Yamaha Vmax Vz150 Vz175 Z150 Z175 Z200 Lz150 Lz200 V6 Outboard Complete Service Manual 2004 -2014 by www.heydownloads.com

(L)Z150C VZ150C (V)Z175C (L)Z200C VZ200C SERVICE MANUAL *LIT186160282* LIT-18616-02-82

68F-28197-1F-11

NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use. Because Yamaha has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual.

Important information

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

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. (L)Z150C, VZ150C, (V)Z175C, (L)Z200C, VZ200C SERVICE MANUAL ©2003 by Yamaha Motor Corporation, USA 1st Edition, November 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-18616-02-82

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 â&#x20AC;&#x201C;

Electrical systems Troubleshooting Index

ELEC

TRBL SHTG

1 2 3 4 5 6 7 8 9

GEN INFO

General information How to use this manual ................................................................................. 1-1 Manual format............................................................................................ 1-1 Symbols..................................................................................................... 1-2 Safety while working......................................................................................1-3 Fire prevention........................................................................................... 1-3 Ventilation..................................................................................................1-3 Self-protection ........................................................................................... 1-3 Parts, lubricants, and sealants ..................................................................1-3 Good working practices .............................................................................1-4 Disassembly and assembly ....................................................................... 1-4 Identification...................................................................................................1-5 Applicable models .....................................................................................1-5 Serial number ............................................................................................ 1-5 Propeller selection ......................................................................................... 1-5 Propeller size............................................................................................. 1-5 Selection.................................................................................................... 1-6 Predelivery checks ........................................................................................1-7 Checking the fuel system ..........................................................................1-7 Checking the gear oil level ........................................................................ 1-7 Checking the engine oil level..................................................................... 1-7 Checking the battery.................................................................................. 1-7 Checking the outboard motor mounting height.......................................... 1-8 Checking the remote control cables .......................................................... 1-8 Checking the steering system ...................................................................1-9 Checking the gear shift and throttle operation...........................................1-9 Checking the power trim and tilt system.................................................... 1-9 Checking the engine start switch and engine stop lanyard switch ............1-9 Checking the cooling water pilot hole ......................................................1-10 Test run ................................................................................................... 1-10 Break-in ................................................................................................... 1-10 After test run ............................................................................................ 1-10

68F1F11

1 2 3 4 5 6 7 8 9

GEN INFO

General information

How to use this manual

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. NOTE: For troubleshooting procedures, see Chapter 9, “Troubleshooting.”

LOWR

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

Lower unit

Plastic tie

Hose

Check screw

Gasket

Dowel pin

Bolt

Drain screw

Not reusable

Disassembling the drive shaft

Grommet

Bolt

M10

Bolt

Thrust washer

Propeller

Washer

Cotter pin

Propeller nut

Trim tab

6-5

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

Not reusable

M10

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

Remarks

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

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

40 mm

45 mm 60 mm

CAUTION: CAUTION: • 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.

6-19

62Y5A11

1-1

68F1F11

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

â&#x20AC;&#x201C;

ELEC

Troubleshooting

TRBL SHTG

LOWR

Symbols 1 to 6 indicate specific data. 1

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

0 A

E 7 8 9 0

A M

B D

C C

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

D Apply Gasket Maker E Apply Yamabond No. 4 F Apply LOCTITE 271 (red) 68F1F11

271

242

572

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

1-2

1 2 3 4 5 6 7 8 9

GEN INFO

General information

Safety while working

To prevent an accident or injury and to ensure quality service, follow the safety procedures provided below.

Fire prevention Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames.

Parts, lubricants, and sealants Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the outboard motor.

Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If inhaled in large quantities they may cause loss of consciousness and death within a short time. When test running an engine indoors (e.g., in a water tank) be sure to do so where adequate ventilation can be maintained.

Under normal conditions, the lubricants mentioned in this manual should not harm or be hazardous to your skin. However, you should follow these precautions to minimize any risk when working with lubricants. 1. Maintain good standards of personal and industrial hygiene. 2. Change and wash clothing as soon as possible if soiled with lubricants.

Self-protection Protect your eyes by wearing safety glasses or safety goggles during all operations involving drilling and grinding, or when using an air compressor. Protect your hands and feet by wearing protective gloves and safety shoes when necessary.

1-3

3. Avoid contact with skin. Do not, for example, place a soiled rag in your pocket. 4. Wash hands and any other part of the body thoroughly with soap and hot water after contact with a lubricant or lubricant soiled clothing has been made. 5. To protect your skin, apply a protective cream to your hands before working on the outboard motor.

68F1F11

Safety while working 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc.

Disassembly and assembly 1. Use compressed air to remove dust and dirt during disassembly.

Good working practices Special service tools Use the recommended special service tools to protect parts from damage. Use the right tool in the right mannerâ&#x20AC;&#x201D;do not improvise.

Tightening torques Follow the tightening torque specifications provided throughout the manual. When tightening nuts, bolts, and screws, tighten the large sizes first, and tighten fasteners starting in the center and moving outward. Non-reusable parts Always use new gaskets, seals, O-rings, cotter pins, circlips, etc., when installing or assembling parts.

68F1F11

2. Apply engine oil to the contact surfaces of moving parts before assembly.

3. Install bearings with the manufacture identification mark in the direction indicated in the installation procedure. In addition, be sure to lubricate the bearings liberally. 4. Apply a thin coat of water-resistant grease to the lip and periphery of an oil seal before installation. 5. Check that moving parts operate normally after assembly.

1-4

1 2 3 4 5 6 7 8 9

GEN INFO

General information

Identification

Applicable models This manual covers the following models. Applicable models Z150TR, LZ150TR, VZ150TR, Z175TR, VZ175TR, Z200TR, LZ200TR, VZ200TR

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

Propeller selection

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.

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

b c

S69J1100

1 2 3 4

Model name Approved model code Transom height Serial number

b c

Model name

Approved model code

Starting serial No.

Z150TR

6G4

1006970–

LZ150TR

6K0

1000468–

VZ150TR

6J9

1003950–

Z175TR

6G5

1000348–

VZ175TR

62H

1000310–

Z200TR

6G6

1008788–

LZ200TR

6K1

1001418–

VZ200TR

60F

1001055–

1-5

S60C1125

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

68F1F11

Identification / Propeller selection

Selection

Counter rotation model

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.

13 1/2 × 23 - M

13 3/4 × 21 - ML Stainless

15 1/4 × 15 - ML 15 1/4 × 17 - ML 15 1/4 × 19 - ML

13 3/4 × 21 - M 14 × 19 - M

1 2 3 4 5 6 7 8 9

13 3/4 × 19 - ML1

14 7/8 × 21 - ML Material

Material

13 3/4 × 17 - ML1

14 1/2 × 23 - ML

Regular rotation model For Z150, Z175, Z200 Propeller size (in)

Propeller size (in)

Aluminum

14 1/2 × 17 - M 15 1/4 × 15 - M 13 3/8 × 23 - M 13 3/8 × 25 - M 13 3/4 × 17 - M2 13 3/4 × 19 - M2 13 3/4 × 21 - M 14 1/2 × 15 - M 14 1/2 × 23 - M

Stainless

14 5/8 × 16 - M 14 7/8 × 21 - M 15 1/4 × 15 - M 15 1/4 × 17 - M 15 1/4 × 19 - M 15 3/4 × 13 - M For VZ150, VZ175, VZ200 Propeller size (in)

Material

13 3/4 × 17 - M2 14 1/2 × 21 - M 14 1/2 × 23 - M 14 1/2 × 25 - M

Stainless

14 1/2 × 25 - M2 14 1/2 × 27 - M 14 1/2 × 27 - M1

68F1F11

1-6

GEN INFO

General information

Predelivery checks

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 the engine oil level. 2. Make sure the oil level is between the upper and lower level marks.

Recommended engine oil: YAMALUBE 2-stroke outboard motor oil

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

CAUTION: • Use unleaded straight gasoline only. • Do not use gasoline mixed with oil (premixed fuel).

1-7

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

68F1F11

Predelivery checks

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.

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.

a 1 S68F1040C

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.

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

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

S60C1190

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

68F1F11

1-8

1 2 3 4 5 6 7 8 9

GEN INFO

General information

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.

S68F1060C

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 into 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 positions 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

1-9

68F1F11

Predelivery checks

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

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

S68F1070C

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

a b Ă&#x2C6; 0

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.

S60V1120

Ă&#x2C6; Hour

After test run 1. Check for water in the gear oil. 2. Check for fuel leakage in the cowling. 3. Flush the cooling water passage with fresh water using the flushing kit and with the engine running at idle.

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

68F1F11

1-10

1 2 3 4 5 6 7 8 9

SPEC

Specifications General specifications................................................................................... 2-1 Maintenance specifications ..........................................................................2-7 Power unit (Z150 models) ......................................................................... 2-7 Lower unit (Z150 models)..........................................................................2-9 Electrical (Z150 models)..........................................................................2-10 Power unit (Z175 models) ....................................................................... 2-13 Lower unit (Z175 models)........................................................................2-14 Electrical (Z175 models)..........................................................................2-15 Power unit (Z200 models) ....................................................................... 2-18 Lower unit (Z200 models)........................................................................2-20 Electrical (Z200 models)..........................................................................2-21 Dimensions..............................................................................................2-24 Tightening torques....................................................................................... 2-27 Specified torques.....................................................................................2-27 General torques....................................................................................... 2-29

68F1F11

1 2 3 4 5 6 7 8 9

SPEC

Specifications

General specifications Item Dimension Overall length Overall width Overall height (L) (X) Boat transom height (L) (X) Weight (without propeller) (L) (X) 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

2-1

Unit mm (in) mm (in)

Z150TR

Model LZ150TR

VZ150TR

792 (31.2) 554 (21.8)

mm (in) mm (in)

1,655 (65.2) — 1,782 (70.2)

1,693 (66.7) —

mm (in) mm (in)

508 (20.0) — 635 (25.0)

508 (20.0) —

kg (lb) kg (lb)

212 (467) — 216 (476)

213 (470) —

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

cm3 (cu. in) mm (in)

V, A

110.3 (150) at 5,000 r/min 4,500–5,500 55.0 (14.5, 12.1) at 5,500 r/min 700 ± 30 2-stroke, 76°, V6, HPDI 2,596 (158.4) 90.0 × 68.0 (3.54 × 2.68) Cylinders #1–#4: 6.7 Cylinders #5–#6: 6.4 Remote control Electric starter Fuel injection TCI 12, 45 BKR6EKU (NGK) Water Propeller boss Oil injection

68F1F11

General 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)

Z150TR

Model LZ150TR

VZ150TR

Regular unleaded gasoline 90 86 YAMALUBE 2-stroke outboard motor oil 0.9 (0.24, 0.20) 10.5 (2.77, 2.31)

SAE 3 cm (US oz, lmp oz)

GEAR CASE LUBE 90 980 870 980 (33.1, 34.6) (29.4, 30.7) (33.1, 34.6)

Degree

–4 to 16

Degree Degree

70 32 + 32 F-N-R 1.86 (26/14) 2.00 (28/14) Spiral bevel gear Dog clutch Spline Clockwise CounterClockwise clockwise M ML M

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 2-stroke 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

68F1F11

2-2

1 2 3 4 5 6 7 8 9

SPEC

Specifications Item

Dimension Overall length Overall width Overall height (L) (X) Boat transom height (L) (X) Weight (without propeller) (L) (X) 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

2-3

Unit

Model Z175TR

mm (in) mm (in)

VZ175TR 792 (31.2) 554 (21.8)

mm (in) mm (in)

— 1,782 (70.2)

1,693 (66.7) —

mm (in) mm (in)

— 635 (25.0)

508 (20.0) —

kg (lb) kg (lb)

— 216 (476)

213 (470) —

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

cm3 (cu. in) mm (in)

V, A

128.7 (175) at 5,000 r/min 4,500–5,500 64.0 (16.9, 14.1) at 5,500 r/min 750 ± 30

700 ± 30

2-stroke, 76°, V6, HPDI 2,596 (158.4) 90.0 × 68.0 (3.54 × 2.68) Cylinders #1–#4: 6.5 Cylinders #5–#6: 6.1 Remote control Electric starter Fuel injection TCI 12, 45 BKR7EKU (NGK) Water Propeller boss Oil injection

68F1F11

Unit

RON(*1) PON

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

Model Z175TR

VZ175TR

Regular unleaded gasoline 90 86 YAMALUBE 2-stroke outboard motor oil 0.9 (0.24, 0.20) 10.5 (2.77, 2.31) GEAR CASE LUBE 90 980 (33.1, 34.6)

Degree

–4 to 16

Degree Degree

70 32 + 32 F-N-R 1.86 (26/14) Spiral bevel gear Dog clutch Spline Clockwise M

A A Minute

512 675 182

(*1)

68F1F11

2-4

1 2 3 4 5 6 7 8 9

SPEC

Specifications Item

2-5

Unit mm (in) mm (in)

Z200TR

Model LZ200TR

VZ200TR

792 (31.2) 554 (21.8)

mm (in) mm (in)

— 1,782 (70.2)

1,693 (66.7) —

mm (in) mm (in)

— 635 (25.0)

508 (20.0) —

kg (lb) kg (lb)

— 216 (476)

213 (470) —

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

cm (cu. in) mm (in)

V, A

147.1 (200) at 5,000 r/min 4,500–5,500 68.0 (18.0, 15.0) at 5,500 r/min 700 ± 30 2-stroke, 76°, V6, HPDI 2,596 (158.4) 90.0 × 68.0 (3.54 × 2.68) Cylinders #1–#4: 6.3 Cylinders #5–#6: 6.0 Remote control Electric starter Fuel injection TCI 12, 45 BKR7EKU (NGK) Water Propeller boss Oil injection

68F1F11

Unit

RON(*1) PON

Z200TR

Model LZ200TR

VZ200TR

Regular unleaded gasoline 90 86 YAMALUBE 2-stroke outboard motor oil

L (US gal, lmp gal) L (US gal, lmp gal)

0.9 (0.24, 0.20) 10.5 (2.77, 2.31)

SAE 3 cm (US oz, lmp oz)

GEAR CASE LUBE 90 980 870 980 (33.1, 34.6) (29.4, 30.7) (33.1, 34.6)

Degree

–4 to 16

Degree Degree

70 32 + 32

Clockwise M

A A Minute

F-N-R 1.86 (26/14) Spiral bevel gear Dog clutch Spline Counterclockwise ML

Clockwise M

512 675 182

(*1)

68F1F11

2-6

1 2 3 4 5 6 7 8 9

SPEC

Specifications

Maintenance specifications

Power unit (Z150 models) 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

Z150TR

Model LZ150TR

VZ150TR

kPa (kgf/cm2, psi)

470 (4.7, 68)

mm (in)

0.1 (0.004)

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

90.000–90.020 (3.5433–3.5441) 90.100 (3.5472) 0.08 (0.0031) 0.05 (0.0020)

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

89.845–89.869 (3.5372–3.5381) 10 (0.39) 0.150–0.156 (0.0059–0.0061) 23.074–23.085 (0.9084–0.9089)

mm (in) mm (in)

0.25 (0.010) 0.50 (0.020)

mm (in) mm (in)

90.095–90.119 (3.5470–3.5480) 90.345–90.369 (3.5569–3.5578)

mm (in)

23.065–23.070 (0.9081–0.9083)

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

2-7

68F1F11

Maintenance 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

68F1F11

Unit

Z150TR

Model LZ150TR

VZ150TR

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

1.97–1.99 (0.0776–0.0783) 2.70–2.90 (0.1063–0.1142) 0.30–0.40 (0.0118–0.0157) 0.02–0.06 (0.0008–0.0024)

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

1.97–1.99 (0.0776–0.0783) 2.70–2.90 (0.1063–0.1142) 0.30–0.45 (0.0118–0.0177) 0.02–0.06 (0.0008–0.0024)

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

28.070–28.082 (1.1051–1.1056) 0.12–0.26 (0.0047–0.0102) 2.0 (0.08)

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

53.975–53.991 (2.1250–2.1256) 35.985–36.000 (1.4167–1.4173) 0.02 (0.0008)

°C (°F) °C (°F) mm (in)

48–52 (118–126) 60 (140) 3.0 (0.12)

1 2 3 4 5 6 7 8 9

68H00 Screw type mm (in) mm (in)

7.8–8.4 (0.31–0.33) 0.2 (0.008)

2-8

SPEC

Specifications

Lower unit (Z150 models) Item

Unit

Gear backlash Pinion-to-forward gear

mm (in)

Pinion-to-reverse gear

mm (in)

Pinion shims Forward gear shims Reverse gear shims Propeller shaft shims

mm mm mm mm

Propeller shaft End play

2-9

mm (in)

Z150TR

Model LZ150TR

VZ150TR

0.25–0.46 0.20–0.44 0.71–1.01 (0.0098– (0.0079– (0.0280– 0.0181) 0.0173) 0.0398) 0.73–1.30 0.97–1.30 0.78–1.38 (0.0287– (0.0381– (0.0307– 0.0512) 0.0512) 0.0543) 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)

—

68F1F11

Maintenance specifications

Electrical (Z150 models) Item Ignition and ignition control system Ignition timing (cylinder #1) at engine idle speed at 5,500 r/min 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) Pulser coil resistance(*1) (W/R, W/B, W/Y, W/G, W/L, W/Br – B) Throttle position sensor Input voltage (O – R) Output voltage (P – O) at engine idle speed at throttle fully closed 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 (*1)

Unit

Z150TR

Model LZ150TR

Degree Degree

BTDC 5 ± 3 BTDC 17 ± 2

Ω

1.87–2.53

kΩ

8.93–12.08

V V V

270 250 250

V V V V Ω

4.0 4.0 20.0 35.0 294–398

5.0

V V

0.58 ± 0.02 0.50 ± 0.02

V V V V Ω

8.5 8.0 26.0 31.0 178.5–241.5

mm (in)

0.5–1.5 (0.02–0.06)

VZ150TR

The figures are for reference only.

68F1F11

2-10

1 2 3 4 5 6 7 8 9

SPEC

Specifications Item

Sensor assembly 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) at engine idle speed Oxygen density sensor output voltage(*1) (Gy – B/W) Starter motor Type Output Cranking time limit Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit (*1)

Unit

Z150TR

Model LZ150TR

kΩ kΩ

5.4–6.6 0.3–0.4

kΩ kΩ

54.2–69.0 3.12–3.48

V V V

60 65 65

Ω

0.9–1.1

V V

3.2 0.0–1.0

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)

VZ150TR

The figures are for reference only.

2-11

68F1F11

Maintenance specifications Item 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(*1) (R – ground) at 1,500 r/min (unloaded) at 3,500 r/min (unloaded) Power trim and tilt system Trim sensor Setting resistance (P – B) Resistance (P – B) Fluid type (*1)

Unit

Z150TR

Model LZ150TR

20, 30, 80

V V V

5.5 37 86

Ω

0.16–0.24

V V

13.0 13.0

Ω Ω

9–11 9–378.8 ATF Dexron II

VZ150TR

1 2 3 4 5 6 7 8 9

The figures are for reference only.

68F1F11

2-12

SPEC

Specifications

Power unit (Z175 models) Item Power unit Minimum compression pressure* Cylinder heads Warpage limit

Unit

Model Z175TR

VZ175TR

kPa (kgf/cm2, psi)

470 (4.7, 68)

mm (in)

0.1 (0.004)

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

90.000–90.020 (3.5433–3.5441) 90.100 (3.5472) 0.08 (0.0031) 0.05 (0.0020)

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

89.845–89.869 (3.5372–3.5381) 10 (0.39) 0.150–0.156 (0.0059–0.0061) 23.074–23.085 (0.9084–0.9089)

mm (in) mm (in)

0.25 (0.010) 0.50 (0.020)

mm (in) mm (in)

90.095–90.119 (3.5470–3.5480) 90.345–90.369 (3.5569–3.5578)

mm (in)

23.065–23.070 (0.9081–0.9083)

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

2-13

68F1F11

Unit

Model Z175TR

VZ175TR

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

1.97–1.99 (0.0776–0.0783) 2.70–2.90 (0.1063–0.1142) 0.30–0.40 (0.0118–0.0157) 0.02–0.06 (0.0008–0.0024)

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

1.97–1.99 (0.0776–0.0783) 2.70–2.90 (0.1063–0.1142) 0.30–0.45 (0.0118–0.0177) 0.02–0.06 (0.0008–0.0024)

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

28.070–28.082 (1.1051–1.1056) 0.12–0.26 (0.0047–0.0102) 2.0 (0.08)

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

53.975–53.991 (2.1250–2.1256) 35.985–36.000 (1.4167–1.4173) 0.02 (0.0008)

°C (°F) °C (°F) mm (in)

48–52 (118–126) 60 (140) 3.0 (0.12)

1 2 3 4 5 6 7 8 9

68L00 Screw type mm (in) mm (in)

7.8–8.4 (0.31–0.33) 0.2 (0.008)

Lower unit (Z175 models) Item Gear backlash Pinion-to-forward gear Pinion-to-reverse gear Pinion shims Forward gear shims Reverse gear shims

68F1F11

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

Model Z175TR

VZ175TR

0.25–0.46 (0.0098–0.0181) 0.74–1.30 (0.0287–0.0512) 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

2-14

SPEC

Specifications

Electrical (Z175 models) Item Ignition and ignition control system Ignition timing (cylinder #1) at engine idle speed at 5,500 r/min 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) Pulser coil resistance(*1) (W/R, W/B, W/Y, W/G, W/L, W/Br – B) Throttle position sensor Input voltage (O – R) Output voltage (P – O) at engine idle speed at throttle fully closed 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 (*1)

Unit

Degree Degree

Model Z175TR

VZ175TR

BTDC 4 ± 3 BTDC 20 ± 2

BTDC 5 ± 3 BTDC 17 ± 2

Ω

1.87–2.53

kΩ

8.93–12.08

V V V

270 250 250

V V V V Ω

4.0 4.0 20.0 35.0 294–398

5.0

V V

0.60 ± 0.02 0.50 ± 0.02

V V V V Ω

8.5 8.0 26.0 31.0 178.5–241.5

mm (in)

0.5–1.5 (0.02–0.06)

The figures are for reference only.

2-15

68F1F11

Maintenance specifications Item Sensor assembly 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) at engine idle speed Oxygen density sensor output voltage(*1) (Gy – B/W) Starter motor Type Output Cranking time limit Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit (*1)

Unit

Model Z175TR

VZ175TR

kΩ kΩ

5.4–6.6 0.3–0.4

kΩ kΩ

54.2–69.0 3.12–3.48

V V V

60 65 65

Ω

0.9–1.1

V V

3.2 0.0–1.0

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)

1 2 3 4 5 6 7 8 9

The figures are for reference only.

68F1F11

2-16

SPEC

Specifications Item

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(*1) (R – ground) at 1,500 r/min (unloaded) at 3,500 r/min (unloaded) Power trim and tilt system Trim sensor Setting resistance (P – B) Resistance (P – B) Fluid type (*1)

Unit

Model Z175TR

VZ175TR

20, 30, 80

V V V

5.5 37 86

Ω

0.16–0.24

V V

13.0 13.0

Ω Ω

9–11 9–378.8 ATF Dexron II

The figures are for reference only.

2-17

68F1F11

Maintenance specifications

Power unit (Z200 models) Item Power unit Minimum compression pressure* Cylinder heads Warpage limit

Unit

Z200TR

Model LZ200TR

VZ200TR

kPa (kgf/cm2, psi)

470 (4.7, 68)

mm (in)

0.1 (0.004)

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

90.000–90.020 (3.5433–3.5441) 90.100 (3.5472) 0.08 (0.0031) 0.05 (0.0020)

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

89.845–89.869 (3.5372–3.5381) 10 (0.39) 0.150–0.156 (0.0059–0.0061) 23.074–23.085 (0.9084–0.9089)

mm (in) mm (in)

0.25 (0.010) 0.50 (0.020)

mm (in) mm (in)

90.095–90.119 (3.5470–3.5480) 90.345–90.369 (3.5569–3.5578)

mm (in)

23.065–23.070 (0.9081–0.9083)

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

68F1F11

2-18

1 2 3 4 5 6 7 8 9

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

2-19

Unit

Z200TR

Model LZ200TR

VZ200TR

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

1.97–1.99 (0.0776–0.0783) 2.70–2.90 (0.1063–0.1142) 0.30–0.40 (0.0118–0.0157) 0.02–0.06 (0.0008–0.0024)

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

1.97–1.99 (0.0776–0.0783) 2.70–2.90 (0.1063–0.1142) 0.30–0.45 (0.0118–0.0177) 0.02–0.06 (0.0008–0.0024)

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

28.070–28.082 (1.1051–1.1056) 0.12–0.26 (0.0047–0.0102) 2.0 (0.08)

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

53.975–53.991 (2.1250–2.1256) 35.985–36.000 (1.4167–1.4173) 0.02 (0.0008)

°C (°F) °C (°F) mm (in)

48–52 (118–126) 60 (140) 3.0 (0.12) 68F00 Screw type

mm (in) mm (in)

8.7–9.3 (0.34–0.37) 0.2 (0.008)

68F1F11

Maintenance specifications

Lower unit (Z200 models) Item

Unit

Gear backlash Pinion-to-forward gear

mm (in)

Pinion-to-reverse gear

mm (in)

Pinion shims Forward gear shims Reverse gear shims Propeller shaft shims

mm mm mm mm

Propeller shaft End play

68F1F11

mm (in)

Z200TR

Model LZ200TR

VZ200TR

0.25–0.46 0.20–0.44 0.25–0.46 (0.0098– (0.0079– (0.0098– 0.0181) 0.0173) 0.0181) 0.73–1.30 0.97–1.30 0.73–1.30 (0.0287– (0.0381– (0.0287– 0.0512) 0.0512) 0.0512) 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)

—

2-20

1 2 3 4 5 6 7 8 9

SPEC

Specifications

Electrical (Z200 models) Item Ignition and ignition control system Ignition timing (cylinder #1) at engine idle speed at 5,500 r/min 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) Pulser coil resistance(*1) (W/R, W/B, W/Y, W/G, W/L, W/Br – B) Throttle position sensor Input voltage (O – R) Output voltage (P – O) at engine idle speed at throttle fully closed 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 (*1)

Unit

Z200TR

Model LZ200TR

Degree Degree

BTDC 4 ± 3 BTDC 17 ± 2

Ω

1.87–2.53

kΩ

8.93–12.08

V V V

270 250 250

V V V V Ω

4.0 4.0 20.0 35.0 294–398

5.0

V V

0.62 ± 0.02 0.50 ± 0.02

V V V V Ω

8.5 8.0 26.0 31.0 178.5–241.5

mm (in)

0.5–1.5 (0.02–0.06)

VZ200TR

0.60 ± 0.02

The figures are for reference only.

2-21

68F1F11

Unit

Z200TR

Model LZ200TR

kΩ kΩ

5.4–6.6 0.3–0.4

kΩ kΩ

54.2–69.0 3.12–3.48

V V V

60 65 65

Ω

0.9–1.1

V V

3.2 0.0–1.0

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)

VZ200TR

1 2 3 4 5 6 7 8 9

The figures are for reference only.

68F1F11

2-22

SPEC

Specifications Item

Unit

Z200TR

Model LZ200TR

20, 30, 80

V V V

5.5 37 86

Ω

0.16–0.24

V V

13.0 13.0

Ω Ω

9–11 9–378.8 ATF Dexron II

VZ200TR

The figures are for reference only.

2-23

68F1F11

Maintenance specifications

Dimensions Exterior (L)Z150, Z175, (L)Z200

277 (10.9)

32˚

660 (26.0)

396 (15.6)

mm (in)

L: 1,034 (40.7) X: 1,150 (45.3)

574 (22.6) 180 (7.1)

613 (24.1)

L: 53 (2 X: 69 .1) (2.7) ˚

L: 774 (30.5) X: 850 (33.5)

44 (1.7)

308 (12.1) 14 (0.6)

708 (27.9) L: 516 (20.3) X: 643 (25.3)

168 (6.6)

211 (8.3)

L: 947 (37.3) X: 1,074 (42.3)

835 (32.9)

74 (2.9)

32 (1.3)

1 2˚

68F1F11

L: 42 (1.7) X: 50 (2.0)

4˚ 646 (25.4) S68F2010C

2-24

1 2 3 4 5 6 7 8 9

SPEC

Specifications

VZ150, VZ175, VZ200

277 (10.9)

32˚

396 (15.6)

mm (in)

574 (22.6)

1,034 (40.7)

180 (7.1)

613 (24.1)

44 (1.7)

308 (12.1) 14 (0.6)

746 (29.4) 516 (20.3)

168 (6.6)

53 (2

774 (30.5)

.1)

211 (8.3)

947 (37.3)

945 (37.2)

74 (2.9)

32 (1.3)

1 2˚

2-25

4˚ 42 (1.7)

646 (25.4) S68F2020C

68F1F11

Maintenance specifications Clamp bracket mm (in)

1 2 3 4 5 6 7 8 9

180 (7.1)

163.5 (6.4) 50.8 (2.0)

163.5 (6.4)

254 (10.0)

13 (0.5)

52 (2.0)

55.5 (2.2)

367 (14.4)

13 (0.5)

18.5 (0.7)

82 (3.2)

102 (4.0)

125.4 (4.9)

102 (4.0)

125.4 (4.9)

S60X2020

68F1F11

2-26

SPEC

Specifications

Tightening torques

Specified torques Part to be tightened

Thread size

Fuel system Fuel filter holder bolt Fuel filter bracket bolt Fuel pump screw Emergency switch Oil pump mounting bolt Intake silencer mounting screw Throttle body bolt and nut High-pressure fuel pump bolt Fuel rail mounting bolt Injector holder bolt Power unit Drive belt tensioner bolt Apron bolt Power unit mounting bolt and nut Flywheel magnet nut Starter motor bolt Starter motor terminal nut Negative battery lead bolt PTT motor lead bolt Rectifier Regulator bolt

1st 2nd

Oxygen density sensor Oxygen density sensor bracket bolt Oxygen density sensor cover bolt Intake manifold bolt Reed valve screw Shift position switch screw Cylinder head cover bolt Thermostat cover bolt Spark plug Cylinder head bolt

Pressure control valve cover bolt

2-27

8 8 3 4 7 3 10 23 23 26

0.8 0.8 0.3 0.4 0.7 0.3 1.0 2.3 2.3 2.6

5.9 5.9 2.2 3.0 5.2 2.2 7.4 17.0 17.0 19.2

M10 M6 M8 M24 M8 M8 M8 M6

39 8 21 187 29 9 18 4 6 12 49 14 9 10 1 3 5 11 5 11 25 15 29 15 4 8 4 8

3.9 0.8 2.1 18.7 2.9 0.9 1.8 0.4 0.6 1.2 4.9 1.4 0.9 1.0 0.1 0.3 0.5 1.1 0.5 1.1 2.5 1.5 2.9 1.5 0.4 0.8 0.4 0.8

28.8 5.9 15.5 137.9 21.4 6.6 13.3 3.0 4.4 8.9 36.1 10.3 6.6 7.4 0.7 2.2 3.7 8.1 3.7 8.1 18.4 11.1 21.4 11.1 3.0 5.9 3.0 5.9

M6 M6 —

1st 2nd

Engine temperature sensor Exhaust cover bolt

M6 M6 M5 — M6 M6 M6 M8 M8 M8

— M6 M6 M6 M5 M4 1st 2nd 1st 2nd

M8 —

1st 2nd 1st 2nd

Tightening torques N·m kgf·m ft·lb

M6 M6

68F1F11

Tightening torques Part to be tightened

Crankcase bolt

Connecting rod cap bolt

Cylinder block plug Lower unit (regular rotation model) Trim tab bolt Lower case mounting bolt Propeller nut Gear oil drain screw Gear oil check screw Ring nut Pinion nut Lower unit (counter rotation model) Trim tab bolt Lower case mounting bolt Propeller nut Gear oil drain screw Gear oil check screw Ring nut Pinion nut Bracket unit Shift rod detent bolt Flushing hose adapter screw Upper mounting nut Lower mounting nut Muffler assembly bolt Muffler bolt Exhaust manifold bolt Lower exhaust guide bolt Trim stopper nut Self-locking nut Trim sensor cam screw

68F1F11

M14

Tightening torques N·m kgf·m ft·lb 10 1.0 7.4 18 1.8 13.3 20 2.0 14.8 39 3.9 28.8 19 1.9 14.0 36 3.6 26.6 Loosen completely 19 1.9 14.0 36 3.6 26.6 23 2.3 17.0

M10 M10 M18 — — — M16

39 39 54 9 9 142 93

3.9 3.9 5.4 0.9 0.9 14.2 9.3

28.8 28.8 39.8 6.6 6.6 104.7 68.6

M10 M10 M18 — — — M16

39 39 54 9 9 142 93

3.9 3.9 5.4 0.9 0.9 14.2 9.3

28.8 28.8 39.8 6.6 6.6 104.7 68.6

— M5 M12 M14 M8 M8 M8 M8 M10 M22 M6

24 5 51 71 21 18 18 18 36 15 2

2.4 0.5 5.1 7.1 2.1 1.8 1.8 1.8 3.6 1.5 0.2

17.7 3.7 37.6 52.4 15.5 13.3 13.3 13.3 26.6 11.1 1.5

Thread size 1st 2nd 1st 2nd 1st 2nd 3rd 4th 5th

M8 M10

2-28

1 2 3 4 5 6 7 8 9

SPEC

Specifications Part to be tightened

Power trim and tilt unit Reservoir cap Reservoir mounting bolt PTT motor mounting bolt Gear pump cover bolt Gear pump housing mounting bolt Manual valve Trim cylinder end screw Tilt cylinder end screw Tilt piston nut

Thread size — — — — — — — — —

Tightening torques N·m kgf·m ft·lb 0.7 5 5 6 8 3 78 130 96

0.07 0.5 0.5 0.6 0.8 0.3 7.8 13.0 9.6

0.5 3.7 3.7 4.4 5.9 2.2 57.5 96.0 70.8

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

2-29

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

68F1F11

CHK ADJ

Periodic checks and adjustments Special service tools .....................................................................................3-1 Maintenance interval chart............................................................................3-2 Top cowling .................................................................................................... 3-3 Checking the top cowling...........................................................................3-3 Fuel system .................................................................................................... 3-3 Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector) ..............3-3 Checking the fuel filter ............................................................................... 3-4 Checking the high-pressure fuel pump gear oil level.................................3-4 Changing the high-pressure fuel pump gear oil......................................... 3-4 Power unit....................................................................................................... 3-5 Checking the engine oil level..................................................................... 3-5 Checking the drive belt ..............................................................................3-5 Checking the spark plugs ..........................................................................3-5 Checking the thermostats..........................................................................3-6 Checking the cooling water passage.........................................................3-6 Control system ............................................................................................... 3-7 Checking the engine idle speed ................................................................3-7 Adjusting the throttle cable ........................................................................ 3-7 Checking the gear shift operation.............................................................. 3-8 Oil injection system .......................................................................................3-9 Adjusting the oil pump link rod...................................................................3-9 Power trim and tilt unit .................................................................................. 3-9 Checking the power trim and tilt operation ................................................ 3-9 Checking the power trim and tilt fluid level .............................................. 3-10 Lower unit ..................................................................................................... 3-10 Checking the gear oil level ...................................................................... 3-10 Changing the gear oil .............................................................................. 3-11 Checking the lower unit for air leakage ...................................................3-11 Checking the propeller............................................................................. 3-12 General..........................................................................................................3-12 Checking the anodes............................................................................... 3-12 Checking the battery................................................................................ 3-12 Lubricating the outboard motor................................................................3-13

68F1F11

1 2 3 4 5 6 7 8 9

CHK ADJ

Periodic checks and adjustments

Special service tools

Digital tachometer YU-39951-B

Pressure/vacuum tester YB-35956-A

3-1

68F1F11

Special service tools / Maintenance interval chart

Maintenance interval chart

Use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Initial

Every

Refer to page

Item

Remarks

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 Thermostats Throttle link/throttle cable/ throttle pick-up timing Water pump

Check/replace Check/replace Check/charge Clean Check

3-12 3-12 3-12 3-6 3-3

Check/replace

3-4

Check Change Lubricate

3-3 3-11 3-13

Check/adjust

3-7

Check Check Check/replace Check/adjust Check

5-29 3-9 3-12 3-8 3-6

Check/adjust

3-7

Check Clean/adjust/ replace

6-8

Spark plugs High-pressure fuel pump drive belt High-pressure fuel pump oil level Oil pump Oil tank water drain Throttle position sensor

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

3-5

Check/replace

3-5

Check/fill

3-4

Check/adjust Check/clean Check/adjust

3-9 â&#x20AC;&#x201D; 4-25

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

Every Item High-pressure fuel pump drive belt

68F1F11

Remarks Replace

500 hours (2.5 years)

1,000 hours (5 years)

Refer to page 5-15

3-2

1 2 3 4 5 6 7 8 9

CHK ADJ

Periodic checks and adjustments

Top cowling

Checking the top cowling 1. Check the fitting by pushing the cowling with both hands. Adjust if necessary.

