plastigauge “1”. 5 in “Checking the camshaft journal oil
Check the camshaft journal outside diam- clearance” (7-54).
eter and cylinder head journal inside diam-
eter if the oil clearance is out of 3. Measure the camshaft journal inside diam-
specification. See “Checking the camshaft eter “a”. Replace the cylinder head and
journal outside diameter and camshaft camshaft cap as a set if the cylinder head
journal inside diameter” (7-56). journal inside diameter is above specifica-
tion.
1
1

a
Camshaft journal oil clearance
0.020–0.061 mm (0.0008–0.0024
in)
Limit
0.080 mm (0.0032 in)
Journal inside diameter
Checking the camshaft journal out- 25.000–25.021 mm (0.9843–
side diameter and camshaft journal in- 0.9851 in)
side diameter
1. Measure the camshaft journal outside di- Installing the camshaft and driven
ameter “a”. Replace the camshaft if the sprocket
camshaft journal outside diameter is below If the valve clearances are adjusted or any
specification. parts related to valve movement are replaced
after installing the timing belt, check the valve
a clearances. See “Checking the valve clear-
ance” (7-2).

When the timing belt is not installed, do not

turn the crankshaft or camshaft. Otherwise,
the pistons and valves could collide with
a
each other and be damaged.

Journal diameter
24.960–24.980 mm (0.9827–
0.9835 in)

7-56
 Camshaft
1. Check that the “” mark “a” on the drive
sprocket is aligned with the mating surface
of the crankcase and cylinder block.
STBD 1
STBD PORT

a 2

2. Apply a thin, even coat of sealant to the

mating surface of the camshaft caps “1”
and cylinder heads “2”.

Do not block the oil passages or oil holes with 3. Install the valve lifters “1”, and then install
the sealant. the camshafts “2”, “3”, “4”, and “5” in the
proper positions and new oil seals “6”.

PORT
Install the valve lifters in their original positions.

1
1
PORT 6 STBD
2 6

5 6P2
6 S-IN
6P2
P-IN 1 2

6P2 6P2
P-EX S-EX
3
4

7-57
 Camshaft
4. Check that the camshaft dowel holes are 7. Tighten the camshaft cap bolts “1”, “2” and
in the proper position. “3” to the specified torques in 2 stages and
in the order [1], [2], and so on.
BOW
PORT STBD
Do not tighten the bolt “4” in this step.

PORT [4] STBD [5]

[4] [4]
4
2
1
AFT [2]
[2] [2] 2 [2]
5. Install the collars “1” and camshaft caps
“2”, “3”, “4”, and “5” in their proper positions [3] [3]
[3] [3]
and with the stamped numbers upside
down. [1] [1]
[1] [1]
6. Install the camshaft cap bolts “6”, “7”, “8”,
and “9”. 3 3 [4]
5
1
8 Camshaft cap bolts “1”, “2” and “3”
4 1st: 8 Nm (0.8 kgf·m, 5.9 ft·lb)
T.
R.

3 2nd: 17 Nm (1.7 kgf·m, 12.5 ft·lb)

9 3
2 1 8. Tighten the camshaft cap bolt “1” to the
general tightening torque.

PORT STBD 1
7
7
6

9 3 9

5 PORT 4 STBD 2
6S 1S
1P 5P
7S 2S
2P 6P
8S 3S
3P 7P
9S 4S 9. Install the dowels “1” and driven sprockets
4P 8P “2”.
5S
3
3

7-58
 Camshaft
10. Secure the exhaust camshaft using a
a
wrench, and then tighten the driven
sprocket bolts “3” to the specified torque.
3 2 b
1

3
2 STBD

2
Driven sprocket bolt “3”
60 Nm (6.0 kgf·m, 44.3 ft·lb) 1
T.
R.

11. Install the dowels “1” and VCT assemblies

“2”.
2
12. Secure the intake camshaft using a
3
wrench, and then tighten the VCT bolts “3”
to the specified torque.

When tightening the VCT bolt, do not se- VCT bolt “3”
cure the driven sprocket. Otherwise, the 60 Nm (6.0 kgf·m, 44.3 ft·lb)
VCT assembly could be damaged.
T.
R.

13. Check that the lower edges “a” and “b” of

the VCT assemblies and driven sprockets
Slightly turn the VCT assemblies in direction are aligned.
“a” to remove any free play “b” before tighten-
ing the VCT bolts “3”.

b
a a b

PORT

7-59
 Camshaft
14. Install a new gasket “1” and the VCT cap
“2”, and then tighten the VCT cap to the PORT
specified torque while securing the VCT
assembly using the special service tool
“3”.

When tightening the VCT cap, do not se-

cure the camshaft. Otherwise, the VCT as- a
sembly could be damaged.
16. Align the “” mark “a” on the drive sprock-
2 et with the “” mark “b” on the cylinder
block by turning the crankshaft clockwise
1
60° gradually.
2

Do not turn the crankshaft clockwise more

than 60. Otherwise, the pistons and valves
3 could collide with each other and be dam-
aged.

b
a

STBD PORT

Sheave holder “3”

90890-01701

VCT cap “2” S6P25480

32 Nm (3.2 kgf·m, 23.6 ft·lb)

T.

17. Check that the “I” marks “a” on the VCT as-
R.

15. Check that the “II” marks “a” on the VCT sembly (STBD) and driven sprocket
assembly (PORT) and driven sprocket (STBD) are aligned.
(PORT) are aligned.
STBD

Be careful when turning the VCT assembly and

driven sprocket. Depending on the position of
the camshafts, the force of the valve springs
may cause the VCT assembly and driven
sprocket to be rotated too far. a

7-60
 Exhaust cover

Exhaust cover

12

7
5
4
9
8

1 9
8
11
10
3
2
6 11
10

6 Nm (0.6 kgf·m, 4.4 ft·lb) 1

12 Nm (1.2 kgf·m, 8.9 ft·lb) 15

14
2.5 Nm (0.25 kgf·m, 1.84 ft·lb)
5 6
3 13
55 Nm (5.5 kgf·m, 40.6 ft·lb) 2

No. Part name Q’ty Remarks

1 Bolt 28 M6  50 mm
2 Plug 2 M18  17 mm
3 Gasket 2 Not reusable
4 Exhaust outer cover (PORT) 1
5 Gasket 2 Not reusable
6 Dowel 2
7 Exhaust inner cover (PORT) 1
8 Anode 2
9 Screw 2 M6  16 mm
10 Anode 2
11 Screw 2 M4  12 mm
12 Gasket 1 Not reusable
13 Exhaust outer cover (STBD) 1
14 Exhaust inner cover (STBD) 1
15 Gasket 1 Not reusable

7-61
 Exhaust cover

Removing the exhaust cover 2. Install the dowel “4” and new gaskets “5”
1. Loosen the exhaust cover bolts “1” in the and the exhaust covers “6” and “7”, and
order [1], [2], and so on, and then remove then tighten the exhaust cover bolts “8” to
the exhaust covers “2” and “3”. the specified torques in 2 stages and in the
order [1], [2], and so on.
1 1
[1]
[1] 3. Tighten the exhaust outer cover plugs “9”
[6] [5] to the specified torque.
[6] [5]
[10] [9] 6
5
[10] [9] 6 1
[14] [13]
[14] [13] 8 2 3
PORT [11] [12] STBD
[11] [12][7] [8] 1
[7] [8] [2]
[4]
[2] [4] [3]
[3] 3
4

2
2
1
2
7
5 4
8 7

8 [14]
[14]
[9]
[10]
1 [9] [10]
[5] [6]
[5] [6]
[1] [2]
3 [2]
PORT [1] [4] [3] STBD
[4] [3] [8]
3 [7]
[7] [13] 9
[8]
[11]
Checking the exhaust cover anode 9
[11]
[13]
1. Check the anodes. Replace if eroded. [12][12]
Clean if there is grease, oil, or scales. 8

Anode screw “3”

Do not apply grease, oil, or paint to the an-
3 Nm (0.3 kgf·m, 2.2 ft·lb)
odes.
T.
R.

Exhaust cover bolt “8”

1st: 6 Nm (0.6 kgf·m, 4.4 ft·lb)
Installing the exhaust cover 2nd: 12 Nm (1.2 kgf·m, 8.9 ft·lb)
1. Install the anodes “1” and “2”, and then Exhaust outer cover plug “9” (M18)
tighten the screws “3” to specified torque. 55 Nm (5.5 kgf·m, 40.6 ft·lb)

7-62
 Cylinder head

Cylinder head
*1 1 7 Nm (0.7 kgf㺃m, 5.2 ft㺃lb)
1 30 Nm (3.0 kgf㺃m, 22.1 ft㺃lb)
2 60 Nm (6.0 kgf㺃m, 44.3 ft㺃lb) 12 Nm (1.2 kgf㺃m, 8.9 ft㺃lb)
3 (* 2)
4 30 Nm (3.0 kgf㺃m, 22.1 ft㺃lb) 2 7 1
5 60 Nm (6.0 kgf㺃m, 44.3 ft㺃lb)
6 90°
28 3

2
7

3
31 4
7 9
5
5
27
8
30

6 32 11
29 7
32 10
21
26
20 25 14
24 19
23 18
1 14 Nm (1.4 kgf㺃m, 10.3 ft㺃lb)
17
2 28 Nm (2.8 kgf㺃m, 20.7 ft㺃lb) 22
13 15
12 16

No. Part name Q’ty Remarks

1 Bolt 6 M6  35 mm
2 OCV 2
3 Filter 2 Not reusable
4 Engine hanger (PORT) 1
5 Bolt 6 M6  18 mm
6 Gasket (PORT) 1 Not reusable
7 Dowel 4
8 Gasket (STBD) 1 Not reusable
9 Engine hanger (STBD) 1
10 Cylinder head (STBD) 1
11 Exhaust valve 12
12 Hose 1
13 Clip 1
14 Valve guide 24 Not reusable
15 Valve spring retainer 24

*1: Only the tightening torques for new cylinder head bolts are shown in the exploded diagram. For the
tightening torques when reusing the cylinder head bolts, see “Installing the cylinder head” (7-74).
*2: Loosen completely
7-63
 Cylinder head

*1 1 7 Nm (0.7 kgf㺃m, 5.2 ft㺃lb)

1 30 Nm (3.0 kgf㺃m, 22.1 ft㺃lb)
2 60 Nm (6.0 kgf㺃m, 44.3 ft㺃lb) 12 Nm (1.2 kgf㺃m, 8.9 ft㺃lb)
3 (* 2)
4 30 Nm (3.0 kgf㺃m, 22.1 ft㺃lb) 2 7 1
5 60 Nm (6.0 kgf㺃m, 44.3 ft㺃lb)
6 90°
28 3

2
7

3
31 4
7 9
5
5
27
8
30

6 32 11
29 7
32 10
21
26
20 25 14
24 19
23 18
1 14 Nm (1.4 kgf㺃m, 10.3 ft㺃lb)
17
2 28 Nm (2.8 kgf㺃m, 20.7 ft㺃lb) 22
13 15
12 16

No. Part name Q’ty Remarks

16 Valve cotter 48
17 Valve spring 24
18 Valve seal 24 Not reusable
19 Valve spring seat 24
20 Bolt 4 M8  40 mm
21 Anode assembly 4
22 Bolt 4 M6  20 mm
23 Gasket 4 Not reusable
24 Cover 4
25 Anode 4
26 Grommet 4
27 Intake valve 12
28 Cylinder head (PORT) 1
29 Bolt 2 M8  90 mm
30 Bolt 4 M8  55 mm

*1: Only the tightening torques for new cylinder head bolts are shown in the exploded diagram. For the
tightening torques when reusing the cylinder head bolts, see “Installing the cylinder head” (7-74).
*2: Loosen completely
7-64
 Cylinder head

*1 1 7 Nm (0.7 kgf㺃m, 5.2 ft㺃lb)

1 30 Nm (3.0 kgf㺃m, 22.1 ft㺃lb)
2 60 Nm (6.0 kgf㺃m, 44.3 ft㺃lb) 12 Nm (1.2 kgf㺃m, 8.9 ft㺃lb)
3 (* 2)
4 30 Nm (3.0 kgf㺃m, 22.1 ft㺃lb) 2 7 1
5 60 Nm (6.0 kgf㺃m, 44.3 ft㺃lb)
6 90°
28 3

2
7

3
31 4
7 9
5
5
27
8
30

6 32 11
29 7
32 10
21
26
20 25 14
24 19
23 18
1 14 Nm (1.4 kgf㺃m, 10.3 ft㺃lb)
17
2 28 Nm (2.8 kgf㺃m, 20.7 ft㺃lb) 22
13 15
12 16

No. Part name Q’ty Remarks

31 Bolt 16 M10  120 mm/T55
32 Water shut grommet 2

*1: Only the tightening torques for new cylinder head bolts are shown in the exploded diagram. For the
tightening torques when reusing the cylinder head bolts, see “Installing the cylinder head” (7-74).
*2: Loosen completely

7-65
 Cylinder head

Removing the cylinder head

1. Remove the fuel rails. See “Removing the 3 2
fuel injector” (6-39). 4
1
2. Remove the engine hangers “1”.

3. Remove the OCVs “2” and filters “3”.

3 5
2

4. Loosen the cylinder head bolts “1”, “2”, and

“3” in the order [1], [2], and so on, and then Disassembling the cylinder head
remove the cylinder heads “4” and gaskets 1. Remove the anode assemblies “1”.
“5”.

Do not scratch or damage the mating sur-

faces of the cylinder head and cylinder
block.

PORT STBD
3 3 1

[6] [7]
[7] [6]

(T55) [11]
[11]
[10] [10]
[9] [8]
[8] [9]
2
[5] [4]
[4] [5]
[3]
[2] [3]
1 [1] [2] [1] 1

7-66
 Cylinder head
2. Remove the intake and exhaust valves.
1

Make sure to keep the parts in the order of re-

moval.

3
Checking the cylinder head
1. Remove carbon deposits from the com-
bustion chambers, and then check the cyl-
inder head for damage and scratches.

2. Check the cylinder head warpage using a

straightedge “1” and a thickness gauge “2”
in 6 directions. Replace the cylinder head
if out of specification.

2
1

A. Conventional tool
B. New special service tool

Warpage limit
Valve spring compressor “1” 0.10 mm (0.0039 in)
90890-04019
Valve spring compressor “2”
90890-06689
Valve spring compressor attach-
ment “3”
90890-06320

3. Remove the valve seals “1”.

7-67
 Cylinder head

Checking the valve spring a

1. Measure the valve spring free length “a”.
Replace if below specification.

Margin thickness IN
a
0.50–0.90 mm (0.0197–0.0354
in)
Free length IN Margin thickness EX
48.08 mm (1.89 in) 0.90–1.30 mm (0.0354–0.0512
Limit in)
45.68 mm (1.80 in)
Free length EX 3. Measure the valve stem diameter “a”. Re-
48.08 mm (1.89 in) place if out of specification.
Limit
45.68 mm (1.80 in) a

2. Measure the valve spring tilt “a”. Replace if

above specification.

Diameter IN
5.477–5.492 mm (0.2156–0.2162
in)
Limit
5.447 mm (0.2144 in)
Tilt limit IN Diameter EX
1.7 mm (0.07 in) 5.464–5.479 mm (0.2151–0.2157
Tilt limit EX in)
1.7 mm (0.07 in) Limit
5.434 mm (0.2139 in)
Checking the valve
1. Check the valve face. Replace if pitted or
worn.

2. Measure the valve margin thickness “a”.

Replace if below specification.

7-68
 Cylinder head
4. Measure the valve stem runout. Replace if
out of specification. Valve stem to valve guide clearance
= valve guide inside diameter – valve
stem diameter
Clearance IN
0.012–0.045 mm (0.0005–0.0018
in)
Limit
0.070 mm (0.0028 in)
Clearance EX
0.025–0.058 mm (0.0010–0.0023
in)
Limit
Runout limit EX 0.080 mm (0.0032 in)
0.01 mm (0.0004 in)
Runout limit IN Replacing the valve guide
0.01 mm (0.0004 in) After replacing a valve guide, check the valve
seat contact area.
Checking the valve guide
Before checking the valve guides, make sure 1. Remove the valve guide “1” from the com-
that the valve stem diameter is within specifica- bustion chamber side using the special
tion. service tool “2”.

1. Measure the valve guide inside diameter

“a”. Replace if out of specification.
1 2

Valve guide remover/installer “2”

90890-06801

Inside diameter IN 2. Install a new valve guide “1” using the spe-
5.504–5.522 mm (0.2167–0.2174 cial service tools “2” from the camshaft
in) side until the valve guide installer “3” to the
Inside diameter EX specified height “a”.
5.504–5.522 mm (0.2167–0.2174
in)
2
2. Calculate the valve stem to valve guide
3
clearance. Replace the valve and valve a
guide if out of specification.
1

7-69
 Cylinder head
3. Push the valve lightly against the valve
Valve guide remover/installer “2” seat using the special service tool “1”.
90890-06801
Valve guide installer “3” 1
90890-06810

Installation height
11.30–11.70 mm (0.4449–0.4606
in)

3. Insert the special service tool “1” into the

valve guide “2”, and then ream the valve
guide. Valve lapper “1”
90890-04101
• To ream the valve guide, turn the special ser-
4. Measure the valve seat contact width “a”
vice tool “1” clockwise.
where the blue layout fluid is adhered to
• When removing the special service tool “1”,
the valve face. Reface the valve seat if the
do not turn it counterclockwise.
valve is not seated properly or if the valve
• After reaming the valve guide, make sure to
seat contact width is out of specification.
clean it.
Check the valve guide if the valve seat
contact width is uneven.
1

2 a

Valve guide reamer “1”

90890-06804

4. Measure the valve guide inside diameter.

Inside diameter IN
5.504–5.522 mm (0.2167–0.2174
in)
Inside diameter EX
5.504–5.522 mm (0.2167–0.2174
in)

Checking the valve seat

1. Remove carbon deposits from the valve.

2. Apply a thin, even layer of blue layout fluid

(Dykem) onto the valve seat.

7-70
 Cylinder head
2. Cut the surface of the valve seat using a
Seat contact width IN 45 cutter by turning the cutter clockwise
1.10–1.40 mm (0.0433–0.0551 until the valve seat face has become
in) smooth.
Limit
1.850 mm (0.0728 in)
Seat contact width EX Do not overcut the valve seat. To prevent
1.40–1.70 mm (0.0551–0.0669 chatter marks, make sure to turn the cutter
in) evenly using a downward force of 40–50 N
Limit (4.0–5.0 kgf, 8.8–11.0 lbf).
2.150 mm (0.0846 in)

Refacing the valve seat

After every lapping procedure, make sure

to clean off any remaining lapping com-
pound from the cylinder head and valves.

1. Reface the valve seat using the special

service tools.
45°
a

30 45 60

a. Slag or rough surface

3. Adjust the top edge of the valve seat con-

Valve seat cutter holder tact width using a 30 cutter.
90890-06316
Intake
30°
Valve seat cutter 30
a
90890-06817
Valve seat cutter 45
90890-06816
Valve seat cutter 60
90890-06324
Exhaust
Valve seat cutter 30
90890-06326 a. Previous contact width
Valve seat cutter 45
90890-06325
Valve seat cutter 60
90890-06324

7-71
 Cylinder head
4. Adjust the bottom edge of the valve seat a. Previous contact width
contact width using a 60 cutter.
• If the valve seat contact area is too nar-
row and situated near the top edge of the
valve face, cut the top edge of the valve
a
seat using a 30 cutter to center the area.
Set its width using a 45 cutter.

30°
a
60°

a. Previous contact width

5. Adjust the valve seat contact width to

specification using a 45 cutter.

a. Previous contact width

a • If the valve seat contact area is too nar-
b row and situated near the bottom edge of
the valve face, cut the bottom edge of the
valve seat using a 60 cutter to center
the area. Set its width using a 45 cutter.
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”
60°
(7-70).

Example: a. Previous contact width

• If the valve seat contact area is too wide
and situated in the center of the valve
face, cut the top edge of the valve seat
using a 30 cutter, and then cut the bot-
tom edge using a 60 cutter to center the
area and set its width.

30°
a

60°

7-72
 Cylinder head
7. After refacing the valve seat to the speci- 2. Install the valve “1”, valve spring seat “2”,
fied contact width, apply a thin, even layer valve spring “3”, and valve spring retainer
of lapping compound onto the valve seat, “4” in this order, and then install the tools
and then lap the valve using the special “5” or “6” and “7”.
service tool “1”. A

4
Do not get the lapping compound on the 3
valve stem and valve guide. 4
2
3
2 5
1

1
1

Valve lapper “1”

90890-04101
B
8. Recheck the valve seat contact area of the
valve. See “Checking the valve seat” 6
(7-70).

Checking the cylinder head anode

1. Check the anodes. Replace the anode if 7
half of it has eroded. Clean if there is 4
grease, oil, or scales.

3
Do not apply grease, oil, or paint to the an- 1
odes. 2

A. Conventional tool
Assembling the cylinder head B. New special service tool
1. Install a new valve seal “1” onto the valve
guide.
Valve spring compressor “5”
1 90890-04019
Valve spring compressor “6”
90890-06689
Valve spring compressor attach-
ment “7”
90890-06320

7-73
 Cylinder head
3. Compress the valve spring, and then in-
stall the valve cotters “1”.

1
1

4. Tap the valve spring retainer lightly using a

plastic hammer to set the valve cotters “1”
securely.

PORT STBD

2. Install the dowels “1”, new gaskets “2”, and

the cylinder heads “3”, and then tighten the
cylinder head bolts “4” to the specified
torques in 6 stages and in the order [1], [2],
and so on.

3. Tighten the cylinder head bolts “5” and “6”

to the specified torques in 2 stages and in
1 1 the order [9], [10], and so on.

• Make sure to install the cylinder head gaskets

(PORT and STBD) onto the proper cylinder
heads.
• In the 6th stage, mark the M10 bolts “4” and
the cylinder heads with identification marks
“a”, and then tighten the bolts 90° from the
5. Install the anode assemblies “1”. mark.

Installing the cylinder head

1. Install the water shut grommets “1” into the
cylinder block.

7-74
 Cylinder head
Tightening procedure when reusing the
4 5 cylinder head bolts:
6 3
Cylinder head bolt “4” [1]–[8] (M10)
1st: 27 Nm (2.7 kgf·m, 19.9 ft·lb)

T.
R.
2nd: 54 Nm (5.4 kgf·m, 39.8 ft·lb)
3rd: Loosen completely
4th: 27 Nm (2.7 kgf·m, 19.9 ft·lb)
5th: 54 Nm (5.4 kgf·m, 39.8 ft·lb)
6th: 90
2 Cylinder head bolt “5” and “6” [9]–
[11] (M8)
1 1st: 14 Nm (1.4 kgf·m, 10.3 ft·lb)
2nd: 28 Nm (2.8 kgf·m, 20.7 ft·lb)

4. Install new filters “1” and the OCVs “2”, and

1 then tighten the OCV bolts “3” to the spec-
ified torque.

5. Install the engine hangers “4”, and then

4 PORT STBD tighten the engine hanger bolts “5” to the
4
specified torque.
[6] [5]
[5] [6] 5
4
[2] [1]
[1] [2]
1
[3] [4] 2
[4] [3] 5
[7] [8]
[8] [7]
[9]
[9] 3
6 [10] [11] 6
[11] [10]
a 90
OCV bolt “3”
7 Nm (0.7 kgf·m, 5.2 ft·lb)
T.
R.

Engine hanger bolt “5”

Tightening procedure when using new cyl- 12 Nm (1.2 kgf·m, 8.9 ft·lb)
inder head bolts:
6. Install the fuel rails. See “Installing the fuel
Cylinder head bolt “4” [1]–[8] (M10) injector” (6-40).
1st: 30 Nm (3.0 kgf·m, 22.1 ft·lb)
T.
R.

2nd: 60 Nm (6.0 kgf·m, 44.3 ft·lb)

3rd: Loosen completely
4th: 30 Nm (3.0 kgf·m, 22.1 ft·lb)
5th: 60 Nm (6.0 kgf·m, 44.3 ft·lb)
6th: 90
Cylinder head bolt “5” and “6” [9]–
[11] (M8)
1st: 14 Nm (1.4 kgf·m, 10.3 ft·lb)
2nd: 28 Nm (2.8 kgf·m, 20.7 ft·lb)

7-75
 Cooling water passage cover

Cooling water passage cover

2.5 Nm (0.25 kgf㺃m, 1.84 ft㺃lb) 12 Nm (1.2 kgf㺃m, 8.9 ft㺃lb)
1 16
22
1 19 23
2 18 21
20 2
4 3
B
B 20
2
16 17 2 24
5 2
2 25
3 2
15 12 26
14
2 11 27
10
6 13

3 32 Nm (3.2 kgf·m, 23.6 ft·lb)

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

3
9
9 mm 7 mm 12 mm
(0.35 in) (0.28 in) (0.47 in) A

No. Part name Q’ty Remarks

1 Hose 1 Joint to joint
2 Plastic tie 16
3 Joint 4
4 Hose 1 Joint to joint
5 Hose 1 Joint to joint
6 Hose 1 Joint to joint
7 Hose 1 Cylinder block to joint
8 Clamp 1
9 Hose 1 Joint to joint
10 Hose 1 Joint to joint
11 Clamp 1
12 Joint 1
13 Holder 1
14 Hose 1 Joint to check valve
15 Holder 1
16 Holder 1
17 Bolt 1 M6  12 mm

7-76
 Cooling water passage cover

2.5 Nm (0.25 kgf㺃m, 1.84 ft㺃lb) 12 Nm (1.2 kgf㺃m, 8.9 ft㺃lb)

1 16
22
1 19 23
2 18 21
20 2
4 3
B
B 20
2
16 17 2 24
5 2
2 25
3 2
15 12 26
14
2 11 27
10
6 13

3 32 Nm (3.2 kgf·m, 23.6 ft·lb)

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

3
9
9 mm 7 mm 12 mm
(0.35 in) (0.28 in) (0.47 in) A

No. Part name Q’ty Remarks

18 Holder 1
19 Hose 1 Check valve to bottom cowling
20 Check valve 1
21 Screw 4 M4  12 mm
22 Anode 4
23 Bolt 13 M6  30 mm
24 Knock sensor 1
25 Cover 1
26 Hose 1 Joint to cooling water passage cover
27 Gasket 1

7-77
 Cooling water passage cover

Removing the cooling water passage Installing the cooling water passage
cover cover
1. Remove the knock sensor, and then dis- 1. Install the anodes “1” to the cooling water
connect the flushing hose. passage cover “2”, and then tighten the
anode screws “3” to the specified torque.
2. Loosen the cooling water passage cover
bolts “1” in the order [1], [2], and so on, and 2. Install a new gasket “4” and the cooling
then remove the cooling water passage water passage cover “2”.
cover “2” and gasket “3”.
4
[4] 2 3
1
[5] 1
[3]
[9]
[8]
[13]
[12]
[10]
[11]
[6]
[7] Anode screw “3”
3 Nm (0.3 kgf·m, 2.2 ft·lb)
T.

[1]
R.

[2]
3. Tighten the cooling water passage cover
bolts “1” to the specified torque in the order
3 [1], [2], and so on.
2
1 [10]

[9]
[11]
[5]
[6]
[14], [1]
[2], [15]
[17], [4]
Checking the cooling water passage [3], [16]
cover anode [8]
1. Check the anodes. Replace if eroded. [7]
Clean if there is grease, oil, or scales. [13] [12]
1

Do not apply grease, oil, or paint to the an-

odes. Cooling water passage cover bolt
“1”
T.
R.

12 Nm (1.2 kgf·m, 8.9 ft·lb)

Checking the knock sensor
1. Check the knock sensor. See “Checking
the knock sensor” (5-42).

7-78
 Cooling water passage cover
4. Connect the flushing hose “1”, and then
fasten it using the plastic tie “2”.

2
1

5. Install the knock sensor “1”, and then tight-

en it to the specified torque.

6. Fasten the knock sensor lead “2” and

flushing hose “3” using the plastic tie “4”.

Fasten the knock sensor lead “2” so that it is

taut.

2 2
4
4
3
3

Knock sensor “1”

32 Nm (3.2 kgf·m, 23.6 ft·lb)
T.
R.

7-79
 Crankcase

Crankcase
18 Nm (1.8 kgf㺃m, 13.3 ft㺃lb) 15 Nm (1.5 kgf㺃m, 11.1 ft㺃lb)

1
2
3 18
8 17 19
5 7 22
9
6 24
10
15
4 23 21
11 25
18
16
20 17
26
12 27 27
4 Nm (0.4 kgf㺃m, 3.0 ft㺃lb)
13
15
14 28 29
32
12 Nm (1.2 kgf㺃m, 8.9 ft㺃lb)

34 Nm (3.4 kgf㺃m, 25.1 ft㺃lb) 30

14 Nm (1.4 kgf·m, 10.3 ft·lb)
28 Nm (2.8 kgf·m, 20.7 ft·lb) 31

No. Part name Q’ty Remarks

1 Bolt 5 M6  45 mm
2 Oil pressure sensor 1
3 O-ring 1 Not reusable
4 Oil filter 1
5 Union bolt 1
6 Oil filter bracket 1
7 Gasket 1 Not reusable
8 Oil filler cap 1
9 O-ring 1 Not reusable
10 Holder 1
11 Engine hanger 1
12 Bolt 2 M6  18 mm
13 Crankcase cover 1
14 Bolt 17 M8  45 mm
15 Dowel 2
16 Gasket 1 Not reusable
17 Bolt 4 M6  25 mm

7-80
 Crankcase

18 Nm (1.8 kgf㺃m, 13.3 ft㺃lb) 15 Nm (1.5 kgf㺃m, 11.1 ft㺃lb)

1
2
3 18
8 17 19
5 7 22
9
6 24
10
15
4 23 21
11 25
18
16
20 17
26
12 27 27
4 Nm (0.4 kgf㺃m, 3.0 ft㺃lb)
13
15
14 28 29
32
12 Nm (1.2 kgf㺃m, 8.9 ft㺃lb)

34 Nm (3.4 kgf㺃m, 25.1 ft㺃lb) 30

14 Nm (1.4 kgf·m, 10.3 ft·lb)
28 Nm (2.8 kgf·m, 20.7 ft·lb) 31

No. Part name Q’ty Remarks

18 Damper 2
19 Engine stopper (STBD) 1
20 Engine stopper (PORT) 1
21 Engine temperature sensor 1
22 Washer 1
23 Bolt 1 M6  20 mm
24 Blowby hose joint 1
25 O-ring 1 Not reusable
26 Oil seal 1 Not reusable
27 O-ring 2 Not reusable
28 Gasket 1 Not reusable
29 Oil seal 1 Not reusable
30 Oil seal 2 Not reusable
31 Bolt 4 M6  40 mm
32 Oil pump assembly 1

7-81
 Crankcase

Removing the oil filter bracket

1. Remove the oil filter “1”.

1
2
1 2 3

Removing the crankcase cover

1. Remove the fuel filter assembly. See “Re-
moving the fuel filter assembly” (6-7).
Oil filter wrench “2”
90890-06874 2. Remove the throttle body assembly. See
“Removing the throttle body assembly”
2. Loosen the oil filter bracket bolts “1” in the (6-18).
order [1], [2], and so on, and then remove
the oil filter bracket “2” and gasket “3”. 3. Remove the engine hanger “1”.

STBD PORT 4. Loosen the crankcase cover bolts “2” in

the order [1], [2], and so on, and then re-
[5]
move the crankcase cover “3” and gasket
[1] “4”.

[2] [4] [3] [2] [1] 2

[3] [8]
1 [9]

[12]
[13]
PORT
STBD
1 [17] [16]

[14] [15]

[11]
[10]
3
[4] [5] [6] [7]
2

Removing the oil pump

1. Remove the oil pump assembly “1”, O-
rings “2”, and oil seal “3”.

7-82
 Crankcase
2. Check the gear teeth of the inner rotor and
outer rotor. Replace the oil pump assem-
4 bly if the gear teeth are cracked or worn.

3 3. Measure the inner rotor to outer rotor tip

1 clearance “a”, outer rotor to oil pump hous-
ing clearance “b”, and oil pump housing to
inner rotor and outer rotor clearance “c”.
Replace the oil pump rotor if out of specifi-
cation.

b
a
2 c
3
5. Remove the engine temperature sensor
“1”. A A
A-A

1 2 3

1. Inner rotor
1 2. Outer rotor
3. Oil pump housing

Inner rotor to outer rotor tip clear-

ance (reference data)
Disassembling the oil pump 0.12 mm (0.0047 in)
1. Remove the oil pump cover “1”, gasket “2”, Limit (reference data)
outer rotor “3”, inner rotor “4”, and oil seals 0.16 mm (0.0063 in)
“5” and “6”.
Outer rotor to oil pump housing
clearance (reference data)
0.1 mm (0.0040 in)
1 Limit (reference data)
0.20 mm (0.0079 in)

2 5

6 Oil pump housing to inner rotor and

3 outer rotor clearance (reference da-
ta)
4 0.03 mm (0.0012 in)
Limit (reference data)
0.12 mm (0.0047 in)

Checking the oil pump

1. Check the inner surface of the oil pump
housing. Replace the oil pump assembly if
scratched.

7-83
 Crankcase

Assembling the oil pump

1. Install new oil seals “1” into the oil pump 5
housing “2”.
4

Install an oil seal halfway into the oil pump

housing, and then install the other oil seal. 3
2

1
3
2

Oil pump cover screw “5”

4 4 Nm (0.4 kgf·m, 3.0 ft·lb)

T.
R.
Installing the crankcase cover
Driver rod L3 “3”
90890-06652 1. Install the washer “1” and engine tempera-
Needle bearing attachment “4” ture sensor “2”, and then tighten the en-
90890-06613 gine temperature sensor to the specified
torque.
2. Install a new oil seal “1” into the oil pump
housing “2”.

1 1
3
2
4 2

Engine temperature sensor “2”

15 Nm (1.5 kgf·m, 11.1 ft·lb)
T.
R.

Driver rod L3 “3”

90890-06652 2. Install the dowels “1” a new gasket “2”, and
Needle bearing attachment “4” the crankcase cover “3”, and then tighten
90890-06607 the crankcase cover bolts “4” to the speci-
fied torques in 2 stages and in the order
3. Install the inner rotor “1”, the outer rotor [1], [2], and so on.
“2”, a new gasket “3”, and the oil pump
cover “4”, and then tighten the oil pump
cover screws “5” to the specified torque.

7-84
 Crankcase
3. Install the engine hanger “5”, and then
tighten the engine hanger bolts “6” to the 1
specified torque.

1 2
2

3 2
5

3. Fill the oil pump assembly with engine oil

through the oil passage.

6 4. Install the oil pump assembly “1” by align-

1 ing the oil pump gear with the crankshaft.
4

4 [15] [16] [17]

[9] [10]

[6]
[5]
STBD [2] PORT
[1]
[4] [3]

[7]
[8]
[14] [13] [12] [11]

Crankcase cover bolt “4” [1]–[17]

1st: 14 Nm (1.4 kgf·m, 10.3 ft·lb)
T.
R.

2nd: 28 Nm (2.8 kgf·m, 20.7 ft·lb)

1
Engine hanger bolt “6”
12 Nm (1.2 kgf·m, 8.9 ft·lb)

4. Install the throttle body assembly. See “In-

stalling the throttle body assembly” (6-19). Installing the oil filter bracket
1. Install a new gasket “1” and the oil filter
5. Install the fuel filter assembly. See “Install-
bracket “2”, and then tighten the oil filter
ing the fuel filter assembly” (6-9).
bracket bolts “3” in the order [1], [2], and so
on.
Installing the oil pump
1. Install a new oil seal “1” so that it is facing 2. Install the oil filter union bolt “4”, and then
in the proper direction. tighten it to the specified torque.
2. Install new O-rings “2”.

7-85
 Crankcase
3. Install a new O-ring “5” and the oil pressure
sensor “6”, and then tighten the oil pres-
sure sensor “6” to the specified torque. 1
2
3

5
1
2
6 4

STBD PORT
[1] Oil filter “1”
18 Nm (1.8 kgf·m, 13.3 ft·lb)

T.
R.
[5]

[4] Oil filter wrench “2”

[2]
90890-06874
[3]
3

Oil filter union bolt “4”

34 Nm (3.4 kgf·m, 25.1 ft·lb)
T.
R.

Oil pressure sensor “6”

18 Nm (1.8 kgf·m, 13.3 ft·lb)

4. Add a small amount of engine oil through

the oil passage “a” of the oil filter bracket.

