Yamaha Marine Outboard Z300c Lz300c Service Repair Manual - Download.pdf

Z300C LZ300C

SUPPLEMENTARY SERVICE MANUAL *LIT186160253* LIT-18616-02-53

6D0-28197-1F-1X

NOTICE This Supplementary Service Manual has been prepared to introduce new service and new data information for the Z300 and LZ300 which are based on the Z250 and LZ250. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual.

Z250B, LZ250B SERVICE MANUAL: 60V-28197-1E-11 (LIT-18616-02-43)

Important information

1

Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.

NOTE: A NOTE provides key information to make procedures easier or clearer.

CAUTION: USE UNLEADED STRAIGHT GASOLINE ONLY • Gasoline containing lead can cause performance loss and engine damage.

• Do not use gasoline mixed with oil during the break-in period or anytime thereafter.

YAMALUBE 2-STROKE OUTBOARD OIL IS RECOMMENDED.

Z300C, LZ300C SUPPLEMENTARY SERVICE MANUAL ©2003 by Yamaha Motor Corporation, USA 1st Edition, July 2003 All rights reserved.

Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited.

Printed in USA LIT-18616-02-53

Contents General information Specifications Periodic checks and adjustments Fuel system Power unit Lower unit Bracket unit

GEN INFO

SPEC

CHK ADJ

FUEL

POWR

LOWR

BRKT –

Electrical systems Troubleshooting Index

+

ELEC

TRBL SHTG

1 2 3 4 5 6 7 8 9

General information How to use this manual .................................................................................... 1 Manual format............................................................................................... 1 Symbols........................................................................................................ 2 Identification...................................................................................................... 3 Applicable models ........................................................................................ 3 Serial number ............................................................................................... 3 Features and benefits ....................................................................................... 4 Crankcase and cylinders .............................................................................. 4 Intake system ............................................................................................... 6 Upper case ................................................................................................... 8 Lower case ................................................................................................... 9 ECM (Electronic Control Module) ............................................................... 10 Wiring harness connector holder................................................................ 10 Propeller selection .......................................................................................... 11 Propeller size.............................................................................................. 11 Selection..................................................................................................... 11 Predelivery checks ......................................................................................... 12 Checking the fuel system ........................................................................... 12 Checking the gear oil level ......................................................................... 12 Checking the engine oil level...................................................................... 12 Checking the battery................................................................................... 12 Checking the outboard motor mounting height........................................... 13 Checking the remote control cables ........................................................... 13 Checking the steering system .................................................................... 14 Checking the gear shift and throttle operation............................................ 14 Checking the power trim and tilt system..................................................... 14 Checking the engine start switch and engine stop lanyard switch ............. 14 Checking the cooling water pilot hole ......................................................... 15 Test run ...................................................................................................... 15 Break-in ...................................................................................................... 15 After test run ............................................................................................... 15

6D01F1X

Specifications General specifications.................................................................................... 16 Maintenance specifications ........................................................................... 18 Power unit................................................................................................... 18 Lower unit ................................................................................................... 20 Electrical ..................................................................................................... 20 Dimensions................................................................................................. 23 Tightening torques.......................................................................................... 25 Specified torques........................................................................................ 25 General torques.......................................................................................... 27

Periodic checks and adjustments Special service tools ...................................................................................... 28 Maintenance interval chart............................................................................. 30 Oil injection system ........................................................................................ 31 Adjusting the oil pump link rod.................................................................... 31 Lower unit ........................................................................................................ 31 Checking the lower unit for air leakage ...................................................... 31 General............................................................................................................. 32 Lubricating the outboard motor................................................................... 32

Fuel system Fuel filter .......................................................................................................... 34

6D01F1X

Power unit Power unit........................................................................................................ 35 Removing the power unit............................................................................ 36 Crankcase ........................................................................................................ 38 Removing the crankcase covers ................................................................ 39 Installing the crankcase covers .................................................................. 39 Installing the power unit.............................................................................. 39

Lower unit Propeller shaft housing (regular rotation model) ........................................ 42 Shimming (regular rotation model) ............................................................... 44 Selecting the pinion shims.......................................................................... 45 Backlash (regular rotation model)................................................................. 46 Measuring the forward and reverse gear backlash .................................... 46 Propeller shaft housing (counter rotation model) ....................................... 48 Drive shaft and lower case (counter rotation model) .................................. 50 Disassembling the reverse gear ................................................................. 52 Assembling the lower case......................................................................... 52 Shimming (counter rotation model) .............................................................. 54 Selecting the pinion shims.......................................................................... 55 Backlash (counter rotation model)................................................................ 56 Measuring the forward and reverse gear backlash .................................... 56

Bracket unit Bottom cowling ............................................................................................... 59 Upper case, steering arm, swivel bracket, and clamp brackets ................. 62 Power trim and tilt unit ................................................................................... 67 Checking the hydraulic pressure ................................................................ 67

6D01F1X

Electrical systems Electrical components.................................................................................... 70 Port view..................................................................................................... 70 Top view ..................................................................................................... 71 Wiring harness............................................................................................ 72

Troubleshooting Self-diagnosis.................................................................................................. 76 Diagnosing the electronic control system ................................................... 76 Wiring diagram

6D01F1X

GEN INFO

General information

How to use this manual

1

Only chapters containing revisions or additional items in the base manual have been included in this manual.

All special service tools introduced in this manual are mentioned in Chapter 3.

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

1 Parts are shown and detailed in an exploded diagram and are listed in the components list.

2 Tightening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions.

3 Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and lubrication point.

4 The components list consists of part names and part quantities, as well as bolt and screw dimensions.

5 Service points regarding removal, checking, and installation are shown in individual illustrations to explain the relevant procedure.

LOWR

3

Lower unit

2

1

Lower unit

LOWR

Lower unit

Removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the forward gear.

S62Y6740K

CAUTION: S62Y6850K

No.

Part name

Q’ty

1

Lower unit

1

2

Plastic tie

1

3

Hose

1

4

Check screw

1

5

Gasket

2

6

Dowel pin

2

7

Bolt

4

8

Drain screw

1

Not reusable

Disassembling the drive shaft

M10

9

Grommet

1

Bolt

1

M10

11

Bolt

1

M8

Thrust washer

1

13

Propeller

1

14

Washer

1

15

Washer

16

Cotter pin

1

17

Propeller nut

1

18

Trim tab

1

1. Install the pinion nut 1, tighten it finger tight, and then remove the drive shaft bearing 2 using a press.

Not reusable

10 12

Drive shaft holder 4 1: 90890-06518 Pinion nut holder 2: 90890-06505 Socket adapter 2 3: 90890-06507

Remarks

Bearing separator 1: 90890-06534 2. Remove the needle bearing from the forward gear.

40 mm

45 mm 60 mm

CAUTION: CAUTION:

1

6-5

Do not reuse the bearing, always replace it with a new one.

• Do not press the drive shaft threads a directly.

• Do not reuse the bearing, always replace it with a new one.

Not reusable

Bearing inner race attachment 3: 90890-06639

62Y5A11

Do not reuse the bearing, always replace it with a new one.

Stopper guide plate 2: 90890-06501 Stopper guide stand 3: 90890-06538 Bearing puller 4: 90890-06535 Bearing puller claw 1 5: 90890-06536

Disassembling the forward gear 1. Remove the taper roller bearing from the forward gear using a press.

4

6-19

62Y5A11

5

1

6D01F1X

How to use this manual

Symbols The symbols below are designed to indicate the content of a chapter.

General information

Fuel system

GEN INFO

Bracket unit

FUEL

Specifications

BRKT

Power unit

SPEC

Electrical systems

POWR

Periodic checks and adjustments Lower unit

CHK ADJ

–

ELEC

+

Troubleshooting

TRBL SHTG

LOWR

Symbols 1 to 6 indicate specific data.

1

2

3

4

5

6

T.

R.

1 2 3 4

5 Specified measurement 6 Specified electrical value (resistance, voltage, electric current)

Special tool Specified oil or fluid Specified engine speed Specified tightening torque

Symbols 7 to C in an exploded diagram indicate the grade of lubricant and the lubrication point.

7

8

9

0 A

E 7 8 9 0

A M

B D

C C

I

G

Apply 2-stroke outboard motor oil Apply gear oil Apply water resistant grease (Yamaha grease A) Apply molybdenum disulfide grease

A Apply corrosion resistant grease (Yamaha grease D) B Apply low temperature resistant grease (Yamaha grease C) C Apply injector grease

Symbols D to I in an exploded diagram indicate the type of sealant or locking agent and the application point.

D

E GM

F

4

D Apply Gasket Maker E Apply Yamabond No. 4 F Apply LOCTITE 271 (red) 6D01F1X

G

H

I

LT

LT

LT

271

242

572

SS

G Apply LOCTITE 242 (blue) H Apply LOCTITE 572 I Apply silicon sealant

2

1 2 3 4 5 6 7 8 9

GEN INFO

General information

Identification

1

Applicable models This manual covers the following models.

Applicable models Z300TR, LZ300TR

Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket.

1 2 3 4

Model name Approved model code Transom height Serial number

Model name

Approved model code

Z300TR

6D0

LZ300TR

6D1

3

Starting serial No. X: 1000001– U: 1000001– X: 1000001– U: 1000001–

6D01F1X

Identification / Features and benefits

Features and benefits

1

Crankcase and cylinders The following modifications have been adopted to increase the output as compared to the Z250 power unit.

• The material of the crankshaft has been changed to a high-grade clean steel(*1) to increase durability against stress.

• Wider exhaust ports with planed-off edges have been adopted and the exhaust timing has been changed to reduce the exchange loss of the exhaust gas.

• Cooling water jackets have been incorporated to the crankcase to increase engine-cooling ability. *1: Steel with decreased nonmetallic inclusion content

1 Crankshaft identification Identification mark: 2 mm (0.079 in) punch mark 2 Exhaust port 3 Crankcase water jackets È Water flow

6D01F1X

4

GEN INFO

General information

• Newly-forged lightweight pistons with a hard anodic coating on the piston pin boss have been adopted to increase durability and reduce the inertia mass of the pistons.

• The top piston rings are made of steel and are ion-plated to increase durability.

• The heat treatments for the piston pins and connecting rods have been changed so that there is multiphase carbonization to increase durability.

1 2 3 4 5 6

5

Ion plating (chromium) Identification mark: R Identification mark: 6D0 Oil groove Hard anodic coating Identification mark

È Top ring É Second ring

6D01F1X

Features and benefits • The anti-corrosion anodes in the cooling water passages of the cylinder block are larger to increase reliability and performance.

1 Anodes

Intake system The openings in the throttle bodies were enlarged to a 46 mm (1.81 in) diameter to increase power output.