2. Check the low-pressure fuel hose connections and fuel joints for leaks. Replace if necessary. Also, check the fuel filter 1 and fuel pumps 2 for leaks or deterioration. Replace if necessary. 3. Check the medium-pressure fuel hose connections and fuel joints for leaks. Replace if necessary. Also, check the vapor separator 3, fuel filter 4, and pressure regulator 5 for leaks or deterioration. Replace if necessary.

2. Loosen the bolts 1. 3. Move the hook 2 up or down slightly to adjust its position.

NOTE: • To loosen the fitting, move the hook in direction a. • To tighten the fitting, move the hook in direction b.

4. Check the high-pressure fuel hose connections for leaks. Replace if necessary. Also, check the fuel rails 6 and fuel injectors 7 for leaks or damage. Replace if necessary.

4. Tighten the bolts. 5. Check the fitting again and, if necessary, repeat steps 2–4.

Fuel system

Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector) 1. Remove the flywheel magnet cover and injector driver cover.

3-3

68F1F11

Top cowling / Fuel system

Checking the fuel filter 1. Check the fuel filter element 1 for dirt and residue and check the fuel filter cup 2 for foreign substances and cracks. Clean the cup with straight gasoline and replace the element if necessary.

Recommended gear oil: GEAR CASE LUBE SAE: 90 4. Install the check bolt.

Changing the high-pressure fuel pump gear oil 1

1. Remove the flywheel magnet cover.

2. Remove the harness cover and the injector driver cover.

S60V3100

NOTE: Be sure not to spill any fuel when removing the fuel filter cup.

3. Place a drain pan under the drain bolt, remove the drain bolt 1, then the check bolt 2 to drain the oil.

Checking the high-pressure fuel pump gear oil level 1. Remove the flywheel magnet cover. 2. Remove the check bolt 1, and then check the gear oil level in the high-pressure fuel pump.

1 S68F3050C

4. Insert a gear oil tube into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible.

1 1

S68F3040C

NOTE: If the oil is at the correct level, the oil should overflow out of the check hole when the check bolt is removed. 3. If necessary, add sufficient gear oil of the recommended type until it overflows out of the check hole.

68F1F11

S68F3060C

Recommended gear oil: GEAR CASE LUBE SAE: 90 Oil quantity: 45 cm3 (1.5 US oz, 1.6 Imp oz)

3-4

1 2 3 4 5 6 7 8 9

CHK ADJ

Periodic checks and adjustments

5. Install the check bolt and quickly install the drain bolt. 6. Install the injector driver cover, harness cover and flywheel magnet cover.

Power unit

Checking the spark plugs 1. Disconnect the spark plug wires, and then remove the spark plugs. 2. Clean the electrodes 1 with a spark plug cleaner or wire brush. Replace the spark plug if necessary.

Checking the engine oil level 1. Place the outboard motor in an upright position. 2. Check the engine oil level. 3. Make sure the oil level is between the upper and lower level marks.

3. Check the electrodes for erosion and excessive carbon or other deposits, and the gasket for damage. Replace the spark plug if necessary. 4. Check the spark plug gap a. Adjust if out of specification. Recommended engine oil: YAMALUBE 2-stroke outboard motor oil

Checking the drive belt 1. Remove the flywheel magnet cover. 2. While turning the flywheel magnet clockwise, check the interior a and the exterior b of the drive belt for cracks, damage, or wear. Replace if necessary.

Specified spark plug: Z150 models: BKR6EKU (NGK) Z175, Z200 models: BKR7EKU (NGK) Spark plug gap a: 1.5–1.6 mm (0.059–0.063 in)

b 5. Install the spark plugs, tighten them finger tight, then to the specified torque with a spark plug wrench. S68F3070C

T. R.

3-5

Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb)

68F1F11

Fuel system / Power unit

Checking the thermostats Water temperature

1. Remove the flywheel magnet cover.

Valve lift a

2. Remove the harness cover and the injector driver cover.

48–52 °C (118–126 °F)

0.05 mm (0.002 in) (valve begins to lift)

3. Remove the thermostat covers 1 and thermostats 2.

above 60 °C (140 °F)

more than 3.0 mm (0.12 in)

7. Install the thermostats and covers, and then tighten the cover bolts to the specified torques in two stages.

T. R.

S68F3080C

4. Suspend the thermostats in a container of water.

Thermostat cover bolt: 1st: 5 N·m (0.5 kgf·m, 3.7 ft·lb) 2nd: 11 N·m (1.1 kgf·m, 8.1 ft·lb)

Checking the cooling water passage 1. Check the cooling water inlet cover 1 and cooling water inlet for clogs. Clean if necessary.

5. Place a thermometer in the water and slowly heat the water.

1 S69J5E40

6. Check the thermostat valve opening at the specified water temperatures. Replace if out of specification. S60V3130

2. Place the lower unit in water, and then start the engine.

68F1F11

3-6

1 2 3 4 5 6 7 8 9

CHK ADJ

Periodic checks and adjustments

3. Check for water flow at the cooling water pilot hole. If there is no water flow, check the cooling water passage inside the outboard motor.

4. Turn the throttle stop screw 3 in direction a or b until the specified engine idle speed is obtained. 5. Align the center of the throttle cam roller 4 with the alignment mark c.

S68F1070C

Control system

2 S68F3090C

Checking the engine idle speed 1. Start the engine and warm it up for 5 minutes. 2. Attach the special service tool to spark plug wire #1 1, and then check the engine idle speed. Adjust if out of specification.

NOTE: • To increase the idle speed, turn the throttle stop screw in direction a. • To decrease the idle speed, turn the throttle stop screw in direction b. 6. Press down on the throttle cam roller and tighten throttle adjusting screw #4 by turning it counterclockwise.

Adjusting the throttle cable NOTE: • Be sure to synchronize the throttle valves before adjusting the throttle cable. • For synchronizing procedures, see Chapter 4, “Synchronizing the throttle valves.” Digital tachometer: YU-39951-B

Engine idle speed (reference data): (L)Z150, VZ150, VZ175, (L)Z200, VZ200: 700 ± 30 r/min Z175C: 750 ± 30 r/min 3. Loosen the throttle adjusting screw #4 2 by turning it clockwise.

3-7

1. Loosen the locknut 1 and stopper screw 2. 2. Loosen the locknut 3, remove the clip 4, and then disconnect the throttle cable joint 5. 3. Set the remote control lever to the fully closed position. 4. Align the center of the throttle cam roller 6 with the alignment mark a.

68F1F11

Power unit / Control system

Checking the gear shift operation 6

1. Check that the gear shift operates smoothly when shifting from neutral into forward or reverse. Adjust the shift cable length if necessary. 2. Set the gear shift to the neutral position. 3. Loosen the locknut 1, remove the clip 2, and then disconnect the shift cable joint 3.

1 4 2

S68F3100C

5. Tighten the stopper screw until it contacts the throttle lever. 6. Tighten the locknut. 7. Adjust the position of the throttle cable joint until its hole is aligned with the set pin on the throttle lever.

S68F3110C

4. Align the center of the set pin a with the alignment mark b on the bottom cowling.

b S69J3200

WARNING The throttle cable joint must be screwed in a minimum of 8.0 mm (0.31 in) b. 8. Connect the cable joint, install the clip, and then tighten the locknut. 9. Check the throttle cable for smooth operation and adjust the cable length, if necessary, repeat steps 1â&#x20AC;&#x201C;8.

68F1F11

3-8

1 2 3 4 5 6 7 8 9

CHK ADJ

Periodic checks and adjustments

5. Adjust the position of the shift cable joint until its hole is aligned with the set pin.

4. Connect the oil pump link rod. 5. Check that the oil pump lever 3 contacts the stopper 4 when the throttle valve is in the fully open position.

3 c

S69J3370

WARNING The shift cable joint must be screwed in a minimum of 8.0 mm (0.31 in) c. 6. Connect the cable joint, install the clip, and then tighten the locknut. 7. Check the gear shift for smooth operation and adjust the shift cable length, if necessary, repeat steps 3â&#x20AC;&#x201C;6.

Oil injection system

Adjusting the oil pump link rod 1. Loosen the locknut 1 and then disconnect the oil pump link rod 2. 2. Fully close the throttle valves. 3. Adjust the oil pump link rod so that the gap a between the oil pump lever 3 (in the fully closed position) and the stopper 4 is less than 0.5 mm (0.02 in).

S68F3130C

Power trim and tilt unit

Checking the power trim and tilt operation 1. Fully tilt the outboard motor up and down a few times and check the entire trim and tilt range for smooth operation. Check the power trim and tilt fluid level if necessary. NOTE: Be sure to listen to the winding sound of the power trim and tilt motor for smooth operation. 2. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1 to check the lock mechanism of the lever.

2 3 3 1 a

S68F3120C S60X3020

NOTE: Do not contact the oil pump lever to the stopper.

3-9

68F1F11

Control system / Oil injection system / Power trim and tilt unit / Lower unit

Checking the power trim and tilt fluid level

Recommended power trim and tilt fluid: ATF Dexron II

1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1.

4. Install the reservoir cap, and then tighten it to the specified torque.

T. R.

Reservoir cap: 0.7 N·m (0.07 kgf·m, 0.5 ft·lb)

Lower unit

Checking the gear oil level 1. Fully tilt the outboard motor down. 2. Remove the check screw 1, and then check the gear oil level in the lower case. S60X3020

1 S60V3320

2. Remove the reservoir cap 2, and then check the fluid level in the reservoir.

NOTE: If the oil is at the correct level, the oil should overflow out of the check hole when the check screw is removed. 3. If necessary, add sufficient gear oil of the recommended type until it overflows out of the check hole.

2 Recommended gear oil: GEAR CASE LUBE SAE: 90

S60X3030

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

68F1F11

3. If necessary, add sufficient fluid of the recommended type until it overflows out of the filler hole.

4. Install the check screw, and then tighten it to the specified torque. Gear oil check screw: 9 N·m (0.9 kgf·m, 6.6 ft·lb)

3-10

1 2 3 4 5 6 7 8 9

CHK ADJ

Periodic checks and adjustments

Changing the gear oil Recommended gear oil: GEAR CASE LUBE SAE: 90 Oil quantity: Regular rotation model: 980 cm3 (33.1 US oz, 34.6 Imp oz) Counter rotation model: 870 cm3 (29.4 US oz, 30.7 Imp oz)

1. Tilt the outboard motor up slightly. 2. Place a drain pan under the drain screw 1, remove the drain screw, then the check screw 2 to drain the oil.

5. Install the check screw and quickly install the drain screw, and then tighten them to the specified torque.

T. R.

3. Check the oil for metal, discoloration, and its viscosity. Check the internal parts of the lower case if necessary.

Gear oil check screw and drain screw: 9 N·m (0.9 kgf·m, 6.6 ft·lb)

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

4. Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible.

Pressure/vacuum tester: YB-35956-A 2. Apply the specified pressure to check that the pressure is maintained in the lower unit for at least 10 seconds.

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

3-11

68F1F11

Lower unit / General 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.

Checking the propeller 1. Check the propeller blades and splines for cracks, damage, or wear. Replace if necessary.

General

CAUTION: Do not oil, grease, or paint the anodes or the trim tab, otherwise they will be ineffective. 2. Replace the anodes or trim tab if excessively eroded.

Checking the anodes 1. Check the anodes and trim tab for scales, grease, or oil. Clean if necessary.

Checking the battery 1. Check the battery electrolyte level. If the level is at or below the minimum level mark a, add distilled water until the level is between the maximum and minimum level marks.

S68F3140C

S69J3620

S60X3080

68F1F11

3-12

1 2 3 4 5 6 7 8 9

CHK ADJ

Periodic checks and adjustments

2. Check the specific gravity of the electrolyte. Fully charge the battery if below specification.

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

WARNING Battery electrolyte is dangerous; it contains sulfuric acid which is poisonous and highly caustic. Always follow these preventive measures: • Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. • Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): • SKIN – Wash with water. • EYES – Flush with water for 15 minutes and get immediate medical attention. Antidote (INTERNAL): • Drink large quantities of water or milk followed with milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention. Batteries generate explosive, hydrogen gas. Always follow these preventive measures: • Charge batteries in a well-ventilated area. • Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). • DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. NOTE: • Batteries vary per manufacturer. The procedures mentioned in this manual may not always apply, therefore, consult the instruction manual of the battery. • Disconnect the negative battery lead first, then the positive battery lead.

A S68F3150C

Electrolyte specific gravity: 1.280 at 20 °C (68 °F)

3-13

68F1F11

General C A

S60X3090

S68F3160C

3. Apply corrosion resistant grease to the area shown.

S60X3100

4. Apply injector grease to the areas shown.

S60X3120

NOTE: Apply grease to the grease nipples until it flows from the bushings a. 2. Apply low temperature resistant grease to the area shown.

68F1F11

3-14

1 2 3 4 5 6 7 8 9

FUEL

Fuel system Special service tools .....................................................................................4-1 Hose routing ...................................................................................................4-2 Fuel hoses and fuel pipes..........................................................................4-2 Fuel filter ......................................................................................................... 4-3 Fuel pump ....................................................................................................... 4-4 Checking the fuel pumps ...........................................................................4-6 Disassembling the fuel pumps...................................................................4-6 Assembling the fuel pumps ....................................................................... 4-7 Oil injection system .......................................................................................4-8 Checking the check valve........................................................................4-10 Checking the oil filter ............................................................................... 4-10 Checking the oil tank ............................................................................... 4-10 Assembling the oil tank............................................................................4-10 Installing the oil pump.............................................................................. 4-10 Bleeding the oil injection system ............................................................. 4-11 Throttle body assembly and vapor separator ...........................................4-12 Measuring the fuel pressure (medium-pressure fuel line) .......................4-21 Checking the pressure regulator ............................................................. 4-21 Reducing the fuel pressure (medium-pressure fuel line)......................... 4-22 Disconnecting the medium-pressure fuel hose joint................................4-22 Removing the throttle body assembly .....................................................4-22 Removing the medium-pressure fuel hose clamps .................................4-23 Installing the medium-pressure fuel hose clamps ................................... 4-23 Removing the electric fuel pump filter .....................................................4-23 Checking the vapor separator .................................................................4-23 Installing the electric fuel pump filter .......................................................4-23 Installing the throttle body assembly .......................................................4-24 Synchronizing the throttle valves............................................................. 4-24 Adjusting the throttle position sensor.......................................................4-25 High-pressure fuel line ................................................................................ 4-27 High-pressure fuel pump............................................................................. 4-29 Installing the joints ...................................................................................4-32 Installing the fuel pipes ............................................................................4-32 Installing the fuel injectors ....................................................................... 4-32

68F1F11

1 2 3 4 5 6 7 8 9

FUEL

Fuel system

Special service tools

Pressure/vacuum tester YB-35956-A

Fuel pressure gauge YB-06766

Digital multimeter YU-34899-A

Test harness (3 pins) New: YB-06857 Current: YB-06757

4-1

68F1F11

Special service tools / Hose routing

Hose routing

Fuel hoses and fuel pipes 4

7 5

3 1

S68F4010C

1 2 3 4 5 6 7

Fuel hose (fuel tank-to-fuel filter) Fuel hose (fuel filter-to-fuel pump) Fuel hose (fuel pump-to-vapor separator) Medium-pressure fuel hose (vapor separator-to-fuel filter) Medium-pressure fuel hose (fuel filter-to-high-pressure fuel pump) High-pressure fuel pipe (high-pressure fuel pump-to-fuel rail) Fuel hose (high-pressure fuel pump-to-vapor separator)

68F1F11

4-2

1 2 3 4 5 6 7 8 9

FUEL

Fuel system

Fuel filter

8 N · m (0.8 kgf · m, 5.9 ft · Ib)

12 13

14 10 15

1 2 5

6 16

17 7

S68F4020C

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

4-3

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

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

Remarks M6 × 16 mm

M6 × 14 mm

M6 × 25 mm

Not reusable Not reusable

68F1F11

Fuel filter / Fuel pump

Fuel pump

7 8 9 5 6

23 15

24 15

8 9

9 8

7 21

22 15

20 2

15 19

14 12

13 15

15 T.

3 N · m (0.3 kgf · m, 2.2 ft · Ib)

S68F4030C

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

Part name Gasket Fuel pump assembly Gasket Diaphragm Plate Spring Nut Screw Valve Body Gasket Diaphragm Cover Screw Plastic tie Fuel hose Joint

68F1F11

Q’ty 2 2 2 2 2 2 8 8 8 2 2 2 2 6 10 1 2

Remarks Not reusable Not reusable

ø3 × 6 mm

Not reusable

ø5 × 35 mm Not reusable

4-4

1 2 3 4 5 6 7 8 9

FUEL

Fuel system 4

7 8 9 5 6

23 15

24 15

8 9

9 8

7 21

22 15

20 2

15 19

14 12

13 15

15 T.

3 N · m (0.3 kgf · m, 2.2 ft · Ib)

S68F4030C

No. 18 19 20 21 22 23 24

4-5

Part name Fuel hose Bolt Fuel hose Corrugated tube Fuel hose Fuel hose Hose

Q’ty 1 4 1 1 1 1 1

Remarks M6 × 50 mm

68F1F11

Fuel pump

Checking the fuel pumps 1. Place a drain pan under the fuel hose connections, and then disconnect the fuel hoses from the fuel pumps.

6. Apply the specified positive pressure and check that there is no air leakage. Disassemble the fuel pump if necessary.

2. Connect the special service tool to the fuel pump inlet. 3. Cover the fuel pump outlet with a finger, and then apply the specified positive pressure. Check that there is not air leakage. S60V4150

NOTE: Assemble the fuel pump valve to the fuel pump body, and moisten the inside of fuel pump with gasoline to ensure a better seal.

S60V4130

Specified pressure: 50 kPa (0.5 kgf/cm2, 7.3 psi)

Disassembling the fuel pumps

Pressure/vacuum tester: YB-35956-A

1. Disassemble the fuel pumps. 2. Check the diaphragms for tears or damage. Replace if necessary.

Specified pressure: 50 kPa (0.5 kgf/cm2, 7.3 psi) 4. Apply the specified negative pressure and check that there is no air leakage.

3. Check the valves for bends or damage. Replace if necessary. Also, check the fuel pump bodies and springs for damage. Replace if necessary. 4. Clean the fuel pump bodies.

S60V4140

Specified pressure: 30 kPa (0.3 kgf/cm2, 4.4 psi) 5. Connect the special service tool to the fuel pump outlet.

68F1F11

4-6

1 2 3 4 5 6 7 8 9

FUEL

Fuel system

Assembling the fuel pumps NOTE: Clean the parts and soak the valves and the diaphragms in gasoline before assembly to obtain prompt operation of the fuel pumps when starting the engine.

NOTE: Make sure that the gaskets and diaphragms are kept in place through the assembly process.

1. Install the valves 1 onto the fuel pump body.

1 1

S60V4170

2. Install the spring 2.

S60V4180

3. Install new gaskets 3, the diaphragms 4, and cover 5.

3 4

3 4 5

4-7

S60V4190

68F1F11

Fuel pump / Oil injection system

Oil injection system

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

Part name Oil level sensor Oil filter Washer Oil tank Air vent hose Emergency switch Bolt Bracket Collar Grommet Plastic tie Cap Oil hose Oil hose Joint Clamp Oil hose

68F1F11

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 3 1 3 3 6 1 1 2 1 1 2

1 2 3 4 5 6 7 8 9

Remarks

M6 Ă&#x2014; 30 mm

Not reusable

4-8

FUEL

Fuel system 4

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

4-9

Part name Check valve Electric oil pump Clamp Oil hose Check valve Cotter pin Washer Oil pump link rod Bolt Oil pump Oil hose Oil hose

Qâ&#x20AC;&#x2122;ty 1 1 30 2 7 1 1 1 2 1 6 6

Remarks

Not reusable

M6 Ă&#x2014; 20 mm

68F1F11

Oil injection system

Checking the check valve

Assembling the oil tank

1. Connect the special service tool to the check valve.

1. Install the washer 1, oil filter 2, and oil level sensor 3 into the oil tank 4.

2. Apply pressure to each check valve port. Replace if necessary.

NOTE: Check that no air comes out of the opposite end of the check valve.

NOTE: • Align the alignment marks a on the oil filter 2 and oil level sensor 3. • Align the alignment marks b on the oil level sensor 3 and oil tank 4.

Installing the oil pump Pressure/vacuum tester: YB-35956-A

Checking the oil filter

1. Connect the oil hoses to the oil pump. 2. Install the oil pump, and then tighten the bolts to the specified torque.

1. Check the oil filter for dirt, residue, or cracks. Clean or replace if necessary.

Checking the oil tank 1. Check the oil tank for cracks, leaks, or damage. Replace if necessary.

T. R.

68F1F11

Oil pump bolt: 7 N·m (0.7 kgf·m, 5.2 ft·lb)

4-10

1 2 3 4 5 6 7 8 9

FUEL

Fuel system

Bleeding the oil injection system CAUTION: 1

â&#x20AC;˘ Use unleaded straight gasoline only. â&#x20AC;˘ Do not use gasoline mixed with oil (premixed fuel).

2 1. Place rags around the air bleed screw to catch any oil that might spill. 2. Fill the oil tank with engine oil. Recommended engine oil: YAMALUBE 2-stroke outboard motor oil

S68F4080C

9. Check that oil flows from the oil pump. 3. Disconnect the oil pump link rod joint from the oil pump lever.

10. Connect the oil pump feed hose.

4. Start the engine and let it idle.

11. Connect the oil pump link rod joint to the oil pump lever.

5. Loosen the air bleed screw 1 and make sure that both the oil and air bubbles flow out. 6. Hold the oil pump lever in the fully open position.

S68F4070C

7. When there are no air bubbles left, tighten the air bleed screw. 8. Disconnect an oil pump feed hose 2 from the oil pump.

4-11

68F1F11

Oil injection system / Throttle body assembly and vapor separator

Throttle body assembly and vapor separator T.

10 N • m (1.0 kgf • m, 7.4 ft • Ib)

11 12 13

14 15

7 2

18 5

19 20 21 22

23 6 16 24 7 T.

10 N • m (1.0 kgf • m, 7.4 ft • Ib)

4 3 LT

242 T.

3 N • m (0.3 kgf • m, 2.2 ft • Ib) S68F4090C

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

Part name Throttle body assembly Intake silencer Screw Collar Seal Hose Hose Bolt Nut Throttle link rod Bolt Bracket Grommet Sensor assembly Gasket Oil pump link rod Bolt

68F1F11

Q’ty 1 1 6 6 1 1 1 11 2 1 1 1 1 1 1 1 1

Remarks

ø6 × 45 mm

M6 × 60 mm

M6 × 16 mm

Not reusable

M6 × 12 mm

4-12

1 2 3 4 5 6 7 8 9

FUEL

Fuel system 4

10 N • m (1.0 kgf • m, 7.4 ft • Ib)

11 12 13

14 15

7 2

18 5

19 20 21 22

23 6 16 24 7 T.

10 N • m (1.0 kgf • m, 7.4 ft • Ib)

4 3 LT

242 T.

3 N • m (0.3 kgf • m, 2.2 ft • Ib) S68F4090C

No. 18 19 20 21 22 23 24

4-13

Part name Fuel hose Fuel inlet hose Fuel hose Fuel hose Plastic tie Oil hose Clamp

Q’ty 1 1 1 1 3 1 1

Remarks

Not reusable

68F1F11

Throttle body assembly and vapor separator 4

2 3

6 7 8

4 3 12

9 8

12 11

S68F4100C

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

Part name Vapor separator Fuel filter Clamp Fuel hose Holder Screw Screw Washer Holder Bolt Washer Washer Collar Grommet Collar Hose Grommet

68F1F11

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

Remarks

Not reusable

ø4 × 10 mm ø5 × 15 mm

M6 × 35 mm

4-14

1 2 3 4 5 6 7 8 9

FUEL

Fuel system 4

1 2 10

3 4 9

5 6

8 13 11

7 14

20 16 17 21 18 22

23 24

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

4-15

Part name Pressure regulator O-ring Filter Screw O-ring Joint O-ring Cap Screw Hose Joint Hose Hose Hose Hose Damper Holder

Q’ty 1 1 1 2 1 1 1 1 9 1 2 1 1 1 1 1 1

S68F4110C

Remarks Not reusable

ø6 × 14 mm Not reusable Not reusable

ø4 × 16 mm

68F1F11

Throttle body assembly and vapor separator 4

1 2 12

3 4 9

5 6

8 13 11

7 14

20 16 17 21 18 22

23 24

25 No. 18 19 20 21 22 23 24 25 26

Part name Filter Gasket Float chamber Bracket Bolt Fuel pump relay Bolt O-ring Drain screw

68F1F11

Q’ty 1 1 1 1 2 1 1 1 1

S68F4110C

Remarks Not reusable

M6 × 20 mm M6 × 15 mm Not reusable

4-16

1 2 3 4 5 6 7 8 9

FUEL

Fuel system 4

2 3 4 5

1 6

6 7

6 16

17 9 15

10 11

19 20

13 14 S68F4120C

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

4-17

Part name Electric fuel pump lead Nut Washer Nut Washer Insulator O-ring Cover O-ring Collar O-ring Plate Electric fuel pump Terminal O-ring Needle valve Clip

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

Remarks ø4 mm ø5 mm

Not reusable Not reusable Not reusable

Not reusable

68F1F11

Throttle body assembly and vapor separator 4

2 3 4 5

1 6

6 7

6 16

17 9 15

10 11

19 20

13 14 S68F4120C

No. 18 19 20

Part name Pin Screw Float

68F1F11

Q’ty 1 1 1

Remarks ø4 × 7 mm

4-18

1 2 3 4 5 6 7 8 9

FUEL

Fuel system 4

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

4-19

Part name Throttle body Engine hanger Bolt Spring Pin Lever Collar Grommet Bracket Washer Screw Throttle position sensor Screw Lever Pin Joint Link rod

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

Remarks

M6 × 20 mm

ø5 × 30 mm ø5 × 12 mm

68F1F11

Throttle body assembly and vapor separator 4

No. 18 19 20 21 22 23

Part name Bolt Collar Wave washer Throttle cam Washer Stud bolt

68F1F11

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 2

1 2 3 4 5 6 7 8 9

Remarks M6 Ă&#x2014; 30 mm

4-20

FUEL

Fuel system

Measuring the fuel pressure (medium-pressure fuel line) 1. Remove the cap 1. 2. Connect the fuel pressure gauge to the pressure check valve.

5. Start the engine, warm it up for 5 minutes, and then measure the fuel pressure. If below specification, check the medium-pressure fuel line and the vapor separator. Fuel pressure: 350 kPa (3.5 kgf/cm2, 50.8 psi)

Checking the pressure regulator 1. Remove the cap 1. 2. Connect the fuel pressure gauge to the pressure check valve.

WARNING

3. Disconnect the pressure regulator hose 2, and then connect the special service tools to the pressure regulator.

Fuel pressure gauge: YB-06766

WARNING 3. Turn the engine start switch to ON, and then measure the fuel pressure within 5 seconds. NOTE: The fuel pressure decreases 5 seconds after the engine start switch is turned to ON. Fuel pressure: 350 kPa (3.5 kgf/cm2, 50.8 psi) 4. Measure the fuel pressure 5 seconds after turning the engine start switch to ON. Fuel pressure: 300 kPa (3.0 kgf/cm2, 43.5 psi)

4-21

• When connecting the fuel pressure gauge, first cover the connection between the gauge and the vapor separator pressure check valve with a clean, dry rag to prevent fuel from leaking out. • Gently screw in the gauge until it is firmly connected. Fuel pressure gauge: YB-06766 Pressure/vacuum tester: YB-35956-A 4. Start the engine and let it idle. 5. Check that the fuel pressure reduces when vacuum pressure is applied to the pressure regulator. If the fuel pressure does not reduce, replace the pressure regulator. 68F1F11

Throttle body assembly and vapor separator NOTE: When the vacuum pressure reaches the specified level, the fuel pressure reduces.

Disconnecting the medium-pressure fuel hose joint 1. Push the collar a into the hose joint 1 with a flat head screwdriver, and then slide the fuel filter out from the hose joint.

Reducing the fuel pressure (medium-pressure fuel line)

1. Remove the cap 1. 2. Cover the pressure check valve a of the vapor separator with a rag, and then press in the pressure check valve a using a thin screwdriver to release the fuel pressure.

WARNING Always reduce the fuel pressure in the medium-pressure fuel line before servicing the line or the vapor separator. If the fuel pressure is not released, pressurized fuel may spray out. 3. Place a container under the vapor separator and then loosen the drain screw 2.

S60V4320

Removing the throttle body assembly 1. Remove the throttle body assembly bolts and nuts in the sequence shown.

4. Drain the fuel from the vapor separator by pressing the pressure check valve using a thin screwdriver.

WARNING Reduce the fuel pressure before loosening the vapor separator drain screw, or pressurized fuel will spray out and may result in serious injury.

