Home

Grey Whale 200 EFI Fin Whale 225 EFI

1. S6P24450E Cooling water hose cylinder block to fuel cooler Cooling water hose fuel cooler to R ectifier Regulator Cooling water hose Rectifier R egulator to cooling water pilot hole Cooling water hose port thermostat cover to cylinder block Cooling water hose starboard thermostat cover to cylinder block Cooling water hose starboard cylinder head to cooling water pressure sensor adapter Flushing hose joint to cooling water passage cover Fuel cooler Rectifier Regulator Cooling water pilot hole on the bottom cowling Cooling water pressure sensor adapter Cooling water passage cover on the cylinder block 4 3 6AL3 11 Hose routing WAN SD I QD Ne 9 S6P24490 Cooling water hose cylinder block to fuel cooler Cooling water hose Rectifier R egulator to cooling water pilot hole Flushing hose joint to cooling water passage cover Flushing hose flushing hose adapter to joint Speedometer hose 6AL3 11 4 4 el D Fuel system
2. S6AL8430 Fasten the PTT motor lead and ground lead of the wiring harness to the holder Install the starter motor lead and brown lead of the wiring harness with the bolt Fasten the starter motor lead and sub wiring harness to the holders Fasten the starter motor lead oil pressure sensor lead PTT motor lead sub wiring harness and isolator lead to the holder Route the oil pressure sensor lead isolator lead and PTT motor lead through the guide Align the white tape on the oil pressure sensor lead with the guide of the positive battery terminal Fasten the oil pressure sensor lead water detection switch lead isolator lead and PTT motor lead to the holder Route the battery cables along the bottom of the bottom cowling ol 0 a e m 7 a 8 11 6AL3J 11 Wiring harness routing
3. S6AL8430 Fasten the fuel injector lead in the order of J K and MI Fasten the fuel injector lead 5 to the clip at the white tape Fasten the fuel injector lead 3 to the clip It is not necessary to fasten the lead if its length is short Fasten the fuel injector lead 1 and then fasten the fuel injector lead 3 and 5 to the clip Fasten the fuel injector harness using a plastic tie Fasten the fuel injector lead and quick connector to the holder 2 B E Bl e E 6AL3J 11 8 12 evec ELEC ES Electrical system Aft view p WD e RTS
4. Neutral switch coupler blue Shift cut switch coupler black S6P28040E 6AL3 11 Electrical component Wiring harness routing Wiring harness routing Port view S6P 28320E Install the low pressure fuel pump coupler onto the wiring harness guide Fasten the thermoswitch connectors and wiring harness oil control valve and fuel injectors to the holder Fasten the engine temperature sensor lead and thermoswitch lead on the hook of the wiring harness guide Install the engine temperature sensor coupler onto the wiring harness guide Fasten the wiring harness to the holder at the white tape Fasten the fuel injector lead in the order of G H
5. Hp LE ui i ie mem se mW a O a EE nn Na e Se ee EE Mi ee I SIS Hee RER Dee Ge a 063 ET Q A f WEE ee i ia a o re er HAD oui Al A AAT Pr FEE Hlp reent pen a Arena ee H PE RUE nja ell wi PA UL id SST j i IT IT m N i ee S _ i hi a ai aia ai md 1 06600000 I CEE ed fake ERE B bl GE EE A eS ee SH GG MG BESS EAR BE 1 89800000 al el II Me BOQOOOSOS o E ES PPE B 2 ken P Nan mmm jon nn NT aa EG T EE i A Lehr 5555 Se ED ae
6. S6AL8070 6AL3 11 5 Tighten the crank position sensor screws and then check the crank position sensor air gap Adjust again if out of specification Crank position sensor screw 4 N m 0 4 kgf m 3 0 ft lb 6 Install the wiring harness guide and the wiring harness guide bolts Checking the intake air temperature sensor 1 Measure the ambient temperature 2 Connect a computer to the outboard motor and use the YDIS to display Intake temperature S6P28270 NOTE gt To connect and operate the YDIS see Chap ter 9 YDIS and the YDIS Ver 1 23a or later Instruction Manual 3 Check that the difference between the ambient temperature and the displayed intake air temperature is within 5 9 F NOTE e Check the intake air temperature sensor when the engine is cold e When checking the intake air temperature sensor remove the top cowling and do not start the engine 4 Disconnect the intake air temperature sensor coupler 6AL3 11 Ignition and ignition control system 5 Turn the engine start switch to ON and then measure the input voltage at the intake air temperature sensor coupler wiring harness end Check the wiring harness if out of specification S6AL8450 Intake air temperature sensor input voltage reference data Black yellow B Y Black B 4 75 5 25 V 6 Turn the engine start swi
7. S6AL8380 Shift cut switch input voltage reference data Blue yellow L Y Black B 4 75 5 25 V Turn the engine start switch to OFF Disconnect the test harness 2 pins from the shift cut switch coupler wiring harness end and connect it to the shift cut switch coupler shift cut switch end To check the shift cut switch measure the shift cut switch resistance at position Replace if out of specification 6AL3 11 S6AL8390 Shift cut switch resistance 4 465 4 935 kQ at position 7 Check the shift cut switch for continuity at position Replace if there is no conti nuity NOTE TT TL If the shift cut switch is installed check the continuity when the shift bracket is at position Lead color Blue yellow L Y S witch position Black B Free Gi Push O 8 Disconnect the test harness 2 pins from the shift cut switch coupler black and then connect the shift cut switch cou pler black Checking the neutral switch 1 Disconnect the neutral switch coupler blue 2 Connect the test harness 2 pins to the neutral switch coupler wiring har ness end 6AL3 11 Ignition and ignition control system Test harness 2 pins 90890 06867 3 Turn the engine start switch to ON and then measure the input voltage at the neutral switch coup
8. S6AL8020 Cooling water pressure sensor coupler J oint connector Fasten the wiring harness and cam position sensor lead PORT IN using a plastic tie Fasten the cam position sensor lead PORT IN to the holder Install the clip of the knock sensor coupler to the hole of the ECM bracket Fasten the cooling water pressure sensor lead to the holder at the white tape Fasten the ignition coil lead 5 and cam position sensor lead STBD IN to the holder at the white tape Fasten the wiring harness and condenser assembly using a plastic tie F i l e e gt 8 13 6AL3J 11 Top view Stator coil lead Wiring harness Thermoswitch connector High pressure fuel hose Vapor gas hose Engine temperature sensor lead J oint connector 6AL3 11 Wiring harness routing S6AL8030 A Fasten the fuel injector lead and quick connector to the holder B Fasten the fuel injector lead and vapor gas hose to the holder C Face the white mark on the wiring harness upward D Install the crank position sensor coupler to the bracket 8 14 evec ELEC Electrical system Bottom cowling OG SX NGO 2C S e S a
9. S6AL 7320 NOTE Install the cooling water pipe positioned as shown V2 Muffler bolt 3 20 N m 2 0 kgf m 14 8 ft lb Assembling the upper case NOTE 1 Install the drive shaft bushing into the Be sure to insert the tip of the cooling water upper case and then install the circlip pipe into the joint hole of the upper case Oil pan assembly bolt M8 amp 20 N m 2 0 kgf m 14 8 ft lb Oil pan assembly bolt M 10 42 N m 4 2 kgf m 31 0 ft lb PCV 8 N m 0 8 kgf m 5 9 ft lb S6AL7330 NOTE After installing the drive shaft bushing apply grease to the inside of the bushing GC Needle bearing attachment 90890 06653 Driver rod L3 4 90890 06652 2 Install the dowels onto the upper case 6AL3J 11 7 18 Bracket unit 6 Install the damper cover and engine oil drain bolt and then tighten the drain bolt to the specified torque Engine oil drain bolt 27 N m 2 7 kgf m 19 9 ft lb 7 Install the upper mounts and upper mount bolts into the upper case 8 Install the bracket and then tighten the upper mount bracket bolts to the specified torque S6AL7360 NOTE First tighten the center located when tighten the upper mount bracket bolts g Upper mount bracket bolt 49 54 N m 5 4 kgf m 39 8 ft lb 7 19 9 Install the lower mounts g lower mount bolts 9 and mo
10. lo S 6AS 8040 Flushing hose Fuel hose PTT motor lead Battery cable Trim sensor lead Wiring harness Water detection switch coupler blue LAN communication coupler Isolator coupler black g PTT switch extension lead 10 pin main harness PTT switch lead Throttle cable PTT switch Gauge harness Shift cable Speedometer hose 8 15 6AL3 11 0 05 D c gt Make sure that the white paint mark on the flushing hose and the white tape on the PTT motor leads are positioned as shown Fasten the PTT switch lead with the holder Fasten the neutral switch lead and wiring harness with the holder Fasten the neutral switch lead and wiring harness with the clamp Fasten the flushing hose and trim sensor lead with the plate elle Jo m 6AL3J 11 Wiring harness routing S 6AS 8040 F Fasten the flushing hose trim sensor lead and speedometer hose with the plate G Fasten the flushing hose and trim sensor lead with the clamp H Fasten the PTT switch lead isolator lead and wire lead with the clamp J Route the water detection switch lead so that there is no excess slack between the fuel
11. 56P25990 NOTE eder TT e Crankcase bolts Dh can be reused 5 times e Do not turn the crankshaft until the crank shaft journal oil clearance measurement has been completed e Tighten the M8 bolts 1 8 and M10 bolts oie to the specified torques in 2 stages In the 2nd stage make a mark on the crankcase and crankcase bolts and then tighten crankcase bolts 1 H16 90 from the mark e After tightening the bolts 1 116 has been completed tighten the M8 bolts 17 29 to the specified torques in 2 stages 6AL3 11 Cylinder block Crankcase bolt 1 8 M8 1st 25 N m 2 5 kgf m 18 4 ft lb 2nd 90 Crankcase bolt 9 H i6 M10 1st 40 N m 4 0 kgf m 29 5 ft lb 2nd 90 Crankcase bolt 17 29 M8 1st 14 N m 1 4 kgf m 10 3 ft lb 2nd 28 N m 2 8 kgf m 20 7 ft lb Gently remove the crankcase and then measure the width of the compressed Plastigauge PG 1 on each crankshaft journal Replace the main bearing if out of specification S69J5D90 NOTE SE When loosening the crankcase bolts loosen them in the opposite order used for tighten Crankshaft journal oil clearance 0 025 0 050 mm 0 0010 0 0020 in Selecting the main bearing When replacing the main bearing select the suitable bearing as follows 5 68 Power unit 2 Check the crankshaftjournal mark on the crankshaft and the cylinder block Cylinder block mark 98 9 0 01 02
12. Ber er S al S6P25530 CAUTION Do not reuse the bolts with seal washers Q always replace them with new ones NOTE ee See the exploded diagram 5 7 16 Remove the valve lifters from the cylinder heads NOTE Do not mix the valve train parts Keep them organized in their proper groups Checking the timing belt and sprocket 1 Check the interior and exterior of the tim ing belt Replace if cracked damaged or worn 6AL3 11 Power unit check and adjustment 2 Check the drive sprocket Replace the crankshaft assembly if cracked dam aged or worn 3 Check the driven sprockets Replace the variable camshaft timing assembly or driven sprocket if cracked damaged or worn Checking the valve lifter 1 Check the valve lifters Replace if dam aged scratched or worn 2 Measure the valve lifter outside diameter Replace if out of specification S6AL5B40 Valve lifter outside diameter 32 982 32 997 mm 1 2985 1 2991 in 5 24 Checking the camshaft 1 Check the edge and face of the brim on Cam lobe the port camshafts and starboard intake Intake camshaft that is used for the cam posi 46 30 46 40 mm tion sensor Replace if rough damaged 1 823 1 827 in o
13. S6AL8760 NOTE 0 Be sure to move the screwdriver in front of the cam position sensor in direction as shown otherwise the correct output voltage measurement cannot be obtained Cam position sensor output voltage White blue W L Black B PORT EX White black W B Black B STBD IN Position Voltage V More than 4 8 Less than 1 0 White green W G Black B PORT IN Position Voltage V Less than 1 0 More than 4 8 8 Turn the engine start switch to OFF 9 Disconnect the wire leads 10 Install the cam position sensors 6AL3 11 Variable camshaft timing control system 11 Connect the cam position sensor cou plers and then install all parts removed during disassembly Checking the oil control valve 1 Check the operation of the oil control valves using the Stationary test of the YDIS and listen for the operating sound N Disconnect the oil control valve couplers ban Turn the engine start switch to ON and then measure the input voltage between the oil control valve coupler and ground Check the wiring harness if below specifi cation pal STBD NE ig 29 e SCH o V FEB LEZ MY S i NG A PAGE li z ED H ons d rd N pp SG S6AL8680 Oil control valve input voltage Red yellow RAY Ground 12 V battery voltage 4 Turn the engine start switch to OFF 8
14. S6P26270 6AL3 11 6 22 Lower unit Shimming NOTE e Shimming is not required when assembling the original lower case and inner parts e Shimming is required when assembling the original inner parts anda new lower case e Shimming is required when replacing the inner part s Selecting the pinion shim 1 Install the special service tool onto the drive shaft CC ZAR E too RS 2 I I S6AL6250 NOTE 0 e Select the shim thickness T3 by using the specified measurement s and the calcula tion formula e Hold the special service tool in a vise and then install the drive shaft into the special service tool so that the shaft is at the center of the hole e Tighten the wing nuts another 1 4 of a turn after they contact the plate e Make sure that the special service tool and drive shaft are parallel Z Pinion height gauge 90890 06710 6 23 2 Install the pinion and pinion nut and then tighten the nut to the specified torque Pinion nut 142 N m 14 2 kgf m 104 7 ft lb 3 Measure the distance M4 between the Special service tool and the pinion as shown S6AL6260 NOTE a Measure the pinion at 4 points to find the dis tance average Digital caliper 90890 06704 4 Turn the thrust bearing 2 or 3 times to seat the drive shaft housing and then measure the housing height M3 as shown S6AL6270 NOTE
15. 5 Remove the fuel rail covers port and starboard and plastic ties NOTE See the exploded diagram 4 23 6 Disconnect all fuel injector couplers 7 Disconnect the quick connectors and remove the high pressure fuel hose assembly vapor separator to starboard fuel rail S6AL5710 6AL3 11 NOTE To disconnect the quick connector see Chapter 4 Disconnecting the quick connec tor 8 Remove the wiring harness guide bolts S6AL5170 9 Remove the plastic ties from the wir ing harness and the projections on the plastic ties from the wiring harness guide and then pull up the wiring har ness Sr NE OVE NOTE lt When removing the wiring harness guide the wiring harness does not need to be completely removed e To completely remove the wiring harness see the exploded diagrams 5 4 5 38 10 Remove the wiring harness guide 6AL3 11 Power unit S6AL5190 5 42 Cylinder head Cylinder head m 2 3 kgf m 17 0 ft m 4 5 kgf m 33 2 ft m 2 3 kgf m 17 0 ft m 4 5 kgf m 33 2 ft Ne 14N m 1 4 kgf m 10 3 ft Ib 28 N m 2 8 kgf m 20 7 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib RS N m 0 3 kgf m 2 2 ft Ib 24 s6AL5410 Remarks CO DJ On Un BUN Mm Part name O lt Bolt Oil control valve assembly Filter Engine
16. and 5 77 11 Fasten the oil pressure sensor lead 49 isolator lead op and positive terminal lead with its cap using the plastic tie making sure to align the white tape on the oil pressure sensor lead with the guide of the positive battery terminal e P SE GN yal Q M G TI i DE 8 Les gt iD 9 EO f AD S6AL5590 NOTE Do not fasten the PTT relay lead 44 with the plastic tie e It is recommended to temporarily install the plastic ties to the sections of the junction box to improve working efficiency 12 Tighten the junction box bolts com pletely 13 Install the terminals of the starter motor lead brown white and the wiring har ness lead brown using the same bolt S6AL5H30 6AL3 11 CAUTION Do not bend the terminals of the starter motor leads when installing them 14 Install the wiring harness onto the ECM bracket and then fasten it at the white tape O H 11 S6AL5620 15 Check that the wiring harness hoses and other parts do not interfere with any moving parts Installing the power unit 1 Retract the port and starboard top cowl ing lock levers 6AL3 11 Cylinder block S6AL5220 CAUTION Make sure that the top cowling lock levers are retracted and the engine
17. 180 mm 7 1 in eeN b k k k A k PNP k k RP k kb 350 mm 13 8 in 7 23 6AL3J 11 Removing the PTT unit 1 Fully tilt the outboard motor up and then support it with the tilt stop lever S69J7110 WARNING lt 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 PTT unit should lose fluid pressure lt When removing the PTT unit with the power unit installed be sure to suspend the outboard motor If the outboard motor is not suspended it can fall sud denly and result in severe injury EEE Ifthe PTT does not operate open the manual valve by turning it counter clockwise and then tilt the outboard motor up manually 2 Remove the holder plastic ties and PTT motor lead from the holder and then pull out the PTT motor lead 3 Loosen the self locking nut of the through tube 4 Remove the anode and the PTT unit bolts 8 bolts and then move the clamp brackets slightly in the direction of the arrows WARNING Do not remove the tilt stop lever from the clamp brackets 6AL3 11 Clamp bracket and swivel bracket 5 Remove the circlip and shaft then the upper end of the tilt rod from the swivel bracket 6 Remove the PTT unit A S6AL7470 7 24 Bracket unit Removing the clamp bracket 1 Remove the ground lead and self lock
18. Check the Woo druff key Water leakage from water pump hous ing Check the water pump housing Check the cartridge insert Check the plate cartridge outer Clogged cooling wa ter passage Check the cooling water passage power unit exhaust guide and upper case Thermostat malfunc tion Check the thermo stat Buzzer comes on e Oil pressure warning indicator comes on 9 23 Insufficient engine oil Add sufficient oil Engine oil pressure decrease Oil pump malfunc tion Check the oil pump Clogged oil strainer Check the oil strain er Clogged oil sage pas Check the engine oil passage power unit and oil pump Clogged oil filter Replace the oil fil ter Troubleshooting the PTT unit Symptom 1 PTT unit does not operate Symptom 2 Cause 1 Troubleshooting the power unit Cause 2 Checking step PTT relay does not operate PTT switch mal function Check switch the PTT Short open or loose connection of the wiring harness PTT relay malfunc tion Check the wiring harness continuity Check relay the PTT PTT motor does not operate Short open or loose connection of the PTT motor lead Check the PTT mo tor lead PTT motor malfunc tion Disassemble and check the PTT mo tor Blown fuse Check the fuse Loose connection of the battery te
19. X CA sd Wiring harness A B C D E F H Stator coil lead A D F Sub wiring harness B C D E F Rectifier Regulator lead B C D E F H Starter motor lead B D F CHIC PTT motor lead A F DHEHF Oil pressure sensor lead and water detection switch lead DI G EHF Isolator lead D G E F 6AL3 11 S6AL8430 NOTE re dl The captions identifying the locations where the leads are routed fastened etc are enclosed by parentheses The captions are listed in random order evec ELEC ES Electrical system
20. Brush Continuity For all brush and terminal combinations not listed above No continuity 2 Measure the length of each brush Replace the brush assembly if below specification 6AL3 11 S69J8430 Starter motor Brush standard length 15 5 mm 0 61 in Wear limit amp 9 5 mm 0 37 in Assembling the starter motor CAUTION Do not allow grease or oil to contact the commutator of the armature 1 Install the bracket washer and clutch assembly onto the pinion shaft S6AL8311 2 Confirm that the clutch assembly is properly installed onto the pinion shaft amp and will not come loose and then install the E clip S6AL8320 NOTE Push the clutch assembly completely down onto the pinion shaft in direction rotate it 1 spline in direction and then slide itin direction 8 48 evec ELEC E Electrical system 3 Install the pinion shaft assembly shift lever and rubber seal S6AL8800 4 Install the spring pinion pinion stopper and clip S6AL8340 NOTE Be sure to install the clip into the slot of the pinion stopper 5 Install the spring and magnet switch S6AL8350 8 49 6 Push the brushes g into the holders and then install the armature to the brush holder assembly 7 Install the plate SE rm ul ri S6AL8290 8 Align the screw h
21. 4 6 S6P25930 3 Remove the oil pump NOTE See the exploded diagram 5 59 4 Remove the crankcase cover bolts in the sequence shown S6P25940 5 Remove the connecting rod cap bolts and the connecting rod caps and then remove the connecting rod and piston assemblies NOTE See the exploded diagram 5 57 5 61 6 Remove the clips and piston pin and then remove the piston S6AL5G20 NOTE e See the exploded diagram 5 57 Be sure to keep the bearings in the order as they were removed lt Mark each piston with an identification number of the corresponding cylinder lt Mark each connecting rod and connecting rod cap on the side facing up flywheel magnet side with an identification mark lt Do not mix the connecting rods and con necting rod caps Keep them organized in their proper groups 7 Remove the piston rings and arrange them in order 8 Remove the crankcase bolts in the sequence shown i eee TE eee 2 o CO CS o Et REA le PORT p se er pr era me S6P 25960 9 Remove the crankshaft and bearings 6AL3 11 Cylinder block NOTE Cylinder bore D D Be sure to keep the bearings in the order as 94 000 94 017 mm they were removed 3 7008 3 7014 in Checking the piston diamete
22. 1 Hold the PTT body in a vise using alu minum plates on both sides 6AL3 11 S69J7455 2 Fill the trim cylinders with the recom mended fluid to the correct level as shown S69J7460 NY Recommended PTT fluid ATF Dexron II Install the trim ram assemblies into the trim cylinders and then tighten the trim cylinder end screws Q to the specified torque w S6AL7910 WARNING Do not push the trim rams down while installing them into the trim cylinders Otherwise the PTT fluid may spurt out from the unit 6AL3 11 Tilt cylinder and trim cylinder CZ Cylinder end screw wrench 90890 06568 Trim cylinder end screw 160 N m 16 0 kgf m 118 0 ft lb Installing the PTT motor CAUTION Do not use a rag when assembling the PTT unit as dust and particles on the PTT unit components can lead to poor perfor mance 1 Install the joint into the gear pump S6AL7920 2 Fill the pump housing with the recom mended fluid to the correct level as shown S69J7475 AC Recommended PTT fluid ATF Dexron I Bracket unit 3 Remove all of the air bubbles with a syringe or suitable tool NOTE _ _ Turn the joint with a screwdriver and then remove any air between the pump gear teeth 4 Install a new O ring and the PTT motor and then tighten the bolts to the specified torque S6AL7930 NOTE Align the armature shaft with the rec
23. 11 Connect the vapor gas hose to the Starboard top cowling lock 6AL3 11 Cylinder block S6AL5570 12 Connect the PTT motor leads blue and light green and then fasten them 13 Route the positive battery cable 24 and negative battery cable along the bot tom of the bottom cowling and then connect them 7 E HU l x lt STBD a EISE Ss S6AL5580 NOTE EE To wire the PTT motor leads and battery cables see Chapter 8 Wiring harness rout ing PTT motor lead bolt 4 N m 0 4 kgf m 3 0 ft lb Positive battery cable bolt 18 N m 1 8 kgf m 13 3 ft lb Negative battery cable nut 13 Nem 1 3 kgf m 9 6 ft lb 14 Connect the fuel hose 5 80 15 Install the grommet with the speedome ter hose fuel hose positive battery cable on negative battery cable shift cable 08 gauge harness throttle cable 60 and 10 pin main harness 8 16 Install the cable holder and retaining plate 63 S6AL5650 17 Connect the shift cable and throttle cable and then adjust their lengths NOTE ee To adjust the shift cable and throttle cable see Chapter 3 Adjusting the throttle cable and Checking the gear shift operation 18 Install the starboard intake manifold NOTE To install the intake manifold
24. 6AL3 11 Clamp bracket and swivel bracket 6 Connect the ground lead install the through tube and then tighten the self locking nut temporarily S6AL7550 NOTE ee e Do not pinch the trim sensor pin when down the swivel bracket e Be sure to install the through tube with its flat corner pointing down as shown Friction plate screw 4N m 0 4 kgf m 3 0 ft lb Grease nipple 3 N m 0 3 kgf m 2 2 ft lb 7 26 Bracket unit Installing the PTT unit 1 Fully tilt the outboard motor up and then support it with the tilt stop lever S6P27890E lt When installing the PTT unit with the power unit installed be sure to suspend the outboard motor If the outboard motor is not suspended it can fall sud denly and result in severe injury lt After tilting the outboard motor up be sure to support it with the tilt stop lever 2 Install the PTT unit mounting bolts onto both clamp brackets together with the PTT unit and then tighten them 3 Install the upper end of the tilt ram into the swivel bracket with the shaft 4 and circlip 4 Tighten the self locking nut of the through tube to the specified torque NOTE lt Make sure that the flat corner of the through tube is pointing down as shown before tightening the self locking nut e Do not pinch the trim sensor pin when down the swivel bracket 5 Install the anode and ground lead 6 Install t
25. FR OC E i PE 2 S6P25910E CAUTION Do not reuse the cylinder head gaskets always replace them with new ones NOTE Be sure to install the port and starboard cyl inder head gaskets onto the correct cylin der heads Apply engine oil to the cylinder head bolts before installation e Tighten the M10 bolts 1 8 to the speci fied torques in 6 stages However when loosening the bolts in the 3rd stage loosen them in the opposite order used for tighten ing In the 6th stage make a mark on the M10 bolts and the cylinder heads and then tighten the bolts 90 from the mark e After tightening the M10 bolts Del has been completed tighten the M8 bolts 9 11 to the specified torques in 2 stages 6AL3 11 Cylinder head bolt 1 H8 M10 1st 23 N m 2 3 kgf m 17 0 ft lb 2nd 45 Nem 4 5 kgf m 33 2 ft lb 3rd Loosen completely Ath 23 Nem 2 3 kgf m 17 0 ft lb 5th 45 N m 4 5 kgf m 33 2 ft lb 6th 90 Cylinder head bolt 9 11 M8 1st 14 N m 1 4 kgf m 10 3 ft lb 2nd 28 N m 2 8 kgf m 20 7 ft lb 3 Install new filters and the oil control valve assemblies CAUTION Do not reuse the oil control valve filters always replace them with new ones NOTE Make sure thatthe oil control valve filter does not come off when installing the oil control valve 4 Install the camshafts driven sprocke
26. Fuel system Reducing the fuel pressure WARNING Always reduce the fuel pressure in the high pressure fuel line before servicing the line or the vapor separator If the fuel pressure is not released pressurized fuel may spray out 1 Remove the fuse holder cover and then remove the high pressure fuel pump fuse 15 A S6P24260 2 Startthe engine NOTE 0 e If the engine starts it will stall after a few seconds e If the engine does not start crank the engine 2 or 3 times 3 After the engine stalls crank the engine 2 or 3 times 4 Turn the engine start switch to OFF 4 5 Disconnecting the quick connector AA WARNING If the quick connector is disconnected suddenly pressurized fuel could spray out Be sure to reduce the fuel pressure before disconnecting the quick connec tor 1 Reduce the fuel pressure NOTE TT To reduce the fuel pressure see Chapter 4 Reducing the fuel pressure 2 Wrap the quick connector with a rag and then rotate the quick connector tab to the stopper position CAUTION lt Do not rotate the quick connector tab past the stopper position otherwise it could be damaged lt When the fuel hose is disconnected quickly remove the retainer from the qui
27. P art name Remarks n O OS Bolt Plug Gasket Plug Gasket Exhaust outer cover PORT Gasket Exhaust inner cover PORT Anode Screw Anode Screw Gasket Exhaust outer cover STBD Exhaust inner cover STBD Gasket M6x50 mm M8x14mm M18 x 17 mm Not reusable Not reusable Not reusable kA FA k k M k M k Ab BS FS Not reusable 5 45 6AL3J 11 Removing the cylinder head 1 Remove the cylinder head bolts in the sequence shown T Ela Le IT EI Ee Ye S6P25810E CAUTION Do not scratch or damage the mating sur faces of the cylinder head and cylinder block 2 Remove the intake and exhaust valves S6AL5H10 NOTE Be sure to keep the valves springs and other parts in the order as they were removed 6AL3 11 Cylinder head Valve spring compressor 90890 04019 Valve spring compressor attachment 90890 06320 Checking the valve spring 1 Measure the valve spring free length Gi Replace if below specification S69J5720 ET spring free AP 44 2 mm 2 a 74 in 2 Measure the valve spring tilt amp Replace if above specification S69J5730 Valve spring tilt limit amp 1 2 mm 0 05 in Checkin
28. S6P25800E Checking the exhaust cover anode 1 Check the anodes Clean if there are scales grease or oil CAUTION Do not oil grease or paint the anodes otherwise they will be ineffective 2 Replace the anodes if excessively eroded Installing the exhaust cover 1 Install the anodes to the exhaust covers 2 Install new gaskets and the exhaust cov ers and then tighten the bolts to the specified torques in 2 stages and in the sequence shown 5 53 S6P25D20E S6P25920E NOTE a l Apply engine oil to the exhaust cover bolts before installation Anode screw 3 N m 0 3 kgf m 2 2 ft lb Exhaust cover bolt 1st 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 Nem 1 2 kgf m 8 9 ft lb Removing the cooling water passage cover 1 Remove the knock sensor 6AL3 11 NOTE SE To check the knock sensor see Chapter 8 Checking the knock sensor 2 Disconnectthe flushing hose 3 Remove the cooling water passage cover bolts in the sequence shown RA A O DI 6 O ei IST N NOTE See the exploded diagram 5 43 Checking the cooling water passage cover anode 1 Check the anodes Clean if there are scales grease or oil CAUTION Do not oil grease or paint the anodes otherwise they will be ineffective 2 Replace the anodes if excessively eroded Installing the cooling water passage cover 1 Install the anodes to the cooling
29. Trim sensor setting resistance Pink P Black B 10410 7 28 Bracket unit 8 Fully tilt the outboard motor up and then Support it with the tilt stop lever After tilting up the outboard motor be sure to Support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the PTT unit should lose fluid pressure 9 Tighten the trim sensor screws Q 10 Fully tiltthe outboard motor down NOTE e Check the trim sensor resistance again after tightening the trim sensor screws and fully tilting the outboard motor down e To check the trim sensor see Chapter 7 Checking the trim sensor 7 29 6AL3 11 Clamp bracket and swivel bracket PTT unit PTT unit 19 N m 1 9 kgf m 14 0 ft Ib 19N m 1 9 kgf m 14 0 ft Ib Se 7 N m 0 7 kgf m 5 2 ft Ib Na 15 Nm 1 5 kgf m 11 1 ft Ib S6AL7610 Part name Remarks CO o A um P WW N Ha CH lt PTT body Reservoir Bolt O ring Reservoir cap O ring Sheet Filter Spacer PTT motor assembly O ring J oint O ring Manual valve Circlip Shaft Circlip M8 x 20 mm Not reusable M12 x 10 mm Not reusable Not reusable The height is greater than the height Not reusable A k k k k k k H OO k k 6AL3J 11 7 30 Bracket unit 15N m 1 5 kgf m 11 1 ft Ib 19 N m 1 9 kgf m 14 0 ft Ib 19N m 1 9 kgf m 14 0 ft Ib 7 N m
30. sensor resistance Electronic throttle system malfunction 1 Check the ECM circuit Check the electronic throttle valve relay and fuse Check the electronic throttle valve circuit 9 15 Electronic throttle system malfunction Check the battery cables and terminals for proper connection 2 Check the ECM circuit 3 Check the electronic throttle valve circuit Check the electronic throttle valve relay and fuse 6AL3 11 Troubleshooting the power unit Trouble Symptom code Remarks Checking steps Check the battery cables and terminals for proper connection Electronic 2 Check the ECM circuit throttle system 3 Check the electronic throttle malfunction valve circuit Check the electronic throttle valve relay and fuse Electronic Check the electronic throttle throttle system valve operation malfunction Check the battery cables and terminals for proper connection Electronic Check the ECM circuit throttle system 3 Check the electronic throttle malfunction valve circuit Check the electronic throttle valve relay and fuse Electronic Check the electronic throttle throttle system valve operation malfunction 6AL3J 11 9 16 TRBL D SHTG e Troubleshooting Troubleshooting the power unit using the diagnostic flash indicator 1 Connect the special serv
31. 2 500 0 0981 0 0984 2 496 2 504 0 0983 0 0986 2 500 2 508 0 0984 0 0987 Thrust bearing thickness J 3 i 1 907 1 957 0 0751 0 0770 Thermostat Opening temperature at 0 05 mm 0 0020 in 58 62 136 144 Fully open temperature 70 158 Valve open lower limit 4 3 0 17 Fuel system Item Fuel system Fuel pressure at engine start switch to ON Within 5 seconds kPa 300 3 0 43 5 kgf cm psi at engine idle speed kPa 260 2 6 37 7 kgf cm psi Canister holding pressure kP a 19 6 0 196 2 8 kgf cm psi ED The figures are for reference only 6AL3J 11 2 6 ele Specification Item Fuel filter assembly holding pressure Fuel inlet positive pressure kPa kgf cm psi kPa kgf cm psi 200 2 0 29 0 Fuel outlet negative pressure 80 0 8 11 6 Float height Water detection position Vapor separator float height PTT unit 30 1 18 60 5 3 0 2 38 0 12 mm in mm in Model 200 L 225R 200 R PTT unit Hydraulic pressure Down 6 7 8 7 67 87 Up 13 0 15 0 130 150 1 07 1 27 0 042 0 050 1 95 2 45 0 077 0 096 Up relief lock screw height Down relief lock screw depth ED The figures are for reference only Lower unit Model Item Unit 200 L 225R Lower unit Holding pressure kPa kgf cm psi 70 0 7 10 Gear backlash Pinion t
32. 3 Connect fuel pressure gauge adapter B between the quick connector and vapor separator 4 7 4 Connect the fuel pressure gauge to fuel pressure gauge adapter B 5 Disconnect the pressure regulator hose and then connect the special service tool to the pressure regulator S6P 24300E WARNING lt Gently screw in the gauge until it is firmly connected to prevent fuel from leaking out lt Before measuring the fuel pressure make sure that the drain screw is tight ened securely lt Do not loosen the drain screw while measuring the fuel pressure Loosening the drain screw can cause fuel to spray out creating a fire hazard Fuel pressure gauge 90890 06786 Fuel pressure gauge adapter B 90890 06942 Vacuum pressure pump gauge set 90890 06756 6 Startthe engine and letitidle 7 Check that the fuel pressure is reduced when vacuum pressure is applied to the pressure regulator If the fuel pressure is not reduced replace the pressure regu lator 6AL3 11 NOTE When the specified vacuum pressure is reached the pressure regulator is operated and the fuel pressure is reduced 8 Reduce the fuel pressure NOTE Ee To reduce the fuel pressure see Chapter 4 Reducing the fuel pressure 9 Disconnectthe special service tools WARNING lt After measuring the fuel pressure cover the end of the hose with a clean dry rag point the hose downward and then loosen the drain s
33. 3 pin communication coupler Low pressure fuel pump Condenser assembly connect to the intake air Intake air pressure sensor pressure sensor Oil control valve PORT Water detection switch in fuel filter Fuel injector Ignition coil 8 3 6AL3 11 Electrical component Starboard view S6P 28020E Ignition coil Fuel injector Cam position sensor STBD IN Oil control valve STBD PTT relay Rectifier Regulator Accelerator position sensor Oil pressure sensor Starter motor Diode connect to the PTT relay 6AL3 11 8 4 evec E ELEC EH Electrical system Fuse holder DI CG L30A Fuse 10 A electronic throttle valve ECM Fuse 30 A ignition coil fuel injector variable camshaft timing ECM Fuse 20 A engine start switch PTT switch Fuse 30 A starter relay Fuse 5 A low pressure fuel pump Fuse 15 A high pressure fuel pump relay Fuse 80 A starting battery Fuse 80 A accessory battery 8 5 S6P28025 High pressure fuel pump relay Electronic throttle valve relay Main relay ignition coil fuel injector variable camshaft timing ECM low pressure fuel pump high pressure fuel pump Star
34. Check the battery voltage using the YDIS Measure the Rectifier Regulator output peak voltage Measure the stator coil output peak voltage 4 Check the fuse Check the battery cables and terminals for proper connection Intake temp sensor malfunction TI Crank position sensor 2 Engine temperature sensor 3 Intake air temperature sensor WD See the wiring diagram 9 9 Check the intake air temperature using the YDIS Measure the input voltage 3 Measure the resistance 6AL3 11 Trouble code Symptom Remarks Troubleshooting the power unit Checking steps Cam position sensor EXH U malfunction Check the cam timing using the YDIS 2 Measure the input voltage 3 Check the white blue W L lead cam position sensor to ECM for continuity 4 Measure the output voltage 5 Check the brim of the camshaft Shift position Switch malfunction 1 Check the switch operation using the YDIS 2 Check the switch continuity 3 Measure the input voltage 4 Check the shift bushing and shift mechanism Intake press sensor malfunction Maximum power decreases Check the intake air pressure using the YDIS 2 Check the vacuum hoses 3 Measure the input voltage 4 Check the operation of the intake air pressure sensor Check t
35. No continuity Lg Red R 3 Connect the positive battery lead to the sky blue Sb lead and the negative bat tery lead to the terminal as shown Down O and then check the PTT relay for continu ity Replace the PTT relay if out of speci fication S6AL7A00 7 59 6AL3 11 Checking the trim sensor 1 Measure the trim sensor resistance Replace the trim sensor if out of specifi cation a RE o B P A NG OSE C S6AL7A10 NOTE e Turn the trim sensor lever from to and measure the resistance as it gradually changes e The positon is the trim sensor lever position when the outboard motor is tilted down To adjust the trim sensor see Chap ter 7 Adjusting the trim sensor e The trim sensor resistance will be lower at the position than at the position e The range is the trim and tilt operation range Trim sensor resistance Pink P Black B 247 6 387 6 Q at 9 11 Q at 6AL3 11 PTT electrical system 7 60 Electrical system Checking the electrical component 8 1 CHECKING USING YDIS sl a an nagan aba nb aan gg e EE de 8 1 Measuring the peak voltage ssssseaaae eaaa anaa nean a naa aana nana nana anana 8 1 Electrical componentimuusanminesmneuminisdumnanivmdinakinkvi 8 3 POE ET 8 3 Starboard VEN Luer 8 4 EE ae EE 8 5 AVEW ENE AEE 8 6 TOPVIEW EE ER 8 7