6D01F1X

6

GEN INFO

General information

An oil groove has been added to each reed valve seat. Oil in the groove helps to reduce impact when the reed valve contacts the reed valve seat.

The dimensions of the reed valve assembly are the same as those for the Z250.

1 Oil groove 2 Identification mark: 6D0

The oil pump has been newly designed to obtain optimal oil supply.

Ăˆ Model É Identification mark

7

6D01F1X

Features and benefits

Upper case Water jackets have been incorporated to both sides of the lower part of the upper case. This structure reduces the heat transfer to the upper case from the exhaust gas.

The cooling water discharged from the water pump is supplied to the upper case around the muffler from the pipe connected to the exhaust guide, flows down into the water jacket, and then drains to the lower case.

Water jackets have been incorporated to the exhaust manifold to protect it from the high-temperature exhaust gas.

Fresh cooling water from the water pump accumulates in the water jacket, and then drains into the muffler.

1 2 3 4 5 6 7 8 9 0

Muffler Upper case Gasket Upper case water jacket Lower case Exhaust guide Hose Exhaust manifold Water Water pump

6D01F1X

Ăˆ Water flow É Exhaust passage

8

GEN INFO

General information

Lower case The propeller shaft housing and the ring are newly designed to reduce the exhaust back-pressure and cool the propeller damper.

Cooling water is taken in from the front of the trim tab, flows through the pipe in the lower case and propeller shaft housing, and then is supplied directly to the propeller boss.

This prevents the cooling water from mixing with the exhaust gas in the exhaust passage in the lower case and also prevents the cooling water from obstructing the exhaust gas.

Therefore, the exhaust back-pressure can be reduced.

A low gear ratio has been adopted to match the power output characteristics.

1 2 3 4 5

Water pipe (for cooling the propeller boss) Heli-sert bushing Ring Fluorine-coated oil seals Propeller shaft housing (with water passage)

È Water flow É Pinion gear Ê Reduction gear

Ë Model

Gear ratio

Z250

1.81

VZ250 Z300

1.75

Ì Identification mark

Model Z300 LZ300

60X1

Notes Same as VZ250

Í Identification mark

Model Z300 LZ300

9

Notes

F

60X00

Same as VZ250

R

69L00

Same as VX250

F

6D100

New

R

6D100

New

6D01F1X

Features and benefits

ECM (Electronic Control Module) ECMs have been adopted that are specific to each model to control the ignition and injection timing.

NOTE: The diagnostic codes are the same as those for the Z250, and the latest version of the YDIS covers all previous models with fuel injection.

È

É

VZ225 (Z250H)

60Y-01

VZ250 (Z250F)

60X-01

Z250 (Z250D) Z300 (Z300A)

Ê

60V-01 60V-21

Ë

6D0-00 S6D01100

È Model É ECM identification

Ê Note Ë For Brazil

Wiring harness connector holder A wiring harness connector holder has been added to the side of bottom cowling to secure the 10pin main harness, remote oil tank harness, warning indicator harness, and trim meter harness.

The wiring harness connector holder helps to organize the harnesses and hold them in place.

1 2 3 4 5 6 7

10-pin main harness Remote oil tank harness (Blue connector) Bottom cowling seal Holder Trim meter harness Warning indicator harness Isolator lead

6D01F1X

10

GEN INFO

General information

Propeller selection

1

The performance of a boat and outboard motor will be critically affected by the size and type of propeller you choose. 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 seriously damage the engine.

Use the following information as a guide for selecting a propeller that meets the operating conditions of the boat and the outboard motor.

Selection When the engine speed is at the full throttle operating range (4,500–5,500 r/min), the ideal propeller for the boat is one that provides maximum performance in relation to boat speed and fuel consumption.

Regular rotation model Propeller size (in)

Material

13 3/8 × 23 - M 13 3/8 × 25 - M 13 3/4 × 17 - M2 13 3/4 × 19 - M2

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

13 3/4 × 21 - M 14 1/2 × 19 - T 14 1/2 × 21 - T 14 1/2 × 23 - M 14 3/4 × 25 - T

×

a

-

14 7/8 × 21 - M

b c

15 × 17 - T

Stainless

15 1/8 × 27 - T 15 1/4 × 15 - M 15 1/4 × 17 - M S69J1100

15 1/4 × 19 - M 15 3/4 × 13 - M Counter rotation model Propeller size (in)

-

13 3/8 × 23 - ML

b c

13 3/4 × 17 - ML1

Material

13 3/4 × 19 - ML1 S60C1125

a Propeller diameter (in inches) b Propeller pitch (in inches) c Propeller type (propeller mark)

13 3/4 × 21 - ML 14 1/2 × 19 - TL

Stainless

14 1/2 × 21 - TL 15 × 17 - TL 15 1/4 × 15 - ML

11

6D01F1X

Propeller selection / Predelivery checks

Predelivery checks

1

To make the delivery process smooth and efficient, the predelivery checks should be completed as explained below.

Checking the gear oil level 1. Check the gear oil level.

Checking the fuel system 1. Check that the fuel hoses are securely connected and that the fuel tank is full with fuel.

S60V1290

Checking the engine oil level 1. Check that the engine oil level is between the maximum and minimum level marks.

S60V3260

Recommended engine oil: YAMALUBE 2-stroke outboard motor oil

Checking the battery 1. Check the capacity, electrolyte level, and specified gravity of the battery.

Recommended battery capacity: CCA/SAE: 512 A MCA/ABYC: 675 A RC/SAE: 182 Minute Electrolyte specified gravity: 1.280 at 20 °C (68 °F)

CAUTION: • Use unleaded straight gasoline only.

• Do not use gasoline mixed with oil (premixed fuel).

6D01F1X

2. Check that the positive and negative battery leads are securely connected.

12

GEN INFO

General information

Checking the outboard motor mounting height 1. Check that the anti-cavitation plate is aligned with the bottom of the boat. If the mounting height is too high, cavitation will occur and propulsion will be reduced.

Also, the engine speed will increase abnormally and cause the engine to overheat. If the mounting height is too low, water resistance will increase and reduce engine efficiency.

2

a 1 S60V1040

3. Check that the center of the set pin b is aligned with the alignment mark c on the bottom cowling.

NOTE: The optimum mounting height is affected by the combination of the boat and the outboard motor. To determine the optimum mounting height, test run the outboard motor at different heights.

2. Check that the clamp brackets are secured with the clamp bolts.

d

S60C1190

Checking the remote control cables 1. Set the remote control lever to the neutral position and fully close the throttle lever.

2. Check that the throttle cam 1 is in its fully closed position and align the center of the throttle cam roller 2 with the alignment mark a.

13

CAUTION: The shift/throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) d.

6D01F1X

Predelivery checks

Checking the steering system 1. Check the steering friction for proper adjustment.

2. Check that smoothly.

the

steering

operates

Checking the power trim and tilt system 1. Check that the outboard motor tilts up and down smoothly when operating the power trim and tilt unit.

2. Check that there is no abnormal noise produced when the outboard motor is tilted up or down.

3. Check that there is no interference with wires or hoses when the tilted-up outboard motor is steered.

S60V1060

3. Check that there is no interference with wires or hoses when the outboard motor is steered.

Checking the gear shift and throttle operation 1. Check that the gear shift operates smoothly when the remote control lever is shifted from neutral to forward or reverse.

4. Check that the trim meter points down when the outboard motor is tilted all the way down.

Checking the engine start switch and engine stop lanyard switch 1. Check that the engine starts when the engine start switch is turned to START. 2. Check that the engine turns off when the engine start switch is turned to OFF.

2. Check that the throttle operates smoothly when the remote control lever is shifted from the fully closed position to the fully open position a.

N F

S60V1070

R a

3. Check that the engine turns off when the engine stop lanyard is pulled from the engine stop lanyard switch.

a S69J1210

6D01F1X

14

GEN INFO

General information

Checking the cooling water pilot hole 1. Check that cooling water is discharged from the cooling water pilot hole.

a b Ăˆ 0

c

1

d

2

10

S60V1120

Ăˆ Hour

After test run S60V3140

1. Check for water in the gear oil.

Test run

2. Check for fuel leakage in the cowling.

1. Start the engine, and then check that the gear shift operates smoothly.

3. Flush the cooling water passage with fresh water using the flushing kit and with the engine running at idle.

2. Check the engine idle speed after the engine has been warmed up.

3. Operate at trolling speed.

4. Run the outboard motor for 1 hour at 3,000 r/min or at half throttle, then for another hour at 4,000 r/min or at 3/4 throttle.

5. Check that the outboard motor does not tilt up when shifting into reverse and that water does not flow in over the transom.

NOTE: The test run is part of the break-in operation.

Break-in During the test run, perform the break-in operation in the following four stages.

1. First 10 minutes a of operation at idle 2. Fifty minutes b at 3,000 r/min or less 3. One hour c at 4,000 r/min or less 4. Eight hours d at 5,000 r/min or less with repeated wide-open-throttle operation for 5 minutes or less

15

6D01F1X

Predelivery checks / General specifications

General specifications Item Dimension Overall length Overall width Overall height (X) (U) Boat transom height (X) (U) Weight (without propeller) (X) (U) Performance Maximum output Full throttle operating range Maximum fuel consumption Engine idle speed Power unit Type Total displacement Bore × stroke Compression ratio Control system Starting system Enrichment system Ignition control system Maximum generator output Spark plug Cooling system Exhaust system Lubrication system

6D01F1X

2

Unit

Model Z300TR

LZ300TR

mm (in) mm (in)

868 (34.2) 568 (22.4)

mm (in) mm (in)

1,830 (72.0) 1,957 (77.0)

mm (in) mm (in)

635 (25.0) 762 (30.0)

kg (lb) kg (lb)

247 (545) 252 (556)

kW (hp) r/min L (US gal, lmp gal)/hr r/min

220.7 (300) at 5,000 r/min 4,500–5,500 105.0 (27.7, 23.1) at 5,500 r/min

cm3 (cu. in) mm (in)

V, A

1 2 3 4 5 6 7 8 9

700–760 2-stroke, 76°, V6, HPDI 3,342 (203.9) 93.0 (3.66) × 82.0 (3.23) 6.2 Remote control Electric starter Fuel injection TCI 12, 50 BKR7EKU (NGK) Water Propeller boss Oil injection

16

SPEC

Specifications Item

Fuel and oil Fuel type Fuel minimum rating Engine oil(*2) Engine oil tank capacity Oil tank Remote oil tank Gear oil type Gear oil grade Gear oil quantity Bracket unit Trim angle (at 12° boat transom) Tilt-up angle Steering angle Drive unit Gear shift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction (rear view) Propeller mark Electrical Battery minimum capacity(*3) CCA/SAE MCA/ABYC RC/SAE

Unit

RON(*1) PON

L (US gal, lmp gal) L (US gal, lmp gal) SAE 3 cm (US oz, lmp oz)