68F1F11

4-22

1 2 3 4 5 6 7 8 9

FUEL

Fuel system

Removing the medium-pressure fuel hose clamps 1. Remove the medium-pressure fuel hose clamps by cutting the crimped section of the clamp.

NOTE: To remove the filter, turn it clockwise.

Checking the vapor separator CAUTION: If the medium-pressure fuel hose clamps are removed without cutting the crimp first, the fuel hose could be damaged.

Installing the medium-pressure fuel hose clamps 1. Crimp the medium-pressure fuel hose clamps properly to securely fasten them.

1. Check the needle valve for bends or wear. Replace if necessary. 2. Check the float for deterioration. Replace if necessary. 3. Check the filter for dirt or residue. Clean if necessary.

Installing the electric fuel pump filter 1. Install the rubber damper 1, damper holder 2, and electric fuel pump filter 3 onto the electric fuel pump.

WARNING Do not reuse the fuel hose clamps, always replace them with new ones.

Removing the electric fuel pump filter 1. Remove the electric fuel pump filter, damper holder, and rubber damper from the electric fuel pump.

4-23

68F1F11

Throttle body assembly and vapor separator NOTE: • Make sure that the damper holder is correctly installed on the rubber damper. • To install the filter, firmly push it onto the electric fuel pump, and then turn it counterclockwise until it clicks.

4 a 3

Installing the throttle body assembly 1. Install the new gasket and throttle body assembly, and then tighten the bolts and nuts to the specified torque in the sequence shown.

S68F4210C

NOTE: Disconnect the end a of the oil pump link rod from the throttle link lever. Do not disconnect the oil pump link rod from the oil pump lever. 3. Loosen throttle adjusting screw #4 5 by turning it clockwise. 4. Loosen the throttle stop screw 6 until it no longer contacts the stopper b. 5. Check that all the throttle valves are fully closed.

T. R.

Throttle body bolt and nut: 10 N·m (1.0 kgf·m, 7.4 ft·lb)

Synchronizing the throttle valves 1. Remove the intake silencer 1.

2. Disconnect the throttle link rod 2 and the oil pump link rod 3 from the throttle link lever 4.

b 5 7

S68F4220C

S68F4200C

68F1F11

NOTE: If all the throttle valves are not fully closed, loosen throttle adjusting screws #1, #2, #3, #5, and #6 7 by turning them counterclockwise, and then tighten them.

4-24

1 2 3 4 5 6 7 8 9

FUEL

Fuel system

6. Connect the oil pump link rod. 7. Turn the throttle stop screw 6 in until the throttle valves start to open.

8. Connect the test harness (3 pins) to the throttle position sensor.

2 9

9. Turn the engine start switch to ON, and then turn the throttle stop screw in until the throttle position sensor output voltage is within specification. 10. Align the center of the throttle cam roller 8 with the alignment mark c, and then turn throttle adjusting screw #4 5 counterclockwise.

8 5

Throttle link rod length d: 163 mm (6.4 in) 13. Install the intake silencer. 14. Adjust the throttle cable length. NOTE: For adjustment procedures, see Chapter 3, “Adjusting the throttle cable.”

Adjusting the throttle position sensor

c S68F4230C

Test harness (3 pins): New: YB-06857 Current: YB-06757 Digital multimeter: YU-34899-A Throttle position sensor output voltage at engine idle speed: Pink (P) – Orange (O) Z150 models: 0.58 ± 0.02 V Z175 models, Z200 (L-transom) models: 0.60 ± 0.02 V Z200 (X-transom) models: 0.62 ± 0.02 V 11. Disconnect the throttle cable joint 9. 12. Adjust the throttle link rod length d, and then connect the throttle link rod 2.

4-25

S68F4240C

NOTE: Before adjusting the throttle position sensor output voltage, synchronize the throttle valves. 1. Disconnect the oil pump link rod from the throttle link lever. 2. Loosen the throttle stop screw until it no longer contacts the stopper. 3. Connect the test harness (3 pins) to the throttle position sensor. 4. Turn the engine start switch to ON. 5. Loosen the screws 1.

throttle

position

sensor

6. Adjust the position of the throttle position sensor until the specified output voltage is obtained.

68F1F11

Throttle body assembly and vapor separator 12. Check the throttle position sensor output voltage is within specification. If out of specification, repeat steps 1–11.

1 2 3 4 5 6 7 8 9

Test harness (3 pins): New: YB-06857 Current: YB-06757 Digital multimeter: YU-34899-A Throttle position sensor output voltage with throttle fully closed: Pink (P) – Orange (O) 0.50 ± 0.02 V 7. Tighten the throttle position sensor screws. 8. Operate the throttle valves several times, and then check that the throttle position sensor output voltage is within specification. Repeat steps 5–7 if necessary. 9. Turn the throttle stop screw in until the throttle valves start to open. 10. Turn the throttle stop screw in until the throttle position sensor output voltage is within specification. Throttle position sensor output voltage at engine idle speed: Pink (P) – Orange (O) Z150 models: 0.58 ± 0.02 V Z175 models, Z200 (L-transom) models: 0.60 ± 0.02 V Z200 (X-transom) models: 0.62 ± 0.02 V 11. Start the engine and let it idle.

68F1F11

4-26

FUEL

Fuel system

High-pressure fuel line

23 N • m (2.3 kgf • m, 17.0 ft • Ib)

26 N • m (2.6 kgf • m, 19.2 ft • Ib)

4 LT

271

6 5 10

19 23 22

18 15

7 7

17 16

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

4-27

Part name Bolt Bolt Washer Fuel pipe Backup ring O-ring Bolt Bracket Fuel rail (port side) Fuel pipe Plug Backup ring O-ring Bracket Bolt Collar Fuel rail (starboard side)

Q’ty 4 8 8 1 4 4 4 1 1 1 1 1 1 1 6 4 1

23 N • m (2.3 kgf • m, 17.0 ft • Ib)

S68F4260C

Remarks M8 × 70 mm M6 × 16 mm

Not reusable Not reusable

M6 × 14 mm

Not reusable Not reusable

M8 × 55 mm

68F1F11

High-pressure fuel line 4

23 N • m (2.3 kgf • m, 17.0 ft • Ib)

26 N • m (2.6 kgf • m, 19.2 ft • Ib)

4 LT

271

6 5 10

19 23 22

18 15

7 7

17 16

No. 18 19 20 21 22 23

Part name Bolt Holder Holder Gasket set Fuel injector Gasket

68F1F11

Q’ty 6 6 6 6 6 12

23 N • m (2.3 kgf • m, 17.0 ft • Ib)

S68F4260C

Remarks M8 × 25 mm

Not reusable Not reusable

4-28

1 2 3 4 5 6 7 8 9

FUEL

Fuel system

High-pressure fuel pump

2 34

32 4

3 6

23 22

7 8

13 12 11

14 17 18 14 19 15 28 16 1415

31 29

4 5 10 5

27 30

39 38

37 36 35

25 26

24 S68F4270C

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

4-29

Part name Bolt Oil seal Cover O-ring Bolt Ball bearing O-ring Camshaft Ball bearing High-pressure fuel pump body O-ring Gasket High-pressure fuel pump O-ring Backup ring Joint O-ring

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

Remarks M6 × 35 mm Not reusable Not reusable

M8 × 10 mm Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable

68F1F11

High-pressure fuel pump 4

2 34

32 4

3 6

23 22

7 8

13 12 11

14 17 18 14 19 15 28 16 1415

31 29

4 5 10 5

27 30

39 38

37 36 35

25 26

24 S68F4270C

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

Part name Joint O-ring O-ring Joint Washer Bolt High-pressure fuel pump cover Washer Bolt Bolt Holder Screw Clamp Clamp Fuel hose Corrugated tube Fuel hose

68F1F11

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

Remarks Not reusable Not reusable

M8 × 70 mm

M8 × 40 mm M6 × 35 mm ø4 × 10 mm Not reusable

4-30

1 2 3 4 5 6 7 8 9

FUEL

Fuel system 4

2 34

32 4

3 6

23 22

7 8

13 12 11

14 17 18 14 19 15 28 16 1415

31 29

4 5 10 5

27 30

39 38

37 36 35

25 26

24 S68F4270C

No. 35 36 37 38 39 40

4-31

Part name O-ring Backup ring Fuel pressure sensor Plate Washer Bolt

Q’ty 1 1 1 1 2 2

Remarks Not reusable Not reusable

M8 × 20 mm

68F1F11

High-pressure fuel pump

Installing the joints 1. Install new O-rings 1, 2, and 3, and new backup rings 4 onto the joints. LT

271

2. Install the joints into the high-pressure fuel pump.

1 4 4 1 2

3 2

1 4

S68F4300C

1 S68F4280C

Installing the fuel pipes 1. Install new O-rings 1 and new backup rings 2 into the fuel pipes. 2. Install the fuel pipes onto the high-pressure fuel pump and fuel rails.

1 2

1 S68F4290C

Installing the fuel injectors 1. Install new gaskets 1 and 2, and new O-rings 3. 2. Install the fuel injectors onto the fuel rails.

68F1F11

4-32

1 2 3 4 5 6 7 8 9

POWR

Power unit Special service tools .....................................................................................5-1 Power unit....................................................................................................... 5-2 Checking the compression pressure .........................................................5-2 Removing the drive belt and sprockets ...................................................5-15 Checking the drive belt and sprockets.....................................................5-15 Installing the sprockets and drive belt .....................................................5-16 Removing the power unit.........................................................................5-17 Removing the flywheel magnet ...............................................................5-19 Removing the stator coil and pulser coil.................................................. 5-19 Removing the starter motor ..................................................................... 5-20 Intake manifold............................................................................................. 5-21 Removing the intake manifold .................................................................5-22 Checking the reed valve ..........................................................................5-22 Throttle lever and shift position switch .....................................................5-23 Cylinder head ...............................................................................................5-25 Removing the cylinder head .................................................................... 5-27 Checking the cylinder head ..................................................................... 5-27 Exhaust cover ..............................................................................................5-28 Removing the exhaust cover ................................................................... 5-29 Checking the pressure control valve .......................................................5-29 Installing the pressure control valve ........................................................ 5-29 Crankcase ..................................................................................................... 5-30

68F1F11

Cylinder block ..............................................................................................5-31 Removing the crankcase .........................................................................5-34 Disassembling the bearing housing......................................................... 5-34 Removing the piston and connecting rod assemblies and crankshaft assembly .............................................................................. 5-35 Disassembling the piston and connecting rod assemblies ......................5-35 Disassembling the crankshaft.................................................................. 5-36 Checking the oil pump driven gear and the oil pump drive gear ............. 5-36 Checking the bearings............................................................................. 5-36 Checking the piston diameter .................................................................. 5-36 Checking the cylinder bore ...................................................................... 5-37 Checking the piston clearance ................................................................5-37 Checking the piston rings ........................................................................5-37 Checking the piston ring side clearance.................................................. 5-38 Checking the piston pin boss bore .......................................................... 5-38 Checking the piston pin ...........................................................................5-38 Checking the connecting rod small end axial play................................... 5-39 Checking the connecting rod big end side clearance ..............................5-39 Checking the crankshaft ..........................................................................5-39 Assembling the crankshaft ...................................................................... 5-40 Assembling the bearing housing ............................................................. 5-41 Assembling the oil seal housing ..............................................................5-41 Assembling the piston and connecting rod assemblies........................... 5-41 Assembling the power unit ...................................................................... 5-42 Installing the power unit...........................................................................5-47

68F1F11

1 2 3 4 5 6 7 8 9

POWR

Power unit

Special service tools

Compression gauge YU-33223-1

Crankshaft bearing installer YB-06205-1

Universal magnet and rotor holder YU-01235

Needle bearing installer YB-06434 Bearing installer YB-41446

Primary sheave holder YS-01880 Driver handle YB-06071, YB-06229

Flywheel magnet holder YB-06139 Drive shaft seal installer YB-06348

Universal puller YB-06117 Standard piston ring installer YB-37462

5-1

68F1F11

Special service tools / Power unit

Power unit

Checking the compression pressure 1. Start the engine, warm it up for 5 minutes, and then turn it off. 2. Remove the engine stop lanyard clip from the engine stop lanyard switch on the remote control box.

NOTE: â&#x20AC;˘ If the compression pressure increases, check the pistons and piston rings for wear. Replace if necessary. â&#x20AC;˘ If the compression pressure does not increase, check the cylinder head gasket and cylinder head. Replace if necessary.

3. Remove all spark plugs, and then install the special service tools into a spark plug hole.

S68F5010C

CAUTION: Before removing the spark plugs, blow compressed air in the spark plug well to clear out any dirt or dust that may fall into the cylinder.

Compression gauge: YU-33223-1 4. Fully open the throttle, and then crank the engine until the reading on the compression gauge stabilizes. Minimum compression pressure (reference data): 470 kPa (4.7 kgf/cm2, 68 psi) 5. If the compression pressure is below specification and the compression pressure for each cylinder is unbalanced, add a small amount of engine oil to the cylinders, and then check the compression pressure again.

68F1F11

5-2

1 2 3 4 5 6 7 8 9

POWR

Power unit 5

1 T.

4 2

39 N • m (3.9 kgf • m, 28.8 ft • Ib)

12 10

14 E

15 17

16 18

20 21

S68F5020C

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

5-3

Part name Damper Flywheel magnet cover Grommet Bolt Tensioner Bolt Spring Bolt Holder Bracket Drive belt Bolt Washer Plate Drive sprocket Dowel Bolt

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

Remarks

M10 × 45 mm M8 × 45 mm M8 × 12 mm

M8 × 25 mm

M8 × 12 mm

68F1F11

Power unit 5

1 T.

4 2

39 N • m (3.9 kgf • m, 28.8 ft • Ib)

12 10

14 E

15 17

16 18

20 21

S68F5020C

No. 18 19 20 21

Part name Bracket Nut Driven sprocket Woodruff key

68F1F11

Q’ty 1 1 1 1

Remarks

5-4

1 2 3 4 5 6 7 8 9

POWR

Power unit 5

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

5-5

Part name Apron Rubber seal Screw Nut Bolt Collar Grommet Joint Hose Bolt Expansion chamber Grommet Gasket Joint Collar Bolt Clamp

Q’ty 1 1 1 1 2 4 2 1 1 9 1 4 1 1 9 2 1

Remarks

ø6 × 20 mm M6 × 16 mm

M6 × 16 mm

Not reusable

M6 × 16 mm

68F1F11

Power unit 5

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

Part name Power unit Dowel Gasket Plastic tie Bolt Bracket Holder Bolt Holder Washer Nut Bolt Bolt Clip Bushing Shift rod assembly Bolt

68F1F11

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

1 2 3 4 5 6 7 8 9

Remarks

Not reusable

M6 × 10 mm

M6 × 20 mm

M8 × 30 mm M8 × 135 mm

M8 × 30 mm

5-6

POWR

Power unit 5

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

5-7

Part name Flywheel magnet Nut Washer Bolt Holder Stator coil Screw Pulser coil Woodruff key Pointer Screw Cover Screw

Q’ty 1 1 1 4 1 1 3 1 1 1 1 1 2

Remarks

M6 × 35 mm

ø5 × 30 mm

ø6 × 10 mm ø5 × 20 mm

68F1F11

Power unit 5

29 N • m (2.9 kgf • m, 21.4 ft • Ib)

18 N • m (1.8 kgf • m, 13.3 ft • Ib) C

1 15 2 4 A

16 3

11 12

13 5

8 T.

9 N • m (0.9 kgf • m, 6.6 ft • Ib) S68F5060C

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

Part name Starter motor Bolt Plastic tie PTT relay lead Starter relay lead Terminal Nut Cap Positive battery lead Washer Nut Cap Bolt Cap Negative battery lead Bolt

68F1F11

Q’ty 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Remarks M8 × 45 mm Not reusable

M6 × 10 mm

M8 × 16 mm

5-8

1 2 3 4 5 6 7 8 9

POWR

Power unit 5

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

5-9

Part name Grommet Holder Screw Fuse holder Terminal plate Terminal Terminal Fuse holder Screw Screw Screw Fuse Relay Fuse Fuse Cover

Q’ty 1 1 2 1 4 8 8 1 6 3 4 2 2 3 1 1

Remarks

ø5 × 15 mm

ø3 × 10 mm ø5 × 20 mm ø5 × 10 mm 80 A 20 A 30 A

68F1F11

Power unit 5

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

Part name Power trim and tilt relay Bolt PTT relay lead Washer Nut Cap Ground lead Connector Bolt Bolt Rectifier Regulator Gasket Cover Bolt Clamp Cooling water hose Starter relay

68F1F11

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

1 2 3 4 5 6 7 8 9

Remarks M6 × 30 mm

M6 × 12 mm M6 × 30 mm Not reusable

M6 × 25 mm

5-10

POWR

Power unit 5

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

5-11

Part name Holder Screw Bolt Starter relay lead Cap Collar Grommet Collar Bolt Junction box Hook Holder Holder Holder Ground lead PTT motor lead Bolt

Q’ty 1 1 1 1 2 4 5 1 5 1 2 1 1 1 1 1 2

Remarks ø6 × 20 mm M6 × 10 mm

M6 × 30 mm

M6 × 10 mm

68F1F11

Power unit 5

10 9

2 11

1 13 14

15 16

16 5

5 5

3 5 5

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

Part name Bolt Cover Spark plug cap Ignition coil Corrugated tube Grommet Bolt Cover (port side) Injector driver cover Bolt Grommet Collar Collar Grommet Cover (starboard side) Bolt

68F1F11

6 Q’ty 4 1 6 6 6 4 12 1 1 4 4 4 10 10 1 10

S68F5090C

Remarks M6 × 14 mm

M5 × 20 mm

M6 × 35 mm

M6 × 25 mm

5-12

1 2 3 4 5 6 7 8 9

POWR

Power unit 5

No. 1 2 3 4 5 6 7 8

5-13

Part name Plastic tie Oxygen density sensor Bolt Cover Bolt Bracket Gasket Joint

Q’ty 1 1 2 1 3 1 1 1

Remarks Not reusable

M6 × 30 mm M6 × 30 mm Not reusable

68F1F11

Power unit 5

13 LT

572

15 10 14

1 3

4 1

4 8

2 5 5

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

Part name Injector driver ECM Bracket Bolt Bolt Holder Bolt Grommet Collar Collar Bolt Crank position sensor Screw Wiring harness Wiring harness

68F1F11

7 Q’ty 2 1 1 4 2 1 4 4 2 2 2 1 2 1 1

S68F5110C

Remarks

M6 × 20 mm M6 × 14 mm M6 × 35 mm

M6 × 25 mm ø5 × 12 mm

5-14

1 2 3 4 5 6 7 8 9

POWR

Power unit

Removing the drive belt and sprockets 1. Remove the flywheel magnet cover. 2. Remove the drive belt tensioner 1 and the tensioner spring 2, and then remove the drive belt 3.

7 6

3 S68F5150C

Universal magnet and rotor holder: YU-01235

5. Remove the driven sprocket 8. S68F5120C

3. Remove the tensioner bracket 4 and spring holder 5.

4 5

S68F5130C

4. Remove the drive sprocket 6 and the drive sprocket bracket 7.

Primary sheave holder 9: YS-01880 Universal puller 0: (commercially available)

S68F5140C

Checking the drive belt and sprockets 1. Check the interior and exterior of the drive belt for cracks, damage, or wear. Replace if necessary. 2. Check the drive sprocket and driven sprocket for cracks, damage, or wear. Replace if necessary.

5-15

68F1F11

Power unit

Installing the sprockets and drive belt 1. Install the Woodruff key 1, then the driven sprocket 2.

Universal magnet and rotor holder: YU-01235 3. Install the spring holder 5 and tensioner bracket 6.

2 E

6 5

S68F5180C

S68F5220C

4. Install the drive belt 7 from the drive sprocket side with its part number in the upright position, and then turn the belt a half turn counterclockwise to align it.

Primary sheave holder: YS-01880 2. Install the drive sprocket bracket 3 and the drive sprocket 4.

S68F5230C

5. Finger tighten the drive belt tensioner bolt 8, and then loosen it 90Â°.

6. Install the tensioner spring 9 onto the drive belt tensioner 0 and spring holder A.

S68F5200C

90Ë&#x161; 9 A

S68F5240C

S68F5210C

68F1F11

5-16

1 2 3 4 5 6 7 8 9

POWR

Power unit

7. Turn the flywheel magnet 120° clockwise to take up the drive belt slack.

120˚

S68F5250C

NOTE: Do not turn the flywheel magnet counterclockwise.

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

Universal magnet and rotor holder: YU-01235 8. Tighten the drive belt tensioner bolt to the specified torque. 4. Remove the clip 4 and shift rod bushing 5.

S68F5260C

T. R.

Drive belt tensioner bolt: 39 N·m (3.9 kgf·m, 28.8 ft·lb)

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

5. Remove the bracket 6.

1. Remove the flywheel magnet cover. 2. Disconnect the battery leads 1. S68F5290C

6. Disconnect the PTT switch coupler and trim sensor coupler (or connector).

5-17

68F1F11

Power unit 7. Remove the junction box cover, and then disconnect the PTT motor leads 7.

11. Remove the apron C and exhaust expansion chamber D. 12. Disconnect the cooling water hose E.

8. Disconnect the fuel hose 8 and the oil hose 9.

13. Remove the nuts F and the bolts G, then the power unit.

9. Remove the holder 0 and shift rod bracket bolts A.

10. Disconnect the cooling water pilot hose B.

S68F5330C

68F1F11

5-18

1 2 3 4 5 6 7 8 9

POWR

Power unit

Removing the flywheel magnet 1. Loosen the flywheel magnet nut.

NOTE: Apply force to the crankshaft end until the flywheel magnet comes off the tapered portion of the crankshaft.

Universal puller: YB-06117 3. Remove the Woodruff key.

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

Removing the stator coil and pulser coil 1. Remove the junction box cover 1. 2. Disconnect the stator coil couplers 2.

Flywheel magnet holder: YB-06139 2. Remove the flywheel magnet.

3. Disconnect the pulser coil coupler. 4. Remove the stator coil 3 and pulser coil 4.

CAUTION:

S68F5370C

To prevent damage to the engine or tools, screw in the puller set bolts evenly and completely so that the puller is parallel to the flywheel magnet.

5-19

68F1F11

Power unit

Removing the starter motor 1. Disconnect the starter relay lead 1 from the starter relay.

1 2 3 4 5 6 7 8 9

S68F5380C

2. Disconnect the PTT relay lead 2 from the starter motor. 3. Remove the starter motor 3.

68F1F11

S60V5510

5-20

POWR

Power unit

Intake manifold

1 N • m (0.1 kgf • m, 0.7 ft • Ib)

13 5 LT

242

4 12 1

5 6

8 11 9 8

11 11

10 11 10

10 N • m (1.0 kgf • m, 7.4 ft • Ib) S68F5390C

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

5-21

Part name Intake manifold Reed valve assembly Reed valve Reed valve Stopper Stopper Bolt Screw Holder Hose Hose Gasket Screw Gasket

Q’ty 1 6 12 12 12 12 2 12 2 6 6 6 60 1

Remarks

M6 × 30 mm ø5 × 16 mm

Not reusable

ø3 × 6 mm Not reusable

68F1F11

Intake manifold

Removing the intake manifold 1. Disconnect the hoses. 2. Remove the intake manifold bolts 1, and then remove the intake manifold.

Valve stopper height b: Z150, Z175 models: 7.8–8.4 mm (0.31–0.33 in) Z200 models: 8.7–9.3 mm (0.34–0.37 in)

1 2 3 4 5 6 7 8 9

S68F5400C

Checking the reed valve 1. Check the reed valves for bends a. Replace if above specification.

S60V5530

Valve bend limit a: 0.2 mm (0.008 in) 2. Measure the valve stopper height b. Replace if out of specification.

S60V5540

68F1F11

5-22

POWR

Power unit

Throttle lever and shift position switch

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

5-23

Part name Bolt Collar Wave washer Throttle lever Throttle link rod Nut Joint Washer Screw Plate Shift position switch Bracket Bolt Bolt Stopper screw assembly Bolt Bracket

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

Remarks M6 × 30 mm

ø4 × 16 mm

M6 × 12 mm M6 × 20 mm M8 × 25 mm

68F1F11

Throttle lever and shift position switch 5

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

Part name Collar Hose Hose Hose Holder Hose Bolt Ground lead Hose Ground lead Ground lead

68F1F11

Qâ&#x20AC;&#x2122;ty 2 6 3 2 1 1 6 1 1 1 1

1 2 3 4 5 6 7 8 9

Remarks

M6 Ă&#x2014; 12 mm

5-24

POWR

Power unit

Cylinder head

3 4 7

1 5 N • m (0.5 kgf • m, 3.7 ft • Ib) 2 11 N • m (1.1 kgf • m, 8.1 ft • Ib)

4 3 2 LT

572 T.

25 N • m (2.5 kgf • m, 18.4 ft • Ib)

1 6 T.

1 5 N • m (0.5 kgf • m, 3.7 ft • Ib) 2 11 N • m (1.1 kgf • m, 8.1 ft • Ib)

572

No. 1 2 3 4 5 6 7 8 9

5-25

Part name Spark plug Bolt Thermostat cover Gasket Thermostat Bolt Cylinder head cover Gasket Holder

Q’ty 6 8 2 2 2 36 2 2 1

S68F5420C

Remarks M6 × 40 mm Not reusable

M6 × 30 mm Not reusable

68F1F11

Cylinder head 5

12 13 14

15 16 17

572

5 7

11 10

5 1

9 8

4 T.

1 15 N • m (1.5 kgf • m, 11.1 ft • Ib) 2 29 N • m (2.9 kgf • m, 21.4 ft • Ib)

15 N • m (1.5 kgf • m, 11.1 ft • Ib) S68F5430C

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

Part name Thermoswitch Engine temperature sensor Washer Bolt Bolt Engine hanger Cylinder head Anode Screw Gasket Dowel Bolt Plate Bolt Cover Anode Grommet

68F1F11

Q’ty 2 1 1 28 4 2 2 7 7 2 4 1 1 1 1 1 1

Remarks

M8 × 60 mm M6 × 20 mm

ø4 × 12 mm Not reusable

M6 × 20 mm M5 × 12 mm

5-26

1 2 3 4 5 6 7 8 9

POWR

Power unit

Removing the cylinder head

Checking the cylinder head

1. Remove the spark plugs.

1. Eliminate carbon deposits from the combustion chambers and check for deterioration.

2. Remove the thermostat cover bolts and cylinder head cover bolts in the sequence shown.

2. Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in four directions as shown. Replace if above specification.

2 S60V5580 S68F5440C

3. Remove the cylinder head bolts in the sequence shown.

S60V5590

Cylinder head warpage limit: 0.1 mm (0.004 in)

S68F5450C

CAUTION: Do not scratch or damage the mating surfaces of the cylinder head and cylinder block.

5-27

68F1F11

Cylinder head / Exhaust cover

Exhaust cover

1 4 N • m (0.4 kgf • m, 3.0 ft • Ib) 2 8 N • m (0.8 kgf • m, 5.9 ft • Ib)

7 LT

572

6 5

10 11

572

8 9

12 S68F5460C

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

Part name Bolt Cover Gasket Spring Pressure control valve Grommet Bolt Exhaust cover Gasket Clamp Hose Clamp Hose

68F1F11

Q’ty 2 1 1 1 1 1 23 1 1 1 1 1 1

Remarks M6 × 20 mm Not reusable

M6 × 30 mm Not reusable

5-28

1 2 3 4 5 6 7 8 9

POWR

Power unit

Removing the exhaust cover 1. Remove the exhaust cover bolts in the sequence shown.

S68F5470C

Checking the pressure control valve 1. Remove the pressure control valve. 2. Check the pressure control valve for wear or damage. Replace if necessary. 3. Check the grommet for deformation. Replace if necessary. 4. Check the spring for fatigue or deformation. Replace it if necessary.

Installing the pressure control valve 1. Install a new gasket and the pressure control valve, and then tighten the bolts to the specified torques in two stages.

572

S68F5480C

T. R.

5-29

Pressure control valve cover bolt: 1st: 4 N·m (0.4 kgf·m, 3.0 ft·lb) 2nd: 8 N·m (0.8 kgf·m, 5.9 ft·lb)

68F1F11

Exhaust cover / Crankcase

Crankcase

No. 1 2 3 4 5 6 7 8 9 10

Part name Bolt Bolt Bolt Bolt Crankcase Oil seal housing O-ring Oil seal Oil seal Dowel

68F1F11

Q’ty 12 8 4 4 1 1 1 1 1 2

1 2 3 4 5 6 7 8 9

Remarks M8 × 30 mm M10 × 60 mm M6 × 25 mm M6 × 20 mm

Not reusable Not reusable Not reusable

5-30

POWR

Power unit

Cylinder block

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

Part name Oil seal Bearing housing O-ring Needle bearing Bolt Piston and connecting rod assembly Connecting rod bearing Seal ring Crankshaft Main bearing Circlip Oil pump drive gear Ball bearing Circlip Cap Stopper Bolt

Q’ty 1 1 2 1 12 6 6 9 1 2 2 1 1 1 2 2 4

Remarks

Not reusable Not reusable

M8 × 24 mm

Not reusable Not reusable

M6 × 20 mm

*: Loosen completely

5-31

68F1F11

Cylinder block 5

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

Part name Dowel Grommet O-ring Washer Oil pump driven gear Cylinder block Anode Screw Gasket Plug Gasket Cover Holder Bolt

68F1F11

Q’ty 2 1 1 1 1 1 8 8 2 2 1 1 2 6

1 2 3 4 5 6 7 8 9

Remarks

Not reusable

ø4 × 12 mm Not reusable Not reusable

M6 × 20 mm

5-32

POWR

Power unit 5

No. 1 2 3 4 5 6 7

5-33

Part name Clip Piston pin Piston Washer Needle bearing Ring set Connecting rod

Qâ&#x20AC;&#x2122;ty 12 6 6 12 6 6 6

Remarks Not reusable

68F1F11

Cylinder block

Removing the crankcase

Disassembling the bearing housing

1. Remove the bearing housing bolts.

1. Remove the oil seal. 2. Remove the needle bearing using a press.

2. Remove the oil seal housing. Crankshaft bearing installer 1: YB-06205-1

S68F5530C

3. Remove the crankcase bolts in the sequence shown.

68F1F11

5-34

1 2 3 4 5 6 7 8 9

POWR

Power unit

Removing the piston and connecting rod assemblies and crankshaft assembly 1. Remove the connecting rod bolts and the connecting rod caps, and then remove the piston and connecting rod assemblies.

a S68F5570C

NOTE: Be sure to keep the bearings in the order as they were removed.

Disassembling the piston and connecting rod assemblies

1. Remove the clips 1 with pliers, and then remove the piston pin 2 and needle bearing 3. S60V5720

2. Remove the top ring 4 and 2nd piston ring 5.

NOTE: â&#x20AC;˘ Be sure to keep the bearings in the order as they were removed. â&#x20AC;˘ Mark each piston with the identification number a of the corresponding cylinder. Also, mark each connecting rod and connecting rod cap with an identification number b as shown. â&#x20AC;˘ Do not mix the connecting rods and caps. Keep them organized in their proper groups. 2. Remove the crankshaft assembly.

5-35

68F1F11

Cylinder block

Disassembling the crankshaft

Checking the oil pump driven gear and the oil pump drive gear

1. Remove the seal rings 1.

1. Check the oil pump driven gear and the oil pump drive gear for cracks, damage, or wear. Replace if necessary.

Checking the bearings 1. Check the bearings for pitting or rumbling. Replace if necessary.

Checking the piston diameter

S68F5600C

NOTE: To remove the seal rings 1, widen the seal ring end gap a, and then remove the ring from the groove and the crankpin b.

1. Measure the piston outside diameter at the specified measuring point. Replace if out of specification.

a b

2. Remove the circlip 2, and then remove the ball bearing and oil pump drive gear.

S68F5610C

4 3

S68F5990C

Piston diameter a: 89.845–89.869 mm (3.5372–3.5381 in) Measuring point b: 10 mm (0.39 in) up from the bottom of the piston skirt Oversize piston diameter a: 1st: 90.095–90.119 mm (3.5470–3.5480 in) 2nd: 90.345–90.369 mm (3.5569–3.5578 in)

S68F5620C

Universal puller 3: (commercially available) Bearing separator 4: (commercially available)

68F1F11

5-36

1 2 3 4 5 6 7 8 9

POWR

Power unit

Checking the cylinder bore

Checking the piston clearance

1. Measure the cylinder bore (D1–D6) at measuring points a, b, and c, and in direction d (D1, D3, D5), which is parallel to the crankshaft, and direction e (D2, D4, D6), which is at a right angle to the crankshaft.