36. Replace the armature if out of specifica tions Terminal 0 Terminal Q Terminal S Terminal S Terminal L Terminal Lg For all terminal combinations not listed above Continuity No continuity 2 Measure the length of each brush Replace the brushes if below specifica tion S69J8420 Commutator segments Continuity Segment Armature core No continuity Segment Armature shaft No continuity Checking the brush 1 Check the PTT motor base assembly for continuity Replace the PTT motor base assembly if out of specification S69J8430 Motor brush standard length 11 5 mm 0 45 in Wear limit 4 5 mm 0 18 in 7 37 6AL3J 11 PTT motor 3 Check the PTT motor base Replace the 3 Install the brushes and springs to PTT motor base assembly if cracked or the PTT motor base assembly as shown damaged 4 Check the bearing and oil seal Replace the bearing or oil seal if damaged or worn Assembling the PTT motor CAUTION Do not allow grease or oil to contact the commutator of the armature 1 Install the bearings and onto the armature S6AL7680 4 Push the brushes into the holders pain e E ES and then install the armature h b 1 0 mm 0 04 in S6AL7690 S6AL7660 5 Install the wave washer and washer NOTE gt
37. Tilt piston assembly Tilt ram assembly P ower tilt assembly Tilt ram Dust seal Tilt cylinder end screw Not reusable Not reusable PPP PRP HN N N N N ON N ON NO N ON 7 47 6AL3 11 Tilt cylinder and trim cylinder Se 1160 N m 16 0 kgf m 118 0 ft Ib Se 90 N m 9 0 kgf m 66 4 ft Ib 55 N m 5 5 kgf m 40 6 ft Ib S6AL7790 Part name i Remarks Not reusable Not reusable O ring Backup ring O ring Spring Adapter Tilt piston O ring Backup ring Ball Pin Spring Bolt Free piston O ring Tilt cylinder Not reusable M6 x 10 mm T30 Not reusable A k k ka Un Um UP k KRA k k k bm 6AL3J 11 7 48 Bracket unit Disassembling the tilt cylinder and trim cylinder 1 Hold the tilt cylinder in a vise using aluminum plates on both sides 2 Loosen the tilt cylinder end screw and then remove the tilt ram assembly S6AL7800 WARNING Make sure that the ram are fully extended before removing the end screw RA Cylinder end screw wrench 90890 06568 3 Drain the PTT fluid 4 Blow compressed air through the hole amp to remove the free piston S6AL7C09 7 49 WARNING Never look into the tilt cylinder opening when removing the free piston The free piston and PTT fluid can be forcefully expelled out NOTE EE Be sure to cover the opposite end of the tilt cylinder with a rag 5 Hold the t
38. and J Fasten the fuel injector lead 6 using a plastic tie at the white tape fl MP el ol mo 6AL3 11 8 8 evec ELEC ES Electrical system S6P 28320E Fasten the fuel injector lead 4 to the clip It is not necessary to fasten the lead if its length is short Fasten the fuel injector lead 2 and then fasten the fuel injector lead 4 and 6 to the clip Fasten the fuel injector harness using a plastic tie Fasten the fuel injector harness to the fuel rail cover after installing the cover Fasten the intake air temperature sensor lead to the holder on the oil filler neck EE B H E 8 9 6AL3J 11 Starboard view Wiring harness routing A RES SAR SR
39. valve system 1 For checks related to the APS and TPS see Chapter 8 NOTE e To check the electronic throttle valve assembly see Chapter 8 ECM and elec tronic throttle valve control system e To check the vapor shut off valve see Chapter 8 Checking the vapor shut off valve e To check the electronic throttle valve relay see Chapter 8 Checking the main relay and electronic throttle valve relay e To check the intake air pressure sensor see Chapter 8 Checking the intake air pressure sensor e To check the fuse see Chapter 8 Fuse holder Checking the canister 1 Check the canister Replace the canister if cracked 2 Connect the special service tool to the atmospheric port and cover the other ports each with a finger S6P24180 3 Apply the specified positive pressure and check that there is no air leakage Replace the canister if there is air leak age 6AL3 11 Throttle body Vacuum pressure pump gauge set 90890 06756 Specified pressure 19 6 kPa 0 196 kgf cm 2 8 psi Checking the canister check valve 1 Connect the special service tool to the check valve port as shown S6P24190 Vacuum pressure pump gauge set 90890 06756 2 Apply positive pressure to the check valve port 3 Check that air comes out of the opposite end of the check valve Replace the can ister check valve if no air comes out 4 Connect the special
40. x 4 N m 0 4 kgf m 3 0 ft Ib 25N m 2 5 kgf m 18 4 ft Ib KA 90_ S6AL5660 No Part name Q ty Remarks 1 Bolt 8 M10 x 105 mm 2 Bolt 8 M8 x 95 mm 3 Bolt 13 M8 x55 mm 4 Crankcase assembly 1 5 Main bearing 3 6 Main bearing 1 7 Oilseal 1 8 Crankshaft 1 9 Main bearing 4 10 Thrust bearing 2 11 O ring 2 12 O ring 1 13 Oil seal 1 14 Oil seal 1 15 O ring 2 16 Gasket 1 17 Oil seal 1 5 59 6AL3J 11 Cylinder block 27 d d 97 21 7 N m 0 7 kgf m 5 2 ft Ib 40N m 4 0 kgf m 29 5 ft Ib 90 DAJAN m 0 4 kgf m 3 0 ft Ib NO 25 Nm 2 5 kgf m 18 4 ft Ib lo S6AL5660 Part name Remarks Not reusable M6 x 40 mm M6 x 20 mm Oil seal Oil pump assembly Bolt Bolt Plug O ring Gasket Thermostat cover STBD Anode Thermoswitch Bolt Bolt Thermostat Plug Gasket Thermostat cover PORT Bolt Not reusable Not reusable M6 x 16 mm M6 x 25 mm M14 x 12 mm Not reusable A k k Fa 4 P ANNE NRBR FA BB Fa ND M5 x 20 mm 6AL3J 11 5 60 Disassembling the cylinder block 1 Remove the oil filter using a 72 5 mm 2 9 in oil filter wrench Oil filter wrench 90890 06830 2 Remove the oil filter bracket bolts in the sequence shown CSD DEI PORT p a 1O
41. 0 47 in 0 35 in S6AL4320 P art name Remarks Not reusable Not reusable a Oo LO ON DU P GA NN KE O ring Grommet Fuel filter element Fuel filter element assembly Fuel cup assembly Fuel filter assembly Bracket Bolt Bolt Fuel hose Holder J oint Plastic tie Holder Not reusable PWRRPNNNRPRP k k k k km 4 19 6AL3J 11 Checking the fuel filter assembly NOTE e To check the fuel filter element see Chap ter 3 Checking the fuel filter e To check the water detection switch see Chapter 8 Checking the water detection Switch 1 Connect a vacuum pressure pump gauge and a meter to the fuel inlet 2 Cover the fuel outlet with a finger and then apply the specified positive pres sure Replace the O ring fuel cup assembly or fuel filter assembly if the Specified pressure cannot be maintained for atleast 15 seconds S6AL4330 NOTE Use a commercially available vacuum pres sure pump gauge and meter that can be pressurized up to 200 kPa 2 0 kgf cm 29 0 psi AS Specified positive pressure 200 kPa 2 0 kgf cm 29 0 psi 3 Connect a vacuum pressure pump gauge and a meter to the fuel outlet 6AL3 11 Fuel filter 4 Cover the fuel inlet with a finger and then apply the specified negative pres sure Replace the O ring fuel cup assembly or fuel filter assembly if the specified pressure cannot be maintained for at least 1
42. 4 2 kgf m 31 0 ft Ib 47 N m 4 7 kgf m 34 7 ft Ib 2 9 N m 0 9 kgf m 6 6 ft Ib S6AL6610 No Part name Q ty Remarks 18 Extension 1 U transom model 19 Rubber seal 1 U transom model 20 Dowel 2 U transom model 21 Rubber seal 1 U transom model 22 Stud bolt 6 M10 x 190 mm U transom model 23 Bolt 1 M10 x 200 mm U transom model 24 Bolt 1 M10 x 174 mm U transom model 25 Nut 6 U transom model 26 Spring washer 6 U transom model 27 Washer 6 U transom model U transom model F225B regular rotation model only 6AL3 11 6 2 Lower unit S6AL6620 Remarks CO LO OO JO mn P GO A Mm Part name lt Shift rod Oil seal Oil seal housing O ring Bolt Seal Woodruff key Bolt Water pump housing O ring Insert cartridge O ring Impeller Outer plate cartridge Gasket Dowel Dowel Not reusable Not reusable M6 x 20 mm M8 x 45 mm Not reusable Not reusable Not reusable KA FA k PRP RPP RPP BPP WP EH 6 3 6AL3J 11 Removing the lower unit 1 Drain the gear oil 2 Setthe 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 S69J6015 WARNING e Do not hold the propeller with your hands when loosening or tightening it lt Be sure to disconnect the battery
43. Checking the piston ring EE 5 62 Checking the piston ring end gap reference isaaeranaa anaa n anan anen 5 63 Checking the piston ring tele TE 5 63 Checking the piston ring side clearance 5 63 Checking the piston pin boss bore kuk 5 63 Checking the piston pin gasser 5 64 Checking the connecting rod small end inside diameter 5 64 Checking the connecting rod big end side clearance sssisaeenarei 5 64 Checking the Crank avant 5 65 Checking the crankpin oil clearance mmseemrrvrvrvvrrvrrvrerrrrrnrrrerrrrrrrrrrnnenn 5 65 Selecting the connecting rod bearing kee 5 66 Checking the crankshaft journal oil clearance secsec 5 67 Selecting the main D arning ssasss mures im cebiteaddna eens ea mene 5 68 Assembling the power unit EE 5 69 Disassembling the oil pump sasa anaa anaa keanan atenerne 5 73 CHECKING Me DIT PUMP E 5 73 Assembling the oil pump ENNEN 5 73 Installing the oil pip ass 5 75 Installing the wiring harness 44 5 76 Installing the power UNIES er ee Me D rc nt ne 5 78 6AL3 11 Power unit check and adjustment Checking the compression pressure 1 Start the engine warm it up for 5 min utes and then turn it off 2 Remove the engine stop lanyard from the engine stop lanyard switch 3 Disconnect all fuel injector couplers 4 Remove the ECM cover all ignition coils and spark plugs and then install the spe cial service to
44. Dimension B 2 40 2 47 0 094 0 097 Dimension T i 2 30 2 70 0 091 0 106 End gap i 0 15 0 60 0 006 0 024 Side clearance i 0 04 0 13 0 002 0 005 Camshaft Intake A i 46 30 46 40 1 823 1 827 Exhaust A i 45 35 45 45 1 785 1 789 Intake and i 35 95 36 05 1 415 1 419 exhaust B B Camshaft journal diameter i 24 96 24 98 0 9826 0 9834 Camshaft runout limit 0 015 0 0006 Valve Valve clearance cold Intake i 0 20 0 03 0 008 0 001 Exhaust i 0 34 0 03 0 013 0 001 Head diameter A Intake i 36 4 36 6 1 43 1 44 Exhaust a A i 31 4 31 6 1 24 1 24 Face width B Intake i a 2 35 2 78 0 092 0 110 Exhaust i 2 13 3 30 0 084 0 130 4 Seat contact width C Intake Exhaust 1 10 1 40 0 043 0 055 1 40 1 70 0 055 0 067 Margin thickness D Intake i 3 i 0 50 0 90 0 020 0 035 Exhaust F i 0 90 1 30 0 035 0 051 ED The figures are for reference only 6AL3 11 2 4 SPEC BEZ Specification Item Model Stem diameter Intake Exhaust Stem runout limit Guide inside diameter Intake and exhaust Stem to guide clearance Intake Exhaust Guide installation position 5 477 5 492 0 2156 0 2162 5 464 5 479 0 2151 0 2157 0 01 0 0004 5 504 5 522 0 2167 0 2174 0 012 0 045 0 0005 0 0018 0 025 0 058 0 0010 0 0023 13 8 0 2 0 5 0 01 Valve spri
45. Driver rod L3 90890 06652 Disassembling the reverse gear 1 Remove the circlip from the reverse gear 6AL3 11 Ze S6AL6840 2 Remove the needle bearing from the reverse gear using a chisel S68S6160 CAUTION Do not reuse the bearing always replace it with a new one 6 44 Lower unit Disassembling the lower case 1 Remove the needle bearing from the lower case S6AL6230 NOTE e Since the diameter of the passage in the lower case and the diameter of the special service tool are both 40 mm 1 57 in the special service tool may not fit into the lower case In that case use a special ser vice tool with a smaller diameter lt Be sure to remove the reverse gear before removing the needle bearing GA Ball bearing attachment D 4 90890 06655 Driver rod LL 90890 06605 2 Remove the retainer and shim s S6AL6470 KA Flywheel puller 90890 06521 Bearing outer race puller assembly 90890 06523 3 Remove the needle bearing from the retainer 6 45 S6AL6480 CZ Needle bearing attachment 90890 06654 Driver rod L3 90890 06652 Checking the pinion and reverse gear 1 Check the teeth of the pinion and the teeth and dogs of the reverse gear Replace the pinion or reverse gear if cracked or worn Checking the bearing 1 Check the bearings Replace the bear ings if pitted or if there is rumbling Checking the
46. M4 is 30 57 mm and P is 2 then T3 82 00 2 100 50 75 30 57 mm 82 00 0 02 50 75 30 57 mm 0 70 mm If M3 is 50 70 mm M4 is 30 53 mm and P is 3 then T3 82 00 3 100 50 70 30 53 mm 82 00 0 03 50 70 30 53 mm 0 74mm 6 Select the pinion shim s T3 as follows Calculated number at 1 100 place 1 2 Rounded number 3 4 5 6 7 8 9 10 6 55 Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Example If T3 is 0 70 mm then the pinion shim is 0 68 mm If T3 is 0 74 mm then the pinion shim is 0 72 mm Selecting the reverse gear shim 1 Turn the thrust bearing 2 or 3 times to seat the bearing retainer and then measure the bearing height M1 as shown T1 S6P26610 S6AL6520 NOTE AN NE e Select the shim thickness T1 by using the specified measurement s and the calcula tion formula e Measure the bearing retainer at 4 points to find the height average Digital caliper 90890 06704 2 Calculate the reverse gear shim thick ness T1 as shown in the examples below 6AL3 11 S69J6570 NO0OTE F is the deviation of the lower case dimen sion from standard The F mark 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
47. NOTE It is recommended to check the crank posi tion sensor air gap before installing the wiring harness guide to improve working efficiency 6AL3 11 Crank position sensor air gap 1 4 1 6 mm 0 055 0 063 in Crank position sensor screw 4 N m 0 4 kgfm 3 0 ft lb 20 Install the timing belt guides and then adjust the timing belt to timing belt guide clearance 0 5 S6AL5090 Timing belt to timing belt guide clearance Q 1 0 0 5 mm 0 04 0 02 in 21 Install the wiring harness guide NOTE i To install the wiring harness guide see Chapter 5 Installing the wiring harness 22 Install the spark plugs and ignition coils Spark plug 25 N m 2 5 kgf m 18 4 ft lb Ignition coil bolt 7 N m 0 7 kgf m 5 2 ft lb 23 Install all parts removed during disas sembly 5 14 24 Check that the wiring harness hoses and other parts do not interfere with any moving parts Replacing the timing belt CAUTION lt Do not turn the flywheel magnet coun terclockwise otherwise the water pump impeller may be damaged lt Do not turn the flywheel magnet or the driven sprockets when the timing belt is not installed Otherwise the pistons and valves or intake and exhaust valves will collide with each other and be damaged NOTE es To remove and install the timing belt without replacing it see Chapter 5 Removing the timing belt dr
48. S into the stator 49 Do not install the bearing more than 1 0 mm 0 04 in past the end of the armature shaft as shown 2 Install a new oil seal into the PTT motor base assembly as shown S6AL7700 S6AL7670 6AL3J 11 7 38 Bracket unit 6 Install a new O ring and the stator to the motor base S6AL7710 CAUTION Hold the end of the armature shaft with a pair of pliers as shown and then install the armature together with the PTT motor base assembly otherwise the armature could separate from the base assembly due to the magnetic force of the stator On and damage the brushes 7 39 6AL3J 11 PTT motor Gear pump Gear pump 7 N m 0 7 kgf m 5 2 ft Ib S6AL7720 No 1 2 3 4 5 6 7 8 Part name i Remarks Gear housing 1 Bolt Plate F ilter Plate Valve lock screw Down relief spring Valve support pin Relief valve seal Up relief spring Valve support pin O ring Ball Circlip Main valve seal Shuttle piston O ring Not reusable A k A b k k PRP RP k k NHH RUH Not reusable 6AL3J 11 7 40 Bracket unit 7 N m 0 7 kgf m 5 2 ft Ib S6AL7720 Part name Remarks Return spring Shuttle piston Driven gear Drive gear Ball Gear housing 2 Manual release spring Pin Ball Valve pin Spring Spacer O ring Pin Filter Bracket Washer Not reus
49. Wiring harness FOUTING EE 8 8 POE T 8 8 Starboard ven rs tn a aa een rennet 8 10 EM GE 8 13 TOP ERE EE Laa a ea Ba a cae 8 14 Bottom COMMISE SR me 8 15 Ignition and ignition control System 8 18 Checking the ignition spark AAA 8 18 Checking the ignition coil input voltage ANN 8 18 Checking the crank position sensor 8 18 Checking the crank position sensor air gap 8 19 Checking the intake air temperature sensgor nean eaaa anan 8 20 Checking the intake air pressure sensor 8 21 Checking the engine temperature sensor 8 21 Checking the thermoswitch AANEREN 8 22 CHECKING the shift cut switch ne ren entr da arte 8 23 Checking the neutral SWIkNunemumnsnmrenssssnvsunjvvradirisdri 8 24 CHECKING the knock SANSOM sen pn entiere tenme lentes Ae 8 25 Checking the engine start switch aee e eaaa nana a aana nean nen ae anang 8 25 Checking the engine stop lanyard switch 8 26 ECM and electronic throttle valve control system 8 26 Checking the throttle valve operation aee n eaaa anaa n ena aran 8 26 Checking the main relay and electronic throttle valve relay 8 27 Checking the E LEE 8 27 Checking the accelerator position sensor 8 29 Checking the accelerator position sensor circuit 8 31 Checking the electronic throttle valve ANd TPS 8 31 Checking the electronic throttle valve and TPS circuit 8 33 Variable camshaft timing control system sen 8 34 Checking the cam position sensor anaa anana nana ana
50. and check that the I marks on the starboard driven sprockets are aligned 6AL3 11 S6P25100 11 Measure each valve clearance and according to steps 12 17 EDS S6P25110 S6AL5070 NOTE Note the measurement data 6AL3 11 12 13 14 15 16 17 Power unit check and adjustment Valve clearance cold Intake 0 20 0 03 mm 0 008 0 001 in Exhaust 0 34 0 03 mm 0 013 0 001 in Measure the intake and exhaust valve clearances for cylinder 4 Turn the flywheel magnet an additional 120 clockwise and align the 2TDC mark on the flywheel magnet with the pointer Measure the intake and exhaust valve clearances for cylinder 5 Turn the flywheel magnet an additional 120 clockwise and align the 3TDC mark on the flywheel magnet with the pointer Measure the intake and exhaust valve clearances for cylinder 6 69J5120 Similarly measure the valve clearances for cylinders 1 2 and 3 in order and be sure to turn the flywheel magnet 120 clockwise each time Adjust the valve clearances if out of specification
51. and then install the other oil seal Bearing inner race attachment 90890 06640 SC Depth 5 0 0 25 mm 0 20 0 01 in 3 Install a new ball bearing into the propel ler shaft housing S6AL6680 CAUTION Do not reuse the bearing always replace it with a new one NOTE SE Install the ball bearing with the manufacture identification mark facing toward the propeller shaft housing propeller side Driver rod LS 90890 06606 Ball bearing attachment 90890 06656 E 6 10 Lower unit 4 Install the reverse gear and original shim s into the propeller shaft hous ing using a press S6AL6A90 NOTE SS lt Be sure to select the reverse gear shim s if replacing the propeller shaft housing ball bearing or lower case lt Be sure to select the propeller shaft shim if replacing the reverse gear e To select the shims see Chapter 6 Shim ming regular rotation model e After installing the reverse gear and shim s check that the reverse gear rotates smoothly GC Bearing outer race attachment 90890 06622 6 11 6AL3 11 Propeller shaft housing regular rotation model Drive shaftand lower case regular rotation model Drive shaft and lower case regular rotation model I 142 N m 14 2 kgf m 104 7 ft Ib S6AL6220 Remarks a CO CDJ On Un P DU NN Hm Part name lt Drive shaft Thrust bearing Spring Washe
52. nuity Shift cut off switch 2 malfunction Shifting to neutral is difficult Check the switch operation using the YDIS Check the switch continuity and resistance Measure the input voltage 4 Check the shift bracket and shift mechanism Overheat thermoswitch 3 malfunction El Oil pressure sensor 2 Shift cut switch 3 Thermoswitch WD See the wiring diagram Check the switch condition using the YDIS Measure the input voltage 3 Check the switch continuity 4 Check the engine temperature sensor 6AL3 11 Trouble code Symptom Remarks Troubleshooting the power unit Checking steps Cam position sensor STBD INT V malfunction Check the cam timing using the YDIS 2 Measure the input voltage 3 Check the white black W B lead cam position sensor to ECM for continuity 4 Measure the output voltage Check the brim of the camshaft 6 Check the battery cables and terminals for proper connection Cam position sensor PORT INT malfunction Check the cam timing using the YDIS Measure the input voltage 3 Check the white green W G lead cam position sensor to ECM for continuity 4 Measure the output voltage 5 Check the brim of the camshaft 6 Check the battery cables and terminals for proper connection Oil co
53. 0 7 kgf m 5 2 ft Ib Part name S6AL7610 Remarks 7 31 Bushing Pipe Pipe Spacer O ring Adapter Not reusable 6AL3 11 Checking the hydraulic pressure NOTE me Check the hydraulic pressure Using the spe cial service tool check the internal parts if out of specification 1 Fully extend the trim and tilt rams 2 Loosen the pipe joints and then remove the pipe joint at the end WARNING Make sure that the trim and tilt rams are fully extended when removing the pipe joints otherwise fluid can spurt out from the unit due to internal pressure 3 Install the special service tool S6P27610 NOTE Putthe PTT unitin the drain pan Cz PTT oil pressure gauge assembly 90890 06580 4 Connect the PTT motor leads to the bat tery terminals to retract the trim rams and then measure the maximum hydrau lic pressure when the reading on the PTT oil pressure gauge stabilizes 6AL3 11 PTT unit PTT motor lead S6AL7C04 Battery terminal Light green Lg CH Sky blue Sb Hydraulic pressure down 6 7 8 7 MPa 67 87 kgf cm 5 Reverse the PTT motor leads between the battery terminals to fully extend the trim and tilt rams PTT motor lead S6AL7C05 Battery terminal Sky blue Sb Q Light green Lg 7 32 Bracket unit 6 Remove the special service tool WARNI
54. 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 2 mark on the cylinder block amp 8 gt D N e E E m e en N NIN ml ml rf nal na DEN EN EN EN EN EN EN NIN VP mlm mlm sain a A KO KO KN NT KN KA KA KO APA EA PA PAPA PAE PA PAPAR N HJ El eee j ejej elje rl elel lel elelel lelele HJ El KH El E KIR KI KIKIR HJ El KH El E KIR HIK en PT ee KO KG KKN KON KAN KAN KAN KON KO valsalralsairalnairalralsalral sain nj salsaluisairalsatralsalsalrnal sol CO EMI EM EM EM EU EM EU EM EM EM EM ES nal mw sall KIR EI RR KIR ER nin DIE EN njoj na vainalralsalra njofin njoj DIE EN na DEEE TO TAA el el el cl eee e TA A TO TA TU TAK AT TAPA PAPA APA TAN AJA DEEE TA KA KA KO KA TA KO TAA TA JA AA AA TAA PA JA w wl w TA A TO TA TU TAK TA TA KO sele A ele ele ww wl w OEM KA TO TAA TA NT TAPA PA A AA vull al wl wll al w w wlwlwl wl wf wl w w w wf wl w wl wll al w w wf wl w wl wf ww w w wf wl w wl www w w wlwlwl wi wll al wl a 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 1fifilili 1fifilili 1f1f1lif2 HERE HEHE 2 X Hp 2 D 212 2 2 2 E 2 2 2 2 2 2 D 2 2 2 KE 2 2 2 3 2 2 2 Q 2 2 2 2 d 2 DEER 2 2 2 2 lt 2 2 3 Y 2 2 3 C 2 3
55. 0354 in M 0 68 x 0 71 Shim thickness To be decreased by M Measurement Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 6AL3 11 Backlash counter rotation model 19 Remove the special service tools and then install the water pump assembly 20 Fill the gear oil to the correct level 6 62 Bracket unit Shift rod and bottom Cowling ssssssssssssnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnna 7 1 Disassembling the bottom CONS Esebuer 7 5 Disassembling the shift bracket 7 6 Assembling the shift br ket acuta ie An eee 7 6 Assembling the bottom cowlmg NNN 7 7 Upper case and Steering arm 7 10 Removing the upper case 7 15 Disassembling the upper Case suse nt anni ae 7 15 Checking the drive shaft bushing ssseeaee eea aee eea nenen aane ena anna 7 16 Disassembling the oil pan and exhaust manifold eccerre 7 16 Checking the oil pan and exhaust manifold seenen 7 16 Checking the oil Strain r ssis sise ciara ENNER Nn nne anan 7 16 Assembling the oil pan and exhaust manifold sssr 7 16 Assembling the upper CaSe vtcccsieevecey ced REENEN EES 7 18 Installing Beie 7 19 REMOVING the steering arm 7 20 Installing the steering arm EE 7 20 Clamp bracket and swivel bracket ns 7 22 Removing the PTT UNE esse Entente nr cdots 7 24 Removing the clamp bracketiuvsarvqvarataiukdsynnireiunsmvidasdnnde 7 25 Installing the clamp br cketuuvunonmsqeng
56. 067 in 4 Measure the valve seat contact width where the blueing dye is adhered to the valve face Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification Replace the valve guide if the valve seat contactis uneven Refacing the valve seat 1 Reface the valve seat with the valve seat cutter DNT Valve seat cutter holder 90890 06316 Valve seat cutter 30 intake 90890 06817 30 exhaust 90890 06326 S69J5830 45 intake 90890 06816 45 exhaust 90890 06325 60 intake and exhaust 90890 06324 2 Cutthe surface of the valve seat with a 45 cutter by turning the cutter clockwise until the valve seat face has become smooth 5 49 6AL3J 11 S6AL5760 S69J5870 Slag or rough surface CAUTION Do not over cut the valve seat Be sure to turn the cutter evenly downward at a pres sure of 40 50 N 4 5 kgf 8 8 11 Ibf to prevent chatter marks 3 Use a 30 cutter to adjust the contact width of the top edge of the valve seat 30 S69J5880 O Previous contact width 4 Use a 60 cutter to adjust the contact width of the bottom edge of the valve seat 6AL3J 11 Cylinder head 0 er g 5 Use a 45 cutter to adjust the contact width of the valve seat to specification S69J5890 Previous contact width Xe 45 69J5900 Previous contact width Specified conta
57. 1 Install a new needle bearing into the reverse gear to the specified depth rer GC Needle bearing attachment D 90890 06653 S6AL6500 Driver rod SS 90890 06604 Depth 7 0 25 mm 0 28 0 01 in 6 46 Lower unit 2 Install a new circlip into the reverse AD S6AL6860 Assembling the drive shaft housing 1 Install the needle bearing into the drive shaft housing to the specified depth ZA Needle bearing attachment D 4 90890 06610 Driver rod SS 90890 06604 ZX Depth 4 5 0 25 mm 0 18 0 01 in 2 Apply grease to new oil seals and then install them into the drive shaft housing to the specified depth S6AL6090 6 47 NOTE TL Install an oil seal halfway into the drive shaft housing and then install the other oil seal CS Bearing outer race attachment 90890 06628 Driver rod LS 4 90890 06606 Depth 0 5 0 25 mm 0 02 0 01 in Installing the drive shaft 1 Install the thrust bearing and reverse gear into the lower case S6AL6870 2 Install the washer spring thrust bearing drive shaft thrust bearing and original shim s into the lower case 3 Install the pinion washer and pinion nut temporarily S6AL6100 6AL3 11 Drive shaftand lower case Counter rotation model NOTE SE e Be sure to select the pinion shim s if replacing the thrust bearing drive shaft housing dri
58. 100 19 92 mm 21 00 0 03 0 05 19 92 mm 1 16 mm 6AL3 11 Shimming regular rotation model 3 Select the reverse gear shim s T2 as follows Calculated number at 1 100 place 1 2 3 4 5 6 7 8 9 10 Rounded number 0 2 5 8 Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Example If T2 is 1 10 mm then the reverse gear shim is 1 08 mm If T2 is 1 16 mm then the reverse gear shim is 1 15 mm Selecting the propeller shaft shim NOTE Be sure to make this measurement in met rics 6 26 Lower unit 1 Measure the forward gear heights M1 and M2 as shown and then calculate the value Cl lor M2 S6P26330 S6AL6300 NOTE Measure the gear height at 4 points to find the height average Digital caliper 90890 06704 Calculation formula Forward gear height C1 M1 M2 2 Measure the reverse gear heights M3 and M4 as shown and then calculate the value C2 6 27 S6AL6300 NOTE SS Measure the gear height at 4 points to find the height average Calculation formula Reverse gear height C2 M3 M4 3 Measure the propeller shaft spline width C3 S6AL6320 6AL3 11 Shimming regular rotation model Backlash regular rotation model NOTE SE Measure the spline width at 4 points to find the width average 4 Selectthe propeller shaft shim T4 S6P
59. 2 Check the crankpin mark on the 3 Install half of the main bearings and crankshaft the crankshaft into the cylinder block S69J5D60 NOTE _ _ e Install the bearings in their original posi tions e Insert the projection of each bearing into the slots in the cylinder block Pi P2P3 P4 P5 P6 S6P25980 4 Put a piece of Plastigauge PG 1 on each crankshaft journal parallel to the crankshaft 3 Select the suitable color for the con necting rod bearing from the table S69J5D50 S69J5D70 Crankpin mark Q Bearing color amp NOTE 92 00 Yellow Do not put the Plastigauge PG 1 over the 84 91 Green oil hole in the main journals of the crankshaft 76 83 Blue 5 Install the remaining half of the main Checking the crankshaft journal oil bearings into the crankcase clearance 1 Clean the bearings crankshaft journals NOTE and bearing portions of the crankcase e Install the bearings in their original posi and cylinder block tions ae e Insert the projection of each bearing into 2 Place the cylinder block upside down on the slots in the crankcase a bench 5 67 6AL3 11 6 Install the crankcase onto the cylinder block and apply engine oil to the threads of the crankcase bolts 7 Tighten the crankcase bolts to the speci fied torques in 2 stages and in the sequence shown a HE de MELKEN
60. 3 0 2 3 3 3 3 O 313131313 313131313 331313131313 313 3 3 3 3 3 3 3 JAHE wlw wl wl vol at al wl w wl w wl wl wl wl w wl w ww wl wl wl wl w wl w N D D D D D D w w w w w NOTE a lt Example If the crankshaft journal mark is 81 and the cylinder block mark is S6P25A10 04 then the main bearing number is ZE e Lower main bearing for J 3 is a thrust bear ing Assembling the power unit NOTE See the exploded diagram 5 59 VES 1 Assemble the piston connecting rod 3 Select the suitable main bearing number piston pin and new piston pin clips from the table Je KR S6P25D30 S6AL5490 5 69 6AL3 11 CAUTION Do not reuse the piston pin clips always replace them with new ones NOTE nn e If a connecting rod is reused face the mark on the connecting rod in the same direc tion as the UP mark on the piston e If a new connecting rod is installed it can be installed with either side facing up lt Do not allow the piston pin clip end to align with the piston pin slot 2 Install the oil rings second ring and top ring to the piston with the 2R mark of the second ring and the R mark of the top ring facing upward 3 Offset the piston ring end gaps as shown S6AL5800 CAUTION Do not scratch the pistons or break the piston rings NOTE After installing the piston ring
61. 3 Remove the plates and clamp and then pull out the trim sensor lead PTT motor lead and flushing hose 4 Remove the wire lead extension counter rotation model 7 5 A D S6AL7A30 A Regular rotation model B Counter rotation model C To the PTT relay D To the cooling water passage cover via the joint 5 Remove the holder regular rotation model and holder om and then remove the PTT switch S6AL7050 6AL3 11 Ste ud S6AL7A20 Regular rotation model Counter rotation model To check the PTT switch see Chapter 7 Checking the PTT switch Disassembling the shift bracket 1 Remove the bolt and then disassem ble the shift bracket assembly S6AL7070 2 Remove the neutral switch and shift cut switch from the brackets and 6AL3J 11 Shift rod and bottom cowling S6AL7080 NOTE Se To check the neutral switch and shift cut switch see Chapter 8 Checking the neu tral switch and Checking the shift cut switch Assembling the shift bracket 1 Install the neutral switch onto the bracket and the shift cut switch onto the bracket S6AL7090 Neutral switch screw and shift cut Switch screw Gi 2 N m 0 2 kgf m 1 5 ft lb 7 6 Bracket unit 2 Hook the spring end into the cutout in Assembling the bo
62. 36 evec ELEC ai Electrical system 5 Measure the oil control valve resistance Replace the oil control valve if out of specification S6AL8690 key Oil control valve resistance 6 7 7 7 Q at 20 C 68 F 6 Connect the battery leads to the oil con trol valve terminals and check the opera tion of the spool valve Replace the oil control valve if it does not operate S6AL8700 7 Disconnect the battery leads from the oil control valve terminals and then connect the oil control valve couplers Fuel control system Checking the water detection switch NOTE Be sure to check the water detection switch each time the fuel filter is checked 1 Disconnect the water detection switch coupler blue 2 Connect the test harness 2 pins to the water detection switch coupler wiring harness end 8 37 3 Turn the engine start switch to ON and then measure the input voltage at the water detection switch coupler wiring harness end Check the wiring harness if out of specification Water detection switch input voltage reference data Blue white L W Black B 4 75 5 25V 4 Turn the engine start switch to OFF 5 Disconnect the test harness 2 pins from the water detection switch coupler wiring harness end 6 Remove the fuel filter cup assembly NOTE Do not twist the water detection switch lead when removing the fuel filter cup assemb
63. 6 20 Shimming regular rotation model sms 6 22 SMIL Ne 6 23 Selecting the pinion STE 6 23 Selecting the forward gear ehm 6 24 Selecting the reverse gear sShim ENEE 6 25 Selecting the propeller shaft SHIM AN 6 26 Backlash regular rotation model ss 6 28 Measuring the forward and reverse gear backlash siisseseseserenenani 6 28 6AL3 11 Lower unit counter rotation model uuvervannnnnnnnnnnvevnnnnnnnnnnnnnnaveenernnnnnnnnnenn 6 31 Removing the lower unit 6 33 Removing the water pump and shift rod 6 33 Checking the water pump and shift rod 6 34 Propeller shaft housing counter rotation model 6 35 Removing the propeller shaft housing assembly 6 37 Disassembling the propeller shaft housing 6 37 Checking the propeller Shaft housing sssscssrccsrrreerrennn 6 38 Checking the propeller SAT Lee n s et one setene 6 39 Assembling the propeller shaft housing 6 39 Drive shaft and lower case counter rotation model 6 42 Removing the drive shaft AAA 6 44 Disassembling the drive shaft housing 6 44 Disassembling the reverse gear 6 44 Disassembling the lower Case sagaene Keene 6 45 Checking the pinion and reverse gear 6 45 Checking h DEG RET 6 45 Checking the drive Shatt ET 6 45 Checking the lower case ouer SEENEN Re 6 45 Assembling ae 6 46 Assembling the reverse gear 6 46 Assembling the drive shaft housing 6 47 Installing the drive SNA ind reine drage ha 6 47 Installing the pro
64. Bolt Lower mount Engine oil drain bolt Gasket Bolt Damper Apron stay M14 x 190 mm M10 x45 mm M10 x45 mm M 14 x 205 mm M14 x 12 mm Not reusable M6 x 14 mm ON k k NNN GO Fa NNNNDQN k 6AL3J 11 7 10 Bracket unit 72 N m 7 2 kgf m 53 1 ft Ib 8 gt 427 N m 2 7 kgf m 19 9 ft Ib d S6AL7200 Partname Remarks M6x10mm Bolt Dowel Speedometer hose adapter Bolt Drive shaft bushing Circlip Nut Circlip Bushing O ring Bushing Washer Steering yoke Washer Steering arm Washer Washer M6 x 30 mm Not reusable NN NR NN BRP PP ka t th 7 11 6AL3 11 Upper case and steering arm Sel 8 N m 0 8 kgf m 5 9 ft Ib Se 42 N m 4 2 kgf m 31 0 ft Ib S6AL7210 Part name Remarks No 1 2 3 4 5 6 7 8 Bolt Plate Collar Bolt O ring O ring PCV Bolt Rubber seal Rubber seal Screw Baffle plate Rubber seal Dowel Upper case Rubber seal M10 x 45 mm Not reusable Not reusable M8 x 30 mm PRPNFPPFPNPFP PNP k k zl k H 6AL3 11 7 12 BRKT TL Bracket unit PJ 10 N m 1 0 kgf m 7 4 ft Ib oi 20 N m 2 0 kof m 14 8 ft Ib x 20 N m 2 0 kgf m 14 8 ft Ib S6AL7220 Remarks No 1 2 3 4 5 6 7 8 9 Part name Upper exhaust guide Gasket Dowel Lower exhaust gu
65. ECM and electronic throttle valve control system 8 26 ECM base assembly 5 4 Electrical gesteet 2 8 Electrical component 8 3 Exhaust cover 5 45 F Feature and benefit 1 14 Fire prevention 1 4 Fuel control system 8 37 Fuel TET seen dee gea 4 19 Fuel hose and blowby hose sesser 4 1 FUGIINJGCtOl sara sena aa aa eag anil 4 23 Fuel system 2 6 3 3 4 5 Fuse DOM aat Aeg 5 37 Fuse holdereri ak an n ad side 8 5 G n Geal pumpene 7 40 Generalist ieee toa Tana aan 3 16 General Specification sserarreen aa 2 1 General torque soenan nenen en anane nana 2 17 Good working practice secese 1 5 6AL3 11 H E HOSE OUTING nnani 4 1 How to use this manual 1 1 l Identification A 1 6 Ignition and ignition control system 8 18 Injecto T iced NG GAN a aaaeei 1 15 Installing the camshaft driven sprocket and timing belt 5 26 Installing the clamp bracket 7 25 Installing the cooling water passage cover 5 54 Installing the cylinder head 5 55 Installing the drive shaft 6 16 6 47 Installing the exhaust cover 5 53 Installing the fuel hose clamp 4 29 Installing the fuel injector ee 4 24 Installing the intake manifold 4 10 Installing the intake silencer 4 11 Installing the lower unit 6 20 6 50 Installing the oil pump 5 75 Installing the power unit 5 78 Installing
66. Pink green Oil pressure sensor P ink white Neutral switch Blue green Accelerator position sensor 2 sub Pink Engine start switch Yellow Accelerator position sensor 2 ground sub Crank position sensor ground Black Crank position sensor White black Accelerator position sensor 1 ground main Engine temperature sensor Black yellow Sensor ground Black Cooling water pressure sensor optional Blue black Trim sensor LAN Pink LAN communication H White Speed sensor optional Blue LAN communication L Blue Accelerator position sensor 2 power source sub Orange TPS 1 main Pink Intake air temperature sensor Black yellow Unit ground Black TPS ground Black Sensor power source Orange Accelerator position sensor 1 power source main Orange Battery power source Red yellow TPS 2 sub P ink white 6AL3 11 Feature and benefit Connecting part Color code TPS power source Orange Connecting part S6P21150 Color code Thermoswitch Pink Engine stop lanyard switch White
67. Remove the rubber seal shift lever and pinion shaft assembly S6AL8790 8 46 ELE ELEC Ss Electrical system 8 Remove the E clip and then remove 2 Measure the commutator diameter the clutch assembly from the pinion Replace the armature if below specifica shaft 49 tion S69J8400 Commutator standard diameter 29 0 mm 1 14 in S6AL8240 Wear limit 28 0 mm 1 10 in 3 Measure the commutator undercut Replace the armature if below specifica tion S6AL8250 NOTE ge Push the clutch assembly completely down onto the pinion shaft in direction Gu rotate it 1 spline in direction and then remove it in direction Commutator standard undercut 0 8 mm 0 03 in Wear limit 0 2 mm 0 01 in Checking the starter motor 1 Check the commutator Clean with 600 grit sandpaper and compressed air if dirty 4 Check the armature for continuity Replace the armature if out of specifica tions S69J7185 S69J8420 8 47 6AL3J 11 Armature continuity Commutator segments Continuity Segment Armature core No continuity Segment Armature shaft No continuity Checking the brush 1 Check the brush holder assembly for continuity Replace the brush holder assembly if out of specification S6AL8280 Brush holder assembly continuity Brush Brush Brush Terminal Brush Terminal Brush
68. SS Measure the thrust bearing at 4 points to find the height average Z Digital caliper 90890 06704 Shimming plate 90890 06701 6AL3 11 5 Calculate the pinion shim thickness T3 as shown in the examples below S69J6555 NOTE SE P is the deviation of the lower case dimen sion from standard The P mark 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 measure the backlash when the unit is assembled Calculation formula Pinion shim thickness T3 82 00 P 100 M3 M4 Example If M3 is 50 75 mm M4 is 30 57 mm and P is 2 then T3 82 00 2 100 50 75 30 57 mm 82 00 0 02 50 75 30 57 mm 0 70 mm If M3 is 50 70 mm M4 is 30 53 mm and P is 3 then T3 82 00 3 100 50 70 30 53 mm 82 00 0 03 50 70 30 53 mm 0 74mm 6 Select the pinion shim s T3 as follows Calculated number at 1 100 place 1 2 Rounded number 3 4 5 6 7 8 9 10 6AL3 11 Shimming regular rotation model Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Example If T3 is 0 70 mm then the pinion shim is 0 68 mm If T3 is 0 74 mm then the pinion shim is 0 72 mm Selecting the forward gear shim 1 Turn the taper roller bearing outer race 2