5. Install the oil filter “1”, and then tighten it to

the specified torque.

7-86
 Cylinder block

Cylinder block
7 Nm (0.7 kgf·m, 5.2 ft·lb) 21
19 22 3 Nm (0.3 kgf·m, 2.2 ft·lb) 21
17 25
18 23 34
16 4 26 32 19
20 24
27
13 33
15 35
14 18
10 13 28 17
24
12 20
33 Nm (3.3 kgf·m, 24.3 ft·lb) 23
90 29
36
11 30 15
7 10
37 38
10
5 9 30 10
4
6 31
8
41 39
6 44 42
1

2
3 43
46 45 41 40
14 Nm (1.4 kgf·m, 10.3 ft·lb)
43
28 Nm (2.8 kgf·m, 20.7 ft·lb) 13 Nm (1.3 kgf·m, 9.6 ft·lb)
28 Nm (2.8 kgf·m, 20.7 ft·lb) 23 Nm (2.3 kgf·m, 17.0 ft·lb)
90 90

No. Part name Q’ty Remarks

1 Bolt 8 M10  102 mm
2 Bolt 8 M8  93 mm
3 Bolt 13 M8  55 mm
4 Crankcase assembly 1
5 Crankshaft journal bearing 4 Lower
6 Thrust bearing 2 Lower
7 Oil seal 1 Not reusable
8 Crankshaft 1
9 Thrust bearing 2 Upper
10 Plastic tie 6
11 Hose 1
12 Holder 2
13 Joint 1
14 Hose 1
15 Bolt 4 M6  25 mm
16 Thermostat cover 1
17 Bolt 2 M5  20 mm

7-87
 Cylinder block

7 Nm (0.7 kgf·m, 5.2 ft·lb) 21

19 22 3 Nm (0.3 kgf·m, 2.2 ft·lb) 21
17 25
18 23 34
16 4 26 32 19
20 24
27
13 33
15 35
14 18
10 13 28 17
24
12 20
33 Nm (3.3 kgf·m, 24.3 ft·lb) 23
90 29
36
11 30 15
7 10
37 38
10
5 9 30 10
4
6 31
8
41 39
6 44 42
1

2
3 43
46 45 41 40
14 Nm (1.4 kgf·m, 10.3 ft·lb)
43
28 Nm (2.8 kgf·m, 20.7 ft·lb) 13 Nm (1.3 kgf·m, 9.6 ft·lb)
28 Nm (2.8 kgf·m, 20.7 ft·lb) 23 Nm (2.3 kgf·m, 17.0 ft·lb)
90 90

No. Part name Q’ty Remarks

18 Gasket 2 Not reusable
19 Bolt 4 M6  16 mm
20 Anode 2
21 Thermo switch 2
22 Bracket 1
23 Thermostat 2
24 Gasket 2 Not reusable
25 Bolt 2 M6  20 mm
26 Plug 1
27 O-ring 1 Not reusable
28 Dowel 8
29 Crankshaft journal bearing 4 Upper
30 O-ring 2 Not reusable
31 O-ring 1 Not reusable
32 Holder 1
33 Bracket 1
34 Holder 1

7-88
 Cylinder block

7 Nm (0.7 kgf·m, 5.2 ft·lb) 21

19 22 3 Nm (0.3 kgf·m, 2.2 ft·lb) 21
17 25
18 23 34
16 4 26 32 19
20 24
27
13 33
15 35
14 18
10 13 28 17
24
12 20
33 Nm (3.3 kgf·m, 24.3 ft·lb) 23
90 29
36
11 30 15
7 10
37 38
10
5 9 30 10
4
6 31
8
41 39
6 44 42
1

2
3 43
46 45 41 40
14 Nm (1.4 kgf·m, 10.3 ft·lb)
43
28 Nm (2.8 kgf·m, 20.7 ft·lb) 13 Nm (1.3 kgf·m, 9.6 ft·lb)
28 Nm (2.8 kgf·m, 20.7 ft·lb) 23 Nm (2.3 kgf·m, 17.0 ft·lb)
90 90

No. Part name Q’ty Remarks

35 Thermostat cover 1
36 Holder 1
37 Holder 1
38 Hose 1
39 Piston ring set 6
40 Piston 6
41 Clip 12 Not reusable
42 Piston pin 6
43 Connecting rod assembly 6
44 Crankshaft pin bearing 12
45 Bolt 12 Not reusable M9  42 mm
46 Collar 1 Not reusable

7-89
 Cylinder block

Disassembling the cylinder block

1. Remove the thermo switches “1”.
• Remove the piston pin from the side marked
2. Remove the thermostat covers “2”, and with “a”.
then remove the thermostats “3” and an- • Make sure to keep the parts in the order of re-
odes “4”. moval.

1
3
4
a
2
2
1
3

3. Remove the connecting rod caps “1”, and

then remove the crankshaft pin bearings
“2”, connecting rods, and piston assem-
1
blies “3”.
5. Remove the piston rings and arrange them
• To prevent mixing the piston and connecting in order.
rod assemblies “3” and connecting rod caps
6. Remove the crankcase bolts “1”, “2”, and
“1”, mark each with an identification number
“3” in the order [1], [2], and so on.
“a” of the corresponding cylinder.
• Make sure to keep the parts in the order of re- 7. Remove the thrust bearings “4”.
moval.
3 2
1

1
1

4
4

4. Remove the piston pin clips “1” and piston

pin “2”, and then remove the connecting
rod “3”.

7-90
 Cylinder block

2 1 3 2
[1] [4] 1
[25] [17] [16] [24] 4
[5] 3
a
[8]
[9] [29] [21] [20] [28] PORT b
STBD [12]
[13] [26] [18] [19] [27] 4
[22] [14] [15] [23] [11]
[10] Bearing separator “2”
[2] [3] (commercially available)
[6] [7]
Gear puller “3”
(commercially available)
8. Remove the crankshaft “1”, crankshaft
General cylindrical tool “4”
journal bearings “2”, thrust bearings “3”,
“a” = 19 mm (0.7 in)
and oil seal “4”.
“b” = 90 mm (3.5 in)

Make sure to keep the bearings in the order as Checking the thermostat
they were removed. 1. Suspend the thermostat in a container of
water.
2
2. Place a thermo meter in the water, and
then heat the water slowly.

1
4

3
3
2 2

3. Measure the thermostat valve opening “a”

at the specified water temperatures. Re-
place if out of specification.

a
9. Remove the collar “1”.

7-91
 Cylinder block

Water temperature Valve opening “a” a. 20.0 mm (0.79 in)

b. 50.0 mm (1.97 in)
58–62 C c. 80.0 mm (3.15 in)
Starts opening
(136–144 F)
d. Parallel to the crankshaft
above 70 C 4.3 mm (0.17 in) or e. At a right angle to the crankshaft
(158 F) above

Checking the piston diameter Cylinder

Bore
1. Measure the piston diameter “a” at the
94.000–94.017 mm (3.7008–
specified measuring point “b”. Replace the
3.7014 in)
piston if out of specification.
Limit
94.071 mm (3.7036 in)

Checking the piston clearance

1. Measure the piston diameter. See “Check-
b ing the piston diameter” (7-92).
a
2. Measure the cylinder bore. See “Checking
the cylinder bore” (7-92).

3. Calculate the piston clearance. Replace

the piston or cylinder block if out of specifi-
Piston
cation.
Diameter
93.921–93.941 mm (3.6977–
Piston clearance = maximum cylinder
3.6985 in)
bore – piston outside diameter
Limit
Piston clearance
93.881 mm (3.6961 in)
0.075–0.080 mm (0.0030–0.0032
Measuring point
in)
13.5 mm (0.53 in)
Limit
above the bottom of the piston
0.190 mm (0.0075 in)
skirt
Checking the piston ring
Checking the cylinder bore
1. Measure piston ring dimensions B and T.
1. Measure the cylinder bore (D1–D6) at
Replace if below specification.
measuring points “a”, “b”, and “c”, and in
directions “d” (D1, D3, D5) and “e” (D2, D4, a b
D6). Replace the cylinder block if out of
B B
specification.
T T

a
b D2 D1 c B
c d
D4 D3 e T
D6 D5 a. Top ring
b. 2nd ring
c. Oil ring

7-92
 Cylinder block

Piston ring dimensions Piston ring end gap

Top ring Measuring point
Height (B) 20.0 mm (0.79 in)
1.170–1.190 mm (0.0461–0.0469 Top ring
in) End gap
Width (T) 0.20–0.30 mm (0.0079–0.0118
2.800–3.000 mm (0.1102–0.1181 in)
in) Limit
2nd ring 0.470 mm (0.0185 in)
Height (B) 2nd ring
1.170–1.190 mm (0.0461–0.0469 End gap
in) 0.35–0.50 mm (0.0138–0.0197
Width (T) in)
3.600–3.800 mm (0.1417–0.1496 Limit
in) 0.650 mm (0.0256 in)
Oil ring Oil ring
Height (B) End gap
2.400–2.470 mm (0.0945–0.0972 0.15–0.60 mm (0.0059–0.0236
in) in)
Width (T)
2.300–2.700 mm (0.0906–0.1063 Checking the piston ring groove
in) 1. Measure the piston ring grooves. Replace
if above specification.
Checking the piston ring end gap
1. Level the piston ring “1” in the cylinder us-
ing a piston crown at the specified measur- a
ing point “a”.
b
2. Measure the piston ring end gap “b”. Re-
place if out of specification.
c

a. Ring groove (Top)

b. Ring groove (2nd)
c. Ring groove (Oil)
a
1 Piston ring groove
Ring groove (Top)
1.22–1.25 mm (0.0480–0.0492
in)
b
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)

7-93
 Cylinder block

Checking the piston ring side clear-

ance
1. Measure the piston ring side clearance. a
Check the piston ring grooves and piston b
ring if above specification. See “Checking
the piston ring groove” (7-93) and “Check-
ing the piston ring” (7-92).
c c

c
Pin boss inside diameter
21.021–21.031 mm (0.8276–
a. Top ring side clearance 0.8280 in)
b. 2nd ring side clearance Limit
c. Oil ring side clearance 21.051 mm (0.8288 in)

Checking the piston pin diameter

Piston ring side clearance 1. Measure the piston pin outside diameter
Top ring “a” at measuring points “b”, “c”, and “d”,
Side clearance and in directions “e” and “f”. Replace if out
0.03–0.08 mm (0.0012–0.0032 of specification.
in)
Limit a
0.130 mm (0.0051 in)
2nd ring
Side clearance
0.03–0.07 mm (0.0012–0.0028
in)
Limit
0.110 mm (0.0043 in)
Oil ring
Side clearance
0.04–0.13 mm (0.0016–0.0051 b
e
in)
c
f
Checking the piston pin boss inside
diameter d
1. Measure the piston pin boss inside diame-
ter “a”. Replace if out of specification.

Pin outside diameter

When measuring the piston pin boss inside di-
21.008–21.017 mm (0.8271–
ameter, do not measure it at the ring groove “b”
0.8274 in)
or oil groove “c”.
Limit
20.998 mm (0.8267 in)

7-94
 Cylinder block

Checking the connecting rod small Checking the connecting rod big end
end inside diameter and big end in- side clearance
side diameter 1. Measure the connecting rod big end side
1. Tighten the connecting rod bolts “1” to the clearance “a”. Check the crankshaft pin
specified torques in 3 stages. width if out of specification. See “Checking
the crankshaft” (7-95).
2. Measure the connecting rod small end in-
side diameter “a” and big end inside diam-
eter “b”.

• When checking the big end inside diameter,

reuse the removed connecting rod bolt. a
• Make sure that the protrusions “c” on the con-
necting rod and connecting rod cap are
aligned.
• In the 3rd tightening stage for the connecting
rod bolts “1”, mark the connecting rod bolts
and the connecting rod cap with identification
marks “d”, and then tighten the bolts 90° from
the marks on the connecting rod cap.
Big end side clearance
d 90 a 0.150–0.300 mm (0.0059–0.0118
in)
Limit
b 0.35 mm (0.0138 in)

Checking the crankshaft

1. Measure the crankshaft journal diameters
c “a”, crankshaft pin diameters “b”, and
1 crankshaft pin widths “c”. Replace the
crankshaft if below specification.
Connecting rod bolt “1”
1st: 13 Nm (1.3 kgf·m, 9.6 ft·lb)
T.
R.

2nd: 23 Nm (2.3 kgf·m, 17.0 ft·lb)

3rd: 90

Small end inside diameter

21.022–21.037 mm (0.8276–
0.8282 in) a
Big end inside diameter
53.015–53.035 mm (2.0872–
2.0880 in)

7-95
 Cylinder block

A b a

d c
B b a

b c e c
c
A. M10  102 mm
Journal diameter B. M8  93 mm
62.968–62.992 mm (2.4791–
2.4800 in)
Crankcase bolt diameter difference
Crankshaft pin diameter
limit
49.976–50.000 mm (1.9676–
“a” – “b” = Less than 0.20 mm
1.9685 in)
(0.0079 in)
Crankshaft pin width
Measuring point “c”: 10.0 mm
21.50–21.55 mm (0.8465–0.8484
(0.39 in)
in)
Measuring point “d”: 65.0 mm
(2.56 in)
2. Measure the crankshaft runout. Replace if
Measuring point “e”: 60.0 mm
out of specification.
(2.36 in)

Checking the big end oil clearance

1. Clean the crankshaft pin bearings, con-
necting rod, connecting rod cap, and
crankshaft pin.

2. Install the crankshaft pin bearings “1” into

the connecting rod “2” and connecting rod
cap “3”.

Runout Install the crankshaft pin bearings in their orig-

0.03 mm (0.0012 in) inal positions.
Limit
0.04 mm (0.0016 in)
2
1
Checking the crankcase bolt 3
1. Measure the diameters “a” and “b” of the
crankcase bolt at the specified measuring
points “c” and “d”, and “c” and “e”. Replace
the crankcase bolt if the difference be-
tween the diameters is out of specification.

7-96
 Cylinder block
3. Place a piece of Plastigauge (PG-1) on the
crankshaft pin, parallel to the crankshaft.
In the third tightening stage for the connecting
rod bolts “1”, mark the connecting rod bolts and
Do not place the Plastigauge (PG-1) over the connecting rod cap with identification
the oil hole in the crankshaft pin of the marks “a”, and then tighten the bolts 90 from
crankshaft. the marks on the connecting rod cap.

a 90r

4. Install the connecting rod “1” and connect-

ing rod cap “2” onto the crankshaft pin.

• When checking the oil clearance, reuse the

removed connecting rod bolts. Connecting rod bolt “1”
• Make sure that the protrusions “a” on the con- 1st: 13 Nm (1.3 kgf·m, 9.6 ft·lb)
T.
R.

necting rod “1” and connecting rod cap “2” 2nd: 23 Nm (2.3 kgf·m, 17.0 ft·lb)
face toward the flywheel magneto end of the 3rd: 90
crankshaft.
• Do not turn the connecting rod until the big 6. Remove the connecting rod cap, and then
end oil clearance measurement has been measure the width of the compressed
completed. Plastigauge (PG-1) on the crankshaft pin.
Check the journal diameter if out of speci-
fication. See “Checking the crankshaft”
(7-95).

1
2 a

Big end oil clearance

5. Tighten the connecting rod bolts “1” to the 0.028–0.066 mm (0.0011–0.0026
specified torques in 3 stages. in)
Limit
0.096 mm (0.0038 in)

7-97
 Cylinder block

Selecting the crankshaft pin bearing Checking the journal oil clearance
When replacing the crankshaft pin bearing, se- After checking the crankshaft journal oil clear-
lect the bearing as follows: ance, check the crankcase bolts. See “Check-
ing the crankcase bolt” (7-96).
1. Check the crankshaft pin mark “a” on the
crankshaft. 1. Clean the crankshaft journal bearings,
P1 P2 P4 crankshaft journals, and bearing portions
of the crankcase and cylinder block.

2. Place the cylinder block upside down.

3. Install the crankshaft journal bearings “1”

and crankshaft “2” into the cylinder block
P3 P5 P6 “3”.

Install the crankshaft journal bearings “1” in the

original positions.

a 3

1
P1 P2P3 P4 P5 P6
2
2. Select the suitable colors “1” for the con-
necting rod bearing from the table.
1
4. Place a piece of Plastigauge (PG-1) on
each crankshaft journal, parallel to the
crankshaft.

Do not place the Plastigauge (PG-1) over

1 the oil hole in each crankshaft journal.

Crankshaft pin mark

Bearing color “1”
“a”
92–00 Yellow
84–91 Green
76–83 Blue

7-98
 Cylinder block
5. Install the crankshaft journal bearings into
the crankcase. a 90
3 2

• Install the crankshaft journal bearings in the

original positions. [29] [26]
4
• Insert the protrusion of each bearing into the [5] [13] [14] [6]
[25]
slots in the crankcase.
[22]
[21] [1] [9] [10] [2]
6. Install the crankcase “1”, and then tighten PORT
the crankcase bolts “2” and “3” to the spec- STBD [18]
ified torques in 2 stages and in the order [17] [4] [12] [11] [3]
[1], [2], and so on.
[8] [16] [15] [7] [19]
7. Tighten the crankcase bolts “4” to the [20]
specified torques in 2 stages and in the or- [28] [27]
der [17], [18], and so on. [24] [23]

• Do not turn the crankshaft until the crankshaft Crankcase bolt “2” [1]–[8] (M8)
journal oil clearance measurement has been 1st: 28 Nm (2.8 kgf·m, 20.7 ft·lb)
T.

completed.
R.

2nd: 90
• In the second tightening stage for the M8 Crankcase bolt “3” [9]–[16] (M10)
bolts “2” and M10 bolts “3”, mark the bolts 1st: 33 Nm (3.3 kgf·m, 24.3 ft·lb)
and the crankcase with identification marks 2nd: 90
“a”, and then tighten the bolts 90 from the Crankcase bolt “4” [17]–[29] (M8)
marks on the crankcase. 1st: 14 Nm (1.4 kgf·m, 10.3 ft·lb)
2nd: 28 Nm (2.8 kgf·m, 20.7 ft·lb)
4 2
3 8. Remove the crankcase, and then measure
the width of the compressed Plastigauge
(PG-1) on each crankshaft journal.

When loosening the crankcase bolts, loosen

1
them in the opposite order used for tightening.

7-99
 Cylinder block

Journal oil clearance 1

0.035–0.050 mm (0.0014–0.0020
in)
Limit
0.070 mm (0.0028 in)

Selecting the crankshaft journal bear-

ing
When replacing the crankshaft journal bearing,
select the bearing as follows: Block side bear- Crankcase side
ing color bearing color
1. Remove the crankshaft journal bearings.
“a” Yellow Yellow
2. Check the mark “a” on the crank web and “b” Green Green
the mark “b” on the cylinder block. “c” Blue Blue

J1 J2 J3 J4 Example:
If the crankshaft journal mark is “69” and
the cylinder block mark is “07”, select the
bearing colors in “c”. The upper bearing
color is brown and the lower bearing color
is brown.

J2 J3 98 99 9 06 07 08 09
J1
J4 68
69
a c
70

J4 J3 J2 J1 b

3. Select the suitable colors “1” for the crank-

shaft journal bearing from the “Crankshaft
journal bearing selection table” (7-101).

7-100
 Cylinder block

Crankshaft journal bearing selection table

B
98 99 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22
68
69
70
71
72 c
73
74
75
76
77
78
79
A
80 b
81
82
83
84
85
86
87
88 a
89
90
91
92

A. Crankshaft journal mark

B. Cylinder block mark

7-101
 Cylinder block

Checking the cylinder block anode

4 4
1. Check the anodes. Replace the anode if
half of it has eroded. Clean if there is
grease, oil, or scales.
c b
3

Do not apply grease, oil, or paint to the an-

ode.

Assembling the cylinder block

Before assembling the cylinder block, check
the crankcase bolts. See “Checking the crank-
a 2 1
case bolt” (7-96). 4

1. Install a new collar “1” by striking it using a 3. Install the oil rings “1”, 2nd ring “2”, and top
plastic hammer. ring “3”.

1 Do not scratch the pistons or break the pis-

ton rings.

• Make sure that the “RN” 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
2. Assemble the piston “1”, the connecting smoothly.
rod “2”, the piston pin “3”, and new piston
pin clips “4”. 4. Offset the piston ring end gaps.

• Face the protrusion “a” on the connecting rod 1 a

“2” in the same direction as the mark “b” on
#5 #4
the piston crown.
• Install the piston pin from the side marked #3 2
with “b”. 3
• Make sure that the clip “4” end is not aligned #2
#1
with the groove “c” in the piston pin boss. 45° 45°
#3 #2

b
#1
#4 #5

7-102
 Cylinder block
5. Install the crankshaft pin bearings “1” into
the connecting rod “2” and connecting rod
cap “3”. Install the crankshaft journal bearings “1” in
their original positions.

Install the crankshaft pin bearings in the origi-

nal positions.

2
1 1 1
3

6. Apply engine oil to the side of the piston,

piston rings, and cylinder wall, and then in- 8. Install a new oil seal “1” onto the crank-
stall the piston so that the mark “a” on the shaft “2”, and then install the crankshaft
piston crown is facing toward the flywheel and thrust bearings “3”.
magneto end of the crankshaft.

Install each thrust bearing with its grooves fac-

• There are stamped mark “b” on the piston to ing outward.
differentiate the sides; mark “P” is PORT, “S”
is STBD.
• Use the special service tool “90890-05158” to
install the oversized piston.

3
1

a b
2

Piston slider 94 mm “1”

90890-06683

7. Install the crankshaft journal bearings “1”.

7-103
 Cylinder block
9. Install the connecting rod caps “1” to the
connecting rods, and then tighten new
connecting rod bolts “2” to the specified • Install the crankshaft journal bearings “1” in
torques in 3 stages. their original positions.
• Do not apply any sealant to the crankshaft
journal bearings “1”.
• Make sure that the protrusions “a” on the con-
necting rod and connecting rod caps “1” are
facing toward the flywheel magneto end of
the crankshaft.
• In the third tightening stage for the connecting
rod bolts “2”, mark the connecting rod bolts 2 1
and connecting rod cap with paint marks “b”,
and then tighten the bolts 90 from the marks
on the connecting rod cap.
• After tightening the connecting rod bolts “2”, STBD PORT
make sure that the crankshaft turns smooth- 1
ly.

b 90
12. Install the thrust bearings “1”.
a
2 • Install each thrust bearing with its grooves
1
facing outward.
• Fit the protrusion on each thrust bearing into
the slot in the crankcase.

Connecting rod bolt “2”

1st: 13 Nm (1.3 kgf·m, 9.6 ft·lb)
T.
R.

2nd: 23 Nm (2.3 kgf·m, 17.0 ft·lb)

3rd: 90

10. Install the crankshaft journal bearings “1”.

11. Apply a thin, even layer of sealant onto the

mating surface of the crankcase “2”.

7-104
 Cylinder block
13. Install new O-rings “1”, “2” and the crank-
case “3”, and then tighten crankcase bolts a 90
“4” and “5” to the specified torques in 2
5 4
stages and in the order [1], [2], and so on.

[29] [26]
In the second tightening stage for the M8 bolts [5] [13] [14] [6] 6
[25]
“4” and M10 bolt “5”, mark the bolts and the
crankcase “3” with identification marks “a”, and [22]
then tighten the bolts 90 from the marks on the [21] [1] [9] [10] [2]
PORT
crankcase. STBD [18]
[17] [4] [12] [11] [3]
14. Tighten the crankcase bolts “6” to the
[8] [16] [15] [7] [19]
specified torques in 2 stages and in the or-
[20]
der [17], [18], and so on.
[28] [27]
[24] [23]
After tightening the crankcase bolts “4”, “5” and
“6”, make sure that the crankshaft turns
smoothly. Crankcase bolt “4” [1]–[8] (M8)
1st: 28 Nm (2.8 kgf·m, 20.7 ft·lb)
T.
R.

6
4 2nd: 90
5 Crankcase bolt “5” [9]–[16] (M10)
1st: 33 Nm (3.3 kgf·m, 24.3 ft·lb)
2nd: 90
Crankcase bolt “6” [17]–[29] (M8)
1st: 14 Nm (1.4 kgf·m, 10.3 ft·lb)
2nd: 28 Nm (2.8 kgf·m, 20.7 ft·lb)
3
15. Install new gaskets “1” and the anode bolts
“2” to the thermostat covers “3”, and then
1
2 tighten the anode bolts to the specified
torque.

16. Install the anodes “4” to the thermostat

covers “3”, and then tighten them to the
specified torque.

17. Install new gaskets “5” to the thermostats

“6”, and then install the thermostats to the
cylinder block.

18. Install the thermostat covers “3”.

7-105
 Cylinder block
19. Install the thermo switches “7”.

6
5
4

1
7
3
2

Anode bolt “2”

7 Nm (0.7 kgf·m, 5.2 ft·lb)
T.
R.

Anode “4”
3 Nm (0.3 kgf·m, 2.2 ft·lb)

7-106
 Lower unit

Lower unit (regular rotation model).................................. 8-1

Removing the lower unit............................................................. 8-3
Disassembling the propeller
(Shift Dampener System [SDS] propeller).................................. 8-3
Checking the propeller ............................................................... 8-3
Checking the lower unit anode ................................................... 8-4
Assembling the propeller
(Shift Dampener System [SDS] propeller).................................. 8-4

Water pump and shift rod (regular rotation model) ........ 8-6
Removing the water pump and shift rod (F200B)....................... 8-8
Removing the water pump and shift rod (F250H) ...................... 8-8
Disassembling the water pump housing..................................... 8-9
Checking the water pump and shift rod...................................... 8-9
Assembling the water pump housing ......................................... 8-9

Propeller shaft housing (regular rotation model).......... 8-10

Removing the propeller shaft housing assembly (F200B)........ 8-12
Removing the propeller shaft housing assembly (F250H) ....... 8-12
Disassembling the propeller shaft assembly ............................ 8-13
Disassembling the propeller shaft housing assembly
(F200B) .................................................................................... 8-13
Disassembling the propeller shaft housing assembly
(F250H) .................................................................................... 8-14
Checking the propeller shaft..................................................... 8-14
Checking the dog clutch ........................................................... 8-14
Checking the propeller shaft housing ....................................... 8-14
Checking the reverse gear ....................................................... 8-14
Assembling the propeller shaft assembly................................. 8-14
Assembling the propeller shaft housing assembly (F200B) ..... 8-15
Assembling the propeller shaft housing assembly (F250H) ..... 8-16

Drive shaft and lower case (regular rotation model) .... 8-17
Removing the drive shaft (F200B)............................................ 8-19
Removing the drive shaft (F250H) ........................................... 8-19
Disassembling the oil seal housing .......................................... 8-19
Disassembling the forward gear (F200B)................................. 8-19
Disassembling the forward gear (F250H)................................. 8-20
Disassembling the lower case.................................................. 8-20
Checking the pinion.................................................................. 8-21
Checking the forward gear ....................................................... 8-21
Checking the drive shaft........................................................... 8-21
Checking the lower case .......................................................... 8-21
Assembling the lower case....................................................... 8-21
 Lower unit

Assembling the forward gear (F200B)...................................... 8-22

Assembling the forward gear (F250H) ..................................... 8-22
Assembling the oil seal housing ............................................... 8-23
0
Installing the drive shaft (F200B).............................................. 8-23
Installing the drive shaft (F250H) ............................................. 8-24
Installing the propeller shaft housing assembly (F200B).......... 8-24
Installing the propeller shaft housing assembly (F250H) ......... 8-25
1
Installing the shift rod ............................................................... 8-26
Installing the water pump ......................................................... 8-26
Checking the lower unit for air leakage .................................... 8-27 2
Installing the lower unit............................................................. 8-27

Shimming (regular rotation model) ................................ 8-29 3

Shimming workflow .................................................................. 8-29
Shimming check sheet ............................................................. 8-30
Measuring the forward gear backlash and reverse gear
backlash before disassembly ................................................... 8-32
4
Shimming procedure ................................................................ 8-36
Shim location (F200B).............................................................. 8-36
Shim location (F250H).............................................................. 8-37
Selecting the pinion shim (T3).................................................. 8-38
5
Selecting the propeller shaft shim (T4) (F250H) ...................... 8-41

6
Measuring the forward gear backlash ...................................... 8-42
Adjusting the forward gear shim thickness (T1) ....................... 8-42
Measuring the reverse gear backlash ...................................... 8-44
Adjusting the reverse gear shim thickness (T2) ....................... 8-44

Lower unit (counter rotation model)............................... 8-47

7
Removing the lower unit........................................................... 8-49
Disassembling the propeller
(Shift Dampener System [SDS] propeller)................................ 8-49 8
Checking the propeller ............................................................. 8-49
Checking the lower unit anode ................................................. 8-49
Assembling the propeller
(Shift Dampener System [SDS] propeller)................................ 8-49
9
Water pump and shift rod (counter rotation model) ..... 8-50
Removing the water pump and shift rod................................... 8-52
10
Disassembling the water pump housing................................... 8-52
Checking the water pump and shift rod.................................... 8-52
Assembling the water pump housing ....................................... 8-52

A
 Lower unit

Propeller shaft housing (counter rotation model)......... 8-53

Removing the propeller shaft housing assembly (FL200B)...... 8-56
Removing the propeller shaft housing assembly (FL250H) ..... 8-56
Disassembling the propeller shaft assembly ............................ 8-56
Disassembling the propeller shaft housing assembly
(FL200B) .................................................................................. 8-56
Disassembling the propeller shaft housing assembly
(FL250H) .................................................................................. 8-57
Checking the propeller shaft..................................................... 8-58
Checking the dog clutch ........................................................... 8-59
Checking the propeller shaft housing ....................................... 8-59
Checking the forward gear ....................................................... 8-59
Assembling the propeller shaft housing assembly (FL200B) ... 8-59
Assembling the propeller shaft housing assembly (FL250H) ... 8-61

Drive shaft and lower case (counter rotation model) ... 8-63
Removing the drive shaft (FL200B).......................................... 8-65
Removing the drive shaft (FL250H) ......................................... 8-65
Disassembling the oil seal housing .......................................... 8-65
Disassembling the reverse gear............................................... 8-65
Disassembling the lower case (FL200B).................................. 8-65
Disassembling the lower case (FL250H).................................. 8-66
Checking the pinion.................................................................. 8-66
Checking the reverse gear ....................................................... 8-66
Checking the drive shaft........................................................... 8-66
Checking the lower case .......................................................... 8-66
Assembling the lower case (FL200B)....................................... 8-66
Assembling the lower case (FL250H) ...................................... 8-67
Assembling the reverse gear.................................................... 8-67
Assembling the oil seal housing ............................................... 8-68
Installing the drive shaft (FL200B)............................................ 8-68
Installing the drive shaft (FL250H) ........................................... 8-68
Installing the propeller shaft housing assembly (FL200B)........ 8-68
Installing the propeller shaft housing assembly (FL250H) ....... 8-68
Installing the shift rod ............................................................... 8-69
Installing the water pump ......................................................... 8-69
Checking the lower unit for air leakage .................................... 8-69
Installing the lower unit............................................................. 8-69

Shimming (counter rotation model) ............................... 8-70

Shimming workflow .................................................................. 8-70
Shimming check sheet ............................................................. 8-71
Measuring the forward gear backlash and reverse gear
backlash before disassembly ................................................... 8-73
Shimming procedure ................................................................ 8-77
Shim location (FL200B)............................................................ 8-77
 Lower unit

Shim location (FL250H)............................................................ 8-78

Selecting the pinion shim (T3).................................................. 8-79
Pinion shim (T3) selection table ............................................... 8-79
0
Selecting the propeller shaft shim (T4)..................................... 8-79
Measuring the forward gear backlash ...................................... 8-80
Adjusting the forward gear shim (T2) thickness ....................... 8-81
Measuring the reverse gear backlash ...................................... 8-82
1
Adjusting the reverse gear shim (T1) thickness ....................... 8-83

2
3
4
5
6
7
8
9
10

A
 Lower unit (regular rotation model)

Lower unit (regular rotation model)

A 26
23
25 24
7 42 Nm (4.2 kgf·m, 31.0 ft·lb)
27 9 Nm (0.9 kgf·m, 6.6 ft·lb)
24 6
54 Nm (5.4 kgf·m, 39.8 ft·lb)

31
30 10 11
20 12
21 28 4 3 5
29
8
19
3 9
2 13
22 14

47 Nm (4.7 kgf·m, 34.7 ft·lb) 1

15
17

17 17
1
18 16

9 Nm (0.9 kgf·m, 6.6 ft·lb)

33
32
47 Nm (4.7 kgf·m, 34.7 ft·lb)

No. Part name Q’ty Remarks

1 Gasket 2 Not reusable
2 Check screw 1
3 Dowel 2
4 Plate 1
5 Rubber seal 1
6 Bolt 1 M10  45 mm
7 Grommet 1
8 Lower unit 1
9 Spacer 1
10 Propeller 1
11 Cotter pin 1 Not reusable
12 Propeller nut 1
13 Washer 1
14 Spacer 1 Except for Shift Dampener System (SDS) propeller
15 Trim tab 1
16 Bolt 1 M10  70 mm/X-transom model
17 Bolt 7 M10  45 mm/X-transom model

A. U-transom model
8-1
 Lower unit (regular rotation model)

A 26
23
25 24
7 42 Nm (4.2 kgf·m, 31.0 ft·lb)
27 9 Nm (0.9 kgf·m, 6.6 ft·lb)
24 6
54 Nm (5.4 kgf·m, 39.8 ft·lb)

31
30 10 11
20 12
21 28 4 3 5
29
8
19
3 9
2 13
22 14

47 Nm (4.7 kgf·m, 34.7 ft·lb) 1

15
17

17 17
1
18 16

9 Nm (0.9 kgf·m, 6.6 ft·lb)

33
32
47 Nm (4.7 kgf·m, 34.7 ft·lb)

No. Part name Q’ty Remarks

18 Drain screw 1
19 Adapter 1 U-transom model
20 Dowel 1 U-transom model
21 Plastic tie 1 U-transom model
22 Bolt 1 M6  25 mm/U-transom model
23 Rubber seal 1 U-transom model
24 Dowel 2 U-transom model
M10  190 mm/U-transom model/Point the flat
25 Stud bolt 6
end of the stud bolt up.
26 Rubber seal 1 U-transom model
27 Extension 1 U-transom model
28 Bolt 1 M10  200 mm/U-transom model
29 Bolt 1 M10  175 mm/U-transom model
30 Nut 6 U-transom model
31 Washer 6 U-transom model
32 Damper 1 Not reusable, Shift Dampener System (SDS) propeller
33 Spacer 1 Shift Dampener System (SDS) propeller

A. U-transom model
8-2
 Lower unit (regular rotation model)

Removing the lower unit

A

• Make sure to disconnect the battery ca-

bles from the battery, and remove the clip
from the engine shut-off switch.
• When removing the lower unit with the
power unit installed, make sure to sus-
pend the outboard motor. Otherwise, the 3
outboard motor could fall suddenly and
1
result in severe injuries.
• When loosening or tightening the propel- 2
ler nut, do not hold the propeller using
your hands.
a

1. Drain the gear oil. See steps 1–5 in

“Changing the gear oil” (10-13).

2. Remove the cotter pin. A. U-transom model

3. Set the gear shift to the N position. Disassembling the propeller (Shift
Dampener System [SDS] propeller)
4. Place a block of wood between the anti- 1. Remove the damper “1”.
cavitation plate and the propeller to keep
the propeller from turning, and then re- 3 1
2 3
move the propeller nut and propeller.

Driver rod L3 “2”

90890-06652
5. Make a mark “a” on the trim tab “1” and Needle bearing attachment “3”
lower case, and then remove the trim tab. 90890-06653

6. Remove the lower unit “2” and extension Checking the propeller
“3” (U-transom model). 1. Check the propeller blades and splines.
Replace the propeller if cracked, dam-
aged, or worn.
When disassembling the lower unit, measure
the backlash before disassembly. See “Mea-
suring the forward gear backlash and reverse
gear backlash before disassembly” (8-32).