Model Z300TR

LZ300TR

Regular unleaded gasoline 90 86 YAMALUBE 2-stroke outboard motor oil 1.2 (0.32, 0.26) 10.5 (2.77, 2.31) GEAR CASE LUBE 90 1,150 (38.9, 40.6) 1,000 (33.8, 35.3)

Degree

–3 to 16

Degree Degree

70 30 + 30 F-N-R 1.75 (28/16) Spiral bevel gear Dog clutch Spline Clockwise Counterclockwise T, M TL, ML

A A Minute

512 675 182

(*1)

RON: Research Octane Number PON: Pump Octane Number = (RON + Motor Octane Number)/2 (*2) If 2-stroke outboard motor oil is not available, a 2stroke NMMA-certified TC-W3 oil of equivalent quality must be used. (*3) CCA: Cold Cranking Ampere MCA: Marine Cranking Ampere ABYC: American Boat and Yacht Council SAE: Society of Automotive Engineers RC: Reserve Capacity

17

6D01F1X

General specifications / Maintenance specifications

Maintenance specifications

2

Power unit Item Power unit Minimum compression pressure* Cylinder heads Warpage limit

(lines indicate straightedge position) Cylinders Bore size Bore size limit Taper limit Out-of-round limit Pistons Piston diameter (D) Measuring point (H) Piston-to-cylinder clearance Piston pin boss bore Oversize piston 1st 2nd Oversize piston diameter 1st 2nd Piston pins Outside diameter

Unit

Model Z300TR

LZ300TR

kPa (kgf/cm2, psi)

580 (5.8, 84)

mm (in)

0.1 (0.004)

mm (in) mm (in) mm (in) mm (in)

93.000–93.020 (3.6614–3.6622) 93.100 (3.6654) 0.08 (0.0031) 0.05 (0.0020)

mm (in) mm (in) mm (in) mm (in)

92.830–92.850 (3.6547–3.6555) 10 (0.39) 0.165–0.171 (0.0065–0.0067) 26.004–26.015 (1.0238–1.0242)

mm (in) mm (in)

0.25 (0.010) 0.50 (0.020)

mm (in) mm (in)

93.080–93.100 (3.6646–3.6653) 93.330–93.350 (3.6744–3.6752)

mm (in)

25.995–26.000 (1.0234–1.0236)

* Measuring conditions: Ambient temperature 20 °C (68 °F), wide open throttle, with spark plugs removed from all cylinders.

The figures are for reference only.

6D01F1X

18

SPEC

Specifications Item

Piston rings Top ring Dimension B Dimension T End gap Side clearance 2nd piston ring Dimension B Dimension T End gap Side clearance Connecting rods Small end inside diameter Big end side clearance Small end axial play limit Crankshaft Crankshaft journal diameter Crankpin diameter Runout limit Thermostats Opening temperature Fully open temperature Valve open lower limit Oil pump Identification mark Bleeding Reed valves Valve stopper height limit Valve bending limit

19

Unit

Model Z300TR

LZ300TR

mm (in) mm (in) mm (in) mm (in)

2.05 (0.0807) 3.00–3.20 (0.118–0.126) 0.30–0.50 (0.0118–0.0197) 0.02–0.06 (0.0008–0.0024)

mm (in) mm (in) mm (in) mm (in)

2.05 (0.0807) 2.70–2.90 (0.106–0.114) 0.30–0.45 (0.0118–0.0177) 0.02–0.06 (0.0008–0.0024)

mm (in) mm (in) mm (in)

31.000–31.012 (1.2205–1.2209) 0.12–0.26 (0.0047–0.0102) 2.0 (0.08)

mm (in) mm (in) mm (in)

58.975–58.991 (2.3219–2.3225) 40.485–40.500 (1.5939–1.5945) 0.02 (0.0008)

°C (°F) °C (°F) mm (in)

48–52 (118–126) 60 (140) 4.3 (0.17) 6D000 Screw type

mm (in) mm (in)

8 (0.31) 0.2 (0.008)

6D01F1X

Maintenance specifications

Lower unit Item

Unit

Gear backlash Pinion-to-forward gear

mm (in)

Pinion-to-reverse gear Pinion shims Forward gear shims Reverse gear shims Propeller shaft shims

mm (in) mm mm mm mm

Propeller shaft End play

mm (in)

Model Z300TR

LZ300TR

0.12–0.44 0.30–0.62 (0.0047–0.0173) (0.0118–0.0244) 0.61–0.90 (0.0240–0.0354) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 — 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 —

0.25–0.35 (0.0098–0.0138)

Electrical Item Ignition and ignition control system Ignition timing (cylinder #1) Spark plug gap Ignition coil resistance Primary coil (R – B/W) at 20 °C (68 °F) Secondary coil (R – spark plug wire) at 20 °C (68 °F) ECM output peak voltage (R – B/W) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Pulser coil output peak voltage (W/R, W/B, W/Y, W/G, W/L, W/Br – B) at cranking (unloaded) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded)

6D01F1X

Unit

Model Z300TR

LZ300TR

Degree Degree mm (in)

ATDC 7 at engine idle speed BTDC 14 at 5,500 r/min 1.5–1.6 (0.059–0.063)

Ω

1.36–1.84

kΩ

7.31–9.89

V V V

265 240 240

V V V V

3.5 3.5 20.0 30.0

20

SPEC

Specifications Item

Unit (*1)

Pulser coil resistance (W/R, W/B, W/Y, W/G, W/L, W/Br – B) Throttle position sensor Input voltage (O – R) Output voltage (P – O) Crank position sensor output peak voltage (G/L – G/W) at cranking (unloaded) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Crank position sensor resistance(*1) (G/L – G/W) Crank position sensor air gap Intake air temperature sensor resistance at 0 °C (32 °F) at 80 °C (176 °F) Engine temperature sensor resistance (B/Y – B/Y) at 20 °C (68 °F) at 100 °C (212 °F) Fuel control system Injector driver output peak voltage(*1) (Pu/R – O/R, Pu/B – O/B, Pu/Y – O/Y, Pu/G – O/G, Pu/L – O/L, Pu/W – O/W) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Fuel injector resistance(*1) at 20 °C (68 °F) Fuel pressure sensor output voltage(*1) (O – P) (*1)

21

Model Z300TR

LZ300TR

Ω

294–398

V V

5 0.58–0.62 at engine idle speed (0.48–0.52 at throttle valve full closed)

V V V V Ω

1.5 1.5 8.0 10.0 178.5–241.5

mm (in)

0.5–1.5 (0.02–0.06)

kΩ kΩ

5.4–6.6 0.3–0.4

kΩ kΩ

54.2–69.0 3.12–3.48

V V V

70 80 80

Ω V

0.9–1.1 3.2 at engine idle speed

The figures are for reference only.

6D01F1X

Maintenance specifications Item Starter motor Type Output Cranking time limit Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit Charging system Fuse Stator coil output peak voltage (G – G) at cranking (unloaded) at 1,500 r/min (unloaded) at 3,500 r/min (unloaded) Stator coil resistance(*1) at 20 °C (68 °F) (G – G) Rectifier Regulator output peak voltage (R – ground) at 1,500 r/min (unloaded) at 3,500 r/min (unloaded) Power trim and tilt system Trim sensor Setting resistance Resistance (P – B) Fluid type (*1)

Unit

Model Z300TR

LZ300TR

kW Second

Sliding gear 1.4 30

mm (in) mm (in)

15.5 (0.61) 9.5 (0.37)

mm (in) mm (in)

29.0 (1.14) 28.0 (1.10)

mm (in) mm (in)

0.5–0.8 (0.02–0.03) 0.2 (0.01)

A

20, 30, 100

V V V

5.5 40 90

Ω

0.11–0.17

V V

14.5 14.5

Ω Ω

9–11 9–387.6 ATF Dexron II

The figures are for reference only.

6D01F1X

22

SPEC

Specifications

Dimensions Exterior

284 (11.2)

30˚

660 (26.0)

420 (16.5)

mm (in)

X: 1,152 (45.4) U: 1,270 (50.0)

628 (24.7) 211 (8.3)

645 (25.4)

X: 67 (2 U: 86 .6) (3.4) ˚

67

X: 848 (33.4) U: 925 (36.4)

45 (1.8)

404 (15.9) 32 (1.3)

757 (29.8) X: 640 (25.2) U: 766 (30.2)

245 (9.6)

216 (8.5)

X: 1,074 (42.3) U: 1,201 (47.3)

907 (35.7)

75 (3.0)

25 (1.0)

1 2˚

23

X: 48 (1.9) U: 55 (2.2)

3˚ 677 (26.7) S60V2010

6D01F1X

Maintenance specifications Clamp bracket mm (in)

180 (7.1)

180 (7.1)

163.5 (6.4) 50.8 (2.0)

163.5 (6.4)

55.5 (2.2)

254 (10.0)

411 (16.2)

13 (0.5)

18.5 (0.7)

79 (3.1)

13 (0.5) 125.4 (4.9)

125.4 (4.9)

S60V2020

6D01F1X

24

SPEC

Specifications

Tightening torques

2

Specified torques Part to be tightened

Thread size

Fuel system Fuel pump screw Emergency switch High pressure fuel pump bolt Power unit Negative battery terminal nut Drive belt tensioner bolt Starter motor bolt Intake air temperature sensor Rectifier Regulator bolt

1st 2nd

PTT motor lead bolt Shift position switch screw Control lever stopper screw

Connecting rod cap

Crankshaft balancer nut Crankcase bolt

Cylinder head cover bolt Exhaust outer cover bolt

1st 2nd 1st 2nd

25

(M8) M10 M8 —

12 39 29 8 6 12 4 3 2 28 45

M6

M9

M10 M6 M6

1st 2nd 1st 2nd 1st 2nd

Flywheel magnet nut Fuel rail mounting bolt Fuel filter cup holder mounting bolt Injector holder bolt Intake silencer mounting screw Reed valve mounting screw Intake manifold bolt Oil pump mounting bolt Pressure control valve cover bolt

3 4 23

(M32)

Crankcase cover bolt Cylinder head bolt

M5 — M8

M6 M4 — 1st 2nd 3rd 4th 5th

M8 M6 M6 (M24) M8 M6 M8 M6 M5 M6 M6

1st 2nd

Tightening torques N·m kgf·m ft·lb

M6

0.3 0.4 2.3

2.2 3.0 17.0

1.2 8.9 3.9 28.8 2.9 21.4 0.8 5.9 0.6 4.4 1.2 8.9 0.4 3.0 0.3 2.2 0.2 1.5 2.8 20.7 4.5 33.2 Loosen completely 28 2.8 20.7 45 4.5 33.2 100 10.0 73.8 17 1.7 12.5 34 3.4 25.1 4 0.4 3.0 9 0.9 6.6 11 1.1 8.1 15 1.5 11.1 30 3.0 22.1 5 0.5 3.7 11 1.1 8.1 5 0.5 3.7 11 1.1 8.1 190 19.0 140 23 2.3 17.0 8 0.8 5.9 26 2.6 19.2 3 0.3 2.2 3 0.3 2.2 13 1.3 9.6 7 0.7 5.2 5 0.5 3.7 11 1.1 8.1