69. See the wiring diagram 9 21 Measure the com pression pressure Disassemble and check the power unit Troubleshooting the power unit Symptom 1 High engine idle speed below 1 200 r min Symptom 2 Cause 1 Checking step Air leakage throttle valve cylinder head Check the O rings and gaskets of the intake manifold surge tank and throttle body Symptom 1 Engine stalls unstable engine idle speed or poor acceleration Symptom 2 Cause 1 Cause 2 Checking step Incorrect intake cam timing check using the YDIS 6AL3 11 Variable camshaft timing operation mal function Stuck oil control valve plunger Check the oil con trol valve operation using the YDIS Check the oil con trol valve plunger Clogged oil control valve filter Replace the oil con trol valve filter Clogged oil sage pas Check the oil pas sage Stuck variable cam shaft timing Replace the vari able camshaft tim ing TRBL D SHTG Troubleshooting Symptom 1 Limited engine speed below 2 000 r min Symptom 2 Cause 1 Checking step e Buzzer comes on lt Overheat warning indicator comes on e Cooling water does not discharge from the cooling water pilot hole Clogged cooling wa ter inlet Check the cooling water inlet Water pump mal function Water pump impel ler malfunction Check the impeller
70. Turn the lower unit back to its original position 8 Install the backlash indicator onto the drive shaft 22 4 mm 0 88 in in diame ter and then install the dial gauge 6 29 S6AL6940 NOTE ER Install the dial gauge so that the plunger contacts the mark on the backlash indica tor rod Cz Backlash indicator 90890 06706 Magnet base plate 90890 07003 Dial gauge set 90890 01252 Magnet base B 90890 06844 9 Slowly turn the drive shaft clockwise and counterclockwise and measure the back lash when the drive shaft stops in each direction NOTE Measure the backlash at 4 points to find the average Forward gear backlash 0 26 0 65 mm 0 0102 0 0256 in 10 Add or remove shim s if out of specifica tion Forward gear backlash Less than Shim thickness To be decreased by 0 26 mm 0 0102 in 0 46 M x 0 71 More than To be increased by 0 65 mm 0 0256 in M 0 46 x 0 71 M Measurement 6AL3 11 Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 11 Remove the special service tools from the propeller shaft 12 Apply a load to the reverse gear by installing the propeller spacer without the washer oO and washer ou as shown NOTE 0 Tighten the propeller nut while turning the drive shaft until the drive shaft can no longer be turned 13 Slowly turn the drive shaft clockwise and coun
71. and operate the YDIS see Chapter 9 YDIS and the YDIS Ver 1 23a or later Instruction Manual 2 Check that the accelerator lever con tacts the fully closed stopper when the remote control lever is at the fully closed position S6P 21030 NOTE TT TUL To adjust the throttle cable see Chapter 3 Adjusting the throttle cable 3 Turn the engine start switch to ON operate the remote control lever and then check the output voltages of accel erator position sensor 1 and accelerator position sensor 2 at the fully closed posi tion and fully open position 6AL3 11 S6AL8150 NOTE SE Do not start the engine when checking the accelerator position sensor Accelerator position sensor output voltage Remote control lever position Item Fully closed Fully open Sensor 1 0 550 0 850 V Above 3 250 V Sensor 2 0 400 1 000 V reference data 4 Operate the remote control lever and check that the output voltages of acceler ator position sensor 1 and accelerator position sensor 2 change continuously 5 Turn the engine start switch to OFF 6 Disconnect the throttle cable joint from the accelerator position sensor 7 Disconnect the accelerator position sen sor coupler 8 Operate the accelerator lever and mea sure the resistance of the accelerator position sensor at the fully cl
72. battery terminal and holder oil pressure sensor lead isolator lead and PTT lead must be removed before removing the oil pressure sensor e Use a general oil pressure gauge 3 Startthe engine and warm it up for 5 min utes 4 Measure the oil pressure Check for oil leakage and check the oil pump and oil strainer if out of specification NOTE If the engine is started with the coupler dis connected from the oil pressure sensor the ECM will determine that an oil pressure sensor malfunction trouble code 39 has occurred and increase the engine idle Speed approximately 900 r min Delete the diagnosis record using the YDIS after checking the oil pressure The actual oil pressure may vary depend ing on the temperature and viscosity of the engine oil being used Oil pressure reference data 600 kPa 6 0 kgf cm 87 0 psi at 600 900 r min Checking the oil pressure sensor 1 Connect the test harness 3 pins to the oil pressure sensor 6AL3 11 Power unit check and adjustment S6AL5020 Start the engine and warm it up for 5 min utes Measure the oil pressure sensor input voltage Check the wiring harness con nection or replace the ECM if out of spec ification 5 2 4 Measure the oil pressure sensor output voltage Replace if out of specification EE aa aan KEE B 600 kpa 6 0 kgf cm 87 0 psi S6P25040 A Output voltage B Oil p
73. cables from the battery and the clip from the engine stop lanyard switch lt Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning lt When removing the lower unit with the power unit installed be sure to Suspend the outboard motor If the outboard motor is not suspended it can fall sud denly and result in severe injury 6AL3 11 Lower unit regular rotation model 3 Mark the trim tab at the area shown and then remove it 4 Remove the bolts nuts and then remove the lower unit from the upper case S6AL6630 U transom model 6 4 Lower unit Removing the water pump and shift rod 1 Remove the water pump housing and impeller 2 Remove the Woodruff key 3 Remove the outer plate cartridge and water pipe 4 Set the gear shift to the neutral position and then remove the shift rod assembly S6AL6640 Checking the water pump and shift rod 1 Check the water pump housing Replace if there is deformation NOTE be If the engine overheated the inside of the water pump housing may be deformed so be sure to remove the insert cartridge when checking the housing 2 Check the impeller insert cartridge and outer plate cartridge Replace if cracked or worn 6 5 3 Check the water pipe Replace if corro sion deformation or cracked Check the Woodruff key and the groove on the drive shaft Replace if worn Ch
74. 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 Item Remarks 10 hours 1 month 50 hours 3 months 100 hours 6 months 200 hours 1 year Refer to page Anodes external Check replace O O 3 16 Anodes cylinder head thermostat cover Check replace O 3 16 Battery Check charge 3 17 Cooling water passages Clean 3 10 Top cowling Check 3 3 Fuel filter Check replace 3 4 Fuel filter low pressure fuel pump Check replace 4 22 Fuel system Check 3 3 Gear oil Change Lubrication points Lubricate Engine idle speed Check PCV Check PTT unit Check Propeller and cotter pin Check replace Shift link shift cable Check adjust Thermostat Check replace Throttle link throttle cable throttle pick up timing Check adjust Water pump Check replace Engine oil Check change Oil filter cartridge Change Spark plugs Clean adjust replace Timing belt Check replace ED Check the water detection switch each time the fuel filter is checked To check the water detection switch see Chapter 8 Checking the water detection switch NOTE as ar re oe rn When operating in
75. circuit Check the electronic throttle valve relay and fuse Check the electronic throttle valve motor continuity Electronic throttle system malfunction Check the electronic throttle valve circuit Electronic throttle system malfunction Replace the ECM 9 13 Electronic throttle system malfunction Replace the electronic throttle valve assembly electronic throt tle valve motor malfunction 6AL3 11 Trouble code Symptom Remarks Troubleshooting the power unit Checking steps Electronic throttle system malfunction Check the electronic throttle valve relay and fuse Check the electronic throttle valve circuit Check the electronic throttle valve motor continuity Throttle position sensor malfunction Check the TPS output voltage using the YDIS Check the throttle opening angle using the YDIS Check the electronic throttle valve circuit Throttle position sensor malfunction Check the TPS output voltage using the YDIS Check the throttle opening angle using the YDIS Check the electronic throttle valve circuit Throttle position sensor malfunction Check the TPS output voltage using the YDIS Check the throttle opening angle using the YDIS Check the electronic throttle valve circuit Electronic throttle system m
76. 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 Win dows 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 Function 1 Diagnosis Displays each part name and the ECM trouble codes and status when the engine start switch is turned to ON This allows you to quickly specify malfunctioning parts The trou ble codes displayed are the same as those described in Trouble code and checking step in this chapter 9 9 2 Diagnosis record Displays each part name and the ECM trouble codes that have been regis tered This allows you to check the outboard motor s record of malfunctions The trouble codes displayed are the same as those described in Trouble code and checking step in this chapter 9 9 9 1 6AL3J 11 YDIS 3 Engine monitor Each sensor status and the ECM data are displayed while the engine is run ning This enables you to find malfunctioning parts quickly In addition the data displayed using the Engine Monitor function can be displayed in a graph Items For F L 200C F L 225B Engine speed Fuel injection duration Dual engine system switch Intake pressure Ignition timing Shift cut off switch Throt
77. disassemble the oil pump 5 73 S6P25E60E NOTE See the exploded diagram 5 59 Checking the oil pump 1 Check the gear teeth and inner surface of the oil pump case Replace the oil pump assembly if the gear teeth are cracked or worn or if inner surface of the oil pump case is scratched Assembling the oil pump 1 Install a new oil seal into the oil pump 6 o S6S15660E Ko Bearing inner race attachment 90890 06661 2 Install new oil seals into the oil pump housing 6AL3J 11 Cylinder block gt WR No 2 56515670 CZ Driver rod L3 90890 06652 Needle bearing attachment 90890 06613 3 Install a new oil seal into the oil pump housing S6P25A50E Oil pump cover screw 4 N m 0 4 kgf m 3 0 ft lb 56515680 Driver rod L3 90890 06652 Needle bearing attachment 90890 06607 4 Install a new gasket and then tighten the screws to the specified torque 5 Install a new oil seal into the oil pump making sure to install it in the proper direction 6AL3J 11 5 74 Installing the oil pump 1 Install the oil pump by aligning the oil pump gear with the crankshaft A lt J G LCE AN CAUTION Before installing the oil pump be sure to fill it with engine oil through the oil pas sage NOTE When installing the oil pump install it so that the oil seal does not get da
78. dog clutch shift rod joint and slider Replace the dog clutch shift rod joint or slider if cracked or worn Assembling the propeller shaft housing 1 Install the needle bearing into the propel ler shaft housing to the specified depth S6AL6570 6 39 NOTE TT TL e Install the needle bearing with the manufac ture identification mark facing toward the oil seal propeller side e When using the driver rod do not strike the Special service tool in a manner that will force the stopper out of place Z Driver rod SS D 90890 06604 Needle bearing attachment 90890 06610 Bearing depth plate 90890 06603 Depth 25 3 0 25 mm 1 00 0 01 in 2 Apply grease to new oil seals and then install them into the propeller shaft hous ing to the specified depth S6AL6820 NOTE i ss Install an oil seal halfway into the propeller shaft housing and then install the other oil seal Bearing inner race attachment 90890 06640 Depth 5 0 0 25 mm 0 20 0 01 in 3 Install the original shim s and thrust bearing with the propeller shaft into the propeller shaft housing 6AL3 11 S6ALGA80 NOTE e Be sure to select the propeller shaft shim s if replacing the propeller shaft propeller shaft housing thrust bearing or taper roller bearing e To select the shims see Chapter 6 Shim ming counter rotation model 4 Install a new taper ro
79. drive shaft 1 Check the drive shaft Replace the drive shaft if bent or worn 2 Measure the drive shaft runout Replace the drive shaft if above specification S6AL6690 Drive shaft runout limit 0 2 mm 0 008 in Checking the lower case 1 Check the skeg torpedo and anti cavita tion plate Replace the lower case if cracked or damaged 6AL3 11 Drive shaftand lower case Counter rotation model Assembling the lower case 1 Install the needle bearing into the retainer to the specified depth or Q ge W S6AL6850 GJ Needle bearing attachment D d 90890 06654 Driver rod L3 90890 06652 ZX Depth 0 0 25 mm 0 0 01 in 2 Install the original shim s and retainer into the lower case NOTE e Be sure to select the reverse gear shim s if replacing the thrust bearing retainer or lower case e To select the shims see Chapter 6 Shim ming counter rotation model lt Make sure that the slots in the retainer are aligned vertically as shown WA Ball bearing attachment 90890 06657 Driver rod LL 90890 06605 3 Install the needle bearing into the lower case 6AL3 11 S6AL6460 NOTE Apply gear oil to the needle bearing outer case before installation lt The needle bearing contains 24 rollers Ball bearing attachment 4 90890 06655 Bearing outer race puller assembly 90890 06523 Assembling the reverse gear
80. filter and the clamp 8 16 evec E ELEC s Electrical system OG NGO gt J S e 6 a lo A holder le trim sender lead with the clamp 8 17 Fasten the PTT switch lead wiring harness side and PTT switch extension lead with the Fasten the flushing hose PTT switch lead and vd Per Ke a a FL200C FL225B S 6AS 8040 6AL3 11 Wiring harness routing Ignition and ignition control system Ignition and ignition control system Checking the ignition spark 1 Remove the ECM cover 2 Remove the ignition coils NOTE To prevent the engine from starting when cranking it be sure to remove all of the igni tion coils or disconnect all of the injector cou plers 3 Connect an ignition coil assembly to the special service tool Ignition tester 90890 06754 4 Crank the engine and check the spark If the spark is weak check the ignition sys tem WARNING lt Do not touch any of the connections of the special service tool lt Be sure to install the special service tool to the ignition coil so that sparks do not leak out lt Keep flammable gas or liquids away since this test can produce sparks NOTE EE The
81. flywheel magnet NOTE E Apply force to the crankshaft end until the fly wheel magnet comes off the tapered portion of the crankshaft Flywheel puller 90890 06521 7 Remove the stator assembly bolts and then move the stator assembly 6AL3 11 S6AL5110 8 Remove the timing belt driven sprock ets and camshafts NOTE To remove the timing belt driven sprockets and camshafts see Chapter 5 Removing the timing belt driven sprocket and cam shaft 9 Remove the valve shim Q from the valve lifter using compressed air S6AL5680 NOTE EE Do not mik the valve train parts Keep them organized in their proper groups 10 Measure the valve shim thickness using a micrometer and then note the mea surement data 5 12 11 Select the necessary valve shim by cal culating its thickness using the following formula Necessary valve shim thickness Removed valve shim thickness Measured valve clearance Specified valve clearance Example If the Removed valve shim thickness is 2 10 mm the Measured valve clearance is 0 30 mm and the Specified valve clearance is 0 20 mm then the Necessary valve shim thickness 2 10 0 30 0 20 2 20 mm 12 Install the necessary valve shim into the valve lifter 13 Install the camshafts driven sprockets and timing belt NOTE To install the camshafts driven sprockets and timing belt see Chapter
82. gap at the specified measuring point oO CO RD MG s6pP25D50 Piston ring end gap reference data Top ring 0 15 0 30 mm 0 006 0 012 in Second ring 0 30 0 45 mm 0 012 0 018 in Oil ring 0 15 0 60 mm 0 006 0 024 in Measuring point reference data 20 mm 0 8 in Checking the piston ring groove 1 Measure the piston ring grooves Replace the piston if out of specification 10 T fe S6AL5G30 5 63 Piston ring groove Top ring 1 23 1 25 mm 0 048 0 049 in Second ring 1 22 1 24 mm 0 048 0 049 in Oil ring 2 51 2 53 mm 0 099 0 100 in Checking the piston ring side clearance 1 Measure the piston ring side clearance Replace the piston and piston rings asa setif out of specification S6AL5G40 Piston ring side clearance Top ring 0 04 0 08 mm 0 002 0 003 in Second ring 0 03 0 07 mm 0 001 0 003 in Oil ring 0 04 0 13 mm 0 002 0 005 in Checking the piston pin boss bore 1 Measure the piston pin boss bore Replace the piston if out of specification 6AL3 11 Cylinder block S6AL5790 Connecting rod small end inside diameter S6AL5470 21 017 21 031 mm 0 8274 0 8280 in NOTE SS When measuring the piston pin boss bore do not measure it at the oil grooves or ring groove Checking the connecting rod big end side clearance 1 Measure the connecting rod big end
83. installation procedure In addition be sure to lubricate the bearings liberally Apply a thin coat of water resistant grease to the lip and periphery of an oil seal before installation Check that moving parts operate nor mally after assembly 6AL3J11 Identification Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket S69J1080 S6AL1D00 Model name Approved model code Transom height Serial number Approved Starting model code serial No 200 R 6AL 1000001 Model name 200 L 6AM 1000001 225R 6AS 1000001 225 L 6AT 1000001 6AL3J11 Safety while working Identification 1 6 an General information Special service tool Oil filter wrench 90890 06830 Leakage tester 90890 06840 Fuel pressure gauge adapter B 90890 06942 Fuel pressure gauge 90890 06786 Vacuum pressure pump gauge set 90890 06756 Compression gauge 90890 03160 Compression gauge extension 90890 06563 Test harness 3 pins 90890 06869 Flywheel holder 90890 06522 Flywheel puller 90890 06521 6AL3J11 Sheave holder 90890 01701 Valve spring compressor 90890 04019 TV gt gt Valve spring compressor attachment 90890 06320 a Valve guide remover installer 90890 06801 Valve guide installer 90890 06810 6AL3J11 Special service tool ee Valve gu
84. kgf m 4 4ft lb 12 N m 1 2 kgf m 8 9 ft Ib S6AL5750E No Partname Q ty Remarks 1 Cap 2 2 Nut 2 3 Bolt 3 M6 x 20 mm 4 Sub wiring harness 1 5 Bolt 2 M6 x 25 mm 6 PTT relay 1 7 Bolt 2 M6x 35mm 8 Rectifier Regulator 1 9 Gasket 1 10 Anode 1 11 Cover 1 12 Bolt 4 M6 x 25 mm 13 Bolt 5 M6 x 28 mm 14 Junction box 1 15 Grommet 5 16 Collar 5 17 Wiring harness 1 6AL3 11 5 36 Fuse box S6AL5400 Part name f Remarks Fuse box assembly Screw Cover Fuse puller Fuse Fuse Fuse Fuse Fuse Screw Cover Screw Fuse Grommet Terminal 95 x 20 mm 10 Spare is included 30 Spare is included 20 A Spare is included 5 Spare is included 15 Spare is included 3 x 10 mm 95 x 10 mm 80 A Spare is included HkKUSKHEHRANNNUNHEEA kb N CH 5 37 6AL3J 11 ECM I MALZ N m 0 7 kgf m 5 2 ft Ib RIT N m 0 7 kgf m 5 2 ft Ib A A Power unit S6AL5630 No Part name Q ty Remarks 1 Bolt 4 M6 x 20 mm 2 ECM 1 3 Holder 1 4 Plastic tie 3 5 Holder 4 6 Bolt 2 M6 x 16 mm 7 Plate 1 8 Holder 1 9 Holder 1 10 Plate 1 11 Holder 2 12 ECM bracket 1 13 Grommet 4 14 C
85. mm 4 27 6AL3J 11 Vapor separator hse 5 N m 0 5 kgf m 3 7 ft Ib Part name Remarks Gasket Float chamber Vapor separator drain screw Drain hose J oint Hose Cap 6AL3J 11 4 28 e D Fuel system Removing the fuel hose clamp NOTE To reduce the fuel pressure see Chapter 4 Reducing the fuel pressure 1 Remove the fuel hose clamps by cutting the crimped section of the clamp C O S69J4030 CAUTION If the fuel hose clamps are removed with out cutting the crimp first the fuel hose could be damaged Installing the fuel hose clamp 1 Crimp the fuel hose clamps properly to securely fasten them Ki S69J4040 WARNING Do not reuse the fuel hose clamps always replace them with new ones otherwise the fuel leakage may occur Checking the high pressure fuel pump NOTE e To check the high pressure fuel pump see Chapter 8 Checking the low pressure fuel pump and high pressure fuel pump e To check the high pressure fuel pump relay see Chapter 8 Checking the high pressure fuel pump relay e To check the fuse see Chapter 8 Fuse holder Checking the vapor separator NOTE ees To drain the fuel see Chapter 3 Draining the fuel 1 Check the needle valve Replace needle valve assembly if bent or worn S6AL4350 2 Check the float Replace the float if there is deterioration 3 Check th
86. not get any sealant on the main bear ings 9 Install the crankcase onto the cylinder block and then tighten the crankcase bolts to the specified torques in 2 stages and in the sequence shown 1 9 7 fide Ld ere m l e 8 16 d S6AL5840 6AL3 11 NOTE e Crankcase bolts Del can be reused 5 times e The oil seal must be installed before tightening the crankcase bolts e Apply engine oil to the crankcase bolts before installation e Tighten the M8 bolts 1 8 and M10 bolts oHe to the specified torques in 2 stages In the 2nd stage make a mark on the crankcase and crankcase bolts and then tighten crankcase bolts 1 18 90 from the mark e After tightening the bolts 1 116 has been completed tighten the M8 bolts 1729 to the specified torques in 2 stages e After tightening the crankcase bolts check that the crankshaft rotates smoothly Crankcase bolt 4 Hs M8 Ist 25 N m 2 5 kgf m 18 4 ft lb 2nd 90 Crankcase bolt 9 16 M10 1st 40 N m 4 0 kgf m 29 5 ft lb 2nd 90 Crankcase bolt 17H 29 M8 1st 14 N m 1 4 kgf m 10 3 ft lb 2nd 28 N m 2 8 kgf m 20 7 ft lb 10 Install the piston with the UP mark on the piston crown facing towards the fly wheel magnet S6D85610 NOTE Apply engine oil to the side of the pistons and piston rings before installation 6AL
87. position sensor input voltage reference data 980000 1 060066 1 Terminal 0 Terminal B 00089000 Terminal 0 Terminal B 4 75 5 25 V S6P28850 6 Turn the engine start switch to OFF 7 Connect the accelerator position sensor coupler Checking the electronic throttle valve and TPS 1 Connect a computer to the outboard motor and use the YDIS to display Throttle position sensor 1 Throttle valve opening and Throttle position sensor 2 8 31 6AL3J 11 ECM and electronic throttle valve control system S6P24140 NOTE e TPS 1 and TPS 2 are components of the electronic throttle valve which cannot be disassembled e To connect and operate the YDIS see Chapter 9 YDIS and the YDIS Ver 1 23a or later Instruction Manual 2 Check that the accelerator lever con tacts the fully closed stopper when the remote control lever is at the fully closed position 56P 21030 NOTE EE To adjust the throttle cable see Chapter 3 Adjusting the throttle cable 3 Start the engine warm it up and then turn it off 6AL3 11 4 Turn the engine start switch to ON operate the remote control lever and then check the output voltages of TPS 1 and TPS 2 and the throttle valve opening angle at the fully closed position and fully open positio
88. remove shim s if out of specifica tion 6 61 Forward gear backlash Shim thickness Less than 0 46 mm 0 0181 in 0 64 M x 0 71 To be decreased by More than To be increased by 0 82 mm 0 0323 in M 0 64 x 0 71 M Measurement Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 11 Remove the special service tools from the propeller shaft 12 Tum the shift rod in direction to the reverse position using the shift rod push arm 13 Turn the drive shaft clockwise until the dog clutch is fully engaged 14 Turn the shift rod in direction to the neutral position using the shift rod push arm 15 Turn the drive shaft counterclockwise approximately 90 S6AL6190 6AL3 11 16 Turn the shift rod in direction to the reverse position using the shift rod push arm 17 Slowly turn the drive shaft clockwise and counterclockwise and measure the back lash when the drive shaft stops in each direction NGT Tam S6AL6960 NOTE n O O e When measuring the reverse gear back lash add force to the reverse direction using the shift rod push arm e Measure the backlash at 4 points to find the average ZX Reverse gear backlash 0 45 0 90 mm 0 0177 0 0354 in 18 Add or remove shim s if out of specifica tion Reverse gear backlash Less than 0 45 mm 0 0177 in 0 68 M x 0 71 More than To be increased by 0 90 mm 0
89. salt water turbid or muddy water the engine should be flushed with clean water after each use 3 1 6AL3J 11 Maintenance interval chart Every Remarks ES SR ru Page Timing belt Replace O 5 15 Valve clearance DOHC Check adjust O 5 9 Fuel filter Replace O 4 27 vapor separator tank Refer to Oil control valve filter Replace 5 43 Anodes Replace 3 16 exhaust cover cooling water passage cover Rectifier Regulator cover Exhaust guide exhaust Check replace manifold 6AL3J 11 3 2 CHK Q ADJ Periodic check and adjustment Top cowling Checking the top cowling 1 Check the fitting by pushing the cowling with both hands Adjust if necessary 569J3010 2 Loosen the bolts 3 Move the hook up or down slightly to adjust its position S69J3020 NOTE ee ees e To loosen the fitting move the hook in direction e To tighten the fitting move the hook in direction 4 Tighten the bolts 5 Check the fitting again and if necessary repeat steps 2 4 6 Check the top cowling hoses Replace if cracked or damaged 3 3 S6P23010 Fuel system Checking the fuel joint and fuel hose fuel joint to fuel injector 1 Remove the flywheel magnet cover port intake manifold and fuel rail covers port and starboard NOTE See the exploded diagram 4 9 4 23 2 Check the low pressure fuel hose con nections Also check the fuel fil
90. see Chapter 4 Installing the intake manifold 19 Install all the parts that were removed 5 81 6AL3J 11 Cylinder block MEMO 6AL3J 11 5 82 Lower unit Lower unit regular rotation model ss 6 1 Removing the lower uk ruse een cutie nen 6 4 Removing the water pump and shift rod 6 5 Checking the water pump and shift Odette 6 5 Propeller shaft housing regular rotation model 6 6 Removing the propeller shaft housing assembly 6 8 Disassembling the propeller shaft assembly 6 8 Disassembling the propeller shaft housing 6 8 Checking the propeller shaft housing essssssssrsrrererrreren 6 9 Checking the propeller Shaun attenant 6 9 Assembling the propeller shaft assembly 6 9 Assembling the propeller shaft housing 6 10 Drive shaft and lower case regular rotation model 6 12 Removing the CHIVES EE 6 14 Disassembling the drive shaft housing 6 14 Disassembling the forward gear 6 14 Disassembling the lower CaSe sinus aana anan anaa aana nana nana anana 6 14 Checking the pinion and forward gear 6 15 Checking the BEEN kua nn ais due aaa wi Attente 6 15 Checking the drive SNA cena ann sr 6 15 CHECKING EE 6 15 Assembling the lower case 6 15 Assembling the forward Bet 6 16 Assembling the drive shaft housing 6 16 Installing the e TE EE 6 16 Installing the propeller Shaft housing 6 17 Installing the water pump and shift rod 6 18 Installing the lower unit rat de nn ananas
91. service tool to the opposite check valve port as shown S6P24200 5 Apply positive pressure to the check valve port 6 Check that no air comes out of the oppo site end of the check valve Replace the canister check valve if air comes out 4 16 ory Fuel system Installing the throttle body 1 Connect the check valve to the hoses and SP wg S6AL4210 To the intake silencer 2 Connectthe hoses and fasten them K S6AL4070 To the intake silencer To the pressure regulator To the atmosphere top cowling lock To the vapor separator ooa gt NOTE SS Fasten the pressure regulator hose and canister vent hose 4 to the holder 3 Fasten the hoses and amp to the holder 4 17 S6AL4220 9 4 Install the throttle body 5 Connectthe hoses and fasten them S6AL4230 NOTE SS Fasten the pressure regulator hose and vapor separator hose to the holder 6 Fasten the wiring harness to the holders 7 Fasten the vapor gas hose and fuel hose to the holder 6AL3 11 Throttle body S6AL4240 4 18 6AL3 11 el H Fuel system Fuel filter 9 12 mm 12mm 9mm 0 47 in
92. shift rod After assembling the lower unit check that the shift rod operates smoothly and check that the drive shaft and propeller shaft rotate smoothly When measuring the backlash be sure to measure it before installing the water pump To measure the backlash see Chapter 6 Measuring the forward and reverse gear backlash counter rotation model 2 Install a new gasket the outer plate cartridge Q and dowels 6 49 S6AL6710 Install the Woodruff key into the drive shaft Align the groove on the impeller with the Woodruff key and then install the impeller onto the drive shaft S69J6300 Install a new O ring and the insert car tridge into the pump housing 6AL3 11 Drive shaftand lower case Counter rotation model NOTE Sg Align the insert cartridge projections with the holes in the pump housing 6 Install a new O ring and the pump housing assembly into the lower case tighten the bolts and then install the seal d and cover S6AL6720 CAUTION Do not turn the drive shaft counterclock wise otherwise the water pump impeller may be damaged NOTE e When installing the pump housing apply grease to the inside of the insert cartridge and then turn the drive shaft clockwise while pushing down the pump housing lt Align the cover projection with the hole in the pump housing 6AL3 11 Installing the lower unit AA WARNING When
93. side clearance Piston pin boss bore 21 017 21 031 mm 0 8274 0 8280 in Checking the piston pin 1 Measure the piston pin outside diameter Replace the piston pin if out of specifica tion S69J5C50 Connecting rod big end side clearance reference data 0 15 0 30 mm 0 006 0 012 in S69J5C30 Piston pin outside diameter 20 995 21 000 mm 0 8266 0 8268 in Checking the connecting rod small end inside diameter 1 Measure the connecting rod small end inside diameter Replace the connect ing rod assembly if out of specification 6AL3J 11 5 64 Checking the crankshaft 1 Measure the crankshaft journal diameter crankpin diameter amp and crankpin width Replace the crankshaft if out of Specification 869J5C70 Crankshaft journal diameter amp 62 968 62 992 mm 2 4791 2 4800 in Crankpin diameter 49 976 50 000 mm 1 9676 1 9685 in Crankpin width 21 50 21 55 mm 0 8465 0 8484 in 2 Measure the crankshaft runout Replace the crankshaft if above specification S6AL5480 5 65 Crankshaft runout limit 0 03 mm 0 0012 in Checking the crankpin oil clearance 1 Clean the bearings and the connecting rod 2 Install the upper bearing into the con necting rod and the lower bearing into the connecting rod cap S6AL5B10 NOTE SE e Install the connecting rod bearings in their original positions e Insert the project
94. special service tool to the check valve port as shown S6P24220 6AL3J 11 90890 06756 Apply positive pressure to the check valve port Check that air comes out of the opposite end of the check valve Replace the check valve if no air comes out Connect the special service tool to the opposite check valve port as shown S6P24230 Apply positive pressure to the check valve port Check that no air comes out of the oppo site end of the check valve Replace the check valve if air comes out 4 22 el D Fuel system Fuel injector S6AL4120 Part name Remarks Not reusable CO CDJ On Un P DI FA Hm Fuel injector O ring set Holder Fuel rail PORT Bolt Cover Bolt Fuel rail STBD Cover Plastic tie Fuel rail assembly PORT Fuel rail assembly STBD M6 x 35 mm M6 x 20 mm kA kA D k SR P kA ON On 4 23 6AL3J 11 Fuel injector Checking the fuel rail 1 Check the fuel rails Replace the fuel rail if cracked or deformed NOTE e To reduce the fuel pressure see Chapter 4 Reducing the fuel pressure e To check the fuel injectors see Chapter 8 Checking the fuel injector Installing the fuel injector 1 Apply engine oil to new O rings and then install them onto the fuel injectors S6AL4140 4 Install the fuel rails onto the cyli
95. the level is at or below the minimum level mark add distilled water until the level is between the maximum and minimum level marks 3 17 569 3620 2 Check the specific gravity of the electro lyte Fully charge the battery if below specification WARNING Battery electrolyte is dangerous it con tains sulfuric acid which is poisonous and highly caustic Always follow these preventive measures lt Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury lt Wear protective eye gear when handling or working near batteries Antidote EXTERNAL lt SKIN Wash with water lt EYES Flush with water for 15 minutes and get immediate medical attention Antidote INTERNAL e 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 mea sures lt Charge batteries in a well ventilated area lt Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes lt DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN 6AL3 11 NOTE e Batteries vary per manufacturer The pro cedures mentioned in this manual may not always apply therefore consult the instruc tion manual of the battery e Disconnect th
96. the pin inserted into the hole of the timing belt tensioner until the timing belt is installed again 6 Remove the timing belt from the driven sprockets then from the drive sprocket 7 Align the A mark on the drive sprocket with the mating surface of the crankcase and cylinder block by turning the crankshaft counterclockwise 60 gradually ENN NY KN S6P25480 6AL3 11 Power unit check and adjustment CAUTION Do not turn the crankshaft counterclock wise more than 60 Otherwise the piston and valves will collide with each other and be damaged 8 Align the I marks on the port driven sprockets by turning them clockwise 60 gradually S6AL5730 CAUTION e Do not turn the port driven sprockets clockwise more than 60 and do not turn the starboard driven sprockets Otherwise the intake and exhaust valves will collide with each other and be dam aged e Be careful when turning the driven sprockets Depending on the position of the camshafts the force of the valve springs may cause the driven sprockets to be rotated too far 5 22 9 Hold the intake driven sprocket using the special service tool and then remove the variable camshaft timing cap EL EX SN D d S6P25500 CAUTION lt Do not hold the camshaft when remov ing the variable
97. the slit in the wiring harness guide and then install the wiring har ness guide onto the power unit S6AL5600 NOTE SE It is recommended to check the crank posi tion sensor air gap before installing the wiring harness guide to improve working efficiency To check the crank position sensor air gap see Chapter 8 Checking the crank position sensor air gap 5 76 5 Install the wiring harness onto the wiring harness guide with the mark facing upward and then insert the projections on the plastic ties into the holes in the wiring harness guide in the sequence shown 6 Fasten the wiring harness using the plas tic ties NOTE e Be sure to install the wiring harness onto the wiring harness guide so that the wiring harness does not protrude above the top edge of the wiring harness guide e Be sure to install the wiring harness between the swells 7 Install the sub wiring harness fuse box PTT relay and Rectifier Regulator to the junction box NOTE To install the sub wiring harness fuse box PTT relay and Rectifier Regulator to the junction box see the exploded diagram 5 37 5 36 8 Install the junction box onto the power unit and then tighten the bolts tempo rarily 9 Install the wiring harness to the junction box and then fasten the wiring harness at the white tape and the sub wiring harness at the white tape using the plastic tes 10 Install the plastic ties
98. tightening the variable camshaft timing bolt Variable camshaft timing bolt 60 N m 6 0 kgf m 44 3 ft lb 13 Install a new gasket and the variable camshaft timing cap and then tighten the cap to the specified torque while holding the driven sprocket using the Special service tool S6AL5B00 CAUTION e Do not reuse the gaskets always replace them with new ones lt Do not hold the camshaft when tighten ing the variable camshaft timing cap Otherwise the variable camshaft timing assembly could be damaged e Do not turn the driven sprocket when tightening the variable camshaft timing cap Otherwise the intake and exhaust valves will collide with each other and be damaged Sheave holder 90890 01701 Variable camshaft timing cap 32 N m 3 2 kgf m 23 6 ft lb 14 Align the Il marks on the port driven sprockets by turning them counterclock wise 60 gradually 6AL3 11 Power unit check and adjustment S6AL5740 S6AL5750 CAUTION e Do not turn the port driven sprockets counterclockwise more than 60 and do not turn the starboard driven sprockets Otherwise the intake and exhaust valves will collide with each other and be dam aged Be careful when turning the driven sprockets Depending on the position of the camshafts the force of the valve springs may cause the driven sprockets to be rotated too far 15 Align the A mark on the drive sprocket
99. tool may not fit into the lower case In that case use a special ser vice tool with a smaller diameter lt Be sure to remove the forward gear before removing the needle bearing CZ Ball bearing attachment 90890 06655 Driver rod LL 90890 06605 6 14 Lower unit 2 Remove the taper roller bearing outer race and shim s S6AL6A60 NOTE Install the claws as shown Z Bearing outer race puller assembly 90890 06523 Outer race puller claw A 90890 06532 Checking the pinion and forward gear 1 Check the teeth of the pinion and the teeth and dogs of the forward gear Replace the pinion or forward gear if cracked or worn Checking the bearing 1 Check the bearings Replace the bearing if pitted or if there is rumbling Checking the drive shaft 1 Check the drive shaft Replace the drive shaft if bent or worn 2 Measure the drive shaft runout Replace the drive shaft if above specification S6AL6690 6 15 Drive shaft runout limit 0 2 mm 0 008 in Checking the lower case 1 Check the skeg torpedo and anti cavita tion plate Replace the lower case if cracked or damaged Assembling the lower case 1 Install the original shim s and taper roller bearing outer race J e Be sure to select the forward gear shim s if replacing the lower case or taper roller bearing assembly e Be sure to select the propeller shaft shim if replacing t
100. water passage cover yp Anode screw 3 N m 0 3 kgf m 2 2 ft lb 6AL3 11 Cylinder head 2 Install a new gasket and the cooling water passage cover 3 Connect the cooling water hose GO cylin der block to fuel cooler to the cylinder block on fe gt a y oe Le S6AL5440 A 572 NOTE EEN See the hose routing 4 3 and exploded dia gram 5 43 4 Tighten the cooling water passage cover bolts to the specified torque in the sequence shown EN T lt A Si Cooling water passage cover bolt 12 N m 1 2 kgf m 8 9 ft lb 5 Connect the flushing hose and fasten it S6P25890E NOTE See the hose routing 4 3 and exploded dia gram 5 43 6 Tighten the knock sensor to the specified torque and then fasten the knock sensor lead and flushing hose as shown S6AL5450 NOTE 0 Fasten the knock sensor lead so that it is taut y Knock sensor 32 N m 3 2 kgf m 23 6 ft lb Installing the cylinder head 1 Install the grommets and collars into the cylinder block NOTE See the exploded diagram 5 43 2 Install new gaskets and the cylinder heads and then tighten the bolts to the Specified torques in the sequence shown 5 55 o 50 pe JON SO JAN O