8-3
 Lower unit (regular rotation model)

Checking the lower unit anode

1. Check the trim tab. Replace if eroded.
Clean if there is grease, oil, or scales. 3

Do not apply grease, oil, or paint to the trim

tab.

Assembling the propeller (Shift 3

3
Dampener System [SDS] propeller) 2
1. Place a new damper “1” in the propeller a
“2”.
Align the mark “a” on the damper “1” with
the mark “b” on the propeller “2”. 1

1 a 2 b

Needle bearing attachment “2”

90890-06653

Installation height (reference data)

4.0 mm (0.158 in)
2. Install the damper “1” using the special
service tool “2” and spacer “3” to the spec- 3. Check the installation depth “a” of the
ified height “a”. damper “1”.

Be careful not to install the spacer in the The damper “1” will be in the proper position
opposite direction. (the damper “1” is in contact with the spacer
“2”) after the propeller nut “3” has been tight-
ened to the specified torque. Therefore, when
installing the propeller to the outboard motor,
When installing the damper “1”, make sure that
make sure to tighten the propeller nut “3” to the
the spacer “3” does not contact the propeller
specified torque. See step 6 in “Installing the
boss.
lower unit” (8-27).

a
1
1

8-4
 Lower unit (regular rotation model)

3
2
1
B 1

3
2
A. Before tightening the propeller nut “3” to
the specified torque.
B. After tightening the propeller nut “3” to
the specified torque.

Installation height (reference data)

9.4 mm (0.37 in)

8-5
 Water pump and shift rod (regular rotation model)

Water pump and shift rod (regular rotation model)

20 21

4 22
17 20
3 3 16
14
15
14
19
5 13 23
18
6 12
7
11
8 24
2
10
10 9

No. Part name Q’ty Remarks

1 Seal 1
2 Shift rod 1
3 Bolt 3 M6  20 mm
4 Oil seal 1 Not reusable
5 Plate 1
6 O-ring 1 Not reusable
7 Spring 1
8 E-clip 1
9 Woodruff key 1
10 Dowel 2
11 Gasket 1 Not reusable
12 Outer plate cartridge 1
13 Impeller 1
14 Washer 2 F200B
15 Wave washer 1 F200B
16 Spacer 1 F200B
17 Collar 1 F200B

8-6
 Water pump and shift rod (regular rotation model)

20 21

4 22
17 20
3 3 16
14
15
14
19
5 13 23
18
6 12
7
11
8 24
2
10
10 9

No. Part name Q’ty Remarks

18 O-ring 1 Not reusable
19 Water pump housing 1
20 Bolt 4 M8  45 mm
21 Cover 1
22 Seal 1
23 Insert cartridge 1
24 O-ring 1 Not reusable

8-7
 Water pump and shift rod (regular rotation model)

Removing the water pump and shift

2
rod (F200B)
1. Remove the water pump housing “1” , col-
lar “2”, spacer “3”, washers “4”, wave 4
washer “5”, impeller “6 , and Woodruff key
“7”. 1
3
2. Remove the outer plate cartridge “8” and
gasket “9”.

1 8

9 Removing the water pump and shift

2
3
rod (F250H)
7
1. Remove the water pump housing “1”, im-
4
peller “2”, and Woodruff key “3”.
5
4 2. Remove the outer plate cartridge “4” and
gasket “5”.
6

3. Set the gear shift to the N position.

4

1 5

2
R
1
N
F

Shift rod socket “1” 3. Set the gear shift to the N position, and
90890-06681 then remove the plate, oil seal, O-ring, and
shift rod. See steps 3 and 4 in “Removing
4. Remove the plate “1”, oil seal “2”, O-ring the water pump and shift rod (F200B)”
“3”, and shift rod “4”. (8-8).

8-8
 Water pump and shift rod (regular rotation model)

Disassembling the water pump hous-

2
ing
1. Remove the O-ring “1”, insert cartridge “2” 1
and O-ring “3”.

3
2

1 2. Install a new O-ring “1”, the insert cartridge

“2”, and a new O-ring “3”.

Fit the protrusions “a” on the insert cartridge “2”

2. Remove the cover “1” and seal “2”.
into the slots “b” in the water pump housing “4”.
1
3 2
2 4

1
Checking the water pump and shift
rod
1. Check the water pump housing. Replace if
deformed.

If the engine overheats, the inside of the water

pump housing may be deformed.
Therefore, make sure to remove the insert car-
tridge when checking the water pump housing.

2. Check the impeller, insert cartridge, and

outer plate cartridge. Replace if cracked or
worn.

3. Check the Woodruff key and the keyway in

the drive shaft. Replace if deformed or
worn.

4. Check the shift rod. Replace if bent,

cracked, or worn.

Assembling the water pump housing

1. Install the seal “1” and cover “2”.

8-9
 Propeller shaft housing (regular rotation model)

Propeller shaft housing (regular rotation model)

11 10
6 13 7 8

4 5
3 8
12 7
9

30
30
9 29 30
1 2 28
7 11 10 27
6 12 30
13
7 25 26

15
22
24
14 23
31
21
20 23 24
19
1 Nm (0.1 kgf·m, 0.7 ft·lb)
18 32
16 25
29 Nm (2.9 kgf·m, 21.4 ft·lb)

17 6 Nm (0.6 kgf·m, 4.4 ft·lb)

No. Part name Q’ty Remarks

1 Self-locking nut 1
2 Water inlet cover (STBD) 1
3 Water pipe 1 F250H
4 Rubber seal 1 F250H
5 Rubber seal 1 F250H
6 Shift rod joint 1
7 Ball 2
8 Propeller shaft 1
9 Spring 1
10 Cross pin 1
11 Dog clutch 1
12 Shift plunger 1
13 Slider 1
14 Screw 1 M5  55 mm
15 Water inlet cover (PORT) 1
16 Washer 1 F200B
17 Propeller shaft shim (T4) — F250H

8-10
 Propeller shaft housing (regular rotation model)

11 10
6 13 7 8

4 5
3 8
12 7
9

30
30
9 29 30
1 2 28
7 11 10 27
6 12 30
13
7 25 26

15
22
24
14 23
31
21
20 23 24
19
1 Nm (0.1 kgf·m, 0.7 ft·lb)
18 32
16 25
29 Nm (2.9 kgf·m, 21.4 ft·lb)

17 6 Nm (0.6 kgf·m, 4.4 ft·lb)

No. Part name Q’ty Remarks

18 Reverse gear 1
19 Reverse gear shim (T2) —
20 Ball bearing 1 Not reusable
21 Propeller shaft housing 1
22 Rubber seal 1 F250H
23 Washer 2
24 Bolt 2 M8  33 mm
25 O-ring 2 Not reusable
26 Needle bearing 1 Not reusable
27 Oil seal 2 Not reusable
28 Cover 1 F200B
29 Cover 1 F250H
30 Bolt 2 M8  20 mm
31 Grease nipple 1
32 Dowel 1 F250H

8-11
 Propeller shaft housing (regular rotation model)

Removing the propeller shaft housing

assembly (F200B)
1. Remove the cover “1” and bolts “2”.

2 1

2. Remove the propeller shaft housing as-

sembly, and then remove the propeller 2. Remove the cover “1”, bolts “2”, water inlet
shaft assembly and washer. cover “3” and screw “4”.

1 2
3
3

2 1
4
1

3. Remove the propeller shaft housing as-

Bearing housing puller claw L “1” sembly, and then remove the propeller
90890-06502 shaft assembly and propeller shaft shim
Stopper guide plate “2” (T4).
90890-06501
Center bolt “3”
90890-06504 1 2
3
Removing the propeller shaft housing
assembly (F250H)
1. Remove the water pipe “1”.

Bearing housing puller claw L “1”

90890-06502
Stopper guide plate “2”
90890-06501
Center bolt “3”
90890-06504

8-12
 Propeller shaft housing (regular rotation model)

Disassembling the propeller shaft as-

sembly
1. Remove the spring “1”, and then remove
the cross pin “2”, dog clutch “3”, shift rod
joint “4”, slider “5”, and shift plunger “6”.

When removing the slider “5”, make sure that

the balls “7” do not fall out of position. 1

7
4
2
6
5
1
7
3 Slide hammer handle “1”
90890-06531
2 Bearing outer race puller assembly
“2”
90890-06523
Disassembling the propeller shaft
housing assembly (F200B) 3. Remove the oil seals “1”.
1. Remove the reverse gear and reverse
gear shims. 1

1 4. Remove the needle bearing “1”.

Bearing separator “1” 3

90890-06534
Stopper guide plate “2”
90890-06501 2
Stopper guide stand “3”
90890-06538 1
Bearing puller assembly “4”
90890-06535

2. Remove the ball bearing. Needle bearing attachment “2”

90890-06611
Driver rod L3 “3”
90890-06652

8-13
 Propeller shaft housing (regular rotation model)

Disassembling the propeller shaft 2. Check the propeller shaft housing. Re-
housing assembly (F250H) place if cracked or damaged.
1. Remove the rubber seal “1”.
Checking the reverse gear
1. Check the teeth and dogs of the reverse
1 gear. Replace if cracked or worn.

Assembling the propeller shaft as-

sembly
1. Install the shift plunger “1”, slider “2”, balls
“3”, and shift rod joint “4” into the propeller
shaft “5”.

2. Disassemble the propeller shaft housing When installing the slider “2”, make sure that
assembly. See “Disassembling the propel- the balls “3” do not fall out of position.
ler shaft housing assembly (F200B)”
(8-13).
4 2 3
Checking the propeller shaft
1. Check the propeller shaft. Replace if dam-
aged or worn. 1 3

2. Measure the propeller shaft runout. 5

2
3
4
1
3

2. Align the hole “a” in the dog clutch “1” with

the hole “b” in the propeller shaft.

1 2
Runout
0.02 mm (0.0008 in) (F200BET,
c
F250HET)
3
3. Check the dog clutch, shift rod joint, and
slider. Replace if cracked or worn.
3
2
Checking the dog clutch
1. Check the dog clutch, shift plunger, cross
pin, spring, balls, and slider. Replace if a
cracked or worn. b
1
Checking the propeller shaft housing
1. Check the cooling water pipe. Replace if
corroded, cracked, or deformed.

8-14
 Propeller shaft housing (regular rotation model)
3. Install the cross pin “2”, and then install the
spring “3”.
Make sure to face the “F” mark “c” on the
dog clutch “1” toward the shift rod joint. 1
a
Assembling the propeller shaft hous-
ing assembly (F200B)
1. Install a new needle bearing “1” to the
specified depth “a”.

Face the bearing identification mark “b” on the Bearing inner race attachment “1”
needle bearing “1” toward the propeller side. 90890-06640

b
2 Depth “a”
4.75–5.25 mm (0.187–0.207 in)
4 1
a 3. Install a new ball bearing “1” and original
reverse gear shims “2”.

3 Needle bearing attachment “3”

90890-06654

Driver rod SS “2”

90890-06604 • Do not reuse a shim if deformed or scratched.
Needle bearing attachment “3” • Face the bearing identification mark “a” on
90890-06610 the ball bearing “1” toward the propeller side.
Bearing depth plate “4”
90890-06603 a
1

Depth “a”
25.05–25.55 mm (0.986–1.006 3
in) 2

2. Install new oil seals into the propeller shaft

housing to the specified depth “a”.

Install an oil seal halfway into the propeller

shaft housing, and then install the other oil • Use heat-resistant gloves. Otherwise,
seal. burns could result.
• To prevent fires, remove any flammable
substances, such as gasoline and oil,
around the working area.
• Keep good ventilation while working.

8-15
 Propeller shaft housing (regular rotation model)
4. Heat the installation area of the ball bear-
ing in the propeller shaft housing “1” using
a gas torch, and then install the reverse 1
gear assembly “2”.

When heating the propeller shaft housing,

heat the entire installation area evenly. Oth-
erwise, the propeller shaft housing could
be damaged.

5. Install the grease nipple “1”, and then tight-

en it to the specified torque.

Grease nipple “1”

6 Nm (0.6 kgf·m, 4.4 ft·lb)
T.
R.

Assembling the propeller shaft hous-

ing assembly (F250H)
1. Assemble the propeller shaft assembly.
See “Assembling the propeller shaft hous-
ing assembly (F200B)” (8-15).

2. Install the rubber seal “1”.

8-16
 Drive shaft and lower case (regular rotation model)

Drive shaft and lower case (regular rotation model)

8 13

12
7
11
18
6
6 17
6 10
16
15
14

5
9
4

3 19
2

1 20
21
22
142 Nm (14.2 kgf㺃m, 104.7 ft㺃lb)

No. Part name Q’ty Remarks

1 Thrust bearing 1
2 Pinion shim (T3) —
3 O-ring 1 Not reusable
4 Needle bearing 1 Not reusable
5 Oil seal housing 1
6 Bolt 4 M8  25 mm
7 Oil seal 2 Not reusable
8 Cover 1
9 Drive shaft 1
10 Lower case 1
11 Washer 1 F250H
12 Spring 1 F250H
13 Thrust bearing 1 F250H
14 Forward gear shim (T1) —
15 Taper roller bearing 1 Not reusable
16 Circlip 1 Not reusable, F250H
17 Needle bearing 1 Not reusable, F250H

8-17
 Drive shaft and lower case (regular rotation model)

8 13

12
7
11
18
6
6 17
6 10
16
15
14

5
9
4

3 19
2

1 20
21
22
142 Nm (14.2 kgf㺃m, 104.7 ft㺃lb)

No. Part name Q’ty Remarks

18 Forward gear 1
19 Needle bearing 1 Not reusable
20 Pinion 1
21 Washer 1
22 Pinion nut 1

8-18
 Drive shaft and lower case (regular rotation model)

Removing the drive shaft (F200B)

1. Remove the cover “1”, oil seal housing “2”,
pinion shim “3”, and thrust bearing “4”. 1

1
4

2
2. Remove the needle bearing “1”.
3
2 3
2. Remove the pinion nut and washer. 3

1
2
1
2

Needle bearing attachment “2”

2 90890-06610
Driver rod L3 “3”
90890-06652

Disassembling the forward gear

(F200B)
Drive shaft holder 6 “1” 1. Remove the taper roller bearing.
90890-06520
Pinion nut holder “2”
90890-06715 1

3. Remove the drive shaft and pinion.

4. Remove the forward gear assembly.

Removing the drive shaft (F250H)

1. Remove the cover, oil seal housing, pinion
shim, thrust bearing and pinion nut. See
step 1–2 in “Removing the drive shaft Bearing separator “1”
(F200B)” (8-19). 90890-06534

2. Remove the drive shaft, pinion, thrust

bearing, spring, washer, and forward gear
assembly.

Disassembling the oil seal housing

1. Remove the oil seals “1”.

8-19
 Drive shaft and lower case (regular rotation model)

Disassembling the forward gear Disassembling the lower case

(F250H) 1. Remove the needle bearing.
1. Remove the taper bearing.

• Since the diameter of the passage in the low-

er case and the diameter of the special ser-
1
vice tool “1” are both 40 mm (1.57 in), the
special service tool may not fit into the lower
case. In that case, use a special service tool
with a smaller diameter.
• Make sure to remove the forward gear before
removing the needle bearing.

Bearing separator “1” 2

2
90890-06534
1
2. Remove the circlip “1”.
1
1

Ball bearing attachment “1”

90890-06655
Driver rod LL “2”
90890-06605

3. Remove the needle bearing “1”.

• Use heat-resistant gloves. Otherwise,
3 1 burns could result.
2 • To prevent fires, remove any flammable
3
substances, such as gasoline and oil,
4 4
around the working area.
5 5 • Keep good ventilation while working.
5
4 5
2. Heat the installation area of the taper roller
bearing outer race in the lower case using
a gas torch, and then remove the outer
Stopper guide plate “2” race “1” and forward gear shims “2”.
90890-06501
Bearing puller assembly “3”
90890-06535 When heating the lower case, heat the en-
Bearing puller claw 1 “4” tire installation area evenly. Otherwise, the
90890-06536 paint on the lower case could be burned.
Stopper guide stand “5”
90890-06538

8-20
 Drive shaft and lower case (regular rotation model)

Runout
• Before removing the taper roller bearing out- 0.2 mm (0.008 in) (F200BET,
er race “1”, place some cushioning material F250HET)
below the lower case to catch the outer race
when it falls out. Checking the lower case
• If the taper roller bearing outer race does not
1. Check the lower case. Replace if cracked
come out, lightly tap the lower unit torpedo
or damaged.
using a plastic hammer.
Assembling the lower case
1. Install the original forward gear shims “1”.

• Use heat-resistant gloves. Otherwise,

burns could result.
• To prevent fires, remove any flammable
substances, such as gasoline and oil,
around the working area.
• Keep good ventilation while working.
2
2. Heat the installation area of the taper roller
1
bearing outer race in the lower case using
a gas torch, and then install a new outer
Checking the pinion race “2”.
1. Check the teeth of the pinion. Replace if
cracked or worn.
When heating the lower case, heat the en-
Checking the forward gear tire installation area evenly. Otherwise, the
1. Check the teeth and dogs of the forward paint on the lower case could be burned.
gear. Replace if cracked or worn.

Checking the drive shaft Do not reuse a shim if deformed or scratched.

1. Check the drive shaft. Replace if damaged
or worn.
2
2. Measure the drive shaft runout.
1

8-21
 Drive shaft and lower case (regular rotation model)
3. While holding the special service tool “1”,
strike it to check that the taper roller bear-
ing outer race is installed properly.

1 1
2 1

Bearing inner race attachment “1”

90890-06659

Driver rod LL “1” Assembling the forward gear (F250H)

90890-06605 1. Install a new needle bearing to the speci-
Bearing inner race attachment “2” fied depth “a”.
90890-06658

4. Install a new needle bearing “1”.

a 2
1
The needle bearing contains 24 rollers.

3 1
Needle bearing attachment “1”
90890-06653
Driver rod SS “2”
2 90890-06604

Depth “a”
Ball bearing attachment “2”
9.75–10.25 mm (0.3839–0.4035
90890-06655
in)
Bearing outer race puller assembly
“3”
2. Install a new circlip “1”.
90890-06523

Assembling the forward gear (F200B) 1

1. Install a new taper roller bearing.

8-22
 Drive shaft and lower case (regular rotation model)
3. Install a new taper roller bearing. See “As- Installing the drive shaft (F200B)
sembling the forward gear (F200B)” 1. Install the forward gear assembly into the
(8-22). lower case.

Assembling the oil seal housing 2. Install the drive shaft “1”, thrust bearing “2”,
1. Install a new needle bearing to the speci- and original pinion shims “3”.
fied depth “a”.
3

2
a
2
1

Needle bearing attachment “1”

90890-06610
Driver rod L3 “2”
3. Install the pinion and washer, and then
90890-06652
tighten the pinion nut temporarily.

Depth “a”
When installing the pinion, lift up the drive shaft
4.25–4.75 mm (0.167–0.187 in)
slightly and align the splines on the drive shaft
with the splines on the pinion.
2. Install new oil seals into the oil seal hous-
ing.
4. Install a new O-ring “1” to the oil seal hous-
ing “2”, and then install the oil seal housing
Install one oil seal so that it contacts the bottom “2”.
of the oil seal housing, and then the other oil
seal.
Make sure to install the oil seal housing “2” so
that the notch “a” is facing forward.

2
1
2

Needle bearing attachment “1”

1
90890-06610
Driver rod L3 “2”
90890-06652

8-23
 Drive shaft and lower case (regular rotation model)
5. Tighten the pinion nut to the specified
6 3
torque.

2 2
1

2 1 4

4. Install the oil seal housing, and then tight-

en the pinion nut to the specified torque.
See steps 4 and 5 in “Installing the drive
Drive shaft holder 6 “1” shaft (F200B)” (8-23).
90890-06520
Pinion nut holder “2” Installing the propeller shaft housing
90890-06715 assembly (F200B)
1. Install new O-rings to the propeller shaft
Pinion nut housing.
142 Nm (14.2 kgf·m, 104.7 ft·lb)
T.

2. Set the shift rod joint “1” and dog clutch “2”
R.

to the N position.
Installing the drive shaft (F250H)
1. Install the forward gear assembly into the
3. Install the washer “3” and propeller shaft
lower case.
assembly “4” into the propeller shaft hous-
ing assembly “5”.
2. Install the washer “1”, spring “2”, thrust
bearing “3”, drive shaft “4”, thrust bearing
“5”, and original pinion shims “6”. F N R

3. Install the pinion and washer, and then

tighten the pinion nut temporarily.
1 2

• When installing the pinion, lift up the drive

shaft slightly and align the splines on the 5
drive shaft with the splines on the pinion. 3
• To install the pinion nut, push down on the
drive shaft. 4
2

4. Install the propeller shaft housing assem-

bly, and then tighten the propeller shaft
housing bolts “1” to the specified torque.

5. Install the cover “2”.

8-24
 Drive shaft and lower case (regular rotation model)
6. Install the water inlet covers “3”, and then 6. Install the water inlet covers “3”, and then
tighten the water inlet cover screw “4” to tighten the water inlet cover screw “4” to
the specified torque. the specified torque.

1 2 1 2
4
3
4

Propeller shaft housing bolt “1” Propeller shaft housing bolt “1”
29 Nm (2.9 kgf·m, 21.4 ft·lb) 29 Nm (2.9 kgf·m, 21.4 ft·lb)
T.

T.
R.

R.
Water inlet cover screw “4” Water inlet cover screw “4”
1 Nm (0.1 kgf·m, 0.7 ft·lb) 1 Nm (0.1 kgf·m, 0.7 ft·lb)

Installing the propeller shaft housing 7. Install the water pipe “1” and rubber seals
assembly (F250H) “2” and “3”.
1. Install new O-rings to the propeller shaft
housing. 3
2
2. Set the shift rod joint “1” and dog clutch “2” 1
to the N position.

3. Install the propeller shaft shim (T4) “3” and

propeller shaft assembly “4” into the pro-
peller shaft housing assembly “5”.

F N R

1 2

5
3

4
2

4. Install the propeller shaft housing assem-

bly, and then tighten the propeller shaft
housing bolts “1” to the specified torque.

5. Install the cover “2”.

8-25
 Drive shaft and lower case (regular rotation model)

Installing the shift rod 3. Align the slot “a” on the impeller “2” with
1. Check that the shift rod joint is in the N po- the Woodruff key “1”, and then install the
sition, and then install the shift rod “1”, the impeller “2”.
spring “2”, a new O-ring “3”, the plate “4”,
and a new oil seal “5”. 2
Make sure to fit the tip “a” of the shift rod
a
“1” into the slot “b” in the shift rod joint.
5

1
1

3
4 2 4. Install the washers “1”, wave washer “2”,
spacer “3”, and collar “4”. (F200B)

The spacer “3” and collar “4” should fit together

firmly. (F200B)

4
a
b 3

1
Installing the water pump 2
1. Install the dowels “1”, a new gasket “2”,
and the outer plate cartridge “3”. 1

5. Install the water pump assembly “1”.

Do not turn the drive shaft counterclock-

3
wise. Otherwise, the water pump impeller
could be damaged.
2
1
1

2. Install the Woodruff key “1”.

8-26
 Drive shaft and lower case (regular rotation model)

Installing the lower unit

While turning the drive shaft clockwise, push
the water pump housing down to install it. • Make sure to disconnect the battery ca-
bles from the battery, and remove the clip
from the engine shut-off switch.
• When installing the lower unit with the
power unit installed, make sure to sus-
pend the outboard motor. Otherwise, the
outboard motor could fall suddenly and
result in severe injuries.
1 • When loosening or tightening the propel-
ler nut, do not hold the propeller using
your hands.

1. Align the pin “a” on the shift lever with the

alignment mark “b” on the bottom cowling.

Checking the lower unit for air leakage

1. Remove the check screw “1”, and then
connect the special service tool “2”.

1
a
2
b

2. Set the gear shift to the N position.

Leakage tester “2”

90890-06840

2. Apply the specified pressure. Check that R

the pressure is maintained in the lower unit 1
N
for 10 seconds or more. F

Do not overpressurize the lower unit. Oth- Shift rod socket “1”
erwise, the oil seals could be damaged. 90890-06681

3. Install the dowels “1”.

Holding pressure
68.6 kPa (0.69 kgf/cm², 9.9 psi) 4. Install the extension “2” (U-transom model)
(F200BET, F250HET) and lower unit “3”, and then tighten the
lower case mounting bolts “4” and lower
case mounting nuts “5” (U-transom model)
to the specified torques.

8-27
 Drive shaft and lower case (regular rotation model)
5. Install the trim tab “6” to its original position A. Except for Shift Dampener System (SDS)
“a”, and then tighten the trim tab bolt “7” to propeller
the specified torque. B. Shift Dampener System (SDS) propeller

Point the flat end of the stud bolt “8” up.

A
8

2 7

5
1
4 Propeller nut “2”
54 Nm (5.4 kgf·m, 39.8 ft·lb)

T.
6

R.
1 7. Install a new cotter pin “2”.

4
3 a If the slots in the propeller nut “1” are not
aligned with the cotter pin hole, tighten the pro-
4 peller nut “1” until they are aligned.

A. U-transom model

Lower case mounting bolt “4”

47 Nm (4.7 kgf·m, 34.7 ft·lb) 2
T.
R.

Lower case mounting nut “5”

47 Nm (4.7 kgf·m, 34.7 ft·lb)
Trim tab bolt “7”
42 Nm (4.2 kgf·m, 31.0 ft·lb) 1

6. Install the propeller “1”, place a block of 8. Fill the lower unit with gear oil up to the
wood between the anti-cavitation plate proper level. See steps 5–8 in “Changing
and propeller to keep the propeller from the gear oil” (10-13).
turning, and then tighten the propeller nut
“2” to the specified torque.

A
2
B

8-28
 Shimming (regular rotation model)

Shimming (regular rotation model)

Shimming workflow

1. Remove the water pump

assembly and cover.

2. Measure the backlash before

disassembly.

4. YES
3. Within specification? 5. Shimming is not required.

6. NO
7. Disassemble the lower unit.

8. Select the pinion shims (T3)

and propeller shaft shims (T4).

9. Assemble the lower unit.

10. Measure the backlash.

6. NO 11. Adjust the forward gear shim

3. Within specification? thickness (T1) and reverse gear
shim thickness (T2).
4. YES
12. Install the water pump
assembly and cover.

1. Remove the water pump assembly and 8. Select the pinion shims (T3) and propel-
cover. ler shaft shims (T4).
2. Measure the backlash before disassem- 9. Assemble the lower unit.
bly. 10. Measure the backlash.
3. Within specification? 11. Adjust the forward gear shim thickness
4. YES (T1) and reverse gear shim thickness
5. Shimming is not required. (T2).
6. NO 12. Install the water pump assembly and
7. Disassemble the lower unit. cover.

• For the F200B, it is not necessary to select the propeller shaft shims (T4).
• 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 hous-
ing, shimming is required.

8-29
 Shimming (regular rotation model)

Shimming check sheet

Lower case deviation
Serial number P F R Remarks

Pinion height
Measurements (mm)
Measuring point “a”
Measuring point “b”
Measuring point “c”
Measuring point “d”
Average
Round-down average
(M)

Forward gear backlash

Measurements (mm)
Before disassembly After disassembly
Measuring point “a”
Measuring point “b”
Measuring point “c”
Measuring point “d”
Average
Round-down average

Reverse gear backlash

Measurements (mm)
Before disassembly After disassembly
Measuring point “a”
Measuring point “b”
Measuring point “c”
Measuring point “d”
Average
Round-down average

8-30
 Shimming (regular rotation model)
Forward gear shim (T2) thickness measurement in 2 places
(mm) Number of shim(s) Subtotal
0.10
0.12
0.15
0.18
0.30
0.40
0.50
Total

Reverse gear shim (T1) thickness measurement in 2 places

(mm) Number of shim(s) Subtotal
0.10
0.12
0.15
0.18
0.30
0.40
0.50
Total

8-31
 Shimming (regular rotation model)

Measuring the forward gear backlash 5. Turn the drive shaft 10 times or more to
and reverse gear backlash before dis- seat the taper roller bearing.
assembly
6. Tighten the center bolt “1” to the specified
1. Remove the water pump assembly and
torque while holding the drive shaft not to
outer plate cartridge. See steps 1 and 2 in
turn.
“Removing the water pump and shift rod
(F200B)” (8-8). (F200B) See steps 1 and 2
in “Removing the water pump and shift rod
(F250H)” (8-8). (F250H) 1

2. Set the gear shift to the N position.

Center bolt “1”

R T.
R.
6.9 Nm (0.69 kgf·m, 5.09 ft·lb)
1
N
F 7. Turn the lower unit so that it is in an upright
position.

Shift rod socket “1” 8. Remove the cover “1”, and then install the
90890-06681 outer plate cartridge “2”.

3. Set up the special service tools “1”, “2”,

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

1 2

Bearing housing puller claw L “1”

90890-06502
Stopper guide plate “2”
90890-06501
Center bolt “3”
90890-06504

4. Turn the lower unit so that the propeller

shaft is pointing downward.

8-32
 Shimming (regular rotation model)
9. Place the spring “1” on the outer plate car-
tridge, and then install the handle holder
“2” so that the spring “1” is compressed the 1
specified compression distance “a” from its
free length.

• After installing the handle holder, pull the

drive shaft up to confirm that there is no free
play.
• Do not compress the spring more than 5.0
mm (0.197 in). Otherwise, the drive shaft will 4
not turn easily, making it difficult to obtain cor- 2
3
rect measurements.

Backlash indicator “1”

90890-06706
Magnet base plate “2”
90890-07003
2 Dial gauge set “3”
a 90890-03238
Magnet base B “4”
1 90890-06844

Spring “1”
90501-450A2 *1
Handle holder “2”
EU0-23814-30 (2 required) *1
*
1. Order from Yamaha Parts warehouse.

Compression distance “a”

3.0–5.0 mm (0.118–0.197 in)

10. Install the special service tool “1” at the

lowest possible position where the drive
shaft diameter is 22.4 mm (0.882 in).

11. Set up the special service tools “2”, “3”,

and “4”.

8-33
 Shimming (regular rotation model)
12. Turn the drive shaft slowly clockwise and
counterclockwise and measure the back-
lash between where the drive shaft stops
in each direction. a

• The resistance force of the spring makes it

b
difficult to turn the drive shaft. Therefore, to
d
obtain correct measurements, consider the
spring resistance force when turning the drive
shaft.
• Do not turn the drive shaft using too much
force. Otherwise, the forward gear will turn, c
leading to incorrect measurements.
• When turning the drive shaft, hold it using a
14. Determine the backlash average, and then
little force. A knocking sound may be heard
round down the average to the 1/100
when the drive shaft is turned, but this is the
place.
sound of the pinion contacting the reverse
gear and does not affect the backlash mea-
Example:
surement.
(mm)
Measurement point “a” 0.60
Measurement point “b” 0.51
Measurement point “c” 0.51
Measurement point “d” 0.55
Average 0.5425
Round-down average 0.54

15. Check that the forward gear backlash av-

erage is within specification.

Forward gear backlash

0.29–0.67 mm (0.0114–0.0264
in) (F200BET)
13. Turn the drive shaft 180° clockwise and
0.18–0.90 mm (0.0071–0.0354
measure the backlash again.
in) (F250HET)

• Measure the backlash at 4 points: “a”, “b”, “c”,

and “d”, turning the drive shaft 180° clockwise Adjust the shim thicknesses if the forward gear
after each measurement. backlash is out of specification.
• Write down the measurement data in the
shimming check sheet.
16. Remove the special service tools from the
propeller shaft.

17. Apply a load to the reverse gear by install-

ing the propeller “1”, spacer “2”, (without
the spacer “3”), and washer “4”.

8-34
 Shimming (regular rotation model)
18. Tighten the propeller nut “5” to the speci-
fied torque.
3
1

5
4

Propeller nut “5” (shimming)

10 Nm (1.0 kgf·m, 7.4 ft·lb)
T.
R.

19. Repeat steps 13 and 14 to measure the re-

verse gear backlash.

20. Check that the reverse gear backlash av-

erage is within specification.

Reverse gear backlash

0.25–0.88 mm (0.0098–0.0346
in) (F200BET)
0.63–1.44 mm (0.0248–0.0567
in) (F250HET)

Adjust the shim thicknesses if the reverse gear

backlash is out of specification.

21. Remove the special service tools, handle

holder, spring, and outer plate cartridge,
and then install the cover, outer plate car-
tridge, and water pump assembly. See “In-
stalling the water pump” (8-26).
(F200B/F250H)

8-35
 Shimming (regular rotation model)

Shimming procedure
• Before selecting the forward gear shim (T1) and reverse gear shims (T2), make sure to select the pin-
ion shims (T3) and propeller shaft shims (T4).
• After selecting the pinion shims (T3), do not apply gear oil, grease or sealant to the lower unit parts
to measure the backlash.
• When assembling the lower unit after shimming is completed, make sure to apply gear oil, grease,
and sealant to the specified areas.

Shim location (F200B)

F R
T3 P

T2
T1

8-36
 Shimming (regular rotation model)

Shim location (F250H)

F R
T3 P

T4

T1 T2

8-37
 Shimming (regular rotation model)

Selecting the pinion shim (T3)

• Spray anti-rust lubricant on the gears and Pinion height gauge “1”
bearings before installation. Do not apply 90890-06672
gear oil to the parts. Otherwise, correct mea-
surements cannot be obtained. 2. Tighten the oil seal housing bolts “1”.
• Keep the parts free of foreign material, such
as dirt and lint.

1
Be careful not to damage the measurement
plane surface of the special service tool.
Otherwise, correct measurements cannot
be obtained.

1. Secure the special service tool “1”, and

then install the drive shaft “2”, thrust bear-
ing “3”, and oil seal housing.

• Do not install the pinion shims (T3) or O-ring. 3. Install the pinion “1”, washer “2”, and pin-
Make sure to check the thrust bearing outer ion nut “3”, and then tighten the pinion nut
race since the pinion shims (T3) sometimes temporarily.
become affixed to the thrust bearing outer
race. 3
• Make sure to install the thrust bearing outer 2
race so that it is facing the same direction as
when it was removed.
• Make sure that the notch “a” in the oil seal 1
housing is facing the opposite side from the
plate “b” of the special service tool “1”.

When tightening the pinion nut, check that

a
the drive shaft turns smoothly.

b 3 4. Check that there is a gap “a” between the

1 pinion “1” and the special service tool “2”.

If there is no gap and the drive shaft does

2 not turn, the special service tool could be
damaged.

8-38
 Shimming (regular rotation model)

Drive shaft holder 6 “1”

Make sure that the outer race “3” is installed 90890-06520
and that the pinion shim (T3) “4” has been re-
moved. If they are not in the correct state, the
gap cannot be correctly measured. Even if the Pinion nut
above-mentioned parts are in the correct state, 142 Nm (14.2 kgf·m, 104.7 ft·lb)

T.
R.
check the outer race, thrust bearing, and drive
shaft for distortion or damage in case that there 7. Secure the special service tool “1” so that
is no gap or the gap is excessive. the pinion is facing up.

a a

1
2

8. Turn the drive shaft 10 times or more to

3 seat the thrust bearing.

5. Install the special service tool “1” to the

drive shaft, and then secure the special
service tool “1”.

6. Tighten the pinion nut to the specified

torque.

8-39
 Shimming (regular rotation model)
9. Push down on the pinion “1” so that it does
not lift up, and then measure the gap be-
tween the pinion “1” and the special ser- In the “Pinion shim (T3) selection table”, use
vice tool “2”. When measuring the gap, the round-down average for the pinion height
insert the end of the thickness gauge “3” measurement (M).
straight into the gap at the measurement
point. Do not insert the thickness gauge at 11. Determine the pinion shim (T3) thickness
an angle. using the “Pinion shim (T3) selection table”
according to the pinion height measure-
ment (M) and the deviation “P” stamped on
• Measure the gap at 4 points: “a”, “b”, “c”, and
the lower case.
“d”.
• Write down the measurement data in the
Example:
shimming check sheet.
Pinion height measurement (M) = 0.18 mm
“a”
Deviation “P” = +10 “b”
1 Use the determined shim thickness of 1.12
3 mm instead of the current shim thickness.