1. Calculate the piston clearance using the piston outside diameter and the cylinder bore specifications. Replace the piston and piston rings as a set or the cylinder block or all parts, or rebore the cylinder if out of specification. Piston clearance: 0.150–0.156 mm (0.0059–0.0061 in)

Checking the piston rings 1. Check the piston ring dimensions of B and T. Replace if out of specification. a: 10 mm (0.39 in) from the cylinder block surface b: 5 mm (0.20 in) above the exhaust port upper edge c: 5 mm (0.20 in) below the scavenging port lower edge

Cylinder bore (D1–D6): 90.000–90.020 mm (3.5433–3.5441 in) 2. Calculate the taper limit. Replace or rebore the cylinder block if above specification. Taper limit: D1–D5 (direction d) D2–D6 (direction e) 0.08 mm (0.0031 in) 3. Calculate the out-of-round limit. Replace or rebore the cylinder block if above specification.

B T S60V5840

Piston ring dimensions: Top ring and 2nd piston ring: B: 1.97–1.99 mm (0.0776–0.0783 in) T: 2.70–2.90 mm (0.1063–0.1142 in) 2. Level the piston rings 1 in a cylinder with a piston crown. 3. Check the piston ring end gap a at the specified measuring point. Replace if out of specification.

Out-of-round limit: D2–D1 (measuring point a) D6–D5 (measuring point c) 0.05 mm (0.0020 in)

5-37

68F1F11

Cylinder block

Checking the piston pin boss bore b

1. Measure the piston pin boss bore. Replace the piston if out of specification.

1 1

a S60V5870 S68F5A10C

Piston ring end gap a: Top ring: 0.30–0.40 mm (0.0118–0.0157 in) 2nd piston ring: 0.30–0.45 mm (0.0118–0.0177 in) Measuring point b: 20 mm (0.8 in)

Piston pin boss bore: 23.074–23.085 mm (0.9084–0.9089 in)

Checking the piston pin 1. Measure the piston pin diameter. Replace if out of specification.

Checking the piston ring side clearance 1. Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification.

Piston pin diameter: 23.065–23.070 mm (0.9081–0.9083 in)

S68F5A20C

Piston ring side clearance: Top ring and 2nd piston ring: 0.02–0.06 mm (0.0008–0.0024 in)

68F1F11

5-38

1 2 3 4 5 6 7 8 9

POWR

Power unit

Checking the connecting rod small end axial play 1. Measure the connecting rod small end axial play. Replace the bearing and connecting rod if above specification.

Checking the crankshaft 1. Measure the crankshaft journal diameter a and crankpin diameter b. Replace the crankshaft if out of specification.

a S60V5900 S60V5880

NOTE: To measure the axial play, set the dial gauge at the connecting rod small end and parallel to the crankshaft. Connecting rod small end axial play limit: 2.0 mm (0.08 in)

Checking the connecting rod big end side clearance 1. Measure the connecting rod big end side clearance a. Replace the connecting rod or crankshaft or both if out of specification.

b S68F5630C

Crankshaft journal diameter a: 53.975–53.991 mm (2.1250–2.1256 in) Crankpin diameter b: 35.985–36.000 mm (1.4167–1.4173 in) 2. Measure the crankshaft runout. Replace the crankshaft if above specification.

S60V5890

Connecting rod big end side clearance a: 0.12–0.26 mm (0.0047–0.0102 in) S68F5640C

5-39

68F1F11

Cylinder block

CAUTION:

Crankshaft runout limit: 0.02 mm (0.0008 in)

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

Assembling the crankshaft 1. Install the oil pump drive gear 1.

Bearing separator 3: (commercially available) General pipe 5: b = 42 mm (1.65 in)

2 a

3. Install the seal rings 6.

1 E

d 3

S68F5650C E

CAUTION: Do not reuse the oil pump drive gear, always replace it with a new one. General pipe 2: a = 50 mm (1.97 in) Bearing separator 3: (commercially available)

S68F5680C

NOTE: First pass the seal ring 6 over the crankpin c, and then widen the seal ring end gap d to install the ring into the crankshaft groove. 4. Install the main bearings onto the crankshaft.

2. Install the ball bearing 4, then the circlip.

5 b E

4 E

S68F5690C

NOTE: Face the dowel hole on the main bearings toward the bottom of the power unit.

S68F5660C

68F1F11

5-40

1 2 3 4 5 6 7 8 9

POWR

Power unit

Assembling the bearing housing 1. Install the needle bearing.

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

Needle bearing installer: YB-06434 2. Apply grease to the new oil seal, and then install it into the bearing housing.

Drive shaft seal installer 1: YB-06348 Driver handle 2: YB-06229 Bearing installer 3: YB-41446 Driver handle 4: YB-06071

Assembling the piston and connecting rod assemblies 1. Assemble the pistons 1, connecting rods 2, needle bearings 3, washers 4, piston pins 5, and new piston pin clips 6.

Bearing installer 1: YB-41446 Driver handle 2: YB-06071

Assembling the oil seal housing 1. Apply grease to the new oil seals, and then install them into the oil seal housing.

NOTE: • Face the embossed “YAMAHA” mark a on the connecting rod in the same direction as the “UP” mark b on the piston. • Always use new piston pin clips. • Be sure to align the piston pin clip end with the piston pin slot c.

5-41

68F1F11

Cylinder block 2. Install the 2nd piston ring 7 and top ring 8 onto the pistons.

CAUTION: Do not scratch the pistons or break the piston rings. NOTE: Install the piston rings with the recess for the locating pin facing up toward the piston crown.

Assembling the power unit

S68F5760C

NOTE: â&#x20AC;˘ Fit dowels 1 on the cylinder block into the dowel holes 2 in the main bearings. â&#x20AC;˘ Align the seal ring end gaps a with the crankcase center line.

1. Install the oil pump driven gear onto the cylinder block.

2. Set the crankshaft in the cylinder block.

68F1F11

5-42

1 2 3 4 5 6 7 8 9

POWR

Power unit

3. Install the pistons into the cylinders with the “UP” mark on the piston crown facing towards the flywheel magnet.

NOTE: • Apply engine oil to the pistons and piston rings before installation. • Be sure to install the piston and connecting rod assemblies into the corresponding cylinders according to the marks b made during disassembly. Also, be sure to install the assemblies with an “S” mark on the starboard side, and the assemblies with a “P” mark on the port side. Standard piston ring installer: YB-37462 4. Install the connecting rod bearings and connecting rod caps onto the connecting rods, and then tighten the connecting rod bolts 3 to the specified torques in five stages.

b S68F5770C

1 UP

S68F5950C UP

NOTE: • Align the identification numbers c on the connecting rod caps and connecting rods, which you made during disassembly. • Apply engine oil to the connecting rod bearings, connecting rod caps, and connecting rod bolts before installation.

S68F5780C T. R.

Connecting rod bolt 3: 1st: 19 N·m (1.9 kgf·m, 14.0 ft·lb) 2nd: 36 N·m (3.6 kgf·m, 26.6 ft·lb) 3rd: Loosen completely 4th: 19 N·m (1.9 kgf·m, 14.0 ft·lb) 5th: 36 N·m (3.6 kgf·m, 26.6 ft·lb)

5. Install the bearing housing onto the cylinder block.

5-43

68F1F11

Cylinder block NOTE: Do not get any sealant on the journals. 8. Install the crankcase onto the cylinder block, and then install the crankcase bolts finger tight. NOTE: Apply engine oil to the crankcase bolts before installation. 9. Install the bearing housing bolts finger tight. NOTE: Install the bearing housing with the arrow mark facing toward the cylinder block. 6. Install the oil seal housing onto the cylinder block.

10. Install the oil seal housing bolts finger tight.

S68F5800C

NOTE: Install the oil seal housing with the projections facing toward the cylinder block. 7. Apply sealant to the mating surface of the crankcase.

68F1F11

S68F5530C

5-44

1 2 3 4 5 6 7 8 9

POWR

Power unit

11. Tighten the crankcase bolts to the specified torques in two stages and in the sequence shown.

S68F5820C

NOTE: Apply LOCTITE 572 to the exhaust cover bolts before installation.

T. R.

1–8 Crankcase bolt (M10): 1st: 20 N·m (2.0 kgf·m, 14.8 ft·lb) 2nd: 39 N·m (3.9 kgf·m, 28.8 ft·lb) 9–J Crankcase bolt (M8): 1st: 10 N·m (1.0 kgf·m, 7.4 ft·lb) 2nd: 18 N·m (1.8 kgf·m, 13.3 ft·lb)

NOTE: Tighten crankcase bolts 1–8 to the specified torques in two stages first, and then tighten crankcase bolts 9–J to the specified torques in two stages.

Exhaust cover bolt: 1st: 4 N·m (0.4 kgf·m, 3.0 ft·lb) 2nd: 8 N·m (0.8 kgf·m, 5.9 ft·lb)

14. Install the dowels, a new gasket, and the cylinder head, and then tighten the cylinder head bolts to the specified torques in two stages and in the sequence shown.

12. Tighten the bearing housing bolts and oil seal housing bolts. 13. Install the new gasket and exhaust cover, and then tighten the exhaust cover bolts to the specified torques in two stages and in the sequence shown.

S68F5830C

NOTE: Apply engine oil to the cylinder head bolts before installation.

T. R.

5-45

Cylinder head bolt: 1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb) 2nd: 29 N·m (2.9 kgf·m, 21.4 ft·lb) 68F1F11

Cylinder block 15. Install the thermoswitches and the engine temperature sensor onto the cylinder head.

19. Install the intake manifold assembly, and then tighten the intake manifold bolts 4 to the specified torque.

16. Install a new gasket and the cylinder head cover, and then tighten the cylinder head cover bolts to the specified torques in two stages and in the sequence shown.

20. Connect the hoses.

4 17. Install the new gaskets, thermostats and the thermostat covers, and then tighten the thermostat cover bolts to the specified torques in two stages and in the sequence shown.

S68F5850C

T. R.

Intake manifold bolt 4: 10 N·m (1.0 kgf·m, 7.4 ft·lb)

21. Install the starter motor, pulser coil, and stator coil onto the power unit.

S68F5840C

NOTE: Apply LOCTITE 572 to the cylinder head cover bolts and thermostat cover bolts before installation.

T. R.

Cylinder head cover bolt and thermostat cover bolt: 1st: 5 N·m (0.5 kgf·m, 3.7 ft·lb) 2nd: 11 N·m (1.1 kgf·m, 8.1 ft·lb)

18. Install the spark plugs, tighten them finger tight, then to the specified torque with a spark plug wrench.

T. R.

Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb)

68F1F11

5-46

1 2 3 4 5 6 7 8 9

POWR

Power unit

Installing the power unit 1. Clean the power unit matching surface, and install new dowels 1 and a new gasket 2.

3. Install the shift rod bushing 7 and clip 8.

2. Install the power unit 3, and then tighten the power unit mounting bolts and nuts 4 to the specified torque.

4. Connect the cooling water hose 9. 5. Install the exhaust expansion chamber 0.

5 S68F5A30C

6. Install the hose joint.

CAUTION: Make sure to push the shift rod lever 5 to the outside when placing the power unit onto the bottom cowling, otherwise, interference with the shift position switch plate a may occur and the shift rod lever could be damaged.

A B

NOTE: Make sure to place the shift rod lever 5 in the shift rod lever bracket 6 after placing the power unit securely onto the bottom cowling.

T. R.

5-47

S68F5970C

NOTE: First insert the hose joint A into the exhaust expansion chamber hose B, and then insert the apron securely in the hose joint.

Power unit mounting bolt and nut 4: 21 N·m (2.1 kgf·m, 15.5 ft·lb)

68F1F11

Cylinder block 7. Install the apron.

C b S68F5980C

CAUTION:

Make sure not to get the flushing hose C caught between the mating surfaces b of the apron when installing it.

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

11. Connect the PTT switch coupler and trim sensor coupler (or connector). 12. Install the bracket H.

T. R.

Apron bolt: 8 N·m (0.8 kgf·m, 5.9 ft·lb)

8. Connect the cooling water pilot hose D.

S68F5910C

13. Tighten the shift rod bracket bolts I and install the holder J. S68F5880C

9. Connect the fuel hose E and oil hose F.

10. Connect the PTT motor leads G and then tighten the PTT motor lead bolts to the specified torque.

68F1F11

5-48

1 2 3 4 5 6 7 8 9

POWR

Power unit

14. Connect the shift cable K and throttle cable L, and then adjust their lengths. For adjustment procedures, see Chapter 3, “Adjusting the throttle cable,” and “Checking the gear shift operation.”

15. Install the Woodruff key and flywheel magnet. 16. Tighten the flywheel magnet nut to the specified torque.

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: 187 N·m (18.7 kgf·m, 137.9 ft·lb)

17. Install all removed parts.

5-49

68F1F11

LOWR

Lower unit Special service tools .....................................................................................6-1 Lower unit (regular rotation model) ............................................................. 6-4 Removing the lower unit ............................................................................6-7 Removing the water pump and shift rod.................................................... 6-7 Checking the water pump and shift rod .....................................................6-8 Propeller shaft housing (regular rotation model) ....................................... 6-9 Removing the propeller shaft housing assembly..................................... 6-11 Disassembling the propeller shaft assembly ...........................................6-11 Disassembling the propeller shaft housing.............................................. 6-11 Checking the propeller shaft housing ......................................................6-12 Checking the propeller shaft.................................................................... 6-12 Assembling the propeller shaft assembly ................................................ 6-12 Assembling the propeller shaft housing...................................................6-12 Drive shaft and lower case (regular rotation model) ................................6-14 Removing the drive shaft.........................................................................6-15 Disassembling the drive shaft housing ....................................................6-15 Disassembling the forward gear ..............................................................6-15 Disassembling the lower case .................................................................6-15 Checking the pinion and forward gear.....................................................6-16 Checking the bearings............................................................................. 6-16 Checking the drive shaft ..........................................................................6-16 Checking the lower case .........................................................................6-16 Assembling the lower case...................................................................... 6-16 Assembling the forward gear................................................................... 6-17 Assembling the drive shaft housing......................................................... 6-17 Installing the drive shaft...........................................................................6-18 Installing the propeller shaft housing .......................................................6-18 Installing the water pump and shift rod....................................................6-19 Installing the lower unit ............................................................................6-20 Shimming (regular rotation model) ............................................................ 6-22 Shimming.................................................................................................6-23 Selecting the pinion shims....................................................................... 6-23 Selecting the forward gear shims ............................................................ 6-24 Selecting the reverse gear shims ............................................................ 6-25 Backlash (regular rotation model)..............................................................6-26 Measuring the forward and reverse gear backlash .................................6-26

68F1F11

Lower unit (counter rotation model) .......................................................... 6-29 Removing the lower unit ..........................................................................6-32 Removing the water pump and shift rod.................................................. 6-32 Checking the water pump and shift rod ...................................................6-33 Propeller shaft housing (counter rotation model) .................................... 6-34 Removing the propeller shaft housing assembly..................................... 6-36 Disassembling the propeller shaft assembly ...........................................6-36 Disassembling the forward gear ..............................................................6-36 Disassembling the propeller shaft housing.............................................. 6-37 Checking the propeller shaft housing ......................................................6-37 Checking the propeller shaft.................................................................... 6-37 Assembling the propeller shaft housing...................................................6-37 Drive shaft and lower case (counter rotation model) ...............................6-39 Removing the drive shaft.........................................................................6-41 Disassembling the drive shaft housing ....................................................6-41 Disassembling the reverse gear ..............................................................6-41 Disassembling the lower case .................................................................6-41 Checking the pinion and reverse gear.....................................................6-42 Checking the bearings............................................................................. 6-42 Checking the drive shaft ..........................................................................6-42 Checking the lower case .........................................................................6-42 Assembling the lower case...................................................................... 6-42 Assembling the reverse gear................................................................... 6-43 Assembling the drive shaft housing......................................................... 6-43 Installing the drive shaft...........................................................................6-44 Installing the propeller shaft housing .......................................................6-44 Installing the water pump and shift rod....................................................6-45 Installing the lower unit ............................................................................6-46 Shimming (counter rotation model) ........................................................... 6-48 Shimming.................................................................................................6-49 Selecting the pinion shims....................................................................... 6-49 Selecting the reverse gear shims ............................................................ 6-50 Selecting the forward gear shims ............................................................ 6-51 Selecting the propeller shaft shims.......................................................... 6-52 Backlash (counter rotation model)............................................................. 6-52 Measuring the forward and reverse gear backlash .................................6-52

68F1F11

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

Special service tools

Gland nut wrench YB-34447

Driver handle YB-06071

Bearing housing puller YB-06207

Oil seal installer YB-06195 Forward gear needle bearing and tapered roller bearing installer YB-06200

Universal puller YB-06117 Needle bearing installer YB-06434

Slide hammer and adapters YB-06096 Drive shaft holder YB-06201

Drive shaft needle bearing installer and remover YB-06196 Roller bearing installer YB-06246

6-1

Puller claw YB-06523 68F1F11

Special service tools

Needle bearing installer and remover YB-06194

Shift rod push arm YB-06052

Bearing cup installer YB-06258

Pinion shim selecting tools YB-34432-7, YB-34432-11A

Pinion gear bushing installer YB-06029

Forward gear shim selecting tools YB-34446-1, YB-34446-3, YB-34446-4, YB-34446-8

Needle bearing guide plate YB-06213

Bearing installer YB-06261

68F1F11

1 2 3 4 5 6 7 8 9

Shimming gauge YB-34468-1A

Backlash indicator gauge YB-06265

6-2

LOWR

Lower unit

Magnetic plate YB-07003

Forward bearing race installer YB-06336

Dial gauge YU-03097

Magnetic flexible stand YU-34481

Ring nut wrench YB-06578

Bearing puller legs YB-06334

6-3

68F1F11

Special service tools / Lower unit (regular rotation model)

Lower unit (regular rotation model)

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

Part name Lower unit Bolt Bolt Trim tab Spacer Propeller Washer Washer Cotter pin Nut Dowel Bolt Grommet Bolt O-ring Cover

68F1F11

Q’ty 1 6 1 1 1 1 1 1 1 1 2 1 1 2 2 2

1 2 3 4 5 6 7 8 9

Remarks M10 × 45 mm M10 × 70 mm

Not reusable

M10 × 45 mm M6 × 42 mm

6-4

LOWR

Lower unit 6

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

6-5

Part name Shift rod Oil seal Oil seal housing O-ring Spring Circlip Bolt Joint Woodruff key Bolt Cover Seal Water pump housing O-ring Insert cartridge O-ring Collar

Q’ty 1 1 1 1 1 1 3 1 1 4 1 1 1 1 1 1 1

Remarks Not reusable Not reusable

M6 × 20 mm

M8 × 45 mm

Not reusable Not reusable

68F1F11

Lower unit (regular rotation model) 6

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

Part name Spacer Washer Wave washer Impeller Outer plate cartridge Gasket Dowel Rubber seal Plate Check screw Gasket Drain screw

68F1F11

Qâ&#x20AC;&#x2122;ty 1 2 1 1 1 1 2 1 1 1 2 1

1 2 3 4 5 6 7 8 9

Remarks

Not reusable

6-6

LOWR

Lower unit

Removing the lower unit 1. Drain the gear oil. For draining procedures, see Chapter 3, “Changing the gear oil.” 2. Set the gear shift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller.

Removing the water pump and shift rod 1. Remove the water pump assembly and shift rod assembly 1.

3. Mark the trim tab 1 at the area shown, and then remove it. 4. Remove the lower mount covers, and then disconnect the speedometer hose. 5. Loosen the bolts, and then remove the lower unit from the upper case.

6-7

68F1F11

Lower unit (regular rotation model)

Checking the water pump and shift rod 1. Check the water pump housing for deformation. Replace if necessary.

1 2 3 4 5 6 7 8 9

2. Check the impeller and insert cartridge for cracks or wear. Replace if necessary. 3. Check the Woodruff key 1 and the keyway a in the drive shaft for wear. Replace if necessary.

a 1

S68F6290C

4. Check the shift rod for cracks or wear. Replace if necessary.

68F1F11

6-8

LOWR

Lower unit

Propeller shaft housing (regular rotation model)

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

6-9

Part name Shift rod joint Ball Shift slider Ball Ball Spring Dog clutch Cross pin Spring Propeller shaft Reverse gear shim Washer Reverse gear Thrust washer Ball bearing O-ring Propeller shaft housing

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

Remarks

Not reusable Not reusable

68F1F11

Propeller shaft housing (regular rotation model) 6

No. 18 19 20 21 22 23 24 25

Part name Straight key Needle bearing Oil seal Claw washer Ring nut Cooling water inlet cover Nut Screw

68F1F11

Q’ty 1 1 2 1 1 2 1 1

1 2 3 4 5 6 7 8 9

Remarks

Not reusable

ø5 × 45 mm

6-10

LOWR

Lower unit

Removing the propeller shaft housing assembly

Disassembling the propeller shaft housing

1. Straighten the claw washer tabs a, and then remove the ring nut and claw washer.

1. Remove the reverse gear.

Slide hammer and adapters 1: YB-06096 Gland nut wrench 1: YB-34447 2. Pull out the propeller shaft housing assembly.

2. Remove the ball bearing using a press.

S68F6060C

CAUTION: Bearing housing puller 2: YB-06207 Universal puller 3: YB-06117

Disassembling the propeller shaft assembly 1. Remove the spring 1, then the cross pin 2, dog clutch 3, balls 4, spring 5, shift slider 6, and shift rod joint 7.

6-11

Do not reuse the bearing, always replace it with a new one. Bearing splitter plate 2: (commercially available) 3. Remove the oil seals and needle bearing.

68F1F11

Propeller shaft housing (regular rotation model) Drive shaft needle bearing installer and remover 3: YB-06196 Driver handle 4: YB-06071

Checking the propeller shaft housing 1. Clean the propeller shaft housing using a soft brush and cleaning solvent, and then check it for cracks. Replace if necessary. 2. Check the teeth and dogs of the reverse gear for cracks or wear. Replace the gear if necessary. 3. Check the bearings for pitting or rumbling. Replace if necessary.

Checking the propeller shaft 1. Check the propeller shaft for bends or wear. Replace if necessary. 2. Check the dog clutch, shift rod joint and shift slider for cracks or wear. Replace if necessary.

Assembling the propeller shaft assembly

NOTE: Install the needle bearing with the manufacture identification mark a facing toward the oil seal (propeller side). Driver handle 1: YB-06071 Drive shaft needle bearing installer and remover 2: YB-06196 Depth b: 24.75–25.25 mm (0.974–0.994 in) 2. Apply grease to new oil seals, and then install them into the propeller shaft housing to the specified depth.

1. Assemble the propeller shaft assembly as shown.

Assembling the propeller shaft housing 1. Install the needle bearing into the propeller shaft housing to the specified depth.

NOTE: Install an oil seal halfway into the propeller shaft housing, then the other oil seal. Oil seal installer 3: YB-06195 Driver handle 4: YB-06071 Depth c: 4.75–5.25 mm (0.187–0.207 in)

68F1F11

6-12

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

3. Install the thrust washer 5 and new ball bearing 6 onto the reverse gear 7 using a press.

NOTE: Install the ball bearing with the manufacture identification mark d facing outward (propeller side). Forward gear needle bearing and tapered roller bearing installer 8: YB-06200 4. Install the reverse gear assembly into the propeller shaft housing using a press.

Needle bearing installer 9: YB-06434

6-13

68F1F11

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

Drive shaft and lower case (regular rotation model)

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

Part name Drive shaft Sleeve Cover Oil seal Bolt Drive shaft housing Needle bearing O-ring Pinion shim Thrust bearing Lower case Needle bearing assembly Pinion Forward gear shim Taper roller bearing assembly Needle bearing Forward gear

68F1F11

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

1 2 3 4 5 6 7 8 9

Remarks

Not reusable

M8 × 25 mm

Not reusable

6-14

LOWR

Lower unit

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

S69J6186

CAUTION: S68S6150

Drive shaft holder 1: YB-06201

Disassembling the drive shaft housing 1. Remove the cover, oil seals, and needle bearing.

Do not reuse the bearing, always replace it with a new one. Bearing splitter plate 1: (commercially available) 2. Remove the needle bearings from the forward gear using a chisel.

S68S6160

CAUTION: Drive shaft needle bearing installer and remover 1: YB-06196 Driver handle 2: YB-06071

Disassembling the forward gear

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

Disassembling the lower case 1. Remove the taper roller bearing outer race and shim(s).

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

6-15

68F1F11

Drive shaft and lower case (regular rotation model) NOTE: Install the claws as shown. Slide hammer and adapters 1: YB-06096 Puller claw 2: YB-06523 2. Remove the needle bearing.

CAUTION: Add or remove shim(s), if necessary, if replacing the forward gear or lower case. Bearing cup installer 1: YB-06258 Driver handle 2: YB-06071

Needle bearing installer and remover 3: YB-06194 Driver handle 4: YB-06071

2. Install the needle bearing outer case into the lower case.

Checking the pinion and forward gear 1. Check the teeth of the pinion, and the teeth and dogs of the forward gear for cracks or wear. Replace if necessary.

Checking the bearings 1. Check the bearings for pitting or rumbling. Replace if necessary.

Checking the drive shaft 1. Check the drive shaft for bends or wear. Replace if necessary.

Checking the lower case 1. Check the skeg and torpedo for cracks or damage. Replace the lower case if necessary.

Assembling the lower case 1. Install the original shim(s) and taper roller bearing outer race.

68F1F11

NOTE: Apply gear oil to the needle bearing outer case before installation. Roller bearing installer 3: YB-06246 Pinion gear bushing installer 4: YB-06029 Needle bearing guide plate 5: YB-06213 3. Install the needle bearing into the needle bearing outer case. NOTE: Apply gear oil or grease to the needle bearing before installation.

6-16

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

Assembling the forward gear 1. Install new needle bearings into the forward gear to the specified depth.

Bearing installer 1: YB-06261 Driver handle 2: YB-06071 Depth a: 20.95–21.45 mm (0.825–0.844 in) Depth b: 4.45–4.95 mm (0.175–0.195 in)

Drive shaft needle bearing installer and remover 1: YB-06196 Driver handle 2: YB-06071 Depth a: 5.75–6.25 mm (0.226–0.246 in) 2. Apply grease to new oil seals, and then install them into the drive shaft housing to the specified depth.

2. Install a new taper roller bearing into the forward gear using a press.

Needle bearing installer 3: YB-06434

Assembling the drive shaft housing 1. Install the needle bearing into the drive shaft housing to the specified depth.

6-17

NOTE: Install an oil seal halfway into the drive shaft housing, then the other oil seal. Oil seal installer 3: YB-06195 Driver handle 4: YB-06071 Depth b: 0.25–0.75 mm (0.010–0.030 in)

68F1F11

Drive shaft and lower case (regular rotation model)

Installing the drive shaft

4. Tighten the drive shaft housing bolts.

1. Install the forward gear into the lower case.

Installing the propeller shaft housing

2. Install the drive shaft housing 1, thrust bearing 2, and original shim(s) 3 onto the drive shaft 4.

1. Install the washer 1 and propeller shaft assembly 2 into the propeller shaft housing assembly 3. 2. Apply grease to a new O-ring, and then install it onto the propeller shaft housing.

CAUTION: Add or remove shim(s), if necessary, if replacing the drive shaft housing or drive shaft. 3. Install the sleeve, drive shaft and drive shaft housing into the lower case, then the pinion and pinion nut, and then tighten the nut to the specified torque.

3. Install the original shim(s) 4 and propeller shaft housing assembly 5 into the lower case, and then install the straight key 6, claw washer 7, and ring nut 8.

S63P6300

NOTE: Install the drive shaft by lifting it up slightly, then aligning it with the pinion and the spline of the drive shaft.

CAUTION: Drive shaft holder 5: YB-06201

T. R.

Pinion nut: 93 N·m (9.3 kgf·m, 68.6 ft·lb)

68F1F11

Add or remove shim(s), if necessary, if replacing the reverse gear, ball bearing, propeller shaft housing, thrust washer, or lower case.

6-18

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

4. Tighten the ring nut to the specified torque.

NOTE: • To secure the ring nut, bend one tab a of the claw washer into a slot in the ring nut. • Bend all other tabs toward the propeller shaft housing assembly.

T. R.

Gland nut wrench 9: YB-34447

3. Install the Woodruff key into the drive shaft.

Ring nut 8: 142 N·m (14.2 kgf·m, 104.7 ft·lb)

4. Align the groove in the impeller 5 with the Woodruff key 6, and then install the impeller onto the drive shaft.

Installing the water pump and shift rod 1. Install the shift rod assembly 1.

5. Install the washers 7, wave washer 8, spacer 9, and collar 0 onto the drive shaft.

2. Install a new gasket 2, the outer plate cartridge 3, and dowels 4.

6-19

68F1F11

Drive shaft and lower case (regular rotation model) NOTE: • The collar and spacer should fit together firmly. • While pulling the drive shaft up, install the collar with an appropriate tool a that fits over the drive shaft as shown. 6. Install the new O-ring A and insert cartridge B into the pump housing C.

A 4

Installing the lower unit 1. Set the gear shift to the neutral position at the lower unit.

NOTE: • When installing the pump housing, apply grease to the inside of the housing, and then turn the drive shaft clockwise while pushing down the pump housing. • Align the cover projection d with the hole e in the pump housing.

B b

2. Align the center of the set pin a with the alignment mark b on the bottom cowling.

c S68F6150C

NOTE: Align the insert cartridge projections b with the holes c in the pump housing. 7. Install the new O-ring D and pump housing assembly E into the lower case, tighten the bolts F, and then install the seal G and cover H.

Shift rod push arm: YB-06052

68F1F11

6-20

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

3. Install the two dowels 1 into the lower unit. 4. Install the lower unit into the upper case, and then tighten the lower case mounting bolts 2 to the specified torque. 5. Connect the speedometer hose, and then install the lower mount covers. 6. Install the trim tab 3 to its original position, and then tighten the trim tab bolt 4 to the specified torque.

WARNING

T. R.

Lower case mounting bolt 2: 39 N·m (3.9 kgf·m, 28.8 ft·lb) Trim tab bolt 4: 39 N·m (3.9 kgf·m, 28.8 ft·lb)

6-21

NOTE: If the grooves in the propeller nut 5 do not align with the cotter pin hole, tighten the nut until they are aligned.

7. Install the propeller and propeller nut, and then tighten the nut finger tight. Place a block of wood between the anticavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque.

• Do not hold the propeller with your hands when loosening or tightening it. • Be sure to disconnect the battery leads from the battery and the clip from the engine stop lanyard switch. • Put a block of wood between the anticavitation plate and propeller to keep the propeller from turning.

Propeller nut 5: 54 N·m (5.4 kgf·m, 39.8 ft·lb)

68F1F11

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

Shimming (regular rotation model)

F P

1 2 3 4 5 6 7 8 9

B4 T3

61.0

T2 B1 37.0

A2 B2

S68F6170C

((L)Z150, (V)Z175, (L)Z200, VZ200) * : 17.2 16.3 (VZ150)

68F1F11

6-22

LOWR

Lower unit

Shimming

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

NOTE: • Shimming is not required when assembling the original lower case and inner parts. • Shimming is required when assembling the original inner parts and a new lower case. • Shimming is required when replacing the inner part(s).

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

Pinion shim selecting tools: YB-34432-7 4, YB-34432-11A 5

T. R.

Pinion nut: 93 N·m (9.3 kgf·m, 68.6 ft·lb)

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

S68V6750

NOTE: Measure the pinion at three points to find the clearance average. 5. Select the pinion shim(s) (T3).

2. Install the drive shaft 1, thrust bearing 2, and drive shaft housing 3 onto the special service tools.

6-23

68F1F11

Shimming (regular rotation model) 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

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

NOTE: Tighten the nut four turns after it contacts the spring. Forward gear shim selecting tools: YB-34446-1 2, YB-34446-3 3, YB-34446-4 4, YB-34446-8 5 NOTE: “F” is the deviation of the lower case dimension from standard. The “F” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “F” mark is unreadable, assume that “F” is zero and check the backlash when the unit is assembled.

3. Measure the clearance (M) between the gauge pin and the press plate.

Calculation formula: Specified value (M0) = 1.60 + F/100 mm Example: If “F” is (+5), then M0 = 1.60 + (+5)/100 mm = 1.60 + 0.05 mm = 1.65 mm If “F” is (–3), then M0 = 1.60 + (–3)/100 mm = 1.60 – 0.03 mm = 1.57 mm 2. Install the taper roller bearing 1 onto the special service tools.

68F1F11

6-24

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

4. Select the forward gear shims (T1). Calculation formula: (L)Z150, (V)Z175, (L)Z200, VZ200: Specified value (M0) = 1.80 – R/100 mm VZ150: Specified value (M0) = 0.90 – R/100 mm T1

S63P6430

NOTE: The sum of T1 and M should not be more than M0. Calculation formula: Forward gear shim thickness (T1) = M0 – M Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm

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

Example: (L)Z150, (V)Z175, (L)Z200, VZ200 If “R” is (+5), then M0 = 1.80 – (+5)/100 mm = 1.80 – 0.05 mm = 1.75 mm If “R” is (–3), then M0 = 1.80 – (–3)/100 mm = 1.80 + 0.03 mm = 1.83 mm Example: VZ150 If “R” is (+5), then M0 = 0.90 – (+5)/100 mm = 0.90 – 0.05 mm = 0.85 mm If “R” is (–3), then M0 = 0.90 – (–3)/100 mm = 0.90 + 0.03 mm = 0.93 mm 2. Install the ball bearing, thrust washer, and reverse gear onto the propeller shaft housing. 3. Set the special service tool on the thrust washer. 4. Measure the clearance (M) between the special service tool 1 and the reverse gear 2 as shown.