101. wires or hoses when the outboard motor is steered Checking the gear shift and throttle operation ik Check that the gear shift operates smoothly when the remote control lever is shifted from the neutral position to for ward or reverse Check that the throttle operates smoothly when the remote control lever is shifted from forward or reverse to the fully open position S6P21070 oe the PTT system Check that the outboard motor tilts up and down smoothly when operating the PTT unit Check that there is no abnormal noise produced when the outboard motor is tilted up or down 6AL3 11 1 Check that the engine starts when the engine start switch is turned to START Check that the engine turns off when the engine start switch is turned to OFF OFF ON START ON START ET OPEN A Qo a gi gO amp YAMAHA A S6P21080 Check that the engine turns off when the engine stop lanyard is pulled from the engine stop lanyard switch S6P 21090E 1 24 an General information Checking the cooling water pilot hole 1 Startthe engine check that cooling water is discharged from the cooling water pilot hole S6AL3180 Test run 1 Start the engine and then check that the gear shift operates smoothly 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 2 000 r min or at h
102. 0 87 1 40 0 055 0 90 0 035 6AL3 11 Maintenance specification Dimension Exterior Grey Whale 200 Fin Whale 225 pr P mm in N og LO st Ty Q O ei N N y a N E 45 619 24 4 U 1 272 50 1 219 8 6 pl 651 25 6 75 3 0 I z 8 1 i ae A U O 1 gig ai amp 1 oO a Em A 3 y ae as mA 2 1 toe Fi Wo Lo H ao ell a 230 9 1 FF SE b JF SK tm x D T AN LQ 5 eo RS 9 2 3 no ON g 2e SE TT M G iy FA Oo 4 G a il NAN D x D y X 52 2 0 U 59 2 3 k 673 26 5 gt 25 1 0 S6P22020 U U transom model F225B regular rotation model only 6AL3 11 2 12 SPEC ge Specification Grey Whale 200 Fin Whale 225 Clamp bracket 180 7 1 180 7 1 mm in 163 5 6 4 163 5 6 4 ra 2 13 50 8 2 0 411 16 2 254 10 0 101 5 4 0 101 5 4 0 125 4 4 9 pp Lt ra 125 4 4 9 ra S6P22010 6AL3 11 Tightening torgue Specified torque Part to be tightened Thread size Tightening torques Maintenance specification Tightening torque kgf m ft lb Fue
103. 1 ory Fuel system Throttle body 13 N m 1 3 kgf m 9 6 ft Ib 13N m 1 3 kgf m 9 6 ft Ib 13 N gt m 1 3 kat m 9 6 ft Ib he 5 N m 0 5 kgf m 3 7 ft Ib Part name Remarks No 1 2 3 4 5 6 7 8 Joint Plastic tie Nut Washer Electronic throttle valve assembly Gasket Bolt Plate Gasket Surge tank Collar Bolt Holder Bolt Canister Bolt Bracket Not reusable M8 x 18 mm Not reusable A k k 4 b P A k k k P k N P k kb 4 13 6AL3J 11 Throttle body 13 N m 1 3 kgf m 9 6 ft Ib 13N m 1 3 kgf m 9 6 ft Ib WI3N m 1 3 kgf m 9 6 ft Ib Pl 5 N m 0 5 kgf m 3 7 ft Ib Part name Remarks M6 x 28 mm Bolt Collar Grommet Bracket Nut Holder Bracket Vapor shut off valve Sub wiring harness Bolt Washer Intake air pressure sensor Plastic tie M6 x 20 mm A k k k k k k k k k kA FA FA Not reusable 6AL3J 11 4 14 el D Fuel system 0 35 in 0 27 in 3 SR 7 IN 9mm 7 mm 9 mm 0 35 in 0 27 in 0 35 in 9 mm 12mm 9mm 0 35 in 0 47 in 0 35 in S6AL4060 lt Remarks Check valve Holder Holder Joint Joint Joint Holder Joint Holder Holder Joint 1 2 3 4 5 6 7 8 9 FPRPFNNNPFPRPHEPN WH m me e O 4 15 6AL3J 11 Checking the electronic throttle
104. 11 Tightening torque Tightening torques N m kgf m ft lb Gear oil drain screw 9 0 9 6 6 Lower case mounting bolt nut M10 47 4 7 34 7 Trim tab bolt M10 42 4 2 31 0 Propeller nut 54 5 4 39 8 Grease nipple 6 0 6 4 4 Propeller shaft housing bolt M8 30 3 0 22 1 Cooling water inlet cover screw M5 3 0 3 2 2 Pinion nut 14 2 104 7 Lower unit counter rotation model Gear oil check screw 0 9 6 6 Gear oil drain screw 0 9 6 6 Lower case mounting bolt 4 7 34 7 Trim tab bolt 4 2 31 0 Propeller nut 5 4 39 8 Ring nut 79 7 Grease nipple 0 6 4 4 Propeller shaft housing bolt 3 0 22 1 Cooling water inlet cover screw 0 3 2 2 Pinion nut 104 7 Bracket unit Shift cut switch screw 1 5 Shift bracket bolt Neutral switch screw 1 5 Shift rod detent bolt Grease nipple 1 0 7 Hose joint adapter screw 5 3 7 Upper mount bracket bolt Apron stay 5 9 Engine oil drain bolt Upper mounting nut Lower mounting nut Partto be tightened Thread size Oil pan assembly bolt PCV Baffle plate screw Oil strainer bolt Oil pan bolt Exhaust manifold bolt Muffler bolt Friction plate Screw Grease nipple Self locking nut Thrust receiver nut 6AL3J 11 2 16 ele Specification Part to be tightened Thread size Tightening torques N m kgf m ft lb PTT unit Reservo
105. 15 73 12 50 mm 28 70 0 03 0 05 15 73 12 50 mm 0 49 mm If M6 is 15 73 mm M7 is 12 50 mm A is 7 and B is 6 then T4 28 70 7 100 6 100 15 73 12 50 mm 28 70 0 07 0 06 15 73 12 50 mm 0 60 mm 4 Round the numbers for the propeller shaft shim s T 4 as follows Calculated number at 1 100 place 1 2 Rounded number 3 4 5 6 7 8 9 10 6 59 Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Example If T 4 is 0 49 mm then the propeller shaft shim is 0 48 mm If T 4 is 0 60 mm then the propeller shaft shim is 0 58 mm 5 If the A mark or B mark is unreadable measure the propeller shaft free play as shown 6 Install the shim s thrust bearing propeller shaft taper roller bearing and claw washer and then tighten the ring nut to the specified torque Q E aw S6AL6920 Ring nut wrench 90890 06578 Ring nut 108 N m 10 8 kgf m 79 7 ft lb 7 Measure the propeller shaft axial free play Reselect the propeller shaft shim s T 4 if out of specification S6AL6170 6AL3 11 Shimming counter rotation model Backlash counter rotation model Z Magnet base B 90890 06844 Dial gauge set on 90890 01252 AS Propeller shaft free play 0 25 0 35 mm 0 0098 0 0138 in Backlash counter rotation model Me
106. 2 or 3 times to seat the rollers and then measure the bearing height M6 as shown TEN ia aay Ir SR vi S69J6705 S6AL6540 6AL3 11 Shimming counter rotation model NOTE 0 e Select the shim thickness T 4 by using the specified measurement s and the calcula tion formula e Measure the taper roller bearing at 4 points to find the height average C Shimming plate 90890 06701 Digital caliper 90890 06704 2 Install the thrust bearing onto the pro peller shaft and then measure the propeller shaft flange and thrust bearing thickness M7 as shown S6AL6900 6 58 Lower unit 3 Calculate the propeller shaft shim thick ness T 4 as shown in the examples below Se Lo S6AL6910 NOTE A and B are the deviation of the propeller shaft housing dimension from standard The A mark and B mark are stamped on the propeller shaft housing in 0 01 mm units If the A mark or B mark is unreadable assume that A and B are zero and check the free play when the unit is assembled Calculation formula Propeller shaft shim thickness T 4 28 70 A 100 B 100 M6 M7 Example If M6 is 15 73 mm M7 is 12 50 mm A is 3 and B is 5 then T4 28 70 3 100 5 100
107. 26310 NOTE After calculating the shim thickness select the shim with the closest thickness from the table Calculation formula Propeller shaft shim thickness T4 79 8 C1 C2 C3 Calculated number Shim thickness mm 1 81 1 84 1 80 1 85 1 94 1 90 1 95 2 04 2 00 2 05 2 14 2 10 2 15 2 20 2 20 5 Assemble the lower unit with the selected shim 6 Measure the propeller shaft axial free play Reselect the propeller shaft shim if out of specification 6AL3J 11 S6AL6760 CZ Magnet base plate 90890 07003 Dial gauge set 90890 01252 Magnet base B 90890 06844 AS Propeller shaft free play 0 20 0 50 mm 0 0079 0 0197 in Backlash regular rotation model Measuring the forward and reverse gear backlash 1 Install the lower unit onto a repair stand 2 Remove the water pump assembly 3 Set the gear shift to the neutral position atthe lower unit S6AL6930 4 Turn the lower unit so that it is positioned as shown 5 Install the special service tool 6 28 Lower unit 6 Tighten the center bolt to the specified torque while turning the drive shaft S6AL6160 NOTE The drive shaft can no longer be turned when the center bolt is tightened to the specified torque Z Bearing housing puller claw L 4 90890 06502 Stopper guide plate 90890 06501 Center bolt 90890 06504 Center bolt 7 N m 0 7 kgf m 5 2 ftlb 7
108. 3 11 Cylinder block CZ Piston ring compressor 90890 05158 11 Install the connecting rod cap to the connecting rod and then tighten new connecting rod cap bolts to the specified torques in 3 stages S6AL5850 CAUTION Do not reuse the connecting rod cap bolts always replace them with new ones NOTE e Align the marks on the connecting rod cap and connecting rod Apply engine oil to the connecting rod caps and connecting rod cap bolts before instal lation lt In the 3rd stage make a mark on the connecting rod cap bolts and connecting rod caps and then tighten the bolts 90 from the mark e After tightening the connecting rod cap bolts check that the crankshaft rotates smoothly Connecting rod cap bolt 1st 23 N m 2 3 kgf m 17 0 ft lb 2nd 43 Nem 4 3 kgf m 31 7 ft lb 3rd 90 5 72 12 Install a new gasket and the crankcase cover and then tighten the bolts to the specified torques in 2 stages and in the sequence shown S6P25B40 CAUTION Do not reuse the gasket always replace them with new ones NOTE e Apply engine oil to the crankcase bolts before installation e Tighten the crankcase bolts 1117 to the specified torques in 2 stages Crankcase cover bolt 4 H17 1st 14 N m 1 4 kgf m 10 3 ft lb 2nd 28 N m 2 8 kgf m 20 7 ft lb Disassembling the oil pump 1 Remove the screws and
109. 3 11 5 32 Power unit Power unit assembly Se 8 N m 0 8 kgf m 5 9 ft Ib Aa 4 N m 0 4 kgf m 3 0 ft Ib 42 N m 4 2 kgf m 31 0 ft Ib S6AL5030 Part name Remarks lt Power unit Gasket Dowel Bolt Bolt Oil dipstick Dipstick guide O ring Bolt Upper case cover Bolt Apron STBD Grommet Apron PORT Bolt Nut Bolt Not reusable M10 x 140 mm M10 x 35 mm Not reusable M6 x 20 mm M6 x 14 mm M6 x 30 mm KA M k k On k zl k k k k k zl ON HR Fi M6 x 10 mm 5 33 6AL3J 11 Power unit D 8 N m 0 8 kgf m 5 9 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib Se 42 N m 4 2 kgf m 31 0 ft Ib S6AL5030 P art name Remarks Cap PTT motor lead Clamp Retaining plate Cable holder Grommet Bolt Bolt M6 x 30 mm M6 x 20 mm OD PE RE PG 6AL3 11 5 34 Starter motor 18 N m 1 8 kgf m 13 3 ft Ib 26 N m 2 6 kgf m 19 2 ft Ib hx 13 N m 1 3 kgf m 9 6 ft Ib S6AL5640 Remarks a CO DJ On Un PS DU NN Mm Part name Starter motor Bolt Nut Bolt Positive battery cable Terminal Bolt Terminal bolt Negative battery cable Washer Nut Bolt Starter motor lead Q lt M8 x 45 mm M8 x 16 mm M8 x 20 mm M6 x 20 mm NO k k k M k M k PNP UR 5 35 6AL3J 11 Power unit Junction box 16N m 0 6
110. 310 WARNING Reduce the fuel pressure before loosen ing the vapor separator drain screw or pressurized fuel will spray out and may result in serious injury 6 Tighten the vapor separator drain screw 3 5 Vapor separator drain screw 2 N m 0 2 kgf m 1 5 ft lb Power unit Checking the engine oil 1 Place the outboard motor in an upright position 2 Remove the oil dipstick wipe it clean and then insert it back into the dipstick guide 3 Remove the oil dipstick again to check the oil level and to check the oil for dis coloration and its viscosity S6P21020E NOTE EE lt Change the oil if it appears milky or dirty e If the engine oil is below the minimum level mark L add sufficient oil until the level is between H and L Changing the engine oil extracting 1 Start the engine warm it up and then turn it off 2 Remove the oil dipstick and oil filler cap gud S6P23040 6AL3 11 3 Insert the tube of the oil changer into the dipstick guide d S6AL3130 4 Operate the oil changer to extract the oil NOTE Be sure to clean up any oil spills 5 Pourthe specified amount of the recom mended engine oil into the oil filler hole Recommended engine oil 4 stroke motor oil API SE SF SG SH SJ or SL SAE 5W 30 10W 30 or 10W 40 Engine oil quantity Without oil filter replacement 5 6 L 5 92 US qt 4 93 Imp qt 6 Insta
111. 5 Installing the camshaft driven sprocket and timing belt 14 Install the stator assembly 15 Install the Woodruff key then the fly wheel magnet 5 13 NOTE SS e Be sure to remove any grease from the tapered portion of the crankshaft and the flywheel magnet e Apply engine oil to the thread of the fly wheel magnet nut and upper and lower sur face of the washer before installation 16 Tighten the flywheel magnet nut to the specified torque S6AL5A20 Flywheel magnet nut 240 N m 24 0 kgf m 177 0 ft lb 17 Measure each valve clearance and adjust again if out of specification NOTE SE To checking the valve clearance see Chap ter 5 Checking the valve clearance Valve clearance cold Intake 0 20 0 03 mm 0 008 0 001 in Exhaust 0 34 0 03 mm 0 013 0 001 in 18 Install the cylinder head covers port and starboard and then tighten the bolts to the specified torque in 2 stages 6AL3J 11 Power unit check and adjustment NOTE gt e Apply sealant to the edge of the cylinder head cover gasket before installation e Tighten the cylinder head cover bolts to the same torque in both stages e See the exploded diagram 5 7 Cylinder head cover bolt 1st 8 N m 0 8 kgf m 5 9 ft lb 2nd 8 N m 0 8 kgf m 5 9 ft lb S6AL5100
112. 5 10 Adjusting the valve clearance CAUTION Do not turn the flywheel magnet or the driven sprockets when the timing belt is not installed Otherwise the pistons and valves or intake and exhaust valves will collide with each other and be damaged NOTE Check the valve clearances when the engine is cold 1 Reduce the fuel pressure NOTE SSS To reduce the fuel pressure see Chapter 4 Reducing the fuel pressure 2 Turn the flywheel magnet clockwise and align the ITDC mark on the flywheel magnet with the pointer 3 Check that the Il marks on the port driven sprockets are aligned and check that the I marks on the starboard driven sprockets are aligned S6P25100 4 Remove the wiring harness guide S6AL5150 NOTE To remove the wiring harness guide see Chapter 5 Removing the wiring harness 5 Loosen the flywheel magnet nut S6AL5A10 CAUTION Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily NOTE Use a 36 mm socket wrench to loosen the fly wheel magnet nut Flywheel holder 90890 06522 6 Remove the flywheel magnet and Woo druff key 6AL3 11 Power unit check and adjustment S6AL5A00 S6P25E00 CAUTION To prevent damage to the engine or tools screw in the puller set bolts evenly and completely so that the flywheel puller is parallel to the
113. 5 seconds S6AL4340 NOTE Use a commercially available vacuum pres sure pump gauge and meter that can be depressurized down to 80 kPa 0 8 kgf cm 11 6 psi Specified negative pressure 80 kPa 0 8 kgf cm 11 6 psi 4 20 Tih Fuel system Low pressure fuel pump Oo Part name lt x 4 N m 0 4 kgf m 3 0 ft Ib S6AL4090 Remarks o SI On UU BUN Hm 4 21 Low pressure fuel pump Cover Bolt Screw Holder Check valve Clamp Clamp Joint Holder Cover Fuel filter Plastic tie Plastic tie Low pressure fuel pump coupler A k kA k A EH P OO kA kA HN k kb M6 x 15 mm ob x 8 mm Not reusable Not reusable 6AL3 11 Low pressure fuel pump Checking the low pressure fuel Z Vacuum pressure pump gauge set pump 1 Drain the fuel from the vapor separator and check the condition of the fuel NOTE L e To drain the fuel see Chapter 3 Draining the fuel e If the fuel is dirty check and clean the fuel lines 2 Check the low pressure fuel pump NOTE EE To check the low pressure fuel pump see Chapter 8 Checking the low pressure fuel pump and high pressure fuel pump e To check the fuse see Chapter 8 Fuse holder Checking the fuel filter 1 Check the fuel filter Replace the fuel fil ter if there is dirt residue or external damage S6AL4260 Checking the check valve 1 Connect the
114. 8 Timing belt to timing belt guide i 1 0 0 5 0 04 0 02 clearance Cylinder head Warpage limit i 0 1 0 0039 lines indicate straightedge position Camshaft cap inside diameter i 25 000 25 021 0 9843 0 9851 Cylinder Bore size i 94 000 94 017 3 7008 3 7014 Piston Piston diameter D gal i 93 921 93 941 3 6977 3 6985 Measuring point H ht i 5 0 0 20 Piston clearance i 0 075 0 080 0 0030 0 0031 Piston pin boss bore i 21 017 21 031 0 8274 0 8280 Piston ring groove Top ring i 1 23 1 25 0 048 0 049 Second ring i 1 22 1 24 0 048 0 049 Oil ring i 2 51 2 53 0 099 0 100 Piston pin Outside diameter i 20 995 21 000 0 8266 0 8268 FD 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 For details of the checking method see Chapter 5 Checking the oil pressure The figures are for reference only 3 The figures are for reference only 2 3 6AL3J 11 Maintenance specification Piston ring Top ring Dimension B 1 17 1 19 0 046 0 047 Dimension T i 2 80 3 00 0 110 0 118 End gap i 0 15 0 30 0 006 0 012 Side clearance i 0 04 0 08 0 002 0 003 2nd piston ring Dimension B 1 17 1 19 0 046 0 047 Dimension T i 3 70 3 90 0 146 0 154 End gap i 0 30 0 45 0 012 0 018 Side clearance i 0 03 0 07 0 001 0 003 Oil ring
115. 8 21 Checking the intake air temperature sensor 8 20 Checking the intake manifold 4 10 Checking the knock sensor 8 25 Checking the lower case 6 15 6 45 Checking the lower unit for air leakage 3 15 Checking the low pressure fuel pump 4 22 Checking the low pressure fuel pump and high pressure fuel pump 8 39 Checking the magnet switch 8 45 Checking the main relay and electronic throttle valve relay 8 27 Checking the neutral switch 8 24 Checking the oil control valve ss 8 36 Checking the oil pan and exhaust manifold 7 16 Checking the oil pressure 0 eee 5 1 Checking the oil pressure sensor 5 2 Checking the oil pump eects 5 73 Checking the oil strainer oo eee 7 16 Checking the outboard motor mounting height 1 23 Checking the pinion and forward gear 6 15 Checking the pinion and reverse gear 6 45 Checking the piston Clearance reference 5 62 Checking the piston diameter 5 62 Checking the piston pin 5 64 Checking the piston pin boss bore 5 63 Checking the piston ring 0 e eee 5 62 Checking the piston ring end gap reference nessecserecreeee 5 63 Checking the piston ring groove 5 63 Checking the piston ring side clearance 5 63 Checking the pressure regulator 4 7 Checking the propeller eee 3 16 Checking t
116. AL6750 NOTE R is the deviation of the lower case dimen sion from standard and A is the deviation of the propeller shaft housing dimension from standard The R mark is stamped on the trim tab mounting surface of the lower case and the A mark is stamped on the pro peller shaft housing in 0 01 mm units If the R mark or A mark is unreadable assume that R and A are zero and check the back lash when the unit is assembled Calculation formula Forward gear shim thickness T2 8 45 R 100 A 100 M5 M6 Example If M5 is 22 95 mm M6 is 15 73 mm R is 1 and A is 3 then T2 8 45 1 100 3 100 22 95 15 73 mm 8 45 0 01 0 03 22 95 15 73 mm 1 25mm If M5 is 22 95 mm M6 is 15 73 mm R is 1 and A is 2 then T2 8 45 1 100 2 100 22 95 15 73 mm 8 45 0 01 0 02 22 95 15 73 mm 1 20 mm 6AL3 11 3 Select the forward gear shim s T2 as follows Calculated number at 1 100 place 1 2 3 4 5 6 7 8 9 10 Rounded number Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Example If T2 is 1 25 mm then the forward gear shim is 1 22 mm If T2 is 1 20 mm then the forward gear shim is 1 18 mm Selecting the propeller shaft shim 1 Turn the taper roller bearing outer race
117. Clean if there is dirt or residue 6AL3 11 i S6P27570J Checking the gear pump housing 1 Check the gear pump housing Replace if scratched Checking the reservoir 1 Check the reservoir Replace if cracked or if there is corrosion Checking the filter 1 Check the gear pump filters and and shuttle piston filters Clean if there is dirt or residue 69J7380 Assembling the gear pump CAUTION Do not use a rag when assembling the PTT unit as dust and particles on the PTT unit components can lead to poor perfor mance 1 Install the relief valve seat into gear housing 202 6AL3 11 Gear pump S6AL7730 2 Install the drive gear driven gear 4 pins balls and shuttle pistons D and into gear housing 1 3 Install gear housing 2 onto gear hous ing 1 dE ee SD J S6AL7740 7 44 Bracket unit 4 Install the balls manual release spring and bracket by installing the bolts and tightening them to the specified torque Gear pump bracket bolt 7 N m 0 7 kgf m 5 2 ftlb UT Install the relief valve seal and ball into gear housing 1 and then install the up relief lock screw and down relief lock screw as shown S6AL7760 6 TY 1 JEG i dk nehi S6AL7770 7 45 NOTE
118. Color code B Black Br Brown G Green L Blue Lg Lightgreen 0 Orange P Pink R Red Sb Sky blue W White Y Yellow BIR Black red B W Black white BIV Black yellow Br W Brown white G B Green black G R Green red G Y Green yellow L G Blue green L W Blue white LN Blue yellow O W Orange white P B Pink black P G Pink green PI Pink white Pu B Purple black PU R Purple red R B Red black R Y Red yellow W B White black W L White blue W R White red NOTE Depending on the outboard motor the loca tion of the coupler terminal may be changed as indicated in the table below Coupler Terminal No Color on the wiring 2through 18 B harness guide except 13 on the ECM 1through12 B bracket 14 through 17 R Y 20 through 24 O land 8 R Y W 16 17 23 B 24 and 32 27 and 28 R Y Q 1 through22 R Y except 11 through 15 3 and 4 R 11 and 12 R G omm mom mmm Grey Whale 200 Fin Whale 225 x E 1 dD ED Ge Rf KA AT oe Sy Q mar motfr SS MERITI O
119. EE RYN Fi 7 35 6AL3J 11 Disassembling the PTT motor 1 Remove the PTT motor assembly O ring and joint from the PTT unit WARNING Do not push the trim and tilt rams down while the PTT motor is removed from the PTT unit otherwise fluid can spurt out 2 Remove the PTT motor screws I then the stator S6AL7630 CAUTION Hold the end of the armature shaft with a pair of pliers as shown and then remove the armature together with the PTT motor base assembly otherwise the armature could separate from the base assembly due to the magnetic force of the stator and damage the brushes 3 Remove the springs brushes and oil seal from the PTT motor base assembly S6AL7640 6AL3 11 PTT motor CAUTION Do not disassemble the PTT motor assembly otherwise the circuit breaker may be damaged Checking the PTT motor 1 Check the commutator Clean with 600 grit sandpaper and compressed air if dirty S69J7185 2 Measure the commutator diameter Replace the armature if below specifica tion S69J8400 Motor commutator standard diameter 23 0 mm 0 91 in Wear limit 22 0 mm 0 87 in 7 36 Bracket unit 3 Measure the commutator undercut Replace the armature if below specifica tion S69J8410 Motor commutator standard undercut 1 40 mm 0 055 in Wear limit 0 90 mm 0 035 in 4 Check the armature for continuity
120. ET KE Part name Propeller shaft housing counter rotation model NGANG 271 pr 22 304 6N m 0 6 kof m 4 4 ft Ib s 29 S6AL6330 Remarks lt Propeller shaft shim O ring Propeller shaft housing Dowel Grease nipple Rubber seal O ring Needle bearing Oil seal Ring Bolt Bolt Washer Cooling water inlet cover Nut Screw 6AL3 11 Not reusable Not reusable Not reusable Not reusable M8 x 20 mm M8 x 33 mm Go HHH HO Hoor 6 36 Lower unit Removing the propeller shaft housing assembly 1 Remove the water pipe and shift rod S6AL6810 2 Remove the bolts ring and bolts S6AL6B10 3 Remove the propeller shaft housing with the propeller shaft S6AL6340 NOTE Before removing the propeller shaft from the lower case remove the shift rod 6 37 Slide hammer 90890 06531 Puller head 90890 06514 Disassembling the propeller shaft housing 1 Remove the spring and then remove the cross pin dog clutch slider shift plunger and shift rod joint 569J6375 2 Remove the forward gear and forward gear shim s from the propeller shaft housing using a press S6AL6350 3 Remove the dowel amp from the lower case 4 Install the propeller shaft housing assem bly in the reverse direction into the lower case 6AL3 11 S6AL6370 NOTE To prevent damage
121. Grey Whale 200 EFI Fin Whale 225 EFI SERVICE MANUAL Marine NOTICE This manual has been prepared by Selva primarily for use by Selva dealers and their trained mechanics when performing maintenance procedures and repairs to Selva 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 Selva 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 Selva 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 N 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 ora person inspecting or repairing the outboard motor CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the out board motor NOTE A NOTE provides key information to m
122. I SE SF SG SH SJ or SL SAE 5W 30 10W 30 or 10W 40 Engine oil quantity without oil filter replacement L US at 5 6 5 92 4 93 Imp at with oil filter replacement L US at 5 8 6 13 5 10 Imp at Gear oil type Hypoid gear oil Gear oil gradel API GL 4 SAE 90 Gear oil guantity cm US oz 1 150 1 000 1 150 1 000 Imp oz 38 9 33 8 38 9 33 8 40 6 35 3 40 6 35 3 Bracket unit Trim angle Degree 3 to 16 at 12 boat transom Tilt up angle Degree 70 Steering angle Degree 32 32 Drive unit Gear shift positions F N R Gear ratio 2 00 30 15 Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction rear view Clockwise Counter Clockwise Counter clockwise clockwise Propeller mark T M TL ML T M TL ML Electrical Battery minimum capacity CCA EN A 711 20HR IEC Ah 100 Electrolyte specific gravity at20 68 F 1 280 CD If the recommended engine oil grades are not available use engine oil with an SAE classification of 15W 40 20W 40 or 20W 50 and an API classification of SH SJ or SL 2 Meeting both API and SAE requirements 6AL3 11 2 2 ele Specification Maintenance specification Power unit Model Item Unit 200 L 225 R Power unit Minimum compression kPa 740 7 4 107 3 pressure kgf cm psi Oil pressure kPa 600 6 0 87 0 at 600 900 r min kgf cm psi Timing belt Timing belt installation height i 2 0 0 0
123. If T1 is 0 40 mm then the forward gear shim is 0 38 mm Selecting the reverse gear shim 1 Turn the ball bearing 2 or 3 times and then measure the bearing height M2 as shown S69J6595 S6AL6290 NOTE e Select the shim thickness T2 by using the specified measurement s and the calcula tion formula e Measure the bearing outer race at 4 points to find the height average C Shimming plate 90890 06701 Digital caliper 90890 06704 2 Calculate the reverse gear shim thick ness T2 as shown in the examples below 6AL3 11 S69J6585 S6AL6750 NOTE R is the deviation of the lower case dimen sion from standard and A is the deviation of the propeller shaft housing dimension from standard The R mark is stamped on the trim tab mounting surface of the lower case and the A mark is stamped on the pro peller shaft housing in 0 01 mm units If the R mark or A mark is unreadable assume that R and A are zero and check the back lash when the unit is assembled Calculation formula Reverse gear shim thickness T2 21 00 R 100 A 100 M2 Example If M2 is 19 92 mm R is 1 and A is 3 then T2 21 00 1 100 3 100 19 92 mm 21 00 0 01 0 03 19 92 mm 1 10 mm If M2 is 19 92 mm R is 3 and A is 5 then T2 21 00 3 100 5
124. Ignition coil 6 Black brown Ignition coil 5 Black blue Electronic throttle valve power source Red green Fuel injector 6 Purple white Fuel injector 5 Purple blue Electronic throttle valve power source Red green Fuel injector 4 Purple green Fuel injector 3 Purple yellow Electronic throttle valve motor Green black Fuel injector 1 Purple red Fuel injector 2 Purple black Electronic throttle valve motor Green red Low pressure fuel pump Blue white Electronic throttle valve ground Black Ignition coil 4 Black green Vapor shut off valve Green black Ignition coil 3 Black yellow Tachometer Green High pressure fuel pump relay Blue red Electronic throttle valve relay Yellow Buzzer Pink ECM ground Black ECM ground Black Ignition coil 2 Black white Ignition coil 1 Black orange Low oil pressure warning indicator Pink white Overheat warning indicator Pink black Diagnostic flash indicator B Blue white Electronic throttle valve ground Black ECM ground Black Oil control valve PORT 6AL3 11 Purple Oil control valve STBD Purple General information Circuit diagram F L 200C F L 225B NOTE The circled numbers in the illustration indicate the ECM terminal nu
125. L3 11 Charging system NOTE Be sure to set the measurement range and display the mark by pushing the SHIFT switch when checking the Rectifier Regulator continuity Rectifier Regulator continuity testing diode Tester lead DG RO DG RO GO RO GO RO GO RO GO RO RO GO RO GO RO GO OL RO GO over load RO GO RO GO Display value V 0 42 0 45 V reference data 8 52 evec ELEC m Electrical system MEMO 8 53 6AL3J 11 TRBL Troubleshooting YDIS skak an E FE EE tee eee RE 9 1 Introduction ARTE NA a rn rere aa ANE EE 9 1 Connecting the communication cable to the outboard motor 9 5 Troubleshooting the power unit 9 6 Troubleshooting the power unit using the YDIS mmsrrrnaravvrrrrrrvrrrrrerrsrrreenr 9 6 Trouble code and checking E vvs 9 9 Troubleshooting the power unit using the diagnostic flash indicator 9 17 Troubleshooting the power unit trouble code not detected 9 19 Troubleshooting the PT TUM Lee de en are nee 9 24 Troubleshooting the lower unit 9 25 6AL3 11 TRBL 1 SHTG 6 Troubleshooting YDIS Introduction Feature The newly developed YDIS provides quicker detection and analysis of engine malfunctions By connecting your computer to the ECM of an outboard motor using the communication cable this software can be used to display sensor data and
126. NG Make sure that the trim and tilt rams are fully extended when removing the special service tool otherwise fluid can spurt out from the unit due to internal pressure 7 Install the pipe joint at the end and then tighten the pipe joints M to the specified torque Pipe joint 15 N m 1 5 kgf m 11 1 ft lb 8 Connectthe PTT motor leads to the bat tery terminals to fully retract the trim and tilt rams 9 Loosen the pipe joints and then remove the pipe joint at the end WARNING Make sure that the trim and tilt rams are fully retracted when removing the pipe joints otherwise fluid can spurt out from the unit due to internal pressure 10 Install the special service tool S6P27640 NOTE Put the PTT unit in the drain pan 1 33 gt PTT oil pressure gauge assembly 90890 06580 11 Connect the PTT motor leads to the bat tery terminals to extend the trim rams and then measure the hydraulic pres Sure S6AL7C06 Battery terminal Sky blue Sb Light green Lg O Hydraulic pressure up 13 0 15 0 MP a 130 150 kgf cm 12 Reverse the PTT motor leads between the battery terminals to fully retract the trim and tilt rams PTT motor lead S6AL7C07 6AL3 11 Battery PTT motor lead terminal Light green Lg Sky blue Sb O 13 Remove the special service tool WARNING Make sure that the trim and tilt
127. POWR ELEC Troubleshooting Periodic check and adjustment Lower unit CHK Special service tool Specified measurement Specified oil or fluid Specified electrical value Specified engine speed resistance voltage electric current Specified tightening torque Symbols to in an exploded diagram or illustration indicate the grade of lubricant and the lubri cation point Apply 4 stroke motor oil Apply corrosion resistant grease Apply gear oil Apply water resistant grease Apply low temperature resistant grease Apply molybdenum disulfide grease Apply injector grease Symbols to in an exploded diagram or illustration indicate the type of sealant or locking agent and the application point Apply Gasket Maker Apply LOCTITE 242 blue Apply ThreeBond 1104J Apply LOCTITE 572 Apply LOCTITE 271 red Apply silicon sealant 6AL3J11 1 2 a General information Abbreviation The following abbreviations are used in this service manual Abbreviation Aft end American Petroleum Institute Bow end Cold Cranking Ampere Dual Engine System Electronic Control Module European Norm European standard Exhaust International Electrotechnical Commission Intake Local Area Network Pressure Control Valve Port side Power Trim and Tilt Society of Automotive Engineers Starboard side Transistor controlled ignition Top Dead Center Throttle Position Sensor Upside Version Wiring
128. S6AL8580 Terminal Y Ground 12 V battery voltage 6 Turn the engine start switch to OFF 7 Connect the ECM coupler l S6AL8570 3 Connect the ECM couplers and 4 Disconnect the ECM coupler 5 Turn the engine start switch to ON and then measure the input voltage at ECM coupler terminal 13 wiring harness end and ground Check the fuse wiring harness and engine start switch if below specification 6AL3J 11 8 28 evec ELEC E Electrical system 8 Disconnect the ECM coupler 9 Turn the engine start switch to ON and then measure the input voltage at ECM coupler terminals 27 and 34 wiring harness end and ground Check the fuse relay and wiring harness if below specification S6AL8590 Terminal R Y 6 Ground 84 Ground 12 V battery voltage 10 Turn the engine start switch to OFF 11 Connect the ECM coupler Checking the accelerator position sensor 1 Connect a computer to the outboard motor and use the YDIS to display Accelerator position sensor 1 and Accelerator position sensor 2 8 29 S6P24140 NOTE ma Accelerator position sensor 1 and accelera tor position sensor 2 are a single unit which cannot be disassembled e To connect
129. Se e If reinstalling the removed parts install them according to the screw height and screw depth measurements noted before they were removed e If installing new parts install them accord ing to the following reference data for the screw height and screw depth Up relief lock screw height reference data From the top of the gear housing 1 07 1 27 mm 0 042 0 050 in Down relief lock screw depth reference data From the top of the gear housing 1 95 2 45 mm 0 077 0 096 in 6 Install the filters and and gear pump by installing the bolts and tightening them to the specified torque 7 Install the manual valve S6AL7780 Gear pump bolt 7 N m 0 7 kgfm 5 2 ft lb 6AL3 11 Gear pump 8 Check the hydraulic pressure NOTE os e To check the hydraulic pressure see Chap ter 7 Checking the hydraulic pressure e If the hydraulic pressure is out of specifica tion adjust the relief lock screws to adjust the pressure to specification 6AL3J 11 7 46 Bracket unit Tilt cylinder and trim cylinder Se 1160 N m 16 0 kgf m 118 0 ft Ib oi 90 N m 9 0 kgf m 66 4 ft Ib 55 N m 5 5 kgf m 40 6 ft Ib S6AL7790 P art name Remarks Not reusable Not reusable a Oo LO ON ADU P GA A KE Circlip Dust seal Trim cylinder end screw O ring Trim ram assembly Trim piston Backup ring O ring Spring Adapter Circlip
130. Whale 225 Condenser connect to the intake air pressure sensor PTT switch Trim sensor Crank position sensor Stator coil Starter motor Battery Accessory battery PTT motor Rectifier Regulator PTT relay Fuse box Diode connect to the PTT relay Oil pressure sensor Shift cut switch Neutral switch Accelerator position sensor Fuel injector Thermoswitch STBD Oil control valve STBD Knock sensor Cam position sensor STBD IN Ignition coil 6 Spark plug ECM Cam position sensor PORT IN Cam position sensor PORT EX Engine temperature sensor Oil control valve PORT 69 Thermoswitch PORT High pressure fuel pump Low pressure fuel pump Intake air temperature sensor Electronic throttle valve assembly Vapor shut off valve Intake air pressure sensor Condenser connect to the cam position sensor PORT EX 68 Water detection switch in fuel filter LAN communication coupler To remote control switch panel To warning indicator trim meter To diagnostic test lead special service tool To personal computer for diagnosis To cooling water pressure sensor optional To speed sensor optional To trim meter To 6Y8 Multifunction Meter E lo m me le 1 Isolator cable optional 2 Negative battery cable commercially available 3 The 6Y 8 Multifunction Meter is a meter designed to be used in a local area network LAN
131. a part the coupler or connector must be disconnected As a result the ECM determines that the part is disconnected and a trouble code is detected There fore be sure to delete the diagnosis record after checking the input voltage Since the main relay comes on for approximately 10 seconds after the start switch is turned to OFF the power of the ECM cannot be turned off Therefore if the start switch is turned to ON within 10 seconds after it was turned to OFF the trouble codes cannot be deleted Troubleshooting the power unit using the YDIS NOTE Use the trouble codes displayed by the YDIS to check each part according to the Trouble code and checking step table Delete the trouble codes after checking repairing or replacing a part and check that the trouble codes are not detected again If the same trouble codes are detected the ECM may be faulty Check the items listed in the table if all the items are in good condition delete the trouble code and then check the trouble codes again If the same trouble codes are detected again the ECM is faulty A breakdown of the engine symptoms are described in the table below however multiple mal functions that have been duplicated cannot be limited to these items The symptoms may change according to the operating conditions and other conditions 6AL3 11 9 6 TRBL w SHTG e Troubleshooting Trouble code table Code No Diagnostic flash indicator B code o
132. able Nb k AAA MAMA AR k k AA k FN 7 41 6AL3 11 Gear pump 7 N m 0 7 kgf m 5 2 ft Ib S6AL7720 Part name Remarks M5 x 25 mm Not reusable Bolt O ring Spacer Filter Gear pump assembly Relief valve seat O ring Down relief valve Up relief valve Down absorber valve Up absorber valve Down main valve Up main valve Not reusable PP RR k k k k k NNNPNDD 6AL3J 11 7 42 Bracket unit Disassembling the gear pump 1 Remove the manual valve then the gear pump and filters 2 DQ S69J7285 y y A i Ka E a oF S6AL7771 NOTE Before removing the relief valves measure and note the screw height and screw depth O 7 43 3 Remove the bracket then the balls O lo S o Gee s ALES I NS S C oO S6517100J 4 Remove gear housing 2 then the Shuttle pistons Remove the drive gear driven gear balls and pins S6P27160J Checking the gear pump 1 Check the drive gear and driven gear Replace if damaged or excessive worn 2 Check the up relief valve and down relief valve Clean if there is dirt or res idue 3 Check the main valves and Clean if there is dirt or residue 4 Check the absorber valves and