2 b

d b a
A
P/M
0.16 0.17 0.18 0.19
b
13
c 12
B 11
10. Determine the gap average, and then
10 1.12
round down the average to the 1/100
place. 9

A. Pinion height measurement (M)

Example: B. Deviation “P”
(mm)
Measuring point “a” 0.25 Pinion shims
Measuring point “b” 0.24 0.10/0.12/0.15/0.18/0.30/0.40/
Measuring point “c” 0.25 0.50 mm (F200BET, F250HET)

Measuring point “d” 0.25

Average 0.2475
Round-down average 0.24

8-40
 Shimming (regular rotation model)

Dial gauge set “1”

The deviation “P” is stamped on the trim tab 90890-03238
mounting surface of the lower case in 0.01 mm Magnet base B “2”
units. If the value is unreadable, replace the 90890-06844
lower case.

Propeller shaft free play

12. Remove the special service tool, and then
0.20–0.50 mm (0.0079–0.0197
install the determined pinion shims (T3).
in) (F250HET)
Selecting the propeller shaft shim (T4)
4. Remove the original propeller shaft shim,
(F250H)
and then measure the propeller shaft free
1. Install the original propeller shaft shim.
play again without any propeller shaft
shim.
• If the original shim is missing, install a new
5. Select the propeller shaft shim (T4) thick-
shim with a thickness of 1.80 mm.
ness from the following table according to
• Do not reuse a shim if deformed or scratched.
the free play measurement.
(mm)
2. Install the propeller shaft assembly and
propeller shaft housing assembly. See Free play measure-
Shim thickness
steps 2–4 in “Installing the propeller shaft ment
housing assembly (F200B)” (8-24). 2.16–2.19 1.80
2.20–2.29 1.90
3. Set up the special service tools “1” and “2”,
and then measure the propeller shaft free 2.30–2.39 2.00
play. 2.40–2.49 2.10
2.50–2.59 2.20
If the free play is within specification, the pro-
peller shaft shim thickness does not need to be Propeller shaft shims
adjusted. 1.80/1.90/2.00/2.10/2.20 mm
(F250HET)

6. Remove the special service tools, and

then install the selected propeller shaft
shim.
2

8-41
 Shimming (regular rotation model)

Measuring the forward gear backlash 8. Measure the forward gear backlash. See
• Spray anti-rust lubricant on the gears and steps 2–15 in “Measuring the forward gear
bearings before installation. Do not apply backlash and reverse gear backlash be-
gear oil to the parts. Otherwise, correct mea- fore disassembly” (8-32).
surements cannot be obtained.
• Keep the parts free of foreign material, such Forward gear backlash
as dirt and lint. 0.29–0.67 mm (0.0114–0.0264
• When measuring the forward gear or reverse in) (F200BET)
gear backlash, use the original bearings and 0.18–0.90 mm (0.0071–0.0354
shims. in) (F250HET)

1. Install the original forward gear shims.

• If the original shims are missing, install new

shims with a combined thickness of 0.42 mm.
• Do not reuse a shim if deformed or scratched.

2. Install the taper roller bearing outer race.

See steps 2 and 3 in “Assembling the low-
er case” (8-21).

3. Install the forward gear assembly into the

lower case.

4. Install the pinion shims, drive shaft, pinion, Adjusting the forward gear shim thick-
and oil seal housing. See steps 2–5 in “In- ness (T1)
stalling the drive shaft (F200B)” (8-23). 1. Remove the propeller shaft housing as-
(F200B) See steps 2 and 3 in “Installing sembly and propeller shaft assembly. See
the drive shaft (F250H)” (8-24) and steps 4 “Removing the propeller shaft housing as-
and 5 in “Installing the drive shaft (F200B)” sembly (F200B)” (8-12). (F200B) See “Re-
(8-23). (F250H) moving the propeller shaft housing
assembly (F250H)” (8-12). (F250H)
5. Check that the drive shaft turns smoothly.
2. Remove the oil seal housing, pinion, drive
6. Install the propeller shaft assembly (with-
shaft, and forward gear assembly. See
out the dog clutch) and propeller shaft
“Removing the drive shaft (F200B)” (8-19).
housing assembly (without the O-ring).
(F200B) See step 1–2 in “Removing the
See steps 2–4 in “Installing the propeller
drive shaft (F200B)” (8-19) and steps 2 in
shaft housing assembly (F200B)” (8-24).
“Removing the drive shaft (F250H)” (8-19).
(F200B) See steps 2–4 in “Installing the
(F250H)
propeller shaft housing assembly
(F250H)” (8-25). (F250H) 3. Remove the taper roller bearing outer
race. See step 2 in “Disassembling the
lower case” (8-20).
When assembling the lower unit to measure
the backlash, do not install the dog clutch and
O-ring.

7. Check that the drive shaft turns smoothly.

8-42
 Shimming (regular rotation model)
4. Measure the thickness of each original for-
ward gear shim in 2 places.
• If the shim thickness adjustment value is pos-
itive, the current shim thickness must be in-
Do not reuse a shim if deformed or scratched. creased by that amount and, if the value is
negative, the current shim thickness must be
decreased by that amount.
5. Determine the forward gear shim (T1)
• The gray-colored area on the selection chart
thickness adjustment using the “Forward
indicates the range of the specified backlash.
gear shim (T1) selection chart” according
Shimming is not required if the measured
to the backlash measurement (BL1) from
backlash is within the gray-colored area.
“Measuring the forward gear backlash”.
• The values for the shim thickness adjust-
See “Forward gear shim (T1) selection
ments specified in the selection chart are in-
chart (regular rotation model: F200B)”
tended to obtain the median value within the
(A-10). (F200B) See “Forward gear shim
range for the specified forward gear back-
(T1) selection chart (regular rotation mod-
lash.
el: F250H)” (A-11). (F250H)
• The table that follows the selection chart
shows the shim thickness adjustments for the
Example:
points marked on the chart.
Backlash measurement (BL1) = 0.15 mm
“a”
Forward gear shim (T1) thickness adjust- 6. Calculate the new forward gear shim (T1)
ment = –0.35 mm “b” thickness.
The current shim thickness must be de- Calculation formula:
creased by 0.35 mm. New forward gear shim (T1) thickness =
Current forward gear shim thickness +
–0.10
Shim thickness adjustment
B (mm)

–0.20
–0.30 Example:
b –0.40 Use the following formula when the shim
–0.50 thickness adjustment value is negative.
0 5 10 15 20 25 Current forward gear shim thickness =
A (1/100 mm) 0.42 mm
a
Shim thickness adjustment = –0.12 mm
New forward gear shim (T1) thickness =
A 0 5 10 15 20 25 0.42 mm – 0.12 mm = 0.30 mm

B –0.45 –0.42 –0.38 –0.35 –0.30 –0.27 Forward shims

0.10/0.12/0.15/0.18/0.30/0.40/
A. Backlash measurement (BL1) 0.50 mm (F200BET, F250HET)
B. Shim thickness adjustment

• Use the least number of shims to obtain the

required shim thickness.
• If the calculated shim thickness cannot be ob-
tained with a combination of the available
shims, increase the shim thickness by 0.01
mm.

8-43
 Shimming (regular rotation model)
7. Install the determined forward gear shims
(T1) and taper roller bearing outer race. Reverse gear backlash
See steps 2 and 3 in “Assembling the low- 0.25–0.88 mm (0.0098–0.0346
er case” (8-21). in) (F200BET)
0.63–1.44 mm (0.0248–0.0567
Measuring the reverse gear backlash in) (F250HET)
• Spray anti-rust lubricant on the gears and
bearings before installation. Do not apply
gear oil to the parts. Otherwise, correct mea-
In the “Reverse gear shim (T2) selection
surements cannot be obtained.
chart”, use the round-down average for the
• Keep the parts free of foreign material, such
backlash measurement (BL2).
as dirt and lint.
• When measuring the forward gear or reverse
gear backlash, use the original bearings and
shims.

1. Install the original reverse gear shims and

ball bearing. See steps 3 and 4 in “Assem-
bling the propeller shaft housing assembly
(F200B)” (8-15). (F200B/F250H)

• If the original shims are missing, install new

shims with a combined thickness of 1.25 mm.
• Do not reuse a shim if deformed or scratched.

2. Install the propeller shaft assembly (with- Adjusting the reverse gear shim thick-
out the dog clutch) and propeller shaft ness (T2)
housing assembly (without the O-ring).
1. Remove the propeller shaft housing as-
See steps 2–4 in “Installing the propeller
sembly. See “Removing the propeller shaft
shaft housing assembly (F200B)” (8-24).
housing assembly (F200B)” (8-12).
(F200B) See steps 2–4 in “Installing the
(F200B) See “Removing the propeller
propeller shaft housing assembly
shaft housing assembly (F250H)” (8-12).
(F250H)” (8-25). (F250H)
(F250H)

2. Remove the reverse gear. See step 1 in

When assembling the lower unit to measure
“Disassembling the propeller shaft hous-
the backlash, do not install the dog clutch and
ing assembly (F200B)” (8-13).
O-ring.
(F200B/F250H)

3. Check that the drive shaft turns smoothly. 3. Measure the thickness of each original re-
verse gear shim in 2 places.
4. Measure the reverse gear backlash. See
steps 17–20 in “Measuring the forward
gear backlash and reverse gear backlash Do not reuse a shim if deformed or scratched.
before disassembly” (8-32).

8-44
 Shimming (regular rotation model)
4. Determine the reverse gear shim (T2)
thickness adjustment using the “Reverse
gear shim (T2) selection chart” according • If the shim thickness adjustment value is pos-
to the backlash measurement (BL2) from itive, the current shim thickness must be in-
“Measuring the reverse gear backlash.” creased by that amount and, if the value is
See “Reverse gear shim (T2) selection negative, the current shim thickness must be
chart (regular rotation model: F200B)” decreased by that amount.
(A-10). (F200B) See “Reverse gear shim • The gray-colored area on the selection chart
(T2) selection chart (regular rotation mod- indicates the range of the specified backlash.
el: F250H)” (A-11). (F250H) Shimming is not required if the measured
backlash is within the gray-colored area.
Example: • The values for the shim thickness adjust-
Backlash measurement (BL2) = 0.95 mm ments specified in the selection chart are in-
“a” tended to obtain the median value within the
Reverse gear shim (T2) thickness adjust- range for the specified reverse gear back-
ment = 0.28 mm “b” lash.
The current shim thickness must be in- • The table that follows the selection chart
creased by 0.28 mm. shows the shim thickness adjustments for the
points marked on the chart.
0.40
0.30
b
0.20 5. Calculate the new reverse gear shim (T2)
thickness.
0.10
B (mm)

Calculation formula:
0
New reverse gear shim (T2) thickness =
–0.10 Current reverse gear shim thickness +
–0.20 Shim thickness adjustment
–0.30
–0.40 Example:
0 5 85 90 95 10 Use the following formula when the shim
A (1/100 mm) thickness adjustment value is negative.
a Current reverse gear shim thickness =
1.25 mm
A 0 5 85 90 95 10 Shim thickness adjustment = –0.20 mm
New reverse gear shim (T2) thickness =
B –0.40 –0.37 0.21 0.24 0.28 0. 1.25 mm – 0.20 mm = 1.05 mm

A. Backlash measurement (BL2) Reverse shims

B. Shim thickness adjustment 0.10/0.12/0.15/0.18/0.30/0.40/
0.50 mm (F200BET, F250HET)

• Use the least number of shims to obtain the

required shim thickness.
• If the calculated shim thickness cannot be ob-
tained with a combination of the available
shims, increase the shim thickness by 0.01
mm.

8-45
 Shimming (regular rotation model)
6. Install the determined reverse gear shims
(T2) and reverse gear. See steps 3 and 4
in “Assembling the propeller shaft housing
assembly (F200B)” (8-15).
(F200B/F250H)

8-46
 Lower unit (counter rotation model)

Lower unit (counter rotation model)

A 26
23
24
25
7 42 Nm (4.2 kgf·m, 31.0 ft·lb)
27 9 Nm (0.9 kgf·m, 6.6 ft·lb)
24 6
55 Nm (5.5 kgf·m, 40.6 ft·lb)

31
11
30 10
20 12
21 3 5
29 4
28 8
19 23 9 13
22 14
47 Nm (4.7 kgf·m, 34.7 ft·lb)
1

15
17
1 17
17
18
16
33
9 Nm (0.9 kgf·m, 6.6 ft·lb) 32

47 Nm (4.7 kgf·m, 34.7 ft·lb)

No. Part name Q’ty Remarks

1 Gasket 2 Not reusable
2 Check screw 1
3 Dowel 2
4 Plate 1
5 Rubber seal 1
6 Bolt 1 M10  45 mm
7 Grommet 1
8 Lower unit 1
9 Spacer 1
10 Propeller 1
11 Cotter pin 1 Not reusable
12 Propeller nut 1
13 Washer 1
14 Spacer 1 Except for Shift Dampener System (SDS) propeller
15 Trim tab 1
16 Bolt 1 M10  70 mm/X-transom model
17 Bolt 7 M10  45 mm/X-transom model

A. U-transom model
8-47
 Lower unit (counter rotation model)

A 26
23
24
25
7 42 Nm (4.2 kgf·m, 31.0 ft·lb)
27 9 Nm (0.9 kgf·m, 6.6 ft·lb)
24 6
55 Nm (5.5 kgf·m, 40.6 ft·lb)

31
11
30 10
20 12
21 3 5
29 4
28 8
19 23 9 13
22 14
47 Nm (4.7 kgf·m, 34.7 ft·lb)
1

15
17
1 17
17
18
16
33
9 Nm (0.9 kgf·m, 6.6 ft·lb) 32

47 Nm (4.7 kgf·m, 34.7 ft·lb)

No. Part name Q’ty Remarks

18 Drain screw 1
19 Adapter 1 U-transom model
20 Dowel 1 U-transom model
21 Plastic tie 1 U-transom model
22 Bolt 1 M6  25 mm/U-transom model
23 Rubber seal 1 U-transom model
24 Dowel 2 U-transom model
M10  190 mm/U-transom model/Point the flat
25 Stud bolt 6
end of the stud bolt up.
26 Rubber seal 1 U-transom model
27 Extension 1 U-transom model
28 Bolt 1 M10  200 mm/U-transom model
29 Bolt 1 M10  175 mm/U-transom model
30 Nut 6 U-transom model
31 Washer 6 U-transom model
32 Damper 1 Not reusable, Shift Dampener System (SDS) propeller
33 Spacer 1 Shift Dampener System (SDS) propeller

A. U-transom model
8-48
 Lower unit (counter rotation model)

Removing the lower unit

1. Drain the gear oil. See steps 1–5 in
“Changing the gear oil” (10-13).

2. Remove the propeller, trim tab, lower unit,

and extension (U-transom model). See
steps 2–6 in “Removing the lower unit”
(8-3).

When disassembling the lower unit, measure

the backlash before disassembly. See “Mea-
suring the forward gear backlash and reverse
gear backlash before disassembly” (8-73).

Disassembling the propeller (Shift

Dampener System [SDS] propeller)
1. Disassemble the propeller. See “Disas-
sembling the propeller (Shift Dampener
System [SDS] propeller)” (8-3).

Checking the propeller

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

Checking the lower unit anode

1. Check the trim tab. See “Checking the low-
er unit anode” (8-4).

Assembling the propeller (Shift

Dampener System [SDS] propeller)
1. Assemble the propeller. See “Assembling
the propeller (Shift Dampener System
[SDS] propeller)” (8-4).

8-49
 Water pump and shift rod (counter rotation model)

Water pump and shift rod (counter rotation model)

20 21

4 22
17 20
3 3 16
14
15
14
19
5 13 23
18
6 12
7
11
8 24
2
10
10 9

No. Part name Q’ty Remarks

1 Seal 1
2 Shift rod 1
3 Bolt 3 M6  20 mm
4 Oil seal 1 Not reusable
5 Plate 1
6 O-ring 1 Not reusable
7 Spring 1
8 E-clip 1
9 Woodruff key 1
10 Dowel 2
11 Gasket 1 Not reusable
12 Outer plate cartridge 1
13 Impeller 1
14 Washer 2 FL200B
15 Wave washer 1 FL200B
16 Spacer 1 FL200B
17 Collar 1 FL200B

8-50
 Water pump and shift rod (counter rotation model)

20 21

4 22
17 20
3 3 16
14
15
14
19
5 13 23
18
6 12
7
11
8 24
2
10
10 9

No. Part name Q’ty Remarks

18 O-ring 1 Not reusable
19 Water pump housing 1
20 Bolt 4 M8  45 mm
21 Cover 1
22 Seal 1
23 Insert cartridge 1
24 O-ring 1 Not reusable

8-51
 Water pump and shift rod (counter rotation model)

Removing the water pump and shift

rod
1. Remove the water pump housing, impel-
ler, Woodruff key, outer plate cartridge,
and gasket, and then set the gear shift to
the N position. See steps 1–3 in “Remov-
ing the water pump and shift rod (F200B)”
(8-8).

2. Remove the plate “1”, oil seal “2”, O-ring

“3”, and shift rod “4”.

4
1
3

Disassembling the water pump hous-

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

Checking the water pump and shift

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

Assembling the water pump housing

1. Assemble the water pump housing. See
“Assembling the water pump housing”
(8-9).

8-52
 Propeller shaft housing (counter rotation model)

Propeller shaft housing (counter rotation model)

15 14 108 Nm (10.8 kgf･m, 79.7 ft･lb)
6 8 7 20
A
5
4
10
16 7 9 3
9
12
13
14
7 8
1 2

16 15 33
7 17 33
6
32
22 29 Nm (2.9 kgf･m, 21.4 ft･lb)
19 L

30
33
18
29
28
21 27
1 Nm (0.1 kgf･m, 0.7 ft･lb) 26 31

27
20 24
11 24 25 28
23
34
35
6 Nm (0.6 kgf･m, 4.4 ft･lb)

No. Part name Q’ty Remarks

1 Self-locking nut 1
2 Water inlet cover (STBD) 1
3 Water pipe 1 FL250H
4 Rubber seal 1 FL250H
5 Rubber seal 1 FL250H
6 Shift rod joint 1
7 Ball 2
8 Slider 1
9 Spring 1
10 Forward gear 1
11 Claw washer 1
12 Ring nut 1 FL250H
13 Ring nut 1 FL200B
14 Forward gear shim (T2) —
15 Cross pin 1

A. See steps 3–4 in “Assembling the propeller shaft housing assembly (FL250H)” (8-61).

8-53
 Propeller shaft housing (counter rotation model)

15 14 108 Nm (10.8 kgf･m, 79.7 ft･lb)

6 8 7 20
A
5
4
10
16 7 9 3
9
12
13
14
7 8
1 2

16 15 33
7 17 33
6
32
22 29 Nm (2.9 kgf･m, 21.4 ft･lb)
19 L

30
33
18
29
28
21 27
1 Nm (0.1 kgf･m, 0.7 ft･lb) 26 31

27
20 24
11 24 25 28
23
34
35
6 Nm (0.6 kgf･m, 4.4 ft･lb)

No. Part name Q’ty Remarks

16 Dog clutch 1
17 Shift plunger 1
18 Screw 1 M5  53 mm
19 Water inlet cover (PORT) 1
20 Taper roller bearing 1 Not reusable
21 Propeller shaft 1
22 Thrust bearing 1
23 Propeller shaft shim (T4) 1
24 O-ring 2 Not reusable
25 Propeller shaft housing 1
26 Rubber seal 1 FL250H
27 Washer 2
28 Bolt 2 M8  33 mm
29 Needle bearing 1 Not reusable
30 Oil seal 2 Not reusable

A. See steps 3–4 in “Assembling the propeller shaft housing assembly (FL250H)” (8-61).

8-54
 Propeller shaft housing (counter rotation model)

15 14 108 Nm (10.8 kgf･m, 79.7 ft･lb)

6 8 7 20
A
5
4
10
16 7 9 3
9
12
13
14
7 8
1 2

16 15 33
7 17 33
6
32
22 29 Nm (2.9 kgf･m, 21.4 ft･lb)
19 L

30
33
18
29
28
21 27
1 Nm (0.1 kgf･m, 0.7 ft･lb) 26 31

27
20 24
11 24 25 28
23
34
35
6 Nm (0.6 kgf･m, 4.4 ft･lb)

No. Part name Q’ty Remarks

31 Cover 1 FL200B
32 Cover 1 FL250H
33 Bolt 2 M8  20 mm
34 Grease nipple 1
35 Dowel 1 FL250H

A. See steps 3–4 in “Assembling the propeller shaft housing assembly (FL250H)” (8-61).

8-55
 Propeller shaft housing (counter rotation model)

Removing the propeller shaft housing

assembly (FL200B) 2
1
1. Remove the cover and bolts. See “Remov-
ing the propeller shaft housing assembly
(F200B)” (8-12).

2. Remove the propeller shaft housing as-

sembly.

2
1
Slide hammer handle “1”
90890-06531
Puller head “2”
90890-06514

3. Remove the dowel “1”.

Slide hammer handle “1”

90890-06531
Puller head “2”
90890-06514

Removing the propeller shaft housing

assembly (FL250H) 1
1. Remove the water pipe “1”, cover, and
bolts. See steps 1 and 2 in “Removing the Disassembling the propeller shaft as-
propeller shaft housing assembly sembly
(F250H)” (8-12). 1. Disassembling the propeller shaft assem-
bly. See “Disassembling the propeller
shaft assembly” (8-13).

Disassembling the propeller shaft

housing assembly (FL200B)
1
1. Remove the dog clutch. See “Disassem-
bling the propeller shaft assembly” (8-13).

2. Remove the forward gear and forward

gear shims.

1
2. Remove the propeller shaft housing as-
sembly.

8-56
 Propeller shaft housing (counter rotation model)

Bearing separator “1”

90890-06534

3. Install the propeller shaft housing assem- a

bly “1” in the reverse direction into the low-
er case.
3
1
2

6. Remove the oil seals and needle bearing.

See steps 3 and 4 in “Disassembling the
propeller shaft housing assembly (F200B)”
4. Remove the ring nut “1” and claw washer (8-13).
“2”.
Disassembling the propeller shaft
housing assembly (FL250H)
1. Remove the dog clutch. See “Disassem-
bling the propeller shaft assembly” (8-13).
1
2. Install the propeller shaft housing assem-
bly “1” in the reverse direction into the low-
2 er case.

1
3

Ring nut wrench “3”

90890-06578

5. Remove the taper roller bearing “1”, thrust

bearing “2”, and propeller shaft shims “3”.

Do not press the threads “a” of the propel-

ler shaft directly.

8-57
 Propeller shaft housing (counter rotation model)
3. Loosen the ring nut “1”.

Loosen the ring nut “1” until the ring nut is com-
pletely removed from the threads of the propel-
ler shaft housing “2”. a

3
1
2
3
1

3
2
5. Remove the forward gear “1”, forward gear
shims “2”, ring nut “3”, claw washer “4”,
and taper roller bearing “5”.

1
2

Housing nut wrench “3” 4

90890-06876
3
4. Remove the forward gear assembly “1”,
thrust bearing “2”, and propeller shaft 2
shims “3”.
1
6
Do not press the threads “a” of the propel-
ler shaft directly.
Bearing separator “6”
90890-06534

Checking the propeller shaft

1. Check the propeller shaft. Replace if dam-
aged or worn.

8-58
 Propeller shaft housing (counter rotation model)
2. Measure the propeller shaft runout.

1
2

3. Install the propeller shaft housing “1” in the

reverse direction.
Runout
0.02 mm (0.0008 in) (FL200BET,
FL250HET)

3. Check the dog clutch, shift rod joint, and

slider. Replace if cracked or worn.

Checking the dog clutch 1

1. Check the dog clutch, shift plunger, cross
pin, spring, balls, and slider. Replace if
cracked or worn.

Checking the propeller shaft housing • Use heat-resistant gloves. Otherwise,

1. Check the cooling water pipe. Replace if burns could result.
corroded, cracked, or deformed. • To prevent fires, remove any flammable
substances, such as gasoline and oil,
2. Check the propeller shaft housing. Re- around the working area.
place if cracked or damaged. • Keep good ventilation while working.

Checking the forward gear

1. Check the teeth and dogs of the forward
gear. Replace if cracked or worn.

Assembling the propeller shaft hous-

ing assembly (FL200B)
1. Install a new needle bearing and oil seals.
See steps 1 and 2 in “Assembling the pro-
peller shaft housing assembly (F200B)”
(8-15).

2. Install the original propeller shaft shims “1”

and thrust bearing “2”.

Do not reuse a shim if deformed or scratched.

8-59
 Propeller shaft housing (counter rotation model)
4. Heat the installation area of the taper roller
bearing outer race in the propeller shaft 1
housing “1” using a gas torch, and then in-
stall the propeller shaft “2” and a new taper
roller bearing “3”.

When heating the propeller shaft housing,

heat the entire installation area evenly. Oth-
erwise, the propeller shaft housing could
be damaged.
Ring nut wrench “1”
90890-06578
1
6. Install the claw washer “2” and ring nut “3”,
and then tighten the ring nut “3” to the
specified torque.

3
2

1
Ring nut wrench “1”
90890-06578

5. While holding the special service tool “1”, Ring nut “3”
strike it to check that the taper roller bear- 108 Nm (10.8 kgf·m, 79.7 ft·lb)
T.
R.

ing outer race is installed properly.

If a high-pitched metallic sound is produced

when the special service tool is struck, the ta-
per roller bearing outer race is installed proper-
ly.

8-60
 Propeller shaft housing (counter rotation model)
7. Install the original forward gear shims “1”
1 2
and forward gear “2” using the dog clutch
“3” and special service tool “4”.
Face the “F” mark “a” on the dog clutch to-
ward the forward gear. a 3

Do not reuse a shim if deformed or scratched.

1
3 3
c
4 2
b
a
Assembling the propeller shaft hous-
2 ing assembly (FL250H)
1 1. Install the original propeller shaft shims,
thrust bearing, taper roller bearing. See
steps 1–5 in “Assembling the propeller
shaft housing assembly (FL200B)” (8-59).

2. Install the claw washer “1” and ring nut “2”,

original forward gear shims “3” and for-
Ring nut wrench “4” ward gear “4” using the dog clutch “5” and
90890-06578 special service tool “6”.
Face the “F” mark “a” on the dog clutch to-
8. Install the shift plunger “1”, slider “2”, balls ward the forward gear.
“3”, and shift rod joint “4”.

When installing the slider “2”, make sure that 2

the balls “3” do not fall out of position.
1
4 2 3

1 3
3
4
1
2
3

9. Make sure to face the “F” mark “a” on the

dog clutch “1” toward the forward gear.
Align the hole “b”, in the dog clutch “1”, with
the hole “c”, in the propeller shaft.

10. Install the cross pin “2”, and then install the
spring “3”.

8-61
 Propeller shaft housing (counter rotation model)

• Install the ring nut “2” temporarily.

• Do not reuse a shim if deformed or scratched.

6 0.081m Am

a
4 Housing nut wrench “2”
3 90890-06876
2

Specified tightening torque for the

propeller shaft housing ring nut

T.
R.
Torque wrench setting value =
118 Nm ÷ (A + 0.081)  A
118 Nm (11.8 kgf·m, 86.7 ft·lb)
Ring nut wrench “6”
0.081 m
90890-06578
Housing nut wrench length
Am
3. Tighten the ring nut “1” to the specified
Torque wrench length
torque.
Example:
Torque wrench length (A) = 0.5 m
The correct setting value of the torque
Torque wrench setting value = 118 Nm ÷
wrench varies depending on its length.
(0.5 + 0.081)  0.5
When tightening the drive shaft ring nut to
= 102 Nm (10.2 kgf·m, 75.2 ft·lb)
the specified torque, use the following cal-
culation formula to obtain the correct set-
4. Install the shift plunger, slider, balls, shift
ting value.
rod joint, cross pin, and spring. See steps
8–10 in “Assembling the propeller shaft
housing assembly (FL200B)” (8-59).
1

8-62
 Drive shaft and lower case (counter rotation model)

Drive shaft and lower case (counter rotation model)

8
13

12
7
11 17
6
6
6 10 16

15
14
5

4 18

3
2 19
20
1 21

9 22
23
142 Nm (14.2 kgf㺃m, 104.7 ft㺃lb)
24

No. Part name Q’ty Remarks

1 Thrust bearing 1
2 Pinion shim (T3) —
3 O-ring 1 Not reusable
4 Needle bearing 1 Not reusable
5 Oil seal housing 1
6 Bolt 4 M8  25 mm
7 Oil seal 2 Not reusable
8 Cover 1
9 Drive shaft 1
10 Lower case 1
11 Washer 1 FL250H
12 Spring 1 FL250H
13 Thrust bearing 1 FL250H
14 Reverse gear shim (T1) —
15 Retainer 1
16 Needle bearing 1 Not reusable
17 Thrust bearing 1

8-63
 Drive shaft and lower case (counter rotation model)

8
13

12
7
11 17
6
6
6 10 16

15
14
5

4 18

3
2 19
20
1 21

9 22
23
142 Nm (14.2 kgf㺃m, 104.7 ft㺃lb)
24

No. Part name Q’ty Remarks

18 Reverse gear 1
19 Needle bearing 1 Not reusable
20 Circlip 1 Not reusable
21 Needle bearing 1 Not reusable
22 Pinion 1
23 Washer 1
24 Pinion nut 1

8-64
 Drive shaft and lower case (counter rotation model)

Removing the drive shaft (FL200B)

1. Remove the oil seal housing and drive Stopper guide plate “2”
shaft. See steps 1–3 in “Removing the 90890-06501
drive shaft (F200B)” (8-19). Bearing puller assembly “3”
90890-06535
2. Remove the reverse gear assembly and Bearing puller claw 1 “4”
thrust bearing. 90890-06536
Stopper guide stand “5”
Removing the drive shaft (FL250H) 90890-06538
1. Remove the oil seal housing, pinion shim,
thrust bearing, and pinion nut. See step 1– Disassembling the lower case
3 in “Removing the drive shaft (F200B)” (FL200B)
(8-19). 1. Remove the needle bearing. See step 1 in
“Disassembling the lower case” (8-20).
2. Remove the drive shaft, pinion, thrust
bearing, spring, and washer.
Before removing the needle bearing, make
3. Remove the reverse gear assembly and sure to remove the reverse gear.
thrust bearing.

Disassembling the oil seal housing

1. Disassemble the oil seal housing. See • Use heat-resistant gloves. Otherwise,
“Disassembling the oil seal housing” burns could result.
(8-19). • To prevent fires, remove any flammable
substances, such as gasoline and oil,
Disassembling the reverse gear around the working area.
1. Remove the circlip “1”. • Keep good ventilation while working.

2. Heat the installation area of the retainer in

1
the lower case using a gas torch, and then
remove the retainer “1” and reverse gear
shims “2”.

When heating the lower case, heat the en-

tire installation area evenly. Otherwise, the
paint on the lower case could be burned.
2. Remove the needle bearing “1”.

3 1
2
3
4 4

5 5 5
4 5

8-65
 Drive shaft and lower case (counter rotation model)
2. Remove the retainer, reverse gear shims,
and needle bearing. See steps 2 and 3 in
• Before removing the retainer “1”, place some “Disassembling the lower case (FL200B)”
cushioning material below the lower case to (8-65).
catch the retainer “1” when it falls out.
• If the retainer does not come out, lightly tap Checking the pinion
the lower unit torpedo using a plastic ham- 1. Check the teeth of the pinion. Replace if
mer. cracked or worn.

Checking the reverse gear

1. Check the teeth and dogs of the reverse
gear. Replace if cracked or worn.

Checking the drive shaft

1. Check the drive shaft. See “Checking the
drive shaft” (8-21).

Checking the lower case

2 1. Check the lower case. See “Checking the
lower case” (8-21).
1
Assembling the lower case (FL200B)
3. Remove the needle bearing “1”.
• Use heat-resistant gloves. Otherwise,
burns could result.
2 3
• To prevent fires, remove any flammable
substances, such as gasoline and oil,
around the working area.
• Keep good ventilation while working.
1
1. Install a new needle bearing “1” to the
specified depth “a”.

Needle bearing attachment “2”

90890-06654
Driver rod L3 “3”
90890-06652 a 3 1

Disassembling the lower case

(FL250H)
1. Remove the needle bearing. See step 1 in 2
“Disassembling the lower case” (8-20).
Needle bearing attachment “2”
Before removing the needle bearing, make 90890-06654
sure to remove the reverse gear. Driver rod L3 “3”
90890-06652

8-66
 Drive shaft and lower case (counter rotation model)

Depth “a” Driver rod L3 “1”

-0.25–0.25 mm (-0.010–0.010 in) 90890-06652
Needle bearing attachment “2”
2. Install the original reverse gear shims “1”. 90890-06654

3. Heat the installation area of the retainer in 5. Install a new needle bearing. See step 4 in
the lower case using a gas torch, and then “Assembling the lower case” (8-21).
install the retainer “2”.
Assembling the lower case (FL250H)
1. Install a new needle bearing, the original
When heating the lower case, heat the en- reverse gear shim, and retainer. See steps
tire installation area evenly. Otherwise, the 1–4 in “Assembling the lower case
paint on the lower case could be burned. (FL200B)” (8-66).

2. Install a new needle bearing. See step 4 in

• Do not reuse a shim if deformed or scratched. “Assembling the lower case” (8-21).
• Align the notches “a” in the retainer “2” with
the bolt holes in the torpedo. Assembling the reverse gear
1. Install a new needle bearing to the speci-
a fied depth “a”.
2
a
1
a 2
1

Needle bearing attachment “1”

90890-06653
4. While holding the special service tool “1”, Driver rod SS “2”
strike it to check that the retainer is in- 90890-06604
stalled properly.
Depth “a”
6.75–7.25 mm (0.2657–0.2854
1 in)

8-67
 Drive shaft and lower case (counter rotation model)
2. Install a new circlip “1”.
R N F
1

F
L

1 2

Assembling the oil seal housing

1. Assemble the oil seal housing. See “As-
sembling the oil seal housing” (8-23).
3. Install the propeller shaft housing assem-
Installing the drive shaft (FL200B) bly, cover, and water inlet covers. See
1. Install the thrust bearing and reverse gear steps 4–6 in “Installing the propeller shaft
assembly into the lower case. housing assembly (F200B)” (8-24).

2. Install the drive shaft and oil seal housing. Installing the propeller shaft housing
See steps 2–5 in “Installing the drive shaft assembly (FL250H)
(F200B)” (8-23). 1. Install new O-rings and set the shift rod
joint and dog clutch to the N position. See
Installing the drive shaft (FL250H) steps 1 and 2 in “Installing the propeller
1. Install the thrust bearing and reverse gear shaft housing assembly (FL200B)” (8-68).
assembly into the lower case.
2. Install the propeller shaft housing assem-
2. Install the drive shaft and pinion nut tem- bly, cover, water inlet covers, and water
porarily. See steps 2 and 3 in “Installing the pipe. See steps 4–6 in “Installing the pro-
drive shaft (F200B)” (8-23). peller shaft housing assembly (F250H)”
(8-25).
3. Install the oil seal housing, and then tight-
en the pinion nut to the specified torque.
See steps 4 and 5 in “Installing the drive
shaft (F200B)” (8-23).

Installing the propeller shaft housing

assembly (FL200B)
1. Install new O-rings to the propeller shaft
housing.

2. Set the shift rod joint “1” and dog clutch “2”
to the N position.

8-68
 Drive shaft and lower case (counter rotation model)

Installing the shift rod

1. Check that the shift rod joint is in the N po-
sition, and then install the shift rod “1”, the
spring “2”, a new O-ring “3”, the plate “4”,
and a new oil seal “5”.
Make sure to fit the tip “a” of the shift rod
“1” into the slot “b” in the shift rod joint.
5

4 3
2

a
b

Installing the water pump

1. Install the water pump. See “Installing the
water pump” (8-26).

Checking the lower unit for air leakage

1. Check the lower unit for air leakage. See
“Checking the lower unit for air leakage”
(8-27).

Installing the lower unit

1. Install the extension (U-transom model),
lower unit, trim tab, and propeller. See
steps 1–7 in “Installing the lower unit”
(8-27).

2. Fill the lower unit with gear oil up to the

proper level. See steps 5–8 in “Changing
the gear oil” (10-13).

8-69
 Shimming (counter rotation model)

Shimming (counter rotation model)

Shimming workflow

1. Remove the water pump

assembly.

2. Measure the backlash before

disassembly.