1 2 NOTE: “R” is the deviation of the lower case dimension from standard. The “R” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “R” mark is unreadable, assume that “R” is zero and check the backlash when the unit is assembled.

6-25

S68F6180C

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

68F1F11

Shimming (regular rotation model) / Backlash (regular rotation model) Shimming gauge 1: YB-34468-1A 5. Select the reverse gear shim(s) (T2).

Backlash (regular rotation model)

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.

S63P6450

NOTE: The sum of T2 and M should be more than M0. Calculation formula: Reverse gear shim thickness (T2) = M0 â&#x20AC;&#x201C; M

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

Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm

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.

68F1F11

6-26

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

5. Set the lower unit upside down.

(L)Z150, (V)Z175, (L)Z200, VZ200: Forward gear backlash

Shim thickness

Less than 0.25 mm (0.0098 in)

To be decreased by (0.36 – M) × 0.72

More than 0.46 mm (0.0181 in)

To be increased by (M – 0.36) × 0.72

VZ150:

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

Shim thickness

Less than 0.71 mm (0.0280 in)

To be decreased by (0.86 – M) × 0.67

More than 1.01 mm (0.0398 in)

To be increased by (M – 0.86) × 0.67

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.

Forward gear backlash: (L)Z150, (V)Z175, (L)Z200, VZ200: 0.25–0.46 mm (0.0098–0.0181 in) VZ150: 0.71–1.01 mm (0.0280–0.0398 in) 7. Add or remove shim(s) if out of specification.

6-27

NOTE: Tighten the propeller nut A while turning the drive shaft until the drive shaft can no longer be turned.

68F1F11

Backlash (regular rotation model) 10. Slowly turn the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction.

Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm 12. Remove the special service tools, and then install the water pump assembly.

Reverse gear backlash: (L)Z150, (V)Z175, (L)Z200, VZ200: 0.73–1.30 mm (0.0287–0.0512 in) VZ150: 0.78–1.38 mm (0.0307–0.0543 in) 11. Add or remove shim(s) if out of specification. (L)Z150, (V)Z175, (L)Z200, VZ200: Reverse gear backlash

Shim thickness

Less than 0.73 mm (0.0287 in)

To be increased by (1.02 – M) × 0.72

More than 1.30 mm (0.0512 in)

To be decreased by (M – 1.02) × 0.72

VZ150: Reverse gear backlash

Shim thickness

Less than 0.78 mm (0.0307 in)

To be increased by (1.08 – M) × 0.67

More than 1.38 mm (0.0543 in)

To be decreased by (M – 1.08) × 0.67

M: Measurement

68F1F11

6-28

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

Lower unit (counter rotation model)

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

6-29

Part name Lower unit Bolt Bolt Trim tab Spacer Propeller Washer Washer Cotter pin Nut Dowel Bolt Grommet Bolt O-ring Cover

Q’ty 1 6 1 1 1 1 1 1 1 1 2 1 1 2 2 2

Remarks M10 × 45 mm M10 × 70 mm

Not reusable

M10 × 45 mm M6 × 42 mm

68F1F11

Lower unit (counter rotation model) 6

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

Part name Shift rod Oil seal Oil seal housing O-ring Spring Circlip Bolt Plug Woodruff key Bolt Cover Seal Water pump housing O-ring Insert cartridge O-ring Collar

68F1F11

Q’ty 1 1 1 1 1 1 3 1 1 4 1 1 1 1 1 1 1

1 2 3 4 5 6 7 8 9

Remarks Not reusable Not reusable

M6 × 20 mm

M8 × 45 mm

Not reusable Not reusable

6-30

LOWR

Lower unit 6

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

6-31

Part name Spacer Washer Wave washer Impeller Outer plate cartridge Gasket Dowel Rubber seal Plate Check screw Gasket Drain screw

Qâ&#x20AC;&#x2122;ty 1 2 1 1 1 1 2 1 1 1 2 1

Remarks

Not reusable

68F1F11

Lower unit (counter rotation model)

Removing the water pump and shift rod 1. Remove the water pump assembly and shift rod assembly 1.

WARNING • Do not hold the propeller with your hands when loosening or tightening it. • Be sure to disconnect the battery leads from the battery and the clip from the engine stop lanyard switch. • Put a block of wood between the anticavitation plate and propeller to keep the propeller from turning. 3. Mark the trim tab 1 at the area shown, and then remove it. 4. Loosen the bolts, and then remove the lower unit from the upper case.

68F1F11

6-32

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

Checking the water pump and shift rod 1. Check the water pump housing for deformation. Replace if necessary. 2. Check the impeller and insert cartridge for cracks or wear. Replace if necessary. 3. Check the Woodruff key 1 and the keyway a in the drive shaft for wear. Replace if necessary.

a 1

S68F6290C

4. Check the shift rod for cracks or wear. Replace if necessary.

6-33

68F1F11

Lower unit (counter 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 Shift rod joint Ball Shift slider Ball Ball Spring Dog clutch Cross pin Spring Forward gear shim Forward gear Thrust washer Taper roller bearing assembly Propeller shaft Thrust bearing Propeller shaft shim O-ring

68F1F11

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

1 2 3 4 5 6 7 8 9

Remarks

Not reusable

6-34

LOWR

Lower unit 6

No. 18 19 20 21 22 23 24 25 26

6-35

Part name Propeller shaft housing Straight key Needle bearing Oil seal Claw washer Ring nut Cooling water inlet cover Nut Screw

Qâ&#x20AC;&#x2122;ty 1 1 1 2 1 1 2 1 1

Remarks

Not reusable

68F1F11

Propeller shaft housing (counter rotation model)

Removing the propeller shaft housing assembly

Disassembling the propeller shaft assembly

1. Straighten the claw washer tabs a, and then remove the ring nut and claw washer.

1. Remove the spring 1, then the cross pin 2, dog clutch 3, shift slider, balls, spring, and shift rod joint. 2. Remove the forward gear assembly.

2 3 Gland nut wrench 1: YB-34447 2. Pull out the propeller shaft housing assembly.

S63P6500

Disassembling the forward gear 1. Remove the bearing outer race, taper roller bearing, and thrust washer from the forward gear.

1 Bearing housing puller 2: YB-06207 Universal puller 3: YB-06117 S68F6230C

CAUTION: Do not reuse the bearing, always replace it with a new one. Bearing splitter plate 1: (commercially available)

68F1F11

6-36

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

Disassembling the propeller shaft housing 1. Remove the oil seals and needle bearing.

NOTE: Install the needle bearing with the manufacture identification mark a facing toward the oil seal (propeller side). Drive shaft needle bearing installer and remover 1: YB-06196 Driver handle 2: YB-06071

Driver handle 1: YB-06071 Drive shaft needle bearing installer and remover 2: YB-06196

Checking the propeller shaft housing 1. Clean the propeller shaft housing using a soft brush and cleaning solvent, and then check it for cracks or damage. Replace if necessary. 2. Check the teeth and dogs of the forward gear for cracks or wear. Replace the gear if necessary.

Depth b: 24.75–25.25 mm (0.974–0.994 in) 2. Apply grease to new oil seals, and then install them into the propeller shaft housing to the specified depth.

3. Check the bearings for pitting or rumbling. Replace if necessary.

Checking the propeller shaft 1. Check the propeller shaft for bends or wear. Replace if necessary. 2. Check the dog clutch, shift rod joint, and shift slider for cracks or wear. Replace if necessary.

Assembling the propeller shaft housing 1. Install the needle bearing into the propeller shaft housing to the specified depth.

NOTE: Install an oil seal halfway into the propeller shaft housing, then the other oil seal. Oil seal installer 3: YB-06195 Driver handle 4: YB-06071 Depth c: 4.75–5.25 mm (0.187–0.207 in)

6-37

68F1F11

Propeller shaft housing (counter rotation model) 3. Install the original shim(s) 5 and thrust bearing 6 with the propeller shaft into the propeller shaft housing.

S68F6320C

CAUTION: Add or remove shim(s), if necessary, if replacing the propeller shaft, thrust bearing, or propeller shaft housing. 4. Install a new taper roller bearing 7 and the bearing outer race 8 into the propeller shaft housing using a press.

Ring nut wrench 9: YB-06578 6. Install the spring C, balls, and shift slider D into the propeller shaft, and then install the cross pin E and spring F.

F C E S63P6570

Ring nut wrench 9: YB-06578 5. Install the thrust washer 0, forward gear A, and dog clutch B using a press.

68F1F11

6-38

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

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

6-39

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

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

Remarks

Not reusable

M8 × 25 mm

Not reusable

68F1F11

Drive shaft and lower case (counter rotation model) 6

No. 18 19

Part name Needle bearing Reverse gear

68F1F11

Qâ&#x20AC;&#x2122;ty 2 1

1 2 3 4 5 6 7 8 9

Remarks Not reusable

6-40

LOWR

Lower unit

Removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the reverse gear and thrust bearing.

S67H6270R

Bearing splitter plate 1: (commercially available) S68S6150

Drive shaft holder 1: YB-06201

2. Remove the needle bearings from the reverse gear using a chisel.

Disassembling the drive shaft housing 1. Remove the cover, oil seals, and needle bearing.

S68S6160

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

Disassembling the lower case Drive shaft needle bearing installer and remover 1: YB-06196 Driver handle 2: YB-06071

1. Remove the roller bearing and shim(s).

Disassembling the reverse gear 1. Remove the roller bearing inner race from the reverse gear using a press.

Slide hammer and adapters 1: YB-06096 Bearing puller legs 2: YB-06334

6-41

68F1F11

Drive shaft and lower case (counter rotation model) 2. Remove the needle bearing from the lower case.

CAUTION: Add or remove shim(s), if necessary, if replacing the reverse gear roller bearing or lower case. Forward bearing race installer 1: YB-06336 Driver handle 2: YB-06071 2. Install the needle bearing outer case into the lower case.

Needle bearing installer and remover 3: YB-06194 Driver handle 4: YB-06071

Checking the pinion and reverse gear 1. Check the teeth of the pinion, and the teeth and dogs of the reverse gear for cracks or wear. Replace if necessary.

Checking the bearings 1. Check the bearings for pitting or rumbling. Replace if necessary.

Checking the drive shaft 1. Check the drive shaft for bends or wear. Replace if necessary.

Checking the lower case 1. Check the skeg and torpedo for cracks or damage. Replace the lower case if necessary.

Assembling the lower case 1. Install the original shim(s) and roller bearing into the lower case.

68F1F11

6-42

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

Assembling the reverse gear

Assembling the drive shaft housing

1. Install new needle bearings into the reverse gear to the specified depth.

1. Install the needle bearing into the drive shaft housing to the specified depth.

Bearing installer 1: YB-06261 Driver handle 2: YB-06071 Depth a: 20.95–21.45 mm (0.825–0.844 in) Depth b: 4.45–4.95 mm (0.175–0.195 in) 2. Install the roller bearing inner race into the reverse gear using a press.

Needle bearing installer 3: YB-06434

NOTE: Install an oil seal halfway into the drive shaft housing, then the other oil seal. Oil seal installer 3: YB-06195 Driver handle 4: YB-06071 Depth b: 0.25–0.75 mm (0.01–0.03 in)

6-43

68F1F11

Drive shaft and lower case (counter rotation model)

Installing the drive shaft

Installing the propeller shaft housing

1. Install the reverse gear into the lower case.

1. Install the original shim(s) 1 and propeller shaft housing assembly 2 into the lower case, and then install the straight key 3, claw washer 4, and ring nut 5.

2. Install the drive shaft housing 1, thrust bearing 2, and original shim(s) 3 onto the drive shaft 4.

CAUTION: Add or remove shim(s), if necessary, if replacing the drive shaft housing or drive shaft. 3. Install the sleeve, drive shaft, and drive shaft housing into the lower case, then the pinion and pinion nut, and then tighten the nut to the specified torque.

CAUTION: Add or remove shim(s), if necessary, if replacing the forward gear, taper roller bearing, propeller shaft housing, thrust washer, or lower case.

S63P6300

NOTE: Install the drive shaft by lifting it up slightly, then aligning it with the pinion and the spline of the drive shaft.

Drive shaft holder 5: YB-06201

T. R.

Pinion nut: 93 N·m (9.3 kgf·m, 68.6 ft·lb)

68F1F11

6-44

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

2. Tighten the ring nut to the specified torque.

NOTE: • To secure the ring nut, bend one tab a of the claw washer into a slot in the ring nut. • Bend all other tabs toward the propeller shaft housing assembly.

T. R.

Gland nut wrench 6: YB-34447

3. Install the Woodruff key into the drive shaft.

Ring nut 5: 142 N·m (14.2 kgf·m, 104.7 ft·lb)

4. Align the groove in the impeller 5 with the Woodruff key 6, and then install the impeller onto the drive shaft.

Installing the water pump and shift rod 1. Install the shift rod assembly 1.

5. Install the washers 7, wave washer 8, spacer 9, and collar 0 onto the drive shaft.

2. Install a new gasket 2, the outer plate cartridge 3, and dowels 4.

6-45

68F1F11

Drive shaft and lower case (counter rotation model) NOTE: • The collar and spacer should fit together firmly. • While pulling the drive shaft up, install the collar with an appropriate tool a that fits over the drive shaft as shown. 6. Install the new O-ring A and insert cartridge B into the pump housing C.

A 4

Installing the lower unit 1. Set the gear shift to the neutral position at the lower unit.

2. Align the center of the set pin a with the mark b on the bottom cowling.

c S68F6150C

Shift rod push arm: YB-06052

68F1F11

6-46

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

3. Install the two dowels 1 into the lower unit. 4. Install the lower unit into the upper case, and then tighten the lower case mounting bolts 2 to the specified torque. 5. Install the trim tab 3 to its original position, and then tighten the trim tab bolt 4 to the specified torque.

T. R.

Lower case mounting bolt 2: 39 N·m (3.9 kgf·m, 28.8 ft·lb) Trim tab bolt 4: 39 N·m (3.9 kgf·m, 28.8 ft·lb)

NOTE: If the grooves in the propeller nut 5 do not align with the cotter pin hole, tighten the nut until they are aligned. Propeller nut 5: 54 N·m (5.4 kgf·m, 39.8 ft·lb)

6. Install the propeller and propeller nut, and then tighten the nut finger tight. Place a block of wood between the anticavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque.

6-47

68F1F11

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

Shimming (counter rotation model)

F P

1 2 3 4 5 6 7 8 9

B4 T3

61.0

T2 TÂ´4 B1 36.5 B2 A1 16.7 A2 A4 A5 B5 B6

68F1F11

B7 S68F6330C

6-48

LOWR

Lower unit

Shimming

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

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

Pinion shim selecting tools: YB-34432-7 4, YB-34432-11A 5

T. R.

Pinion nut: 93 N·m (9.3 kgf·m, 68.6 ft·lb)

S68V6750

NOTE: Measure the pinion at three points to find the clearance average. 5. Select the pinion shim(s) (T3).

2. Install the drive shaft 1, thrust bearing 2, and drive shaft housing 3 onto the special service tools.

6-49

68F1F11

Shimming (counter rotation model) NOTE: The sum of T3 and M should not be more than M0.

3. Turn the thrust bearing two or three times to seat the roller bearing, and then measure the bearing height (M).

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

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

NOTE: Measure the roller bearing at three points to find the clearance average. 4. Select the reverse gear shim(s) (T1).

NOTE: “F” is the deviation of the lower case dimension from standard. The “F” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “F” mark is unreadable, assume that “F” is zero and check the backlash when the unit is assembled. Calculation formula: Specified value (M0) = 29.10 + F/100 mm Example: If “F” is (+5), then M0 = 29.10 + (+5)/100 mm = 29.10 + 0.05 mm = 29.15 mm If “F” is (–3), then M0 = 29.10 + (–3)/100 mm = 29.10 – 0.03 mm = 29.07 mm

S63P6760

NOTE: The sum of T1 and M should not be more than M0. Calculation formula: Reverse gear shim thickness (T1) = M0 – M Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm

2. Set the thrust bearing 1 on the roller bearing 2 as shown.

68F1F11

6-50

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

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

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

3 4

S68F6280C

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

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

Shimming gauge 3: YB-34468-1A 5. Select the forward gear shim(s) (T2).

Calculation formula: Specified value (M0) = 1.30 – R/100 mm Example: If “R” is (+5), then M0 = 1.30 – (+5)/100 mm = 1.30 – 0.05 mm = 1.25 mm If “R” is (–3), then M0 = 1.30 – (–3)/100 mm = 1.30 + 0.03 mm = 1.33 mm 2. Install the thrust washer 1 and taper roller bearing 2 onto the forward gear.

S63P6790

NOTE: The sum of T2 and M should be more than M0. Calculation formula: Forward gear shim thickness (T2) = M0 – M Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm

3. Set the special service tool on the thrust washer.

6-51

68F1F11

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

Selecting the propeller shaft shims 1. Install the shim(s) 1, thrust bearing 2, propeller shaft 3, and taper roller bearing 4 into the propeller shaft housing.

NOTE: Add or remove shim(s) if the free play is out of specification. Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm

Backlash (counter rotation model)

Measuring the forward and reverse gear backlash 2. Measure the propeller shaft free play as shown.

Propeller shaft free play: 0.25–0.35 mm (0.0098–0.0138 in)

1. Remove the water pump assembly. 2. Set the gear shift to the neutral position at the lower unit.

Shift rod push arm: YB-06052

Magnetic flexible stand 5: YU-34481 Dial gauge 6: YU-03097 3. Select the propeller shaft shim(s) (T’4).

T´4

68F1F11

S63P6820

6-52

1 2 3 4 5 6 7 8 9

LOWR

Lower unit

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: 0.20–0.44 mm (0.0079–0.0173 in) 7. Add or remove shim(s) if out of specification. Forward gear backlash

Shim thickness

Less than 0.20 mm (0.0079 in)

To be increased by (0.32 – M) × 0.72

More than 0.44 mm (0.0173 in)

To be decreased by (M – 0.32) × 0.72

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. Install the propeller 7, the spacer 8 (without the washer 9), then the washer 0 as shown.

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

6-53

68F1F11

Backlash (counter rotation model) NOTE: Tighten the propeller nut A while turning the propeller until the propeller can no longer be turned. 10. Turn the shift rod to the reverse position c with the shift rod push arm. 11. Turn the drive shaft clockwise until the dog clutch B 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: 0.97–1.30 mm (0.0381–0.0512 in) 16. Add or remove shim(s) if out of specification.

12. Turn the shift rod to the neutral position d with the shift rod push arm. 13. Turn the drive shaft counterclockwise approximately 30°.

Reverse gear backlash

Shim thickness

Less than 0.97 mm (0.0381 in)

To be decreased by (1.14 – M) × 0.72

More than 1.30 mm (0.0512 in)

To be increased by (M – 1.14) × 0.72

M: Measurement Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm 17. Remove the special service tools, and then install the water pump assembly. 14. Turn the shift rod to the reverse position c with the shift rod push arm. 15. Slowly turn the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction.

68F1F11

6-54

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit Special service tools .....................................................................................7-1 Bottom cowling .............................................................................................. 7-2 Upper case...................................................................................................... 7-6 Disassembling the upper case ................................................................7-10 Checking the upper case.........................................................................7-10 Removing the drive shaft bushing (X-transom model) ............................ 7-11 Checking the drive shaft bushing (X-transom model)..............................7-11 Installing the drive shaft bushing (X-transom model) ..............................7-11 Assembling the upper case ..................................................................... 7-11 Steering arm .................................................................................................7-13 Removing the steering arm ..................................................................... 7-14 Installing the steering arm ....................................................................... 7-14 Installing the upper case..........................................................................7-15 Power trim and tilt unit ................................................................................ 7-16 Removing the power trim and tilt unit ......................................................7-23 Checking the hydraulic pressure ............................................................. 7-24 Disassembling the power trim and tilt motor............................................7-26 Checking the power trim and tilt motor ....................................................7-27 Assembling the power trim and tilt motor ................................................ 7-29 Removing the reservoir ...........................................................................7-29 Disassembling the gear pump housing ...................................................7-29 Checking the gear pump .........................................................................7-31 Assembling the gear pump housing ........................................................ 7-31 Disassembling the tilt cylinder and trim cylinders .................................... 7-32 Checking the tilt cylinder and trim cylinder .............................................. 7-33 Assembling the tilt piston and trim pistons .............................................. 7-34 Assembling the power trim and tilt unit....................................................7-35 Bleeding the power trim and tilt unit ........................................................ 7-37 Installing the power trim and tilt unit ........................................................ 7-38 Bleeding the power trim and tilt unit (built-in) ..........................................7-39 Clamp brackets ............................................................................................ 7-41 Removing the clamp brackets .................................................................7-43 Installing the clamp brackets ................................................................... 7-43 Adjusting the trim sensor cam .................................................................7-43 Power trim and tilt electrical system.......................................................... 7-45 Checking the fuse....................................................................................7-46 Checking the power trim and tilt relay .....................................................7-46 Checking the power trim and tilt switch ...................................................7-47 Checking the trim sensor.........................................................................7-47

68F1F11

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

Special service tools

Slide hammer and adapters YB-06096

Trim and tilt wrench YB-06548

Drive shaft needle bearing installer and remover YB-06196

End screw wrench YB-06175-1A

Driver handle YB-06071

Up relief fitting 90890-06773 Down relief fitting 90890-06774

Hydraulic pressure gauge 90890-06776

7-1

68F1F11

Special service tools / Bottom cowling

Bottom cowling

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

Part name Shift rod Clip Bushing Washer Shift lever Washer Bushing Grease nipple Bracket Ball Spring Bolt Circlip Grommet Bolt Ground lead Washer

68F1F11

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 2 1 1 1 1 1 1 1 1 4 1 1

1 2 3 4 5 6 7 8 9

Remarks

M8 Ă&#x2014; 35 mm

7-2

BRKT

Bracket unit 7

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

7-3

Part name Bolt Plate Bolt Holder Bolt Retaining plate Grommet Bottom cowling Speedometer hose Grommet Grommet Screw Adapter Hose joint Plastic tie Flushing hose

Q’ty 2 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1

Remarks M6 × 20 mm M6 × 16 mm M6 × 20 mm

ø5 × 20 mm

Not reusable

68F1F11

Bottom cowling 7

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

Part name Ground lead Bolt Cover Gasket Grommet Collar Grommet Grommet Collar Bolt Washer Lever Wave washer Bushing Plate Bolt Bushing

68F1F11

Q’ty 1 8 1 1 2 2 4 4 4 3 3 3 3 3 3 6 3

1 2 3 4 5 6 7 8 9

Remarks M6 × 20 mm Not reusable

M6 × 16 mm

M6 × 30 mm

7-4

BRKT

Bracket unit 7

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

7-5

Part name Bolt Stay Spring Cowling lock lever Water outlet Bolt Bracket Grommet Power trim and tilt switch Bolt Cable holder Bolt Bracket Cover

Q’ty 3 3 3 3 1 2 1 2 1 1 1 2 1 1

Remarks M6 × 16 mm

M6 × 16 mm

M6 × 16 mm M6 × 16 mm

68F1F11

Bottom cowling / Upper case

Upper case

9 9

572 T.

51 N • m (5.1 kgf • m, 37.6 ft • Ib)

4 3 5

6 7

20 19

2 1

18 17 16 15 14 LT

572

21 11

13 12

23 LT

71 N • m (7.1 kgf • m, 52.4 ft • Ib)

572 S68F7030C

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

Part name Nut Washer Upper mount Bracket Washer Washer Washer Bolt Bushing Nut Washer Bolt Mount housing Washer Lower mount Washer Washer

68F1F11

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

Remarks

M12 × 190 mm

M10 × 45 mm

7-6

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit 7

9 9

572 T.

51 N • m (5.1 kgf • m, 37.6 ft • Ib)

4 3 5

6 7

20 19

2 1

18 17 16 15 14 LT

572

21 11

13 12

23 LT

71 N • m (7.1 kgf • m, 52.4 ft • Ib)

572 S68F7030C

No. 18 19 20 21 22 23 24

7-7

Part name Ground lead Bolt Upper case assembly Ground lead Bolt Bolt Rubber seal

Q’ty 1 2 1 1 3 1 1

Remarks M14 × 180 mm

M10 × 45 mm M6 × 10 mm

68F1F11

Upper case 7

21 N • m (2.1 kgf • m, 15.5 ft • Ib)

572

GM 4

572 R.

18 N • m (1.8 kgf • m, 13.3 ft • Ib)

15 21

16 17 18

22 18

572

19 26 LT

572

27 23 T.

18 N • m (1.8 kgf • m, 13.3 ft • Ib)

18 N • m (1.8 kgf • m, 13.3 ft • Ib) S68F7040C

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

Part name Bolt Bolt Gasket Joint Upper exhaust guide Gasket Lower exhaust guide Bolt Gasket Exhaust manifold Bolt Gasket Muffler Bolt Rubber damper Clip Gasket

68F1F11

Q’ty 2 2 1 1 1 1 1 4 1 1 4 1 1 5 2 2 1

Remarks M8 × 45 mm M8 × 30 mm Not reusable

Not reusable

M8 × 30 mm Not reusable

M8 × 45 mm Not reusable

M8 × 45 mm

Not reusable

7-8

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit 7

21 N • m (2.1 kgf • m, 15.5 ft • Ib)

572

GM 4

572 R.

18 N • m (1.8 kgf • m, 13.3 ft • Ib)

15 21

16 17 18

22 18

572

19 26 LT

572

27 23 T.

18 N • m (1.8 kgf • m, 13.3 ft • Ib)

18 N • m (1.8 kgf • m, 13.3 ft • Ib) S68F7040C

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

Part name Dowel Upper case Rubber seal Pipe Rubber seal Bushing Circlip Gasket Muffler Gasket

Q’ty 2 1 1 1 1 1 1 1 1 1

Remarks

X-transom model X-transom model Not reusable

X-transom model

7-9

68F1F11

Upper case

Disassembling the upper case 1. Remove the muffler assembly 1 and gasket 2 from the upper case 3.

Ă&#x2C6;

S68F7070C

4. Remove the lower exhaust guide 8 from the upper exhaust guide 9.

8 S68F7050C

Ă&#x2C6; X-transom model

2. Remove the muffler 4, cooling water pipe 5, and rubber dampers 6.

6 S68F7080C

Checking the upper case 1. Check the rubber dampers for deterioration. Replace if necessary.

S68F7060C

3. Remove the exhaust manifold 7.

68F1F11

2. Check the cooling water pipe for deformation or corrosion. Replace if necessary. 3. Check the exhaust guide, exhaust manifold, and muffler for damage or corrosion. Replace if necessary.

7-10

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

Removing the drive shaft bushing (X-transom model) 2

1. Remove the circlip and then drive shaft bushing. LT

572

S68F7120C

S68F7090C

1. Check the drive shaft bushing for wear or cracks. Replace if necessary.

Checking the drive shaft bushing (X-transom model)

Slide hammer and adapters 1: YB-06096

Lower exhaust guide bolt: 18 N·m (1.8 kgf·m, 13.3 ft·lb)

2. Install a new gasket 3, the exhaust manifold 4, and bolts, and then tighten the bolts to the specified torque.

Installing the drive shaft bushing (X-transom model) 1. Install the drive shaft bushing and circlip.

572

S68F7130C

S68F7110C T. R.

Drive shaft needle bearing installer and remover 1: YB-06196 Driver handle 2: YB-06071

Assembling the upper case 1. Install a new gasket 1, the lower exhaust guide 2, and bolts, and then tighten the bolts to the specified torque.

7-11

Exhaust manifold bolts: 18 N·m (1.8 kgf·m, 13.3 ft·lb)

3. Install the rubber dampers 5 and clips 6 onto the muffler 7. 4. Install the cooling water pipe 8 onto the muffler 7. 5. Install a new gasket and the muffler 7 onto the exhaust guide 9, and then tighten the bolts to the specified torque.

68F1F11

Upper case 9. Install the bracket D and bolts.

572 S68F7140C

T. R.

Muffler bolt: 18 N·m (1.8 kgf·m, 13.3 ft·lb)

10. Install the lower mounts E and mount housings F.

6. Install the muffler assembly 0 by inserting the tip of the cooling water pipe A into the joint hole a of the upper case. 7. Tighten the muffler assembly bolts B to the specified torque.

572

0 A

A S68F7150C

È X-transom model

T. R.

Muffler assembly bolt B: 21 N·m (2.1 kgf·m, 15.5 ft·lb)

8. Install the upper mounts C and bolts into the upper case.

68F1F11

7-12

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

Steering arm

36 N • m (3.6 kgf • m, 26.6 ft • Ib)

2 A

5 6

12 8 9

S68F7170C

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

7-13

Part name Steering arm Washer Bushing Bracket assembly O-ring Bushing Washer Steering yoke Circlip Nut Trim stopper Damper

Q’ty 1 1 2 1 1 1 1 1 1 2 2 1

Remarks

Not reusable

68F1F11

Steering arm

Removing the steering arm 1. Remove the circlip 1. 2. Remove the steering yoke 2 by striking it with a plastic hammer.

4. Install the steering arm 3 into the steering yoke 9 by aligning the center a of the yoke with the center b of the steering arm. 3. Remove the steering arm from the swivel bracket by pulling the arm off the bracket.

5. Install the circlip 0.

Installing the steering arm 1. Install the washer 1 and bushing 2 onto the steering arm 3. 2. Place the swivel bracket 4 in an upright position, and then install the steering arm onto the swivel bracket.

3. Install the bushing 5, O-ring 6, bushing 7, and washer 8 onto the swivel bracket.

68F1F11

7-14

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

T. R.

6. Inject grease into the grease nipple until grease comes out from both the upper and lower bushings c.

Upper mounting nut 2: 51 N·m (5.1 kgf·m, 37.6 ft·lb) Lower mounting nut 3: 71 N·m (7.1 kgf·m, 52.4 ft·lb)

Installing the upper case 1. Install the upper and lower mounting bolts into the swivel bracket 1 simultaneously. 2. Install the upper mounting nuts 2 and lower mounting nuts 3, and then tighten them to the specified torques.

7-15

68F1F11

Steering arm / Power trim and tilt unit

Power trim and tilt unit

3 A

9 9

8 7

6 9 A

A A

242 S60X7010

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

Part name Power trim and tilt unit PTT motor lead Shaft Plastic tie Circlip Bolt Washer Shaft Bushing Bolt Ground lead

68F1F11

Q’ty 1 2 1 3 1 2 2 1 6 1 1

Remarks

Not reusable

M8 × 16 mm

M6 × 10 mm

7-16

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit 7

7 1 T.

0.7 N · m (0.07 kgf · m, 0.5 ft · lb)

5 N · m (0.5 kgf · m, 3.7 ft · Ib)

2 9 3

4 5 6

5 N · m (0.5 kgf · m, 3.7 ft · Ib)

S60X7180

No. 1 2 3 4 5 6 7 8 9 10

7-17

Part name Power trim and tilt motor Reservoir Reservoir cap O-ring O-ring Bolt Bolt O-ring Filter Joint

Q’ty 1 1 1 1 1 3 4 1 1 1

Remarks

Not reusable

68F1F11

Power trim and tilt unit 7

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

Part name Screw Stator Armature O-ring Screw Brush holder Brush 2 Brush 1 Brush holder Brush spring PTT motor base Oil seal Bearing Screw

68F1F11

Q’ty 1 1 1 1 2 1 1 1 1 2 1 1 1 2

1 2 3 4 5 6 7 8 9

Remarks ø4 × 15 mm

Not reusable

ø4 × 12 mm

Not reusable Not reusable

ø4 × 15 mm

7-18

BRKT

Bracket unit 7

6 N · m (0.6 kgf · m, 4.4 ft · Ib)

1 T.

15 25 16 22

8 N · m (0.8 kgf · m, 5.9 ft · Ib)

17 18 19

3 4 5 6 7

8 N · m (0.8 kgf · m, 5.9 ft · Ib)

3 N · m (0.3 kgf · m, 2.2 ft · Ib)

10 S60X7200

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

7-19

Part name Bolt Gear pump assembly Ball Shuttle piston O-ring Main valve Ball Bolt Bolt Circlip Manual valve O-ring O-ring Backup ring Spring Absorber valve pin Ball

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

Remarks M5 × 16 mm

Not reusable

Not reusable Not reusable

68F1F11

Power trim and tilt unit 7

6 N · m (0.6 kgf · m, 4.4 ft · Ib)

1 T.

15 25 16 22

8 N · m (0.8 kgf · m, 5.9 ft · Ib)

17 18 19

3 4 5 6 7

8 N · m (0.8 kgf · m, 5.9 ft · Ib)

3 N · m (0.3 kgf · m, 2.2 ft · Ib)

10 S60X7200

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

Part name Up-relief valve seat O-ring Filter O-ring Down-relief valve Valve pin O-ring Valve seat Pin Ball O-ring

68F1F11

Q’ty 1 1 2 1 1 1 4 1 1 1 1

Remarks Not reusable Not reusable

Not reusable

7-20

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit 7

1 A

13 14 T.