133. ag aa SA is 5 36 PUS HORS NK ee NE a nr 5 37 PE Mn te 5 38 Removing the power UML ea rt nee Sie EM er te 5 39 Removing the wiring harness eiisavecsscinsccsteveever aves Advent intense 5 41 Cylinder head sssssssusssnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnannnnnnnnnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnan 5 43 Cylind r hedd EE 5 43 Ree nan nr ua ct ne en tee ate edie 5 45 Removing the cylinder Nadu ht tent den ne Ut nd 5 46 Checking the valve spring sine indien 5 46 Checking the Valve ss nientinsnn mnt nimes Press 5 46 IR NET lee TEE 5 47 Replacing the valve guid ruminants 5 48 Checking the valve Eternal Are A den I AE AE 5 49 Refacing the Valve Seat sun rasriiihnsnnninestes 5 49 Checking the cylinder head save eee 5 51 Installing the valve ard 5 52 Removing the exhaust COVEN noc hai ce eral ean an RE Nr nan 5 53 Checking the exhaust cover anode ss 5 53 Installing the exhaust Cover ANE 5 53 Removing the cooling water passage cover 5 53 Checking the cooling water passage cover anode sisia raen aan 5 54 Installing the cooling water passage cover 5 54 Installing the cylinder h ad asssssassnanantinn hemannenens 5 55 6AL3 11 Cylinder Lu EE 5 57 Centaur CR tree ai 5 57 Cylinder block a SE a aaa s ED ee nt et 5 59 Disassembling the cylinder block ssseaaeea anaa aa aana anna anana aane 5 61 Checking the piston diameter cna ee D AES 5 62 Checking the cylinder bore ss 5 62 Checking the piston clearance reference 5 62
134. agnet base plate 90890 07003 Dial gauge set 90890 01252 Magnet base B 90890 06844 Puller head 90890 06514 Ring nut wrench 90890 06578 6AL3J11 PTT oil pressure gauge assembly 90890 06580 Cylinder end screw wrench 90890 06568 PTT piston vice attachment 90890 06572 Tilt rod wrench 90890 06569 Digital circuit tester 90890 03174 6AL3J11 Special service tool Peak voltage adapter B 90890 03172 Ignition tester 90890 06754 Test harness 2 pins 90890 06867 Test harness 1 pin 90890 06888 Selva diagnostic system 60V 85300 05 00 an General information yanann OUTBOARDS ING WATERCRAFT gt Selva diagnostic system Ver 1 32 60V WS853 05 Diagnostic flash indicator B 90890 06865 6AL3J11 Special service tool Feature and benefit Feature and benefit Water separator For the 2007 models a fuel filter assembly with a water detection switch has been adopted on the fuel line as a system to improve engine protection The water detection warnings are given only if the fuel filter assembly with a water detection switch is connected to the 6Y8 Multifunction Meter The 6Y8 Multifunction Meter is a meter designed to be used in a local area network LAN 2006 model F L 250A 2007 model F L 200C F L 225B F L 250A P N 6P2 24409 00 P N 6P2 24409 10 Water accumulation capacity 55 ml Water accumulation capacity 30 ml Fuel fil
135. ain relay are the same type of relay To check the relay see Chapter 8 Checking the main relay and electronic throttle valve relay 2 Measure the input voltage between the terminal and ground as shown 0600 0939 8 d BEAR ruse SSS E o DDoS eg S6AL8660 Terminal Ground 12 V battery voltage Cd Connectthe tester leads between the ter minals and as shown and then turn the engine start switch to START and measure the input voltage S6AL8670 8 41 Terminal Terminal 12 V battery voltage NOTE Se To check the engine start switch see Chap ter 8 Checking the engine start switch 4 Turn the engine start switch to OFF 5 Install the starter relay and then install all parts removed during disassembly 6AL3 11 Starting system Starter motor Starter motor P Al lA i WE TN Im 16 pone S6AL8181 Part name Remarks O o SI On Un P DI FA Hm Clip Pinion stopper Starter motor pinion Spring Bolt Cover assembly Bearing Clutch assembly E clip Wa
136. aining 3 6 Changing the engine oil extracting 3 5 Changing the gear oil 3 14 Charging system 8 50 Checking the accelerator position sensor 8 29 Checking the accelerator position sensor circuit 8 31 Checking the anode ane nei 3 16 Checking the battery 1 22 3 17 Checking the bearing 111 6 15 6 45 Checking the brush seee 7 37 8 48 6AL3 11 Checking the cam position sensor 8 34 Checking the camshaft 5 25 Checking the canister eects 4 16 Checking the canister check valve 4 16 Checking the check valve 4 22 Checking the compression pressure 5 1 Checking the connecting rod big end side cearance 5 64 Checking the connecting rod small end inside diameter 5 64 Checking the cooling water passage 3 10 Checking the cooling water passage cover anode escrire 5 54 Checking the cooling water pilot hole 1 25 Checking the crank position sensor 8 18 Checking the crank position sensor air gap 00 eects 8 19 Checking the crankpin oil clearance 5 65 Checking the crankshaft 5 65 Checking the crankshaft journal oil clearance 5 67 Checking the cylinder bore seee 5 62 Checking the cylinder head 5 51 Checking the drive shaft 6 15 6 45 Checking the drive shaft bushing 7 16 Checking the ECM circuit 8 27 Checking the electrical component 8 1 Checking the
137. ake manifolds and bolts temporarily S6P 24080E 6AL3 11 Intake manifold NOTE SE When installing the intake manifolds make sure that the gaskets do not come off when the projection of the gasket comes into con tact with the fuel rail cover 3 Tighten the intake manifold bolts M6 to the specified torque in the sequence shown PORT S6P24090 Intake manifold bolt M6 10 N m 1 0 kgf m 7 4 ftlb 4 Tighten the intake manifold bolts M8 in the sequence shown PORT Fares Lee EEE J ET HT me Jo E E Ja ei ep Zoe TE E 4 10 el D Fuel system Installing the intake silencer 1 Install the intake silencer Intake silencer bolt 7 N m 0 7 kgf m 5 2 ft lb 2 Fasten the intake air temperature sensor lead to the holder on the oil filler neck as shown 3 Connect the blowby hose and then fasten the plastic tie as shown S6AL4310 4 11 6AL3 11 Intake manifold Accelerator position sensor Accelerator position sensor S6AL4300 Part name i Remarks Accelerator position sensor assembly Grommet Collar Bolt M6 x 35 mm Accelerator position sensor coupler 6AL3 1
138. ake procedures easier or clearer Contents muh General information z Specification Oo U m O GA Periodic check and adjustment TH A gt Oo G Fuel system As TI C m m ie D O1 a O Lower unit o D Bracket unit n Electrical system ee 4 mmg SE 0 JJ U Troubleshooting Oo L 0 SST 6AL3J11 General information How to use this manual sise diam rene em te a ae rene rs 1 1 Manual format sasa saa ana kagagas an Ta NAN EN Lente GEN TANGANE a ei ea nb sg Raa 1 1 SYMBOL ERE Bak see cae ahd taeda EE akan ag a a dagan naanin 1 2 ee ue EE 1 3 Safety while Working D 1 4 Fire prevention ee EE eech 1 4 KST Es i OM E 1 4 Self protectiOn EE 1 4 Part lubricant and eealant Nn a apen a Bae a aa na dedana 1 4 Good WK elt le eelere 1 5 Disassembly nd assembly vmsusuisnaninemnnpmadeddnrbnnndamdaret 1 5 e Ee E 1 6 MOOG RE 1 6 Serial Number sasa sarak ma Laa a E E See TAN EEE EEN E aa BA A Ba gag ag al ag anaa aga 1 6 Speclal Service 1001 2252 nt dd 1 7 Feature and D nefit ensure uen sn nee Ed nas mun 1 14 VUE e Le a Se ere een te et a se 1 14 112105 10 EE EM RER es 1 15 CNE ee 1 16 Propeller seleclion ss sasarane wa sakang a wan nean sanane na aan ayan anadan aan gaweane 1 21 Propeller Steeg aaa saa eip ir Sa ga NA NINANG Rene Eben Sa RE 1 21 Selecto Ma e SR an SR re aga Gg toques eat Naga Ga Ga Te 1 21 Predeliv
139. alf throttle then for another hour at 3 000 r min or at 3 4 throttle 5 Check that the outboard motor does not tilt up when shifting into reverse and that water does not flow in over the transom NOTE TT The test run is partofthe break in operation Break in During the test run perform the break in operation in the following 3 stages 1 1 hour at 2 000 r min or at approxi mately half throttle 2 1 hour at 3 000 r min or 3 4 throttle and 1 minute out of every 10 at full throt tle 3 8 hours with the engine at any speed However avoid operating at full throttle for more than 5 minutes ata time 1 25 S69J1240 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 CAUTION Be sure to supply sufficient water and water pressure when flushing the cooling water passage If sufficient water and suf ficient water pressure are not supplied the engine can overheat 6AL3 11 Specification General Specifications nine nneeenmiannte 2 1 Maintenance specification ss nnnnnnnns 2 3 Ge gn 2 3 FOSSES An RE aan an NE 2 6 EEGEN 2 7 VET HE pt en aa ae en 2 7 Feel ERREUR Rrra cn nat 2 8 DIMENS ON eee 2 12 Tightening te UC 2 14 Specified LONGUE kue SOE 2 14 General re EEN 2 17 6AL3 11 sreo en Specification General spec
140. alfunction Check the TPS output voltage using the YDIS Check the throttle opening angle using the YDIS Check the electronic throttle valve circuit 6AL3 11 Electronic throttle system malfunction Check the TPS output voltage using the YDIS Check the throttle opening angle using the YDIS Check the electronic throttle valve circuit 9 14 TRBL D SHTG e Troubleshooting Trouble code Symptom Remarks Checking steps Accelerator position sensor malfunction Check the accelerator position sensor output voltage using the YDIS Check the accelerator position sensor circuit Measure the accelerator position sensor resistance Accelerator position sensor malfunction Check the accelerator position sensor output voltage using the YDIS Check the accelerator position sensor circuit Measure the accelerator position sensor resistance Accelerator position sensor malfunction Check the accelerator position sensor output voltage using the YDIS Check the accelerator position sensor circuit Measure the accelerator position sensor resistance Accelerator position sensor malfunction Check the accelerator position sensor output voltage using the YDIS Check the accelerator position sensor circuit Measure the accelerator position
141. all the balls absorber valve pins 7 N m 0 7 kgf m 5 2 ft lb 69 and springs as shown 7 Install the shim s plate washer and bolt to the tilt piston and then tighten the bolt to the specified torque 6AL3 11 7 52 Bracket unit Assembling the trim ram CAUTION Do not use a rag when assembling the PTT unit as dust and particles on the PTT unit components can lead to poor perfor mance 1 Install a new O ring the backup ring the spring the adapter and the circlip to the trim piston ods 2 Install a new dust seal the circlip and a new O ring to the trim cylinder end screw 9 S6AL7880 3 Install the trim cylinder end screw onto the trim ram LOD D S6AL7890 Installing the tilt cylinder CAUTION Do not use a rag when assembling the PTT unit as dust and particles on the PTT unit components can lead to poor perfor mance 1 Install a new O ring to the free piston 7 53 2 Push the free piston into the tilt cylin der until it bottoms out 3 Install the tilt cylinder to the PTT body ent 4 Install the pipes and and then tighten the pipe joints to the specified torque S6AL7900 Pipe joint 15 N m 1 5 kgfm 11 1 ft lb Installing the trim ram CAUTION Do not use a rag when assembling the PTT unit as dust and particles on the PTT unit components can lead to poor perfor mance
142. alve coupler 8 33 OOOOOOO I OOCOOO I 1 800000 J 09900090 S6P28830 Wiring harness continuity Terminal No Coupler Coupler 83 81 47 45 51 50 Connect the electronic throttle valve cou plers and Disconnect the fuse holder couplers and 6AL3 11 ECM and electronic throttle valve control system Variable camshaft timing control system S6P28530 6 Check the wiring harness for continuity O00000000 Q00680000 COOC 000000080 Priore 00000 2 90000 00000 O60000005608 S6P28840 NOTE Depending on the outboard motor the loca tion of the red green terminals 79 and 80 of the coupler amp may be switched Wiring harness continuity Terminal No Coupler Coupler di 79 10 80 11 66 27 7 Connect the ECM coupler and fuse holder couplers and 8 Disconnect the electronic throttle valve coupler 6AL3 11 9 Turn the engine start switch to ON and then measure the TPS input voltage at the electronic throttle valve coupler wiring harness end S6AL8592 TPS input voltage reference data Terminal 0 Terminal B 4 755 25 V 10 Turn the engine start swi
143. ams and tilt ram Polish with 400 600 grit sandpaper if there is light rust or replace if bent or if there is excessive corrosion 5 Check the pipes o Replace the pipes if cracked or if there is corrosion S6AL7D10 Checking the valve 1 Check the tilt piston absorber valves Clean the tilt piston absorber valves if there is dirt or residue 7 51 BS SS Assembling the tilt ram CAUTION Do not use a rag when assembling the PTT unit as dust and particles on the PTT unit components can lead to poor perfor mance 1 Install a new dust seal new O rings and and the backup ring into the tilt cylinder end screw S6P27320 2 Install the tilt cylinder end screw spring adapter and tilt piston to the tilt ram S6P27190E 3 Hold the tilt piston in a vise using the special service tool o on both sides 6AL3 11 Tilt cylinder and trim cylinder 4 Tighten the tilt ram to the specified torque S6AL7860 ZA PTT piston vice attachment 90890 06572 Tilt rod wrench 90890 06569 NOTE e Replace the tilt piston assembly if replacing the tilt piston amp The shim s are not Tilt ram available as individual parts 55 Nem 5 5 kgfm 40 6 ftlb lt If the tilt piston was not replaced use the original shim s S6AL7870 5 Install a new O ring and the backup ring onto the tilt piston Tilt piston bolt 6 Inst
144. ap Bolt Camshaft cap Camshaft cap Bolt Gasket Cylinder head cover PORT Not reusable 4 x 8 mm M6 x 19 mm M6 x 30 mm M7 x 48 mm M7 x 37 mm Not reusable 5 8 Checking the valve clearance CAUTION Do not turn the flywheel magnet counter clockwise otherwise the water pump impeller may be damaged NOTE 0 Measure the valve clearances when the engine is cold 1 Reduce the fuel pressure NOTE When measuring or adjusting the valve clear ances the fuel line must be disconnected so be sure to reduce the fuel pressure before performing the disassembly procedure To reduce the fuel pressure see Chapter 4 Reducing the fuel pressure 2 Remove the flywheel magnet cover and ECM cover 3 Remove the blowby hose 4 Disconnect the ignition coil couplers cam position sensor couplers knock sensor coupler and cooling water pressure sensor adapter hose 5 Remove the speed sensor coupler from the bracket 6 Remove all ignition coils and spark plugs 7 Remove the ECM bracket bolts then the ECM bracket 5 9 S6P 25090C 8 Remove the cylinder head covers port and starboard NOTE See the exploded diagram 5 7 9 Turn the flywheel magnet clockwise and align the ITDC mark on the flywheel magnet with the pointer 10 Check that the Il marks on the port driven sprockets are aligned
145. arter motor lead brown white see Chapter 8 Wiring harness routing 4 Install the starboard intake manifold and intake silencer NOTE FS To install the intake manifold see Chapter 4 Installing the intake manifold Charging system Checking the stator coil 1 Remove the starboard intake manifold 2 Disconnect the stator coil couplers and then install the starboard intake manifold NOTE lt When installing the starboard intake mani fold at this time be sure to leave the stator coil couplers on the outside of the manifold e To install the starboard intake manifold see Chapter 4 Installing the intake manifold 8 50 evec E ELEC We Electrical system 3 Connect the test harness 1 pin to any stator coil coupler 4 Measure the stator coil output peak volt age Replace the stator coil if below specification S6AL8420 NOTE Select any 2 of the 3 couplers leads and measure the output peak voltage between the selected couplers Then measure the output voltage between the coupler that was not measured and any coupler Z Test harness 1 pin 4 90890 06888 Peak voltage adapter B 90890 03172 Stator coil output peak voltage Green G Green G Unloaded Cranking 1 500 8 3 44 7 5 Measure the stator coil resistance NOTE Select any 2 of the 3 couplers leads and measure the resistance between the selected couplers Th
146. asuring the forward and reverse gear backlash 1 Install the lower unit onto a repair stand 2 Remove the water pump assembly 3 Setthe gear shift to the neutral position at the lower unit S6AL6930 4 Turn the lower unit so that it is positioned as shown 5 Install the special service tool 6 Tighten the center bolt to the specified torque while turning the drive shaft 6AL3 11 S6AL6160 NOTE Se The drive shaft can no longer be turned when the center bolt is tightened to the specified torque YO Bearing housing puller claw L 90890 06502 Stopper guide plate 90890 06501 Center bolt 90890 06504 Center bolt 7 N m 0 7 kgf m 5 2 ft lb 7 Turn the lower unit back to its original position 6 60 Lower unit 8 Install the backlash indicator onto the drive shaft 22 4 mm 0 88 in in diame ter and then install the dial gauge S6AL6940 NOTE 0 Install the dial gauge so that the plunger contacts the mark on the backlash indica tor CL Backlash indicator 90890 06706 Magnet base plate 90890 07003 Dial gauge set 90890 01252 Magnet base B 90890 06844 9 Slowly turn the drive shaft clockwise and counterclockwise and measure the back lash when the drive shaft stops in each direction NOTE Measure the backlash at 4 points to find the average AS Forward gear backlash 0 46 0 82 mm 0 0181 0 0323 in 10 Add or
147. asuring the peak voltage is effected by many factors such as fouled spark plugs ora weak battery If one of these factors is present the peak voltage cannot be mea Sured properly S6AL8010 AA WARNING When checking the peak voltage do not touch any of the connections of the digital tester leads CAUTION When testing the voltage between the ter minals of an electrical component with the digital tester do not allow any of the leads to touch any metal parts If touched the electrical component can short and be damaged 6AL3 11 NOTE e Before measuring the peak voltage check all wiring for proper connection and corro sion and check that the battery is fully charged e Use peak voltage adapter B with the rec ommended digital circuit tester e Connect the positive pin of peak voltage adapter B to the positive terminal of the dig ital tester and the negative pin to the nega tive terminal lt When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode GC Digital circuit tester 90890 03174 Peak voltage adapter B 90890 03172 6AL3 11 Checking the electrical component 8 2 evec E ELEC Electrical system Electrical component Port view S6AS8010 Intake air temperature sensor Cam position sensor PORT IN Electronic throttle valve assembly Cam position sensor PORT EX High pressure fuel pump
148. ation 8 Check the fluid level when the trim and tilt rams are fully extended If the fluid level is low add sufficient fluid and then repeat steps 6 7 Bleeding the PTT unit built in 1 Push the PTT switch to fully tilt the out board motor up and down 4 to 5 times 7 57 S6P23190 NOTE SE Connect the PTT motor leads directly to the battery terminals when the power unit is not installed To connect the PTT motor leads see Chapter 7 Bleeding the PTT unit 2 Let the fluid settle for 5 minutes with the outboard motor tilted down 3 Push the PTT switch to fully tilt the out board motor up 4 Support the outboard motor with the tilt stop lever and then let the fluid settle for 5 minutes After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the PTT unit should lose fluid pressure 5 Remove the reservoir cap and then check the fluid level in the reservoir 6AL3 J 11 Tilt cylinder and trim cylinder PTT electrical system FT NOTE 255 2006 If the fluid is at the correct level a small amount of fluid should overflow out of the filler hole when the cap is removed 6 Ifthe fluid is below the correct level add recommended fluid AC Recommended PTT fluid ATF Dexron I 7 Install a new O ring and the reservoir cap and then tighten the reservoir cap to the specified torqu
149. camshaft timing cap Otherwise the variable camshaft timing assembly can be damaged e Do not turn the driven sprocket when removing the variable camshaft timing cap Otherwise the intake and exhaust valves will collide with each other and be damaged e Do not reuse the gasket always replace it with a new one Sheave holder 90890 01701 10 Hold the intake camshaft using a wrench and then remove the variable camshaft timing bolt 11 Remove the variable camshaft timing assembly with the driven sprocket Be f S6P25510 5 23 CAUTION e Do not hold the driven sprocket when removing the variable camshaft timing bolt Otherwise the variable camshaft timing assembly can be damaged lt Do not turn the intake camshaft when removing the variable camshaft timing bolt Otherwise the intake and exhaust valves will collide with each other and be damaged 12 Hold the exhaust camshaft using a wrench and then remove the bolt 13 Remove the exhaust driven sprocket S6P25520 CAUTION Do not turn the exhaust camshaft when removing the bolt Otherwise the intake and exhaust valves will collide with each other and be damaged 14 Remove the camshaft caps in the sequence shown 15 Remove the camshafts and oil seals 6AL3 11 A Ber iE FX N
150. ce specification Item Unit io 200 R 200 L 225R 225L Variable camshaft timing control system Oil control valve resistance at 20 68 F Q 6 7 7 7 Fuel control system Fuel injector resistance at21 C 70 F Q 12 0 Low pressure fuel pump Q 1 3 4 0 resistance High pressure fuel pump Q 0 5 10 resistance Vapor shut off valve resistance at 20 68 F Q 30 0 34 0 Starter motor Type Sliding gear Output kW 1 40 Cranking time limit Second 30 Brushes Standard length mm in 15 5 0 61 Wear limit mm in 9 5 0 37 Commutator Standard diameter mm in 29 0 1 14 Wear limit mm in 28 0 1 10 Standard undercut mm in 0 8 0 03 Wear limit mm in 0 2 0 01 Charging system Fuse A 80 Stator coil output peak voltage G G at cranking unloaded V 8 3 at 1 500 r min unloaded V 44 7 at 3 500 r min unloaded V 97 7 Stator coil resistance G G at 20 68 F 0 0 1144 0 1716 Rectifier Regulator output peak voltage R Ground at 1 500 r min unloaded V 13 0 at 3 500 r min unloaded V 13 0 ED The figures are for reference only 6AL3J 11 2 10 ad awan Specification Item PTT system Trim sensor Setting resistance Resistance Fluid type PTT motor 10 1 9 387 6 ATF Dexron II Output 0 53 Brushes Standard length Wear limit Commutator Standard diameter Wear limit Standard undercut Wear limit 11 5 0 45 4 5 0 18 23 0 0 91 22 0
151. check the backlash when the unit is assembled Calculation formula Reverse gear shim thickness T1 30 60 F 100 M1 Example If M1 is 29 94 mm and F is 5 then T1 30 60 5 100 29 94 mm 30 60 0 05 29 94 mm 0 71 mm If M1 is 29 94 mm and F is 4 then T1 30 60 4 100 29 94 mm 30 60 0 04 29 94 mm 0 70 mm 3 Select the reverse gear shim s T1 as follows SE e Rounded number Ca 0 3 4 5 2 6 7 8 3 9 10 8 Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 6AL3 11 Shimming counter rotation model Example If T1 is 0 71 mm then the reverse gear shim is 0 70 mm If T1 is 0 70 mm then the reverse gear shim is 0 68 mm 6 56 Lower unit Selecting the forward gear shim 1 Turn the taper roller bearing outer race OM 2 or 3 times to seat the rollers and then measure the bearing height M5 and M6 as shown FE JE I ee gt HOLGER el a San S6AL6530 S6AL6540 NOTE e Select the shim thickness T2 by using the Specified measurement s and the calcula tion formula lt Measure the taper roller bearing at 4 points to find the height average 2 Shimming plate 90890 06701 Digital caliper 90890 06704 2 Calculate the forward gear shim thick ness T2 as shown in the examples below 6 57 S69J6585 S6
152. ck connector otherwise the retainer could be lost 3 Disconnect the quick connector from the fuel rail or vapor separator directly 6AL3 11 S6P24280 NOTE ee Cover the quick connector fuel rail and vapor separator with a plastic bag to prevent damage and to protect them from dirt Measuring the fuel pressure 1 Reduce the fuel pressure NOTE a NA To reduce the fuel pressure see Chapter 4 Reducing the fuel pressure 2 Disconnect the quick connector from the vapor separator NOTE ee To disconnect the quick connector see Chapter 4 Disconnecting the quick connec tor 3 Connect the fuel pressure gauge adapter B between the quick connector and vapor separator 4 Connect the fuel pressure gauge to fuel pressure gauge adapter B 6AL3 11 Fuel system S6P24290E WARNING lt Gently screw in the gauge until it is firmly connected to prevent fuel from leaking out lt Before measuring the fuel pressure make sure that the drain screw is tight ened securely lt Do not loosen the drain screw while measuring the fuel pressure Loosening the drain screw can cause fuel to spray out creating a fire hazard Ko Fuel pressure gauge adapter B 90890 06942 Fuel pressure gauge 90890 06786 5 Turn the engine start switch to ON and then measure the fuel pressure within 5 seconds NOTE e The fuel pressure will decrease 5 seconds aft
153. ck the valve seat contact area of the valve again NOTE let To check the valve seat contact area see Chapter 5 Checking the valve seat Checking the cylinder head 1 Eliminate carbon deposits from the com bustion chambers and check for deterio ration 2 Check the cylinder head warpage using a straightedge and thickness gauge in the directions shown Replace the cyl inder head assembly if above specifica tion S69J5A00 S69J5A10 6AL3 11 AS Cylinder head warpage limit 0 1 mm 0 0039 in Installing the valve 1 Install a new valve seal onto the valve guide S69J5A20 2 Install the valve valve spring and valve spring retainer in the sequence shown and then attach the special ser vice tools S6P25D60 NOTE _ IN The valve spring can be installed in any direction CZ Valve spring compressor i 90890 04019 Valve spring compressor attachment 90890 06320 3 Compress the valve spring and then install the valve cotters 6AL3 11 Cylinder head S69J5A40 4 Lightly tap the valve spring retainer with a plastic hammer to set the valve cotters securely S6P25D70 S6AL5430 NOTE Be sure to install the camshafts after com pleting the procedure in Chapter 5 Installing the cylinder head 5 52 Removing the exhaust cover 1 Remove the exhaust cover bolts in the sequences shown 6
154. cord in the YDIS be sure to check the time that the trou ble codes were detected When checking the input voltage of a part the coupler or connector must be discon nected As a result the ECM determines that the partis disconnected and a trouble code is detected Therefore be sure to delete the diagnosis record after checking the input volt age Since the main relay comes on for approxi mately 10 seconds after the start switch is turned to OFF the power of the ECM can not be turned off Therefore if the start switch is turned to ON within 10 seconds after it was turned to OFF the trouble codes can not be deleted NOTE e Before checking the electrical components make sure that the battery is fully charged e The YDIS requires that you use an exclu sive communication cable and CD ROM to connect to a computer For a description of the communication cable and CD ROM to be used see Chapter 9 YDIS Also be sure to check the CD ROM version before using it e To connect the YDIS see Chapter 9 YDIS or the YDIS Ver 1 23a or later Instruction Manual K YDIS connecting kit 60V 85300 02 00 YDIS CD ROM Ver 1 23a 60V WS 853 03 8 1 Measuring the peak voltage To check the electrical components or mea sure the peak voltage use the special ser vice tools A faulty electrical component can be easily checked by measuring the peak voltage The specified engine speed when me
155. crew to drain the remaining fuel from the hose and gauge lt When storing the fuel pressure gauge make sure that the drain screw is tight ened securely 10 Connect the pressure regulator hose and quick connector 6AL3 11 Fuel system 4 8 el D Fuel system Intake manifold Se XJ 10 N m 1 0 kgf m 7 4 ft Ib S6AL4030 Remarks a Oo OANA Un BUN Hm Partname Flywheel magnet cover Blowby hose Joint Blowby hose Blowby hose Intake air temperature sensor Grommet Bolt Bolt Bolt Intake manifold STBD Gasket Gasket Gasket Intake manifold PORT Intake silencer Plastic tie lt M6 x 25 mm M8 x 40 mm M6 x 40 mm Not reusable Not reusable Not reusable k ah Fa k ON k k zl OPP RBK PPP 4 9 6AL3 11 Checking the intake manifold 1 Check the intake manifold Replace the intake manifold if cracked or deformed 2 Check the intake silencer Replace the intake silencer if cracked or deformed 3 Check the blowby hoses Replace the blowby hoses if cracked or damaged NOTE To check the intake air temperature sensor see Chapter 8 Checking the intake air tem perature sensor Installing the intake manifold 1 Install new gaskets onto the intake mani folds S6P24060 NOTE Be sure to install the projection on each gas ket into its corresponding slit in the intake manifolds 2 Install the int
156. ct width 6 Check the valve seat contact area of the valve NOTE SS To check the valve seat contact area see Chapter 5 Checking the valve seat 7 Ifthe valve seat contact width is too wide and situated in the center of the valve face use a 30 cutter to cut the top edge of the valve seat a 60 cutter to cut the bottom edge to center the area and set its width S69J5910 Previous contact width 5 50 8 If the valve seat contact width is too nar row and situated near the top edge of the valve face use a 30 cutter to cut the top edge of the valve seat If necessary use a 45 cutter to center the area and set its width S69J5920 O Previous contact width 9 Ifthe valve seat contact width is too nar row and situated near the bottom edge of the valve face use a 60 cutter to cut the bottom edge of the valve seat If neces sary use a 45 cutter to center the area and set its width 4 3 4 e S69J5937 O Previous contact width 10 After refacing the valve seat to the speci fied contact width apply a thin even layer of lapping compound onto the valve seat and then lap the valve using a valve lapper commercially available S6P25E50 5 51 CAUTION Do not get the lapping compound on the valve stem and valve guide 11 After every lapping procedure be sure to clean off any remaining lapping com pound from the cylinder heads and the valves 12 Che
157. der 90890 06715 2 Remove the drive shaft drive shaft hous ing pinion thrust bearing spring and washer 3 Pull out the forward gear Disassembling the drive shaft housing 1 Remove the cover oil seals and needle bearing ar gt SGALSS9N SALAT Driver rod L3 90890 06652 VG Needle bearing attachment 2 90890 06610 Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear using a press 6AL3J11 S6ALGAOG GAN gt Do not reuse the bearing always replace it with a new one Deel 4 Ur Bearing separator D 90890 06534 Disassembling the lower case 1 Remove the needie bearing from the lower case S6ALE20 Since the diameter of the passage in the lower case and the diameter of the special service tool are both 40 mm 1 57 in the special service tool may not fit into the lower case In that case use a special ser vice tool with a smaller diameter Be sure to remove the forward gear before removing the needle bearing Cat Ball bearing attachment g 90890 06655 Driver rod LL 2 90890 06605 6AL3J11 How to use this manual Symbol The symbols below are designed to indicate the content of a chapter General information Fuel system Bracket unit FUEL BRKT EE a H A Specification Power unit Electrical system SPEC
158. diagram Diagnostic System 1 3 6AL3J11 Safety while working To prevent an accident or injury and to ensure quality service follow the safety pro cedures provided below Fire prevention Gasoline is highly flammable Keep gasoline and all flammable products away from heat sparks and open flames S69J1010 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 ade quate ventilation can be maintained S69J1020 Self protection Protect your eyes by wearing safety glasses or safety goggles during all operations involv ing drilling and grinding or when using an air compressor Protect your hands and feet by wearing pro tective gloves and safety shoes when neces sary 6AL3J11 How to use this manual Safety while working S69J1030 Part lubricant and sealant Use only genuine Selva parts lubricants and sealants or those recommended by Selva when servicing or repairing the out board motor 869J1040 Under normal conditions the lubricants men tioned 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 go
159. dy Poor Decreases Normal Poor Increases Normal Normal unsteady Down Poor Unsteady Down Poor Increases 1 200 1 500 r min Impossible Does not starts Engine does not operate TIGO nl mo DM wl gt A CD 600 700 r min at engine idle speed 2 5 000 6 000 r min 3 Less than the specified engine speed A Engine speed increases according to throttle opening angle 5 Engine speed does not increase according to throttle opening angle 6 Limp home processing 6AL3J 11 9 8 TRBL D SHTG e Troubleshooting Trouble code and checking step Trouble code Symptom Remarks Checking steps Pulser coil malfunction Trolling speed is unstable Measure the crank position sen sor resistance Check the white black W B lead and black B lead ECM to crank position sensor for conti nuity Measure the crank position sen sor output peak voltage Measure the crank position sen sor air gap Check the projections of the fly wheel magnet for damage Engine temp sensor malfunction Check the engine temperature using the YDIS Measure the input voltage Measure the resistance Knock sensor malfunction Maximum power decreases Measure the resistance Check the green G lead ECM to knock sensor for continuity Battery voltage malfunction
160. e NOTE Se Repeat steps 1 7 until the fluid remains at the correct level Reservoir cap 7 N m 0 7 kgf m 5 2 ft lb PTT electrical system Checking the fuse 1 Check the fuse for continuity Replace the fuse if there is no continuity NOTE SS a For the location of the fuse see Chapter 8 Fuse holder Checking the PTT relay 1 Using the special service tool check the PTT relay for continuity Replace the PTT relay if out of specification 6AL3 11 Sky blue Sb Terminal amp Light green Lg Terminal Continuity Terminal Terminal Terminal Terminal Continuity Terminal Terminal Terminal Terminal No continuity 7 58 Bracket unit 2 Connect the positive battery lead to the light green Lg lead and the negative battery lead to the terminal as shown and then check the PTT relay for continu Terminal Terminal amp Continuity ity Replace the PTT relay if out of speci Terminal Terminal fication Terminal Terminal PTT relay continuity No continuity Checking the PTT switch 1 Check the PTT switch for continuity Replace the PTT switch if out of specifi cation S6AL7C03 Lead color Terminal Terminal Continuity Terminal Terminal Terminal Terminal Switch Sky blue position Sb Up o o Free Lightgreen
161. e specified torque Lower case mounting bolt nut 47 N m 4 7 kgf m 34 7 ft lb Trim tab bolt 42 N m 4 2 kgf m 31 0 ft lb 6 20 Lower unit 6 Install the propeller and propeller nut and then tighten the nut temporarily Place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then tighten the nut to the specified torque S6AL6A40 S69J6340 WARNING e Do not hold the propeller with your hands when loosening or tightening it lt Be sure to disconnect the battery cables from the battery and the clip from the engine stop lanyard switch lt Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning NOTE EE If the grooves in the propeller nut do not align with the cotter pin hole tighten the nut until they are aligned Propeller nut 54 N m 5 4 kgf m 39 8 ft lb 7 Fill the gear oil to the correct level Recommended gear oil Hypoid gear oil API GL 4 SAE 90 Gear oil quantity Regular rotation model 1 150 cm 38 9 US oz 40 6 Imp oz 6AL3 11 Drive shaftand lower case regular rotation model Shimming regular rotation model Shimming regular rotation model all B4 E i cl KG dE T3 B B B3 A3 jal ang C1 LIN H T4 B5 Bt 39 4 41 0 AT A2 Le gt
162. e assembly 3 Remove the oil pan assembly bolts and and then remove the oil pan assembly from the upper case S6AL7240 NOTE EE The bolt is used to install the lower exhaust guide onto the upper exhaust guide Therefore if the oil pan assembly will be dis assembled after it is removed from the upper case also remove the bolt 4 Remove the circlip and then remove the drive shaft bushing 6AL3 11 ZA Bearing puller assembly 4 90890 06535 Stopper guide stand o 90890 06538 Stopper guide plate 4 90890 06501 Checking the drive shaft bushing 1 Check the drive shaft bushing Replace if cracked or worn Disassembling the oil pan and exhaust manifold 1 Remove the muffler plate and exhaust manifold from the oil pan S6AL7260 2 Remove the oil pan from the upper exhaust guide and lower exhaust guide 3 Remove the oil strainer from the lower exhaust guide 6AL3 11 Upper case and steering arm S6AL7270 Checking the oil pan and exhaust manifold 1 Clean the removed parts 2 Check the exhaust guides exhaust man ifold and muffler Replace the exhaust guides exhaust manifold and muffler if cracked or replace if there is corrosion 3 Check the oil pan Replace the oil pan if cracked or replace if there is corrosion Checking the oil strainer 1 Check the oil strainer Clean the oil Straine
163. e filter Clean the filter if there is dirt or residue 4 Install the needle valve and float to the vapor separator cover 5 Place the vapor separator cover assem bly in the position shown in the illustra tion and then measure the float height 6AL3 J 11 UT NOTE To measure the height of the float it should be resting on the needle valve Do not press the float ZX Float height amp 60 5 3 0 mm 2 38 0 12 in 6AL3 11 Vapor separator 4 30 pour Power unit Power unit check and adjustment sise 5 1 Checking the compression Pressure nn se fea here Ago 5 1 Checking the oil pressure ss 5 1 Checking the oil pressure Sensor vade 5 2 ECM base assembly aag net a petata a aat 5 4 Ke 5 6 CSS Na TE Aa unten a ga a aa aba aa a re 5 7 Checking the valte Cleirance ssh 5 9 Adjusting the valve clearance sasasi aee aana anana anana anana anana aane 5 11 Replacing the timing bet 5 15 Removing the timing belt driven sprocket and camshaft 5 21 Checking the timing belt and sprocket A 5 24 Checking the valve EE 5 24 Checking the camshaft ss 5 25 Installing the camshaft driven sprocket and timing belt eee 5 26 Power uhita sasa aana na aa NG cc it pme NK den ae term a ere nt et otre lt 5 33 Power UE GEREEST 5 33 Start r NL UE a KE ag EAR 5 35 JUNCTION DORE Seren co ea aa
164. e is no oil leakage If the oil level is low add engine oil to the correct level Oil filter wrench 90890 06830 3 Apply a thin coat of engine oil to the O 9 Install the starboard apron and then ring of the new oil filter tighten the apron bolts to the specified torque 4 Install the oil filter and then tighten it to the specified torque using a 72 5 mm 2 9 in oil filter wrench a Apron bolt 8 N m 0 8 kgf m 5 9 ft lb Replacing the oil filter CAUTION TASS S6AL3040 Do not damage the oil pressure sensor N Oil filter andits lead when replacing the oil filter 18 N m 1 8 kgf m 13 3 ft lb 1 Extract the engine oil with an oil changer P 5 Pour the specified amount of the recom or drain it mended engine oil into the oil filler hole 2 Place a rag under the oil filter and then remove the oil filter using a 72 5 mm 2 9 in oil filter wrench 3 7 6AL3J 11 Power unit Remove the ignition coils and then Recommended engine oil 4 stroke motor oil API SE SF SG SH SJ or SL SAE 5W 30 10W 30 or 10W 40 Engine oil quantity With oil filter replacement 5 8 L 6 13 US qt 5 10 Imp qt 6 Install the oil filler cap and oil dipstick and then start the engine and warm it up for 5 minutes 7 Turn the engine off and then check the oil level and that there is no oil leakage If the oil level is low add engine oil to the correct level Chec