4. YES
3. Within specification? 5. Shimming is not required.

6. NO
7. Disassemble the lower unit.

8. Select the pinion shims (T3)

and propeller shaft shims (T4).

9. Assemble the lower unit.

10. Measure the backlash.

6. NO 11. Adjust the forward gear shim

3. Within specification? thickness (T2) and reverse gear
shim thickness (T1).
4. YES
12. Install the water pump
assembly.

1. Remove the water pump assembly. 8. Select the pinion shims (T3) and propel-
2. Measure the backlash before disassem- ler shaft shims (T4).
bly. 9. Assemble the lower unit.
3. Within specification? 10. Measure the backlash.
4. YES 11. Adjust the forward gear shim thickness
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.

• 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 hous-
ing, shimming is required.

8-70
 Shimming (counter rotation model)

Shimming check sheet

Lower case deviation
Serial number P F R Remarks

Pinion height
Measurements (mm)
Measuring point “a”
Measuring point “b”
Measuring point “c”
Measuring point “d”
Average
Round-down average
(M)

Forward gear backlash

Measurements (mm)
Before disassembly After disassembly
Measuring point “a”
Measuring point “b”
Measuring point “c”
Measuring point “d”
Average
Round-down average

Reverse gear backlash

Measurements (mm)
Before disassembly After disassembly
Measuring point “a”
Measuring point “b”
Measuring point “c”
Measuring point “d”
Average
Round-down average

8-71
 Shimming (counter rotation model)
Forward gear shim (T2) thickness measurement in 2 places
(mm) Number of shim(s) Subtotal
0.10
0.12
0.15
0.18
0.30
0.40
0.50
Total

Reverse gear shim (T1) thickness measurement in 2 places

(mm) Number of shim(s) Subtotal
0.10
0.12
0.15
0.18
0.30
0.40
0.50
Total

8-72
 Shimming (counter rotation model)

Measuring the forward gear backlash

and reverse gear backlash before dis- Bearing housing puller claw L “1”
assembly 90890-06502
Two pieces of washers (90201-31M00) are re- Stopper guide plate “2”
quired to measure the reverse gear backlash 90890-06501
for the shim adjustment on the counter rotation Center bolt “3”
model. Please prepare the washers before 90890-06504
starting procedure.
4. Turn the drive shaft 10 times or more to
1. Remove the water pump assembly and seat the bearings.
outer plate cartridge. See steps 1 and 2 in
5. Tighten the center bolt “1” to the specified
“Removing the water pump and shift rod
torque while holding the drive shaft not to
(F200B)” (8-8). (FL200B) See steps 1 and
2 in “Removing the water pump and shift turn.
rod (F250H)” (8-8). (FL250H)
1
2. Set the gear shift to the N position.

R
1
N
F

Shift rod socket “1”

Center bolt “1” (shimming)
90890-06681
20 Nm (2.0 kgf·m, 14.8 ft·lb)
T.
R.

3. Set up the special service tools “1”, “2”,

6. Turn the lower unit so that it is in an upright
and “3”, and then tighten the center bolt “3”
position.
temporarily.
7. Remove the cover “1”, and then install the
1 2 outer plate cartridge “2”.
3

1
1

8-73
 Shimming (counter rotation model)
9. Install the special service tool “1” at the
lowest possible position where the drive
2 shaft diameter is 22.4 mm (0.882 in).

10. Set up the special service tools “2”, “3”,

and “4”.

8. Place the spring “1” on the outer plate car-

tridge, and then install the handle holder
“2” so that the spring “1” is compressed the
specified compression distance “a” from its
free length.

• After installing the handle holder, pull the 4

2
drive shaft up to confirm that there is no free 3
play.
• Do not compress the spring more than 5.0
mm (0.197 in). Otherwise, the drive shaft will Backlash indicator “1”
not turn easily, making it difficult to obtain cor- 90890-06706
rect measurements. Magnet base plate “2”
90890-07003
Dial gauge set “3”
90890-03238
Magnet base B “4”
90890-06844
2
a

Spring “1”
90501-450A2 *1
Handle holder “2”
EU0-23814-30 (2 required) *1
*
1. Order from Yamaha Parts warehouse.

Compression distance “a”

3.0–5.0 mm (0.118–0.197 in)

8-74
 Shimming (counter rotation model)
11. Turn the drive shaft slowly clockwise and
counterclockwise and measure the back-
lash between where the drive shaft stops
in each direction. a

• The resistance force of the spring makes it

difficult to turn the drive shaft. Therefore, to b
d
obtain correct measurements, consider the
spring resistance force when turning the drive
shaft.
• Do not turn the drive shaft using too much
force. Otherwise, the forward gear will turn, c
leading to incorrect measurements.
• When turning the drive shaft, hold it using a
13. Determine the backlash average, and then
little force. A knocking sound may be heard
round down the average to the 1/100
when the drive shaft is turned, but this is the
place.
sound of the pinion contacting the reverse
gear and does not affect the backlash mea-
Example:
surement.
(mm)
Measurement point “a” 0.60
Measurement point “b” 0.51
Measurement point “c” 0.51
Measurement point “d” 0.55
Average 0.5425
Round-down average 0.54

14. Check that the forward gear backlash av-

erage is within specification.

Forward gear backlash

0.49–0.84 mm (0.0193–0.0331
in) (FL200BET)
12. Turn the drive shaft 180° clockwise and
0.15–0.88 mm (0.0059–0.0346
measure the backlash again.
in) (FL250HET)

• Measure the backlash at 4 points: “a”, “b”, “c”,

and “d”, turning the drive shaft 180° clockwise Adjust the shim thicknesses if the forward gear
after each measurement. backlash is out of specification.
• Write down the measurement data in the
shimming check sheet.
15. Remove the special service tools from the
propeller shaft.

8-75
 Shimming (counter rotation model)
16. Remove the propeller shaft housing as- 20. Repeat steps 12 and 13 to measure the re-
sembly. See step 1 in “Removing the pro- verse gear backlash.
peller shaft housing assembly (F200B)”
(8-12) and step 2 in “Removing the propel- 21. Check that the reverse gear backlash av-
ler shaft housing assembly (FL200B)” erage is within specification.
(8-56). (FL200B) See steps 1 in “Remov-
ing the propeller shaft housing assembly Reverse gear backlash
(F200B)” (8-12) and step 2 in “Removing 0.45–0.97 mm (0.0177–0.0382
the propeller shaft housing assembly in) (FL200BET)
(FL250H)” (8-56). (FL250H) 0.60–1.37 mm (0.0236–0.0539
in) (FL250HET)
17. Install the washers “1” between the re-
verse gear “2” and the propeller shaft “3”.
Adjust the shim thicknesses if the reverse gear
1 backlash is out of specification.

22. Remove the special service tools, handle

holder, spring, and outer plate cartridge.

23. Remove the propeller shaft housing as-

sembly, and then remove the washers “1”.
See step 1 in “Removing the propeller
shaft housing assembly (F200B)” (8-12)
3 and step 2 in “Removing the propeller
shaft housing assembly (FL200B)” (8-56).
1 (FL200B) See step 2 in “Removing the
2 propeller shaft housing assembly
(F250H)” (8-12) and step 2 in “Removing
the propeller shaft housing assembly
(FL250H)” (8-56). (FL250H)

24. Install the propeller shaft housing assem-

bly. See step 2 in “Installing the propeller
Washer “1” shaft housing assembly (FL200B)” (8-68)
90201-31M00 and steps 4 in “Installing the propeller shaft
housing assembly (F200B)” (8-24).
18. Install the propeller shaft housing assem- (FL200B) See step 2 in “Installing the pro-
bly (without the O-ring and dog clutch). peller shaft housing assembly (FL200B)”
See step 2 in “Installing the propeller shaft (8-68) and steps 4 in “Installing the propel-
housing assembly (FL200B)” (8-68) and ler shaft housing assembly (F250H)”
step 4 in “Installing the propeller shaft (8-25). (FL250H)
housing assembly (F200B)” (8-24).
(FL200B) See step 2 in “Installing the pro- 25. Install the cover, outer plate cartridge, and
peller shaft housing assembly (FL250H)” water pump assembly. See “Installing the
(8-68) and step 2 in “Installing the propeller water pump” (8-26). (FL200B) See steps
shaft housing assembly (F250H)” (8-25). 1–3 and 5 in “Installing the water pump”
(FL250H) (8-26). (FL250H)

19. Check that the drive shaft turns smoothly.

8-76
 Shimming (counter rotation model)

Shimming procedure
• Before selecting the forward gear shim (T2) and reverse gear shims (T1), make sure to select the pin-
ion shims (T3) and propeller shaft shims (T4).
• After selecting the pinion shims (T3), do not apply gear oil, grease or sealant to the lower unit parts
to measure the backlash.
• When assembling the lower unit after shimming is completed, make sure to apply gear oil, grease,
and sealant to the specified areas.

Shim location (FL200B)

T3 F
P
R

T2 T4
T1

8-77
 Shimming (counter rotation model)

Shim location (FL250H)

T3 F
P
R

T2 T4
T1

8-78
 Shimming (counter rotation model)

Selecting the pinion shim (T3)

1. See “Selecting the pinion shim (T3)” Propeller shaft free play
(8-38). 0.25–0.35 mm (0.0098–0.0138
in) (FL200BET, FL250HET)
Pinion shim (T3) selection table
See “Pinion shim (T3) selection table” (A-12). 3. Determine the propeller shaft shim (T4)
thickness adjustment using the “propeller
Selecting the propeller shaft shim (T4) shaft shim (T4) selection table” according
1. Install the original propeller shaft shims, to the free play measurement.
and then assemble the propeller shaft
housing assembly. See steps 2–10 in “As- Example:
sembling the propeller shaft housing as- Free play measurement = 0.46 mm “a”
sembly (FL200B)” (8-59). (FL200B) See Propeller shaft shim (T4) thickness adjust-
steps 2–5 in “Assembling the propeller ment = 0.15 mm “b”
shaft housing assembly (FL200B)” (8-59) The current shim thickness must be in-
and steps 2–4 in “Assembling the propeller creased by 0.15 mm.
shaft housing assembly (FL250H)” (8-61).
(FL250H)
A 0.18 0.26 0.28 0.30
B –0.10 –0.10
• If the original shims are missing, measure the
free play without any shims.
A 0.36 0.44 0.46 0.48
• Do not reuse a shim if deformed or scratched.
B +0.10 +0.12 +0.15 +0.15

2. Set up the special service tools “1” and “2”, a b

and then measure the propeller shaft free
play. A. Free play measurement
B. Shim thickness adjustment

• If the shim thickness adjustment value is pos-

itive, the current shim thickness must be in-
2
creased by that amount and, if the value is
negative, the current shim thickness must be
decreased by that amount.
1
• The gray-colored cells on the selection table
indicate the specified propeller shaft free
play. Shimming is not required if the mea-
sured propeller shaft free play is 0.25–0.35
mm.
• The values for the shim thickness adjust-
ments specified in the selection table are in-
Dial gauge set “1” tended to obtain the specified propeller shaft
90890-03238 free play of 0.3 mm.
Magnet base B “2”
90890-06844

8-79
 Shimming (counter rotation model)
4. Calculate the new propeller shaft shim Measuring the forward gear backlash
(T4) thickness. • Spray anti-rust lubricant on the gears and
Calculation formula: bearings before installation. Do not apply
New propeller shaft shim (T4) thickness = gear oil to the parts. Otherwise, correct mea-
Current propeller shaft shim thickness + surements cannot be obtained.
Shim thickness adjustment • Keep the parts free of foreign material, such
as dirt and lint.
Example: • When measuring the forward gear or reverse
Use the following formula when the shim gear backlash, use the original bearings and
thickness adjustment value is negative. shims.
Current propeller shaft shim thickness =
0.82 mm 1. Install the original forward gear shims, and
Shim thickness adjustment = –0.15 mm then assemble the propeller shaft housing
New propeller shaft shim (T4) thickness = assembly. See steps 7–10 in “Assembling
0.82 mm – 0.15 mm = 0.67 mm the propeller shaft housing assembly
(FL200B)” (8-59). (FL200B) See steps 2–4
Propeller shaft shims in “Assembling the propeller shaft housing
0.10/0.12/0.15/0.18/0.30/0.40/ assembly (FL250H)” (8-61). (FL250H)
0.50 mm (FL200BET,
FL250HET)
• If the original shims are missing, install new
shims with a combined thickness of 1.12 mm.
• Do not reuse a shim if deformed or scratched.
Use up to 3 shims to obtain the required shim
thickness.
2. Install the propeller shaft housing assem-
bly (without the O-ring and dog clutch).
5. Remove the dog clutch. See “Disassem- See step 2 in “Installing the propeller shaft
bling the propeller shaft assembly” (8-13). housing assembly (FL200B)” (8-68) and
step 4 in “Installing the propeller shaft
6. Remove the propeller shaft assembly. See
housing assembly (F200B)” (8-24).
steps 2–5 in “Disassembling the propeller
(FL200B) See step 1 in “Installing the pro-
shaft housing assembly (FL200B)” (8-56).
peller shaft housing assembly (FL250H)”
(FL200B) See steps 2–5 in “Disassem-
(8-68) and step 4 in “Installing the propeller
bling the propeller shaft housing assembly
shaft housing assembly (F250H)” (8-25).
(FL250H)” (8-57). (FL250H)
(FL250H)
7. Install the selected propeller shaft shims
3. Check that the drive shaft turns smoothly.
(T4), and then assemble the propeller
shaft housing. See steps 2–10 in “Assem- 4. Measure the forward gear backlash. See
bling the propeller shaft housing assembly steps 2–14 in “Measuring the forward gear
(FL200B)” (8-59). (FL200B) See steps 2–5 backlash and reverse gear backlash be-
in “Assembling the propeller shaft housing fore disassembly” (8-73).
assembly (FL200B)” (8-59) and steps 2–4
in “Assembling the propeller shaft housing Forward gear backlash
assembly (FL250H)” (8-61). (FL250H) 0.49–0.84 mm (0.0193–0.0331
in) (FL200BET)
0.15–0.88 mm (0.0059–0.0346
in) (FL250HET)

8-80
 Shimming (counter rotation model)
4. Determine the forward gear shim (T2)
thickness adjustment using the “Forward
In the “Forward gear shim (T2) selection chart”, gear shim (T2) selection chart” according
use the round-down average for the backlash to the backlash measurement (BL2) from
measurement (BL2). “Measuring the forward gear backlash”.
See “Forward gear shim (T2) selection
chart (counter rotation model: FL200B)”
(A-13). (FL200B) See “Forward gear shim
(T2) selection chart (counter rotation mod-
el: FL250H)” (A-14). (FL250H)

• If the shim thickness adjustment value is pos-

itive, the current shim thickness must be in-
creased by that amount and, if the value is
negative, the current shim thickness must be
decreased by that amount.
• The gray-colored area on the selection chart
indicates the range of the specified backlash.
Shimming is not required if the measured
Adjusting the forward gear shim (T2) backlash is within the gray-colored area.
thickness • The values for the shim thickness adjust-
1. Remove the propeller shaft housing as- ments specified in the selection chart are in-
sembly. See step 1 in “Removing the pro- tended to obtain the median value within the
peller shaft housing assembly (F200B)” range for the specified forward gear back-
(8-12) and step 2 in “Removing the propel- lash.
ler shaft housing assembly (FL200B)” • The table that follows the selection chart
(8-56). (FL200B) See step 2 in “Removing shows the shim thickness adjustments for the
the propeller shaft housing assembly points marked on the chart.
(F250H)” (8-12) and step 2 in “Removing
the propeller shaft housing assembly
(FL250H)” (8-56). (FL250H)

2. Remove the original forward gear shim.

See step 2 in “Disassembling the propeller
shaft housing assembly (FL200B)” (8-56).
(FL200B) See step 5 in “Disassembling
the propeller shaft housing assembly
(FL250H)” (8-57). (FL250H)

3. Measure the thickness of each original for-

ward gear shim in 2 places.

Do not reuse a shim if deformed or scratched.

8-81
 Shimming (counter rotation model)
Example:
Backlash measurement (BL2) = 0.90 mm
“a” • Use the least number of shims to obtain the
Forward gear shim (T2) thickness adjust- required shim thickness.
ment = 0.15 mm “b” • If the calculated shim thickness cannot be ob-
The current shim thickness must be in- tained with a combination of the available
creased by 0.15 mm. shims, increase the shim thickness by 0.01
mm.
0.40
B (mm)

0.30
0.20 6. Install the determined forward gear shims
(T2), and then assemble the propeller
0.10
shaft housing assembly. See steps 7–10
0
in “Assembling the propeller shaft housing
b –0.10
assembly (FL200B)” (8-59). (FL200B) See
–0.20 steps 2–4 in “Assembling the propeller
–0.30 shaft housing assembly (FL250H)” (8-61).
–0.40 (FL250H)
–0.50
0 5 80 85 90 Measuring the reverse gear backlash
A (1/100 mm) • Spray anti-rust lubricant on the gears and
a
bearings before installation. Do not apply
A 0 5 80 85 90 gear oil to the parts. Otherwise, correct mea-
surements cannot be obtained.
B –0.50 –0.45 0.12 0.15 • Keep the parts free of foreign material, such
as dirt and lint.
A. Backlash measurement (BL2) • When measuring the forward gear or reverse
B. Shim thickness adjustment gear backlash, use the original bearings and
shims.
5. Calculate the new forward gear shim (T2)
thickness. 1. Install the original reverse gear shims.
Calculation formula:
New forward gear shim (T2) thickness =
Current forward gear shim thickness + • If the original shims are missing, install new
Shim thickness adjustment shims with a combined thickness of 0.65 mm.
• Do not reuse a shim if deformed or scratched.
Example:
Use the following formula when the shim 2. Install the retainer. See steps 3 and 4 in
thickness adjustment value is negative. “Assembling the lower case (FL200B)”
Current forward gear shim thickness = (8-66).
1.12 mm
Shim thickness adjustment = –0.20 mm 3. Install the thrust bearing and reverse gear
New forward gear shim (T2) thickness = assembly into the lower case.
1.12 mm – 0.20 mm = 0.92 mm
4. Install the pinion shims, drive shaft, pinion,
Forward shims and oil seal housing. See steps 2–5 in “In-
0.10/0.12/0.15/0.18/0.30/0.40/ stalling the drive shaft (F200B)” (8-23).
0.50 mm (FL200BET, (FL200B) See steps 2 and 3 in “Installing
FL250HET) the drive shaft (F250H)” (8-24) and steps 4
and 5 in “Installing the drive shaft (F200B)”
(8-23). (FL250H)

8-82
 Shimming (counter rotation model)
5. Install the 2 pieces of washers (90201- Adjusting the reverse gear shim (T1)
31M00) and propeller shaft housing as- thickness
sembly (without the O-ring and dog 1. Remove the propeller shaft housing as-
clutch). See step 2 in “Installing the propel- sembly. See step 1 in “Removing the pro-
ler shaft housing assembly (FL200B)” peller shaft housing assembly (F200B)”
(8-68) and step 4 in “Installing the propeller (8-12) and step 2 in “Removing the propel-
shaft housing assembly (F200B)” (8-24). ler shaft housing assembly (FL200B)”
(FL200B) See step 2–3 in “Installing the (8-56). (FL200B) See step 2 in “Removing
propeller shaft housing assembly the propeller shaft housing assembly
(FL250H)” (8-68) and step 4 in “Installing (F250H)” (8-12) and step 2 in “Removing
the propeller shaft housing assembly the propeller shaft housing assembly
(F250H)” (8-25). (FL250H) (FL250H)” (8-56). (FL250H)

6. Check that the drive shaft turns smoothly. 2. Remove the retainer and original reverse
gear shims. See step 2 in “Disassembling
7. Measure the reverse gear backlash. See the lower case (FL200B)” (8-65).
steps 12, 13, and 21 in “Measuring the for-
ward gear backlash and reverse gear 3. Measure the thickness of each original re-
backlash before disassembly” (8-73). verse gear shim in 2 places.

Reverse gear backlash

0.45–0.97 mm (0.0177–0.0382 Do not reuse a shim if deformed or scratched.
in) (FL200BET)
0.60–1.37 mm (0.0236–0.0539 4. Determine the reverse gear shim (T1)
in) (FL250HET) thickness adjustment using the “Reverse
gear shim (T1) selection chart” according
to the backlash measurement (BL1) from
In the “Reverse gear shim (T1) selection “Measuring the reverse gear backlash.”
chart,” use the round-down average for the See “Reverse gear shim (T1) selection
backlash measurement (BL1). chart (counter rotation model: FL200B)”
(A-13). (FL200B) See “Reverse gear shim
(T1) selection chart (counter rotation mod-
el: FL250H)” (A-14). (FL250H)

8-83
 Shimming (counter rotation model)
Example: 5. Calculate the new reverse gear shim (T1)
Backlash measurement (BL1) = 1.00 mm thickness.
“a” Calculation formula:
Reverse gear shim (T1) thickness adjust- New reverse gear shim (T1) thickness =
ment = 0.20 mm “b” Current reverse gear shim thickness +
The current shim thickness must be in- Shim thickness adjustment
creased by 0.20 mm.
Example:
0.40
Use the following formula when the shim
0.30
thickness adjustment value is negative.
0.20 Current reverse gear shim thickness =
b 0.10 0.65 mm
0 Shim thickness adjustment = –0.20 mm
B (mm)

–0.10 New reverse gear shim (T1) thickness =

–0.20 0.65 mm – 0.20 mm = 0.45 mm
–0.30
–0.40 Reverse shims
–0.50 0.10/0.12/0.15/0.18/0.30/0.40/
0 5 10 90 95 100 0.50 mm (FL200BET,
A (1/100 mm) a FL250HET)

A 0 5 10 95 100
• Use the least number of shims to obtain the
B –0.50 –0.47 –0.43 0.20 required shim thickness.
• If the calculated shim thickness cannot be ob-
A. Backlash measurement (BL1) tained with a combination of the available
B. Shim thickness adjustment shims, increase the shim thickness by 0.01
mm.

• If the shim thickness adjustment value is pos-

itive, the current shim thickness must be in- 6. Install the determined reverse gear shims
creased by that amount and, if the value is (T1) and retainer. See steps 3 and 4 in “As-
negative, the current shim thickness must be sembling the lower case (FL200B)” (8-66).
decreased by that amount. (FL200B/FL250H)
• The gray-colored area on the selection chart
indicates the range of the specified backlash.
Shimming is not required if the measured
backlash is within the gray-colored area.
• The values for the shim thickness adjust-
ments specified in the selection chart are in-
tended to obtain the median value within the
range for the specified reverse gear back-
lash.
• The table that follows the selection chart
shows the shim thickness adjustments for the
points marked on the chart.

8-84
 Bracket unit

Shift rod and shift bracket................................................. 9-1

Removing the shift rod and shift bracket .................................... 9-3
Disassembling the shift bracket.................................................. 9-3
Assembling the shift bracket ...................................................... 9-4
Installing the shift rod and shift bracket ...................................... 9-4

PTT switch and cowling lock lever ................................... 9-6

Removing the PTT switch .......................................................... 9-9
Removing the cowling lock lever ................................................ 9-9
Removing the flushing hose and cooling water hose ................. 9-9
Installing the flushing hose and cooling water hose ................. 9-10
Installing the cowling lock lever ................................................ 9-11
Installing the PTT switch .......................................................... 9-11

Bottom cowling ................................................................ 9-12

Upper case and mounts .................................................. 9-14

Removing the upper case ........................................................ 9-16
Installing the upper case .......................................................... 9-16

Upper case ........................................................................ 9-18

Disassembling the upper case ................................................. 9-20
Checking the drive shaft bushing ............................................. 9-20
Checking the PCV .................................................................... 9-20
Assembling the upper case ...................................................... 9-20

Oil pan and exhaust manifold ......................................... 9-22

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

Steering arm ..................................................................... 9-27

Removing the steering arm ...................................................... 9-28
Installing the steering arm ........................................................ 9-28

Clamp bracket and swivel bracket.................................. 9-30

Removing the clamp bracket.................................................... 9-32
Checking the clamp bracket anode .......................................... 9-32
Installing the clamp bracket...................................................... 9-32
 Bracket unit

Adjusting the trim sensor cam .................................................. 9-34

0
PTT unit ............................................................................. 9-36
Removing the PTT unit............................................................. 9-37
Checking the hydraulic pressure .............................................. 9-38 1
Bleeding the PTT unit............................................................... 9-40
Installing the PTT unit............................................................... 9-41
2
PTT motor ......................................................................... 9-43
Removing the reservoir ............................................................ 9-45
Removing the PTT motor ......................................................... 9-45
Disassembling the PTT motor .................................................. 9-45
3
Checking the armature (PTT motor)......................................... 9-46
Checking the brush .................................................................. 9-47
Checking the reservoir ............................................................. 9-47
Checking the filter..................................................................... 9-47
4
Assembling the PTT motor....................................................... 9-47
Installing the reservoir .............................................................. 9-49
Installing the PTT motor ........................................................... 9-49 5
PTT gear pump ................................................................. 9-51
Disassembling the gear pump assembly.................................. 9-54 6
Checking the gear pump .......................................................... 9-54
Checking the gear pump housing............................................. 9-55
Checking the filter..................................................................... 9-55
Assembling the gear pump assembly ...................................... 9-55
7
PTT cylinder...................................................................... 9-57
Removing the tilt ram ............................................................... 9-59
8
Removing the trim ram ............................................................. 9-59
Disassembling the tilt ram ........................................................ 9-60
Disassembling the trim ram...................................................... 9-60
Checking the tilt cylinder and trim cylinder ............................... 9-60
9
Checking the absorber valve.................................................... 9-61
Assembling the tilt ram ............................................................. 9-61
Assembling the trim ram........................................................... 9-62 10
Installing the tilt cylinder ........................................................... 9-62
Installing the trim ram ............................................................... 9-63
Installing the tilt ram ................................................................. 9-63

A
 Shift rod and shift bracket

Shift rod and shift bracket

18 Nm (1.8 kgf·m, 13.3 ft·lb) 1 2 Nm (0.2 kgf·m, 1.5 ft·lb) 1
27
19 2 Nm (0.2 kgf·m, 1.5 ft·lb) 1 2
7
20 2 8
21
15
3
4 10
9
20
23 22 6
16
26 11 11
17 24
18 25 5 14
13 12
16

28

29
1 Nm (0.1 kgf·m, 0.7 ft·lb)

19 Nm (1.9 kgf·m, 14.0 ft·lb)

No. Part name Q’ty Remarks

1 Screw 4 M4  16 mm
2 Plate 2
3 Shift position switch 1
4 Bushing 1
5 Bracket 1
6 Plastic tie 1
7 Shift cut-off switch 1
8 Bolt 2 M6  35 mm
9 Holder 1
10 Spring 1
11 Bushing 2
12 Bracket 1
13 Grease nipple 1
14 Bolt 1
15 Washer 1
16 Clip 2
17 Bushing 1

9-1
 Shift rod and shift bracket

18 Nm (1.8 kgf·m, 13.3 ft·lb) 1 2 Nm (0.2 kgf·m, 1.5 ft·lb) 1

27
19 2 Nm (0.2 kgf·m, 1.5 ft·lb) 1 2
7
20 2 8
21
15
3
4 10
9
20
23 22 6
16
26 11 11
17 24
18 25 5 14
13 12
16

28

29
1 Nm (0.1 kgf·m, 0.7 ft·lb)

19 Nm (1.9 kgf·m, 14.0 ft·lb)

No. Part name Q’ty Remarks

18 Shift lever 1
19 Washer 1
20 Bushing 2
21 Bolt 1 M6  35 mm
22 Bracket 1
23 Ball 1
24 Spring 1
25 Shift rod detent bolt 1
26 Pin 1
27 Cotter pin 1 Not reusable
28 Shift rod 1
29 Grommet 1

9-2
 Shift rod and shift bracket

Removing the shift rod and shift 4

bracket 5
1. Remove the shift cut-off switch coupler “a”. 7
2. Remove the clip “1” and bushing “2”, and
3 6
then remove the shift bracket assembly
“3”, holder “4”, and washer “5”. 2
7
1
4
a 2

1
Disassembling the shift bracket
1. Remove the bracket “1”, spring “2”, and
bushings “3”.

1
3
5

2
3
3
3. Remove the clip “1”, and then remove the
shift lever “2” and bushing “3”.
2. Remove the plastic tie “1”, and then re-
4. Remove the shift rod assembly “4” and move the plate “2” and shift position switch
grommet “5”. “3”.

4
2
2 3
5 3 1
1

3. Remove the plate “1” and shift cut-off

switch “2”.

4. Remove the grease nipple “3”.

5. Remove the shift rod detent bolt “1”, spring
“2”, and ball “3”.
1
6. Remove the cotter pin “4”, washer “5”,
2
bracket “6”, and bushings “7”.

9-3
 Shift rod and shift bracket

Assembling the shift bracket

2
1. Install the shift position switch “1” and plate
“2”, and then tighten the shift position 3
switch screws “3” to the specified torque. 4
1
2. Fasten the shift position switch lead “a” us- a
ing the plastic tie “4”.
3

4 b
2
a 3
1 4 1

7. Turn the bracket “1” to position “a”, push it

down, and then tighten the shift bracket
bolt “2” to the specified torque.
Shift position switch screw “3”
2 Nm (0.2 kgf·m, 1.5 ft·lb) Move the shift cut-off switch lever “b” in di-
T.
R.

rection “c” when pushing the shift bracket

3. Install the grease nipple “1”, and then tight- “1” down. Otherwise, the lever may be
en it to the specified torque. damaged.
4. Install the shift cut-off switch “2” and plate
“3”, and then tighten the shift cut-off switch
1
screws “4” to the specified torque.
4
1
a
3
2

c
1
b
2

Grease nipple “1”

1 Nm (0.1 kgf·m, 0.7 ft·lb) Shift bracket bolt “2”
T.
R.

Shift cut-off switch screw “4” 19 Nm (1.9 kgf·m, 14.0 ft·lb)

T.
R.

2 Nm (0.2 kgf·m, 1.5 ft·lb)

Installing the shift rod and shift brack-
5. Install the bushings “1” and spring “2” onto
et
the bracket “3”.
1. Install the bushings “1”, bracket “2”, and
washer “3”, and then install a new cotter
6. Fit the spring end “a” into the slot in the
pin “4”.
bracket “3” and the spring end “b” into the
slot in the bracket “4”.

9-4
 Shift rod and shift bracket
2. Install the ball “5” and spring “6”, and then
tighten the shift rod detent bolt “7” to the 3
specified torque. a 4
4 5
3
1

1 2 4
2
5 1
6 6
7

Shift rod detent bolt “7”

18 Nm (1.8 kgf·m, 13.3 ft·lb)
T.
R.

3. Install the bushing “1” and shift lever “2”,

and then align the center of the pin “a” on
the shift lever “2” with the mark “b” on the
bottom cowling.

4. Install the clip “3”.

5. Install the grommet “4” and shift rod as-

sembly “5”.

3 5

2
1

a
4

6. Install the washer “1”, shift bracket assem-

bly “2”, and holder “3”, and then install the
bushing “4” and clip “5” to the shift lever
“6”.

7. Install the shift switch coupler “a”.

9-5
 PTT switch and cowling lock lever

PTT switch and cowling lock lever

8 10 5 Nm (0.5 kgf·m, 3.7 ft·lb)
6 7 10
5 14
5 10
8
9 15 9
11 7 14
11 12 8
7 12 5 9
A 1 3 31 31 33 11
4 5 13 6
20 32 12 7
6 32 16
28 5
5 6
29
30
1 37 27 34
2
20 26
25
22
24 5
23 5
20
4
3
21 12
1
20
12 12
A 1
17 35
2
19 18
36

No. Part name Q’ty Remarks

1 Gasket 2 Not reusable
2 PTT switch 1
3 Cover 1
4 Holder 2
8 M6  20 mm/Regular rotation model
5 Bolt
7 M6  20 mm/Counter rotation model
6 Hook 3
7 Spring 3
8 Bolt 3 M6  20 mm
9 Washer 3
10 Lever 3
11 Wave washer 3
12 Bushing 6
13 Housing (front) 1
14 Bolt 6 M6  30 mm
15 Housing (STBD) 1
16 Housing (PORT) 1

A. Counter rotation model

9-6
 PTT switch and cowling lock lever

8 10 5 Nm (0.5 kgf·m, 3.7 ft·lb)

6 7 10
5 14
5 10
8
9 15 9
11 7 14
11 12 8
7 12 5 9
A 1 3 31 31 33 11
4 5 13 6
20 32 12 7
6 32 16
28 5
5 6
29
30
1 37 27 34
2
20 26
25
22
24 5
23 5
20
4
3
21 12
1
20
12 12
A 1
17 35
2
19 18
36

No. Part name Q’ty Remarks

17 Cowling lock lever (PORT) 1
18 Cowling lock lever (STBD) 1
19 Cowling lock lever (front) 1
20 Plastic tie 5
21 Grommet 1
22 Hose 1
23 Joint 1
24 Joint 1
25 Gasket 1
26 Adapter 1
27 Hose 1
28 Joint 1
29 Hose 1
30 Clamp 1
31 Bolt 2 M6  25 mm
32 Plate 2
33 Screw 2 ø6  20 mm

A. Counter rotation model

9-7
 PTT switch and cowling lock lever

8 10 5 Nm (0.5 kgf·m, 3.7 ft·lb)

6 7 10
5 14
5 10
8
9 15 9
11 7 14
11 12 8
7 12 5 9
A 1 3 31 31 33 11
4 5 13 6
20 32 12 7
6 32 16
28 5
5 6
29
30
1 37 27 34
2
20 26
25
22
24 5
23 5
20
4
3
21 12
1
20
12 12
A 1
17 35
2
19 18
36

No. Part name Q’ty Remarks

34 Holder 1
35 PTT switch wire harness extension 1 Counter rotation model
36 Holder 1 Counter rotation model
37 Holder 1 Regular rotation model

A. Counter rotation model

9-8
 PTT switch and cowling lock lever

Removing the PTT switch

1. Remove the holder “1” (regular rotation
model) or holder “2” (counter rotation mod-
el) and holder “3”, and then remove the
PTT switch “4” and gasket “5”.
A
3
1
STBD

1
4 5 2

Removing the flushing hose and cool-

B ing water hose
3
1. Remove the adapter “1” and joints “2” and
4 “3”.
PORT 5

2 1

2
A. Regular rotation model 3
B. Counter rotation model

Removing the cowling lock lever

1. Remove the spring “1”.

2. Remove the plates “1” and holder “2” (reg-

ular rotation model).

2. Remove the lever “1” and cowling lock le-

ver “2”.

9-9
 PTT switch and cowling lock lever
3. Remove the cooling water pilot hose “3”,
cooling water hose “4”, and joint “5”.

4
5 5 4

3
1 5
1 2 4 a 1
5
2
b
3 3
2 5

4 2. Install the cooling water pilot hose “1”,

cooling water hose “2”, and joint “3”, and
4. Remove the flushing hose “1”, trim sensor then fasten the hoses “1” and “2” using the
lead “2”, PTT motor lead “3”, and grommet clamp “4” and plastic ties “5”.
“4”.
3. Route the flushing hose “6”, cooling water
4 hose “2”, trim sensor lead “7”, PTT motor
lead “8”, and speedometer hose “9”.

4. Fasten the flushing hose “6”, cooling water

1
hose “2”, and trim sensor lead “7” using the
3 plates “10” and holder “11” (regular rota-
tion model).
2
2
3
Installing the flushing hose and cool- 1
ing water hose 5
1. Pass the flushing hose “1”, trim sensor 4
lead “2”, and PTT motor lead “3” through
10 11 6
the grommet “4”, and then fasten them us-
ing the plastic ties “5” around the grommet
“4”.
8
Align the white paint mark “a” on the flushing 9
hose “1” and the white tape “b” on the PTT mo- 7 2
tor lead “3” with the inner end of the grommet
“4”. 5. Install the adapter “1”, and then tighten the
flushing hose adapter screws “2” to the
specified torque.

6. Route the flushing hose “3” through the

joint “4”, connect the flushing hose “3” to
the joint “5”, and then fasten the flushing
hose “3” using the plastic tie “6”.

9-10
 PTT switch and cowling lock lever
7. Install the gasket “7” and joint “4” to the 3. Inject grease into the housing “1” until
adapter “1”. grease comes out from the housing.