6D01F1X

Tightening torques Part to be tightened

Thread size

Shift cut switch mounting screw Spark plug Positive battery terminal nut Thermostat cover bolt Throttle body mounting bolt and nut Power unit mounting bolt Lower unit (regular rotation model) Exhaust guide bolt Gear oil check screw Lower case mounting bolt Pinion nut Propeller nut Propeller shaft housing bolt Trim tab mounting bolt Gear oil drain screw Grease nipple Lower unit (counter rotation model) Exhaust guide bolt Gear oil check screw Lower case mounting bolt Pinion nut Propeller nut Ring nut Propeller shaft housing bolt Trim tab mounting bolt Gear oil drain screw Grease nipple Bracket unit Flushing hose adapter screw Upper case mounting bolt Lower exhaust guide mounting bolt Exhaust manifold mounting bolt Muffler mounting bolt Lower rubber mount nut Through tube nut Trim rod stopper nut Upper rubber mount nut Friction plate screw

6D01F1X

M4 M14 (M8) M6 1st 2nd

M6 M8

Tightening torques N·m kgf·m ft·lb 3 0.3 2.2 25 2.5 18.4 9 0.9 6.6 11 1.1 8.1 4 0.4 3.0 10 1.0 7.4 32 3.2 23.6

M8 M8 M10 (M16) (M18) M8 M10 — —

32 9 47 142 54 30 42 9 6

3.2 0.9 4.7 14.2 5.4 3.0 4.2 0.9 0.6

23.6 6.6 34.7 104.7 39.8 22.1 31.0 6.6 4.4

M8 M8 M10 (M16) (M18) — M8 M10 — —

32 9 47 142 54 108 30 42 9 6

3.2 0.9 4.7 14.2 5.4 10.8 3.0 4.2 0.9 0.6

23.6 6.6 34.7 104.7 39.8 79.7 22.1 31.0 6.6 4.4

M5 M8 M8 M8 M8 (M14) (M22) (M10) (M14) M6

5 32 22 25 25 72 22 36 72 4

0.5 3.2 2.2 2.5 2.5 7.2 2.2 3.6 7.2 0.4

3.7 23.6 16.2 18.4 18.4 53.1 16.2 26.6 53.1 3.0

26

SPEC

Specifications Part to be tightened

Power trim and tilt unit Blind plug Gear pump housing mounting screw Gear pump housing bolt Trim down spring screw Main valve Manual valve PTT motor unit mounting bolt Oil pipe Relief valve cap screw Reservoir mounting bolt Reservoir cap Tilt cylinder end screw Tilt rod Trim cylinder end screw Trim rod Valve plate bolt PTT unit mounting bolt

Thread size — M4 M5 M5 — — M8 — M5 M8 M12 — — — — M6 M10

Tightening torques N·m kgf·m ft·lb 7 2 4 4 11 2 19 15 4 19 7 90 55 160 38 7 42

0.7 0.2 0.4 0.4 1.1 0.2 1.9 1.5 0.4 1.9 0.7 9.0 5.5 16.0 3.8 0.7 4.2

5.2 1.5 3.0 3.0 8.1 1.5 14.0 11.1 3.0 14.0 5.2 66.4 40.6 118 28.0 5.2 31.0

General torques This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion and progressive stages until the specified torque is reached. Unless otherwise specified, torque specifications require clean, dry threads.

Components should be at room temperature.

Nut (A)

Bolt (B)

8 mm 10 mm 12 mm 14 mm 17 mm

M5 M6 M8 M10 M12

27

General torque specifications N·m kgf·m ft·lb 5 0.5 3.6 8 0.8 5.8 18 1.8 13 36 3.6 25 43 4.3 31

6D01F1X

Tightening torques / Special service tools

Special service tools

3

Pressure/vacuum tester YB-35956-A

Universal puller YB-06117

Flywheel magnet holder YB-06139

Backlash indicator gauge YB-06265

Pinion shimming gauge III YB-06441

Magnetic plate YB-07003

Shift rod push arm YB-06052

Dial gauge YU-03097

Bearing housing puller YB-06207

Magnetic flexible stand YU-34481

6D01F1X

1 2 3 4 5 6 7 8 9 28

CHK ADJ

Periodic checks and adjustments

Needle bearing installer YB-06434

Needle bearing guide plate YB-06213

Needle bearing installer YB-06435

PTT oil pressure gauge assembly YB-06580

Driver handle YB-06071

PTT oil pressure gauge adapter YB-06581

Forward bearing installer YB-06430

Diagnostic flash indicator YB-06444

Pinion gear bushing installer YB-06029-4

29

6D01F1X

Special service tools / Maintenance interval chart

Maintenance interval chart

3

Use the following chart as a guideline for general maintenance.

Adjust the maintenance intervals according to the operating conditions of the outboard motor.

Initial Item Anodes (external) Anodes (internal) Battery Cooling water passages Top cowling Fuel filter (can be disassembled) Fuel system Gear oil Lubrication points Engine idle speed (EFI models) PCV (Pressure Control Valve) Power trim and tilt unit Propeller and cotter pin Shift link/shift cable Thermostat Throttle link/throttle cable/throttle pick-up timing Water pump Spark plugs High pressure fuel pump drive belt High pressure fuel pump oil level Oil pump Oil tank water drain Throttle position sensor

Remarks

Every

10 hours 50 hours 100 hours 200 hours (1 month) (3 months) (6 months) (1 year)

Check/replace Check/replace Check/charge Clean Check Check/replace Check Change Lubricate Check/adjust Check Check Check/replace Check/adjust Check Check/adjust Check Clean/adjust/replace Check/replace Check/fill Check/adjust Check/clean Check/adjust

NOTE: When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.

Item High pressure fuel pump drive belt

Remarks

Every 500 hours (2.5 years)

1,000 hours (5 years)

Replace

CAUTION: If the flywheel magnet cover is removed to service the outboard motor, be sure to check that the fuel hoses are routed correctly before installing it.

6D01F1X

30

CHK ADJ

Periodic checks and adjustments

Oil injection system

3

Adjusting the oil pump link rod 1. Loosen the locknut 1 and then disconnect the oil pump link rod 2.

NOTE: Review “Synchronizing the throttle valves” on page 4-24 and “Adjusting the throttle position sensor” on page 4-26 before proceeding.

Lower unit

3

Checking the lower unit for air leakage 1. Remove the check screw 1, and then install the special service tool.

2. Loosen the throttle stop screw until it no longer contacts the stopper. Check that all the throttle valves are fully closed.

3. Adjust the oil pump link rod so that there is a 0.5 mm (0.02 in) gap a between the oil pump lever 3 (in the fully closed position) and the stopper 4.

2. Apply the specified pressure to check that the pressure is maintained in the lower unit for at least 10 seconds.

2 1

CAUTION:

a 3

4 3

Pressure/vacuum tester: YB-35956-A

S60V3290

4. Connect the oil pump link rod.

5. Turn the throttle stop screw in until the throttle position sensor output voltage is within specification. See “Adjusting the throttle position sensor” on page 4-26.

Do not over pressurize the lower unit, otherwise the oil seals may be damaged.

NOTE: Cover the check hole with a rag when removing the tester from the lower unit.

Lower unit holding pressure: 70 kPa (0.7 kgf/cm2, 10 psi) 3. If pressure drops below specification, check the drive shaft and propeller shaft oil seals for damage.

31

6D01F1X

Oil injection system / Lower unit / General

General

3

Lubricating the outboard motor 1. Apply water resistant grease to the areas shown.

A

S60V3430

6D01F1X

32

CHK ADJ

Periodic checks and adjustments

A

S6D03010

NOTE: Apply grease to the grease nipple until it flows from the bushings a.

2. Apply low temperature resistant grease to the areas shown.

A C

S60V3440

3. Apply corrosion resistant grease to the areas shown.

4. Apply injector grease to the areas shown.

33

6D01F1X

General / Fuel filter

Fuel filter

4

9 T.

R.

8 N · m (0.8 kgf · m, 5.9 ft · Ib)

12 11

13 14

10

1 2 5 15

4

3

6

16

8

7

S6D04010

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name Bolt Washer Holder Bolt Collar Grommet Bracket Bolt Cap Fuel hose Fuel hose O-ring O-ring Fuel filter element Cup Nut

6D01F1X

Q’ty 1 1 1 1 2 2 1 2 1 1 1 1 1 1 1 1

Remarks M6 × 16 mm

M6 × 14 mm

M6 × 25 mm

Not reusable Not reusable

34

1 2 3 4 5 6 7 8 9

POWR

Power unit

Power unit

5

13 11

LT

12

572

10

9 6

LT

572

7

14

16

15

7

1

6

8 7

8 7 T.

R.

32 N · m (3.2 kgf · m, 23.6 ft · Ib)

5

3

4

2 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

35

Part name Apron Bolt Screw grommet Screw Hose Hose Plastic tie Joint Joint Bolt Bracket Bolt Plate Bolt Bolt Bolt

S6D05010

Q’ty 1 4 1 1 2 2 6 2 1 3 1 4 1 2 8 4

Remarks M6 × 16 mm ø4 × 16 mm

Not reusable

M8 × 55 mm M6 × 20 mm M8 × 30 mm M8 × 135 mm M8 × 45 mm

6D01F1X

Power unit

Removing the power unit NOTE: It is recommended to loosen the flywheel magnet nut before removing the power unit to improve working efficiency.

1. Disconnect the battery leads 1.

6. Remove the bracket 8 and disconnect the trim sensor coupler (or connector) 9.

8 9 2. Disconnect the shift cable 2 and the throttle cable 3.

S6D05020

7. Disconnect the PTT switch coupler and the shift lever 0.

3. Disconnect the fuel hose 4 and the oil hose 5.

8. Disconnect the cooling water hose A.

A 4. Remove the flywheel magnet cover.

5. Remove the junction box cover, and then disconnect the cooling water hose 6 and the PTT motor leads 7.

6D01F1X

S6D05040

36

1 2 3 4 5 6 7 8 9

POWR

Power unit

9. Remove the apron B and the hose joint assembly C.

10. Remove the bolts D, then the power unit.

11. Remove the shift rod assembly E and gasket F.

F E

S6D05070

37

6D01F1X

Power unit / Crankcase

Crankcase

5

1 T.

R.

T.

R.