165. e negative battery cable first then the positive battery cable ZX Electrolyte specific gravity 1 280 at 20 C 68 F Lubricating the outboard motor 1 Apply water resistant grease to the areas shown S6AL3170 6AL3J 11 General S69J3660 S69J3670 S69J3690 S69J3700 3 18 AD AD Periodic check and adjustment S6D03010 NOTE Apply grease to the grease nipple until it flows from the bushings 2 Apply low temperature resistant grease to the area shown MD Fn 3 Apply corrosion resistant grease to the area shown S68F3190C 3 19 6AL3J 11 Fuel system HOSS FOUUING sasaka anaa ak ag en Le nr rte nee 4 1 Fuel hose and blowby host none ae date nana anaa aana Te city je skule 4 1 Vapor gaS ASS ae 4 2 COOINg Water Eege ant anaa ea ENG 4 3 Fuel SYS TOM nes ee sen nan er ot ne nn cute en nanan nananana te tue 4 5 Reducing the fuel Eet een Ut er ean 4 5 Disconnecting the quick connector arane eaaa aana aan nana n aaa 4 5 Measuring the fuel pressure 4 6 Checking the pressure regulator sasae aaa aaa n anna anaman anana ENNEN 4 7 Intake manifold ssssasessananan anan ere ee Ad 4 9 Checking the intake manifold AANER 4 10 Installing the intake manifold EE 4 10 Installing the intake silencer ssssssessrssssrrssssrrrrssrrrsserrrsssrrrrnrsrrreeeerrssee 4 11 Accelerator position SENSOM rnmsssrnmsvnnnnannnnnnnnnnn
166. e propeller shaft runout Replace the propeller shaft if above specification S6P26200C Propeller shaft runout limit 0 02 mm 0 0008 in 3 Check the dog clutch shift rod joint and Slider Replace the dog clutch shift rod joint or slider if cracked or worn Assembling the propeller shaft assembly 1 Install the shift plunger slider shift rod joint dog clutch and cross pin and then install the spring as shown S6AL6060 6AL3 11 NOTE a Install the dog clutch with the F mark facing toward the shift rod joint Assembling the propeller shaft housing 1 Install the needle bearing into the propel ler shaft housing to the specified depth S6AL6570 NOTE e Install the needle bearing with the manufac ture identification mark facing toward the oil seal propeller side lt When using the driver rod do not strike the special service tool in a manner that will force the stopper out of place QZ Driver rod SS 90890 06604 Needle bearing attachment 90890 06610 Bearing depth plate 90890 06603 AS Depth 25 3 0 25 mm 1 00 0 01 in 2 Apply grease to new oil seals and then install them into the propeller shaft hous ing to the specified depth 6AL3 11 Propeller shaft housing regular rotation model S6AL6820 NOTE SE Install an oil seal halfway into the propeller shaft housing
167. ease into the grease nipple on 69 J7085 the swivel bracket until grease comes out from both the upper and lower bush 4 Install the steering yoke onto the ings steering arm making sure that they are both facing in the same direction and are aligned S6AL7440 S6AL7420 5 Hold the steering arm Q and then strike the steering yoke until the slot for installing the circlip is visible 6 Install the circlip oo 7 21 6AL3 11 Upper case and steering arm Clamp bracket and swivel bracket Clamp bracket and swivel bracket Sel 8 N m 0 3 kgf m 2 2 ft Ib 22 N m 2 2 kgf m 16 2 ft Ib S6AL7450 P art name Remarks a Oo OO On UL BUN Mm Through tube Clamp bracket PORT Bolt Ground lead Bushing Washer Bushing Friction plate Screw Screw Trim sensor Grease nipple Clamp bracket STBD Self locking nut Collar Pin Distance collar M10 x 45 mm 120 mm 4 7 in 6 x 10 mm 6 x 15 mm KA FA k k RON P N P N NN EH OF BR 30 3 30 4 mm 1 19 1 20 in 6AL3J 11 7 22 Bracket unit Sel 8 N m 0 3 kof m 2 2 ft Ib 22 N m 2 2 kgf m 16 2 ft Ib S6AL7450 Part name Remarks Pin Bolt Spring Spring holder Tilt stop lever PORT Shaft Trim stopper Tilt stop lever STBD Circlip Nut Swivel bracket PTT unit Ground lead Bushing Bushing Anode Ground lead
168. eck the shift rod Replace if cracked or worn 6AL3 11 Lower unit regular rotation model Propeller shaft housing regular rotation model Propeller shaft housing regular rotation model S6AL6030 P art name Remarks No 1 2 3 4 5 6 7 8 Water pipe Rubber seal Rubber seal Shiftrod joint Ball Slider Shift plunger Dog clutch Cross pin Spring Propeller shaft Propeller shaft shim Reverse gear Reverse gear shim Ball bearing O ring Propeller shaft housing A k k k REH PP PNP k k ob Not reusable Not reusable ree 6AL3J 11 6 6 Lower unit S6AL6030 Part name Remarks Not reusable Dowel Grease nipple Rubber seal O ring Needle bearing Oil seal Ring Bolt Bolt Washer Cooling water inlet cover Nut Screw Not reusable Not reusable M8 x 20 mm M8 x 33 mm KE NNNNR NGEREH H ka 6 7 6AL3J 11 Propeller shaft housing regular rotation model Removing the propeller shaft housing assembly gt Bearing housing puller claw L 1 Remove the water pipe and shift rod l 90890 06502 Stopper guide plate 90890 06501 Center bolt 90890 06504 Q s Disassembling the propeller shaft D assembly IT 1 Remove the spring D and then remove z the cross pin dog clutch shift plunger slider and shift rod joint 2 Remove the bolts ring and bo
169. electronic throttle valve and TB 8 31 Checking the electronic throttle valve and TPS circuit 8 33 Checking the electronic throttle valve system 4 16 Checking the engine idle speed 3 11 Checking the engine oil 3 5 Checking the engine oil level 1 22 Checking the engine start switch 8 25 Checking the engine start switch and engine stop lanyard Switch 1 24 Checking the engine stop lanyard switch 8 26 Checking the engine temperature sensor saaraaaa raaa ani 8 21 Checking the exhaust cover anode 5 53 Checking the filter 7 44 Checking the fuel filter 3 4 4 22 Checking the fuel filter assembly 4 20 Checking the fuel injector ees 8 38 Checking the fuel joint and fuel hose fuel joint to fuel injector Checking the fuel rail Checking the fuel system cecer Checking the fuse aranne Index Checking the gear oil level 1 22 3 14 Checking the gear pump 7 43 Checking the gear pump housing 7 44 Checking the gear shift and throttle operation ccecce 1 24 Checking the gear shift operation 3 12 Checking the high pressure fuel pump 4 29 Checking the high pressure fuel pump relay eere 8 39 Checking the hydraulic pressure 7 32 Checking the ignition coil input voltage 8 18 Checking the ignition spark 8 18 Checking the intake air pressure sensor
170. en measure the resistance between the coupler that was not measured and any coupler 8 51 Stator coil resistance reference data Green G Green G 0 1144 0 1716 Q at 20 C 68 F Checking the Rectifier Regulator CAUTION If the battery cables are connected in reverse the Rectifier Regulator can be damaged 1 Remove the starboard intake manifold 2 Remove the fuse holder and disconnect the Rectifier Regulator coupler and then install the starboard intake manifold NOTE Je NG lt When installing the starboard intake mani fold atthis time be sure to leave the Recti fier Regulator coupler on the outside of the manifold e To install the starboard intake manifold see Chapter 4 Installing the intake manifold 3 Measure the Rectifier Regulator output peak voltage If below specification mea sure the stator coil output peak voltage Check the Rectifier Regulator if the out put peak voltage of the stator coil is above specification S6AL8370 6AL3 11 NOTE SS Do not use peak voltage adapter B when measuring the Rectifier Regulator output peak voltage Rectifier Regulator output peak voltage Red R Ground Unloaded 1 500 3 500 13 0 13 0 4 Check the Rectifier Regulator for conti nuity Replace if out of specification RO RO GO GO GO S6P28100 56518360 6A
171. en disconnect them S6AL5210 12 Remove the speed sensor coupler oi from the bracket and then disconnect it 13 Disconnect the flushing hose Gm S6AL5200 14 Remove the aprons and upper case cover 6AL3 11 Power unit S6P25350E 15 Retract the port and starboard top cowl ing lock levers PORT S6AL5220 CAUTION Make sure that the top cowling lock levers are retracted and the engine stoppers are installed before removing the power unit otherwise the fuel rails could be dam aged 5 40 16 Suspend the power unit from the engine hangers 17 Remove the power unit by removing the bolts and Removing the wiring harness NOTE When removing the wiring harness and wir ing harness guide the fuel line must be dis connected so be sure to reduce the fuel pressure before performing the disassembly procedure To reduce the fuel pressure see Chapter 4 Reducing the fuel pressure 1 Remove the joint connector from the wiring harness guide 2 Disconnect the oil control valve couplers engine temperature sensor coupler and thermoswitch connectors 5 41 3 Remove the engine temperature sensor coupler and low pressure fuel pump coupler from the wiring harness guide 4 Remove the 3 pin communication cou pler and diagnosis connector from the bracket
172. er the engine start switch is turned to ON because the high pressure fuel pump will stop e The high pressure fuel pump does not operate when the engine start switch is turned to ON again within 10 seconds after turning the switch to OFF Fuel pressure reference data 300 kPa 3 0 kgf cm 43 5 psi 4 6 el D Fuel system 6 Start the engine warm it up for 5 min utes and then measure the fuel pressure at engine idle speed If below specifica tion check the high pressure fuel line and the vapor separator Fuel pressure reference data 260 kPa 2 6 kgf cm 37 7 psi at engine idle speed 7 Reduce the fuel pressure NOTE To reduce the fuel pressure see Chapter 4 Reducing the fuel pressure 8 Disconnectthe special service tools WARNING lt After measuring the fuel pressure cover the end of the hose with a clean dry rag point the hose downward and then loosen the drain screw to drain the remaining fuel from the hose and gauge lt When storing the fuel pressure gauge make sure that the drain screw is tight ened securely 9 Connectthe quick connector Checking the pressure regulator 1 Reduce the fuel pressure NOTE To reduce the fuel pressure see Chapter 4 Reducing the fuel pressure 2 Disconnect the quick connector from the vapor separator NOTE To disconnect the quick connector see Chapter 4 Disconnecting the quick connec tor
173. ermoswitches one on the port side of the power unit and one on the star board side Turn the engine start switch to ON and then measure the input voltage at the thermoswitch connectors wiring harness end Check the wiring harness if below specification 6AL3 11 Ignition and ignition control system S6AL8510 Thermoswitch input voltage Pink P Black B 12 V battery voltage 3 Turn the engine start switch to OFF 4 Remove the thermoswitches 5 Place the thermoswitches ina container of water and slowly heat the water S6AL8520 00 00000006 8 22 evec ELEC hi Electrical system 6 Check the switch for continuity at the specified temperatures Replace if out of specification CR jf e S6AL8880 Temperature Time No continuity Continuity Thermoswitch continuity temperature Pink P Black B 84 90 C 183 194 F D 68 82 C 154 180 F 7 Install the thermoswitches and then con nect the thermoswitch connectors Checking the shift cut switch 1 Disconnect the shift cut switch coupler black 2 Connect the test harness 2 pins to the shift cut switch coupler wire harness end v Test harness 2 pins 90890 06867 3 Turn the engine start switch to ON and then measure the input voltage at the shift cut switch coupler wiring harness end Check the wiring harness if out of specification 8 23
174. ery check ssenanananaeeeaaa tendres end een rente ronn t tan tac ants 1 22 Checking the fuel system ENEE 1 22 Checking the engine oil evel AAA 1 22 Checking the gear oil level ententes 1 22 Checking the attente et Kab dn den arkene 1 22 Checking the outboard motor mounting height 1 23 Checking the remote control cable 1 23 Checking the steering system EEN 1 24 Checking the gear shift and throttle operation 1 24 Checking the PTT SYSTEMS ns MON a sont M a nu 1 24 Checking the engine start switch and engine stop lanyard switch 1 24 Checking the cooling water pilot hole 1 25 TEU EE 1 25 BIGGIN sasak aa pagan rE E 1 25 After Test E EE 1 25 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 under stand Use the information below as a guide for effective and quality service lt Parts are shown and detailed in an exploded diagram and are listed in the component list see in the figure below for an example page The component list consists of part names and quantities as well as bolt and screw dimensions see in the figure below e Symbols are used to indicate important aspects of a procedure such as the grade of lubricant and lubrication point see 3 in the figure below Tightening torque specifications are provided in the exploded diagrams see in the figure below for an example a
175. ess in the joint PTT motor mounting bolt amp 19 N m 1 9 kgf m 14 0 ftlb Installing the reservoir CAUTION Do not use a rag when assembling the PTT unit as dust and particles on the PTT unit components can lead to poor perfor mance 1 Install the spacer filter and sheet to the PTT body 2 Install a new O ring and the reservoir and then tighten the bolts to the specified torque 7 55 3 Install a new O ring and the reservoir cap and then tighten the reservoir cap to the specified torque S6AL7940 Reservoir mounting bolt 19 N m 1 9 kgf m 14 0 ft lb Reservoir cap 7 N m 0 7 kgf m 5 2 ft lb Installing the tilt ram CAUTION Do not use a rag when assembling the PTT unit as dust and particles on the PTT unit components can lead to poor perfor mance 1 Place the tilt cylinder end screw at the position bottom of the tilt ram 2 Fill the tilt cylinder with the recommended fluid to the correct level amp as shown NY Recommended PTT fluid ATF Dexron II 3 Add a small amount of the recommended fluid through the PTT body hole as shown 6AL3 11 S6AL7950 S6AL7960 4 Install the tilt piston assembly into the tilt cylinder and then tighten the tilt cylinder end screw to the specified torque S6AL7970 NOTE Place the tilt cylinder end screw at the posi tion and install the tilt piston assembly into the tilt cyli
176. flows out of the check hole Recommended gear oil Hypoid gear oil API GL 4 SAE 90 4 Install a new gasket and the gear oil check screw D and then tighten the gear oil check screw to the specified torque Gear oil check screw 9 N m 0 9 kgf m 6 6 ft lb Changing the gear oil 1 Tiltthe outboard motor up slightly 3 14 CHK Q ADJ Periodic check and adjustment Place a drain pan under the gear oil drain hole remove the gear oil drain screw Recommended gear oil OM then the gear oil check screw and Hypoid gear oil letthe oil drain completely API GL 4 SAE 90 Gear oil quantity Regular rotation model 1 150 cm 38 9 US oz 40 6 Imp oz Counter rotation model 1 000 cm 33 8 US oz 35 3 Imp oz 5 Install new gaskets and the gear oil check screw and quickly install the gear oil drain screw and then tighten them to the specified torque S6P23380 Gear oil check screw and drain Check the oil for metal and discoloration screw D and check its viscosity Check the inter 9 N m 0 9 kgf m 6 6 ft lb nal parts of the lower case if necessary Checking the lower unit for air leakage 1 Remove the gear oil check screw D and no air bubbles are visible then install the special service tool 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 S6P23390 S60V3350 2 Apply the specif
177. fuel injector 3 3 Checking the Heller ennemie nn rides 3 4 Draining the fuel essence i E Aa NG KA dine KA KN 3 5 POW IU 5525 anne aa NGA aa Ga int ANE Ga Nagan Eed GE 3 5 Checking the engine oil uanseamndnavenr drdssvinnvsdrrvdseteneanecnen 3 5 Changing the engine oil extracting ss aaaeeen anane a anana aana nne e anan 3 5 Changing the engine oil draining NNN 3 6 Replacing the oil Ne nn a nn anaa anna aana a nn 3 7 Checking the timing bel ssh nnnatenmemienenensihetnneeninte 3 8 CHECKING the E ie Le EE 3 8 Checking the Maggele eseou degen 3 9 Checking the cooling water passage 3 10 Control system done Ne en he du trs 3 11 Checking the engine idle speed series hentai 3 11 Adjusting the throttle cable Lunusmansdmnsdsmnenissn mandarinen 3 11 Checking the gear shift Opere peau ins snresatensstate nn atethees 3 12 Bracket unit asasaran gesanga ngen apen naa eea ka mienne DENE nissens 3 13 Checking the PTT operation sasasi eaaa aee eaaa Nn aana Nan nne ena 3 13 Checking the PTT fluid levels Mine dinnnneintiessns 3 13 Lower unit saga aaa En sasen naa ana atte fn a TE Stones ten s 3 14 Checking the gear oil level EE 3 14 Changing the gear Obit cc esos ns NN 3 14 Checking the lower unit for air leakage AAA 3 15 Be luese 3 16 ET pg EN EE init 3 16 Checking the ANCA asus 3 16 CHECKING the baken ae GE eg 3 17 Lubricating the Outboard motor 3 18 CHK LAK ADJ Periodic check and adjustment Maintenance interval
178. function in low er unit Check the internal parts of the lower unit A Abbreviation ss sasaka es aran pa ena na a 1 3 Accelerator position sensor 4 12 Adjusting the throttle cable 3 11 Adjusting the trim Sensor sssssecscere 7 28 Adjusting the valve clearance 5 11 ATEVIEW Haber 8 6 8 13 AE EEN 1 25 Assembling the bottom cowling 7 7 Assembling the drive shaft housing 6 16 6 47 Assembling the forward gear 6 16 Assembling the gear pump ee 7 44 Assembling the lower case 6 15 6 46 Assembling the oil pan and exhaust manifold 7 16 Assembling the oil pump 5 73 Assembling the power unit 5 69 Assembling the propeller shaft assembly 6 9 Assembling the C propeller shaft housing 6 10 6 39 Assembling the PTT motor 7 38 Assembling the reverse gear 6 46 Assembling the shift bracket 7 6 Assembling the starter motor 8 48 Assembling the tilt ram 7 51 Assembling the trim ram 7 53 Assembling the upper case 7 18 Backlash counter rotation model 6 60 Backlash regular rotation model 6 28 Bleeding the PTT unit 7 56 Bleeding the PTT unit built in 7 57 Bottom cowling 8 15 Bracket unit 3 13 Brake animent nus 1 25 Camsha ft siisasiioanmana nine 5 7 Changing the engine oil dr
179. g Contents 1 CD ROM software instruction manual 1 2 Adapter 1 3 Communication cable 1 gt A J Aa aa a E NG on A N AN A ALA SK Dy my A 2 3 pin communication coupler gray S6P29010 9 5 6AL3J 11 YDIS Troubleshooting the power unit Troubleshooting the power unit NOTE Before troubleshooting the outboard motor make sure that fresh fuel of the specified type has been used Check the trouble code using the YDIS or diagnostic flash indicator B first and then check the electronic control system follow the trouble code chart When a three digit trouble code is detected check the data logger of the ECM record data graph as well It is recommended to use the YDIS for troubleshooting it is not enough to check the electronic throttle valve system electronic throttle valve TPS and accelerator position sensor when only using diagnostic flash indicator B If a trouble code is not detected check the power unit according to Troubleshooting the power unit trouble code not detected Before using the YDIS or diagnostic flash indicator B to check the power unit check the ECM cir cuit To check the ECM circuit see Chapter 8 Checking the ECM circuit Be sure to check that the couplers and connectors are securely connected When deleting the diagnosis record on the YDIS be sure to check the time that the trouble codes were detected When checking the input voltage of
180. g the valve 1 Check the valve face Replace if pitted or worn 5 46 2 Measure the valve margin thickness Replace if out of specification S69J5740 Valve margin thickness amp Intake 0 50 0 90 mm 0 020 0 035 in Exhaust 0 90 1 30 mm 0 035 0 051 in 3 Measure the valve stem diameter Replace if out of specification S69J5750 Valve stem diameter Intake 5 477 5 492 mm 0 2156 0 2162 in Exhaust 5 464 5 479 mm 0 2151 0 2157 in 4 Measure the valve stem runout Replace if above specification 5 47 S69J5760 Valve stem runout limit 0 01 mm 0 0004 in Checking the valve guide NOTE Before checking the valve guides make sure that the valve stem diameter is within specifi cation 1 Measure the valve guide inside diameter 69J5770 Valve guide inside diameter Intake and exhaust 5 504 5 522 mm 0 2167 0 2174 in 2 Calculate the valve stem to valve guide clearance as follows Replace the valve guide if out of specification 6AL3 J 11 Valve stem to valve guide clearance valve guide inside diameter valve stem diameter Intake 0 012 0 045 mm 0 0005 0 0018 in Exhaust 0 025 0 058 mm 0 0010 0 0023 in Replacing the valve guide NOTE ar a After replacing a valve guide check the valve seat contact area To check the valve seat contact area see Chapter 5 Checking the valve seat 1 Remove the valve
181. gine stop mode Low oil pressure Intake pressure Battery voltage Engine start mode Engine stop mode with swa IL Accelerator position sensor 1 IL Accelerator position sensor 2 Intake air pressure IL Target TPS voltage This item shows the target output voltage of the TPS This value is the control voltage that the ECM requires to set the target opening angle of the throttle valve 5 Reference TPS voltage This item shows the criterion output voltage of the TPS This value is used to detect the TPS output voltage during engine operation 6 Reference accelerator position sensor voltage This item shows the criterion output voltage of the accelerator position sensor This value is used to detect the accelerator position sensor output voltage when the remote control throttle lever is opened TI Target TPS voltage for Idle Speed Control ECM controls the engine idle speed by using the throttle valve attached to the TPS This target voltage is used by the ECM to achieve the target opening angle of the throttle valve at the engine idle speed 8 Engine stop mode with switch d Main relay ignition coil fuel injector variable camshaft timing ECM low pressure fuel pump high pressure fuel pump 10 Electronic throttle valve relay TI Low engine oil pressure NOTE To display the displays and graphs see the YDIS Ver 1 23a or later Instruction Manual 6AL3 11 9 4 TRBL D SHTG e Troubleshootin
182. gnet 1 3 Stator assembly 1 4 Bolt 4 M6x35mm 5 Collar 2 6 Holder 1 7 Holder 1 8 Bracket 1 9 Crank position sensor 1 10 Screw 2 95 x 12 mm 11 Timing belt 1 12 Timing belt tensioner 1 13 Bolt 2 M10 x 55 mm 14 Washer 2 15 Pulley 2 16 Collar 2 17 Woodruff key 1 6AL3 1 1 5 6 Camshaft 18N m 0 8 kgf m 5 9 ft Ib 8N m 0 8 kgf m 5 9 ft Ib S6AL5060 CO DJ On Un BUN Mm P art name Remarks Not reusable M12 x 35 mm Cap Gasket Union bolt Variable camshaft timing assembly Bolt Driven sprocket Dowel Oil seal Camshaft STBD IN Camshaft STBD EX Valve lifter Valve shim Camshaft cap Bolt with seal washer 4 M7 x 48 mm Bolt 1 M6 x 30 mm Camshaft cap Bolt M7 x 37 mm M10 x 35 mm Not reusable Pre P BB NN NO NO N NO N NO N et gpi 5 7 6AL3J 11 Power unit check and adjustment ny 8N m 0 8 kgf m 5 9 ft Ib We 8 N m 0 8 kgf m 5 9 ft Ib 8 N m 0 8 kgf m 5 9 ft Ib 8N m 0 8 kgf m 5 9 ft Ib Part name Ny 8N m 0 8 kgf m 5 9 ft Ib 17N m 1 7 kgf m 12 5 ft Ib S6AL5060 Remarks 6AL3 11 Gasket S Crew Plate Cylinder head cover STBD Grommet Bolt Bolt Camshaft PORT EX Camshaft PORT IN Camshaft c
183. guide using the special service tool from the combustion chamber side 569J5790 Valve guide remover installer 90890 06801 2 Install a new valve guide using the special service tools from the camshaft side until the valve guide installer to the specified height S6P25E30 6AL3 11 Cylinder head NOTE _ __ Apply engine oil to the outer surface of a new valve guide Z Valve guide remover installer 90890 06801 Valve guide installer 90890 06810 Valve guide installation position Intake and exhaust Gi 13 8 0 2 mm 0 5 0 01 in 3 Insert the special service tool into the valve guide and then ream the valve guide S6AL5420 NOTE ee Apply engine oil to the inner surface of the valve guide e Turn the valve guide reamer clockwise to ream the valve guide Do not turn the reamer counterclockwise when removing the reamer e Be sure to clean the valve guide after ream ing it Valve guide inside diameter Intake and exhaust 5 504 5 522 mm 0 2167 0 2174 in 5 48 Checking the valve seat 1 Eliminate carbon deposits from the valves 2 Apply a thin even layer of Mechanic s blueing dye Dykem onto the valve seat 3 Lap the valve slowly on the valve seat with a valve lapper commercially avail able as shown S69J5840 Valve seat contact width Intake 1 10 1 40 mm 0 043 0 055 in Exhaust S6P25E40 1 40 1 70 mm 0 055 0
184. hanger PORT Bolt Bolt Bolt Cover Anode Grommet Bolt Bolt Bolt Cylinder head PORT Gasket Collar Knock sensor M6 x 40 mm Not reusable M6 x 20 mm M10 x 120 mm T 55 M6 x 20 mm OO k NN On m DO M8 x 40 mm M8 x 55 mm M8 x 90 mm Not reusable kA P k kA 4 P HHP HP HS Ss Loosen completely 5 43 6AL3J 11 Cylinder head m 2 3 kgf m 17 0 ft m 4 5 kgf m 33 2 ft m 2 3 kgf m 17 0 ft m 4 5 kgf m 33 2 ft Ne 14N m 1 4 kgf m 10 3 ft Ib 28N m 2 8 kgf m 20 7 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib Partname Remarks Flushing hose Bolt M6 x 30 mm Cooling water passage cover Gasket Anode Screw 4 x 12 mm Valve cotter Valve spring retainer Valve spring Valve seal Not reusable Valve guide Not reusable Intake valve Exhaust valve Engine hanger STBD Gasket Cylinder head STBD Cooling water pressure sensor adapter hose Loosen completely 6AL3 11 5 44 Exhaust cover Pl 3 N m 0 3 kgf m 2 2 ft Ib NE 14N m 1 4 kgf m 10 3 ft Ib 28 N m 2 8 kgf m 20 7 ft Ib 6N m 0 6 kgf m 4 4 ft Ib Ne 9 14 N m 1 4 kgf m 10 3 ft Ib 28 N m 2 8 kgf m 20 7 ft Ib 55 N m 5 5 kgf m 40 6 ft Ib S6P25780E a Oo DJ On UL RAUNA
185. he PTT motor lead to the holder 7 27 S6AL7580 Self locking nut 22 N m 2 2 kgf m 16 2 ft lb 7 Pass the PTT motor lead and trim sensor lead through the hole in the starboard clamp bracket 8 Fasten the PTT motor lead and trim sen sor lead with the plastic ties and then install the holder S6AL7590 9 Inject grease into all grease nipples until grease comes out from the bushings 6AL3 11 S6AL7600 Adjusting the trim sensor 1 Fully tilt the outboard motor down 2 Measure the trim sensor resistance and note the measurement data S6AL7C10 Trim sensor setting resistance Pink P Black B 102410 3 Fully tilt the outboard motor up and then Support it with the tilt stop lever 6AL3 11 Clamp bracket and swivel bracket S69J7110 After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the PTT unit should lose fluid pressure 4 Loosen the trim sensor screws 5 Adjust the position of the trim sensor and then tighten the trim sensor screws temporarily S6P27820E NOTE e To decrease the resistance turn the trim sensor in direction e To increase the resistance turn the trim sensor in direction 6 Fully tiltthe outboard motor down 7 Measure the trim sensor resistance Repeat steps 3 6 if out of specification
186. he 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 on the side of the propel ler boss O00 0 0 569J 1100 LI I 0 0 wll 66 S6P21100 Propeller diameter in inches Propeller pitch in inches Propeller type propeller mark 1 21 Selection When the engine speed is at the full throttle operating range 5 000 6 000 r min the ideal propeller for the boat is one that pro vides maximum performance in relation to boat speed and fuel consumption Regular rotation model Propeller size in Material 13 3 4 x 17 M2 13 3 4 x 19 M2 133 4x21 M 14 1 2 x 15 14 1 2 x 19 14 1 2 x 21 14 1 2 x 23 14 7 8 x 21 15x17 T 15x21 T 15 1 4 x 15 15 1 4 x 17 15 1 4 x 19 15 1 4 x 19 15 1 2 x 17 Stainless Counter rotation model Propeller size in Material 133 4x17 ML1 13 3 4 x 19 ML1 13 3 4 x 21 ML 141 2x19 TL 141 2x21 TL 14 1 2 x 23 ML 14 7 8 x 21 15x17 TL 15x21 TL 15 1 4 x 15 15 1 4 x 17 15 1 4 x 19 15 1 4 x 19 15 1 2 x 17 Stainless 6AL3J 11 Predelivery check To make the delivery process smooth and efficient the predelivery checks should be completed as explained below Checking t
187. he forward gear e To select the shims see Chapter 6 S him ming regular rotation model GC Bearing outer race attachment D 90890 06658 Driver rod LL 90890 06605 2 Install the needle bearing into the lower case EI ai S6AL6240 6AL3 11 Drive shaftand lower case regular rotation model NOTE Depth Apply gear oil to the needle bearing outer 4 5 0 25 mm 0 18 0 01 in case before installation The needle bearing contains 24 rollers 2 Apply grease to new oil seals and then install them into the drive shaft housing Ball bearing attachment to the specified depth A 90890 06655 Bearing outer race puller assembly 90890 06523 Assembling the forward gear 1 Install a new taper roller bearing into the forward gear using a press 4 S6AL6090 NOTE SE Install an oil seal halfway into the drive shaft housing and then install the other oil seal D Lat Bearing outer race attachment 4 90890 06628 S6AL6A10 Driver rod LS 90890 06606 YO Bearing inner race attachment Depth 4 90890 06659 0 5 0 25 mm 0 02 0 01 in on Wiere ee Installing the drive shaft ge ee ee 1 Install the forward gear into the lower shaft housing to the specified depth ace S6AL6600 Ga Needle bearing attachment 90890 06610 Driver rod SS 90890 06604 6AL3J 11 6 16 Lower unit 2 Install the washer spring thrust bea
188. he fuel system 1 Check that the fuel hoses are securely connected and that the fuel tank is full with fuel S6AS1010 CAUTION This is a 4 stroke engine Never use pre mixed fuel or 2 stroke outboard motor oil Checking the engine oil level 1 Check the engine oil level Fl S6P21020E 6AL3 11 Propeller selection Predelivery check NOTE SS If the engine oil is below the minimum level mark L add sufficient oil until the level is between H and L Recommended engine oil 4 stroke motor oil API SE SF SG SH ST or SL SAE 5W 30 10W 30 or 10W 40 Engine oil quantity Without oil filter replacement 5 6 L 5 92 US qt 4 93 Imp qt Checking the gear oil level 1 Checkthe gear oil level S60C1140 Checking the battery 1 Check the battery capacity electrolyte level and specific gravity of the electro lyte Recommended battery capacity CCA EN 711A 20HR IEC 100 Ah Electrolyte specific gravity 1 280 at 20 C 68 F 2 Check that the positive and negative bat tery cables are securely connected 1 22 an General information Checking the outboard motor mounting height 1 Check that the anti cavitation plate is aligned with the bottom of the boat If the mounting height is too high cavitation will occur and propulsion will be reduced Also the engine speed will increase abnormally and cause the engine to overheat If the mounting height is
189. he pink green P G lead ECM to sub wiring harness to intake air pressure sensor for continuity Intake air passage malfunction Trolling speed is unstable Check the O rings and gaskets of the intake manifold surge tank and throttle body Check the hose between the vapor shut off valve and surge tank Check the throttle valve condi tion Check the intake air pressure sensor hose Check the pressure regulator hose FD Cam position sensor port exhaust 2 Neutral switch 3 Intake air pressure sensor WD See the wiring diagram 6AL3J 11 9 10 TRBL D SHTG e Troubleshooting Trouble code Symptom Remarks Checking steps Oil press sensor malfunction Check the engine oil pressure using the YDIS 2 Measure the input voltage 3 Measure the output voltage Check the pink white P W lead ECM to oil pressure sensor for continuity Measure the engine oil pressure using an oil pressure gauge Engine stop lanyard switch malfunction Engine stalls when running engine Buzzer comes on Check the switch operation using the YDIS 2 Check the clip 3 Check the switch continuity 4 Check the white W lead ECM to 10 pin main harness coupler for continuity Check the black B lead 10 pin main harness coupler to joint connector to ground for conti
190. he propeller shaft 6 9 6 39 Checking the propeller Shaft housing 6 9 6 38 Checking the PTT fluid level 3 13 Checking the PTT motor 7 Checking the PTT operation 3 Checking the PTT rela 7 Checking the PTT switch 7 Checking the PTT system ccc 1 Checking the Rectifier Regulator 8 Checking the remote control cable 1 Checking the reservoir 7 Checking the shift cut switch 8 Checking the spark plug Checking the starter motor 8 Checking the starter motor operation 8 Checking the starter motor pinion 8 Checking the starter relay 8 Checking the stator coll 8 Checking the steering system 1 Checking the thermostat Checking the thermoswitch 01101 8 Checking the throttle valve operation 8 Checking the tilt cylinder and trim cylinder AA 7 Checking the timing bet Checking the timing belt and sprocket 5 24 Checking the top cowling 3 3 Checking the trim sensor 7 60 Checking the valve ceee 5 46 7 51 Checking the valve clearance 5 9 Checking the valve guide 1111 5 47 Checking the valve ter 5 24 Checking the valve seat 5 49 Checking the valve spring c eee 5 46 Checking the vapor separator 4 29 Checking the vapor shut off valve 8 40 Checking the water detection switch 8 37 Checki
191. hrough are aligned 5 19 S6P25180 26 Install the stator assembly 27 Install the Woodruff key then the fly wheel magnet S6AL5690 NOTE e Be sure to remove any grease from the tapered portion of the crankshaft amp and fly wheel magnet lt Apply engine oil to the thread of the fly wheel magnet nut and washer W before installation 6AL3 11 28 Tighten the flywheel magnet nut to the specified torque S6AL5A20 Flywheel magnet nut 240 Nem 24 0 kgf m 177 0 ft lb 29 Check the crank position sensor air gap S6AL5130 NOTE It is recommended to check the crank posi tion sensor air gap before installing the wiring harness guide to improve working efficiency AS Crank position sensor air gap W 1 4 1 6 mm 0 055 0 063 in Crank position sensor screw 4 N m 0 4 kgf m 3 0 ft lb 30 Install the timing belt guides and then adjust the timing belt to timing belt guide clearance 6AL3 11 Power unit check and adjustment 5 S6AL5120 Timing belt to timing belt guide clearance 1 0 0 5 mm 0 04 0 02 in 31 Install the wiring harness guide NOTE eee na To install the wiring harness guide see Chapter 5 Installing the wiring harness 32 Install all parts removed during disas sembly 33 Check that the wiring ha
192. ice tool to the outboard motor as shown S6AL9020 NOTE When performing this diagnosis all of the electrical wires must be properly connected GC Diagnostic flash indicator B 90890 06865 2 Startthe engine and let it idle 3 Check the flash pattern of the special service tool to determine Trouble code indication Example Normal condition no defective part or irregular process ing is found Light on 0 33 second Light off 4 95 seconds 9 17 56D79010 e Trouble code indication Example The illustration indicates code numbers 23 and 113 Light on 0 33 second Light off 4 95 seconds Light off 0 33 second Light off 1 65 seconds Gi Gi Gi S6D79020 mn aoaaa S 6P 29040E 4 Ifa flash pattern listed in the trouble code chartis displayed check the malfunction ing part according to the flash pattern 6AL3 11 Troubleshooting the power unit NOTE e When more than one problem is detected the light of the special service tool flashes in the pattern of the lowest numbered prob lem After that problem is corrected the light flashes in the pattern of the next low est numbered problem This continues until all of the problems are detected and cor rected If a trouble code is detected see Chapter 9 Trouble code and checking step 6AL3J 11 9 18 TRBL D SHTG e Troubleshooting Troubleshooting the power unit trouble code not de
193. ide Gasket Oil strainer Collar Bolt Gasket Dowel Rubber seal Oil pan Gasket Exhaust manifold Bolt M8 x 60 mm Bolt M8 x 35 mm Bolt 4 M8 x 90 mm lt Not reusable Not reusable M6 x 25 mm Not reusable Not reusable kA k k k 4 k DI DI k k k A k kb LA No 7 13 6AL3J 11 Upper case and steering arm PJ 10 N m 1 0 kgf m 7 4 ft Ib 220 N m 2 0 kgf m 14 8 ft Ib ON Dao N m 2 0 kgf m 14 8 ft Ib S6AL7220 Part name Remarks Rubber seal Gasket Plate Pipe Rubber seal Gasket Dowel Muffler Bolt lt Not reusable Not reusable A 4 k k k RPP H KA CH M8 x 35 mm 6AL3J 11 7 14 Bracket unit Removing the upper case 1 Disconnect the ground lead and speedometer hose 2 Remove the upper and lower mounting nuts and then remove the upper case assembly S6AL7230 NOTE eee e It is recommended to drain the engine oil before removing the upper case lt Be sure to remove the shift rod assembly before removing the upper case assembly from the clamp bracket Disassembling the upper case 1 Remove the engine oil drain bolt cover and damper T S69J7025 NOTE If the engine oil has not already been drained place a drain pan under the drain hole before removing the engine oil drain bolt 7 15 2 Remove the upper mounts and lower mounts from the upper cas
194. ide reamer 90890 06804 ZN Valve seat cutter holder 90890 06316 Valve seat cutter Q 90890 06324 90890 06325 90890 06326 90890 06816 90890 06817 Bearing inner race attachment 90890 06640 90890 06659 90890 06661 D Driver rod L3 90890 06652 aa General information 2 Needle bearing attachment 90890 06607 90890 06610 90890 06611 90890 06612 90890 06613 90890 06653 90890 06654 Piston ring compressor 90890 05158 Bearing housing puller claw L 90890 06502 Stopper guide plate 90890 06501 j Center bolt 90890 06504 Bearing separator 90890 06534 Stopper guide stand 90890 06538 Bearing puller assembly 90890 06535 Slide hammer 90890 06531 Bearing outer race puller assembly 90890 06523 6AL3J11 Special service tool Outer race puller claw A Bearing outer race attachment 90890 06532 90890 06622 90890 06628 90890 06658 Driver rod SS Drive shaft holder 6 90890 06604 90890 06520 Q A Bearing depth plate Pinion nut holder 90890 06603 90890 06715 Ball bearing attachment Ball bearing attachment 90890 06656 90890 06657 90890 06655 Driver rod LS Driver rod LL 90890 06606 90890 06605 6AL3J11 1 10 an General information lt Shift rod push arm 90890 06052 Pinion height gauge 90890 06710 Digital caliper 90890 06704 Shimming plate 90890 06701 Backlash indicator 90890 06706 M
195. ied 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 oth erwise the oil seals may be damaged 3 15 6AL3 11 Lower unit General NOTE SE Cover the check hole with a rag when remov ing the tester from the lower unit ZX Lower unit holding pressure 70 kPa 0 7 kgf cm 10 psi 3 Ifthe specified pressure cannot be main tained check the drive shaft propeller shaft and shift rod oil seals for damage If necessary check each shaft for bends and damage S6P23270E Checking the propeller 1 Check the propeller blades and splines Replace the propeller if cracked dam aged or worn General Checking the anode 1 Check the anodes and trim tab Clean the anodes or trim tab if there are scales grease or oil S6P23210 SS SNA NOS X SAN E S6AL3050 S6P23310E 6AL3 11 3 16 CHK Q ADJ Periodic check and adjustment S69J3600 S69J3610 CAUTION Do not oil grease or paint the anodes or the trim tab otherwise they will be ineffec tive NOTE If itis necessary to disassemble the outboard motor to check an anode refer to the applica ble disassembly procedure in this manual 2 Replace the anodes or trim tab if exces sively eroded In addition check the ground lead Checking the battery 1 Check the battery electrolyte level If