2
1 1

5
4
7

6
3 Installing the PTT switch
1. Install a new gasket “1”, the PTT switch
“2”, and the holder “3”.

2. Fasten the PTT switch lead “4” using the

Flushing hose adapter screw “2” holder “5” (regular rotation model) or hold-
5 Nm (0.5 kgf·m, 3.7 ft·lb) er “6” (counter rotation model).
T.
R.

Installing the cowling lock lever

1. Install the cowling lock lever “1” and lever To fasten the PTT switch lead, see “Wiring har-
“2”. ness routing” (5-7).

A
3
STBD
2
4

5
2 1

B
3
1
PORT 1 2 4
2. Install the spring “1”.

1
6

A. Regular rotation model

B. Counter rotation model

9-11
 Bottom cowling

Bottom cowling

4
3 10 13
8
11
10
14 4
11
10
2 7 5
11
1

11 10 19
12
9 11
18
18
4
15
11 11
15 12 12 6
11
16
12
17

No. Part name Q’ty Remarks

1 Bracket 1
2 Bolt 1 M6  30 mm
3 Bracket 1
4 Bolt 3 M6  20 mm
5 Bracket 1
6 Bracket 1
7 Bracket 1
8 Rivet 2
9 Water outlet 1
10 Bolt 4 M8  35 mm
11 Grommet 8
12 Collar 4
13 Rubber seal 1
14 Grommet 2
15 Grommet 2
16 Rubber seal 1
17 Grommet 1

9-12
 Bottom cowling

4
3 10 13
8
11
10
14 4
11
10
2 7 5
11
1

11 10 19
12
9 11
18
18
4
15
11 11
15 12 12 6
11
16
12
17

No. Part name Q’ty Remarks

18 Grommet 2
19 Bottom cowling 1

9-13
 Upper case and mounts

Upper case and mounts

14 54 Nm (5.4 kgf·m, 39.8 ft·lb)

18 19
13
17
16
11 15
72 Nm (7.2 kgf·m, 53.1 ft·lb) 12 18
9 17 12 16 19
8 16
7 15
6 12

15 17 18

7 8 11
3 5
4

6 9
1 3 23
22 10
3 9
2 21 8 11

26
20 22 6 7
3 A
2 24
5 4
72 Nm (7.2 kgf·m, 53.1 ft·lb) 25 26 20

No. Part name Q’ty Remarks

1 Nut 2 M14
2 Nut 2 M14
3 Washer 4
4 Bolt 4 M10  45 mm
5 Bracket 2
6 Washer 2
7 Lower mount 2
8 Washer 2
9 Washer 2
10 Ground lead 1
11 Bolt 2 M14  205 mm
12 Upper mount 2
13 Bracket 1
14 Bolt 3 M10  45 mm
15 Washer 2
16 Washer 2
17 Washer 2

A. X-transom model
9-14
 Upper case and mounts

14 54 Nm (5.4 kgf·m, 39.8 ft·lb)

18 19
13
17
16
11 15
72 Nm (7.2 kgf·m, 53.1 ft·lb) 12 18
9 17 12 16 19
8 16
7 15
6 12

15 17 18

7 8 11
3 5
4

6 9
1 3 23
22 10
3 9
2 21 8 11

26
20 22 6 7
3 A
2 24
5 4
72 Nm (7.2 kgf·m, 53.1 ft·lb) 25 26 20

No. Part name Q’ty Remarks

18 Bolt 2 M14  190 mm
19 Cap 2
20 Bolt 1 M6  10 mm
21 Nipple 1
22 Plastic tie 2
23 Hose 1
24 Dowel 1 X-transom model
25 Adapter 1 X-transom model
26 Bolt 1 M6  25 mm/X-transom model

A. X-transom model

9-15
 Upper case and mounts

Removing the upper case 2. Install the upper mount bracket “3”, and
1. Drain the remaining engine oil. then tighten the upper mount bracket bolts
“4” temporarily.
2. Disconnect the ground lead “1”.

3. Remove the adapter “2” (X-transom mod- Make sure that the notches “a” in the washer
el). are facing forward.

4. Loosen the upper mount bracket bolts “3” 1 a 2

and lower mount bracket bolts (PORT and
STBD) “4”.
3
4 2

4 3. Install the lower mounts “1”, and lower

2 mount bolts “2”.

1 4. Install the lower mounts “1” and lower

2 mount brackets “3”, and then tighten the
lower mount brackets bolts “4” temporarily.
1

5. Remove the upper mounting nuts “1” and The ground lead should be installed on the
lower mounting nuts “2”, and then remove same side as originally installed.
the upper case assembly “3”.
1 2

1
2

3
1
3 4
2
5. Install the upper and lower mounting bolts
Installing the upper case
into the bracket assembly “1” simultane-
1. Install the upper mounts “1” to the upper
ously.
mount bolts “2”.

9-16
 Upper case and mounts
6. Install the washers “2”, upper mounting
nuts “3”, and lower mounting nuts “4”, and [2]
then tighten the upper mounting nuts “3” [1]
1
and lower mounting nuts “4” to the speci- [3]
fied torque.

3
2

2 Upper mount bracket bolt “1”

54 Nm (5.4 kgf·m, 39.8 ft·lb)

T.
R.
4 2 9. Tighten the lower mount bracket bolts “1”.

Upper mounting nut “3” 10. Connect the ground lead “2”.
72 Nm (7.2 kgf·m, 53.1 ft·lb)
11. Pass the speedometer hose “3” through
T.
R.

Lower mounting nut “4”

the steering arm “4”, and then connect it to
72 Nm (7.2 kgf·m, 53.1 ft·lb)
the adapter “5” (X-transom model).
7. Install the caps “1”.
1
3
4

8. Tighten the upper mount bracket bolts “1” 5 1

to the specified torque in the order [1], [2],
and so on. 2
5
2

9-17
 Upper case

Upper case
4 Nm (0.4 kgf㺃m, 3.0 ft㺃lb)
8 Nm (0.8 kgf㺃m, 5.9 ft㺃lb) 42 Nm (4.2 kgf㺃m, 31.0 ft㺃lb)
17 28 Nm (2.8 kgf·m, 20.7 ft·lb)
20 Nm (2.0 kgf㺃m, 14.8 ft㺃lb)
20 13
18 21
15 15 13
19 22 5 12
16 16
23
4
9 11
8

10
8 14
7
6 1
23 23

24

14

3
25
2
15
8 Nm (0.8 kgf㺃m, 5.9 ft㺃lb)

No. Part name Q’ty Remarks

1 Upper case 1
2 Circlip 1
3 Bushing 1
4 Rubber seal 1
5 Dowel 2
6 Damper 1
7 Cover 1
8 Bolt 2 M6  14 mm
9 Gasket 1 Not reusable
10 Drain bolt 1 M14  12 mm
11 Rubber seal 1
12 Baffle plate 1
13 Screw 2 M6  16 mm
14 Apron stay 6
15 Bolt 2 M8  30 mm
16 Dowel 2
17 PCV 1

9-18
 Upper case

4 Nm (0.4 kgf㺃m, 3.0 ft㺃lb)

8 Nm (0.8 kgf㺃m, 5.9 ft㺃lb) 42 Nm (4.2 kgf㺃m, 31.0 ft㺃lb)
17 28 Nm (2.8 kgf·m, 20.7 ft·lb)
20 Nm (2.0 kgf㺃m, 14.8 ft㺃lb)
20 13
18 21
15 15 13
19 22 5 12
16 16
23
4
9 11
8

10
8 14
7
6 1
23 23

24

14

3
25
2
15
8 Nm (0.8 kgf㺃m, 5.9 ft㺃lb)

No. Part name Q’ty Remarks

18 O-ring 1 Not reusable
19 O-ring 1 Not reusable
20 Bolt 1 M6  20 mm
21 Plate 1
22 Collar 1
23 Bolt 6 M10  45 mm
24 Rubber seal 1
25 Rubber seal 1 Not reusable

9-19
 Upper case

Disassembling the upper case

1. Remove the engine oil drain bolt “1”, cover Bearing puller assembly “3”
“2”, and damper “3”. 90890-06535
Stopper guide stand “4”
3 90890-06538
2
Stopper guide plate “5”
90890-06501

1 Checking the drive shaft bushing

1. Check the drive shaft bushing. Replace if
cracked or worn.

Checking the PCV

2. Remove the bolts “1” and “2” and PCV “3”, 1. Check the PCV. Replace if cracked or
and then remove the oil pan assembly “4”. damaged.

2 1 3 Assembling the upper case

1 1 1. Install the bushing “1”, and then install the
circlip “2”.

1 2
4 4

2 3
3

Needle bearing attachment “3”

90890-06653
Driver rod L3 “4”
90890-06652
3. Remove the circlip “1”, and then remove
the bushing “2”.

1
4
2

3 4

9-20
 Upper case
2. Install the rubber seal “1” into the upper
13
case.
9 12 11
10
Face the “” mark “a” on the rubber seal “1”
up. 3
1
1
4 7
2
14 6
a
8

a 5
8
4
a
3. Install the dowels “1”.

4. Install the baffle plate “2”, and then tighten

Baffle plate screw “3”
the baffle plate screws “3” to the specified
4 Nm (0.4 kgf·m, 3.0 ft·lb)
torque.
T.
R.

Oil pan assembly bolt (M8) “9”

5. Install the rubber seal “4” into the joint hole 20 Nm (2.0 kgf·m, 14.8 ft·lb)
“a” of the upper case. Oil pan assembly bolt (M10) “10”
42 Nm (4.2 kgf·m, 31.0 ft·lb)
6. Install a new rubber seal “5” and the rubber PCV “13”
seal “6”, and then install the oil pan assem- 8 Nm (0.8 kgf·m, 5.9 ft·lb)
bly “7”. Apron stay “14”
8 Nm (0.8 kgf·m, 5.9 ft·lb)
7. Make sure to insert the tip of the water pipe
“8” into the joint hole “a” of the upper case. 12. Install the damper “1”, the cover “2”, a new
gasket “3”, and the engine oil drain bolt “4”,
8. Tighten the oil pan assembly bolts “9” and and then tighten the engine oil drain bolt
“10” to the specified torques. “4” to the specified torque.

9. Install new O-rings “11” and “12” to the 1

PCV “13”. 2

10. Install the PCV “13”, and then tighten it to

the specified torque. 4

11. Install the apron stays “14”, and then tight-

en it to the specified torque.
3

Engine oil drain bolt “4”

28 Nm (2.8 kgf·m, 20.7 ft·lb)
T.
R.

9-21
 Oil pan and exhaust manifold

Oil pan and exhaust manifold

42 Nm (4.2 kgf･m, 31.0 ft･lb)

1
10

20
12
2 11
11 21
3
13 22
4 4
24
23 25
5 16

6 14 26
17
7
8 15
9 27
18
19
20 Nm (2.0 kgf･m, 14.8 ft･lb)
12 Nm (1.2 kgf･m, 8.9 ft･lb)

No. Part name Q’ty Remarks

1 Bolt 1 M10  45 mm
2 Upper exhaust guide 1
3 Gasket 1 Not reusable
4 Dowel 2
5 Lower exhaust guide 1
6 Gasket 1 Not reusable
7 Oil strainer 1
8 Collar 3
9 Bolt 3 M6  25 mm
10 Gasket 1 Not reusable
11 Dowel 2
12 Rubber seal 1
13 Oil pan 1
14 Gasket 1 Not reusable
15 Exhaust manifold 1
16 Bolt 10 M8  60 mm
17 Bolt 2 M8  35 mm

9-22
 Oil pan and exhaust manifold

42 Nm (4.2 kgf･m, 31.0 ft･lb)

1
10

20
12
2 11
11 21
3
13 22
4 4
24
23 25
5 16

6 14 26
17
7
8 15
9 27
18
19
20 Nm (2.0 kgf･m, 14.8 ft･lb)
12 Nm (1.2 kgf･m, 8.9 ft･lb)

No. Part name Q’ty Remarks

18 Bolt 4 M8  90 mm
19 Rubber seal 1 Not reusable
20 Gasket 1 Not reusable
21 Plate 1
22 Water pipe 1
23 Rubber seal 1
24 Gasket 1 Not reusable
25 Dowel 2
26 Muffler 1
27 Bolt 10 M8  35 mm

9-23
 Oil pan and exhaust manifold

Disassembling the oil pan and ex-

haust manifold 1
1. Remove the oil pan assembly bolt “1”.

1 2

2. Remove the muffler “1”, plate “2”, and then

remove the exhaust manifold “3”.

1
3
Checking the oil pan and exhaust
manifold
1. Clean the removed parts.

2. Check the exhaust guide and exhaust

manifold. Replace if corroded or cracked.

3. Check the oil pan. Replace if corroded or

2 cracked.

Checking the oil strainer

1. Check the oil strainer. Clean if there is dirt
or residue.

Assembling the oil pan and exhaust

manifold
3. Remove the oil pan “1”, and then remove
1. Install the dowels “1”, a new gasket “2”,
the oil strainer “2”.
and the lower exhaust guide “3”.

9-24
 Oil pan and exhaust manifold
2. Install a new gasket “4” and the oil strainer
“5”, and then tighten the oil strainer bolts 8
“6” to the specified torque. 9 7
9
5
6
6
2
6

4
1
3

Oil strainer bolt “6”

12 Nm (1.2 kgf·m, 8.9 ft·lb) Exhaust manifold bolt “9”
T.
R.

20 Nm (2.0 kgf·m, 14.8 ft·lb)

T.
R.

3. Install the dowels “1”, a new gasket “2”, Oil pan bolt “4” and “5”
and the oil pan “3”, and then tighten the oil 20 Nm (2.0 kgf·m, 14.8 ft·lb)
pan bolts “4” and “5” temporarily.
6. Install the rubber seal “1” and water pipe
4. Install a new gasket “6”, the exhaust man- “2”.
ifold “7”, and a new rubber seal “8”, and
then tighten the exhaust manifold bolts “9” 7. Install the dowels “3”, a new gasket “4”, the
temporarily. plate “5”, and a new gasket “6”, and then
install the muffler “7”.
5. Tighten the exhaust manifold bolts “9” first,
and then tighten the oil pan bolts “4” and 8. Tighten the muffler bolts “8” to the speci-
“5” to the specified torque. fied torque.
5 7
3 4
2 8 8

1 8
4 3 3
6
1

4
2

9-25
 Oil pan and exhaust manifold

Muffler bolt “8”

20 Nm (2.0 kgf·m, 14.8 ft·lb)
T.
R.

9. Tighten the oil pan assembly bolt “1” to the

specified torque.

Oil pan assembly bolt “1”

42 Nm (4.2 kgf·m, 31.0 ft·lb)
T.
R.

9-26
 Steering arm

Steering arm

2
3

4
5
2

6
8
7

No. Part name Q’ty Remarks

1 Steering arm 1
2 Washer 2
3 Bushing 2
4 O-ring 1 Not reusable
5 Bushing 1
6 Steering yoke 1
7 Circlip 1
8 Grommet 1

9-27
 Steering arm

Removing the steering arm

1. Remove the circlip “1”, and then remove
the steering yoke “2” by striking it with a
copper hammer.

1
2
3
4

4. Install the steering yoke “1” so that the

steering arm and steering yoke “1” are
1
2 both facing in the same direction (“a” and
1
“b” are aligned).
2. Remove the steering arm from the swivel b
bracket.

Installing the steering arm

1. Install the washer “1” and bushing “2” onto
the steering arm “3”.

2. Place the bracket assembly “4” in an up-

right position, and then install the steering
arm “3”.

3 a
4

2 1

5. Hold the steering arm “1”, and then strike

the steering yoke “2” using a copper ham-
mer until the groove “a” for installing the
circlip is visible.

3. Install the bushing “1”, a new O-ring “2”,

the bushing “3”, and the washer “4”.

9-28
 Steering arm
6. Install the circlip “3”.

2 a

3 3

7. Inject grease into the grease nipple “1” un-

til it comes out from both the upper and
lower bushings “a”.

9-29
 Clamp bracket and swivel bracket

Clamp bracket and swivel bracket

22 Nm (2.2 kgf·m, 16.2 ft·lb) 7 2.5 Nm (0.25 kgf·m, 1.84 ft·lb)
4 5
3
5 6 10
9 8
10 11
2
22 2
12
1
15 16 2

18 2 30
16
4 Nm (0.4 kgf·m, 3.0 ft·lb) 15
2
13
3 Nm (0.3 kgf·m, 2.2 ft·lb) 6
25 2
24 26 24 25 21 17
25 25 24
26 18
24 20
10
27 23
31 19 14
32
29 28
32
34
33 33

No. Part name Q’ty Remarks

1 Clamp bracket (STBD) 1
2 Grease nipple 6 M6
3 Self-locking nut 1 M22
4 Bolt 1 M6  14 mm
5 Holder 2
6 Screw 2 M6  12 mm
7 Trim sensor 1
8 Screw 2 M6  16 mm
9 Tilt stop lever 1
10 Bushing 3
11 Tilt stop lever 1
12 Nut 2 M10
13 Through tube 1
14 Clamp bracket (PORT) 1
15 Washer 2
16 Bushing 2
17 Ground lead 1

9-30
 Clamp bracket and swivel bracket

22 Nm (2.2 kgf·m, 16.2 ft·lb) 7 2.5 Nm (0.25 kgf·m, 1.84 ft·lb)

4 5
3
5 6 10
9 8
10 11
2
22 2
12
1
15 16 2

18 2 30
16
4 Nm (0.4 kgf·m, 3.0 ft·lb) 15
2
13
3 Nm (0.3 kgf·m, 2.2 ft·lb) 6
25 2
24 26 24 25 21 17
25 25 24
26 18
24 20
10
27 23
31 19 14
32
29 28
32
34
33 33

No. Part name Q’ty Remarks

18 Screw 4 M6  10 mm
19 Plate 1
20 Trim stopper 2
21 Ground lead 1
22 Plate 1
23 Collar 1
24 Distance collar 2
25 Pin 2
26 Pin 1
27 Spring 1
28 Hook 1
29 Bolt 1 M6  10 mm
30 Swivel bracket 1
31 Anode 1
32 Plate 2
33 Bolt 4 M6  25 mm
34 Ground lead 1

9-31
 Clamp bracket and swivel bracket

Removing the clamp bracket

1. Remove the PTT unit. See “Removing the
PTT unit” (9-37).

2. Remove the anode “1” and ground lead. 3 3

1
2
3. Remove the ground leads “2” and “3”.

4. Remove the self-locking nut “4”.

5. Remove the through tube “5”, and then

disassemble the clamp brackets “6” and 8. Remove the tilt stop levers “1” and “2”, dis-
“7”. tance collar assembly “a”, collar “3”, and
bushings “4”.
2 4

2
3
a
4
1
4 4
3

Checking the clamp bracket anode

1 6 5 1. Check the anode. Replace the anode if
half of it has eroded. Clean if there is
6. Remove the trim sensor “1”. grease, oil, or scales.

Do not apply grease, oil, or paint to the an-

ode.
1

Installing the clamp bracket

1. Assemble the distance collar assembly.

7. Remove the spring “1”, hook “2”, and pins a

“3”.

9-32
 Clamp bracket and swivel bracket

Distance “a”
30.3–30.4 mm (1.19–1.20 in)
2
2. Install the bushings “1”, collar “2”, distance
collar assembly “3”, and tilt stop levers “4”
and “5”.

3. Install the trim stoppers “6” and trim stop- 1 3

per nuts “7”.

1 Trim sensor screw “3”

7
4 2.5 Nm (0.25 kgf·m, 1.84 ft·lb)

T.
R.
3 7. Install the through tube “1” with its flat cor-
1 ner “a” pointing down.
5
1 2 8. Tighten the self-locking nut “2” temporarily.

9. Install the anode “3”, and then face the top

6 of the “DO NOT PAINT” mark “b” on the
anode “3” forward.

6 10. Tighten the self-locking nut “2” to the spec-

ified torque.
4. Install the pins “1”, hook “2”, and spring “3”.
11. Install the grease nipples “4”, and then
1 1
tighten them to the specified torque.

a 12. Install the friction plates “5” and “6”, and

then tighten the friction plate screws “7” to
the specified torque.

4
3
4
1 4
4

2
2
Distance “a” 1
3.0 mm (0.12 in) 4
7 a
5. Route the trim sensor lead “1” through the
clamp bracket (STBD).
6
b
6. Install the trim sensor “2”, and then tighten
the trim sensor screws “3” to the specified 5
3 1
torque.

9-33
 Clamp bracket and swivel bracket

Self-locking nut “2”

22 Nm (2.2 kgf·m, 16.2 ft·lb)
T.

1
R.

Grease nipple “4”

3 Nm (0.3 kgf·m, 2.2 ft·lb)
Friction plate screw “7”
4 Nm (0.4 kgf·m, 3.0 ft·lb)

13. Inject grease into the grease nipples until

grease comes out from the bushings “a”.
2. Loosen the trim sensor screws “1”.

3. Adjust the position of trim sensor, and then

tighten the trim sensor screws “1” tempo-
rarily.

• To decrease the resistance, turn the trim sen-

sor cam in direction “a”.
a • To increase the resistance, turn the trim sen-
sor cam in direction “b”.

14. Install the PTT unit. See “Installing the PTT

unit” (9-41). b a

Adjusting the trim sensor cam 4. Fully tilt the swivel bracket down.

5. Measure the trim sensor setting resis-

After tilting the swivel bracket up, make tance. Adjust if out of specification.
sure to support it using the tilt stop lever.
Otherwise, the swivel bracket could sud-
denly lower.
a b
1. Fully tilt the swivel bracket up, and then
support it using the tilt stop lever “1”. b

Digital circuit tester

90890-03243

9-34
 Clamp bracket and swivel bracket

Setting resistance
9–11 
Terminal “a”–Terminal “b”

6. Fully tilt the swivel bracket up, and then

support it using the tilt stop lever.

7. Tighten the trim sensor screws to the

specified torque. Check that the trim sen-
sor resistance is within specification.

Trim sensor screw

2.5 Nm (0.25 kgf·m, 1.84 ft·lb)
T.
R.

8. Fully tilt the swivel bracket down.

9-35
 PTT unit

PTT unit

4
5

6
1
2
6

7
8

8
8
8

42 Nm (4.2 kgf·m, 31.0 ft·lb) 9

No. Part name Q’ty Remarks

1 Shaft 1
2 Circlip 2
3 Plastic tie 4
4 Bolt 1 M6  14 mm
5 Holder 1
6 Bushing 4
7 PTT unit 1
8 Bolt 8 M10  45 mm
9 Bolt 1 M6  10 mm

9-36
 PTT unit

Removing the PTT unit

1
When removing the PTT unit with the power
unit installed, make sure to suspend the
2
outboard motor.

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
1 rams.

1
Lg Sb

2. Remove the plastic ties “1” and holder “2”.

1 1 Ram PTT motor lead Battery

2 Light green (Lg) (+)
Retract
1 Sky blue (Sb) (–)
1
6. Remove the PTT unit “1”.

3. Disconnect the ground lead “1”.

1
1

4. Remove the circlips “1” and shaft “2”.

1

9-37
 PTT unit

Checking the hydraulic pressure 5. Install the reservoir cap, and then tighten it
Check the hydraulic pressure. Check the inter- to the specified torque.
nal parts if out of specification.
Reservoir cap
1. Place the PTT unit in an upright position. 7 Nm (0.7 kgf·m, 5.2 ft·lb)

T.
R.
2. Connect the battery jumper leads to the 6. Loosen the pipe joints “1”, and then re-
PTT motor lead “1” to fully extend the PTT move the pipe joint at the end “a”.
rams.
7. Install the special service tool “2”.
1
Sb Lg
Place the PTT unit in the drain pan.

a
1

2
Ram PTT motor lead Battery
Sky blue (Sb) (+)
Extend
Light green (Lg) (–)

3. Remove the reservoir cap “1”, and then

check the fluid level in the reservoir.

Before removing the reservoir cap “1”,

make sure that the PTT rams are fully ex- PTT oil pressure gauge assembly
tended. Otherwise, fluid could be expelled “2”
forcefully from the PTT unit due to internal 90890-06580
pressure.
8. Connect the battery jumper leads to the
PTT motor lead “1” to fully retract the trim
rams, and then measure the hydraulic
If the fluid is at the proper level, a small amount
pressure when the reading on the pres-
of fluid should flow out of the filler hole.
sure gauge stabilizes.
1
Lg Sb

4. If the fluid is below the proper level, add

the recommended fluid.

9-38
 PTT unit

Hydraulic pressure 2
Down
7.70 Mpa (77.0 kgf/cm², 1116.5
a
psi)
3
Ram PTT motor lead Battery
Light green (Lg) (+)
Retract
Sky blue (Sb) (–)

9. Reverse the connection between battery

jumper leads and the PTT motor lead “1” to 1
fully extend the trim rams.
1
PTT oil pressure gauge assembly
Sb Lg “1”
90890-06580

Pipe joint “2”

15 Nm (1.5 kgf·m, 11.1 ft·lb)
T.
R.

15. Connect the battery jumper leads to the

Ram PTT motor lead Battery PTT motor lead “1” to fully extend the trim
rams, and then measure the hydraulic
Sky blue (Sb) (+)
Extend pressure when the reading on the pres-
Light green (Lg) (–) sure gauge stabilizes.

10. Remove the special service tool “1”.

1
11. Install the pipe joints “2”, and then tighten Sb Lg
them to the specified torque.

12. Connect the battery jumper leads to the

PTT motor lead to fully retract the PTT
rams.

13. Loosen the pipe joints “3”, and then re-

move the pipe joint at the end “a”.

14. Install the special service tool “1”.

Hydraulic pressure
Up
14.00 Mpa (140.0 kgf/cm², 2030.0
psi)

9-39
 PTT unit

Ram PTT motor lead Battery

Pipe joint “1”
Sky blue (Sb) (+) 15 Nm (1.5 kgf·m, 11.1 ft·lb)
Extend

T.
R.
Light green (Lg) (–)
Ram PTT motor lead Battery
16. Reverse the connection between battery
jumper leads and the PTT motor lead “1” to Sky blue (Sb) (+)
Extend
fully retract the trim rams. Light green (Lg) (–)

1 20. Place the PTT unit in an upright position.

Lg Sb 21. Repeat steps 3–5 to check the fluid level.

Bleeding the PTT unit

1. Place the PTT unit in an upright position.

2. Turn the manual valve “1” clockwise to

close it.

Ram PTT motor lead Battery

Light green (Lg) (+)
Retract
Sky blue (Sb) (–)

17. Remove the special service tool.

18. Install the pipe joints “1”, and then tighten Manual valve “1”
them to the specified torque. 2 Nm (0.2 kgf·m, 1.5 ft·lb)
T.
R.

19. After measuring the hydraulic pressure, 3. Check the fluid level. See steps 2–5 in
connect the battery jumper leads to the “Checking the hydraulic pressure” (9-38).
PTT motor lead “2” to fully extend the PTT
rams.

2
Sb Lg

9-40
 PTT unit
4. Connect the battery jumper leads to the 8. Remove the reservoir cap, and then check
PTT motor lead “1” to fully retract the PTT the fluid level in the reservoir.
rams.

Before removing the reservoir cap, make

If the PTT rams do not move down easily, push sure that the PTT rams are fully extended.
on the PTT rams to assist operation. Otherwise, fluid could be expelled forceful-
ly from the PTT unit due to internal pres-
1 sure.
Lg Sb

If the fluid is below the proper level, add the

recommended PTT fluid. Repeat steps 3–7 un-
til the fluid remains at the proper level.

9. Install a new O-ring and the reservoir cap,

and then tighten the reservoir cap to the
Ram PTT motor lead Battery specified torque.
Light green (Lg) (+)
Retract Reservoir cap
Sky blue (Sb) (–)
7 Nm (0.7 kgf·m, 5.2 ft·lb)
T.
R.

5. Reverse the connection between battery

jumper leads and the PTT motor lead “1” to Installing the PTT unit
fully extend the PTT rams.

• After tilting the swivel bracket up, make

If the PTT rams do not move up easily, pull on sure to support it using the tilt stop lever.
the PTT rams to assist operation. • When installing the PTT unit with the pow-
er unit installed, make sure to suspend
1 the outboard motor.

Sb Lg
1. Connect the battery jumper leads to the
PTT motor lead “1” to retract the PTT
rams.
1
Lg Sb

Ram PTT motor lead Battery

Sky blue (Sb) (+)
Extend
Light green (Lg) (–)

6. Repeat steps 4 and 5 to fully extend and

retract the PTT rams 4 or 5 times. Ram PTT motor lead Battery
7. Fully extend the PTT ram. Light green (Lg) (+)
Retract
Sky blue (Sb) (–)

9-41
 PTT unit
2. Fully tilt the swivel bracket up, and then
support it using the tilt stop lever “1”. 1
Lg Sb

a
1

Ram PTT motor lead Battery

Sky blue (Sb) (+)
3. Install the bushings “1”, “2” and PTT unit Extend
“3”, and then tighten the PTT unit bolts “4” Light green (Lg) (–)
to the specified torque.
6. Install the shaft “1” and circlips “2”.

1
2
4 2
1 2
4 7. Install the ground lead “1”.

4
3

1
PTT unit bolt “4” 1
42 Nm (4.2 kgf·m, 31.0 ft·lb)
T.
R.

4. Pass the PTT motor lead “1” through the 8. Fasten the PTT motor lead and trim sensor
hole “a” in the clamp bracket (STBD). lead using the plastic ties “1”, and then in-
stall the holder “2”.
5. Connect the battery jumper leads to the
PTT motor lead “1” to extend the PTT rams
until the end of the tilt ram is aligned with
the mounting position hole. 1 1
2
1
1

9-42
 PTT motor

PTT motor
7 Nm (0.7 kgf·m, 5.2 ft·lb)

8 14
19 Nm (1.9 kgf·m, 14.0 ft·lb)
13

7 14

8 8
12
15
19 Nm (1.9 kgf·m, 14.0 ft·lb) 16
6 4
5
17

11 16
3
18
19 19
2 20
1 19
10 19
9 20 11
20

21
20

22

No. Part name Q’ty Remarks

1 Spacer 1
2 Filter 1
3 Sheet 1
4 O-ring 1 Not reusable
5 Reservoir cap 1
6 O-ring 1 Not reusable
7 Reservoir 1
8 Bolt 3 M8  20 mm
9 Joint 1
10 O-ring 1 Not reusable
11 Bolt 3 M8  20 mm
12 PTT motor assembly 1
13 Stator 1
14 Bolt 2 M5  12 mm
15 Wave washer 1
16 Bearing 2 Not reusable
17 Armature 1

9-43
 PTT motor

7 Nm (0.7 kgf·m, 5.2 ft·lb)

8 14
19 Nm (1.9 kgf·m, 14.0 ft·lb)
13

7 14

8 8
12
15
19 Nm (1.9 kgf·m, 14.0 ft·lb) 16
6 4
5
17

11 16
3
18
19 19
2 20
1 19
10 19
9 20 11
20

21
20

22

No. Part name Q’ty Remarks

18 O-ring 1 Not reusable
19 Spring 4
20 Brush 4
21 Motor base assembly 1
22 Oil seal 1 Not reusable

9-44
 PTT motor

Removing the reservoir

Secure the end of the armature shaft using

Before removing the reservoir, make sure a pair of pliers, and then remove the arma-
that the PTT rams are fully extended. Other- ture along with the motor base assembly.
wise, fluid could be expelled forcefully from Otherwise, the armature could separate
the PTT unit due to internal pressure. from the motor base assembly due to the
magnetic force of the stator “2” and dam-
age the brushes.
1. Remove the reservoir “1”, O-ring “2”, filter
“3”, and spacer “4”.
2. Remove the armature “3”.

Place a container under the PTT unit to catch 2

the fluid.
1
1

3
4
3. Remove the springs “1” and brushes “2”.
2 1
1 2
2
2
1 2 1
Removing the PTT motor
1. Remove the PTT motor assembly “1”, O-
ring “2”, and joint “3”.

2
3

Disassembling the PTT motor

1. Remove the bolts “1”, and then remove the
stator “2”.

9-45
 PTT motor
4. Remove the bearing “1”. Checking the armature (PTT motor)
1. Check the commutator. Clean using 600-
grit sandpaper and compressed air if dirty.
Before removing the bearing, measure and
write down the bearing depth “a”.

1
1

2
2 2

a 1 2. Measure the commutator diameter “a”.

Replace the armature if out of specifica-
tion.

Bearing splitter “2”

(commercially available)

5. Remove the bearing “1”.

a
Before removing the bearing, measure and
write down the bearing depth “a”. Standard commutator diameter
23.00 mm (0.9055 in)
3 Wear limit
1 22.00 mm (0.8661 in)

3 3. Measure the commutator undercut “a”.

Replace the armature if below specifica-
1 2 2 tion.

2
a
1 a

Bearing splitter “2”

(commercially available)
Bolt “3”
Standard commutator undercut
(commercially available)
1.40 mm (0.0551 in)
M8  15 mm
Wear limit
0.90 mm (0.0354 in)

9-46
 PTT motor
4. Check the armature for continuity. Re-
Motor base assembly continuity
place if out of specification.
“a” “b” “c” “d” “e” “f”

a
b
c d

3. Check the motor base assembly. Replace

Armature continuity the motor base assembly if the base is
“a” “b” “c” “d” cracked or damaged.

Checking the reservoir

1. Check the reservoir. Replace if cracked or
Checking the brush
damaged.
1. Measure the length of each brush. Re-
place if out of specification.
Checking the filter
1. Check the filter. Clean if there is dirt or res-
idue.

Assembling the PTT motor

b
a
Do not apply grease or oil to the commuta-
tor of the armature.

a. Standard brush length 1. Install a new oil seal “1”.

b. Wear limit

Standard brush length

11.50 mm (0.4528 in)
Wear limit
4.5 mm (0.18 in) 1
2. Check the motor base assembly for conti-
nuity. Replace if there is no continuity.
d e 2. Install the brushes “1” and springs “2”.
c f

Sb a

Lg b

9-47
 PTT motor
3. Install a new O-ring “3”.

1 2
2 1 a
1 1
1 2

2 1

2
1

4. Install a new bearing “1” to the specified Depth “a” (reference data)
depth “a”. 0.95 mm (0.04 in)

6. Push the brushes “1” into the holders, and

then install the armature “2”.

1
2

1 a

Depth “a” (reference data) 1

20.10 mm (0.79 in)
7. Install the wave washer “1”.
5. Install a new bearing “1” to the specified
depth “a”.
1

9-48
 PTT motor
8. Install the stator “1”.
Reservoir mounting bolt “6”
19 Nm (1.9 kgf·m, 14.0 ft·lb)

T.
Secure the end of the armature shaft using

R.
Reservoir cap “8”
a pair of pliers, and then install the arma- 7 Nm (0.7 kgf·m, 5.2 ft·lb)
ture along with the motor base assembly.
Otherwise, the armature could separate Installing the PTT motor
from the motor base assembly due to the
magnetic force of the stator “1” and dam-
age the brushes. When assembling the PTT unit, do not use
a rag. Otherwise, dust and particles could
1 get on the PTT unit components, causing
poor performance.

1. Install the joint “1”.

1
Installing the reservoir
1. Install the spacer “1”, filter “2”, and sheet
“3”.

2. Install a new O-ring “4” and the reservoir

“5”, and then tighten the reservoir mount- 2. Fill the gear pump housing with the recom-
ing bolts “6” to the specified torque. mended fluid up to the proper level “a”.

3. Install a new O-ring “7” and the reservoir

cap “8”, and then tighten the reservoir cap
“8” to the specified torque.

6 5 a

6 3
6

2
1 3. Turn the joint “1” using a screwdriver to re-
move any air between the pump gear
7 teeth.
8
4. Remove all of the air bubbles using a sy-
4 ringe or suitable tool.

9-49
 PTT motor
5. Install a new O-ring “2” and the PTT motor
assembly “3”, and then tighten the PTT
motor mounting bolts “4” to the specified
torque.

Align the protrusion “a” on the armature shaft

with the slot “b” in the joint.