15 16 17 18 19 20

130 N · m (13.0 kgf · m, 96.0 ft · lb)

22 23 24

7 8

4 21

6 3

11 12

5 6

8 T.

9 10 2

78 N · m (7.8 kgf · m, 57.5 ft · lb)

11 12

96 N · m (9.6 kgf · m, 70.8 ft · Ib)

S63P7350

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

7-21

Part name Tilt ram Trim ram Cylinder body Free piston Backup ring O-ring Dust seal Seal Trim cylinder end screw O-ring Backup ring O-ring Dust seal Tilt cylinder end screw O-ring O-ring Tilt piston

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

Remarks

Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable

68F1F11

Power trim and tilt unit 7

1 A

13 14 T.

15 16 17 18 19 20

130 N · m (13.0 kgf · m, 96.0 ft · lb)

22 23 24

7 8

4 21

6 3

11 12

5 6

8 T.

9 10 2

78 N · m (7.8 kgf · m, 57.5 ft · lb)

11 12

96 N · m (9.6 kgf · m, 70.8 ft · Ib)

S63P7350

No. 18 19 20 21 22 23 24

Part name O-ring O-ring Washer Nut Ball Valve Spring

68F1F11

Q’ty 1 1 1 1 4 4 4

Remarks Not reusable Not reusable

7-22

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

Removing the power trim and tilt unit 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1.

2. Remove the bolt and disconnect the ground lead at the bottom of the power trim and tilt unit. 3. Remove the plastic ties, and then pull out the PTT motor leads.

S60X3020

4. Remove the circlip, then the upper mounting shaft.

WARNING After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure. NOTE: • If the power trim and tilt does not operate, loosen the manual valve 2 and tilt the outboard motor up manually. • If the manual valve is loosened, be sure to tighten it to the specified torque after tilting the outboard motor up.

T. R.

7-23

S68F7200C

5. Remove the bolts, then the lower mounting shaft.

Manual valve: 3 N·m (0.3 kgf·m, 2.2 ft·lb)

68F1F11

Power trim and tilt unit 2. If necessary, add sufficient fluid of the recommended type until it overflows out of the filler hole. Recommended power trim and tilt fluid: ATF Dexron II 3. Install the reservoir cap, and then tighten it to the specified torque.

T. R.

Reservoir cap: 0.7 N·m (0.07 kgf·m, 0.5 ft·lb)

4. Fully extend the trim and tilt rams.

S68F7210C

NOTE: • Retract the tilt ram before removing the power trim and tilt unit. • Hold the power trim and tilt unit with one hand, and pull the lower mounting shaft out at a downward angle with the other.

5. Remove the circlip 1, then the manual valve 2. 6. Install the up relief fitting 3 and hydraulic pressure gauge 4.

6. Remove the bushings.

Checking the hydraulic pressure 1. Remove the reservoir cap, and then check the fluid level in the reservoir.

S60X7340

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

68F1F11

NOTE: Quickly install the special service tools before any fluid flows out of the hole. Up relief fitting 3: 90890-06773 Hydraulic pressure gauge 4: 90890-06776

7-24

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

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

NOTE: Quickly install the special service tools before any fluid flows out of the hole. Rams Down

PTT motor lead

Battery terminal

Light green (Lg)

Sky blue (Sb)

8. Reverse the PTT motor leads between the battery terminals to fully extend the trim and tilt rams, and then measure the hydraulic pressure.

Down relief fitting 5: 90890-06774 Hydraulic pressure gauge: 90890-06776 10. Remove the reservoir cap, and then check the fluid level.

S60X7340

Rams Up

PTT motor lead

Battery terminal

Sky blue (Sb)

Light green (Lg)

Hydraulic pressure (up): 10â&#x20AC;&#x201C;12 MPa (100â&#x20AC;&#x201C;120 kgf/cm2) 9. Replace the up relief fitting with the down relief fitting 5.

NOTE: If the fluid is at the correct level, the fluid should overflow out of the filler hole when the reservoir cap is removed. 11. If necessary, add sufficient fluid of the recommended type until it overflows out of the filler hole. Recommended power trim and tilt fluid: ATF Dexron II 12. Install the reservoir cap, and then tighten it to the specified torque.

7-25

68F1F11

Power trim and tilt unit

T. R.

Reservoir cap: 0.7 N·m (0.07 kgf·m, 0.5 ft·lb)

T. R.

13. Connect the PTT motor leads to the battery terminals to fully retract the trim and tilt rams, and then measure the hydraulic pressure. If out of specification, overhaul the power trim and tilt unit.

NOTE: Quickly install the manual valve before any fluid flows out of the hole. Manual valve: 3 N·m (0.3 kgf·m, 2.2 ft·lb)

Disassembling the power trim and tilt motor 1. Remove the power trim and tilt motor, Oring, gear pump filter, and joint from the gear pump housing.

Rams Down

PTT motor lead

Battery terminal

Light green (Lg)

Sky blue (Sb)

Hydraulic pressure (down): 6–9 MPa (60–90 kgf/cm2)

S60X7220

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

Rams Up

PTT motor lead

Battery terminal

Sky blue (Sb)

Light green (Lg)

CAUTION: • Make sure that the trim and tilt rams are fully extended when removing the power trim and tilt motor, otherwise fluid can spurt out from the unit due to internal pressure. • Do not push the trim and tilt rams down while the power trim and tilt motor is removed from the power trim and tilt unit, otherwise fluid can spurt out. 2. Check the gear pump filter for dirt or residue and for damage. Clean or replace if necessary.

15. Remove the special service tools, and then install the manual valve and circlip. 68F1F11

7-26

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

3. Remove the lead holder 1 and rubber spacers 2 from the stator, and then slide them away from the stator.

7. Remove the screw, disconnect the PTT motor lead (light green) 5, and then remove the brushes 6.

4. Remove the stator 3.

NOTE: Place a clean cloth over the end of the armature shaft, hold it with a pair of pliers, and then carefully slide the stator off of the armature.

CAUTION: 5. Remove the armature from the PTT motor base.

CAUTION: Do not allow grease or oil to contact the commutator. 6. Disconnect the PTT motor lead (sky blue) 4.

â&#x20AC;˘ Do not pull the PTT motor leads out from the stator. â&#x20AC;˘ Do not touch the bimetal a, otherwise the operation of the circuit breaker can be affected.

Checking the power trim and tilt motor 1. Measure the length of the brushes. Replace if below specification.

S60X7240

NOTE: Hold the brush with a screwdriver as shown, and then disconnect the PTT motor lead (sky blue).

7-27

Brush length limit a: 4.8 mm (0.19 in)

68F1F11

Power trim and tilt unit 2. Check the brush and circuit breaker for continuity. Replace if there is no continuity.

CAUTION: Do not touch the bimetal b, otherwise the operation of the circuit breaker can be affected. 3. Measure the commutator diameter. Replace if below specification.

Armature continuity Commutator segments d

Continuity

Segment d â&#x20AC;&#x201C; Armature core e

No continuity

Segment d â&#x20AC;&#x201C; Armature shaft f

No continuity

5. Check the base for cracks or damage. Replace if necessary.

Commutator diameter limit c: 21.0 mm (0.83 in) 4. Check the armature for continuity. Replace if out of specifications.

68F1F11

6. Check the bearing and oil seal for damage or wear. Replace if necessary. NOTE: If the bearing and oil seal are removed, always replace them with new ones.

7-28

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

Assembling the power trim and tilt motor 1. Connect the PTT motor leads 1, and then tighten the screws 2.

Removing the reservoir 1. Hold the power trim and tilt unit in a vise using aluminum plates a on both sides.

2 S60X7310

CAUTION: 2. Push the brushes 3 into the brush holder, and then install the armature 4.

Do not use rags or paper to clean the hydraulic system components. Small pieces of fibers remaining on them can cause the system to malfunction. NOTE: Place a container under the power trim and tilt unit to catch the fluid. 2. Remove the reservoir and O-rings.

3. Install the stator onto the base.

NOTE: Place a clean cloth over the end of the armature shaft, hold it with a pair of pliers, and then carefully slide the stator over the armature.

CAUTION: â&#x20AC;˘ Make sure that the trim and tilt rams are fully extended when removing the reservoir, otherwise fluid can spurt out from the unit due to internal pressure. â&#x20AC;˘ Do not push the tilt and trim rams down while the power trim and tilt motor is removed from the power trim and tilt unit, otherwise fluid can spurt out. 3. Drain the fluid from the reservoir and check it for damage. Replace if necessary. 4. Check the reservoir cap and O-ring for damage. Replace if necessary.

Disassembling the gear pump housing 1. Remove the gear pump housing.

7-29

68F1F11

Power trim and tilt unit NOTE: Make sure that the shuttle pistons and balls are removed, since they tend to stick to the gear pump cover. 4. Remove the up-relief valve assembly. 5. Remove the main valves.

S60X7410

NOTE: Make sure that the O-rings, valve pin, and valve seat assembly are removed. 2. Remove the filters, down-relief valve, and O-ring from the gear pump housing. NOTE: Remove the back filter using compressed air, being careful not to blow the filter out abruptly. 3. Remove the gear pump cover and drive gears.

S60X7450

WARNING Never look into the pump housing opening while removing the main valves because the main valves and power trim and tilt fluid can be forcefully expelled out. NOTE: To remove the main valves, cover the pump housing with a clean cloth, and then blow compressed air through holes a and b while holding the cloth down.

S60X7430

68F1F11

7-30

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

6. Remove the manual valve.

3. Install the drive gears 8 into the gear pump housing. S60X7460

Checking the gear pump 1. Clean all the valves, pistons, and balls, and then check them for damage or wear. Check the filters for damage or clogs. Replace if necessary. 2. Check the drive gears for damage or wear. Replace the gear pump assembly if necessary.

S60X7500

4. Install the balls 9, shuttle pistons 0, and balls A into the gear pump cover.

Assembling the gear pump housing 1. Install a new O-ring 1, the up-relief valve seat 2, ball 3, absorber valve pin 4, and spring 5 into the gear pump housing.

2. Install new O-rings 6 onto the main valves 7, and then install the main valves into the gear pump housing.

7-31

NOTE: Apply grease to the balls and shuttle pistons to prevent them from falling out of the gear pump cover.

68F1F11

Power trim and tilt unit 5. Install the gear pump cover B into the gear pump housing, and then tighten the bolts.

Disassembling the tilt cylinder and trim cylinders 1. Loosen the tilt cylinder end screw, and then remove the tilt piston assembly.

S60X7520 S60X7540

6. Check that the gear pump turns smoothly, and then tighten the gear pump cover bolts to the specified torque.

T. R.

Gear pump cover bolt: 6 N·m (0.6 kgf·m, 4.4 ft·lb)

7. Install a new O-ring onto the down-relief valve. 8. Install the filter, down-relief valve, and filter into the gear pump housing.

CAUTION: Make sure that the trim and tilt rams are fully extended before removing the tilt cylinder end screw.

Trim and tilt wrench: YB-06548 2. Drain the fluid. 3. Loosen the trim cylinder end screws, and then remove the trim piston assemblies.

S60X7530

9. Install a new O-ring onto the manual valve. 10. Install the manual valve and circlip into the gear pump housing.

T. R.

Manual valve: 3 N·m (0.3 kgf·m, 2.2 ft·lb)

68F1F11

End screw wrench: YB-06175-1A 4. Drain the fluid. 5. Install the trim piston assemblies, and then tighten the trim cylinder end screws finger tight.

7-32

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

6. Cover the tilt cylinder opening with a clean cloth 1, and then blow compressed air through the hole a to remove the free piston 2.

Checking the tilt cylinder and trim cylinder 1. Disassemble the tilt piston assembly.

S60X7570

WARNING Never look into the tilt cylinder opening while removing the free piston because the free piston and power trim and tilt fluid can be forcefully expelled out. 7. Loosen the trim cylinder end screws, and then remove the trim piston assemblies.

2. Check the tilt piston and free piston for scratches. Replace if necessary. 3. Blow the tilt piston absorber valve with compressed air to remove any foreign material. Check the valve for wear and the spring for deterioration. Replace if necessary. 4. Check the tilt ram for bends or excessive corrosion. Polish with 400- to 600-grit sandpaper if there is light rust or replace if necessary. 5. Check the trim pistons for scratches. Replace if necessary. 6. Check the trim rams for bends or excessive corrosion. Polish with 400- to 600grit sandpaper if there is light rust or replace if necessary. 7. Check the inner walls of the trim and tilt cylinders for scratches. Replace if necessary.

7-33

68F1F11

Power trim and tilt unit

Assembling the tilt piston and trim pistons 1. Install the new dust seal 1 and new Orings 2 and 3 onto the tilt cylinder end screw.

7. Install a new oil seal E, a new dust seal F, and a new O-ring G onto each trim cylinder end screw. 8. Install the backup ring H and a new Oring I onto each trim piston. A

2. Install the tilt cylinder end screw onto the tilt ram. 3. Install new O-rings 4 and 5 onto the tilt piston 6.

F E G H I

4. Install the ball 7, valve 8, and spring 9, in this order. 5. Install the tilt piston assembly and washer 0 onto the tilt ram, and then tighten the tilt piston nut A to the specified torque.

H I S68F7300C

T. R.

Tilt piston nut: 96 NÂˇm (9.6 kgfÂˇm, 70.8 ftÂˇlb)

6. Install a new backup ring B and a new O-ring C onto the free piston D.

68F1F11

7-34

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

Assembling the power trim and tilt unit 1. Fill the tilt cylinder with the specified amount of the recommended fluid through the hole a.

Recommended power trim and tilt fluid: ATF Dexron II Fluid quantity: 30 cm3 (1.0 US oz, 1.1 Imp oz) 2. Push the free piston 1 into the tilt cylinder until it bottoms out.

4. Install the trim piston assemblies into the trim cylinders, and then tighten the trim cylinder end screws to the specified torque.

CAUTION: 3. Fill the trim cylinders with the recommended fluid to the correct level through holes b and c, and d as shown.

• Make sure that the trim rams are fully extended when installing them. • Once installed, never push the trim rams down, otherwise fluid can spurt out.

End screw wrench: YB-06175-1A

T. R.

Trim cylinder end screw: 78 N·m (7.8 kgf·m, 57.5 ft·lb)

5. Install new O-rings, the valve pin, and valve seat assembly onto the tilt cylinder.

7-35

68F1F11

Power trim and tilt unit NOTE: Refer to the illustration for valve pin and valve seat assembly installation. 6. Install the gear pump housing.

T. R.

Gear pump housing mounting bolt: 8 N·m (0.8 kgf·m, 5.9 ft·lb)

7. Install the O-ring into the reservoir cap. 8. Install the reservoir and O-ring onto the gear pump housing.

T. R.

Reservoir mounting bolt: 5 N·m (0.5 kgf·m, 3.7 ft·lb)

S63P7050

CAUTION: • Make sure that the tilt ram is fully extended when installing it. • Once installed, never push the tilt ram down, otherwise fluid can spurt out.

Trim and tilt wrench: YB-06548

9. Fill the tilt cylinder with the recommended fluid to the correct level through the hole e as shown. T. R.

Tilt cylinder end screw: 130 N·m (13.0 kgf·m, 96.0 ft·lb)

11. Install the joint 2 and gear pump filter 3 into the gear pump housing.

10. Install the tilt piston assembly into the tilt cylinder, and then tighten the tilt cylinder end screw to the specified torque.

12. Fill the gear pump housing with the recommended fluid to the correct level as shown.

68F1F11

7-36

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

13. Remove all of the air bubble using a syringe or suitable tool.

19. Check the hydraulic pressure of the power trim and tilt unit.

NOTE: Turn the joint with a screwdriver to bleed the gear pump.

Bleeding the power trim and tilt unit 1. Tighten the manual valve 1 by turning it clockwise.

14. Install a new O-ring 4 and the power trim and tilt motor 5, and then tighten the bolts 6 to the specified torque.

NOTE: Align the armature shaft with the recess in the joint.

2. Place the power trim and tilt unit in an upright position. 3. Remove the reservoir cap, and then check the fluid level in the reservoir.

PTT motor mounting bolt: 5 N·m (0.5 kgf·m, 3.7 ft·lb)

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

4. If necessary, add sufficient fluid of the recommended type until it overflows out of the filler hole.

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

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

Recommended power trim and tilt fluid: ATF Dexron II

16. If necessary, add sufficient fluid of the recommended type until it overflows out of the filler hole. 17. Install the reservoir cap, and then tighten it to the specified torque.

7-37

18. Bleed the power trim and tilt unit.

Reservoir cap: 0.7 N·m (0.07 kgf·m, 0.5 ft·lb)

5. Install the reservoir cap, and then tighten it to the specified torque. Reservoir cap: 0.7 N·m (0.07 kgf·m, 0.5 ft·lb)

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

68F1F11

Power trim and tilt unit

Installing the power trim and tilt unit 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1.

Rams Down

PTT motor lead

Battery terminal

Light green (Lg)

Sky blue (Sb)

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

S60X7820

CAUTION: After tilting the outboard motor up, be sure to support it with the tilt stop lever. 2. Install the bushings. 3. Lift the power trim and tilt unit up, and then install the lower mounting shaft, and then tighten the bolts. 4. Install the upper mounting shaft.

Rams Up

PTT motor lead

Battery terminal

Sky blue (Sb)

Light green (Lg)

5. Install the circlip. 6. Install the plastic ties, route the PTT motor leads through the hole, and then install the plastic ties.

NOTE: â&#x20AC;˘ Repeat this procedure so that the rams go up and down four or five times (be sure to wait a few seconds before switching the leads). â&#x20AC;˘ If the rams do not move up and down easily, push and pull on the rams to assist operation. 8. Check the fluid level when the tilt ram is fully extended. Add sufficient fluid if necessary.

68F1F11

7-38

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

7. Connect the ground lead to the bottom of the power trim and tilt unit, and then tighten the bolt.

6. Support the outboard motor with the tilt stop lever 1.

1 A A

A A

S60X3020

242

S60X7130

WARNING

Bleeding the power trim and tilt unit (built-in) 1. Fully turn the manual valve counterclockwise.

After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure. 7. Remove the reservoir cap 2, and then check the fluid level in the reservoir.

2. Fully tilt the outboard motor up, and then release it to let it lower by its own weight four to five times.

2 S60X3030

3. Tighten the manual valve by turning it clockwise. 4. Let the fluid settle for 5 minutes. 5. Push and hold the power trim and tilt switch in the up position to check that the outboard motor is fully tilted up.

NOTE: If the fluid is at the correct level, the fluid should overflow out of the filler hole when the reservoir cap is removed. 8. If necessary, add sufficient fluid of the recommended type to the correct level. Recommended power trim and tilt fluid: ATF Dexron II

7-39

68F1F11

Power trim and tilt unit 9. Install the reservoir cap, and then tighten it to the specified torque. NOTE: Repeat this procedure until the fluid remains at the correct level.

T. R.

1 2 3 4 5 6 7 8 9

Reservoir cap: 0.7 N·m (0.07 kgf·m, 0.5 ft·lb)

68F1F11

7-40

BRKT

Bracket unit

Clamp brackets

29 22

15 N · m (1.5 kgf · m, 11.1 ft · Ib)

910 22

5 10

5 13 T.

2 N · m (0.2 kgf · m, 1.5 ft · Ib)

271

25 22

18 6

19 20

24 28 27

15 5 11

14 A

S68F7270C

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

7-41

Part name Swivel bracket Clamp bracket Clamp bracket Self-locking nut Grease nipple Ground lead Washer Screw Washer Bushing Trim sensor Screw Trim sensor cam Screw Clamp Bolt Bracket

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

Remarks

ø6 × 12 mm

ø6 × 15 mm ø6 × 25 mm M6 × 30 mm

68F1F11

Clamp brackets 7

29 22

15 N · m (1.5 kgf · m, 11.1 ft · Ib)

910 22

5 10

5 13 T.

2 N · m (0.2 kgf · m, 1.5 ft · Ib)

271

25 22

18 6

19 20

24 28 27

15 5 11

14 A

S68F7270C

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

Part name Anode Through tube Bolt Tilt stop lever Bushing Collar Distance collar Spring pin Spring Spring hook Bolt Tilt stop lever

68F1F11

Q’ty 1 1 1 1 4 1 2 2 1 1 1 1

Remarks

M8 × 20 mm

M6 × 10 mm

7-42

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

Removing the clamp brackets 1. Remove the power trim and tilt unit. For removal procedures, see “Removing the power trim and tilt unit.”

4. Install the bolts on the through tube, and then tighten the self-locking nut to the specified torque.

T. R.

2. Remove the anode.

Self-locking nut: 15 N·m (1.5 kgf·m, 11.1 ft·lb)

3. Remove the screw and grease nipples, and then disconnect the ground leads.

5. Install the power trim and tilt unit, then the anode.

4. Remove the trim sensor cam screws. 5. Remove the self-locking nut and bolt.

NOTE: Install the ground lead between the power trim and tilt unit and the anode.

6. Remove the through tube, then disassemble the clamp brackets and swivel bracket.

6. Install the ground lead between the clamp brackets and the swivel bracket. 7. Apply water resistant grease through the grease nipples.

7. Remove the trim sensor. 8. Remove the tilt stop levers.

Installing the clamp brackets

1. Install the tilt stop levers onto the swivel bracket assembly. 2. Install the trim sensor 1 and bushings onto the swivel bracket assembly.

a 1 LT

271 A S60X7140

S63P7320

3. Assemble the clamp brackets, washers, and swivel bracket, and then install the through tube.

NOTE: Apply the grease until it comes out of the bushing a.

NOTE: • Make sure that the trim sensor cam is installed between the swivel bracket holes. • Adjust the trim sensor cam after assembly.

Adjusting the trim sensor cam 1. Fully retract the power trim and tilt unit. 2. Loosen the trim sensor cam screw 1.

7-43

68F1F11

Clamp brackets 3. Adjust the trim sensor cam 2 where the specified trim sensor setting resistance is obtained.

5. Check the trim sensor resistance. If the resistance is out of specification, adjust the trim sensor cam position and check the trim sensor. Trim sensor resistance: Pink (P) – Black (B) 238.8–378.8 Ω at 20 °C (68 °F)

2 P B

1 S63P7250

Trim sensor setting resistance: Pink (P) – Black (B) 9–11 Ω at 20 °C (68 °F)

T. R.

Trim sensor cam screw 1: 2 N·m (0.2 kgf·m, 1.5 ft·lb)

4. Fully tilt the outboard motor up, and then support it with the tilt stop lever 3.

S60X7170

68F1F11

7-44

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

Power trim and tilt electrical system

1 1 7 17 18

1 3

: : : :

R R/W R R

2 7GH 56A 9 BCD EFL M

IJK = N

MLF EDCBAHG 7 KJI N= 65 9

1 2 3 4

5 Sb

R R

6 R/W R/W

Lg Sb R

R R/W

Lg R/W

Lg Sb

Lg Lg

Sb R Lg R

R/W

B Sb B

Sb Lg B

7 B B B

É P

S68F7220C

1 2 3 4 5 6 7 8 9

Fuse holder Fuse (20 A) Fuse (80 A) Starting battery Power trim and tilt motor Power trim and tilt relay Diode Trim sensor Power trim and tilt switch

7-45

È To remote control box/ switch panel É To trim meter

B Lg P R Sb R/W

: Black : Light green : Pink : Red : Sky blue : Red/white

68F1F11

Power trim and tilt electrical system

Checking the fuse 1. Check the fuse for continuity. Replace if there is no continuity.

S69J7525

Checking the power trim and tilt relay 1. Check the power trim and tilt relay for continuity. Replace if out of specification.

Power trim and tilt relay continuity Sky blue (Sb) – Black (B) Light green (Lg) – Black (B)

Continuity

Terminal 1 – Terminal 4 Terminal 2 – Terminal 4

Continuity

Terminal 1 – Terminal 3 Terminal 2 – Terminal 3

No continuity

2. Connect the digital circuit tester between power trim and tilt relay terminals 1 and 3. 3. Connect the light green (Lg) lead to the positive battery terminal and the black (B) lead to the negative battery terminal as shown. 4. Check for continuity between terminals 1 and 3. Replace if there is no continuity.

5. Connect the digital circuit tester between power trim and tilt relay terminals 2 and 3. NOTE: Be sure to set the measurement range a shown in the illustration when checking for continuity.

68F1F11

6. Connect the sky blue (Sb) lead to the positive battery terminal and the black (B) lead to the negative battery terminal as shown.

7-46

1 2 3 4 5 6 7 8 9

BRKT

Bracket unit

7. Check for continuity between terminals 2 and 3. Replace if there is no continuity.

NOTE: Turn the lever 1 and measure the resistance as it gradually changes.

Checking the power trim and tilt switch 1. Check the power trim and tilt switch for continuity. Replace if out of specification.

Trim sensor resistance: Pink (P) – Black (B) 238.8–378.8 Ω at 20 °C (68 °F) a 9–11 Ω at 20 °C (68 °F) b

Lead color Switch position

Sky blue (Sb)

Red (R)

Light green (Lg)

Up Free Down

Checking the trim sensor 1. Measure the trim sensor resistance. Replace if out of specification.

7-47

68F1F11

ELEC

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Electrical systems Special service tools .....................................................................................8-1 Checking the electrical components............................................................ 8-2 Measuring the peak voltage ...................................................................... 8-2 Measuring the lower resistance.................................................................8-2 Electrical components................................................................................... 8-3 Port view.................................................................................................... 8-3 Starboard view........................................................................................... 8-4 Junction box assembly ..............................................................................8-5 Aft view ...................................................................................................... 8-6 Top view .................................................................................................... 8-7 Wiring harness........................................................................................... 8-8 Ignition and ignition control system .......................................................... 8-12 Checking the ignition spark ..................................................................... 8-14 Checking the spark plug caps .................................................................8-14 Checking the ignition coils ....................................................................... 8-14 Checking the ECM...................................................................................8-15 Checking the pulser coil ..........................................................................8-15 Checking the crank position sensor......................................................... 8-16 Checking the crank position sensor air gap............................................. 8-16 Checking the throttle position sensor ......................................................8-16 Checking the sensor assembly................................................................8-17 Checking the engine temperature sensor................................................ 8-17 Checking the thermoswitches.................................................................. 8-17 Checking the shift position switch............................................................ 8-18 Checking the ECM main relay .................................................................8-18 Fuel control system .....................................................................................8-19 Checking the injector drivers ................................................................... 8-21 Checking the fuel pressure sensor .......................................................... 8-21 Checking the water detection switch .......................................................8-22 Checking the electric fuel pump ..............................................................8-22 Checking the electric fuel pump relay......................................................8-22 Checking the injector driver relay ............................................................ 8-23 Checking the oxygen density sensor.......................................................8-23 Starting system ............................................................................................ 8-25 Checking the fuses .................................................................................. 8-26 Checking the starter relay........................................................................8-26

68F1F11

Starter motor ................................................................................................8-27 Disassembling the starter motor..............................................................8-29 Checking the starter motor pinion............................................................ 8-29 Checking the armature ............................................................................8-29 Checking the brushes.............................................................................. 8-30 Checking the magnet switch.................................................................... 8-30 Checking the starter motor operation ......................................................8-30 Charging system .......................................................................................... 8-31 Checking the stator coil ...........................................................................8-32 Checking the Rectifier Regulator............................................................. 8-32 Oil feed pump control system..................................................................... 8-33 Checking the electric oil pump.................................................................8-34 Checking the oil level sensor................................................................... 8-34 Checking the emergency switch..............................................................8-35 Checking the oil pump (remote oil tank) .................................................. 8-35

68F1F11

1 2 3 4 5 6 7 8 9

ELEC

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Electrical systems

Special service tools

Dynamic spark tester YM-34487

Digital multimeter YU-34899-A

Peak voltage adapter YU-39991

Test harness (2 pins) New: YB-06867 Current: YB-06767

Test harness (8 pins) New: YB-06879 Current: YB-06779

8-1

Test harness (3 pins) New: YB-06857 Current: YB-06757

Test harness (2 pins) YB-06861

Test harness (3 pins) New: YB-06869 Current: YB-06769

Test harness (2 pins) New: YB-06887 Current: YB-06787

Test harness (1 pin) New: YB-06888 Current: YB-06788 68F1F11

Special service tools / Checking the electrical components

Checking the electrical components

Measuring the lower resistance 8

Measuring the peak voltage NOTE: Before troubleshooting the peak voltage, check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 V. The condition of the ignition system can be determined by measuring the peak voltage. Cranking speed is effected by many factors, such as fouled or weak spark plugs, or a weak battery. If one of these factors is present, the peak voltage will be lower than specification. In addition, if the peak voltage is lower than specification the engine will not operate properly.

When measuring a resistance of 10 Ω or less with the digital circuit tester, the correct measurement cannot be obtained because of the internal resistance of the tester. To obtain the correct value, subtract the internal resistance from the displayed measurement. NOTE: Obtain the internal resistance of the digital circuit tester by connecting both of its probes and checking the display. Correct value = displayed measurement – internal resistance

WARNING When checking the peak voltage, do not touch any of the connections of the digital tester leads. NOTE: • Use the peak voltage adapter with the digital circuit tester. • When measuring the peak voltage, set the selector on the digital circuit tester to the DC voltage mode. • Connect the positive pin on the peak voltage adapter to the positive terminal of the digital circuit tester.