11 N · m (1.1 kgf · m, 8.1 ft · Ib)

4 5 6

11 N · m (1.1 kgf · m, 8.1 ft · Ib)

13

13 2

4

3

1 T.

R.

11 N · m (1.1 kgf · m, 8.1 ft · Ib)

7 8 1 13 9 14 1014

13 9

11

13

14

14

12

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Part name Bolt Crankcase cover Gasket Hose Crankcase cover Gasket Gasket Crankcase cover Hose Joint Hose Joint Clip Plastic tie

6D01F1X

13

S6D05080

Q’ty 36 1 1 2 1 1 1 1 2 1 1 1 7 4

Remarks M6 × 25 mm Not reusable

Not reusable Not reusable

Not reusable

38

POWR

Power unit

Removing the crankcase covers

Installing the power unit

1. Disconnect the hoses from the crankcase covers.

1. Clean the power unit mating surface, and then install new dowels 1, a new gasket 2, and the shift rod assembly 3.

2. Remove the crankcase cover bolts in the sequences shown.

1

4

1

1

6 2 0

3

3 8

D

B

F

C

F

7 A E

B 8

9

C

D

9

0

A E

4 3

5

6 4

5

0

4

E A 3 7

2

D 9 5

1

4

1

5 9

8

4

3

8

7

B

A C

B S6D05100

T. R.

Crankcase cover bolt: 11 N·m (1.1 kgf·m, 8.1 ft·lb)

NOTE: Replace or reuse the power unit mounting bolts. If reusing the power unit mounting bolts, be sure to completely remove any LOCTITE remaining on the bolts.

T. R.

2. Connect the hoses to the crankcase covers.

39

2. Install the power unit 4, and then tighten the power unit mounting bolts 5 to the specified torque.

F

3

C D

Do not reuse the dowels, always replace them with new ones.

E

0 6 2

6 2

S60V5C20

S6D05090

1. Install the new gaskets and crankcase covers, and then tighten the crankcase cover bolts to the specified torque in the sequences shown.

1

3

CAUTION:

Installing the crankcase covers

F

2

2

2

7

1

Power unit mounting bolt 5: 32 N·m (3.2 kgf·m, 23.6 ft·lb)

6D01F1X

Crankcase 3. Install the hose joint assembly 6 and the apron 7.

T. R.

PTT motor lead bolt: 4 N·m (0.4 kgf·m, 3.0 ft·lb)

8. Install the bracket B and connect the trim sensor coupler (or connector) C. 4. Connect the PTT switch coupler and the shift lever 8.

B C

S6D05130

9. Install the junction box cover.

10. Connect the fuel hose D and oil hose E. 5. Connect the cooling water hose 9.

9

S6D05110

6. Connect the cooling water hose 0 to the Rectifier Regulator.

7. Connect the PTT motor leads A, and then tighten the PTT motor lead bolts to the specified torque.

6D01F1X

40

POWR

Power unit

11. Connect the shift cable F and throttle cable G, and then adjust their lengths.

12. Install the Woodruff key and flywheel magnet.

13. Tighten the flywheel magnet nut to the specified torque.

NOTE: Align the marks a on the pointer H, which you made during disassembly.

15. Install all removed parts.

CAUTION: Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily.

NOTE: Apply engine oil to the flywheel magnet nut before installation.

Flywheel magnet holder: YB-06139

T. R.

Flywheel magnet nut: 190 N·m (19.0 kgf·m, 140 ft·lb)

14. Install the pointer H.

41

6D01F1X

Crankcase / Propeller shaft housing (regular rotation model)

Propeller shaft housing (regular rotation model)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part name Water pipe Rubber seal Rubber seal Shift rod joint Ball Slider Shift plunger Dog clutch Cross pin Spring Propeller shaft Washer Reverse gear Reverse gear shim Ball bearing O-ring Propeller shaft housing

6D01F1X

Q’ty 1 1 1 1 2 1 1 1 1 1 1 1 1 — 1 1 1

6

1 2 3 4 5 6 7 8 9

Remarks

Not reusable Not reusable

42

LOWR

Lower unit 6

No. 18 19 20 21 22 23 24 25 26 27 28 29

43

Part name Dowel Grease nipple Rubber seal O-ring Needle bearing Oil seal Ring Bolt Bolt Cooling water inlet cover Nut Screw

Q’ty 1 1 1 1 1 2 1 2 2 2 1 1

Remarks

Not reusable Not reusable

M8 × 20 mm M8 × 33 mm

6D01F1X

Propeller shaft housing (regular rotation model) / Shimming (regular rotation model)

Shimming (regular rotation model)

6

F P

R

B4

T3 B3 A3

65.0

A

B

B5 T1

T2 B1 39.4 41.0 A1

B2 A2

S6D06020

6D01F1X

44

LOWR

Lower unit

Selecting the pinion shims 1. Calculate the specified value (M0) as shown in the examples below.

NOTE: “P” is the deviation of the lower case dimension from standard. The “P” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “P” mark is unreadable, assume that “P” is zero and check the backlash when the unit is assembled.

4. Measure the clearance (M) between the special service tool and the pinion as shown.

NOTE: Measure the pinion at three points to find the clearance average.

5. Select the pinion shim(s) (T3).

Calculation formula: Specified value (M0) = 1.00 + P/100 mm Example: If “P” is (+5), then M0 = 1.00 + (+5)/100 mm = 1.00 + 0.05 mm = 1.05 mm If “P” is (–3), then M0 = 1.00 + (–3)/100 mm = 1.00 – 0.03 mm = 0.97 mm 2. Install the drive shaft 1, thrust bearing 2, and drive shaft housing 3 onto the special service tool.

3. Install the pinion and pinion nut, and then tighten the nut to the specified torque.

Pinion shimming gauge III 4: YB-06441

T. R.

45

NOTE: The sum of T3 and M should not be more than M0.

Calculation formula: Pinion shim thickness (T3) = M0 – M Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm

Pinion nut: 142 N·m (14.2 kgf·m, 104.7 ft·lb)

6D01F1X

Shimming (regular rotation model) / Backlash (regular rotation model)

Backlash (regular rotation model)

6

Measuring the forward and reverse gear backlash 1. Remove the water pump assembly.

2. Set the gear shift to the neutral position at the lower unit.

NOTE: Install the dial gauge so that the plunger a contacts the mark b on the backlash indicator.

Shift rod push arm: YB-06052 3. Install the special service tools so that it pushes against the propeller shaft.

Backlash indicator gauge 3: YB-06265 Magnetic plate 4: YB-07003 Dial gauge 5: YU-03097 Magnetic flexible stand 6: YU-34481 6. Slowly turn the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction.

Forward gear backlash: 0.12–0.44 mm (0.0047–0.0173 in)

NOTE: Tighten the universal puller while turning the drive shaft until the drive shaft can no longer be turned.

Bearing housing puller 1: YB-06207 Universal puller 2: YB-06117 4. Install the backlash indicator onto the drive shaft (22.4 mm [0.88 in] in diameter), then the dial gauge onto the lower unit.

5. Set the lower unit upside down.

6D01F1X

46

LOWR

Lower unit

7. Add or remove shim(s) if out of specification.

Forward gear backlash

Shim thickness

Less than 0.12 mm (0.0047 in)

To be decreased by (0.28 – M) × 0.81

More than 0.44 mm (0.0173 in)

To be increased by (M – 0.28) × 0.81

M: Measurement Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm 8. Remove the special service tools from the propeller shaft.

9. Apply a load to the reverse gear by installing the propeller 7, the spacer 8 (without the washer 9), then the washer 0 as shown.

Reverse gear backlash: 0.61–0.90 mm (0.0240–0.0354 in) 11. Add or remove shim(s) if out of specification.

Reverse gear backlash

Shim thickness

Less than 0.61 mm (0.0240 in)

To be decreased by (0.76 – M) × 0.81

More than 0.90 mm (0.0354 in)

To be increased by (M – 0.76) × 0.81

M: Measurement Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm NOTE: Tighten the propeller nut A while turning the drive shaft until the drive shaft can no longer be turned.

12. Remove the special service tools, and then install the water pump assembly.

10. Slowly turn the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction.

47

6D01F1X

Backlash (regular rotation model) / Propeller shaft housing (counter rotation model)

Propeller shaft housing (counter rotation model)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part name Water pipe Rubber seal Rubber seal Shift rod joint Ball Slider Shift plunger Dog clutch Cross pin Spring Forward gear Forward gear shim Ring nut Claw washer Taper roller bearing assembly Propeller shaft Thrust bearing

6D01F1X

Q’ty 1 1 1 1 2 1 1 1 1 1 1 — 1 1 1 1 1

6

Remarks

Not reusable

48

LOWR

Lower unit 6

No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

49

Part name Propeller shaft shim O-ring Propeller shaft housing Dowel Grease nipple Rubber seal O-ring Needle bearing Oil seal Ring Bolt Bolt Cooling water inlet cover Nut Screw

Q’ty — 1 1 1 1 1 1 1 2 1 2 2 2 1 1

Remarks Not reusable

Not reusable Not reusable

M8 × 20 mm M8 × 33 mm

6D01F1X

Propeller shaft housing (counter rotation model) / Drive shaft and lower case (counter rotation model)

Drive shaft and lower case (counter rotation model)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part name Drive shaft Cover Oil seal Bolt Drive shaft housing Needle bearing O-ring Pinion shim Thrust bearing Lower case Needle bearing Pinion Washer Nut Reverse gear shim Retainer Needle bearing

6D01F1X

Q’ty 1 1 2 4 1 1 1 — 1 1 1 1 1 1 — 1 1

6

Remarks

Not reusable

M8 × 25 mm

Not reusable

50

LOWR

Lower unit 6

No. 18 19 20

51

Part name Thrust bearing Needle bearing Reverse gear

Q’ty 1 1 1

Remarks Not reusable

6D01F1X

Drive shaft and lower case (counter rotation model)

Disassembling the reverse gear 1. Remove the needle bearing from the reverse gear using a chisel.

CAUTION: Add or remove shim(s), if necessary, if replacing the forward gear or lower case.

Forward bearing installer 3: YB-06430 Driver handle 4: YB-06071 3. Install the needle bearing outer case into the lower case.

Assembling the lower case 1. Install the needle bearing into the retainer to the specified depth.

NOTE: Apply gear oil to the needle bearing outer case before installation.

Needle bearing installer 1: YB-06434 Driver handle 2: YB-06071 Depth a: –0.25–0.25 mm (–0.010–0.010 in) 2. Install the original shim(s) and retainer into the lower case.

6D01F1X

Needle bearing installer 5: YB-06435 Pinion gear bushing installer 6: YB-06029-4 Needle bearing guide plate 7: YB-06213 4. Install the needle bearing into the needle bearing outer case.

NOTE: Apply gear oil or grease to the needle bearing before installation.