4 3
4
4

a
1
b 2

PTT motor mounting bolt “4”

19 Nm (1.9 kgf·m, 14.0 ft·lb)
T.
R.

9-50
 PTT gear pump

PTT gear pump

7 Nm (0.7 kgf·m, 5.2 ft·lb) 5
1 1 5
9
6
2 10
7 11
3 8
12
4
1

31 7 Nm (0.7 kgf·m, 5.2 ft·lb)

13 13
14 14

32 15 18 33
32 16 17
17
34 34
35 35 19
36 36 20
19 21
24
30
22

22 23
37 25
38 25
26 26
39 27
27
30 28
28
2 Nm (0.2 kgf·m, 1.5 ft·lb) 29 29

No. Part name Q’ty Remarks

1 Bolt 3 M5  40 mm
2 Plate 1
3 Filter 1
4 Seal 1
5 Valve lock screw 2
6 Spring 1
7 Valve pin 1
8 Valve seal 1 Not reusable
9 Spring 1
10 Valve support pin 1
11 O-ring 1 Not reusable
12 Ball 1 3.18 mm (0.13 in) (reference data)
13 E-clip 2
14 Main valve seal 2
15 Down-main valve 1
16 O-ring 1 Not reusable
17 Spring 2

9-51
 PTT gear pump

7 Nm (0.7 kgf·m, 5.2 ft·lb) 5

1 1 5
9
6
2 10
7 11
3 8
12
4
1

31 7 Nm (0.7 kgf·m, 5.2 ft·lb)

13 13
14 14

32 15 18 33
32 16 17
17
34 34
35 35 19
36 36 20
19 21
24
30
22

22 23
37 25
38 25
26 26
39 27
27
30 28
28
2 Nm (0.2 kgf·m, 1.5 ft·lb) 29 29

No. Part name Q’ty Remarks

18 Up-main valve 1
19 Ball 2 4.76 mm (0.19 in) (reference data)
20 Relief valve seat 1
21 O-ring 1 Not reusable
22 Ball 2 3.97 mm (0.16 in) (reference data)
23 Manual release plate 1
24 Filter 1
25 Ball 2 3.97 mm (0.16 in) (reference data)
26 Valve pin 2
27 Spring 2
28 Spacer 2
29 O-ring 2 Not reusable
30 Pin 2
31 Bracket 1
32 Bolt 2 M5  25 mm
33 Gear pump assembly 1
34 O-ring 2 Not reusable

9-52
 PTT gear pump

7 Nm (0.7 kgf·m, 5.2 ft·lb) 5

1 1 5
9
6
2 10
7 11
3 8
12
4
1

31 7 Nm (0.7 kgf·m, 5.2 ft·lb)

13 13
14 14

32 15 18 33
32 16 17
17
34 34
35 35 19
36 36 20
19 21
24
30
22

22 23
37 25
38 25
26 26
39 27
27
30 28
28
2 Nm (0.2 kgf·m, 1.5 ft·lb) 29 29

No. Part name Q’ty Remarks

35 Spacer 2
36 Filter 2
37 O-ring 1 Not reusable
38 Manual valve 1
39 Circlip 1

9-53
 PTT gear pump

Disassembling the gear pump assem- 4. Remove the bracket “1”, and then remove
bly the filter “2”, spacers “3”, and valve pins
1. Remove the manual valve “1”, and then re- “4”.
move the gear pump assembly “2”.
3
2. Remove the filters “3”.

3 1
3 3 2

5. Remove the gear housing “1”, and then re-

1 move the down-main valve “2” and up-
main valve “3”.
3. Remove the valve lock screws “1”, and
then remove the valve support pin “2”, 6. Remove the drive gear “4” and driven gear
valve pin “3”, and valve seal “4”. “5”.
1
Before removing the valve lock screws “1”,
measure and write down the screw depth “a” 2
and screw height “b”.

1 1 3
5 4
3 2

Checking the gear pump

A B 1. Check the drive gear “1” and driven gear
“2”. Replace the gear pump assembly if
b damaged or worn.
a
2. Check the up-relief valve “3” and down-re-
1 1
lief valve “4”. Clean if there is dirt or resi-
due.

A. Down-relief valve
B. Up-relief valve

9-54
 PTT gear pump
3. Check the main valves “5”, “6”, and “7”.
13
Clean if there is dirt or residue. 10

4
4 3
11
1 10
1 2
2 3 7
9
8
5
12
6

6
7
5. Install the balls “1”, the valve pins “2”, the
5 springs “3”, the spacers “4”, and new O-
rings “5”.
5
6. Install the balls “6” and manual release
plate “7”.
Checking the gear pump housing
7. Install the filter “8” and bracket “9”, and
1. Check the gear pump housing. Replace
then tighten the pump bracket bolts “10”
the gear pump assembly if corroded or
temporarily.
cracked.
8. Check that the gear pump turns smoothly,
Checking the filter
and then tighten the pump bracket bolts
1. Check the filters. Clean if there is dirt or
“10” to the specified torque.
residue.
10 5
Assembling the gear pump assembly 4
3

When assembling the PTT unit, do not use 2

9
a rag. Otherwise, dust and particles could 1
5
get on the PTT unit components, causing 4
poor performance. 3 8
6
2
1. Install a new O-ring “1”, the main valve 7
seal “2”, and the E-clip “3” to the down- 1
main valve “4”.

2. Install the main valve seal “5” and E-clip “6”

to the up-main valve “7”. Pump bracket bolt “10”
7 Nm (0.7 kgf·m, 5.2 ft·lb)
T.

3. Install the drive gear “8”, driven gear “9”,

R.

down-main valve “4”, up-main valve “7”, 9. Install a new valve seal “1”, the valve pin
springs “10”, and pins “11”. “2”, and the spring “3”, and then install the
valve lock screw “4”.
4. Install the balls “12” and gear housing “13”.

9-55
 PTT gear pump
10. Install a new O-ring “5” to the valve support 15. Install a new O-ring “9”, the manual valve
pin “6”. “10”, and the circlip “11”, and then tighten
the manual valve “10” to the specified
11. Install the ball “7”, valve support pin “6”, torque.
and spring “8”, and then install the valve
lock screw “9”. 8
5 8 8
4 5
• Install the valve lock screw “4” and valve lock 3 4 7
screw “9” to the depth “a” and height “b” that 3 1
were measured before removing them.
• When installing new parts, install them ac- 2
cording to the preceding reference data.
6
4 9
3 8
2 9
6 10 11
1 5
7 Gear pump bolt “8”
7 Nm (0.7 kgf·m, 5.2 ft·lb)
T.
R.

Manual valve “10”

2 Nm (0.2 kgf·m, 1.5 ft·lb)
A B

a b

4 9

A. Down-relief valve
B. Up-relief valve

Installation depth “a” (reference da-

ta)
1.07–1.27 mm (0.042–0.050 in)
Installation height “b” (reference da-
ta)
1.95–2.45 mm (0.077–0.096 in)

12. Install the filter “1” to the seal “2”.

13. Install the filters “3”, the spacers “4”, new

O-rings “5”, and the gear pump assembly
“6”.

14. Install the seal “2” and plate “7”, and then
tighten the gear pump bolts “8” to the spec-
ified torque.
9-56
 PTT cylinder

PTT cylinder
160 Nm (16.0 kgf·m, 118.0 ft·lb)
90 Nm (9.0 kgf·m, 66.4 ft·lb) 24
25
65 Nm (6.5 kgf·m, 47.9 ft·lb)

16 26
20
27
3 21
1
4 22
12 19
5
23
2 6
13 15 Nm (1.5 kgf·m, 11.1 ft·lb)
7
14 28
29

9 9
9 18 30
9

8 31
17
10 32
17 33
11

15 15 Nm (1.5 kgf·m, 11.1 ft·lb)

7 Nm (0.7 kgf·m, 5.2 ft·lb)
20 Nm (2.0 kgf·m, 14.8 ft·lb)

No. Part name Q’ty Remarks

1 Dust seal 1 Not reusable
2 Tilt cylinder end screw 1
3 O-ring 1 Not reusable
4 Backup ring 1
5 O-ring 1 Not reusable
6 Spring 1
7 Adapter 1
8 Tilt piston assembly 1
9 Ball 4 3.97 mm (0.16 in) (reference data)
10 O-ring 1 Not reusable
11 Backup ring 1
12 Tilt ram assembly 1
13 Free piston 1
14 O-ring 1 Not reusable
15 Tilt cylinder 1
16 Tilt cylinder assembly 1
17 Bushing 2

9-57
 PTT cylinder

160 Nm (16.0 kgf·m, 118.0 ft·lb)

90 Nm (9.0 kgf·m, 66.4 ft·lb) 24
25
65 Nm (6.5 kgf·m, 47.9 ft·lb)

16 26
20
27
3 21
1
4 22
12 19
5
23
2 6
13 15 Nm (1.5 kgf·m, 11.1 ft·lb)
7
14 28
29

9 9
9 18 30
9

8 31
17
10 32
17 33
11

15 15 Nm (1.5 kgf·m, 11.1 ft·lb)

7 Nm (0.7 kgf·m, 5.2 ft·lb)
20 Nm (2.0 kgf·m, 14.8 ft·lb)

No. Part name Q’ty Remarks

18 Pipe 1
19 Trim ram assembly 2
20 Backup ring 2
21 O-ring 2 Not reusable
22 Spring 2
23 Circlip 2
24 Circlip 2
25 Dust seal 2 Not reusable
26 Trim cylinder end screw 2
27 O-ring 2 Not reusable
28 Circlip 1
29 Shaft 1
30 Spacer 1
31 O-ring 1 Not reusable
32 Pipe joint adapter 1
33 Pipe 1

9-58
 PTT cylinder

Removing the tilt ram

When removing the free piston, never look

Before removing the tilt cylinder end screw, into the tilt cylinder opening because the
make sure that the PTT rams are fully ex- free piston and PTT fluid could be expelled
tended. Otherwise, fluid could be expelled forcefully.
forcefully from the PTT unit due to internal
pressure. 1

1. Remove the pipes “1” and “2” and pipe

joint adapter “3”. 2
2. Remove the circlip “4”, shaft “5”, and tilt
cylinder assembly “6”. a

6
Removing the trim ram
4
5 1. Loosen the trim cylinder end screws “1”,
and then remove the tilt ram assemblies.

3
1
1
2 2
1
3. Loosen the tilt cylinder end screw “1”, and
then remove the tilt ram assembly.
Cylinder end screw wrench “2”
90890-06591

2 2. Drain the fluid.

Cylinder end screw wrench “2”

90890-06591

4. Drain the PTT fluid.

5. Cover the tilt cylinder using a rag “1”, and

then blow compressed air through the hole
“a” to remove the free piston “2”.

9-59
 PTT cylinder

Disassembling the tilt ram Checking the tilt cylinder and trim cyl-
1. Remove the tilt piston absorber valves “1”. inder
1. Check the PTT body “1” and tilt cylinder
1 1 “2”. Replace if corroded or cracked.

2. Check the inner surface of the PTT body

“1” and tilt cylinder “2”. Replace if
1 scratched.

1 3. Check the outer surfaces of the tilt piston

“3”, trim pistons “4”, and free piston “5”.
Replace if scratched.

4. Check the backup rings “6” and “7”. Re-

place if damaged or worn.

5. Check the trim rams “8” and tilt ram “9”.

2. Remove the tilt piston “1”. Clean using 400–600-grit sandpaper if
there is rust or replace if bent or corroded.

6. Check the pipes “10” and “11”. Replace if

corroded or cracked.

3 3
9 8

2 4
1
7
1
6
5

PTT piston vice attachment “2”

90890-06572
Tilt rod wrench “3” 2
90890-06569
10
Disassembling the trim ram 11
1. Remove the circlip “1” and backup ring “2”.

9-60
 PTT cylinder

Checking the absorber valve

1. Check the tilt piston absorber valves “1”.
Clean if there is dirt or residue.

1 3

1
2

Assembling the tilt ram

PTT piston vice attachment “2”
90890-06572
When assembling the PTT unit, do not use
Tilt rod wrench “3”
a rag. Otherwise, dust and particles could
90890-06569
get on the PTT unit components, causing
poor performance.
Tilt ram “1”
1. Install a new dust seal “1”, the backup ring 65 Nm (6.5 kgf·m, 47.9 ft·lb)
T.
R.

“2”, and new O-rings “3” and “4” to the tilt

cylinder end screw “5”. 4. Install a new O-ring “1” and the backup
ring “2”.
1 1
5. Install the balls “3”, absorber valve pins “4”,
4 2
and springs “5”.

4
3
5
2 5
3

2. Install the tilt cylinder end screw “1”, spring

“2”, adapter “3”, and tilt piston “4”.

3 1

3. Tighten the tilt ram “1” to the specified

torque.

9-61
 PTT cylinder
6. Install the washers “6”, plate “7”, washer 2. Install a new dust seal “1”, the circlip “2”,
“8”, and tilt piston screw “9”, and then tight- and a new O-ring “3” to the trim cylinder
en the tilt piston screw “9” to the specified end screw “4”, and then install the trim cyl-
torque. inder end screw “4” onto the trim ram “5”.
9 2
1 2
8 1
5 4
7
7 5
4 3
2 6
2 3
1
5 5 3 4
4 3 1 4
3 Installing the tilt cylinder
5
4 5 When assembling the PTT unit, do not use
3 4 a rag. Otherwise, dust and particles could
3 get on the PTT unit components, causing
poor performance.

Tilt piston screw “9” 1. Install a new O-ring “1” to the free piston
7 Nm (0.7 kgf·m, 5.2 ft·lb) “2”.
T.
R.

2. Push the free piston “2” into the tilt cylinder

Assembling the trim ram
“3” until it bottoms out.

3. Install the bushing “4”, tilt cylinder “3”, shaft

When assembling the PTT unit, do not use
“5”, and circlip “6”.
a rag. Otherwise, dust and particles could
get on the PTT unit components, causing 4. Install a new O-ring “7” and the pipe joint
poor performance. adapter “8”, and then tighten the pipe joint
adapter “8” to the specified torque.
1. Install the backup ring “1”, a new O-ring
“2”, the spring “3”, the adapter “4”, and the
circlip “5” to the trim piston “6”.

2
6 6
3
1
4 1
2
5

9-62
 PTT cylinder
5. Install the spacer “9” and pipes “10” and
“11”, and then tighten the pipe joints “12” to
the specified torque.
2
1
1
6
5
2
1

3
12
7 Cylinder end screw wrench “2”
4 90890-06591
8
10 4 12 12
9 Trim cylinder end screw “1”
12 11 160 Nm (16.0 kgf·m, 118.0 ft·lb)

T.
R.
Pipe joint adapter “8” Installing the tilt ram
20 Nm (2.0 kgf·m, 14.8 ft·lb) 1. Install the gear pump assembly. See steps
T.
R.

Pipe joint “12” 12–15 in “Assembling the gear pump as-

15 Nm (1.5 kgf·m, 11.1 ft·lb) sembly” (9-55).

Installing the trim ram 2. Install the reservoir. See “Installing the res-
ervoir” (9-49).

When assembling the PTT unit, do not use 3. Place the tilt cylinder end screw “1” at the
a rag. Otherwise, dust and particles could bottom of the tilt ram “2”.
get on the PTT unit components, causing
4. Fill the tilt cylinder and PTT body with the
poor performance.
recommended fluid up to the proper level
“a”.
1. Fill the trim cylinders with the recommend-
ed fluid up to the proper level “a”. 5. Add a small amount of the recommended
fluid through the PTT body hole “b”.
a

2
a
2. Install the trim ram assemblies, and then
tighten the trim cylinder end screws “1” to
the specified torque.

9-63
 PTT cylinder

b a

6. Install the tilt ram assembly, and then tight-

en the tilt cylinder end screw “1” to the
specified torque.

Cylinder end screw wrench “2”

90890-06591

Tilt cylinder end screw “1”

90 Nm (9.0 kgf·m, 66.4 ft·lb)
T.
R.

7. Install the PTT motor. See “Installing the

PTT motor” (9-49).

9-64
 Maintenance

Outline ............................................................................... 10-1

Maintenance interval chart 1 .................................................... 10-1
Maintenance interval chart 2 .................................................... 10-3

Predelivery check............................................................. 10-4

Checking the engine oil level.................................................... 10-4
Checking the battery ................................................................ 10-4
Checking the cooling water pilot hole....................................... 10-5
Checking the main switch/stop switch...................................... 10-5
Checking the fuel line ............................................................... 10-6
Checking the gear oil level ....................................................... 10-6
Checking the shift link/shift cable and throttle link/throttle
cable......................................................................................... 10-6
Checking the outboard motor mounting height ........................ 10-7
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 .................................................................................... 10-8
Break-in .................................................................................... 10-8
After test run............................................................................. 10-8

General periodic maintenance ........................................ 10-9

Checking the anode ................................................................. 10-9
Checking the battery ................................................................ 10-9
Checking the cooling water inlet............................................... 10-9
Checking the cooling water pilot hole....................................... 10-9
Checking the engine idle speed/noise...................................... 10-9
Changing the engine oil using an oil changer ........................ 10-10
Changing the engine oil by removing the drain bolt ............... 10-11
Checking the engine oil level.................................................. 10-12
Replacing the oil filter ............................................................. 10-12
Checking the exhaust guide/exhaust manifold....................... 10-13
Checking the main switch/stop switch.................................... 10-13
Checking the fuel filter............................................................ 10-13
Checking the fuel pump.......................................................... 10-13
Checking for fuel/engine oil leakage ...................................... 10-13
Changing the gear oil ............................................................. 10-13
Checking the gear oil level ..................................................... 10-15
Replacing the OCV filter......................................................... 10-15
Greasing points ...................................................................... 10-15
Greasing the clamp bracket bolt (through tube) ..................... 10-16
Checking the propeller/propeller nut/cotter pin....................... 10-17
Checking the PCV .................................................................. 10-17
Checking the PTT fluid level................................................... 10-17
Checking the power trim and tilt unit operation ...................... 10-17
Adjusting the shift link/shift cable ........................................... 10-18
 Maintenance

Checking the spark plug......................................................... 10-18

Checking the timing belt ......................................................... 10-18
Replacing the timing belt ........................................................ 10-18
0
Checking the thermostat ........................................................ 10-18
Adjusting the throttle link/throttle cable................................... 10-18
Checking the cowling lock lever ............................................. 10-18
Checking the valve clearance ................................................ 10-18
1
Checking the impeller/water pump housing ........................... 10-18

2
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 quality.
Any parts of inferior quality may cause a malfunction, and the resulting loss of control could endanger
the operator and passengers. Yamaha genuine parts and accessories are available from Yamaha
dealers.
• The service intervals provided in the maintenance interval charts are based upon “typical” operating
conditions that include speed variations, sufficient time for engine warm up and cool-down, medium
to light load, and an average cruising speed in the 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 op-
eration for extended periods of time, carrying heavy loads, and frequent starting and stopping or shift-
ing. In most cases, the frequent maintenance pays off in increased engine life and greater owner
satisfaction.
• The maintenance cycle on these charts is based on usage of 100 hours per year and regular flushing
of the cooling water passages. Adjust the maintenance frequency when operating the engine under
adverse conditions, such as extended trolling.
• Disassembly or repairs may be necessary depending on the outcome of maintenance checks.
• Expendable or consumable parts and lubricants will lose their effectiveness over time and through
normal usage regardless of the warranty period.
• When operating the outboard motor in salt water, or in muddy, turbid (cloudy), or acidic water, flush
the engine using clean water after each use.

Maintenance interval chart 1

The “ ” symbol indicates the check-ups which the owners or operators may carry out themselves.
The “ ” symbol indicates work to be carried out by a Yamaha dealer.
Initial Every
Item Actions 20 hours 100 hours 300 hours 500 hours
(3 months) (1 year) (3 years) (5 years)
Inspection or replace-
Anode(s) (external)
ment as necessary
Inspection or replace-
Anode(s) (internal) *1
ment as necessary
Anode(s) (internal) *2 Replacement
Battery (electrolyte level,
Inspection
terminal)
Battery (electrolyte level, Fill, charging or replac-
terminal) ing as necessary
Inspection or replace-
Cooling water leakage
ment as necessary
Cowling lock lever Inspection
Engine starting condi-
Inspection
tion/noise
Engine idle speed/noise Inspection

10-1
 Outline

Initial Every
Item Actions 20 hours 100 hours 300 hours 500 hours
(3 months) (1 year) (3 years) (5 years)
Engine oil Replacement
Engine oil filter (car-
Replacement
tridge)
Fuel filter (can be disas- Inspection or replace-
sembled) ment as necessary
Fuel line (High pressure) Inspection
Inspection or replace-
Fuel line (High pressure)
ment as necessary
Fuel line (Low pressure) Inspection
Inspection or replace-
Fuel line (Low pressure)
ment as necessary
Inspection or replace-
Fuel pump
ment as necessary
Fuel/engine oil leakage Inspection
Gear oil *3 Replacement
Greasing points Greasing
Clamp bracket bolt
Inspection and greasing
(through tube)
Impeller/water pump Inspection or replace-
housing ment as necessary
Impeller/water pump
Replacement
housing
OCV (Oil control Valve)
Inspection
filter
Power trim and tilt unit Inspection
Propeller/propeller Inspection or replace-
nut/cotter pin ment as necessary
PCV (Pressure Control Inspection or replace-
Valve) ment as necessary
Inspection, adjustment
Shift link/shift cable or replacement as nec-
essary
Inspection or replace-
Spark plug(s)
ment as necessary
Ignition coils/ignition coil Inspection or replace-
leads ment as necessary
Water from the cooling
Inspection
water pilot hole

10-2
 Outline

Initial Every
Item Actions 20 hours 100 hours 300 hours 500 hours
(3 months) (1 year) (3 years) (5 years)
Inspection, adjustment
Throttle link/throttle
or replacement as nec-
cable
essary
Inspection or replace-
Thermostat
ment as necessary
Inspection or replace-
Timing belt
ment as necessary
Inspection and adjust-
Valve clearance
ment
Cooling water inlet Inspection
Inspection or replace-
Main switch/stop switch
ment as necessary
Wire harness connec-
Inspection or replace-
tions/wire coupler con-
ment as necessary
nections
(Yamaha) Meter/gauge Inspection
*1. Cylinder head
*2. Cylinder head, thermostat cover, exhaust cover, cooling water passage cover, rectifier regulator
cover
*3. Severe condition: recommended gear oil grade GL-5

Maintenance interval chart 2

Every
Item Actions
1000 hours
Exhaust guide/exhaust Inspection or replace-
manifold ment as necessary
Timing belt Replacement

10-3
 Predelivery check

Predelivery check
To make the delivery process smooth and effi- a
cient, complete the predelivery checks as ex-
plained in the following procedures.
1
Checking the engine oil level

b
Make sure that the engine is filled with en-
gine oil before operating the outboard mo-
tor for the first time. Otherwise, the engine Checking the battery
could be damaged severely.

Battery electrolyte is dangerous; it con-

The outboard motor is shipped from the factory tains sulfuric acid, which is poisonous and
without engine oil. highly caustic. Always follow these preven-
tive measures:
• Avoid bodily contact with electrolyte as it
1. Place the outboard motor in an upright po-
can cause severe burns or permanent eye
sition.
injury.
• Wear protective eye gear when handling
or working near batteries.
If the outboard motor is not level, the oil lev-
Antidote (EXTERNAL):
el indicated on the dipstick may not be cor-
• SKIN - Wash with water.
rect.
• EYES - Flush with water for 15 minutes
and get immediate medical attention.
2. Start the engine and warm it up for 5–10 Antidote (INTERNAL):
minutes. • Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg,
3. Stop the engine and leave it off for 5–10 or vegetable oil. Get immediate medical
minutes. attention.
Batteries generate explosive, hydrogen
4. Remove the top cowling. gas. Always follow these preventive mea-
sures:
5. Remove the dipstick “1” and wipe it clean.
• Charge batteries in a well-ventilated area.
6. Insert the dipstick “1” completely for a cor- • Keep batteries away from fire, sparks, or
rect measurement and remove it again. open flames (for example, welding equip-
ment and lighted cigarettes).
7. Check that the oil level indicated on the • DO NOT SMOKE when charging or han-
dipstick “1” is between the upper mark “a” dling batteries.
and the lower mark “b”. If the engine oil is KEEP BATTERIES AND ELECTROLYTE
not at the proper level, add or extract en- OUT OF REACH OF CHILDREN.
gine oil.

10-4
 Predelivery check
1. Check the battery electrolyte level. If the
level is at or below the minimum level mark
“a”, add distilled water until the level is be-
tween the maximum and minimum level
marks.

Checking the main switch/stop switch

1. Check that the engine starts when the en-
gine start switch is turned to START.
Check the engine start switch if the engine
does not start. See “Checking the engine
2. Check the specific gravity of the electro- start switch” (5-45).
lyte. Fully charge the battery if below spec-
ification. 2. Check that the engine stops when the en-
gine start switch is turned to OFF. Check
the engine start switch if the engine does
• Batteries vary depending on the manufactur- not stop. See “Checking the engine start
er. The procedures mentioned in this manual switch” (5-45).
may not always apply. Therefore, see the in-
struction manual of the battery.
2. ON
• Disconnect the negative battery cable first,
1. OFF 3. START
and then disconnect the positive battery ca-
ble.

Recommended battery capacity

Battery rating (CCA/EN)
510–1080 A
Battery rating (20HR/IEC)
1. OFF
80 Ah
2. ON
Electrolyte specific gravity
3. START
1.280 at 20 C (68 F)

Checking the cooling water pilot hole

1. Place the lower unit in water, and then start
the engine.

2. Check that cooling water is discharged

from the cooling water pilot hole. If there is
no water flow, check the cooling water
passages for clog. See “Cooling diagram”
(2-15).

10-5
 Predelivery check
3. Check that the engine stops when the clip
is removed from the engine shut-off
switch. Check the engine shut-off switch if
the engine does not stop. See “Checking 2
1
the engine shut-off switch” (5-43).
A

3. Install a new gasket and the oil level plug,

and then tighten the oil level plug to the
specified torque.

Oil level plug

B 9 Nm (0.9 kgf·m, 6.6 ft·lb)

T.
R.
Checking the shift link/shift cable and
throttle link/throttle cable

Do not overtighten the friction adjuster. If

there is too much resistance, it could be dif-
ficult to operate the remote control lever,
A. 703 side mount remote control which could result in an accident.
B. 704 binnacle mount remote control
1. Check that the gear shift operates smooth-
Checking the fuel line ly when the remote control lever is moved
1. Check that the fuel hoses are connected from the N position to the F or R position.
securely. See “Fuel hose and blowby Adjust the shift cable joints or check the re-
hose” (2-18). lated parts if the shift operation is not
smooth. See “Installing the shift cable”
(3-9).
This outboard motor is equipped with a 4-
stroke engine. Never use premixed fuel or 2. Check that the throttle operates smoothly
2-stroke outboard motor oil. when the remote control lever is moved
from the F or R position to the fully open
Checking the gear oil level position. Adjust the throttle cable joints or
1. Place the outboard motor in an upright po- check the related parts if the throttle oper-
sition. ation is not smooth. See “Installing the
throttle cable” (3-10).
2. Remove the oil level plug “1” and gasket
“2”, and then check the gear oil level. If the
gear oil is below the proper level, add the
recommended gear oil.

If the oil is at the proper level, a small amount

of oil should flow out of the check hole.

10-6
 Predelivery check

Checking the outboard motor mount- 4. Check that the trim meter, on the boat’s
ing height gauge, displays full down when the out-
1. Check that the anti-cavitation plate “1” is board motor is in the full-down position.
aligned with the bottom of the boat “2”. If Adjust the trim sensor cam if the trim meter
the mounting height is too high, cavitation does not display full down. See “Adjusting
will occur and propulsion will decrease. the trim sensor cam” (9-34).
Besides, the engine speed will increase
abnormally and cause the engine to over- Checking the steering system
heat. If the mounting height is too low, wa- 1. Check that the steering operates smooth-
ter resistance will increase, which will ly.
decrease engine efficiency and perfor-
2. Check that there is no interference with ca-
mance.
bles, hoses, or lead when the outboard
motor is steered.
The appropriate mounting height depends on
the combination of the boat and outboard mo- Checking the throttle cable and shift
tor. To determine the appropriate mounting cable
height, test run the outboard motor at different 1. Move the remote control lever to the N po-
heights. sition.

2. Check that the pin “a” on the bushing “1”

and the mark “b” on the shift bracket “2”
are aligned. Adjust the shift cable joints or
check the related parts if the marks are not
1 aligned. See “Installing the shift cable”
(3-9).
a
2

2. Check that the clamp brackets are se- 2

cured using the clamp bolts.

Checking the power trim and tilt unit 1

1. Check the power trim and tilt unit opera-
b
tion. See “Checking the power trim and tilt
unit operation” (10-17).

2. Check that there is no abnormal noise pro-

duced when the outboard motor is tilted up
or down. Check the PTT if any abnormal
noise is heard.

3. Check that there is no interference with ca-

bles, hoses, leads, or the boat when the
tilted-up outboard motor is steered.

10-7
 Predelivery check
3. Check that the throttle lever “1” contacts 3. For the remaining 8 hours “c” of operation:
the stopper “2”. Adjust the throttle cable Operate the engine at any engine speed.
joints or check the related parts if the throt- However, do not operate the engine at full
tle lever does not contact the stopper. See throttle for more than 5 minutes at a time.
“Installing the throttle cable” (3-10).
4. After the first 10 hours of operation:
Operate the engine normally.
2

Test run
1. Start the engine, and then check that the
gear shift operates smoothly. After test run
1. Check for water in the gear oil. Check the
2. Warm up the engine, and then check the lower case for airtightness and oil seal
engine idle speed. See “Checking the en- damage if the oil is milky. See “Checking
gine idle speed/noise” (10-9). the lower unit for air leakage” (8-27).

3. Operate the boat at trolling speed. 2. Check all the fuel lines for leakage. See
“Fuel hose and blowby hose” (2-18).
4. Operate the outboard motor according to
the break-in procedure. 3. Flush the cooling water passages using
fresh water.
5. Check that the outboard motor does not tilt
up when reverse operation.
When flushing the cooling water passages,
6. Check that the power trim operates do not start the engine. Otherwise, the wa-
smoothly while cruising. Check the PTT if ter pump could be damaged and the engine
the power trim operation is not smooth. could be severely damaged due to over-
heating.
Break-in
Operate the engine under load (in gear with a
propeller installed) for 10 hours as follows:
When using the flushing device (flushing hose
1. For the first hour “a” of operation: joint adapter), flush the cooling water passag-
Operate the engine at varying speeds up es without starting the engine.
to 2000 r/min or approximately 1/2 throttle.

2. For the second hour “b” of operation:

Increase the engine speed until the boat is
on plane (but do not fully open the throttle),
and then back off on the throttle while
keeping the boat at a planing speed.

10-8
 General periodic maintenance

General periodic maintenance

3 1
Checking the anode
1
Do not apply grease, oil, or paint to the an-
odes or the trim tab.

1. Check the anodes and trim tab. See

“Checking the cylinder head anode”
(7-73), “Checking the rectifier/regulator an-
ode” (7-32), “Checking the cooling water
passage cover anode” (7-78), “Checking 4
the cylinder block anode” (7-102), “Check-
2
ing the lower unit anode” (8-4), “Checking a
the exhaust cover anode” (7-62), and
“Checking the clamp bracket anode”
(9-32).

Replace the anodes or trim tab if eroded. Also,

check the ground lead. Water inlet cover screw “3”
1 Nm (0.1 kgf·m, 0.7 ft·lb)
T.
R.

Checking the battery Trim tab bolt “4”

1. Check the battery. See “Checking the bat- 42 Nm (4.2 kgf·m, 31.0 ft·lb)
tery” (10-4).
Checking the cooling water pilot hole
Checking the cooling water inlet 1. Check that cooling water is discharged
1. Remove the water inlet covers “1”. from the cooling water pilot hole. See
“Checking the cooling water pilot hole”
2. Mark the trim tab “2” with an identification (10-5).
mark “a”, and then remove the trim tab “2”.
Checking the engine idle speed/noise
3. Check the water inlet covers and water in- 1. Start the engine and warm it up for 5–10
lets. Clean if clogged. minutes.

4. Install the water inlet covers “1” and trim 2. Check the engine idle speed using the
tab “2”, and then tighten the water inlet Yamaha genuine tachometer (on-board
cover screws “3” and trim tab bolt “4” to the meter) or the YDIS. See the YDIS (Ver.
specified torque. 2.22 or later) instruction manual. Perform
the troubleshooting procedures if out of
specification. See “Troubleshooting proce-
After installing the water inlet covers, make dure” (4-8).
sure that there is no rattling.
Idle speed (in neutral)
600–700 r/min

10-9
 General periodic maintenance

Changing the engine oil using an oil

changer
1

Change the engine oil after the first 20

hours of operation or 3 months, and every
100 hours or at 1-year intervals thereafter.

1. Place the outboard motor in an upright po-

sition.
2
If the outboard motor is not level, the oil lev-
el indicated on the dipstick may not be cor-
rect. 7. Fill the engine with the specified amount of
the recommended engine oil through the
oil filler hole. Install the oil filler cap and dip-
2. Start the engine and warm it up for 5–10
stick.
minutes.

3. Stop the engine and leave it off for 5–10

Do not overfill the engine with engine oil.
minutes.
Otherwise, the engine could be damaged or
oil could leak. If the engine oil is above the
4. Remove the top cowling.
upper level, extract the excess engine oil
5. Remove the oil filler cap “1”. until the oil is at the proper level.

Engine oil quantity (without oil filter

1
replacement)
4.5 L (4.76 US qt, 3.96 Imp.qt)

8. Leave the outboard motor off for 5–10 min-

utes.

9. Remove the dipstick “1” and wipe it clean.

6. Remove the dipstick “1” and extract the 10. Insert the dipstick “1” completely for a cor-
engine oil using the oil changer “2”. rect measurement and remove it again.

10-10
 General periodic maintenance
11. Check that the oil level indicated on the
dipstick “1” is between the upper mark “a”
and the lower mark “b”. 1

b 6. Remove the apron “1”.

12. Start the engine and check that the oil

pressure alert indicator does not come on.
Also, check that there is no oil leakage.

If the oil pressure alert indicator comes on

or if there is oil leakage, stop the engine 1
and find the cause. Continued operation
with a problem could cause severe engine
damage.

Changing the engine oil by removing

the drain bolt 7. Place a drain pan “1” under the engine oil
drain hole.

Change the engine oil after the first 20 8. Remove the drain bolt “2” and gasket “3”
hours of operation or 3 months, and every and let the oil drain completely.
100 hours or at 1-year intervals thereafter.
9. Install a new gasket and the drain bolt “2”,
and then tighten the drain bolt “2” to the
1. Place the outboard motor in an upright po- specified torque.
sition.
3 2

If the outboard motor is not level, the oil lev-

el indicated on the dipstick may not be cor-
rect.

2. Start the engine and warm it up for 5–10 1

minutes.

3. Stop the engine and leave it off for 5–10

minutes. Drain bolt “2”
27 Nm (2.7 kgf·m, 19.9 ft·lb)
T.
R.

4. Remove the top cowling.

5. Remove the oil filler cap “1”.

10-11
 General periodic maintenance
10. Install the apron “1”.
a

b
1
16. Start the engine and check that the oil
pressure alert indicator does not come on.
Also, check that there is no oil leakage.

11. Fill the engine with the specified amount of If the oil pressure alert indicator comes on
the recommended engine oil through the or if there is oil leakage, stop the engine
oil filler hole. Install the oil filler cap. and find the cause. Continued operation
with a problem could cause severe engine
damage.
Do not overfill the engine with engine oil.
Otherwise, the engine could be damaged or
Checking the engine oil level
oil could leak. If the engine oil is above the
1. Check the oil level. See “Checking the en-
upper level, extract the excess engine oil
gine oil level” (10-4).
until the oil is at the proper level.
Replacing the oil filter
Engine oil quantity (without oil filter 1. Extract the engine oil. See steps 1–6 in
replacement) “Changing the engine oil using an oil
4.5 L (4.76 US qt, 3.96 Imp.qt) changer” (10-10) or steps 1–9 in “Chang-
ing the engine oil by removing the drain
12. Leave the outboard motor off for 5–10 min- bolt” (10-11).
utes.
2. Place a rag under the oil filter, and then re-
13. Remove the dipstick “1” and wipe it clean. move the oil filter.

14. Insert the dipstick “1” completely for a cor-

rect measurement and remove it again. Make sure to clean up any oil spills.

15. Check that the oil level indicated on the

dipstick “1” is between the upper mark “a”
and the lower mark “b”.