196. ification Item Model 200 L 225R Dimension Overall length Overall width Overall height X U Boat transom height X U 892 35 1 634 25 0 1 829 72 0 1 956 77 0 635 25 0 762 30 0 Weight with stainless propeller X U 278 0 613 284 0 626 Performance Maximum output Full throttle operating range Maximum fuel consumption Engine idle speed kW hp r min L US gal Imp gal hr r min 147 1 200 at 5 500 r min 165 5 225 at 5 500 r min 5 000 6 000 68 0 18 0 15 0 at 78 0 20 6 17 2 at 6 000 r min 6 000 r min 600 700 Power unit Type Cylinder quantity Total displacement Bore x stroke Compression ratio Control system Starting system Fuel system Ignition control system Advance type Maximum generator output Spark plug Firing order Cooling system Exhaust system Lubrication system 2 1 cm cu in mm in 4 stroke DOHC V6 3 352 204 5 94 0 x 80 5 3 70 x 3 17 9 9 Remote control Electric Fuel injection TCI Micro computer 12 46 LFR6A 11 NGK 1 2 3 4 5 6 Normal operation Water Propeller boss Wet sump 6AL3 11 General specification Item Unit ie 200 R 200 L 225R 225 L Fuel and oil Fuel type Regular unleaded gasoline Engine oil 4 stroke motor oil Engine oil grade AP
197. ignition spark can also be checked using the Stationary test of the YDIS 5 Install the ignition coils 6AL3 11 6 Install the ECM cover NOTE Connect the injector couplers Checking the ignition coil input voltage 1 Disconnect the ignition coil coupler 2 Turn the engine start switch to ON and then measure the input voltage at the ignition coil coupler wiring harness end Check the wiring harness if below specifi cation lt E BE og la Le E ES fe Co j ey Si S6AL8440 Ignition coil input voltage Red yellow R Y Black B 12 V battery voltage 3 Turn the engine start switch to OFF 4 Connectthe ignition coil coupler Checking the crank position sensor 1 Remove the flywheel magnet cover 2 Disconnect the crank position sensor coupler 8 18 evec ELEC m Electrical system 3 Connect the test harness 2 pins to the crank position sensor and then measure the crank position sensor out put peak voltage S6AL8065 CAUTION Check that the wiring harness does not interfere with the flywheel magnet NOTE e If measuring the sensor output peak volt age under the cranking and unloaded conditions disconnect the coupler e If measuring the sensor output peak volt age under the cranking and loaded con ditions re
198. ilt ram end in a vise using alu minum plates on both sides 6 Remove the bolt and then remove the piston absorber valves S6AL7810 NOTE Be sure to keep original shim s 7 Hold the tilt piston in a vise using the special service tool on both sides 8 Remove the tilt piston from the tilt ram assembly 6AL3 J 11 Tilt cylinder and trim cylinder 12 Drain the PTT fluid 13 Remove the circlip op adapter and spring from the trim pistons B oO OG S6AL7850 S6AL7820 GC PTT piston vice attachment D 90890 06572 Tilt rod wrench 90890 06569 9 Hold the PTT body in a vise using alu minum plates on both sides S6AL7830 10 Loosen the trim cylinder end screws and then remove them S6AL7840 Z Cylinder end screw wrench 90890 06568 11 Remove the trim ram assemblies 6AL3 11 7 50 Bracket unit Checking the tilt cylinder and trim cylinder 1 Check the PTT body and tilt cylinder Replace the PTT body or tilt cylin der if cracked or if there is corrosion 2 Check the inner surface of the PTT body and tilt cylinder Replace the PTT body or tilt cylinder if scratched 3 Check the outer surface of the tilt piston trim piston adapter free piston and dust seals of end screw Replace the tilt piston trim piston adapter free piston or dust seals if scratched 4 Check the trim r
199. inannasmetdarovsisnn sv 7 25 Kemner Tut Sn RAR ine ne Re en Nr tree 7 27 Adjusting the trim SES ULA ad 7 28 ET NR TE GA 7 30 Checking the hydraulic pressure ragsanssmernanlsdrn dn verba 7 32 PIT TR 7 35 Disassembling the PTT motor anane a anana aana nne nne anane 7 36 Checking the PTT mobhkusuramasmmienssaarnaigsvindrnvtonndm ess 7 36 CHECKING the TEE 7 37 Assembling the PTT MOD annees uen 7 38 Gear PIMP E 7 40 Disassembling the gear pump fice cared ddr meer anana ios Seca ee 7 43 Checking the gear pump ss 7 43 Checking the gear pump housing ss 7 44 CHECKING the ee EEN 7 44 CHECKING he MST aranana aaa aaa ann Mamans 7 44 Assembling the gear UM enadennennn said eegene 7 44 6AL3 11 Tilt cylinder and trim cylinder msssvvvrnnnvvvnnnnnnnvvnnnnnnnvevnnnnvnnennnnnvvnnnnnnnvevnnnner 7 47 Disassembling the tilt cylinder and trim cylinder scc 7 49 Checking the tilt cylinder and trim cylinder kk 7 51 Checking the valve Lee 7 51 Assembling the tilt AMIS at ees cre ne nee true 7 51 Assembling the trim Ne EE 7 53 Installing the tilt cylinder zh nadia breddene 7 53 Installing the trim TOME OE A qe ner RS rer 7 53 Installing the PIT MOOT sas rarai Gan nn GEN Na NGANAN Na EN apa 7 54 Installing the reservoir Essen nn de hrs nid sr oi sodas eder 7 55 Installing the tiltram sasae inner NEE 7 55 Bleeding the PTT UMt eege eti 7 56 Bleeding the PTT unit built in cecceeteeesseseeessssseeesseeeeeseeeneeesas 7 57 PTT electrica
200. ing nut of the through tube then clamp brackets and o 2 Remove the trim sensor lt S6AL7480 NOTE Be sure to remove the ground lead before removing the self locking nut 3 Remove the spring holder and pins ANG SE Kr S6AL7490 4 Remove the tilt stop levers distance collar o collar d and bushings d Sy S6AL7500 Installing the clamp bracket 1 Assemble the distance collar S6AL7510 NOTE SE Make sure that the distance shown is 30 3 30 4 mm 1 19 1 20 in 2 Install the bushings collar distance collar and tilt stop levers S6AL7520 S6AL7525 6AL3 11 NOTE Be sure to install the distance collars and tilt stop levers so that they are facing in the directions shown 3 Install the pins holder and spring NOTE ee a Make sure that the end of each pin is longer than the end 4 Install the trim sensor onto the star board clamp bracket S6AL7545 NOTE ee e It is possible to install and remove the trim sensor even after the clamp bracket assembly is installed e Adjust the trim sensor after installing the PTT unit To adjust the trim sensor see Chapter 7 Adjusting the trim sensor 5 Install the friction plates onto the clamp brackets then install the bush ings washers 2 and then assemble the clamp brackets and the swivel bracket
201. installing the lower unit with the power unit installed be sure to suspend the outboard motor If the outboard motor is not suspended it can fall suddenly and result in severe injury 1 Align the center of the set pin with the alignment mark on the bottom cowling to set the shift lever to the neutral posi tion NOTE If the power unit is installed the set pin and alignment mark cannot be aligned so align the set pin with the alignment mark on the shift bracket 2 Set the gear shift to the neutral position atthe lower unit 6 50 Lower unit 3 Install the dowels into the lower unit 4 Install the lower unit into the upper case and then tighten the lower case mounting bolts to the specified torque 5 Install the trim tab to its original posi tion and then tighten the bolt to the specified torque S6AL6890 Lower case mounting bolt 47 N m 4 7 kgf m 34 7 ft lb Trim tab bolt 42 N m 4 2 kgf m 31 0 ft lb 6 Install the propeller and propeller nut and then tighten the nut temporarily Place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then tighten the nut to the specified torque 6 51 S6AL6A50 S69J6540 WARNING e Do not hold the propeller with your hands when loosening or tightening it lt Be sure to disconnect the battery cables from the battery and the clip from the engi
202. ion of each bearing into the slots in the connecting rod cap and con necting rod 3 Puta piece of Plastigauge PG 1 onto the crankpin parallel to the crankshaft S69J5D00 NOTE re ne Be sure not to put the Plastigauge PG 1 over the oil hole in the crankpin of the crank shaft 4 Install the connecting rod onto the crank pin 6AL3 11 Cylinder block Connecting rod cap bolt 1st 23 N m 2 3 kgf m 17 0 ftlb 2nd 43 Nem 4 3 kgf m 31 7 ft lb 3rd 90 6 Remove the connecting rod cap and measure the width of the compressed Plastigauge PG 1 on each crankpin Replace the connecting rod bearing if out of specification S6AL5B20 NOTE Make sure that the marks of the connect S69J5D30 ing rod face toward the flywheel magnet end of the crankshaft Crankpin oil clearance 0 028 0 066 mm 0 0011 0 0026 in 5 Tighten the connecting rod cap bolts to the specified torques in 3 stages Selecting the connecting rod bearing 1 When replacing the connecting rod bear ing select the suitable bearing as fol lows S69J5D20 NOTE e Reuse the removed connecting rod cap bolts when checking the oil clearance Do not turn the connecting rod until the crankpin oil clearance measurement has been completed lt In the 3rd stage make a mark on the connecting rod cap bolts and connecting rod caps and then tighten the bolts 90 from the mark 6AL3J 11 5 66
203. ion height 2 0 mm 0 08 in 20 Check that belt position marks through are aligned with each alignment mark on the drive sprocket and driven sprock ets and then remove the pin S6AL5330 6AL3 11 Power unit check and adjustment 21 Turn the crankshaft clockwise 2 full turns and then check that alignment marks through are aligned NOTE Apply sealant to the edge of the cylinder head cover gasket before installation e Tighten the cylinder head cover bolts to the same torque in both stages e See the exploded diagram 5 7 Cylinder head cover bolt 1st 8 N m 0 8 kgf m 5 9 ft lb 2nd 8 N m 0 8 kgf m 5 9 ft lb 23 Install the timing belt guides 4 and then adjust the timing belt to timing belt guide clearance S6P25725 NOTE gt y After installing the timing belt check the valve clearances To check the valve clear ance see Chapter 5 Checking the valve clearance 22 Install the cylinder head covers and then tighten the bolts to the specified torque in 9 2 stages S6AL5390 NOTE ee If the valve clearances are adjusted or any parts related to valve movement are replaced after installing the timing belt check the valve clearances To check the valve clearance see Chapter 5 Checking the valve clear ance Timing belt to timing belt guide clearance Q 1 0 0 5 mm 0 04 0 02 in 6AL
204. ion of the throttle cable joint until its hole is aligned with the set pin on the accelerator lever 0 com CT S6AL3110 A WARNING The throttle cable joint must be screwed in a minimum of 8 0 mm 0 31 in 6AL3 11 Power unit Control system Checking the gear shift operation 1 Check that the gear shift operates smoothly when shifting it from the neutral position to forward or reverse Adjust the shift cable length if necessary NOTE TT TT TL Pull the throttle cable towards the engine to remove any free play in the cable before adjusting the position of the throttle cable joint 2 Check the neutral switch for continuity 5 Connect the throttle cable joint install Adjust the shift cable length or check the the clip and then tighten the locknut neutral switch if necessary OI NOTE o To check the neutral switch see Chapter 8 Checking the neutral switch Lead color Blue green L G Gear shift position Black B Forward or reverse Neutral i S6P23350 6 Operate the remote control lever several times and then check that the mark 3 Setthe gear shiftto the neutral position on the accelerator lever has passed the mark on the fully closed stopper 4 Loosen the locknut remove the clip when the remote control lever is in the and then disconnect the shift cable fully open position of the throttle
205. ir mounting bolt M8 19 1 9 14 0 PTT motor mounting bolt M8 19 1 9 14 0 Reservoir cap M12 7 0 7 5 2 Manual valve 2 0 2 1 5 Pipe joint 15 1 5 Pipe jointadapter 20 2 0 Gear pump bolt M5 7 0 7 Gear pump bracket bolt 7 0 7 Trim cylinder end screw 16 0 Tiltram 55 5 5 Tiltcylinder end screw 90 9 0 Tilt piston bolt General torque 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 man ual To avoid warpage tighten multi fastener assemblies in a crisscross fashion and pro gressive stages until the specified torque is reached Unless otherwise specified torque specifications require clean dry threads Components should be at room temperature General torque specifications N m kgfm ftlb 5 0 5 3 7 8 0 8 5 9 18 1 8 13 3 36 3 6 26 6 43 4 3 31 7 S69J2150 2 17 7 0 7 6AL3 11 CHK ADJ 6AL3 11 Periodic check and adjustment Maintenance interval chart ss 3 1 TOP COMING uansett ane NG YANA tonne anse de 3 3 Checking the top cowlingsnuuannarnnm aana ann imdsregynieinn 3 3 Fuel SYSTEM need ren ed Ee ae tn a dd nat restau dent 3 3 Checking the fuel joint and fuel hose fuel joint to
206. iven sprocket and camshaft and Installing the camshaft driven sprocket and timing belt 1 Reduce the fuel pressure NOTE Ei To reduce the fuel pressure see Chapter 4 Reducing the fuel pressure 2 Remove the flywheel magnet cover and ECM cover 3 Remove the blowby hose 4 Disconnect the ignition coil couplers cam position sensor couplers and knock sensor coupler 5 Remove the speed sensor coupler from the bracket 6 Remove all ignition coils and spark plugs 7 Remove the ECM bracket bolts then the ECM bracket 8 Remove the timing belt guides 5 15 S6AL5140 9 Turn the flywheel magnet clockwise and align the ITDC mark on the flywheel magnet with the pointer 10 Check that the Il marks on the port driven sprockets are aligned and check that the I marks on the starboard driven sprockets are aligned S6P25100 11 Remove the wiring harness guide 6AL3 11 S6AL5160 NOTE To remove the wiring harness guide see Chapter 5 Removing the wiring harness 12 Loosen the flywheel magnet nut S6AL5A10 CAUTION Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily NOTE Use a 36 mm Socket wrench to loosen the fly wheel magnet nut Flywheel holder 90890 06522 13 Remove the flywhee
207. joint ne er as S 6P 23360 ae 6P23370 7 Check that the accelerator lever con tacts the fully closed stopper when the remote control lever is in the fully closed position 8 Check the throttle cable for smooth oper ation and if necessary repeat steps 2 7 6AL3 11 3 12 E ADJ Periodic check and adjustment 5 Align the alignment mark on the bush ing and alignment mark on the bracket S6P23260 6 Adjust the position of the shift cable joint until its hole is aligned with the set pin SLI S6AL3120 WARNING The shift cable joint must be screwed ina minimum of 8 0 mm 0 31 in 7 Connect the cable joint install the clip and then tighten the locknut 8 Check the gear shift for smooth operation check the operation of the neutral switch and if necessary repeat steps 3 7 Bracket unit Checking the PTT 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 PTT fluid level if necessary S6P23190 NOTE ae Be sure to listen to the winding sound of the PTT motor for smooth operation 2 Fully tilt the outboard motor up and then support it with the tilt stop lever to check the lock mechanism ofthe lever S69J3500 Checking the PTT fluid level 1 Fully tilt the outboard motor up and then Suppor
208. king the timing belt CAUTION Do not turn the flywheel magnet counter clockwise otherwise the water pump impeller may be damaged 1 Remove the flywheel magnet cover 2 While turning the flywheel magnet clock wise check the interior and the exte rior of the timing belt Replace the timing belt if cracked damaged or worn S6P23100 NOTE To replace the timing belt see Chapter 5 Replacing the timing belt Checking the spark plug 1 Remove the ECM cover 6AL3 11 remove the spark plugs S6P23110 Clean the electrodes with a spark plug cleaner or wire brush Replace the spark plug if necessary S69J3190 Check the electrodes for erosion and excessive carbon or other deposits and the gasket for damage Replace the spark plug if necessary 3 8 CHK Q ADJ Periodic check and adjustment 5 Check the spark plug gap Gi Adjust the spark plug gap if out of specification JKT S69J3200 Specified spark plug LFR6A 11 NGK S park plug gap 1 0 1 1 mm 0 039 0 043 in 6 Install the spark plugs tighten them tem porarily then to the specified torque using a spark plug wrench Spark plug 25 N m 2 5 kgf m 18 4 ft lb 7 Install the ignition coils Ignition coil bolt 7 N m 0 7 kgf m 5 2 ft lb 8 Install the ECM cover Checking the thermostat 1 Reduce the fuel pressure NOTE To reduce the fuel pressu
209. l magnet and Woo druff key 6AL3 11 Power unit check and adjustment S6AL5A00 S6P25E00 CAUTION To prevent damage to the engine or tools screw in the puller set bolts evenly and completely so that the flywheel puller is parallel to the flywheel magnet NOTE E Apply force to the crankshaftend until the fly wheel magnet comes off the tapered portion of the crankshaft Flywheel puller 90890 06521 5 16 14 Remove the stator assembly bolts and then move the stator assembly S6AL5110 15 Check that the A mark on the drive sprocket and the A mark on the cyl inder block are aligned 16 Check that the Il marks on the port driven sprockets are aligned and check that the I marks on the starboard driven sprockets are aligned S6P25180 17 Turn the timing belt tensioner gradually clockwise using a hexagon wrench and then insert a 55 0 mm 0 2 in pin into the hole 5 17 S6AL5A30 NOTE EE Leave the pin inserted into the hole of the timing belt tensioner until the timing belt is installed again 18 Remove the timing belt from the driven sprockets then from the drive sprocket 19 Check that the A mark on the drive sprocket and the A mark on the cyl inder block are aligned 20 Check that the Il marks on the port driven sprockets are aligned a
210. l system Intake manifold bolt M6 1 0 1 4 Intake silencer bolt M6 0 7 5 2 Electronic throttle valve assembly nut 1 3 9 6 Throttle damper plate bolt M8 1 3 9 6 Canister mounting bolt M6 0 5 3 7 Canister bracket bolt M6 0 5 3 7 Vapor shut off valve mounting nut 0 5 3 7 Intake air pressure sensor bolt M6 0 5 3 7 Fuel filter assembly bolt M6 0 6 4 4 Filter cup 0 5 3 7 Low pressure fuel pump cover bolt M6 0 9 6 6 Check valve holder screw r gt A Fuel cooler bolt UT U1 WH UT OM OT UT OFF UT N Pressure regulator screw Fe k Float chamber cover screw M4 0 2 1 5 NIN Float chamber cover inner plate screw M4 0 2 1 5 Float pin screw M4 gt S gt Vapor separator drain screw N Power unit Ignition coil bolt M6 0 7 5 2 Spark plug Cooling water pressure sensor adapter plug 2 5 18 4 Cam position sensor bolt Flywheel magnet nut Crank position sensor screw Timing belt tensioner bolt Timing belt pulley bolt Variable camshaft timing cap Variable camshaft timing bolt Driven sprocket bolt Cylinder head cover plate screw Camshaft cap bolt Cylinder head cover bolt P ower unit mounting bolt Apron bolt Upper case cover bolt PTT motor lead bolt P o
211. l system ssssssussnnssnnnnnnnnnnnnnnnnnnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnana 7 58 CHECKING th EE 7 58 Checking tie EE nn ir pts ner Sa 7 58 Checking ME PTT switch aus deed ege anana datter 7 59 CHECKING the tim SENSOR asked anbe narr 7 60 6AL3 11 Bracket unit Shift rod and bottom cowling 2N m 0 2 kgf m 1 5 ft Ib 1N m 0 1 kgf m 0 7 ft Ib 18 N m 1 8 kgf m 13 3 ft Ib el 2 N m 0 2 kgf m 1 5 ft Ib GN m 1 8 kgf m 13 3 ft Ib NE Del 5 N m 0 5 kgf m 3 7 ft Ib S6AL7010 a CO CDJ On Un P DU NN Hm P art name Remarks Bracket Shift cut switch Bracket Neutral switch Screw Plate Spring Bushing Grease nipple Shift bracket bolt Bolt Clamp Screw Plate Clip Bushing Washer 94 x 16 mm M6 x 35 mm 4 x 16 mm A k A k NRBR NRBR N k k kA k k k H 7 1 6AL3 11 Shift rod and bottom cowling Sel 2 N m 0 2 kgf m 1 5 ft Ib S 1 N m 0 1 kgf m 0 7 ft Ib 7 02 5ft Ib 4 18 N m 1 8 kgf m 13 3 ft Ib N m O2kgf m 1 5 ft lb he 18 N m 1 8 kgf m 13 3 ft Ib NE Del 5 N m 0 5 kgf m 3 7 ft Ib S6AL7010 P art name Remarks Not reusable M6 x 30 mm Shift lever Cotter pin Bushing Bolt Bracket Ball Spring Bolt Shift rod O ring Grommet Screw Flushing hose joint adapter Hose joint gasket Ho
212. le Clon sr nn de devil 1 21 Self protection sesane ranenena nean nen anan 1 4 Serial number 1 6 Shift rod and bottom cowling 1 7 1 SAIMMING sexes Ka Tah aan a wek e agan 6 23 6 54 Shimming counter rotation model 6 53 Shimming regular rotation model 6 22 Special service tool 1 7 Specified torque 2 14 Starboard view 8 4 8 10 Starter motor 5 35 8 42 Starting system 8 40 Stator assembly 5 6 SYMBOL EEE ER 1 2 U V E TEE 1 25 Throttle body 4 13 Tightening Toroue 2 14 Tilt cylinder and trim cylinder sss 7 47 TOP COWIING agan ewes ANS 3 3 Top view airia aiaia 8 7 8 14 Trouble code and checking step 9 9 Troubleshooting the lower unit 9 25 Troubleshooting the power unit 9 6 Troubleshooting the power unit trouble code not detected 9 19 Troubleshooting the power unit using the diagnostic flash indicator 9 17 Troubleshooting the power unit using the DIS 9 6 Troubleshooting the PTT unit 9 24 Upper case and Steering arm 7 10 Vapor gas NOSE mnnnarrrvrvrrrrrrrrrrrrnrnrrrnnnnnn 4 2 Vapor separat 4 26 Variable camshaft timing control system 8 34 VE Dale ebe aa ter ns 1 4 W Water separator anana 1 14 Wiring harness routing ecer 8 8 Y NDI Sasabana ag anaa ka naa naa kaanan ees eh 9 1 6AL3 11 Index Wiring diagram Grey Whale 200 Fin
213. ler wiring harness end Check the wiring harness if out of specification S6AL8400 Neutral switch input voltage reference data Blue green L G Black B 4 75 5 25 V 8 24 evec ELEC ES Electrical system 4 Turn the engine start switch to OFF 5 Disconnect the test harness 2 pins from the neutral switch coupler wiring harness end and connect it to the neu tral switch coupler neutral switch end 6 Check the neutral switch for continuity Replace if there is no continuity at posi tion S6AL8410 Lead color Blue green L G S witch position Black B Free Gi Push O O 7 Disconnect the test harness 2 pins from the neutral switch coupler blue and then connect the neutral switch cou pler blue Checking the knock sensor 1 Disconnect the knock sensor coupler and connect the tester leads to the sen sor coupler and ground 8 25 S6AL8530 2 Measure the knock sensor resistance Check the installation ground state of the knock sensor if out of specification NOTE TL To check the installation of the knock sensor the cylinder head must be removed Knock sensor resistance 504 616 kQ 3 Disconnectthe tester leads from the sen sor coupler and ground and connect the knock
214. ll the oil filler cap and oil dipstick and then start the engine and warm it up for 5 minutes 7 Turn the engine off and then check the oil level and that there is no oil leakage If the oil level is low add engine oil to the correct level Changing the engine oil draining 1 Start the engine warm it up and then turn it off 2 Remove the oil dipstick and oil filler cap OD 6AL3 11 Fuel system Power unit S6P23060 4 Place a drain pan under the drain hole and then remove the engine oil drain bolt and let the oil drain completely S69J3130 NOTE Be sure to clean up any oil spills 5 Install the engine oil drain bolt and then tighten it to the specified torque Engine oil drain bolt 27 N m 2 7 kgf m 19 9 ft lb 3 6 CHK Q ADJ Periodic check and adjustment 6 Pour the specified amount of the recom mended engine oil into the oil filler hole Recommended engine oil 0 4 stroke motor oil API SE SF SG SH SJ or SL SAE 5W 30 10W 30 or 10W 40 Engine oil quantity ER Without oil filter replacement e 5 6 L 5 92 US qt 4 93 Imp qt S6AL3030 7 Install the oil filler cap and oil dipstick and then start the engine and warm it up for 5 minutes NOTE e Wait more than 5 minutes after turning the engine off to replace the oil filter e Be sure to clean up any oil spills 8 Turn the engine off and then check the oil level and that ther
215. ller bearing and the bearing outer race into the propel ler shaft housing using a press S6AL6830 NOTE After installing the taper roller bearing and bearing outer race check that the propeller shaft rotates smoothly Ring nut wrench 90890 06578 5 Install the propeller shaft housing assem bly in the reverse direction into the lower case 6AL3 11 Propeller shaft housing counter rotation model S6AL6410 Hw S6AL6370 NOTE ee To prevent damage to the parts when install ing the propeller shaft housing assembly in the reverse direction use flangeless bolts M8 x 30 mm without washers 6 Install the claw washer and ring nut and then tighten the ring nut to the specified torque S6AL6420 Ring nut 108 N m 10 8 kgf m 79 7 ft lb 6 40 Lower unit 7 Install the original shim s forward gear 4 and dog clutch using a press S6AL6430 NOTE e Be sure to select the forward gear shim s if replacing the propeller shaft housing taper roller bearing or lower case e To select the shims see Chapter 6 S him ming counter rotation model Install the dog clutch with the F mark facing toward the forward gear e After installing the forward gear check that the propeller shaft and forward gear rotates smoothly Ring nut wrench 90890 06578 8 Install the shift plunger and slider into the propeller shaft and then ins
216. lts S6AL6B20 Disassembling the propeller shaft housing 1 Remove the reverse gear and reverse gear shim s S6AL6980 3 Remove the propeller shaft housing and then remove the propeller shaft S6AL6050 S6AL6660 X Bearing separator D 90890 06534 7 Stopper guide plate 90890 06501 NOTE Stopper guide stand Before removing the propeller shaft from the 90890 06538 lower case remove the shift rod Bearing puller assembly Eee Se 90890 06535 6AL3 11 6 8 Lower unit 2 Remove the ball bearing 56516390 CAUTION Do not reuse the bearing always replace it with a new one Ko Slide hammer 90890 06531 d Bearing outer race puller assembly 90890 06523 3 Remove the oil seals and needle bear ing i Liat af N 2 S6AL6670 Needle bearing attachment D 90890 06611 Driver rod L3 90890 06652 Checking the propeller shaft housing 1 Check the water pipe Replace the water pipe if corrosion deformation or cracked 2 Clean the propeller shaft housing and then check it Replace the propeller shaft housing if cracked or damaged 3 Check the teeth and dogs of the reverse gear Replace reverse gear if cracked or worn 6 9 4 Check the bearings Replace the bear ings if pitted or if there is rumbling Checking the propeller shaft 1 Check the propeller shaft Replace the propeller shaft if bent or worn 2 Measure th
217. ly 7 Check the water detection switch for con tinuity with the float in positions A and B Replace the fuel filter cup assembly if out of specification 6AL3 11 Variable camshaft timing control system Fuel control system S6AL8781 NOTE ME e Before checking the water detection switch make sure that the float is able to move to positions A and B as shown e Be sure not to remove the clip and float otherwise the water detection switch may be damaged Float height Water detection position amp 30 mm 1 18 in Lead color Black B Black B oO o 8 Install the fuel filter cup assembly and connect the water direction switch cau pler blue NOTE TT TT Do not twist the water detection switch lead when installing the fuel filter cup assembly 6AL3J 11 Checking the fuel injector 1 Check the operation of the fuel injectors using the Stationary test of the YDIS and listen for the operating sound 2 Disconnectthe fuel injector couplers 3 Turn the engine start switch to ON and then measure the input voltage between the fuel injector coupler terminal and ground Check the wiring harness if below specification be S6AL8600 Fuel injector input voltage Red yellow R Y Ground 12 V battery voltage 4 Turn the engine start switch to OFF 5 Measure the fuel injector
218. maged 2 Install a new gasket and the oil filter bracket and then tighten the bolts in the sequence shown 5 75 S6AL5870 NOTE Ss Apply engine oil to the oil filter bracket bolts before installation 3 Supply engine oil to the oil passage of the oil filter bracket S6AL5520 4 Install the oil filter and then tighten it to the specified torque using a 72 5 mm 2 9 in oil filter wrench S6AL5880 NOTE Apply a thin coat of engine oil to the O ring of a new oil filter before installation 6AL3 11 Oil filter wrench 90890 06830 Oil filter 18 N m 1 8 kgf m 13 3 ft lb Installing the wiring harness NOTE a e To install all of the wiring harnesses see Chapter 8 Wiring harness routing lt Perform this procedure after assembling the power unit 1 Fasten the cooling water hose vapor gas hoses and check valve using the holder as shown S6AL5890 2 Install the cooling water passage cover and cylinder heads NOTE TT To install the cooling water passage cover and cylinder heads see Chapter 5 Installing the cooling water passage cover and Installing the cylinder head 3 Install the sensors and switches that were removed to the power unit 6AL3 11 Cylinder block NOTE ey For the location of the sensors and switches see Chapter 8 Electrical component 4 Install the engine temperature sensor lead into
219. mbers Crank position sensor Ls Fuel injector 1 mm d 69 F R Fuel injector 2 p 60 eyy 15 Fuel injector 3 68 Kg Cam position sensor 7 Euel injector TON PORT EX 67 4 Fuel injector 5 66 OO e Cam position sensor PORT IN ER Fuel injector 6 65 Ko Cam position sensor STBD IN Y Ignition coil 1 k ra 5V 6 us H E Dor 1 sa A TPS 1 45 7 Ignition coil 2 1 TPS 2 0 je H tr Ground Oh A a et ne Ignition coil 3 Ge Accelerator L position sensor 1 5V 6 v ECM t Ignition coil 4 62 J Accelerator SN h osition sensor 2 Ignition coil 5 p 5V 44 9 4 9 Lux G d D M roun 69 6 4 7 Ignition coil 6 p E pk Intake air pressure sensor V 63 H OR TT Hu Oil pressure Electronic throttle sensor 6 valve relay e a eg Cooling water G pressure sensor 62 ga EEE 83 Electronic throttle 6T valve Speed sensor OI motor e 84 7T ns Ode 1 19 S6P21130C 6AL3 11 Feature and benefit OG OO BB Intake air temperature Oil c
220. move the clip from the engine stop lanyard switch to prevent the engine from starting e Check the crank position sensor air gap and the condition of the projection on the flywheel magnet if below specification Z Test harness 2 pins 4 90890 06867 Peak voltage adapter B 90890 03172 Crank position sensor output peak voltage White red W R Black B Unloaded Loaded Cranking 1 500 3 0 2 7 14 5 8 19 4 Measure the crank position sensor resis tance NOTE Ti Disconnect the test harness coupler but leave the harness connected to the crank position sensor Crank position sensor resistance reference data White red W R Black B 396 594 Q Checking the crank position sensor air gap 1 Remove the wiring harness guide bolts and lift up the wiring harness guide NOTE Ge To completely remove the wiring harness guide when checking the air gap see Chap ter 4 Reducing the fuel pressure and Chap ter 5 Removing the wiring harness 2 Turn the flywheel magnet clockwise to align the projection on the flywheel magnet with the crank position sensor projection 3 Measure the crank position sensor air gap Adjust if out of specification Crank position sensor air gap 1 4 1 6 mm 0 055 0 063 in 4 Loosen the crank position sensor screws and adjust the crank position sensor air gap
221. n S6AL8150 NOTE gt e Check the TPS after the engine has been warmed up e When checking the TPS using the YDIS do not start the engine e The actual TPS output voltage and throttle valve opening angle may vary according to environmental conditions and engine tem perature TPS output voltage and throttle valve opening angle reference data Remote control lever position Fully closed Fully open 0 750 V TPS 1 20 ec 68 F Item 4 550 V eg at20 68 F Above 39 8 Throttle F L 200C valve opening angle Above 53 8 F L 225B 5 Operate the remote control lever and check that the output voltages of TPS 1 and TPS 2 change continuously 6 Turn the engine start switch to OFF 8 32 evec ELEC Ea Electrical system 7 Disconnect the electronic throttle valve coupler 8 Measure the electronic throttle valve motor resistance between the terminals and S6AL8170 CAUTION Do not loosen the throttle stop screw nut and do not turn the throttle stop screw Electronic throttle valve motor resistance Terminal Terminal amp reference data 1 23 1 67 Q at 20 30 C 68 86 F 9 Connectthe electronic throttle valve cou pler Checking the electronic throttle valve and TPS circuit 1 Disconnect the ECM couplers and 2 Disconnect the electronic throttle v
222. na aan anan 8 34 Checking the oil control valve NN 8 36 6AL3 11 Fuel control system sers nt etant teen nenneiaandte tentant 8 37 Checking the water detection switch 8 37 Checking the fuel Injector ad are 8 38 Checking the low pressure fuel pump and high pressure fuel pump 8 39 Checking the high pressure fuel pump relay 8 39 Checking the vapor shut off valve sssssisrirsirsrisrirsirrsiesinsinsrrerrerrisrrns 8 40 Starting System siasat sasabana nt nn de ane dt ti mere ins GANGGA 8 40 Checking the TSG ua 8 40 RV Leen 8 41 Starter motOr nissan 8 42 Removing the starter FOE ege annee entame ain 8 44 Checking the starter motor operation r aee a aana n anaa eea 8 44 Checking the magnet SMIC ES eee 8 45 Checking the starter motor pinion enakane eee n anana anana nane nean 8 45 Disassembling the starter MOT nent nu Mani mt 8 45 Checking the starter motor 8 47 Checking the DS asa aas aka ns aa a a ee eae ca mA A an cade es 8 48 Assembling the starter Motor 28 etes ege mate ren teen 8 48 Installing the starter MOkr Lnasmareantmuetenrvaissbnudansdninkennl 8 50 Charging System EE 8 50 Checking the stator CONN EE 8 50 Checking the Rectifier Regulator uk 8 51 6AL3 11 evec ELEC Re Electrical system Checking the electrical component Checking using the YDIS When checking the electronic throttle valve accelerator position sensor oil control valve or each sensor use the YDIS When deleting the diagnosis re
223. nd intake silencer NOTE See the exploded diagram 4 9 2 Push the throttle valve directly and check that the valve moves smoothly when the engine start switch is turned to OFF 3 Turn the engine start switch to ON and then check that the throttle valve oper ates smoothly when the remote control lever is shifted from the fully closed posi tion to the fully open position S6P24130 4 Turn the engine start switch to OFF 5 Install the intake silencer and flywheel magnet cover NOTE To install the intake silencer see Chapter 4 Installing the intake silencer 8 26 evec ELEC E Electrical system Checking the main relay and electronic throttle valve relay 1 Remove the main relay and electronic throttle valve relay E er O a 2 d BAB ruse FUSE AN 4 ati O Ee ev S6P28150 2 Connect the positive battery lead to the relay terminal and the negative bat tery lead to the relay terminal amp as shown and then check for continuity between terminals and Replace the relay if there is no continuity S6AL8140 CAUTION Do not reverse the battery leads Relay terminal No Connect O _O Disconnec
224. nd check that the I marks on the starboard driven sprockets are aligned 6AL3 11 Power unit check and adjustment oO 0 GE IONO RU DIT NFU LYN ttt t t 4 tot 0123 60 88 133 160 A S6P25230 Belt teeth number CAUTION lt Do not twist turn inside out or bend the timing belt beyond the maximum limit of 25 mm 1 0 in otherwise it can be dam aged S6P25210 e Do not get oil or grease on the timing belt 21 Install new timing belt onto the drive sprocket with its part number in the upright position and align the belt posi tion mark with the mark on the drive sprocket 22 Install the timing belt onto the driven sprockets by aligning belt position marks through with the A marks on the driven sprockets S6AL5350 S6P25240E 6AL3J 11 5 18 23 Adjust the timing belt to the specified installation height D TING S6P25250 ZX Timing belt installation height D 2 0 mm 0 08 in 24 Check that belt position marks through are aligned with each alignment mark on the drive sprocket and driven sprock ets and then remove the pin S6P25260E 25 Turn the crankshaft clockwise 2 full turns and then check that alignment marks t
225. nd in the related detailed instructions Some torque specifications are listed in stages as torque figures or angles in degrees Separate procedures and illustrations are used to explain the details of removal checking and installation where necessary see in the figure below for an example page NOTE For troubleshooting procedures see Chapter 9 Troubleshooting 1 1 LOWR t Lower unit Lower unit regular rotation model LU A 22 19 164 Nom 5 4 kot m 39 8 ft 10 jo 8 20 2g BNI os winner 18 i 20 ao A ee et 24 We ad 25 8 OM 4 47 N m 4 7 kgf m 34 7 ft Ib ALEN m 0 9 kgf apen Ib lt j42 N m 4 2 kgf m 31 04 Ib emt AJAT N m 4 7 kg m 347 11 18 lan m 4 7 kot am 34 7 ft Ib 449 Nm 0 9 kgf m 8 6 ft Ib Pan name ne Remarks Lower unit Piate Rubber seal Check screw Gasket Bolt Drain screw Grommet Bolt Bolt Spacer Propeller Spacer Washer Cotter pin Propeller nut Trim tab Sewage BS Se ok ME een sae ye Mikey ee ae Not reusable M10 x 45 mm X transom model MtO x 45 mm M10 x 70 mm X transom model Not reusable Drive shaft and lower case regular rotation model Removing the drive shaft 1 Remove the pinion nut og Je LJ sen 8070 Va Drive shaft holder 6 90890 06520 Pinion nut hol
226. nder GA Cylinder end screw wrench 90890 06568 Tilt cylinder end screw 90 N m 9 0 kgf m 66 4 ft lb Bleeding the PTT unit 1 Place the PTT unitin an upright position 6AL3 11 Tilt cylinder and trim cylinder 2 Close the manual valve by turning it clockwise S6AL7C01 Manual valve 2 N m 0 2 kgf m 1 5 ft lb 3 Remove the reservoir cap and then check the fluid level in the reservoir AA WARNING Make sure that the trim and tilt rams are fully extended when removing the reser voir cap otherwise fluid can spurt out from the unit due to internal pressure NOTE _ _ If the fluid is at the correct level a small amount of fluid should overflow out of the filler hole 4 lf fluid is below the correct level add rec ommended fluid NY Recommended PTT fluid ATF Dexron I 5 Install the reservoir cap and then tighten it to the specified torque Reservoir cap 7 N m 0 7 kgf m 5 2 ft lb 7 56 Bracket unit 6 Connect the PTT motor leads to the battery terminals to fully retract the trim and tilt rams 7 Reverse the PTT motor leads between the battery terminals to fully extend the trim and tilt rams S6AL7C02 PTT motor lead terminal Light green Lg Sky blue Sb Sky blue Sb Light green Lg NOTE a If the rams do not move up and down easily push and pull on the trim and tilt rams to assist oper
227. nder heads 5 Tighten the bolts equally and gradu ally S6P24330 2 Install the fuel injectors onto the port fuel rail and then install the holders as shown S6AL4150 6 Connect the fuel injector couplers S6AL4130 3 Install the fuel injectors onto the star board fuel rail and then install the holders as shown 6AL3J 11 4 24 el D Fuel system 7 Fasten the wiring harness to the holders and then fasten the plastic ties as shown 4 25 6AL3 11 Fuel injector Vapor separator Vapor separator 12 1 D IG 8 CR 13 14 P 13 12 S S6AL4100 Remarks Partname Bracket Bolt Collar Grommet Nut Bolt Collar Fuel cooler Bolt Clamp Clamp Quick connector Clamp Joint Clamp Clamp M6 x 16 mm M6 x 35 mm M6 x 25 mm Not reusable O FER NE EE ENE ENG Ba E ORRE eg 6AL3J 11 4 26 el D Fuel system Sel 5 N m 0 5 kgf m 3 7 ft Ib Part name i Remarks Cover assembly Pressure regulator Screw Screw Wiring harness High pressure fuel pump Grommet Filter Filter holder Plate Plate Screw O ring Needle valve assembly Float Pin Screw a Oo LO ON DU BUN Hm 96 x 12 mm 4 x 16 mm 4 x 8 mm Not reusable A k k k k DI L k k HI NH kb g4 x 8