68F1F11

8-2

1 2 3 4 5 6 7 8 9

â&#x20AC;&#x201C;

ELEC

Electrical systems

Electrical components

Port view 5

4 3 2 1

7 8

S68F8010C

1 Throttle position sensor 2 Sensor assembly (intake air temperature, atmospheric pressure) 3 Emergency switch 4 Pulser coil 5 Oil level sensor 6 Stator coil 7 Water detection switch

8-3

8 Fuel pump relay 9 Electric oil pump 0 Electric fuel pump

68F1F11

Electrical components

Starboard view

S68F8020C

1 2 3 4

Oxygen density sensor Starter motor Fuse holder Junction box

68F1F11

8-4

1 2 3 4 5 6 7 8 9

ELEC

â&#x20AC;&#x201C;

Electrical systems

Junction box assembly

2 3 8

S68F8030C

1 2 3 4 5 6 7 8

Power trim and tilt relay Fuse (20 A) Fuse (80 A) Main relay Driver relay Fuse (30 A) Rectifier Regulator Starter relay

8-5

68F1F11

Electrical components

Aft view

S68F8040C

1 2 3 4 5 6

Ignition coil Thermoswitch Injector drivers ECM Fuel pressure sensor Engine temperature sensor

68F1F11

8-6

1 2 3 4 5 6 7 8 9

ELEC

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Electrical systems

Top view

1 1

2 2 3

0 9

8 5

S68F8050C

1 2 3 4 5 6

Fuel injector Spark plug Thermoswitch Oil level sensor Emergency switch Sensor assembly (intake air temperature, atmospheric pressure) 7 Power trim and tilt switch 8 Shift position switch 9 Oxygen density sensor

8-7

0 Crank position sensor

68F1F11

Electrical components

Wiring harness

6B P P B

8 O

7 5

GyP

B B/W

B B B

R/W

L L B

Br Br R

Sb BBB O

L P

L/W Y/R

L/G

Lg W

B/Y B B/Y

B Gy

P Br

B/Y

B L/R

B L/R L/W

3 B Sb

1 2 3 4 5 6 7 8 9

B/R B/R

B/R

O O Y

R/W P

B/Y

1 B

: : : : : : : : :

L/W P _ L/R L/R L/G G/R P B

10 11 12 13 14 15 16 17 18

: : : : : : : : :

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

19 20 21 22 23 24 25 26

: : : : : : : :

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

H L/G

I B/R

G/R B

J L

B/R

K Gy

L P

5 L L

4 7 88 L/W L/R B B Y/R L/G L/R

BBB

BGyP

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/G L G Y B/W

0 6

BPP

P O

1 9

O B

B/Y B O P

B/Y B/Y

B DF H 3 C B/R Y Y O O B/R B/R Y O O

B/W Gy

R R/W

B L/G

L/W B

Sb Lg

Br Br

B B

Y Br W G P Sb Lg R B

Sb Lg R/W B B

B B/Y B B Gy

Lg B

B Gy P

B/R P G/R Gy

B/R L Y B

S68F8060C

Connect to: 1 Sensor assembly (intake air temperature, atmospheric pressure) 2 Power trim and tilt switch 3 Water detection switch 4 Oil level sensor 5 Emergency switch 6 Throttle position sensor

68F1F11

7 8 9 0 A B C D E F

Ground Thermoswitch Engine temperature sensor Fuel pressure sensor ECM Oxygen density sensor Power trim and tilt relay Fuse holder Starter relay Fuse holder

G H I J K L

Remote control Shift position switch Oil level meter Remote oil tank Trim meter Trim sensor

8-8

1 2 3 4 5 6 7 8 9

â&#x20AC;&#x201C;

ELEC

Electrical systems

6B P P B

8 O

7 5

GyP

B B/W

B B B

R/W

L L B

Br Br R

Sb BBB O

L P

L/W Y/R

L/G

Lg W

B/Y B B/Y

B Gy

P Br

B/Y

B L/R

B L/R L/W

3 B Sb

1 2 3 4 5 6 7 8 9

B/R B/R

B/R

O O Y

R/W P

B/Y

1 B

: : : : : : : : :

L/W P _ L/R L/R L/G G/R P B

10 11 12 13 14 15 16 17 18

: : : : : : : : :

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

19 20 21 22 23 24 25 26

: : : : : : : :

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

H L/G

I B/R

G/R B

J L

B/R

K Gy

L P

5 L L

4 7 88 L/W L/R B B Y/R L/G L/R

BBB

BGyP

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/G L G Y B/W

0 6

BPP

P O

1 9

O B

B/Y B O P

B/Y B/Y

B DF H 3 C B/R Y Y O O B/R B/R Y O O

B/W Gy

R R/W

B L/G

L/W B

Sb Lg

Br Br

B B

Y Br W G P Sb Lg R B

Sb Lg R/W B B

B B/Y B B Gy

Lg B

B Gy P

B/R P G/R Gy

B/R L Y B

S68F8060C

B Br G Gy L Lg O P R Sb

8-9

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

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

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

Y/R

: Yellow/red

68F1F11

Electrical components

O/B

O/G

R/Y Pu/G

O/W R/Y

W/Y B

O/B

O/B O/L

R/Y

B/G

Pu/L

B/L

R/Y

B/Br

O/R G

O/G

O/L

R/Y

R/W

2 W/Br

W/G W/L

R/Y

R R

R/Y

L B B B

R/Y R/Y

R/Y

R/Y R/Y

Pu/L

O/W

Pu/W

Pu/L Pu/G

22 : R/Y 23 : R/Y 24 : R/W 25 : _ 26 : _ 27 : _ 28 : _

G O/R

W/B W/R

Pu/Y

O/Y

14 : R/Y 15 : R/Y 16 : R/Y 17 : R 18 : R 19 : R/W 20 : R/W 21 : R/W

5 : R/L 6 : R/L 7 : R/W 9 : L/Y 10 : L/Y 11 : R/Y 12 : R/Y 13 : R/Y

B B BBB BB B B

B/Y

R/Y

B/O

B/W

O/R

R/Y

Pu/W

L Y

Pu/R Pu/B

O/Y

Pu/Y

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

W/B

Pu/G B

O/B

Pu/B

Pu/B O/R

R/W

Pu/R

R/W

27 : R/L 28 : W/Y 29 : G 30 : G 31 : Pu/L 32 : Pu/R 33 : B/O

_ 41 : 42 : Y 43 : B 44 : B 45 : W/L 46 : W/R 47 : G

34 : B/W 35 : B/Y 36 : R/L 37 : W/G 38 : L/Y 39 : Pu/W 40 : Pu/B

48 : Pu/Y 49 : W/B _ 50 : 51 : B 52 : B 53 : W/Br 54 : W/B

55 : L _ 56 : 57 : Pu/G 58 : B/Br 59 : B/L 60 : B/G

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

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

B/Br B/G

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

9 B

B/W

B/G R/Y

B B B

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

B R/Y

R/W Pu/W G

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

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

6 R/Y

R/Y

B B B B

B/Y R/Y

W/B R/Y

R/Y L

B/L R/Y

B/Br R/Y

Y R/Y B

R/Y

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

R/Y

R/W

9 S68F8080C

Connect to: 1 2 3 4 5 6 7 8

Electric fuel pump Pulser coil Fuel pump relay Electric oil pump Fuel injector Ignition coil ECM Crank position sensor

68F1F11

9 0 A B

Ground Oxygen density sensor Fuse holder Injector drivers

8-10

1 2 3 4 5 6 7 8 9

ELEC

–

Electrical systems

O/B

O/G

R/Y Pu/G

L W/Y B

R/Y

B/G

Pu/L

R/Y

B/Br

O/R G

O/G

O/L

R/Y

R/W

2 W/Br

W/G W/L

R/Y

R R

R/Y

B B B

Pu/L

R/Y R/Y

R/Y

R/Y R/Y

O/W

Pu/W

Pu/L Pu/G

22 : R/Y 23 : R/Y 24 : R/W 25 : _ 26 : _ 27 : _ 28 : _

G O/R

W/B W/R

B/L

O/B

O/B O/L

Pu/Y

O/Y

14 : R/Y 15 : R/Y 16 : R/Y 17 : R 18 : R 19 : R/W 20 : R/W 21 : R/W

5 : R/L 6 : R/L 7 : R/W 9 : L/Y 10 : L/Y 11 : R/Y 12 : R/Y 13 : R/Y

B B BBB BB B B

B/Y

R/Y

B/O

B/W

R/Y

O/R

R/Y

Pu/W

L Y

R/Y

O/W R/Y

Pu/R Pu/B

O/Y

Pu/Y

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

W/B

Pu/G B

O/B

Pu/B

Pu/B O/R

R/W

Pu/R

R/W

27 : R/L 28 : W/Y 29 : G 30 : G 31 : Pu/L 32 : Pu/R 33 : B/O

_ 41 : 42 : Y 43 : B 44 : B 45 : W/L 46 : W/R 47 : G

34 : B/W 35 : B/Y 36 : R/L 37 : W/G 38 : L/Y 39 : Pu/W 40 : Pu/B

48 : Pu/Y 49 : W/B _ 50 : 51 : B 52 : B 53 : W/Br 54 : W/B

55 : L _ 56 : 57 : Pu/G 58 : B/Br 59 : B/L 60 : B/G

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

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

B/Br B/G

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

9 B

B/W

B B

B/G R/Y

B 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

B R/Y

R/W Pu/W G

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

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

6 R/Y

R/Y

B B B B

B/Y R/Y

W/B R/Y

R/Y L

B/L R/Y

B/Br R/Y

Y R/Y B

R/Y

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

R/Y

R/W

9 S68F8080C

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

8-11

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

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

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

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

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

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

68F1F11

Electrical components / Ignition and ignition control system

Ignition and ignition control system

B W/Y W/B W/R

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

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

B B B

L/G

W/G W/L W/Br

W/Br W/L

L/W

Y/R

G/W

L/W L/W

B B

4 P

B/Y

7GH 56A 9 BCD EFL M

R B/Y

IJK = N

1 2 3 4

MLF EDCBAHG 7 KJI N= 65 9

B/Y

L/Y R/L

P B

1 2 4 5 6 8 9 10 11 12 13 15 16

C B

O B

B Y

B/R

B Gy

B/R

B/O

R/Y

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

: : : :

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

15 : R/Y 16 : R/Y

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

17 18 19 23 27 28 29 30 33 34 35 36 37

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

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

38 43 44 45 46 51 52 53 54 58 59 60

R/Y B/W

B/W

R/Y

R B/W

R/Y

R/Y B/G

lmnopqrst defghijk Z[\]^abc QRSTUVWXY

B/W R/Y

B/W 4

B/W

B/L

B/G

B/W

9 R

R/Y B/L

B B

B/W

R/Y B/Br

R/Y

B/W B/W

P Gy

R/Y

R/Y B/Y

B/W

JKLMNOP DEFGHI 890ABC 1234567

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

B/Y

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

B/W

R/Y B/O

B/W

11 12 13 14

B/Y R

R R/L R/L L/Y

B P P

: : : :

1 5 6 9

B/Y

O P R

L/R

L/R B

G/L G/L

L/R

G/W

R L/G

B/Br

L/G B

B B L/G

È S68F8090C

1 2 3 4 5 6 7 8 9 0

Pulser coil Crank position sensor Fuse holder Fuse (20 A) ECM main relay Fuse (80 A) Battery Spark plug Ignition coil Shift position switch

68F1F11

A B C D E F G H

Thermoswitch ECM Fuel pressure sensor Sensor assembly (intake air temperature, atmospheric pressure) Engine temperature sensor Throttle position sensor Water detection switch Oil level sensor

È To remote control box/ switch panel

8-12

1 2 3 4 5 6 7 8 9

–

ELEC

Electrical systems 8

B W/Y W/B W/R

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

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

B B B

L/G

W/G W/L W/Br

W/Br W/L

L/W

Y/R

L/R

G/W

L/R

L/R B

L/W L/W

B B

4 P

G/L G/L

G/W

B/Y

7GH 56A 9 BCD EFL M

R B/Y

IJK = N

1 2 3 4

MLF EDCBAHG 7 KJI N= 65 9

B/Y

L/Y R/L

P B

1 2 4 5 6 8 9 10 11 12 13 15 16

C B

O B

B Y

B/R

B Gy

B/R

11 12 13 14

: : : :

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

15 : R/Y 16 : R/Y

B/O

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

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

17 18 19 23 27 28 29 30 33 34 35 36 37

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

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

38 43 44 45 46 51 52 53 54 58 59 60

R/Y

B/W

R/Y

B/W

R B/W

B/Y

R/Y

R/Y B/G

lmnopqrst defghijk Z[\]^abc QRSTUVWXY

B/W R/Y

B/W 4

B/W

B/L

B/G

R/Y

B/W

9 B/W

R/Y B/Br B/W

B/W

R/Y B/L

B B

P Gy

R/Y

R/Y B/Y

B/W

JKLMNOP DEFGHI 890ABC 1234567

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

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

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

B/W

B/Y R

R R/L R/L L/Y

B P P

: : : :

1 5 6 9

B/Y

O P R

R L/G

B/Br

L/G B

B B L/G

È S68F8090C

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

8-13

: Black : Green : Gray : Orange : Pink : Red : White : Yellow : Black/brown : Black/green

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

: Black/blue : Black/orange : Black/red : Black/white : Black/yellow : Green/blue : Green/white : Blue/green : Blue/red : Blue/white

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

: Blue/yellow : Red/blue : Red/yellow : White/black : White/brown : White/green : White/blue : White/red : White/yellow : Yellow/red 68F1F11

Ignition and ignition control system

Checking the ignition spark

Checking the spark plug caps

1. Disconnect the spark plug caps from the spark plugs.

1. Remove the spark plug caps from the spark plug wires by turning the caps counterclockwise.

2. Connect a spark plug cap to the special service tool.

S60V8130

2. Measure the spark plug cap resistance. Replace if out of specification. Dynamic spark tester: YM-34487 3. Crank the engine and observe the spark through the discharge window of the spark gap tester. Check the ignition coil if the spark is weak.

Ω × 1K

S60V8140

Spark plug cap resistance: 4–6 kΩ at 20 °C (68 °F)

Checking the ignition coils 1. Remove the spark plug wires from the spark plugs.

WARNING • Do not touch any of the connections of the spark gap tester leads. • Do not let sparks leak out of the removed spark plug caps. • Keep flammable gas or liquids away, since this test can produce sparks.

2. Remove the harness cover and disconnect the ignition coil coupler. 3. Remove the spark plug caps from the spark plug wires.

NOTE: The ignition spark can also be checked using the “Stationary test” of the Yamaha Diagnostic System.

68F1F11

8-14

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ELEC

–

Electrical systems

4. Measure the ignition coil resistance. Replace if out of specification.

ECM output peak voltage: Red (R) – Black/white (B/W) r/min DC V

Loaded Cranking

1,500

3,500

270

250

Checking the pulser coil 1. Disconnect the pulser coil coupler. S60V8150

Ignition coil resistance: Primary coil: Red (R) – Black/white (B/W) 1.87–2.53 Ω at 20 °C (68 °F) Secondary coil: Red (R) – Spark plug wire 8.93–12.08 kΩ at 20 °C (68 °F)

2. Connect the test harness (8 pins) to the pulser coil. 3. Measure the pulser coil output peak voltage. Replace the pulser coil if below specification.

Checking the ECM 1. Remove the harness cover and disconnect a ignition coil coupler. 2. Connect the test harness (2 pins) to the ignition coil. Digital multimeter: YU-34899-A Peak voltage adapter: YU-39991 Test harness (8 pins): New: YB-06879 Current: YB-06779

3. Measure the ECM output peak voltage. If below specification, measure the pulser coil output peak voltage. Replace the ECM if the output peak voltage of the pulser coil is above specification.

Pulser coil output peak voltage: White/red (W/R) – Black (B) White/black (W/B) – Black (B) White/yellow (W/Y) – Black (B) White/green (W/G) – Black (B) White/blue (W/L) – Black (B) White/brown (W/Br) – Black (B) S68F8140C

Digital multimeter: YU-34899-A Peak voltage adapter: YU-39991 Test harness (2 pins): New: YB-06867 Current: YB-06767

8-15

r/min DC V

Unloaded

Loaded

Cranking 4.0

4.0

1,500

3,500

20.0

35.0

Pulser coil resistance (use as reference): 294–398 Ω at 20 °C (68 °F)

68F1F11

Ignition and ignition control system

Checking the crank position sensor 1. Remove the harness cover bolts, and then pull back the injector driver cover. NOTE: The ignition coils are connected to the injector driver cover. Do not remove the injector driver cover. 2. Connect the test harness (2 pins) to the crank position sensor.

Checking the crank position sensor air gap 1. Remove the flywheel magnet cover. 2. Measure the crank position sensor air gap a. Adjust if out of specification. Crank position sensor air gap: 0.5–1.5 mm (0.02–0.06 in) 3. Loosen the screws 1 and adjust the crank position sensor air gap.

3. Measure the crank position sensor output peak voltage. Replace the crank position sensor if below specification.

S68F8170C

4. Tighten the screws, and then check the crank position sensor air gap. Adjust if necessary. Digital multimeter: YU-34899-A Peak voltage adapter: YU-39991 Test harness (2 pins): New: YB-06867 Current: YB-06767

Checking the throttle position sensor 1. Connect the test harness (3 pins) to the throttle position sensor. 2. Turn the engine start switch to ON.

Crank position sensor output peak voltage: Green/blue (G/L) – Green/white (G/W) r/min

Unloaded

Loaded

Cranking

DC V

8.5

3. Measure the throttle position sensor input voltage. Replace the ECM if out of specification.

8.0

1,500

3,500

26.0

31.0

Crank position sensor resistance (use as reference): Green/blue (G/L) – Green/white (G/W) 178.5–241.5 Ω at 20 °C (68 °F)

68F1F11

8-16

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Electrical systems

4. Measure the throttle position sensor output voltage. Adjust the throttle position sensor if out of specification.

2. Measure the sensor assembly resistance. Replace if out of specification. Sensor assembly resistance: at 0 °C (32 °F): 5.4–6.6 kΩ at 80 °C (176 °F): 0.3–0.4 kΩ

Checking the engine temperature sensor 1. Place the engine temperature sensor in a container of water and slowly heat the water. Test harness (3 pins): New: YB-06857 Current: YB-06757 Throttle position sensor input voltage: Orange (O) – Red (R) 5V Throttle position sensor output voltage: Pink (P) – Orange (O) Z150 models: 0.58 ± 0.02 V Z175 models, Z200 (L-transom) models: 0.60 ± 0.02 V Z200 (X-transom) models: 0.62 ± 0.02 V

Checking the sensor assembly 1. Place the sensor assembly in a container of water and slowly heat the water.

S68F8190C

8-17

S69J8240

2. Measure the engine temperature sensor resistance. Replace if out of specification. Engine temperature sensor resistance: Black/yellow (B/Y) – Black/yellow (B/Y) at 20 °C (68 °F): 54.2–69.0 kΩ at 100 °C (212 °F): 3.12–3.48 kΩ

Checking the thermoswitches 1. Place the thermoswitches in a container of water and slowly heat the water.

S69J8250

68F1F11

Ignition and ignition control system 2. Check the switches for continuity at the specified temperatures. Replace if out of specification.

Checking the ECM main relay 1. Remove the fuse holder cover, and then remove the fuse holder. 2. Connect the digital circuit tester leads to ECM main relay terminals 1 and 2. 3. Connect positive battery terminal to the ECM main relay terminal 1. 4. Connect the negative battery terminal to the ECM main relay terminal 3.

a b c d

5. Check for continuity between the ECM main relay terminals. Replace if there is no continuity.

Temperature Time No continuity Continuity

6. Check that there is no continuity between the relay terminals after disconnecting a battery terminal from ECM main relay terminal 1 or 3. Replace if there is continuity.

Thermoswitch continuity temperature: Pink (P) – Black (B) e: 84–90 °C (183–194 °F) f: 60–74 °C (140–165 °F)

Checking the shift position switch 1

1. Check the shift position switch for continuity. Replace if there is no continuity.

3 a b

2 S60V8450 S69J8270

Switch position

Lead color Blue/green (L/G)

Black (B)

Free a Push b

68F1F11

8-18

1 2 3 4 5 6 7 8 9

â&#x20AC;&#x201C;

ELEC

Electrical systems

Fuel control system

W/B W/Y B

B W/Y W/B W/R

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

W/G W/L W/Br

W/Br W/L

R/Y #2

4 3 2

G/W G/L

2G/L

G/W

O/B

R/Y L

90ABCDE #4

12345678

NOPQRST

5 B

Pu/R

O/R Pu/R

Pu/Y

O/Y O/B

O/L O/W Pu/W

O/Y Pu/Y

O/W

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

7 B

O/L

L/W L/W

B B

7GH 56A 9 BCD EFL M

B B P

9 IJK = N

1 2 3 4

MLF EDCBAHG 7 KJI N= 65 9

O P R

1 2 3 4 5 6 8 9 10

R B/Y

O/L Pu/L

L/R

Pu/L

O/G

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

O/R

L/G

L/R

L/W

Y/R

L/G

R/Y

O/R

Pu/W

R/Y

O/G

R/Y

FGHIJKLM

5 O/G Pu/G

R/Y

Pu/G

L/R

O/B Pu/B

R/Y

L/W

5 Pu/B

R/Y 2

B B B

: : : : : : : : :

: : : : : : : :

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

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

11 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 23 24 25 26 28 29 30

R R/L R/L L/Y

10 19 20 21

: : : :

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

22 : R/Y 23 : R/Y 24 : R/W

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

19 20 27 28 29 30 31 32 36 37 38 39 40

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

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

42 43 44 45 46 47 48 51 52 53 54 55 57

B/Y R

R P

B/Y

F O

P P

D JKLMNOP DEFGHI 890ABC 1234567

lmnopqrst defghijk Z[\]^abc QRSTUVWXY

B/W

Y R/Y

B/Y

B B B/R

B/R

E B

O B B

B B

: : : :

1 5 6 9

1 2 4 5 8 9 10 11 12 13 15 17 18

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

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

Gy Gy

1 2 3 4 5 6 7 8 9 0

Pulser coil Crank position sensor Fuel pump relay Injector drivers Fuel injector Fuse holder Fuse (20 A) ECM main relay Injector driver relay Fuse (80 A)

8-19

S68F8200C

B/Y

A B C D E F

Battery Oxygen density sensor Thermoswitch ECM Fuel pressure sensor Sensor assembly (intake air temperature, atmospheric pressure) G Engine temperature sensor H Throttle position sensor

I J K L

Water detection switch Oil level sensor Electric oil pump Electric fuel pump

68F1F11

Fuel control system 8

B W/Y W/B W/R

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

W/G W/L W/Br

W/Br W/L

R/Y #2

4 3 2

G/W G/L

2G/L

G/W

O/B

R/Y L

90ABCDE #4

12345678

NOPQRST

5 B

Pu/R

O/R Pu/R

Pu/Y

O/Y O/B

O/L O/W Pu/W

O/Y Pu/Y

O/W

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

7 B

O/L

L/W L/W

B B

7GH 56A 9 BCD EFL M

B B P

9 IJK = N

1 2 3 4

MLF EDCBAHG 7 KJI N= 65 9

O P R

1 2 3 4 5 6 8 9 10

R B/Y

O/L Pu/L

L/R

Pu/L

O/G

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

O/R

L/G

L/R

L/W

Y/R

L/G

R/Y

O/R

Pu/W

R/Y

O/G

R/Y

FGHIJKLM

5 O/G Pu/G

R/Y

Pu/G

L/R

O/B Pu/B

R/Y

L/W

5 Pu/B

R/Y 2

B B B

: : : : : : : : :

: : : : : : : :

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

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

11 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 23 24 25 26 28 29 30

R R/L R/L L/Y

10 19 20 21

: : : :

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

22 : R/Y 23 : R/Y 24 : R/W

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

19 20 27 28 29 30 31 32 36 37 38 39 40

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

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

42 43 44 45 46 47 48 51 52 53 54 55 57

B/Y R

R P

B/Y

F O

P P

D JKLMNOP DEFGHI 890ABC 1234567

lmnopqrst defghijk Z[\]^abc QRSTUVWXY

B/W

Y R/Y

B/Y

B B B/R

B/R

E B

O B

B B

: : : :

1 5 6 9

1 2 4 5 8 9 10 11 12 13 15 17 18

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

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

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

: Black : Green : Gray : Blue : Orange : Pink : Red : White : Yellow : Black/red

68F1F11

S68F8200C

B/Y

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

: Black/white : Black/yellow : Green/blue : Green/white : Blue/green : Blue/red : Blue/white : Blue/yellow : Orange/black : Orange/green

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

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

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

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

8-20

1 2 3 4 5 6 7 8 9

ELEC

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Electrical systems

Checking the injector drivers 1. Remove the fuel rail covers. 2. Connect the test harness (2 pins) to the fuel injector. 3. Measure the injector driver output peak voltage. If below specification, measure the fuel injector resistance or replace the injector drivers.

S60V8440

Digital multimeter: YU-34899-A

Fuel injector resistance (use as reference): 0.9–1.1 Ω at 20 °C (68 °F)

Checking the fuel pressure sensor 1. Remove the flywheel magnet cover. Digital multimeter: YU-34899-A Peak voltage adapter: YU-39991 Test harness (2 pins): YB-06861 Injector driver output peak voltage (use as reference): Purple/red (Pu/R) – Orange/red (O/R) Purple/black (Pu/B) – Orange/black (O/B) Purple/yellow (Pu/Y) – Orange/yellow (O/Y) Purple/green (Pu/G) – Orange/green (O/G) Purple/blue (Pu/L) – Orange/blue (O/L) Purple/white (Pu/W) – Orange/white (O/W) r/min DC V

NOTE: The ignition coils are connected to the injector driver cover. Do not remove the injector driver cover. 3. Connect the test harness (3 pins) between the fuel pressure sensor and the wiring harness as shown.

Loaded Cranking

1,500

3,500

4. Measure the resistance of the fuel injectors. Replace if out of specification.

8-21

2. Remove the harness cover bolts, and then pull back the injector driver cover 1.

S68F8220C

Test harness (3 pins): New: YB-06869 Current: YB-06769

68F1F11

Fuel control system 4. Start the engine and warm it up for 5 minutes, and then measure the fuel pressure sensor output voltage. If out of specification, check the high-pressure fuel line and the mechanical fuel pump or replace the fuel pressure sensor. Fuel pressure sensor output voltage (use as reference): Orange (O) â&#x20AC;&#x201C; Pink (P) 3.2 V at engine idle speed

NOTE: After the engine start switch is turned to ON, the electric fuel pump will operate for 5 seconds.

Checking the electric fuel pump relay 1. Remove the electric fuel pump relay 1.

Checking the water detection switch 1. Check the water detection switch for continuity. Replace if there is no continuity.

S68F8230C

a b

2. Connect the digital circuit tester leads to electric fuel pump relay terminals 2 and 3. S60V8220

Float position

Lead color Black (B)

Black (B)

On a Off b

Checking the electric fuel pump 1. Turn the engine start switch to ON.

3. Connect the positive battery terminal to the electric fuel pump relay terminal 4. 4. Connect the negative battery terminal to the electric fuel pump relay terminal 5. 5. Check for continuity between the electric fuel pump relay terminals. Replace if there is no continuity.

2. Listen for the operating sound of the electric fuel pump 1.

68F1F11

8-22

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â&#x20AC;&#x201C;

Electrical systems

6. Check that there is no continuity between the relay terminals after disconnecting a battery terminal from electric fuel pump relay terminal 4 or 5. Replace if there is continuity.

4 5 2 3 4

2 S60V8460

Checking the oxygen density sensor 2

3 S68F8240C

Checking the injector driver relay 1. Remove the fuse holder cover, then the fuse holder. 2. Connect the digital circuit tester leads to terminals 1 and 2. 3. Connect the terminal 1 to the positive battery terminal. 4. Connect the terminal 3 to the negative battery terminal. 5. Check for continuity between the injector driver relay terminals. Replace if there is no continuity. 6. Check that there is no continuity between the terminals after disconnecting terminal 1 or 3. Replace if there is continuity.

8-23

1. Check the oxygen density sensor heater for continuity. Replace if there is no continuity. Gy B/W

W W

S68F8250C

2. Remove the oxygen density sensor. 3. Remove any oil from the oxygen density sensor with acetone or a similar solvent and allow the sensor to thoroughly dry. 4. Heat the front end of the oxygen density sensor 1 with a gas torch 2 (in the center of its blue flame a) for 10â&#x20AC;&#x201C;15 seconds. Then, remove the oxygen density sensor from the flame and check the voltage change and time.

68F1F11

Fuel control system

Oxygen density sensor output voltage (use as reference): Gray (Gy) – Black/white (B/W) 0.0–1.0 V

1 2 3 4 5 6 7 8 9

B/W S68F8260C

WARNING To prevent an explosion when performing this procedure, keep all flammable products (e.g., gasoline) away from the testing area and make sure there is proper ventilation.

CAUTION: • Do not let any silicon anticorrosion solvent touch the oxygen density sensor or its accuracy will be affected. • Do not heat the oxygen density sensor above 800 °C (1,472 °F) or continuously for more than 1 minute at a time or the sensor will be damaged. • Do not use a burner with an oxygen tank. The sensor may be damaged by a flame of high temperature. a Inner cone b Outer cone NOTE: If the instantaneous change in the output voltage is 0.6 V or greater, the oxygen density sensor is OK.

68F1F11

8-24

ELEC

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Electrical systems

Starting system

1 1 8 17 18

: : : :

R R R R

1 3

2 7GH 56A 9 BCD EFL M

IJK = N

MLF EDCBAHG 7 KJI N= 65 9

R R

1 2 3 4

4 8

6 12

Br/W R Br

Br R

È Br

S68F8350C

1 2 3 4 5 6 7

Fuse holder Fuse (20 A) Fuse (80 A) Fuse (30 A) Starter relay Starter motor Battery

B Br R Br/W

: Black : Brown : Red : Brown/white

È To remote control box/switch panel

8-25

68F1F11

Starting system

Checking the fuses 1. Check the fuses for continuity. Replace if there is no continuity.

1 2 3 4 5 6 7 8 9

Checking the starter relay 1. Connect the digital circuit tester leads to the starter relay terminals. 2. Connect the positive battery terminal to the brown (Br) lead. 3. Connect the negative battery terminal to the black (B) lead. 4. Check for continuity between the starter relay terminals. Replace if there is no continuity. 5. Check that there is no continuity between the starter relay terminals after disconnecting a battery terminal from the brown or black lead. Replace if there is continuity.

Br B S60V8265

68F1F11

8-26

ELEC

–

Electrical systems

Starter motor

1 2 3 4

7 17 18 19 20 19 21 22

8 9 10

26 11

27 28

30 30

19 31

12 24

14 25 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

8-27

Part name Clip Pinion stopper Starter motor pinion Spring Bolt Housing Bearing Clutch assembly E-clip Washer Bracket Pinion shaft Planetary gear Outer gear Plate Armature Stator

S68F8270C

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

Remarks

M6 × 35 mm

Not reusable

68F1F11

Starter motor 8

1 2 3 4

7 17 18 19 20 19 21 22

8 9 10

26 11

27 28

30 30

19 31

12 24

14 25 No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

Part name Brush assembly Brush spring Brush holder Plate Washer Bracket Screw Bolt Rubber seal Shift lever Screw Spring Dust cover Magnet switch assembly Washer Nut

68F1F11

S68F8270C

Q’ty 1 4 1 1 1 1 2 2 1 1 1 1 3 1 1 1

Remarks

ø4 × 15 mm M6 × 120 mm

ø4 × 20 mm

8-28

1 2 3 4 5 6 7 8 9

ELEC

â&#x20AC;&#x201C;

Electrical systems

Disassembling the starter motor 1. Slide the pinion stopper 1 down as shown, and then remove the clip 2.

NOTE: Remove the clip with a thin screwdriver. 2. Remove the bolts, and then disassemble the starter motor.

2. Measure the commutator diameter. Replace the armature if below specification.

Commutator diameter limit: 28.0 mm (1.10 in) 3. Measure the commutator undercut a. Replace the armature if below specification.

Checking the starter motor pinion 1. Check the teeth of the pinion for cracks or wear. Replace if necessary. 2. Check for smooth operation. Replace if necessary. NOTE: Turn the pinion counterclockwise to check that it operates smoothly and turn it clockwise to check that it locks in place.

Commutator undercut limit a: 0.2 mm (0.01 in)

Checking the armature 1. Check the commutator for dirt. Clean with 600â&#x20AC;&#x201C;grit sandpaper and compressed air if necessary.

8-29

4. Check the armature for continuity. Replace if out of specifications.

68F1F11

Starter motor

Checking the magnet switch 1. Connect the tester leads between the magnet switch terminals as shown.

Armature continuity Commutator segments b

Continuity

Segment – Armature core c

No continuity

Segment – Armature shaft d

No continuity

2. Connect the positive battery lead to the brown and white (Br/W) lead. 3. Connect the negative battery lead to the starter motor body.

Checking the brushes

Br/W

1. Measure the brush length. Replace the brush assembly if below specification.

S69J8450

CAUTION: Do not connect the battery for more than one second, otherwise the magnet switch can be damaged.

Brush length limit a: 9.5 mm (0.37 in) 2. Check the brush holder assembly for continuity. Replace if out of specifications.

4. Check that there is continuity between the magnet switch terminals. Replace if there is no continuity. 5. Check that there is no continuity after the negative battery terminal is removed. Replace if there is continuity. NOTE: The starter motor pinion should be pushed out while the magnet switch is on.

Checking the starter motor operation S69J8440

1. Check the operation of the starter motor after installing it onto the power unit.

Brush continuity Brush 1 – Brush 2

68F1F11

No continuity

8-30

1 2 3 4 5 6 7 8 9

ELEC

â&#x20AC;&#x201C;

Electrical systems

Charging system

3 1 2 3 4

: : : :

R R R R

1 G G G

G G G

2 B

3 4

4 7GH 56A 9 BCD EFL M

IJK = N

MLF EDCBAHG 7 KJI N= 65 9

1 2 3 4

R B

S68F8280C

1 2 3 4 5 6

Stator coil Rectifier Regulator Fuse holder Fuse (80 A) Accessory battery Battery

8-31

B G R

: Black : Green : Red

68F1F11

Charging system

Checking the stator coil

Checking the Rectifier Regulator

1. Remove the junction box cover and disconnect the stator coil coupler.

1. Remove the fuse holder and disconnect the Rectifier Regulator coupler (blue).

2. Connect the test harnesses to the stator coil.

2. Measure the Rectifier Regulator output peak voltage. If below specification, measure the stator coil output voltage. Replace the Rectifier Regulator if the output peak voltage of the stator coil is above specification.

3. Measure the stator coil output peak voltage. Replace the stator coil if below specification.

S68F8300C

Digital multimeter: YU-34899-A Peak voltage adapter: YU-39991 Test harness (2 pins): New: YB-06887 Current: YB-06787 Test harness (1 pin): New: YB-06888 Current: YB-06788 Stator coil output peak voltage: Green (G) – Green (G)

Digital multimeter: YU-34899-A

Rectifier Regulator output peak voltage: Red (R) – Ground r/min DC V

Unloaded 1,500

3,500

13.0

Unloaded

r/min DC V

Cranking

1,500

3,500

5.5

Stator coil resistance (use as reference): Green (G) – Green (G) 0.16–0.24 Ω at 20 °C (68 °F)

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–

ELEC

Electrical systems

Oil feed pump control system

1 3

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

L/W

Y/R

L/G

Y/R

B L/R

L/R

7GH 56A 9 BCD EFL M

IJK = N

1 2 3 4

MLF EDCBAHG 7 KJI N= 65 9

L L

R R

1 : R 17 : R 18 : R B/R

B/R

7 JKLMNOP DEFGHI 890ABC 1234567

4 5 7 17 18

lmnopqrst defghijk Z[\]^abc QRSTUVWXY

B/R

: : : : :

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

19 20 21 24

: : : :

Y/R L B/R Y

Y R Y B

É B

Y/R

G/R

B/R

G/R

B/R

Br B

B Y L B/R

L B B/R

B/R

8 9

S60V8050

1 2 3 4 5 6 7 8 9

Oil level sensor Emergency switch Fuse holder Fuse (20 A) Fuse (80 A) Battery ECM Oil pump (remote oil tank) Oil level sensor (remote oil tank)

8-33

È To diagnostic indicator (special service tool) É To remote control box/ switch panel Ê To oil level warning indicator B Br L O

: Black : Brown : Blue : Orange

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

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

68F1F11

Oil feed pump control system

Checking the electric oil pump L/G

CAUTION: • Use unleaded straight gasoline only. • Do not use gasoline mixed with oil (premixed fuel)

L/W

L/R

1. Remove the flywheel magnet cover and disconnect the electric oil pump hose 1 from the vapor separator.

S68F8320C

a È

On Off

d É

Off On

Off

Off On

S68F8330C

2. Wrap the end of the electric oil pump hose with a rag.

3. Start the engine and let it idle. e B/R

4. Check that the oil flows from the electric oil pump hose end. If no oil flows from the hose end, replace the electric oil pump.