10-12
 General periodic maintenance

Checking the main switch/stop switch

Oil filter wrench “1” 1. Check the engine start switch and engine
90890-06874 shut-off switch. See “Checking the main
switch/stop switch” (10-13).
3. Install a new oil filter “1”, and then tighten it
to the specified torque. Checking the fuel filter
1. Check the fuel filter. See “Checking the
1 fuel filter assembly” (6-7), “Checking the
fuel filter element” (6-8), and “Checking the
fuel cup assembly” (6-8).

Checking the fuel pump

1. Check the fuel pump. See “Checking the
low-pressure fuel pump and high-pressure
fuel pump” (5-32).

Checking for fuel/engine oil leakage

1. Check the fuel joint and fuel hose connec-
tions. See “Fuel hose and blowby hose”
(2-18).

Oil filter “1” 2. Check for oil leakage.

18 Nm (1.8 kgf·m, 13.3 ft·lb)
T.

Changing the gear oil

R.

4. Fill the engine with the specified amount of

the recommended engine oil through the
oil filler hole. Never get under the lower unit while it is tilt-
ed.
Engine oil quantity (with oil filter re-
placement) 1. Tilt the outboard motor so that the drain
4.7 L (4.97 US qt, 4.14 Imp.qt) screw is at the lowest point.

5. Install the oil filler cap and dipstick, and 2. Place a drain pan under the gear oil drain
then start the engine and warm it up for 5– hole.
10 minutes.
3. Remove the drain screw “1” and gasket
6. Stop the engine, and then leave it off for 5– “2”.
10 minutes.

7. Check the oil level. If there is a significant amount of metal par-

ticles on the magnetic drain screw, the low-
Checking the exhaust guide/exhaust er unit may have a problem.
manifold
1. Check the exhaust guide and exhaust
manifold. See “Checking the oil pan and
exhaust manifold” (9-24).

10-13
 General periodic maintenance
4. Remove the oil level plug “3” and gasket
“4” and let the oil drain completely.

After the gear oil has been drained, check

the used oil. If the oil is milky, water is get-
1
ting into the lower case, which can cause 2
gear damage.

5. After the gear oil has been drained, check

the used oil. Pressure test the lower case
and inspect the oil seal for damage if the oil
is milky. See “Checking the lower unit for
air leakage” (8-27).

Gear oil quantity

If the oil is milky, water is getting into the 1.150 L (1.216 US qt, 1.012
lower case, which can cause gear damage. Imp.qt)
(F200BET, F250HET)
1.000 L (1.057 US qt, 0.880
Imp.qt)
(FL200BET, FL250HET)

9. Remove the gear oil pump, and then install

3 4 a new gasket “1” and the drain screw “2”.

2
Before installing the magnetic drain screw,
1 make sure to remove all metal particles.

10. Tighten the oil level plug “3” and drain

screw “2” to the specified torque.

6. Place the outboard motor in an upright po-

sition.

7. Insert the gear oil pump into the drain hole, 3

and then fill the lower unit slowly with gear
oil until oil flows out of the check hole and
1
no air bubbles are visible.
2
8. Install a new gasket “1” and the oil level
plug “2”.
Drain screw “2”
9 Nm (0.9 kgf·m, 6.6 ft·lb)
T.
R.

Oil level plug “3”

9 Nm (0.9 kgf·m, 6.6 ft·lb)

10-14
 General periodic maintenance

Checking the gear oil level

A
1. Check the gear oil level. See “Checking
the gear oil level” (10-6).

Replacing the OCV filter

1. Remove the OCV assembly. See step 1 in
“Removing the cylinder head” (7-66).

2. Replace the OCV gasket/filter “1”.

3. Install the OCV assembly. See step 1 in

“Installing the cylinder head” (7-74). A

Greasing points
1. Apply water resistant grease to the speci-
fied lubrication points.

10-15
 General periodic maintenance

B Greasing the clamp bracket bolt

(through tube)
1. Remove the hydraulic steering cylinder or
steering cable from the through tube.

2. Clean inside of the through tube and the

A hydraulic steering cylinder rod or steering
cable.

3. Apply a sufficient amount of grease to the

A. F200B, FL200B inside of the through tube and to the hy-
B. F250H, FL250H draulic steering cylinder rod or steering ca-
ble.
2. Apply low temperature resistant grease to
the specified lubrication point.

3. Apply corrosion resistant grease to the

specified lubrication point.

4. Assemble the hydraulic steering cylinder

or steering cable to the through tube.

10-16
 General periodic maintenance

Checking the propeller/propeller

nut/cotter pin
1. Check the propeller. See “Checking the
propeller” (8-3) or “Checking the propeller”
(8-49).

2. Check the propeller nut and cotter pin. See 1 2

“Installing the lower unit” (8-27) or “Install-
ing the lower unit” (8-69).

Checking the PCV 3. If the fluid is below the proper level, add
Check the PCV. See “Checking the PCV” the recommended fluid.
(9-20).
4. Install a new O-ring and the reservoir cap,
Checking the PTT fluid level and then tighten the reservoir cap to the
specified torque.

Never get under the outboard motor while it Reservoir cap

is tilted. T.
R.
7 Nm (0.7 kgf·m, 5.2 ft·lb)

1. Fully tilt the outboard motor up, and then Checking the power trim and tilt unit
support it using the tilt stop lever “1”. operation
1. Fully tilt the outboard motor up and down a
few times and check that it tilts up and
down smoothly. Check the PTT fluid level
if the tilt operation is not smooth.
1

Make sure that the PTT motor makes a wind-

ing sound when it is operating smoothly.

2. Fully tilt the outboard motor up, and then

2. Remove the reservoir cap “1” and O-ring support it using the tilt stop lever “1”.
“2”, and then check the fluid level in the Check that the tilt stop lever locks in place
reservoir. properly.

Before removing the reservoir cap, make

sure that the PTT ram is fully extended.
Otherwise, fluid could be expelled forceful- 1
ly from the unit due to internal pressure.

If the fluid is at the proper level, a small amount

of fluid should flow out of the filler hole when
the reservoir cap is removed. 3. Check the PTT unit for fluid leakage.

10-17
 General periodic maintenance

Adjusting the shift link/shift cable

1. Disconnect the shift cable, and then adjust a
it. See “Installing the shift cable” (3-9).

Checking the spark plug

1. Check the spark plugs. See “Checking the 2
1
spark plug” (7-42).

Checking the timing belt b

1. Check the timing belt. See “Checking the
timing belt” (7-46). 4. Tighten the bolts.

Replacing the timing belt 5. Recheck the fitting. Replace the cowling
1. Replace the timing belt. See “Timing belt” seal if looseness or rattling cannot be ad-
(7-44). justed.

Checking the thermostat 6. Check the top cowling hose for cracks or
1. Check the thermostat. See “Checking the damage.
thermostat” (7-91).

Adjusting the throttle link/throttle ca-

ble
1. Install the throttle cable. See “Installing the
throttle cable” (3-10).

Checking the cowling lock lever

1. Check the fitting by pushing the top cowl-
ing. Adjust if there is looseness or rattling.
Checking the valve clearance
1. Check the valve clearance. See “Checking
the valve clearance” (7-2).

Checking the impeller/water pump

housing
1. Check the water pump housing and impel-
ler. See “Checking the water pump and
shift rod” (8-9) or “Checking the water
pump and shift rod” (8-52).
2. Loosen the bolts “1”.

3. Move the hook “2” up or down slightly to

adjust its position.

• To loosen the fitting, move the hook in direc-

tion “a”.
• To tighten the fitting, move the hook in direc-
tion “b”.

10-18
 General periodic maintenance

— MEMO —

10-19
 Appendix

Wiring diagram ...................................................................A-1

How to use the wiring diagram ................................................... A-1 0
Engine control unit...................................................................... A-4
Fuel unit...................................................................................... A-5
Ignition unit ................................................................................. A-6
Charging unit, starting unit, and PTT unit................................... A-7
1
Control unit ................................................................................. A-8

Shim selection table and chart 2

(regular rotation model).....................................................A-9
Pinion shim (T3) selection table ................................................. A-9
Forward gear shim (T1) selection chart 3
(regular rotation model: F200B) ............................................... A-10
Reverse gear shim (T2) selection chart
(regular rotation model: F200B) ............................................... A-10
Forward gear shim (T1) selection chart 4
(regular rotation model: F250H) ............................................... A-11
Reverse gear shim (T2) selection chart
(regular rotation model: F250H) ............................................... A-11
Propeller shaft shim (T4) selection table (F250H).................... A-12
5
Shim selection table and chart
(counter rotation model)..................................................A-12
6
Pinion shim (T3) selection table ............................................... A-12
Propeller shaft shim (T4) selection table (FL200B, FL250H) ... A-12
Forward gear shim (T2) selection chart 7
(counter rotation model: FL200B)............................................. A-13
Reverse gear shim (T1) selection chart
(counter rotation model: FL200B)............................................. A-13
Forward gear shim (T2) selection chart 8
(counter rotation model: FL250H) ............................................ A-14
Reverse gear shim (T1) selection chart
(counter rotation model: FL250H) ............................................ A-14 9
10

A
 Wiring diagram

Wiring diagram
How to use the wiring diagram
Composition of the wiring diagrams
The wiring diagram consists of five categories; “Engine control unit”, “Fuel unit”, “Ignition unit”, “Charg-
ing unit, starting unit, and PTT unit”, and “Control unit”.

Legend symbols in the wiring diagrams

1 2 3

4 5 6

BZ
1. Double colors wire
2. Not used (vacant)
3. A wire is not included in the selected wiring unit.
4. Alert buzzer
5. Optional parts
6. Continuity

Terminal numbers
• Terminal numbers are indicated for cases where terminal locations of wires are unclear.
• In the coupler illustrations, only the rightmost and leftmost terminal numbers are indicated, and termi-
nal numbers between them are omitted.
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9

4 1
8 5
12 9
16 13

A-1
 Wiring diagram
Color code
B : Black L/W : Blue/White
Br : Brown L/Y : Blue/Yellow
G : Green Or/B : Orange/Black
Gy : Gray Or/G : Orange/Green
L : Blue Or/L : Orange/Blue
Lg : Light green Or/R : Orange/Red
Or : Orange Or/W : Orange/White
P : Pink Or/Y : Orange/Yellow
Pu : Purple P/B : Pink/Black
R : Red P/G : Pink/Green
Sb : Sky blue P/R : Pink/Red
W : White P/W : Pink/White
Y : Yellow Pu/B : Purple/Black
B/Br : Black/Brown Pu/G : Purple/Green
B/G : Black/Green Pu/L : Purple/Blue
B/L : Black/Blue Pu/R : Purple/Red
B/Or : Black/Orange Pu/W : Purple/White
B/R : Black/Red Pu/Y : Purple/Yellow
B/W : Black/White R/B : Red/Black
B/Y : Black/Yellow R/G : Red/Green
Br/R : Brown/Red R/L : Red/Blue
Br/W : Brown/White R/W : Red/White
G/B : Green/Black R/Y : Red/Yellow
G/L : Green/Blue W/B : White/Black
G/Or : Green/Orange W/Br : White/Brown
G/R : Green/Red W/G : White/Green
G/W : Green/White W/L : White/Blue
G/Y : Green/Yellow W/R : White/Red
Gy/B : Gray/Black Y/B : Yellow/Black
L/B : Blue/Black Y/G : Yellow/Green
L/G : Blue/Green Y/R : Yellow/Red
L/R : Blue/Red

Example:
R/Y: Red with Yellow tracer stripe wire

A-2
 Wiring diagram

— MEMO —

A-3
 Preface
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained me-
chanics when performing maintenance procedures and repairs to Yamaha equipment. It has been writ-
ten 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. Au-
thorized Yamaha dealers are notified periodically of modifications and significant changes in specifica-
tions 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:

:This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey
all safety messages that follow this symbol to avoid possible injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could result in death or se-
rious injury.

A NOTICE indicates special precautions that must be taken to avoid damage to the outboard
motor or other property.

A TIP provides key information to make procedures easier or clearer.

F200B, FL200B, F250H, FL250H

SERVICE MANUAL
©2017 by Yamaha Motor Co., Ltd.
1st Edition, February 2017
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
6FJ-28197-5W-11

6FJ-28197-5W-11_cover.indd 2 2017/02/13 10:35:32

 (6S1)

(6S2)

(6FJ)

(6FK)

6FJ-28197-5W-11

6FJ-28197-5W-11
Feb. 2017 !
(E)

6FJ-28197-5W-11_cover.indd 1 2017/02/13 10:35:31

 Engine control unit 1. Engine ECM
2. Oil pressure sensor
3. APS
4. Water pressure sensor
21. Fuse box 20. Main relay 1 19. Main relay 2 18. High-pressure 17. Starter relay 16. ETV relay
b c d e f fuel pump relay 5. Cam position sensor (STBD IN)
53 62 70 78 A
B a 6. Cam position sensor (PORT IN)
3 1 3 1 3 1 3 1 3 1
*1 6 4 6 4 6 4 6 4 6 4
7. Cam position sensor (PORT EX)
8. Speed sensor

B
*1 *1 *1 *1 *1 *1
R 1

W
G
8
9. OCV (STBD)

B
Y
64 G 22. Battery 16 9

Br
R
65 L/R 24 17
66 Y 10. OCV (PORT)
67 P
68 B *1 *1 *1 *1 11. ETV
69 B *1 *1 1
3

2
3
4

2
3
4

Br 2
B 3
Br/R 4

2
3
4
5
6
61 69 77 86 6 4
7
3 1 12. Intake air pressure sensor

R/G
R/G
9

R/G

R/Y
Y/R
Y/G

Y/R
Y/G

L/R
72 P/W

R
1. Engine ECM

Y
73 P/B 13. Joint connector 3
75 B
14. Joint connector 2

23
22
21
20
19
18

R/Y 14

3
2
76 B
77 Pu
15. Joint connector 1

R
R
R
R

R
Br
Y/R

Y/R
78 W 1
79 R/G B
Br Br/R
80
81
R/G
G/B B 3
24 12
16. ETV relay
83
84
G/R
B B 6 17. Starter relay
86 Pu B 8 18. High-pressure fuel pump relay
B 9
27 R/Y
B 10 19. Main relay 2
28 W/B B 12
Or 13 20. Main relay 1
Or 14
31 P/W Or
Or
15
16 21. Fuse box
Or 17
34 R/Y B 18 22. Battery
36 P/G B 20
37 P/W B 21 13 1
38 P
27 34 40 46 15. Joint connector 1 a. Fuse (10 A) (ETV)
40 B
41
42
B
L/B b. Fuse (30 A) (ignition coil, fuel injector,
43 R/Y 24
L
44 Or VCT, engine ECM)
45 P 24 12
46
47
B
B
c. Fuse (30 A) (starter relay)
48 Or
49 Or d. Fuse (20 A) (main switch, PTT switch)
50 P/W R/Y 16
33 39 45 52
51 Or R/Y 15 e. Fuse (60 A) (battery)
R/Y 14
1 W/B f. Fuse (60 A) (isolator [accessory])
2 W/G
3 W/L g. Condenser

7 Y/G
B 5 A. To remote control
B 4 13 1
1 8 14 20 B 3 B. To conventional gauge (6Y5/6Y7)
14. Joint connector 2
13 Y
B 1
C. To 6Y8/6YC Network
D. To YDIS

R/Y
24 12

B
18 B
20
21
W
L
*1. Not used (vacant)
g R/Y 8
*2. Standard for Caribbean and China market

R/Y

R/Y

P/G
R/Y 9

Pu

Pu
7 13 19 26

Or
B
B
R/Y 10

P/W

G/R
G/B
P/W

12. Intake air

and optional for other markets. (F250H)
P/W

Or
L/B

W/G

Or
W/B
Or

Or

W/L
Or

P
B
R/Y

R/Y

R/Y
R/Y 12
B
B
B

B
Or

P
B

L
pressure
B
P/W

W/B
B

R/Y
P/B

B R/Y 13

B
Standard for Caribbean market and
W

sensor
L

R/Y 14
R/G 16 optional for other markets. (FL250H)
P/B

Optional. (F200B, FL200B)

B
B
B

C D
B
B 9. OCV 10. OCV
13 1 *3. Standard for Caribbean and China market
B 4. Water 5. Cam 6. Cam
position position
7. Cam
position
(STBD) (PORT) 13. Joint connector 3 and optional for other markets. (F250H)
B pressure (*2) (*3)
2. Oil pressure
3. APS
sensor sensor sensor sensor
(STBD IN) (PORT IN) (PORT EX) 8. Speed sensor 11. ETV Optional. (F200B, FL200B, FL250H)
sensor

A-4

S6DXZU11_W.D.indd 4 2017/02/13 15:02:00

 Fuel unit 1. Engine ECM
2. Fuel injector (STBD)
3. Fuel injector (PORT)
16. Fuse box 15. Main relay 1 14. Main relay 2 13. High-pressure 12. Starter relay 11. ETV relay
4. Water detection switch
b c d e f fuel pump relay 5. High-pressure fuel pump
A
B a
*1
3 1 3 1 3 1 3 1 3 1 6. Low-pressure fuel pump
6 4 6 4 6 4 6 4 6 4
53 62 70 78 7. Vapor shut-off valve

B
55 Pu/W
R
*1 *1 *1 *1 *1 *1 8. Joint connector 3
1

W
Pu/L

G
56 8

B
Y
57 Pu/G 17. Battery 16 9 9. Joint connector 2

Br
R
58 Pu/Y 24 17
59 Pu/R
60 Pu/B 10. Joint connector 1
61 L/W *1 *1 *1 *1
*1 *1 1 11. ETV relay
3

2
3
4
5
6

2
3
4
5
6

2
3
4
5

2
3
4

4
64 G 6 4
65 L/R 9 7
3 1 12. Starter relay

Y/R
Y/G

R/Y
R/Y

Y/R
Y/G

R/Y
R/Y

L/R

Br/R

R/Y
Br
R

R
R

B
61 69 77 86
67
68
P
B
13. High-pressure fuel pump relay

23
22
21
20
19
18

14
69 B
14. Main relay 2

3
2
1. Engine ECM

Y/R

Y/R

R/Y

Br
15. Main relay 1

R
R
R
R
R

R
B 1
Br Br/R
75 B 24 12 16. Fuse box
76 B
17. Battery
78 W

a. Fuse (10 A) (ETV)

B 12
84
85
B
G/B
b. Fuse (30 A) (ignition coil, fuel injector,
VCT, engine ECM)
27 R/Y Or 17
B 18 c. Fuse (30 A) (starter relay)
13 1 d. Fuse (20 A) (main switch, PTT switch)
B 24
10. Joint connector 1 e. Fuse (60 A) (battery)
34 R/Y
f. Fuse (60 A) (isolator [accessory])
R/Y 23
R/Y 22 g. Fuse (10 A) (low-pressure fuel pump)
27 34 40 46 R/Y 21 24 12
R/Y
R/Y
20
19
h. Fuse (15 A) (high-pressure fuel pump)
R/Y 18
R/Y 17

46 B
A. To remote control
48 Or
*1. Not used (vacant)
33 39 45 52

B 5
13 1
B 3
5 L/W B 2 9. Joint connector 2
B 1
7 Y/G

1 8 14 20
g h 24 12
13 Y

G/B
R/Y
R/Y 8
R/Y 9

L/W

L/W
R/Y
R
B
B
R/Y 11
18 B R/Y 12
B
B
B
B
B
B

R/Y 13
B
Pu/W
Pu/G
Pu/R
Pu/Y

Pu/B
Pu/L

7 13 19 26 B
R/Y

R/Y

R/Y

R/Y

R/Y

R/Y

B 17
R/Y
R/Y 18
R 19
R 20
R 21 13 1
R/Y 22
4. Water detection
8. Joint connector 3
switch
#5 #3 #1 #2 #4 #6 5. High-pressure 6. Low-pressure 7. Vapor shut-off valve
2. Fuel injector 3. Fuel injector fuel pump fuel pump
(STBD) (PORT)

A-5

S6DXZU11_W.D.indd 5 2017/02/13 15:02:01

 Ignition unit 1. Engine ECM
2. Shift position switch
3. Shift cut-off switch
4. Knock sensor
18. Fuse box 17. Main relay 1 16. Main relay 2 15. High-pressure 14. Starter relay 13. ETV relay
b c d e f fuel pump relay 5. Ignition coil
53 62 70 78 A a 6. Engine temperature sensor
3 1 3 1 3 1 3 1 3 1
*1 4 4 4 4 4
6 6 6 6 6
7. Thermo switch (STBD)
53 B/Br
54 B/L
*1 *1 *1 *1 *1 *1 8. Thermo switch (PORT)
R 1
8 9. Intake air temperature sensor

W
G

B
Y
19. Battery 16 9
24 17
10. Joint connector 3

Br
R
*1 *1 *1 *1 11. Joint connector 2
62
63
B/G
B/Y
*1 *1 1
3

2
3
4
5
6

2
3
4

2
3
4

2
3
4
5
6
61 69 77 86
64
65
G
L/R
6 4 3 1 12. Joint connector 1
7

Br/R
9

Y/G
R

Br
B

R/G
Y

R/G
R/G
Y/R

R/Y
R/Y

Y/R

L/R
Y/G
20. Pulser coil

R/Y
66 Y
67 P 13. ETV relay
68 B
69 B 14. Starter relay

23
22
21
20
19
18

14

3
2
1. Engine ECM 70 B/W B
71 B/Or W/B
15. High-pressure fuel pump relay

Y/R
R
R
Y/R
R
R

R/Y

R
Br
B 1
B 2
75 B
16. Main relay 2
B 4 24 12
B
76 B 5 17. Main relay 1
78 W B 7
79
80
R/G
R/G
18. Fuse box
Br Br/R
19. Battery
B 12
84 B 20. Pulser coil

R/Y Or 17
27
B 18 a. Fuse (10 A) (ETV)
B 19
13 1 b. Fuse (30 A) (ignition coil, fuel injector,
B 22
12. Joint connector 1
VCT, engine ECM)
34 R/Y
c. Fuse (30 A) (starter relay)
d. Fuse (20 A) (main switch, PTT switch)
27 34 40 46 24 12
e. Fuse (60 A) (battery)
f. Fuse (60 A) (isolator [accessory])
46 B
48 Or 12
A. To remote control
B
B 11
B 10
33 39 45 52 B 9
52 P B 8 *1. Not used (vacant)
B 7
B 5
13 1
B 3
B 11. Joint connector 2
1 8 14 20 6 L/Y 1
7 Y/G
8 G R/Y 1
R/Y 2
R/Y 3
R/Y 4 24 12
12 L/G R/Y 5
13 Y R/Y 6
15 B R/Y 8

B
16 W/B R/Y 9

B/Y
B/Y
17 B/Y

B/Or

B/Br
B/W

B/G
R/Y

R/Y

R/Y

R/Y

R/Y

R/Y
B/Y
B/L

B
B

P
18

B
L/G

B
7 13 19 26 R/Y 12
B

R/Y 13
L/Y
B
B
B

G
B

23 B/Y R/G 16
R/Y 18

13 1
B
B
B

R/Y 22
2. Shift position B 9. Intake air 10. Joint connector 3
#5 #3 #1 #2 #4 #6 7. Thermo 8. Thermo
switch B 3. Shift cut-off switch temperature
B 6. Engine temperature -switch -switch
5. Ignition coil sensor
4. Knock sensor sensor (STBD) (PORT)

A-6

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 Charging unit, starting unit, and PTT unit 1. Engine ECM
2. PTT switch
3. Trim sensor
4. PTT motor
14. Fuse box 12. Main relay 1 11. Main relay 2 10. High-pressure 9. Starter relay 8. ETV relay
fuel pump relay 5. Joint connector 3
B 8
16
1
9
3
6
1
4 3 1 3 1 3 1 3 1 3 1 3 1 6. Joint connector 2

1
2
24 7 4 4 4 4 4
A
17 9 2 1 6 6 6 6 6
7. Joint connector 1
18. Rectifier/regulator
B
b c d e f
8. ETV relay

R
B
a 9. Starter relay
(*3) *1
10. High-pressure fuel pump relay

B
G

B
53 62 70 78 Y
15. Battery

Sb
Lg
11. Main relay 2

B
Lg
Sb

B
G
R
G
G
R
Br
R

*1 *1 *1 *1 *1 *1

2
3
4

2
3
4

2
3
4
5

2
3
4
5
6
16. House
12. Main relay 1

Br/R
Br/W
Br

R/G
R/G
R/G

R/Y
Y/R
Y/G

Y/R
Y/G

L/R
R

Y
(accessory)
13. PTT relay
13. PTT relay
battery
*1 *1 *1 *1 14. Fuse box
64 G *1 *1 Sb Sb
65 L/R R Lg Lg
15. Battery

R
66 Y
67 P B 1

R
61 69 77 86
68
69
B
B 16. House (accessory) battery

Br/W
24 12

R
17. Starter motor 17. Starter motor

23
22
21
20
19
18

R/Y 14

2
1

3
2
1
G
G
1. Engine ECM
72 P/W G
18. Rectifier/regulator

R
73 P/B

Y/R
R
R
Y/R
R
R

R
R

R
Br
R
75 B Br Br/R
76 B 19. Stator assembly
78 W 19. Stator assembly B 12
79 R/G
80 R/G Lg
Sb a. Fuse (10 A) (ETV)
B g Or
B
17
18 b. Fuse (30 A) (ignition coil, fuel injector,
84 B

13 1
VCT, engine ECM)
27 R/Y B 23 7. Joint connector 1
c. Fuse (30 A) (starter relay)
d. Fuse (20 A) (main switch, PTT switch)
e. Fuse (60 A) (battery)
24 12
34 R/Y f. Fuse (60 A) (isolator [accessory])
g. Diode
27 34 40 46
A. To remote control
B. To conventional gauge (6Y5/6Y7)
46 B
48 Or B
B
6
5 *1. Not used (vacant)
13 1
B 3 *2. If the 6Y8/6YC Multifunction meters is
33 39 45 52 6. Joint connector 2
B 1 selected, connect the coupler.
*3. Optional
24 12

7 Y/G
R/Y 8
R/Y 9
R

1 8 14 20
R/Y 12
Sb

Y
P/W

13
Lg

R/Y 13
P/B

Sb
Lg
P
B
R/G 16
P/B

18 B B
P

19 P B
B B
P

B 13 1
B
B
B

7 13 19 26
B 5. Joint connector 3
*2 B B
B
2. PTT switch 3. Trim sensor 4. PTT motor

A-7

S6DXZU11_W.D.indd 7 2017/02/13 15:02:03

 Control unit 1. 703 side mount remote control
2. Engine start switch
1. 703 side mount remote control 14. Switch panel (6R5-82570- 3. Engine shut-off switch
**)
2. Engine start switch 4. PTT switch 2. Engine start switch 4. PTT switch
W B R Y Br 3. Engine shut-off switch Sb R Lg 3. Engine shut-off switch
W B R Y Br 5. ON
5. ON W B 10. UP 5. ON W B
6. OFF 8. Clip removed 11. Free 6. OFF 8. Clip removed 6. OFF
7. START 9. Clip installed 12. DN 7. START 9. Clip installed 7. START
16. Extension wire harness

W
R

Lg
Br
B

B
8. Clip removed

Sb

Y
Y
Br
B
B
W
R A
Y Y 9. Clip installed
B G
BZ 10. UP

Lg
Sb

R
W W
P

B
R
Br P 11. Free
R R L
Y
G
Y
R
L 12. DN
B
G
W B G
R
B
B Sb B
G Br 13. Neutral switch
P P A 15. 704 binnacle mount remote control 14. Switch panel (6R5-82570-**)
Y Lg
Br Y L L
B B 4. PTT switch 15. 704 binnacle mount remote control
Br Br Sb R Lg
10. UP 16. Extension wire harness
13. Neutral switch 11. Free
12. DN
Y P A. To power unit
BZ

Lg
Sb

R
R
Sb B. To gauge, 6Y8/6YC Network
Lg
Lg R
Sb Br
Br Br Br
Br Br B

13. Neutral switch

A-8

S6DXZU11_W.D.indd 8 2017/02/13 15:02:03

 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-9

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 Forward gear shim (T1) selection chart (regular rotation model: F200B)
1.10
1.00
0.90
0.80
0.70
0.60
0.50
B (mm)

0.40
0.30
0.20
0.10
0
–0.10
–0.20
–0.30
–0.40
–0.50
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 –0.45 –0.42 –0.38 –0.35 –0.30 –0.27 –0.13 –0.10 –0.07 –0.04 –0.01 0.02 0.05 0.08 0.10 0.12 0.18 0.20 0.23 0.27 0.30 0.33 0.37 0.42 0.45 0.48 0.52 0.55 0.58 0.62 0.65 0.68 0.72 0.75 0.78 0.82 0.85 0.88 0.92 0.95 0.98

A. Backlash measurement (BL1)

B. Shim thickness adjustment

Reverse gear shim (T2) selection chart (regular rotation model: F200B)
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
–0.40
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 –0.40 –0.37 –0.32 –0.30 –0.27 0.52 0.50 0.47 0.44 0.41 0.38 0.35 0.32 0.29 0.26 0.23 0.21 –0.18 0.23 0.28 0.32 0.37 0.40 0.43 0.47 0.50 0.55 0.58 0.60 0.63 0.67 0.72 0.75 0.78 0.82 0.85 0.90 0.93 0.97 1.00 1.03

A. Backlash measurement (BL2)

B. Shim thickness adjustment
A-10

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 Forward gear shim (T1) selection chart (regular rotation model: F250H)
1.10
1.00
0.90
0.80
0.70
0.60
0.50
B (mm)

0.40
0.30
0.20
0.10
0
–0.10
–0.20
–0.30
–0.40
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 –0.40 –0.37 –0.32 –0.28 –0.18 –0.15 –0.13 –0.10 –0.07 –0.04 –0.01 0.02 0.05 0.08 0.11 0.14 0.16 0.19 0.22 0.28 0.32 0.37 0.40 0.43 0.47 0.50 0.55 0.58 0.60 0.65 0.68 0.72 0.75 0.78 0.82 0.85 0.88 0.93 0.97 1.00 1.03

A. Backlash measurement (BL1)

B. Shim thickness adjustment

Reverse gear shim (T2) selection chart (regular rotation model: F250H)
0.70
0.60
0.50
0.40
0.30
0.20
B (mm)

0.10
0
–0.10
–0.20
–0.30
–0.40
–0.50
–0.60
–0.70
–0.80
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 –0.75 –0.70 –0.67 –0.63 –0.60 –0.57 –0.53 –0.48 –0.45 –0.42 –0.38 –0.35 –0.30 0.29 0.26 0.23 0.21 0.18 0.15 0.12 0.09 0.06 0.03 0.00 –0.03 –0.06 –0.08 –0.11 –0.14 0.30 0.35 0.38 0.42 0.45 0.48 0.52 0.55 0.58 0.63 0.67 0.70

A. Backlash measurement (BL2)

B. Shim thickness adjustment
A-11

S6FJ5W11_shim.indd 11 2017/02/13 15:05:07

 Propeller shaft shim (T4) selection table (F250H)
The shim thickness does not have to be adjusted for the gray-colored cell.

(mm)
A 0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18 0.20 0.22 0.24 0.26 0.28 0.30 0.32 0.34
B –0.28 –0.25 –0.25 –0.22 –0.20 –0.18 –0.15 –0.15 –0.12 –0.10 –0.10 –0.10 –0.10 –0.10

A 0.36 0.38 0.40 0.42 0.44 0.46 0.48 0.50 0.52 0.54 0.56 0.58 0.60 0.62 0.64 0.66 0.68 0.70
B +0.10 +0.10 +0.10 +0.10 +0.12 +0.15 +0.15 +0.18 +0.20 +0.22 +0.25 +0.25 +0.28 +0.30 +0.32 +0.35 +0.35 +0.38

A 0.72 0.74 0.76 0.78 0.80 0.82 0.84 0.86 0.88 0.90 0.92 0.94 0.96 0.98 1.00 1.02 1.04 1.06
B +0.40 +0.42 +0.45 +0.45 +0.48 +0.50 +0.52 +0.55 +0.55 +0.58 +0.60 +0.62 +0.65 +0.65 +0.68 +0.72 +0.72 +0.75

A 1.08 1.10 1.12 1.14 1.16 1.18 1.20 1.22 1.24 1.26 1.28 1.30 1.32 1.34 1.36 1.38 1.40 1.42
B +0.75 +0.78 +0.80 +0.82 +0.85 +0.85 +0.88 +0.90 +0.92 +0.95 +0.95 +0.98 +1.00 +1.02 +1.05 +1.05 +1.08 +1.10

A 1.44 1.46 1.48 1.50 1.52

B +1.12 +1.15 +1.15 +1.18 +1.20

A. Free play measurement

B. Shim thickness adjustment

Shim selection table and chart (counter rotation model)

Pinion shim (T3) selection table
See “Pinion shim (T3) selection table” (A-9).

Propeller shaft shim (T4) selection table (FL200B, FL250H)

See “Propeller shaft shim (T4) selection table (F250H)” (A-12).

A-12

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 Forward gear shim (T2) selection chart (counter rotation model: FL200B)
1.00
0.90
0.80
0.70
0.60
0.50
B (mm)

0.40
0.30
0.20
0.10
0
–0.10
–0.20
–0.30
–0.40
–0.50
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 –0.50 –0.45 –0.42 –0.38 –0.35 –0.30 –0.27 –0.22 –0.18 –0.15 –0.38 –0.36 –0.33 –0.30 –0.27 –0.24 –0.21 0.12 0.15 0.18 0.23 0.27 0.30 0.35 0.38 0.42 0.45 0.48 0.53 0.57 0.60 0.63 0.67 0.70 0.75 0.78 0.82 0.85 0.90 0.93 0.97

A. Backlash measurement (BL2)

B. Shim thickness adjustment

Reverse gear shim (T1) selection chart (counter rotation model: FL200B)
1.00
0.90
0.80
0.70
0.60
0.50
0.40
B (mm)

0.30
0.20
0.10
0
–0.10
–0.20
–0.30
–0.40
–0.50
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 –0.50 –0.47 –0.43 –0.40 –0.37 –0.33 –0.30 –0.27 –0.23 –0.12 0.00 –0.02 –0.05 –0.08 –0.11 –0.14 –0.17 0.12 0.15 0.18 0.20 0.25 0.28 0.32 0.35 0.38 0.42 0.47 0.50 0.53 0.58 0.62 0.65 0.70 0.72 0.75 0.78 0.82 0.87 0.90 0.93

A. Backlash measurement (BL1)

B. Shim thickness adjustment
A-13

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 Forward gear shim (T2) selection chart (counter rotation model: FL250H)
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
–0.40
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 –0.37 –0.33 –0.30 –0.51 –0.48 –0.45 –0.42 –0.39 –0.36 –0.33 –0.30 –0.27 –0.33 –0.30 –0.27 –0.24 –0.21 –0.18 0.28 0.32 0.35 0.40 0.43 0.47 0.50 0.53 0.58 0.62 0.65 0.67 0.72 0.75 0.78 0.83 0.87 0.90 0.93 0.97 1.00 1.03 1.07

A. Backlash measurement (BL2)

B. Shim thickness adjustment

Reverse gear shim (T1) selection chart (counter rotation model: FL250H)
0.80
0.70
0.60
0.50
0.40
0.30
B (mm)

0.20
0.10
0
–0.10
–0.20
–0.30
–0.40
–0.50
–0.60
–0.70
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 –0.70 –0.67 –0.63 –0.60 –0.55 –0.52 –0.48 –0.45 –0.42 –0.38 –0.33 –0.30 –0.33 –0.30 –0.27 –0.24 –0.21 –0.18 –0.15 –0.12 –0.09 –0.07 –0.04 –0.01 0.02 0.05 0.08 0.11 0.30 0.35 0.38 0.42 0.45 0.48 0.53 0.57 0.60 0.63 0.67 0.70 0.75

A. Backlash measurement (BL1)

B. Shim thickness adjustment
A-14

S6FJ5W11_shim.indd 14 2017/02/13 15:05:08

 (6S1)

(6S2)

(6FJ)

(6FK)

6FJ-28197-5W-11

6FJ-28197-5W-11
Feb. 2017 !
(E)

6FJ-28197-5W-11_cover.indd 1 2017/02/13 10:35:31