52

LOWR

Lower unit

5. Install the new needle bearing into the reverse gear to the specified depth.

Needle bearing installer 8: YB-06435 Driver handle 9: YB-06071 Depth b: 6.75–7.25 mm (0.266–0.285 in) 6. Install the thrust bearing and reverse gear into the lower case.

53

6D01F1X

Drive shaft and lower case (counter rotation model) / Shimming (counter rotation model)

Shimming (counter rotation model)

6

F P

R

B4

T3 A3

B3

65.0

A

B

B8 B5 A5 T1

T2 B1 38.4 47.5 A1 B7 B6

A4 A2 T´4

S6D06150

6D01F1X

54

LOWR

Lower unit

Selecting the pinion shims 1. Calculate the specified value (M0) as shown in the examples below.

NOTE: “P” is the deviation of the lower case dimension from standard. The “P” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “P” mark is unreadable, assume that “P” is zero and check the backlash when the unit is assembled.

4. Measure the clearance (M) between the special service tool and the pinion as shown.

NOTE: Measure the pinion at three points to find the clearance average.

5. Select the pinion shim(s) (T3).

Calculation formula: Specified value (M0) = 1.00 + P/100 mm Example: If “P” is (+5), then M0 = 1.00 + (+5)/100 mm = 1.00 + 0.05 mm = 1.05 mm If “P” is (–3), then M0 = 1.00 + (–3)/100 mm = 1.00 – 0.03 mm = 0.97 mm 2. Install the drive shaft 1, thrust bearing 2, and drive shaft housing 3 onto the special service tool.

3. Install the pinion and pinion nut, and then tighten the nut to the specified torque.

Pinion shimming gauge III 4: YB-06441

T. R.

55

NOTE: The sum of T3 and M should not be more than M0.

Calculation formula: Pinion shim thickness (T3) = M0 – M Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm

Pinion nut: 142 N·m (14.2 kgf·m, 104.7 ft·lb)

6D01F1X

Shimming (counter rotation model) / Backlash (counter rotation model)

Backlash (counter rotation model)

6

Measuring the forward and reverse gear backlash 1. Remove the water pump assembly.

2. Set the gear shift to the neutral position at the lower unit.

NOTE: Install the dial gauge so that the plunger a contacts the mark b on the backlash indicator.

Shift rod push arm: YB-06052 3. Install the special service tools so that it pushes against the propeller shaft.

Backlash indicator gauge 3: YB-06265 Magnetic plate 4: YB-07003 Dial gauge 5: YU-03097 Magnetic flexible stand 6: YU-34481 6. Slowly turn the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction.

Forward gear backlash: 0.30–0.62 mm (0.0118–0.0244 in)

NOTE: Tighten the universal puller while turning the drive shaft until the drive shaft can no longer be turned.

Bearing housing puller 1: YB-06207 Universal puller 2: YB-06117 4. Install the backlash indicator onto the drive shaft (22.4 mm [0.88 in] in diameter), then the dial gauge onto the lower unit.

5. Set the lower unit upside down.

6D01F1X

56

LOWR

Lower unit

7. Add or remove shim(s) if out of specification.

Forward gear backlash

Shim thickness

Less than 0.30 mm (0.0118 in)

To be decreased by (0.46 – M) × 0.81

More than 0.62 mm (0.0244 in)

To be increased by (M – 0.46) × 0.81

11. Turn the shift rod to the neutral position d with the shift rod push arm.

12. Turn the drive shaft counterclockwise approximately 30°.

M: Measurement Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm 8. Remove the special service tools from the propeller shaft.

13. Turn the shift rod to the reverse position c with the shift rod push arm.

14. Slowly turn the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction.

9. Turn the shift rod to the reverse position c with the shift rod push arm.

10. Turn the drive shaft clockwise until the dog clutch 7 is fully engaged.

NOTE: When measuring the reverse gear backlash, turn the shift rod push arm towards the reverse position c with force.

Reverse gear backlash: 0.61–0.90 mm (0.0240–0.0354 in)

57

6D01F1X

Backlash (counter rotation model) 15. Add or remove shim(s) if out of specification.

Reverse gear backlash

Shim thickness

Less than 0.61 mm (0.0240 in)

To be decreased by (0.76 – M) × 0.81

More than 0.90 mm (0.0354 in)

To be increased by (M – 0.76) × 0.81

M: Measurement Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm 16. Remove the special service tools, and then install the water pump assembly.

6D01F1X

58

BRKT

Bracket unit

Bottom cowling

7

36

37 28

37

35

29

A

A

A

39

34

30

5

26 24 40

33

27

32

25

7

16 15 14

6 33 32

5

23

4

22

20

19 18

28 31

21 38 26

1

A

13 12

9 1110

4

3 5 7

7 8

4

2

6 17

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

59

Part name Bottom cowling Rubber seal Grommet Bolt Bracket Cowling lock lever Bushing Plate Bolt Wave washer Lever Washer Bolt Spring Hook Bolt Plastic tie

5 4

S6D07010

Q’ty 1 1 2 4 4 3 6 3 6 3 3 3 3 3 3 3 1

Remarks

M6 × 16 mm

M6 × 30 mm

M6 × 16 mm

M6 × 16 mm

6D01F1X

Bottom cowling 7

36

37 28

37

35

29

A

A

A

39

34

30

5

26 24 40

33

27

32

25

7

16 15 14

6 33 32

5

23

4

22

20

19 18

28 31

21 38 26

1

A

13 12

9 1110

4

3 5 7

7 8

4

2

6 17

No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Part name Holder Grommet Holder Bolt Retaining plate Bolt Bolt Cable holder Grommet Power trim and tilt switch Bolt Bracket Bracket Bracket Plate Bolt Grommet

6D01F1X

5 4

S6D07010

Q’ty 1 1 1 1 1 2 1 1 2 1 4 1 1 1 2 2 1

Remarks

M6 × 25 mm M6 × 25 mm M6 × 16 mm

M6 × 20 mm

M6 × 20 mm

60

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit 7

36

37 28

37

35

29

A

A

A

39

34

30

5

26 24 40

33

27

32

25

7

16 15 14

6 33 32

5

23

4

22

20

19 18

28 31

21 38 26

1

A

13 12

9 1110

4

3 5 7

7 8

4

2

6 17

No. 35 36 37 38 39 40

61

Part name Gasket Cover Bolt Cover Ground lead Rubber trim

5 4

S6D07010

Q’ty 1 1 13 1 1 1

Remarks Not reusable

M6 × 20 mm

6D01F1X

Bottom cowling / Upper case, steering arm, swivel bracket, and clamp brackets

Upper case, steering arm, swivel bracket, and clamp brackets

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part name Upper case assembly Cover Ground lead Bolt Bolt Adapter Dowel Plastic tie Hose Circlip Nut Washer Nut Steering yoke Washer Bushing O-ring

6D01F1X

Q’ty 1 2 1 1 1 1 1 1 1 1 2 4 2 1 2 1 1

7

Remarks

M6 × 10 mm M6 × 25 mm

Not reusable

Not reusable

62

BRKT

Bracket unit 7

No. 18 19 20 21 22

63

Part name Bushing Steering arm Washer Washer Grommet

Q’ty 2 1 2 2 4

Remarks

6D01F1X

Upper case, steering arm, swivel bracket, and clamp brackets 7

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part name Upper case Dowel Upper mount Washer Washer Washer Bolt Bracket Muffler assembly Gasket Mount housing Ground lead Washer Washer Lower mount Bolt Bolt

6D01F1X

Q’ty 1 2 2 2 2 2 2 1 1 1 2 1 2 2 2 3 1

Remarks

M14 × 190 mm

Not reusable

M10 × 45 mm M8 × 45 mm

64

BRKT

Bracket unit 7

No. 18 19

Bolt Gasket

Part name

Q’ty 2 1

20 21 22 23 24 25

Muffler Bolt Bolt Bolt Circlip Bushing

1 2 4 2 1 1

Remarks M8 × 30 mm U-transom model Not reusable

65

U-transom model M6 × 35 mm / U-transom model M10 × 45 mm M14 × 205 mm

6D01F1X

Upper case, steering arm, swivel bracket, and clamp brackets 7

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part name Muffler Exhaust manifold Gasket Lower exhaust guide Gasket Upper exhaust guide Flushing hose Plastic tie Joint Hose Rubber seal Pipe Rubber seal Bolt Bolt Bolt Hose

6D01F1X

Q’ty 1 1 1 1 1 1 1 1 1 2 1 1 1 6 4 4 1

Remarks

Not reusable Not reusable

Not reusable

M8 × 50 mm M8 × 50 mm M8 × 35 mm

66

BRKT

Bracket unit

Power trim and tilt unit

7

Checking the hydraulic pressure

Ram

1. Check the hydraulic pressure. Check the internal parts if out of specification.

Down

PTT motor lead

Battery terminal

Light green (Lg)

+

Sky blue (Sb)

-

2. Fully extend the power trim and tilt rams.

Hydraulic pressure (down): 4.7–6.7 MPa (47–67 kgf/cm2)

3. Loosen the pipe joints 1, and then remove the pipe joint a.

4. Install the oil pressure gauge 2.

6. Reverse the PTT motor leads between the battery terminals to fully extend the trim and tilt rams.

NOTE: Wrap the removed pipe joint a in a rag.

Ram PTT oil pressure gauge assembly: YB-06580 5. Connect the PTT motor leads to the battery terminals to retract the trim ram, and then measure the hydraulic pressure.

Up

PTT motor lead

Battery terminal

Sky blue (Sb)

+

Light green (Lg)

-

7. Remove the oil pressure gauge 2.

8. Install the pipe joint a, and then tighten the pipe joints to the specified torque.

T. R.

Pipe joint 1: 15 N·m (1.5 kgf·m, 11.1 ft·lb)

9. Connect the PTT motor leads to the battery terminals to fully retract the trim and tilt rams.

10. Loosen the pipe joints 3, and then remove the pipe joint b.

11. Install the oil pressure gauge 2.

67

6D01F1X

Power trim and tilt unit

NOTE: Wrap the removed pipe joint b in a rag.

PTT oil pressure gauge assembly: YB-06580

14. Remove the oil pressure gauge 2.

15. Install the pipe joint b, and then tighten the pipe joints to the specified torque.

T. R.

12. Connect the PTT motor leads to the battery terminals to extend the trim ram, and then measure the hydraulic pressure.

Pipe joint 3: 15 N·m (1.5 kgf·m, 11.1 ft·lb)

16. After measuring the hydraulic pressure, connect the PTT motor leads to the battery terminals to fully extend the trim and tilt rams.

Hydraulic pressure (up): 11.3–13.3 MPa (113–133 kgf/cm2) 13. Reverse the PTT motor leads between the battery terminals to fully retract the trim and tilt rams.