S68F8340C

Lead color Float position

Blue/ Blue/ Blue/ Black white green red (B) (L/W) (L/G) (L/R)

È On È Off É On É Off 5. Connect the electric oil pump hose.

Checking the oil level sensor 1. Check the oil level sensor for continuity. Replace if there is no continuity.

68F1F11

Ê On Ê Off Float distance: a: 53.5–56.5 mm (2.11–2.22 in) b: 83.5–86.5 mm (3.29–3.41 in) c: 5.0 mm (0.20 in) d: 103.5–106.5 mm (4.07–4.19 in) e: 150–153 mm (5.91–6.02 in)

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ELEC

â&#x20AC;&#x201C;

Electrical systems

Checking the emergency switch 1. Check the emergency switch for continuity. Replace if there is no continuity.

Switch position

Lead color Blue (L)

Black (B)

Home a On b 2. Check that the emergency switch returns automatically to the home position from the on position when released. Replace if necessary.

Checking the oil pump (remote oil tank) 1. Connect the positive battery terminal to the blue (L) lead. 2. Connect the negative battery terminal to the brown (Br) lead. 3. Listen for the operating sound of the oil pump (remote oil tank). Replace if there is no sound.

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Troubleshooting Special service tools .....................................................................................9-1 Yamaha Diagnostic System ..........................................................................9-2 Introduction................................................................................................9-2 Power unit....................................................................................................... 9-5 Self-diagnosis...............................................................................................9-22 Diagnosing the electronic control system ................................................ 9-22

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Troubleshooting

Special service tools

Yamaha Diagnostic System 60V-85300-02

YAMAHA DIAGNOSTIC SYSTEM INSTALLATION MANUAL

Yamaha Diagnostic System 60V-WS853-02

Diagnostic test lead YB-06795

9-1

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Special service tools / Yamaha Diagnostic System

Yamaha Diagnostic System

Introduction Features The newly developed Yamaha Diagnostic System provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods. By connecting your computer to the ECM (Electronic Control Module) of an outboard motor using the communication cable, this software can be used to display sensor data and data stored in the ECM on a computer’s monitor. If this software is run on Microsoft Windows® 95, Windows 98, Windows Me, Windows 2000, or Windows XP the information can be displayed in colorful graphics. Also, the software can be operated using either a mouse or a keyboard. In addition, the data for the main functions (Diagnosis, Diagnosis record, Engine monitor, and Data logger) can be saved on a disk or printed out. Functions 1. Diagnosis: With the engine main switch ON, each sensor’s status and each ECM diagnosis code or item is displayed. This enables you to find malfunctioning parts and controls quickly. 2. Diagnosis record: Sensors that had been activated and ECM diagnostic codes that have been recorded are displayed. This allows you to check the outboard motor’s record of malfunctions. 3. Engine monitor: Each sensor status and the ECM data are displayed while the engine is running. This enables you to find malfunctioning parts quickly. 4. Stationary test: With the engine off, the ignition, fuel injection, electric fuel pump, and electric oil pump are checked. These tests can be performed quickly. 5. Active test: With the engine running, each firing cylinder has dropped and the engine speed is checked for changes to determine whether the cylinder is malfunctioning. 6. Data logger: Displays 13 minutes of recorded data for two or more of the items stored in the ECM. In addition, the operating time as compared to the engine speed and the total operating time are displayed. This allows you to check the operating status of the engine. 7. Some files: Lets you select and run other applications while continuing to run the diagnostic program.

Contents 1. Software (1) 2. Adapter (1)

YAMAHA DIAGNOSTIC SYSTEM

3. Communication cable (1)

YAMAHA DIAGNOSTIC SYSTEM INSTALLATION MANUAL

INSTRUCTION MANUAL

4. Instruction Manual (1) 5. Installation Manual (1)

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Troubleshooting

Hardware requirements Make sure that your computer meets the following requirements before using this software. Computer:

IBM-compatible computer

Operating system:

Microsoft (Windows 95,) Windows 98, Windows Me, Windows 2000, or Windows XP (English version)

CPU: Windows 95/98: Windows Me/2000: Windows XP:

i486X, 100 MHz or higher (Pentium 100 MHz or higher recommended) Pentium, 166 MHz or higher (Pentium 233 MHz or higher recommended) Pentium, 300 MHz or higher (Pentium 500 MHz or higher recommended)

Memory: Windows 95/98: Windows Me: Windows 2000: Windows XP:

16 MB or more (32 MB or more recommended) 32 MB or more (64 MB or more recommended) 64 MB or more (128 MB or more recommended) 128 MB or more (256 MB or more recommended)

Hard disk free space:

20 MB or more (40 MB or more recommended)

Drive:

CD-ROM drive

Display:

VGA (640 × 480 pixels), (SVGA [800 × 600 pixels] or more recommended) 256 or more colors

Mouse:

Compatible with the operating systems mentioned above

Communication port:

RS232C (Dsub-9 pin) port, USB port

Printer:

Compatible with the operating systems mentioned above

NOTE: • The amount of memory and the amount of free space on the hard disk differs depending on the computer. • Using this software while there is not enough free space on the hard disk could cause errors and result in insufficient memory. • This software will not run properly on some computers. • When starting up this program, do not start other software applications. • Do not use the screen saver function or the energy saving feature when using this program. • If the ECM is changed, restart the program. • Window XP is a multiuser operating system, therefore, be sure to end this program if the login user is changed. • The USB adapter cannot be used with Windows 95. For operating instructions of the Yamaha Diagnostic System, refer to the “Yamaha Diagnostic System Instruction Manual.”

9-3

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Yamaha Diagnostic System

Connecting the communication cable to the outboard motor

1 2 3 4 5 6 7 8 9

3-pin communication coupler

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Troubleshooting

NOTE: • Before troubleshooting the outboard motor, check the compression pressure, the mounting and rigging of the outboard motor, and the operation of the engine start switch. Also, make sure that specified fuel has been used and that the battery is fully charged. • To diagnose a mechanical malfunction, use the troubleshooting charts for each trouble located in this chapter. Also, when checking and maintaining the outboard motor, see Chapters 3–8 for safe maintenance procedures. • To diagnose a malfunctioning sensor or switch, use the diagnostic flash indicator to determine the cause.

Power unit

Symptom 1: Engine does not start, or starting the engine is difficult. Starting system Check the starter motor operation.

Good operating condition?

Yes

No Check the battery lead connections and the starter motor positive terminal for damage and check that the ground lead bolt is not loose or that it has not come off. Check for blown fuses.

Good condition?

Check the fuel pressure sensor and the throttle position sensor and check the connectors for proper connections.

Good condition?

Repair or replace the defective parts.

Yes Check the ignition system and fuel system. Repair or replace the defective parts.

Yes Check the starter relay for continuity.

Continued on next page.

9-5

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Power unit

Is there continuity?

1 2 3 4 5 6 7 8 9

Replace the starter relay.

Yes Check the wiring harness for continuity.

Is there continuity?

Repair or replace the wiring harness.

Yes Disassemble and check the starter motor.

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Troubleshooting

Ignition system Check the condition of the spark plugs.

Good condition?

Clean, adjust, or replace the spark plugs.

Yes Check the electric oil pump and oil level sensor.

Good condition?

Replace the defective parts.

Replace the reed valves.

Yes Check the reed valves.

Check the ignition spark using the spark gap tester.

Yes

Good condition?

WARNING • Do not touch any of the connections of the spark gap tester leads. • Do not let sparks leak out of the removed spark plug caps. • Keep flammable gas and liquids away, since this test can produce sparks.

Good spark?

Yes

Check the crank position sensor air gap.

No Air gap within specification?

Adjust the air gap.

Yes Check the starting system or the fuel system.

Continued on next page.

9-7

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Power unit

1 2 3 4 5 6 7 8 9

Check the ignition coil resistance and the ignition coil leads for salt buildup.

Good condition?

Repair or replace the defective parts.

Yes Check the spark plug cap resistance and the spark plug caps for salt buildup.

Good condition?

Repair or replace the spark plug caps.

Yes Check the ECM output peak voltage.

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Troubleshooting

Fuel system Check the electric fuel pump operation.

Can the operation sound be heard?

Check the fuse holder, fuse, fuel pump relay, and wiring harness for continuity.

Yes Is there continuity?

Repair or replace the defective parts.

Yes Check the fuel filters and check valves for clogs and the hoses for leaks.

Clogs or leaks?

Yes

Replace the electrical fuel pump.

Repair or replace the defective parts.

No Check the fuel pump diaphragm.

Cracks or damage?

Yes

Replace the diaphragm.

No Check the vapor separator needle valve.

Is the needle valve bent or worn?

Yes

Replace the needle valve.

No Check the injector resistance and check the injectors for clogs.

Continued on next page.

9-9

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Power unit

Good condition?

1 2 3 4 5 6 7 8 9

Replace the injectors.

Yes Check the injector driver couplers.

Water present or poor connections?

Yes

Repair or replace the defective parts.

No Check the starting system or the ignition system.

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Troubleshooting

Symptom 2: Engine speed at wide open throttle is low, engine speed decreases, or engine stalls (poor acceleration or poor deceleration). Check the battery lead connections and check that the ground lead bolt is not loose or that it has not come off.

Good condition?

Repair or replace the defective parts.

Yes Check the fuel pressure sensor and throttle position sensor and check that the connectors are securely connected.

Good condition?

Repair or replace the defective parts.

Repair or replace the defective part.

Yes Check the shift position switch for continuity.

Is there continuity? Yes

Check the throttle valves for bends or for stuck throttle valve shafts.

Good condition?

Replace the throttle body.

Yes Check the ignition system or the fuel system.

9-11

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Power unit Ignition system Check the condition of the spark plugs.

Good condition?

Clean, adjust, or replace the spark plugs.

Yes Check the electric oil pump and oil level sensor.

Good condition?

Replace the defective parts.

Replace the reed valves.

Yes Check the reed valves.

Check the ignition spark using the spark gap tester.

Yes

Good condition?

Good spark?

Yes

Check the crank position sensor air gap.

No Air gap within specification?

Adjust the air gap.

Yes Check the fuel system.

Continued on next page.

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Troubleshooting

Check the ignition coil resistance and check the ignition coil leads for salt buildup.

Good condition?

Repair or replace the defective parts.

Yes Check the spark plug cap resistance and check the spark plug caps for salt buildup.

Good condition?

Repair or replace the spark plug caps.

Yes Check the ECM output peak voltage.

9-13

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Power unit Fuel system Check the electric fuel pump operation.

Can the operation sound be heard?

Check the fuse holder, fuse, fuel pump relay, and wiring harness for continuity.

Yes Is there continuity?

Repair or replace the defective parts.

Yes Check the fuel filters and check valves for clogs and the hoses for leaks.

Good condition?

Replace the electric fuel pump.

Repair or replace the defective parts.

Yes Check the fuel pump diaphragm.

Cracks or damage?

Yes

Replace the diaphragm.

No Check the vapor separator needle valve.

Is the needle valve bent or worn?

Yes

Replace the needle valve.

No Check the vapor separator pressure regulator.

Continued on next page.

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Troubleshooting

Good condition?

Replace the pressure regulator.

Yes Check the high-pressure fuel pump camshaft.

Is the camshaft bent or damaged?

Yes

Replace the high-pressure fuel pump camshaft.

No Check the injector resistance and check the injectors for clogs.

Good condition?

Replace the injectors.

Yes Check the injector driver couplers.

Water present or poor connections?

Yes

Repair or replace the defective parts.

No Check the starting system or the ignition system.

9-15

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Power unit Symptom 3: Engine speed not stable at low speeds. Check the fuel pressure sensor and throttle position sensor and check that the connectors are securely connected.

Good condition?

Repair or replace the defective parts.

1 2 3 4 5 6 7 8 9

Yes Check the shift position switch for continuity.

Is there continuity? Yes

Check the throttle valve opening of each cylinder.

Is the throttle valve opening incorrect or is the throttle valve link worn?

Yes

Replace the throttle body.

No Check the ignition system or the fuel system.

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Troubleshooting

Ignition system Check the condition of the spark plugs.

Good condition?

Clean, adjust, or replace the spark plugs.

Yes Check the electric oil pump and oil level sensor.

Good condition?

Replace the defective parts.

Replace the reed valves.

Yes Check the reed valves.

Check the ignition spark using the spark gap tester.

Yes

Good condition?

Good spark?

Yes

Check the fuel system.

No Check the ignition coil resistance and check the ignition coil leads for salt buildup.

Continued on next page.

9-17

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Power unit

Good condition?

1 2 3 4 5 6 7 8 9

Repair or replace the defective parts.

Yes Check the spark plug cap resistance and check the spark plug caps for salt buildup.

Good condition?

Repair or replace the spark plug caps.

Yes Check the ECM output peak voltage.

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Troubleshooting

Fuel system Check the fuel pump diaphragm.

Cracks or damage?

Yes

Replace the diaphragm.

No Check the vapor separator needle valve.

Is the needle valve bent or worn?

Yes

Replace the needle valve.

No Check the injector resistance and check the injectors for clogs.

Good condition?

Replace the injectors.

Yes Check the injector driver couplers.

Water present or poor connections?

Yes

Repair or replace the defective parts.

No Check the ignition system.

9-19

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Power unit Symptom 4: Hunting occurs. Check the throttle valve opening of each cylinder.

Do the throttle valves open too much?

Yes

1 2 3 4 5 6 7 8 9

Synchronize the throttle valves or replace the defective parts.

No Adjust the throttle cable.

Symptom 5: Engine speed rises even when the throttle position is fixed. Check the throttle cable operation.

Good condition?

Adjust the throttle cable.

Yes Synchronize the throttle valves.

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Troubleshooting

Symptom 6: Excessive white exhaust smoke.

Check the idle hole rubber seal.

Cracks or damage?

Yes

Replace the rubber seal.

No Check the electric oil pump and oil level sensor.

Good condition?

Replace the defective parts.

Yes Check the fuel pump diaphragm.

Cracks or damage?

Yes

Replace the diaphragm.

No Check the vapor separator needle valve.

Is the needle valve bent or worn?

Yes

Replace the needle valve.

No Check the thermostat.

9-21

68F1F11

Power unit / Self-diagnosis

Self-diagnosis

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

S68F9020C

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

Diagnostic test lead: YB-06795 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

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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

Symptom

Normal

Incorrect pulser coil signal

Incorrect crank position sensor signal

Incorrect engine temperature sensor signal

Incorrect throttle position sensor signal

Incorrect battery voltage

Incorrect sensor assembly (atmospheric pressure) signal

Incorrect sensor assembly (intake air temperature) signal

Incorrect fuel pressure signal

Incorrect injector signal

Incorrect water in fuel signal

Incorrect shift position switch signal

Incorrect engine stop lanyard switch signal

9-23

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Index

A. Adjusting the oil pump link rod ....................3-9 Adjusting the throttle cable..........................3-7 Adjusting the throttle position sensor ........4-25 Adjusting the trim sensor cam...................7-43 Aft view .......................................................8-6 After test run .............................................1-10 Applicable models.......................................1-5 Assembling the bearing housing...............5-41 Assembling the crankshaft........................5-40 Assembling the drive shaft housing ......................................... 6-17, 6-43 Assembling the forward gear ....................6-17 Assembling the fuel pumps.........................4-7 Assembling the gear pump housing..........7-31 Assembling the lower case ............. 6-16, 6-42 Assembling the oil seal housing................5-41 Assembling the oil tank .............................4-10 Assembling the piston and connecting rod assemblies .....................5-41 Assembling the power trim and tilt motor...7-29 Assembling the power trim and tilt unit .....7-35 Assembling the power unit........................5-42 Assembling the propeller shaft assembly.................................................6-12 Assembling the propeller shaft housing ......................................... 6-12, 6-37 Assembling the reverse gear ....................6-43 Assembling the tilt piston and trim pistons..............................................7-34 Assembling the upper case.......................7-11

B. Backlash (counter rotation model) ............6-52 Backlash (regular rotation model) .............6-26 Bleeding the oil injection system...............4-11 Bleeding the power trim and tilt unit..........7-37 Bleeding the power trim and tilt unit (built-in) ...................................................7-39 Bottom cowling............................................7-2 Break-in.....................................................1-10

C. Changing the gear oil................................3-11 Changing the high-pressure fuel pump gear oil ......................................................3-4 Charging system .......................................8-31 Checking the anodes ................................3-12 Checking the armature..............................8-29 Checking the battery ......................... 1-7, 3-12 Checking the bearings ...........5-36, 6-16, 6-42 Checking the brushes ...............................8-30 68F1F11

Checking the check valve......................... 4-10 Checking the compression pressure .......... 5-2 Checking the connecting rod big end side clearance ........................................ 5-39 Checking the connecting rod small end axial play................................................. 5-39 Checking the cooling water passage.......... 3-6 Checking the cooling water pilot hole ....... 1-10 Checking the crank position sensor.......... 8-16 Checking the crank position sensor air gap..................................................... 8-16 Checking the crankshaft ........................... 5-39 Checking the cylinder bore ....................... 5-37 Checking the cylinder head ...................... 5-27 Checking the drive belt ............................... 3-5 Checking the drive belt and sprockets...... 5-15 Checking the drive shaft ..................6-16, 6-42 Checking the drive shaft bushing (X-transom model).................................. 7-11 Checking the ECM.................................... 8-15 Checking the ECM main relay .................. 8-18 Checking the electric fuel pump ............... 8-22 Checking the electric fuel pump relay....... 8-22 Checking the electric oil pump.................. 8-34 Checking the electrical components........... 8-2 Checking the emergency switch............... 8-35 Checking the engine idle speed ................. 3-7 Checking the engine oil level...............1-7, 3-5 Checking the engine start switch and engine stop lanyard switch ....................... 1-9 Checking the engine temperature sensor..................................................... 8-17 Checking the fuel filter ................................ 3-4 Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector) .......................... 3-3 Checking the fuel pressure sensor ........... 8-21 Checking the fuel pumps ............................ 4-6 Checking the fuel system ........................... 1-7 Checking the fuse..................................... 7-46 Checking the fuses ................................... 8-26 Checking the gear oil level ................1-7, 3-10 Checking the gear pump .......................... 7-31 Checking the gear shift and throttle operation....................................... 1-9 Checking the gear shift operation............... 3-8 Checking the high-pressure fuel pump gear oil level ............................................. 3-4 Checking the hydraulic pressure .............. 7-24 Checking the ignition coils ........................ 8-14 Checking the ignition spark ...................... 8-14 Checking the injector driver relay ............. 8-23 Checking the injector drivers .................... 8-21 Checking the lower case .................6-16, 6-42

i-1

1 2 3 4 5 6 7 8 9

Index Checking the lower unit for air leakage.....3-11 Checking the magnet switch .....................8-30 Checking the oil filter.................................4-10 Checking the oil level sensor ....................8-34 Checking the oil pump (remote oil tank) ...8-35 Checking the oil pump driven gear and the oil pump drive gear ...........................5-36 Checking the oil tank.................................4-10 Checking the outboard motor mounting height ........................................................1-8 Checking the oxygen density sensor ........8-23 Checking the pinion and forward gear ......6-16 Checking the pinion and reverse gear ......6-42 Checking the piston clearance..................5-37 Checking the piston diameter ...................5-36 Checking the piston pin.............................5-38 Checking the piston pin boss bore............5-38 Checking the piston ring side clearance ...5-38 Checking the piston rings..........................5-37 Checking the power trim and tilt fluid level .................................................3-10 Checking the power trim and tilt motor .....7-27 Checking the power trim and tilt operation ...................................................3-9 Checking the power trim and tilt relay.......7-46 Checking the power trim and tilt switch.....7-47 Checking the power trim and tilt system .....1-9 Checking the pressure control valve.........5-29 Checking the pressure regulator...............4-21 Checking the propeller ..............................3-12 Checking the propeller shaft ........... 6-12, 6-37 Checking the propeller shaft housing ......................................... 6-12, 6-37 Checking the pulser coil............................8-15 Checking the Rectifier Regulator ..............8-32 Checking the reed valve ...........................5-22 Checking the remote control cables............1-8 Checking the sensor assembly .................8-17 Checking the shift position switch .............8-18 Checking the spark plug caps...................8-14 Checking the spark plugs............................3-5 Checking the starter motor operation........8-30 Checking the starter motor pinion .............8-29 Checking the starter relay .........................8-26 Checking the stator coil.............................8-32 Checking the steering system.....................1-9 Checking the thermostats ...........................3-6 Checking the thermoswitches ...................8-17 Checking the throttle position sensor........8-16 Checking the tilt cylinder and trim cylinder.............................................7-33 Checking the top cowling ............................3-3 Checking the trim sensor ..........................7-47

i-2

Checking the upper case.......................... 7-10 Checking the vapor separator .................. 4-23 Checking the water detection switch ........ 8-22 Checking the water pump and shift rod............................................6-8, 6-33 Clamp brackets......................................... 7-41 Control system............................................ 3-7 Crankcase ................................................ 5-30 Cylinder block ........................................... 5-31 Cylinder head ........................................... 5-25

D. Diagnosing the electronic control system .................................................... 9-22 Dimensions............................................... 2-24 Disassembling the bearing housing.......... 5-34 Disassembling the crankshaft................... 5-36 Disassembling the drive shaft housing ..........................................6-15, 6-41 Disassembling the forward gear ......6-15, 6-36 Disassembling the fuel pumps.................... 4-6 Disassembling the gear pump housing .... 7-29 Disassembling the lower case .........6-15, 6-41 Disassembling the piston and connecting rod assemblies ..................... 5-35 Disassembling the power trim and tilt motor ...................................................... 7-26 Disassembling the propeller shaft assembly .......................................6-11, 6-36 Disassembling the propeller shaft housing ..........................................6-11, 6-37 Disassembling the reverse gear ............... 6-41 Disassembling the starter motor............... 8-29 Disassembling the tilt cylinder and trim cylinders .......................................... 7-32 Disassembling the upper case ................. 7-10 Disassembly and assembly ........................ 1-4 Disconnecting the medium-pressure fuel hose joint ......................................... 4-22 Drive shaft and lower case (counter rotation model) ......................... 6-39 Drive shaft and lower case (regular rotation model) .......................... 6-14

E. Electrical (Z150 models)........................... 2-10 Electrical (Z175 models)........................... 2-15 Electrical (Z200 models)........................... 2-21 Electrical components ................................ 8-3 Exhaust cover........................................... 5-28

68F1F11

Index

F. Fire prevention ............................................1-3 Fuel control system...................................8-19 Fuel filter .....................................................4-3 Fuel hoses and fuel pipes ...........................4-2 Fuel pump ...................................................4-4 Fuel system.................................................3-3

G. General .....................................................3-12 General specifications.................................2-1 General torques ........................................2-29 Good working practices ..............................1-4

H. High-pressure fuel line ..............................4-27 High-pressure fuel pump...........................4-29 Hose routing................................................4-2 How to use this manual...............................1-1

L. Lower unit ................................................. 3-10 Lower unit (counter rotation model).......... 6-29 Lower unit (regular rotation model)............. 6-4 Lower unit (Z150 models)........................... 2-9 Lower unit (Z175 models)......................... 2-14 Lower unit (Z200 models)......................... 2-20 Lubricating the outboard motor................. 3-13

M. Maintenance interval chart ......................... 3-2 Maintenance specifications ........................ 2-7 Manual format............................................. 1-1 Measuring the forward and reverse gear backlash ...................6-26, 6-52 Measuring the fuel pressure (medium-pressure fuel line).................... 4-21 Measuring the lower resistance.................. 8-2 Measuring the peak voltage ....................... 8-2

I. Identification................................................1-5 Ignition and ignition control system...........8-12 Installing the clamp brackets.....................7-43 Installing the drive shaft .................. 6-18, 6-44 Installing the drive shaft bushing (X-transom model) ..................................7-11 Installing the electric fuel pump filter.........4-23 Installing the fuel injectors.........................4-32 Installing the fuel pipes .............................4-32 Installing the joints ....................................4-32 Installing the lower unit ................... 6-20, 6-46 Installing the medium-pressure fuel hose clamps.....................................................4-23 Installing the oil pump ...............................4-10 Installing the power trim and tilt unit..........7-38 Installing the power unit ............................5-47 Installing the pressure control valve..........5-29 Installing the propeller shaft housing ......................................... 6-18, 6-44 Installing the sprockets and drive belt.......5-16 Installing the steering arm.........................7-14 Installing the throttle body assembly.........4-24 Installing the upper case ...........................7-15 Installing the water pump and shift rod ......................................... 6-19, 6-45 Intake manifold..........................................5-21 Introduction .................................................9-2

J. Junction box assembly................................8-5

68F1F11

Oil feed pump control system ................... 8-33 Oil injection system..............................3-9, 4-8

P. Parts, lubricants, and sealants ................... 1-3 Port view..................................................... 8-3 Power trim and tilt electrical system ......... 7-45 Power trim and tilt unit .......................3-9, 7-16 Power unit.................................... 3-5, 5-2, 9-5 Power unit (Z150 models) .......................... 2-7 Power unit (Z175 models) ........................ 2-13 Power unit (Z200 models) ........................ 2-18 Predelivery checks ..................................... 1-7 Propeller selection ...................................... 1-5 Propeller shaft housing (counter rotation model) ......................... 6-34 Propeller shaft housing (regular rotation model) ............................ 6-9 Propeller size.............................................. 1-5

R. Reducing the fuel pressure (medium-pressure fuel line).................... 4-22 Removing the clamp brackets .................. 7-43 Removing the crankcase .......................... 5-34 Removing the cylinder head ..................... 5-27 Removing the drive belt and sprockets .... 5-15 Removing the drive shaft.................6-15, 6-41 Removing the drive shaft bushing (X-transom model).................................. 7-11

i-3

1 2 3 4 5 6 7 8 9

Index Removing the electric fuel pump filter.......4-23 Removing the exhaust cover ....................5-29 Removing the flywheel magnet.................5-19 Removing the intake manifold...................5-22 Removing the lower unit ................... 6-7, 6-32 Removing the medium-pressure fuel hose clamps .....................................4-23 Removing the piston and connecting rod assemblies and crankshaft assembly .....5-35 Removing the power trim and tilt unit........7-23 Removing the power unit ..........................5-17 Removing the propeller shaft housing assembly....................................... 6-11, 6-36 Removing the reservoir.............................7-29 Removing the starter motor ......................5-20 Removing the stator coil and pulser coil ...5-19 Removing the steering arm.......................7-14 Removing the throttle body assembly.......4-22 Removing the water pump and shift rod ........................................... 6-7, 6-32

U. Upper case ................................................. 7-6

V. Ventilation................................................... 1-3

W. Wiring harness............................................ 8-8

Y. Yamaha Diagnostic System ....................... 9-2

S. Safety while working ...................................1-3 Selecting the forward gear shims.... 6-24, 6-51 Selecting the pinion shims .............. 6-23, 6-49 Selecting the propeller shaft shims ...........6-52 Selecting the reverse gear shims.... 6-25, 6-50 Selection .....................................................1-6 Self-diagnosis ...........................................9-22 Self-protection.............................................1-3 Serial number..............................................1-5 Shimming ........................................ 6-23, 6-49 Shimming (counter rotation model)...........6-48 Shimming (regular rotation model)............6-22 Special service tools ............ 3-1, 4-1, 5-1, 6-1, 7-1, 8-1, 9-1 Specified torques ......................................2-27 Starboard view ............................................8-4 Starter motor .............................................8-27 Starting system .........................................8-25 Steering arm .............................................7-13 Symbols ......................................................1-2 Synchronizing the throttle valves ..............4-24

T. Test run.....................................................1-10 Throttle body assembly and vapor separator.......................................4-12 Throttle lever and shift position switch ......5-23 Tightening torques ....................................2-27 Top cowling.................................................3-3 Top view......................................................8-7

i-4

68F1F11

Wiring diagram Z150TR, LZ150TR, VZ150TR, Z175TR, VZ175TR, Z200TR, LZ200TR, VZ200TR 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 [ \ ] È É Ê Ë Ì

Electric fuel pump Fuel pump relay Electric oil pump Fuel injector Ignition coil Spark plug Pulser coil Stator coil Crank position sensor Fuse holder Fuse (20 A) ECM main relay Injector driver relay Fuse (80 A) Fuse (30 A) Rectifier Regulator Starting battery Accessory battery Starter motor Starter relay Power trim and tilt motor Power trim and tilt relay Shift position switch Oil level sensor Emergency switch Throttle position sensor Power trim and tilt switch Water detection switch Sensor assembly (intake air temperature, atmospheric pressure) Engine temperature sensor Thermoswitch Fuel pressure sensor Injector driver ECM Oxygen density sensor Diode Trim sensor Oil pump (remote oil tank) Oil level sensor (remote oil tank) To personal computer for diagnosis To remote control box/switch panel To oil level 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

Z150TR, LZ150TR, VZ150TR, Z175TR, VZ175TR, Z200TR, LZ200TR, VZ200TR B

R L

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

R/Y L

R/Y 2

W/B

W/G W/L

W/L W/Br

G G

G G G

G/W

L R/Y

O/B Pu/B

O/G

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

O/R Sb

O/R O/G Lg

Lg R Sb

6 5

Pu/R

O/R

B/L

R/Y R/Y B/L

B/Br

R/Y

IJK 0 N

1 2 3 4

Br/W R

R Br

Br Br B

O/L

B B B

K B

9 0 A B C D E

L/W L/W

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

Y/R

L/W

R/Y

W Gy

W/B R/Y B

B/W

L/G

B R/Y

W/B

B L/G

L/G

Sb Lg B B

R Lg

Gy B/W

B R/Y

B/W

Sb Lg

L/W

R Gy B/W

Lg Sb

F G H I J K L M

P 7 OIC6 NHB5 MGA4 LF03 KE92 JD81

N O P Q R S T

t Y skcX rjbW ia q V ph^U og]T nf\S me[R ldZQ

1 2 3 4 5 6 7 8

L/R

R/W

L/G

G B

N B L/R L/W L/R L/G

R/W

Pu/L

R R R

O/L Pu/L

O/W Pu/W

(*2)

(*1)

R/W

B/W B/W

R R R/W

O/Y Pu/Y

56A 9 BCD EFL M

Pu/Y

O/Y

B/W

MLF EDCBAHG 7 KJI N0 65 9

R/Y

R/Y B/Br

6 Pu/W

O/W

4 7GH

O/R Pu/R

R/Y B/Y

B/G

B/W

Lg R/W Sb

B/W

B/W B/W

O/G Pu/G

O/L

B/Y

R/Y

R/Y B/G

4 Pu/G

R/Y

R R

B/W

B/W R/Y

B/W

Pu/B

B/W

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

B/W

R/Y B/O

R/Y B/W

O/B R/Y

B/O

R/Y

B B B B B B B B B

G G G

G/W

G/L

R/Y

G G G

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

B B B

W/Y B

W/B

W/R

W/Br

L Y B R/Y

4 3 2

W/Y

É P P

B/Y B/Y

B P

O P R

B P O O

O B B/Y

B B/Y

B/Y

O O Y Y B/R O O Y B/R B/R

BBB

O P

B B

BPO

B/Y

R B

B/R

Ê B/R

G/R

B/Y

B/R

P Gy

G/R B/R Gy P

Gy P B

B Gy

B/Y

Y B

Sb Br

B B B Gy B B B B/Y

[

B P B

B B

Y L B/R B

B B/R L

B/R

] S68FWD01C

! 0 1 2 3 4 5 6 7 8

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

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

G G

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/Y R/Y R/W

: : : : : : : : : :

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/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 B/W 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

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

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

B B

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

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

1 2 3 4 5 6 7 8 9 10

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

X R/W

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

L/R L/R B/Y B/Y P P P L L/G L/W L/W Y/R P L B B Sb Lg R/W B/Y B B B O O

: : : : : : : :

Lg Sb B B B B/W Br W G P G/R L/G

O Y B/R Y Y B/R B/R B B Gy O

P B

R/W Br L/G B Lg Lg Sb Sb B B G Y W P Gy G/R B/R B/R L Y

R Br Lg B Sb

B B B

S68FWD02C

YAMAHA MOTOR CORPORATION, USA

Printed in USA Nov. 2003 – 0.0 × 1 CR (E)