6D01F1X

17. Remove the reservoir cap, and then check the fluid level in the reservoir.

68

BRKT

Bracket unit

18. If necessary, add fluid of the recommended type to the correct level.

NOTE: If the fluid is at the correct level, the fluid should overflow out of the filler hole when the cap is removed.

Recommended power trim and tilt fluid: ATF Dexron II 19. Install the reservoir cap.

T. R.

69

Reservoir cap: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

6D01F1X

Power trim and tilt unit / Electrical components

Electrical components

8

Port view

3

4

5

2 1

9

8

7 6

S6D08010

1 2 3 4 5 6 7 8

Throttle position sensor Emergency switch Pulser coil Oil level sensor Stator coil Water detection switch Atmospheric pressure sensor Electric oil pump

6D01F1X

9 Electric fuel pump

70

1 2 3 4 5 6 7 8 9

–

ELEC

+

Electrical systems

Top view 1

2 2 3 3

A

0

9 4 8 5

7 6

S6D08020

1 2 3 4 5 6 7 8 9 0

71

Ignition coil Fuel injector Spark plug Oil level sensor Emergency switch Throttle position sensor Power trim and tilt switch Shift position switch Shift cut switch Crank position sensor

A Engine temperature sensor

6D01F1X

Electrical components

Wiring harness 8 B

O O Y B/R Y

O

9

O O Y GyP

B

B/R B/R

B

B/Y

D

P P P B

7B 8 P

A B B B/Y

B B B B/Y

O

C

EF

Lg

6

Br Br R

Sb

B B B

BBB

5

G

R

G

0

B

L/W Y/R

6

B/Y

B B

L L

R/W

B/Y

B/Y

Y

Lg W

4

L L

L/G

Sb

P Br B

L/R

3

B L/R L/W L/Y P

O

1 2 3 4 5 6 7 8 9

B

2 Sb

B

Lg

1

R/W

: : : : : : : : :

L/W P _

10 11 12 13 14 15 16 17 18

L/R L/R L/G G/R P B

: : : : : : : : :

O P B/Y B/Y P P L/Y L/W L/G

19 20 21 22 23 24 25 26

: : : : : : : :

Y/R L B/R G W Y Br _

H

B

I L/G Gy

P

J B/R

B

K

G/R

Gy

P B

P Y

B

M

0 L

5 L L

L

4 688 L/W L/R B B Y/R L/G L/R

BBB

BGyP

L

P L/R G/R B P B/Y P L/W Y/R B/R W Br L/W L/R L/G P O B/Y P L/Y L/G L G Y

9 2 7

BPP

P O

B B

O

BA

O P

P

B/Y B/Y

B

B/Y B/Y

D FH I 3 C B/R Y Y O O B/R B/R Y O O

R R/W

B L/Y

B L/G

L/W B

B

B B/Y B B B/Y B B

E6

Sb Lg

Lg B

Br Br

Sb Lg R/W B

B/R

Sb

1

B B

B

Y Br W G P Sb Lg R B

G

B Gy P

K

B/R P G/R Gy

J

B/R L Y B

M

P B

L

S6D08030

Connect to: 1 2 3 4 5 6 7 8

Power trim and tilt switch Atmospheric pressure sensor Water detection switch Oil level sensor Emergency switch Ground Throttle position sensor Thermoswitch

6D01F1X

9 0 A B C D E F G H

Fuel pressure sensor ECM Engine temperature sensor Intake air temperature sensor Power trim and tilt relay Fuse holder Starter relay Fuse holder Remote control Shift cut switch

I J K L M

Shift position switch Warning indicator Trim meter Trim sensor Remote oil tank

72

–

ELEC

+

Electrical systems

8 B

O O Y B/R Y

O

9

O O Y GyP

B

B/R B/R

B

B/Y

D

P P P B

7B 8 P

A B B B/Y

B B B B/Y

O

C

EF

Lg

6

Br Br R

Sb

B B B

BBB

5

G

R

G

0

B

L/W Y/R

6

B/Y

B B

L L

R/W

B/Y

B/Y

Y

Lg W

4

L L

L/G

Sb

P Br B

L/R

3

B L/R L/W L/Y P

O

1 2 3 4 5 6 7 8 9

B

2 Sb

1

B

Lg

R/W

: : : : : : : : :

L/W P _

10 11 12 13 14 15 16 17 18

L/R L/R L/G G/R P B

: : : : : : : : :

O P B/Y B/Y P P L/Y L/W L/G

19 20 21 22 23 24 25 26

: : : : : : : :

Y/R L B/R G W Y Br _

H

B

I L/G Gy

P

J B/R

B

K

G/R

Gy

P B

P Y

B

M

0 L

5 L L

L

4 688 L/W L/R B B Y/R L/G L/R

BBB

BGyP

L

P L/R G/R B P B/Y P L/W Y/R B/R W Br L/W L/R L/G P O B/Y P L/Y L/G L G Y

9 2 7

BPP

P O

B B

O

BA

O P

P

B/Y B/Y

B

B/Y B/Y

D FH I 3 C B/R Y Y O O B/R B/R Y O O

R R/W

B L/Y

B L/G

L/W B

B

B B/Y B B B/Y B B

E6

Sb Lg

Lg B

1

Br Br

Sb Lg R/W B

B/R

Sb

B B

B

Y Br W G P Sb Lg R B

G

B Gy P

K

B/R P G/R Gy

J

B/R L Y B

M

P B

L

S6D08030

B Br G Gy L Lg O P R Sb

73

: Black : Brown : Green : Gray : Blue : Light green : Orange : Pink : Red : Sky blue

W Y B/R B/Y G/R L/G L/R L/W L/Y R/W

: White : Yellow : Black/red : Black/yellow : Green/red : Blue/green : Blue/red : Blue/white : Blue/yellow : Red/white

Y/R

: Yellow/red

6D01F1X

Electrical components

G

O/W Pu/W

Pu/L

Pu/G

Pu/Y Pu/Y

Pu/G

6

G

O/Y

Pu/L

Pu/W

66

O/B

Pu/B

B

Pu/B

R/W

O/R

Pu/R

B

R/W

B

R/W

B Pu/R

5

O/B

Pu/B

O/R

G

G

O/R

O/R

Pu/G

G R/Y

O/W

5 B B B

R/Y

7 R/Y

R/Y

3

7 È

L

Pu/Y

O/G

G

B/O

7 Pu/W

5

O/B

O/L O/G

4

5 6 7 9 10 11 12 13

Pu/R

R/W

O/B

5

É

6

7 B/W

R/Y

7

B/Y

9Y

R/Y

G

R/L R/L R/W L/Y L/Y R/Y R/Y R/Y

: : : : : : : :

14 15 16 17 18 19 20 21

5

B

B/G

O/L R/Y

B/Br

7

: : : : : : :

R/Y R/Y R/W _ _ _ _

B B B B B B B B

Pu/L L

22 23 24 25 26 27 28

R/Y R/Y R/Y R R R/W R/W R/W

5

O/Y

0

: : : : : : : :

4

R/W

B/L R/Y

R/Y

R/Y

É

R/Y R/Y R/Y

2 W/Y B

È

W/B W/R

1

W/G W/L

W/Br

R/Y

8

L

27 28 29 30 31 32 33

: : : : : : :

R/L W/Y G G Pu/L Pu/R B/O

R R

R/Y

34 35 36 37 38 39 40

: : : : : : :

B/W B/Y R/L W/G L/Y Pu/W Pu/B

41 42 43 44 45 46 47

: : : : : : :

_

48 49 50 51 52 53 54

Y B B W/L W/R G

: : : : : : :

Pu/Y W/B _ B B W/Br W/B

55 56 57 58 59 60

: : : : : :

L _

R/Y

Pu/G B/Br B/L B/G

A

KM JL IF NE 0D C B A 5H 6G 97

W/B

B

8 W/Y G Pu/R B/W B/L L/Y Pu/B

1

R/L G Pu/L B/O B/Y W/G Pu/W

B W/L G W/B Y B W/R Pu/Y

B W/B Pu/G B/L B W/Br L

5

B/Br B/G

5

O/G G G O/B O/R O/R G O/L O/B

W/B B W/L W/R W/Y W/G W/Br B

4 B

B/W

B/G R/Y

6 6 6

B B

O/B

Pu/W O/W Pu/G O/G Pu/B

O/L Pu/L

R/W Pu/R Pu/Y O/Y Pu/Y O/R Pu/R

R/W Pu/Y G

B O/R Pu/G O/Y B Pu/R Pu/G

R/W Pu/B Pu/W

4

A

R/W Pu/W G

B O/B Pu/L O/W B Pu/B Pu/L

7

9

R/W R/Y R/Y R/Y L/Y R/L R/W R R/Y R/W R/W R/Y R/Y R/Y L/Y R/L R R/Y R/W B/O

7 R/Y

6

B

GG

B B B B

R/Y

B/Y R/Y

3 B W/B R/Y

R/Y L

B/L R/Y

B/Br R/Y

Y

L

R/Y B

0

L

B

B

R/Y

2

R/Y R/Y R/Y R/Y R/Y R/Y

R/W

4 S6D08040

Connect to: 1 2 3 4 5 6 7 8

Pulser coil Electric fuel pump Electric oil pump Ground Fuel injector Injector drivers Ignition coil ECM

6D01F1X

9 Crank position sensor 0 Fuel pump relay A Fuse holder

74

ELEC

–

+

Electrical systems

G

O/W Pu/W

Pu/L

Pu/G

Pu/Y Pu/Y

Pu/G

6

G

O/Y

Pu/L

Pu/W

66

O/B

Pu/B

B

Pu/B

R/W

O/R

Pu/R

B

R/W

B

R/W

B Pu/R

5

O/B

Pu/B

O/R

G

G

O/R

O/R

Pu/G

G R/Y

O/W

5 B B B

R/Y

7 R/Y

R/Y

3

7 È

L

Pu/Y

O/G

G

B/O

7 Pu/W

5

O/B

O/L O/G

4

5 6 7 9 10 11 12 13

Pu/R

R/W

O/B

5

É

6

7 B/W

R/Y

7

B/Y

9Y

R/Y

G

R/L R/L R/W L/Y L/Y R/Y R/Y R/Y

: : : : : : : :

14 15 16 17 18 19 20 21

5

B

B/G

O/L R/Y

B/Br

7

: : : : : : :

R/Y R/Y R/W _ _ _ _

B B B B B B B B

Pu/L L

22 23 24 25 26 27 28

R/Y R/Y R/Y R R R/W R/W R/W

5

O/Y

0

: : : : : : : :

4

R/W

B/L R/Y

R/Y

R/Y

É

R/Y R/Y R/Y

2 W/Y B

È

W/B W/R

1

W/G W/L

W/Br

R/Y

8

L

27 28 29 30 31 32 33

: : : : : : :

R/L W/Y G G Pu/L Pu/R B/O

R R

R/Y

34 35 36 37 38 39 40

: : : : : : :

B/W B/Y R/L W/G L/Y Pu/W Pu/B

41 42 43 44 45 46 47

: : : : : : :

_

48 49 50 51 52 53 54

Y B B W/L W/R G

: : : : : : :

Pu/Y W/B _ B B W/Br W/B

55 56 57 58 59 60

: : : : : :

L _

R/Y

Pu/G B/Br B/L B/G

KM JL IF

A

NE 0D C B A 5H 6G 97

W/B

B

8 W/Y G Pu/R B/W B/L L/Y Pu/B

1

R/L G Pu/L B/O B/Y W/G Pu/W

B W/L G W/B Y B W/R Pu/Y

B W/B Pu/G B/L B W/Br L

5

B/Br B/G

5

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W/B B W/L W/R W/Y W/G W/Br B

4 B

B/W

B/G R/Y

6 6 6

B B

O/B

Pu/W O/W Pu/G O/G Pu/B

O/L Pu/L

R/W Pu/R Pu/Y O/Y Pu/Y O/R Pu/R

R/W Pu/Y G

B O/R Pu/G O/Y B Pu/R Pu/G

R/W Pu/B Pu/W

4

A

R/W Pu/W G

B O/B Pu/L O/W B Pu/B Pu/L

7

9

3

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7 R/Y

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B

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B W/B R/Y

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B/L R/Y

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0

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4 S6D08040

B G L R Y B/Br B/G B/L B/W B/Y

75

: Black : Green : Blue : Red : Yellow : Black/brown : Black/green : Black/blue : Black/white : Black/yellow

L/Y O/B O/G O/L O/R O/W O/Y Pu/B Pu/G Pu/L

: Blue/yellow : Orange/black : Orange/green : Orange/blue : Orange/red : Orange/white : Orange/yellow : Purple/black : Purple/green : Purple/blue

Pu/R Pu/W Pu/Y R/L R/W R/Y W/B W/Br W/G W/L

: Purple/red : Purple/white : Purple/yellow : Red/blue : Red/white : Red/yellow : White/black : White/brown : White/green : White/blue

W/R : White/red W/Y : White/yellow

6D01F1X

Electrical components / Self-diagnosis

Self-diagnosis

9

Diagnosing the electronic control system 1. Connect the special service tool to the outboard motor as shown.

• Trouble code indication Example: The illustration code number 23. a: Light on, 0.33 second b: Light off, 4.95 seconds c: Light off, 0.33 second d: Light off, 1.65 seconds

indicates

NOTE: When performing this diagnosis, all of the electrical wires must be properly connected.

Diagnostic flash indicator: YB-06444 2. Start the engine and let it idle.

3. Check the flash pattern of the diagnostic flash indicator to determine if there are any malfunctions.

• Normal condition (no defective part or irregular processing is found) • Single flash is given every 4.95 seconds. a: Light on, 0.33 second b: Light off, 4.95 seconds

6D01F1X

76

1 2 3 4 5 6 7 8 9

TRBL SHTG

Troubleshooting

4. If a flash pattern listed in the diagnostic code chart is displayed, check the malfunctioning part according to the flash pattern.

NOTE: When more than one problem is detected, the light of the diagnostic flash indicator flashes in the pattern of the lowest numbered problem. After that problem is corrected, the light flashes in the pattern of the next lowest numbered problem. This continues until all of the problems are detected and corrected.

Code

77

Symptom

1

Normal

13

Incorrect pulser coil signal

14

Incorrect crank position sensor signal

15

Incorrect engine temperature sensor signal

18

Incorrect throttle position sensor signal

19

Incorrect battery voltage

22

Incorrect atmospheric pressure sensor signal

23

Incorrect intake air temperature sensor signal

25

Incorrect fuel pressure signal

26

Incorrect injector signal

27

Incorrect water in fuel signal

28

Incorrect shift position switch signal

44

Incorrect engine stop lanyard switch signal

62

Low fuel pressure warning

6D01F1X

Index

A.

G.

Adjusting the oil pump link rod ..................... 31 After test run ................................................ 15 Applicable models.......................................... 3 Assembling the lower case .......................... 52

B. Backlash (counter rotation model) ............... 56 Backlash (regular rotation model) ................ 46 Bottom cowling............................................. 59 Break-in........................................................ 15

General........................................................ 32 General specifications ................................. 16 General torques........................................... 27

H. How to use this manual ................................. 1

I. Identification .................................................. 3 Installing the crankcase covers ................... 39 Installing the power unit............................... 39 Intake system ................................................ 6

C. Checking the battery .................................... 12 Checking the cooling water pilot hole .......... 15 Checking the engine oil level ....................... 12 Checking the engine start switch and engine stop lanyard switch......................... 14 Checking the fuel system............................. 12 Checking the gear oil level........................... 12 Checking the gear shift and throttle operation ........................................ 14 Checking the hydraulic pressure.................. 67 Checking the lower unit for air leakage........ 31 Checking the outboard motor mounting height ......................................... 13 Checking the power trim and tilt system ...... 14 Checking the remote control cables............. 13 Checking the steering system...................... 14 Crankcase.................................................... 38 Crankcase and cylinders................................ 4

D. Diagnosing the electronic control system .... 76 Dimensions .................................................. 23 Disassembling the reverse gear .................. 52 Drive shaft and lower case (counter rotation model)............................. 50

E. ECM (Electronic Control Module) ................ 10 Electrical ...................................................... 20 Electrical components.................................. 70

F.

L. Lower case .................................................... 9 Lower unit .............................................. 20, 31 Lubricating the outboard motor.................... 32

M. Maintenance interval chart .......................... 30 Maintenance specifications ......................... 18 Manual format................................................ 1 Measuring the forward and reverse gear backlash ......................... 46, 56

O. Oil injection system...................................... 31

P. Port view...................................................... 70 Power trim and tilt unit ................................. 67 Power unit.............................................. 18, 35 Predelivery checks ...................................... 12 Propeller selection ....................................... 11 Propeller shaft housing (counter rotation model) ............................ 48 Propeller shaft housing (regular rotation model) ............................. 42 Propeller size............................................... 11

R. Removing the crankcase covers ................. 39 Removing the power unit............................. 36

Features and benefits .................................... 4 Fuel filter ...................................................... 34

6D01F1X

78

1 2 3 4 5 6 7 8 9

Index

S. Selecting the pinion shims .....................45, 55 Selection ...................................................... 11 Self-diagnosis .............................................. 76 Serial number................................................. 3 Shimming (counter rotation model).............. 54 Shimming (regular rotation model)............... 44 Special service tools .................................... 28 Specified torques ......................................... 25 Symbols ......................................................... 2

T. Test run........................................................ 15 Tightening torques ....................................... 25 Top view....................................................... 71

U. Upper case..................................................... 8 Upper case, steering arm, swivel bracket, and clamp brackets.................................... 62

W. Wiring harness ............................................. 72 Wiring harness connector holder ................. 10

79

6D01F1X

Index

— MEMO —

6D01F1X

80

Wiring diagram Z300TR, LZ300TR 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z [ \ ] _

Electric fuel pump Electric oil pump Oil level sensor Water detection switch Throttle position sensor Emergency switch Atmospheric pressure sensor Thermoswitch Power trim and tilt switch Fuel pressure sensor Pulser coil Stator coil Crank position sensor Fuel injector Fuel pump relay Injector driver Ignition coil Spark plug ECM Diode Engine temperature sensor Trim sensor Oil pump (remote oil tank) Oil level sensor (remote oil tank) Shift cut switch Shift position switch Power trim and tilt relay Power trim and tilt motor Intake air temperature sensor Starter relay Starter motor Starting battery Accessory battery Fuse holder Fuse (20 A) ECM main relay Injector driver relay Fuse (100 A) Fuse (30 A) Rectifier Regulator

È É Ê Ë Ì

To personal computer for diagnosis To remote control box/switch panel To warning indicator To trim meter To diagnostic flash indicator (special service tool)

(*1) Isolator cable (optional) (*2) Negative cable (commercially available)

Color code B Br G Gy L Lg O P R Sb W Y B/Br B/G B/L B/O B/R B/W B/Y G/L G/R G/W L/G L/R L/W L/Y O/B O/G O/L O/R O/W O/Y Pu/B Pu/G Pu/L Pu/R Pu/W Pu/Y R/L R/W R/Y W/B W/Br W/G W/L W/R W/Y Y/R

: Black : Brown : Green : Gray : Blue : Light green : Orange : Pink : Red : Sky blue : White : Yellow : Black/brown : Black/green : Black/blue : Black/orange : Black/red : Black/white : Black/yellow : Green/blue : Green/red : Green/white : Blue/green : Blue/red : Blue/white : Blue/yellow : Orange/black : Orange/green : Orange/blue : Orange/red : Orange/white : Orange/yellow : Purple/black : Purple/green : Purple/blue : Purple/red : Purple/white : Purple/yellow : Red/blue : Red/white : Red/yellow : White/black : White/brown : White/green : White/blue : White/red : White/yellow : Yellow/red

YAMAHA MOTOR CORPORATION, USA

Printed in USA Jul. 2003 – 0.0 × 1 CR (E_1)

Z300TR, LZ300TR 1

G B

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M N S6D0WD01

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1 2 3 4 5 6 7 8 9 10

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Pu/W O/W Pu/G

: : : : : : : : : :

B R/W O/B Pu/B Pu/L Pu/W — O/W B R/W

11 12 13 14 15 16 17 18 19 20

: : : : : : : : : :

Pu/B — Pu/W Pu/L G B R/W O/R Pu/R Pu/G

21 22 23 24 25 26 27 28 29 30

: : : : : : : : : :

Pu/Y — O/Y B R/W Pu/R — Pu/Y Pu/G G

: : : : : : : : : : : : : : : : : : : :

L/W P — L/R L/R L/G G/R P B O P B/Y B/Y P P L/Y L/W L/G Y/R L

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

: : : : : : : : : : : : : : : : : : : :

B/R G W Y Br — R/L W/Y G G Pu/L Pu/R B/O B/W B/Y R/L W/G L/Y Pu/W Pu/B

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

: : : : : : : : : : : : : : : : : : : :

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: : : : : : : :

R R R R R/L R/L R/W R

9 10 11 12 13 14 15 16

: : : : : : : :

L/Y L/Y R/Y R/Y R/Y R/Y R/Y R/Y

17 18 19 20 21 22 23 24

: : : : : : : :

R R R/W R/W R/W R/W R/Y R/W

Pu/R Pu/Y Pu/G

Pu/W Pu/L Pu/B G

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I 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

X ±

1 2 3 4 5 6 7 8

#

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S6D0WD02