228. ne stop lanyard switch lt Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning NOTE a If the grooves in the propeller nut do not align with the cotter pin hole tighten the nut until they are aligned Propeller nut 54 N m 5 4 kgf m 39 8 ft lb 6AL3 11 Drive shaftand lower case counter rotation model 7 Fillthe gear oil to the correct level Recommended gear oil Hypoid gear oil API GL 4 SAE 90 Gear oil quantity Counter rotation model 1 000 cm3 33 8 US oz 35 3 Imp oz 6AL3J 11 6 52 Lower unit Shimming counter rotation model T I pa TERI ij ATI BE S6P26300 6 53 6AL3J 11 Shimming NOTE e Shimming is not required when assembling the original lower case and inner parts e Shimming is required when assembling the original inner parts and a new lower case e Shimming is required when replacing the inner part s Selecting the pinion shim 1 Install the special service tool onto the drive shaft D R WW te RS I I S6AL6250 NOTE SE e Select the shim thickness T3 by using the Specified measurement s and the calcula tion formula e Hold the special service tool in a vise and then install the drive shaft into the Special service tool so that the shaft is at the cen
229. new O ring and the pump housing assembly into the lower case tighten the bolts and then install the seal and cover S6AL6720 CAUTION Do not turn the drive shaft counterclock wise otherwise the water pump impeller may be damaged NOTE a e When installing the pump housing apply grease to the inside of the insert cartridge and then turn the drive shaft clockwise while pushing down the pump housing e Align the cover projection with the hole in the pump housing 6AL3 11 Drive shaftand lower case regular rotation model Installing the lower unit WARNING When installing the lower unit with the power unit installed be sure to suspend the outboard motor If the outboard motor is not suspended it can fall suddenly and result in severe injury 1 Align the center of the set pin with the alignment mark on the bottom cowling to set the shift lever to the neutral posi tion NOTE If the power unit is installed the set pin and alignment mark cannot be aligned so align the set pin with the alignment mark on the shift bracket 2 Set the gear shift to the neutral position at the lower unit 3 Install the dowels into the lower unit 6AL3 11 4 Install the lower unit into the upper case and then tighten the lower case mounting bolts nuts to the specified torque Install the trim tab to its original posi tion and then tighten the bolt to th
230. ng Free length Tilt limit PT RS Gath ed TEAM 44 2 1 74 1 2 0 05 Valve lifter Valve lifter outside diameter Valve lifter to cylinder head clearance 32 982 32 997 1 2985 1 2991 0 020 0 055 0 0008 0 0022 Valve shim Valve shim thickness in 0 020 mm increments 2 320 2 960 0 0913 0 1165 Connecting rod Small end inside diameter Big end inside diameter Big end side clearance Crankpin oil clearance Big end bearing thickness Y ellow Green Blue 21 017 21 031 0 8274 0 8280 53 015 53 035 2 0872 2 0880 0 15 0 30 0 006 0 012 0 028 0 066 0 0011 0 0026 1 492 1 496 0 0587 0 0589 1 496 1 500 0 0589 0 0591 1 500 1 504 0 0591 0 0592 Crankshaft Crankshaft journal diameter Crankpin diameter Crankpin width Crankshaft runout limit ED The figures are for reference only 2 5 62 968 62 992 2 4791 2 4800 49 976 50 000 1 9676 1 9685 21 50 21 55 0 8465 0 8484 0 03 0 0012 200 L 225 R 225 L Maintenance specification Model Em 200 L 225R Crankcase Crankshaft journal oil i 0 025 0 050 0 0010 0 0020 clearance Upper crankcase main bearing thickness 2 494 2 500 0 0982 0 0984 2 498 2 504 0 0983 0 0986 2 502 2 508 0 0985 0 0987 Lower crankcase main bearing thickness 2 494 2 500 0 0982 0 0984 2 498 2 504 0 0983 0 0986 2 502 2 508 0 0985 0 0987 Lower crankcase main bearing thickness J 3 2 492
231. ng the power unit Symptom 1 Engine will not start engine cranks Symptom 2 Cause 1 Checking step ECM does not operate Relay malfunction Check the relay Blown fuse Check the fuse Short open or loose connection in ECM circuit Check the ECM cir cuit Engine start switch malfunction Check the engine start switch S park plug does not spark all cylinders Crank position sen sor malfunction and cam position sensor PORT EX mal function Check the crank position sensor and cam position sen Sor Short open or loose connection in ignition coil ground circuit Check the wiring harness continuity Fuel not supplied all cylinders High pressure fuel pump does not operate Short open or loose connection in high pressure fuel pump circuit Check the wiring harness continuity Blown fuse Check the fuse Relay malfunction Check the relay High pressure fuel pump malfunction Check the high pressure fuel pump continuity fuel not Low pressure pump does operate Short open or loose connection in low pressure fuel pump circuit Check the wiring harness continuity Blown fuse Check the fuse Low pressure fuel pump malfunction Check the low pres sure fuel pump con tinuity Fuel not supplied to the fuel rails Measure the fuel pressure Vapor shut off valve does not close Fixed
232. ng the water pump and shift rod 6 5 6 34 Checking using the Dip 8 1 Clamp bracket and swivel bracket 7 22 Connecting the communication cable to the outboard motor 9 5 Control system 3 11 Cooling water hose ceesre 4 3 CrankCase assimiler 5 57 Cylinder block 5 57 5 59 Cylinder heat 5 43 D Dimensio Mesran sine 2 12 Disassembling the bottom cowling 7 5 Disassembling the cylinder block 5 61 Disassembling the drive Shaft NOUSING eerren 6 14 6 44 Disassembling the forward gear 6 14 6AL3 11 Disassembling the gear pump 7 43 Disassembling the lower case 6 14 6 45 Disassembling the oil pan and exhaust manifold 7 16 Disassembling the oil pump 5 73 Disassembling the propeller shaft assembly 6 8 Disassembling the propeller shaft housing 6 8 6 37 Disassembling the PTT motor 7 36 Disassembling the reverse gear 6 44 Disassembling the shift bracket 7 6 Disassembling the starter motor 8 45 Disassembling the tilt cylinder and trim cylinder 7 49 Disassembling the upper case 7 15 Disassembly and assembly sesse 1 5 Disconnecting the quick connector 4 5 Draining the fuel 3 5 Drive shaft and lower case counter rotation model 6 42 Drive shaft and lower case regular rotation model 6 12 E L ECM EE 1 16 5 38
233. nstall the shift rod assembly and then F align the center of the set pin with the S6AL7120 mark on the bottom cowling NOTE ge Make sure that the white paint mark on the flushing hose and the white tape on the PTT motor leads are positioned as shown 4 Route the flushing hose trim sensor lead and PTT motor lead as shown 5 Install the wire lead extension counter rotation model D S6AL7150 NOTE e Be sure to install the shift rod assembly onto the bottom cowling before installing the power unit e Install the shorter set pin of the shift lever to the shift rod assembly 7 S6AL7A50 A Regular rotation model B Counter rotation model C To the PTT relay D To the cooling water passage cover via the joint 6AL3J 11 7 8 Bracket unit Install the flushing hose joint adapter and screws 8 and then install the shift bracket assembly 69 7 e AKE K KI GY NY S6AL7160 Hose joint adapter screw 9 5 N m 0 5 kgf m 3 7 ft lb 7 9 6AL3J 11 Shift rod and bottom cowling Upper case and steering arm Upper case and steering arm 72 N m 7 2 kgf m 53 1 ft Ib as n 8 27 N m 2 7 kgf m 19 9 ft Ib 12 3433 11 S6AL7200 Partname i Remarks Upper case assembly Bolt Washer Washer Washer Upper mount Bracket Bolt Bolt Mount housing
234. ntrol valve STBD 1 Oil control valve PORT WD See the wiring diagram 6AL3 11 Cam position sensor starboard intake 2 Cam position sensor port intake Check the valve operation using the YDIS 2 Measure the resistance 3 Measure the input voltage Check the purple Pu lead oil control valve to ECM for conti nuity Check the filter and plunger 9 12 TRBL 1 SHTG 6 Troubleshooting Trouble code Symptom Remarks Checking steps Electronic throttle system malfunction 1 Check the ECM circuit 2 Check the electronic throttle valve circuit Check the electronic throttle valve relay and fuse Electronic throttle system malfunction Check the electronic throttle valve operation Check the TPS output voltage using the YDIS Check the throttle opening angle using the YDIS 4 Check the ECM circuit Check the electronic throttle valve circuit Check the electronic throttle valve relay and fuse Check the electronic throttle valve motor continuity Electronic throttle system malfunction Check the electronic throttle valve circuit Check the electronic throttle valve relay and fuse Check the electronic throttle valve motor continuity Electronic throttle system malfunction Check the electronic throttle valve
235. nual 7 Apply negative pressure to the intake air pressure sensor slowly and check that the displayed intake air pressure is var ied NOTE o When checking the intake air pressure sen sor do not start the engine 8 Disconnect the special service tool 9 Install the intake air pressure sensor and then connect the coupler Checking the engine temperature sensor 1 Disconnect the engine temperature sen sor coupler 2 Turn the engine start switch to ON and then measure the input voltage at the engine temperature sensor coupler wir ing harness end Check the wiring har ness if out of specification EE S S6AL8490 Engine temperature sensor coupler input voltage reference data Black yellow B Y Black B 4 75 5 25 V 3 Turn the engine start switch to OFF 6AL3J 11 7 Remove the engine temperature sensor Place the engine temperature sensor in a container of water and slowly heat the water 0000060000 S6AL8500 Measure the engine temperature sensor resistance Replace if out of specifica tion Engine temperature sensor resistance Black yellow B Y Black yellow B Y at 20 C 68 F 54 2 69 0 kQ at 100 C 212 F 3 12 3 48 kQ Install the engine temperature sensor and then connect the engine temperature sensor coupler Checking the thermoswitch 1 Disconnect the thermoswitch connectors NOTE There are 2 th
236. o forward gear Pinion to reverse gear Pinion shims Forward gear shims Reverse gear shims 2 7 mm in mm in 0 26 0 65 0 0102 0 0256 0 32 0 65 0 0126 0 0256 0 46 0 82 0 0181 0 0323 0 45 0 90 0 0177 0 0354 0 26 0 65 0 0102 0 0256 0 32 0 65 0 0126 0 0256 0 46 0 82 0 0181 0 0323 0 45 0 90 0 0177 0 0354 0 10 0 12 0 15 0 18 0 30 0 40 0 50 0 10 0 12 0 15 0 18 0 30 0 40 0 50 0 10 0 12 0 15 0 18 0 30 0 40 0 50 6AL3 11 Item Maintenance specification Model 200R 200 L 225R 225 L Propeller shaft Propeller shaft free play Propeller shaft shims Runout limit 0 20 0 50 0 0079 0 0197 1 80 1 90 2 00 2 10 2 20 0 25 0 35 0 0098 0 0138 0 10 0 12 0 15 0 18 0 30 0 40 0 20 0 50 0 0079 0 0197 1 80 1 90 2 00 2 10 2 20 0 25 0 35 0 0098 0 0138 0 10 0 12 0 15 0 18 0 30 0 40 0 50 0 50 0 02 0 0008 Drive shaft Runout limit Electrical Item 0 2 0 008 Ignition and ignition control system Spark plug gap Crank position sensor output peak voltage W B B at cranking unloaded at cranking loaded at 1 500 r min loaded at 3 500 r min loaded Crank position sensor resistance W R B Crank position sensor air gap Knock sensor resistance Intake air temperature sensor
237. od standards of personal and industrial hygiene 2 Change and wash clothing as soon as possible if soiled with lubricants 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 1 4 aa General information 6 Keep a supply of clean lint free cloths for Good working practice Special service tool 2 Use the recommended special service tools to protect parts from damage Use the right tool in the right manner do not improvise S6AL1040 3 Tightening torque Follow the tightening torque specifications provided throughout the manual When tight ening nuts bolts and screws tighten the large sizes first and tighten fasteners starting 4 in the center and moving outward Non reusable part Always use new gaskets seals O rings cot ter pins circlips etc when installing or assembling parts S69J1060 1 5 Disassembly and assembly wiping up spills etc 1 Use compressed air to remove dust and dirt during disassembly Apply engine oil to the contact surfaces of moving parts before assembly S69J1070 Install bearings with the manufacture identification mark in the direction indi cated in the
238. oles in the brush holder with the holes and in the plate and then install the plate og and bracket AIDA Cm S6AL8300 NOTE _ Align the holes and in the plate with the holes and O in the bracket e 9 Install the plate on outer gear and planetary gears onto the armature assembly 10 Assemble the starter motor body 6AL3 11 NOTE a e Install each planetary gear with its rounded side facing upward e Check the operation of the starter motor before installing it to the power unit To check the operation of the starter motor see Chapter 8 Checking the starter motor operation Installing the starter motor 1 Installthe starter motor to the power unit 2 Install the wiring harness to the starter motor and then fasten the wiring har ness M and starter motor lead brown white with the holders HIT 6AL3 11 Starter motor Charging system 3 Route the starter motor lead brown white as shown fasten it to the junction box using the plastic ties and then install the terminals of the starter motor lead brown white and wiring harness lead brown using the same bolt 6 ING 6 SI AN LA SS S6AL8870 NOTE To wire the st
239. ollar 4 6AL3 11 Removing the power unit NOTE e Be sure to reduce the fuel pressure before removing the power unit To reduce the fuel pressure see Chapter 4 Reducing the fuel pressure e It is recommended to loosen the flywheel magnet nut before removing the power unit to improve working efficiency 1 Remove the flywheel magnet cover 2 Remove the retaining plate grommet and cable holder and then discon nect the remote control cables io eRe Wd S6P25290E 3 Remove the starboard intake manifold NOTE See the exploded diagram 4 9 4 Remove the clamps and caps and then disconnect the PTT motor lead S6AL5G80 5 Disconnect the vapor gas hose from the starboard top cowling lock 5 39 6 Disconnect the cooling water pilot hose 7 Remove the neutral switch coupler blue from the bracket and disconnect the neutral switch coupler and shift cut switch coupler black 8 Remove the oil dipstick and dipstick guide S6AL5H00 9 Disconnect the battery cables NOTE See the exploded diagram 5 35 10 Disconnect the fuel hose from the fuel fil ter 6AL3 11 11 Removing the PTT switch coupler isolator coupler 4 water detection switch coupler blue warning indica tor coupler LAN communication cou pler white 10 pin main harness coupler 8 and trim sensor coupler from the brackets and th
240. ols into a spark plug hole 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 Cz Compression gauge 90890 03160 Compression gauge extension 90890 06563 5 Disconnect the throttle cable joint from the accelerator lever and then place and hold the lever in the fully open position of the throttle 5 1 S6P25015 6 Crank the engine until the reading on the compression gauge stabilizes and then measure the compression pressure Minimum compression pressure reference data 740 kPa 7 4 kgf cm 107 3 psi 7 If the compression pressure is below specification and the compression pres sure for each cylinder is unbalanced add a small amount of engine oil to the cylin der and then measure the compression pressure again NOTE ___ _ e If the compression pressure increases check the pistons and piston rings Replace if worn e If the compression pressure does not increase check the valve clearances valves valve seats cylinder head gaskets and cylinder heads Adjust or replace if necessary Checking the oil pressure 1 Place a rag under the oil pressure sen Sor 2 Remove the oil pressure sensor and then install an oil pressure gauge into the oil pressure sensor installation hole 6AL3 11 e The intake manifold STBD positive bat tery cable positive
241. ontrol valve STBD sensor Ge RAR A L 5V 3 69 Oil control valve PORT Engine temperature D 100 4 sensor SV High pressure fuel Ev 1 D pump relay High pressure fuel pump Trim sensor Lo o r P av TT ee vx 63 rn Thermoswitch Low pressure fuel pump 8 62 O oo Water detection switch Vapor shut off valve o NG 6 gt Kg Shift cut switch sv P t oo T Low oil pressure warning indicator Neutral switch E C M 5V 9 oo OH Overheat warning indicator PA 03 Ground ha Diagnostic flash indicator B O t Knock sensor et 8 Buzzer DES switch TIT BI DO 62 t Teen TT Engine stop e os lanyard switch 64 T sj ES 09 NI 0 LAN communication relay C4 SEN Ee 64 E aaa YDIS a l sasa 7 46 TT 69 C Rectifier 63 Regulator 69 A TIT Engine start switch 0 oo 43 6 TT CT TT E Battery S6AS 8030 6AL3J 11 1 20 an General information 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 t
242. or 3 times to seat the rollers and then measure the bearing height M1 as shown S69J6580 S6AL6280 NOTE e Select the shim thickness T1 by using the specified measurement s and the calcula tion formula e Measure the bearing outer race at 4 points to find the height average YO Shimming plate 90890 06701 Digital caliper 90890 06704 6 24 Lower unit 2 Calculate the forward gear shim thick ness T1 as shown in the examples below S69J6570 N0OTE S F is the deviation of the lower case dimen sion from standard The F mark 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 Forward gear shim thickness T1 29 50 F 100 M1 Example If M1 is 29 10 mm and F is 5 then T1 29 50 5 100 29 10 mm 29 50 0 05 29 10 mm 0 45 mm If M1 is 29 10 mm and F is 0 then T1 29 50 0 100 29 10 mm 29 50 0 29 10 mm 0 40 mm 3 Select the forward gear shim s T1 as follows Calculated number at 1 100 place 1 2 Rounded number 3 4 5 6 7 8 9 10 6 25 Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Example If T1 is 0 45 mm then the forward gear shim is 0 42 mm
243. osed posi tion and fully open position 6AL3 11 ECM and electronic throttle valve control system S6AL8160 A Fully closed position B Fully open position NOTE SE When the accelerator lever is in the fully open position make sure thatitis contact ing the stopper when measuring the sen sor resistance Accelerator position sensor resistance at 20 68 F reference data Accelerator lever position Terminal Fully closed Fully open o o D 5 300 kQ 9 Connect the accelerator position sensor coupler 10 Connect the throttle cable joint to the accelerator position sensor 8 30 evec ELEC E Electrical system Checking the accelerator position sensor circuit Wiring harness continuity 1 Disconnect the ECM coupler Terminal No Coupler Coupler 40 1 44 2 38 3 31 6 7 8 41 T S6P28560 49 2 Disconnect the accelerator position sen 4 Connect the ECM coupler sor coupler 5 Turn the engine start switch to ON and then measure the input voltage at each terminal of the accelerator position sen ai sor coupler wiring harness end S6AL8930 3 Check the wiring harness for continuity Accelerator
244. ove the water pump housing and impeller 2 Remove the Woodruff key 3 Remove the outer plate cartridge and water pipe 4 Set the gear shift to the neutral position and then remove the shift rod assembly 6AL3 11 Lower unit Counter rotation model S6AL6800 Checking the water pump and shift rod 1 Check the water pump housing Replace if there is deformation NOTE If the engine overheated the inside of the water pump housing may be deformed so be sure to remove the insert cartridge when checking the housing 2 Check the impeller insert cartridge and outer plate cartridge Replace if cracked or worn 3 Check the water pipe Replace if corro sion deformation or cracked 4 Check the Woodruff key and the groove on the drive shaft Replace if worn 5 Check the shift rod Replace if cracked or worn 6AL3 11 6 34 Lower unit Propeller shaft housing counter rotation model Partname NGANG a ert pr 22 304 6N m 0 6 kof m 4 4 ft Ib s 29 S6AL6330 Remarks 6 35 Water pipe Rubber seal Rubber seal Shift rod joint Ball Slider Shift plunger Dog clutch Cross pin Spring Forward gear Forward gear shim Ring nut Claw washer Taper roller bearing assembly Propeller shaft Thrust bearing A k k k k k NR k k kb Groo Not reusable 6AL3 11 7 T
245. pe of relay To check the relay see Chapter 8 Checking the main relay and electronic throttle valve relay 2 Connect the tester leads to terminals and as shown turn the engine start switch to ON and then measure the voltage within 5 seconds after turning the Switch to ON 06 ONO o Del CS ei S6AL8630 NOTE EE When the engine start switch is turned to ON voltage is supplied to the high pressure fuel pump relay and the high pressure fuel pump operates After 5 seconds the power to the relay turns off and the fuel pump stops Terminal Terminal 12 V battery voltage 6AL3 11 Fuel control system Starting system 3 Measure the input voltage between the terminal and ground and the terminal and ground as shown O 0G0 8 S6AL8640 Terminal Ground Terminal Ground 12 V battery voltage 4 Turn the engine start switch to OFF 5 Install the high pressure fuel pump relay and then install all parts removed during disassembly Checking the vapor shut off
246. peller shaft housing 6 48 Installing the water pump and Shift rod 6 49 Installing the lower INTE eae nt a ae ie Re NE 6 50 Shimming counter rotation model 6 53 Si IL EEN 6 54 Selecting the pinion shim Nana n aan 6 54 Selecting the reverse gear ehm sasasi aaa neran ena anaa anana nn ana nana anan 6 55 Selecting the forward gear ehm 6 57 Selecting the propeller Shaft SHIM rrennrannnnnnrrnnrnnevnnvnnnnrnnnrnnnernnrenennn 6 58 Backlash counter rotation model sn 6 60 Measuring the forward and reverse gear backlash rrrrnarvrrnnrrrrnrrvrnnnnr 6 60 6AL3 11 Lower unit Lower unit regular rotation model Ge 54 N m 5 4 kgf m 39 8 ft Ib 2442 N m 4 2 kgf m 31 0 ft Ib 47 N m 4 7 kgf m 34 7 ft Ib 47 N m 4 7 kgf m 34 7 ft 1b gt 9 N m 0 9 kgf m 6 6 ft Ib S6AL6610 P art name i Remarks CO LO ON On Un BUN Hm Lower unit Plate Rubber seal Check screw Gasket Bolt Drain screw Grommet Bolt Bolt Spacer Propeller Spacer Washer Cotter pin Propeller nut Trim tab Not reusable M10 x 45 mm X transom model M10 x 45 mm M10 x 70 mm X transom model Not reusable PRP PRP k k k k k k k ANKE k k kb 6 1 6AL3J 11 Ge 47 N m 4 7 kgf m 34 7 ft Ib Lower unit regular rotation model Ge 54 N m 5 4 kgf m 39 8 ft Ib Se 42 N m
247. pter 6 Shim ming regular rotation model 4 Install the propeller shaft housing assem bly into the lower case and then tighten the bolts to the specified torque 5 Install the ring and bolts S6AL6A20 Propeller shaft housing bolt amp 30 N m 3 0 kgf m 22 1 ft lb 6 Install the water pipe and rubber seals Installing the water pump and shift rod 1 Install the shift rod assembly 6AL3 11 S6AL6700 NOTE e Set the gear shift to the neutral position when installing the shift rod e After assembling the lower unit check that the shift rod operates smoothly and check that the drive shaft and propeller shaft rotate smoothly e When measuring the backlash be sure to measure it before installing the water pump To measure the backlash see Chapter 6 Measuring the forward and reverse gear backlash regular rotation model 6 18 Lower unit 2 Install a new gasket the outer plate cartridge and dowels a A e Cedies S6AL6710 3 Install the Woodruff key into the drive shaft 4 Align the groove on the impeller with the Woodruff key and then install the impeller onto the drive shaft S69J6300 5 Install a new O ring and the insert car tridge into the pump housing 6 19 NOTE res Align the insert cartridge projections with the holes amp in the pump housing 6 Install a
248. r Cover Oil seal Bolt Drive shaft housing Needle bearing O ring Pinion shim Thrust bearing Lower case Needle bearing assembly Pinion Washer Nut Not reusable M8 x 25 mm A k k P A k k RPP ob Not reusable ken nb 6AL3J 11 6 12 Lower unit S6AL6220 Part name Forward gear shim Taper roller bearing assembly Forward gear 6 13 6AL3J 11 Drive shaftand lower case regular rotation model Removing the drive shaft 1 Remove the pinion nut S6AL6070 Mo Drive shaft holder 6 90890 06520 Pinion nut holder 90890 06715 2 Remove the drive shaft drive shaft hous ing pinion thrust bearing spring and washer 3 Pull out the forward gear Disassembling the drive shaft housing 1 Remove the cover oil seals and needle bearing 4 i f S6AL6990 GC Needle bearing attachment D 90890 06610 VOOE Driver rod L3 90890 06652 Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear using a press 6AL3 11 S6AL6A00 CAUTION Do not reuse the bearing always replace it with a new one Bearing separator 90890 06534 Disassembling the lower case 1 Remove the needle bearing from the lower case S6AL6230 NOTE a e Since the diameter of the passage in the lower case and the diameter of the special service tool are both 40 mm 1 57 in the special service
249. r Checking the piston clearance 1 Measure the piston outside diameter at reference the specified measuring point Replace 1 Check the clearances by referring to the the piston if out of specification specified values if replacing the piston the piston rings as a set the cylinder block or all parts Piston clearance reference data 0 075 0 080 mm 0 0030 0 0031 in Checking the piston ring 1 Check the piston ring dimensions B and see T Replace the piston ring set if out of specification Piston diameter 93 921 93 941 mm Gees aK 3 6977 3 6985 in r Measuring point amp BE P 5 0 mm 0 20 in up from the L TI T bottom of the piston skirt Cc B Checking the cylinder bore asi 1 Measure the cylinder bore D D at T measuring points and and in direction D D3 Ds which is parallel S69J5B80 to the crankshaft and direction D gt Piston ring dimensions D4 D which is at a right angle to the Top ring crankshaft B 1 17 1 19 mm 0 046 0 047 in T 2 80 3 00 mm 0 110 0 118 in Second ring Cc B 1 17 1 19 mm 0 046 0 047 in T 3 70 3 90 mm 0 146 0 154 in Oil ring 69J5B70 B 2 40 2 47 mm 0 094 0 097 in T 2 30 2 70 mm 0 091 0 106 in 6AL3J 11 5 62 Checking the piston ring end gap reference 1 Level the piston ring in the cylinder with a piston crown 2 Check the piston ring end
250. r cup assembly be sure not to remove the clip and float otherwise the water detection switch may be damaged To check the fuel cup for leaks see Chap ter 4 Checking the fuel filter assembly lt Check the water detection switch each time the fuel filter is checked e To check the water detection switch see Chapter 8 Checking the water detection Switch 6 Install the fuel filter cup assembly NOTE EE Do not twist the water detection switch lead when installing the fuel filter cup assembly 7 Connect the water detection switch cou pler blue 8 Fasten the water detection switch lead isolator lead oil pressure sensor lead and PTT switch lead with the clamp NOTE Be sure to leave a little slack in the water detection switch lead 3 4 CHK Q ADJ Periodic check and adjustment Draining the fuel 1 Reduce the fuel pressure NOTE To reduce the fuel pressure see Chapter 4 Reducing the fuel pressure 2 Remove the cap 3 Cover the pressure check valve of the vapor separator with a rag and then press in the pressure check valve using a thin screwdriver to release the fuel pres sure 4 Place a drain pan under the vapor sepa rator drain hose and then loosen the vapor separator drain screw 5 Drain the fuel from the vapor separator drain hose by pressing the pressure check valve using a thin screwdriver l cl S6P24
251. r if there is dirt and residue Assembling the oil pan and exhaust manifold 1 Install the dowels a new gasket and the lower exhaust guide onto the upper exhaust guide S6AL7280 7 16 Bracket unit 2 Install a new gasket the oil strainer and bolts and then tighten the bolts to the specified torque S6AL7310 5 Tighten the exhaust manifold bolts S6AL7290 first and then tighten the oil pan bolts and to the specified torques Oil strainer bolt 10 N m 1 0 kgf m 7 4 ft lb Exhaust manifold bolt 20 N m 2 0 kgf m 14 8 ft lb 3 Install the dowels a new gasket Oil pan bolt and the oil pan and then tighten the 20 N m 2 0 kgfm 14 8 ft lb oil pan bolts and temporarily 6 Install the dowels 9 a new gasket and the plate 7 Install the rubber seal and cooling water pipe into the muffler 8 Install a new gasket the muffler and bolts onto the oil pan and then tighten the bolts to the specified torque S6AL7300 4 Install a new gasket the exhaust man Hold rubber seal and then tighten the exhaust manifold bolts tempo rarily 7 17 6AL3J 11 Upper case and steering arm 3 Install the rubber seal into the joint ki hole of the upper case 4 Install the oil pan assembly 5 Install the oil pan assembly bolts and and PCV and then tighten them to the specified torques
252. r 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 For the F L 200C F L 225B models you can also save the ECM record data on a file so that you can view and dis play the graph later Items For F L 200C F L 225B 1 Engine speed 3 Throttle position sensor 5 Intake pressurel1 2 Battery voltage 12 16 4 Engine temperature 6 Oil pressurel TI Intake air pressure Engine oil pressure 9 3 6AL3J 11 YDIS 6 ECM record data graph When a malfunction occurs in the electronic throttle valve system 4 seconds 2 seconds before and after the malfunction of recorded data are saved in the ECM This data can be displayed on a graph using the ECM record data graph of the Data logger function When the communication cable is used to connect a computer to the ECM the ECM record data can be saved and viewed on the computer The saved ECM record data can also be viewed offline Items For F L 200C F L 225B Engine speed Target TPS voltage Engine stop lanyard switch Accel position sensor 160 Ref TPS voltage Main relay Accel position sensor 202 Ref acc pos sensor voltage 6 Electronic throttle relay 10 Throttle position sensor 1 Target TPS voltage for ISC M Overheat warning Throttle position sensor 2 En
253. r scratched E xhaust 45 35 45 45 mm 1 785 1 789 in Cam lobe Vo NS Intake and exhaust a 35 95 36 05 mm 1 415 1 419 in 3 Measure the camshaft runout Replace if above specification S6AL5G50 NOTE ___ _ e Do not scratch or damage the face of the brim e If there is a scratch more than 0 2 mm 0 008 in deep or more than 0 5 mm 0 020 in wide on the surface of the brim a mal function may occur in the cam position sen sor signal S6P25560 Camshaft runout limit 2 Measure the cam lobe Replace if out of 0 015 mm 0 0006 in specification 4 Measure the camshaft journal diameter and cylinder head journal inside diam eter Replace the camshaft or cylinder head assembly or both if out of specifi cations Im D 869J5950 xN Joh IE lt lt S6AL5240 5 25 6AL3J 11 Power unit check and adjustment 3 Apply a thin even coat of sealant to the Camshaft journal diameter mating surface of the camshaft caps 24 96 24 98 mm cylinder heads as shown 0 9826 0 9834 in Camshaft cap inside diameter 25 000 25 021 mm 0 9843 0 9851 in Installing the camshaft driven sprocket and timing belt CAUTION Do not turn the crankshaft counterclock wise otherwise the water pump impeller may be damaged Do no
254. r shaft housing counter rotation model 6 35 Propeller shaft housing regular rotation model 6 6 Propeller size AA 1 21 PTT electrical system 7 58 PTT MOTO ses kag sa aaa tr ne akah KA ah a kaka da 7 35 PTT NGNE as codec a one fer in he 2 7 7 30 R Reducing the fuel pressure eee 4 5 Refacing the valve seat 5 49 Removing the clamp bracket s 7 25 Removing the cooling water passage Cover 5 53 Removing the cylinder head 0 5 46 Removing the drive shaft 6 14 6 44 Removing the exhaust cover 5 53 Removing the fuel hose Clamp 4 29 Removing the lower unit 6 4 6 33 Removing the power unit 5 39 Removing the propeller shaft housing assembly 6 8 6 37 Removing the PTT unit 7 24 Removing the starter motor cece 8 44 Removing the steering arm 7 20 Removing the timing belt driven sprocket and camshaft 5 21 Removing the upper case 7 15 Removing the water pump and shift rod 6 5 6 33 Removing the wiring harness 5 41 Replacing the oil filter 3 7 Replacing the timing bet 5 15 i 4 S Replacing the valve guide ee 5 48 Safety while working 1 4 Selecting the connecting rod bearing 5 66 Selecting the forward gear shim 6 24 6 57 Selecting the main bearing 5 68 Selecting the pinion shim 6 23 6 54 Selecting the propeller shaft shim 6 26 6 58 Selecting the reverse gear shim 6 25 6 55 Se
255. rams are fully retracted when removing the special service tool otherwise fluid can spurt out from the unit due to internal pressure 14 Install the pipe joint at the end and then tighten the pipe joints to the specified torque Pipe joint 15 N m 1 5 kgf m 11 1 ft lb 15 After measuring the hydraulic pressure connect the PTT motor leads to the bat tery terminals to fully extend the trim and tilt rams S6AL7C08 16 Place the PTT unitin an upright position 17 Remove the reservoir cap and then check the fluid level in the reservoir 6AL3 11 PTT unit WARNING Make sure that the trim and tilt rams are fully extended when removing the reser voir cap otherwise fluid can spurt out from the unit due to internal pressure NOTE n If the fluid is at the correct level a small amount of fluid should overflow out of the filler hole when the cap is removed 18 If necessary add sufficient fluid of the recommended type to the correct level 19 Install the reservoir cap and then tighten it to the specified torque Ny Reservoir cap 7 N m 0 7 kgf m 5 2 ft lb 7 34 Bracket unit PTT motor S6AL7620 P art name Remarks lt Stator Bolt Wave washer Washer Bearing Armature Brush Spring O ring Oil seal PTT motor base assembly Not reusable Not reusable No 1 2 3 4 5 6 7 8 9 10 11 kA k k P ZP k N
256. re see Chapter 4 Reducing the fuel pressure 2 Remove the flywheel magnet cover 3 Disconnect the oil control valve couplers 4 Disconnect the thermoswitch connectors 5 Disconnectthe quick connectors 3 9 WARNING It is dangerous if the quick connectors are disconnected suddenly since pressur ized fuel will spray out Be sure to reduce the fuel pressure before disconnecting the quick connectors NOTE To disconnect the quick connector see Chapter 4 Disconnecting the quick connec tor 6 Remove the thermostat covers and thermostats port and starboard S6P23320E 6AL3 11 CAUTION Do not reuse the gaskets always replace them with new ones 7 Suspend the thermostat in a container of water 8 Place a thermometer in the water and Slowly heat the water S69J5E40 9 Measure the thermostat valve opening at the specified water temperatures Replace the thermostat if out of specifi cation S6AL3100 Welsh Valve openin temperature H 9 0 05 mm 58 62 C 0 0020 in 136 144 F valve begins to open above more than 70 C 158 F 4 3 mm 0 17 in 10 Install the thermostats and thermostat covers port and starboard 6AL3 11 Power unit NOTE EEE It is recommended to check the thermostat cover anodes before installing the thermostat covers 11 Connect the thermoswitch connectors quick connector
257. regulator to fuel cooler fuel cooler to vapor separator LR PES AR 4 1 vapor separator to quick connec CUT S6AS 4030 Blowby hose starboard cylinder head cover to joint Blowby hose joint to cylinder block Blowby hose joint to intake silencer 6AL3 11 Vapor gas hose Vapor gas hose vapor separator to joint Vapor gas hose vapor separator to joint Vapor gas hose joint to joint Vapor gas hose joint to joint Vapor gas hose joint to canister tank port Vapor gas hose canister purge port to joint Vapor gas hose joint to vapor shut off valve Vapor gas hose vapor shut off valve to surge tank Vapor gas hose intake silencer to check valve Vapor gas hose check valve to joint Vapor gas hose canister atmospheric port to joint 6AL3 11 Hose routing S6AL4160 Vapor gas hose joint to joint Vapor gas hose joint to check valve Vapor gas hose check valve to top cowling lock Vacuum hose pressure regulator to joint Vacuum hose intake air pressure sensor to joint Vacuum hose joint to surge tank 4 2 ue D Fuel system Cooling water hose
258. resistance S6AL8610 Fuel injector resistance reference data 12 0 Q at 21 C 70 F 6 Connectthe fuel injector couplers 8 38 evec ELEC E Electrical system Checking the low pressure fuel pump and high pressure fuel pump 1 Check the fuses for continuity Replace if there is no continuity NOTE For the location of the fuse see Chapter 8 Fuse holder 2 Check the operation of the low pressure fuel pump and high pressure fuel pump using the Stationary test of the YDIS and listen for the operating sound 3 Disconnect the low pressure fuel pump coupler and high pressure fuel pump coupler 4 Measure the resistance of the fuel pump motors S6AL8620 Low pressure fuel pump resistance reference data 1 3 4 0 Q High pressure fuel pump resistance reference data 0 5 10 Q 5 Connect the low pressure fuel pump cou pler and high pressure fuel pump cou pler 8 39 Checking the high pressure fuel pump relay 1 Remove the high pressure fuel pump relay and check it e O O O O f B d R ruse FUSE 4 er e Lo S6P28180 NOTE The high pressure fuel pump relay and main relay are the same ty
259. resistance at 20 68 F Engine temperature sensor resistance B Y BA at 20 68 F at 100 C 212 F Thermoswitch ON temperature Thermoswitch OFF temperature Shift cut switch resistance at free position LAY B ED The figures are for reference only 6AL3 11 1 0 1 1 0 039 0 043 3 0 2 7 14 5 17 8 396 594 1 4 1 6 0 055 0 063 504 616 2 21 2 69 54 2 69 0 3 12 3 48 84 90 183 194 68 82 154 180 4 465 4 935 2 8 ele Specification jin Model 200 L 225R Oil pressure sensor Output voltage P W B 3 4 at engine idle speed Electronic throttle valve control system TPS output voltage at 20 68 F with remote control lever fully closed Sensor 1 with remote control lever fully open Sensor 2 V Throttle valve opening angle with remote control lever fully Degree closed with remote control lever fully Degree Above 39 8 Above 53 8 opened Electronic throttle valve motor resistance at 20 30 C 68 86 F 1 23 1 67 Accelerator position sensor output voltage P B with remote control lever fully closed Sensor 1 0 550 0 850 Sensor 2 0 400 1 000 with remote control lever fully open Sensor 1 and 2 Above 3 250 Accelerator position sensor resistance at 20 C 68 F with accelerator lever fully closed with accelerator lever fully open ED The figures are for reference only 2 9 6AL3J 11 Maintenan
260. ressure Z Test harness 3 pins 4 90890 06869 Oil pressure sensor input voltage reference data Orange O Black B 4 75 5 25 V Oil pressure sensor output voltage reference data Pink white P W Black B 3 4 V at engine idle speed 5 3 6AL3J 11 ECM base assembly Power unit check and adjustment 23 N m 2 3 kgf m 17 0 ft Ib S6AL5040 No Partname Q ty Remarks 1 Wiring harness guide 1 2 Plastic tie 2 3 Bolt 6 M6 x 35 mm 4 Holder 5 5 Damper 2 6 Bolt 4 M6 x 14 mm 7 Timing belt guide PORT 1 8 Timing belt guide STBD 1 9 Bolt 4 M6 x 20 mm 10 ECM cover 1 11 Bolt 4 M6 x 28 mm 12 Bolt 3 M6 x 20 mm 13 Cam position sensor 2 STBD IN PORT EX 14 O ring 3 15 Cam position sensor PORT IN 1 16 Bolt 12 M6 x 20 mm 17 Ignition coil 6 6AL3 11 5 4 S 23 N m 2 3 kgf m 17 0ft 1b 56415040 Partname Remarks lt Spark plug Clamp Cooling water pressure sensor adapter Gasket Plug Bolt ECM base assembly Bolt Holder Hose Not reusable M14 x 12 mm M6 x 30 mm M6 x 12 mm A k k k 4 k RR A ao 5 5 6AL3J 11 Stator assembly 51240 N m 24 0 kgf m 177 0 ft Ib Power unit check and adjustment S6AL5050 No Partname Q ty Remarks 1 Nut 1 Width across flats 36 mm 2 Flywheel ma
261. ring drive shaft thrust bearing and original shim s into the lower case 3 Install the pinion washer and pinion nut temporarily S6AL6100 NOTE Se e Be sure to select the pinion shim s if replacing the thrust bearing drive shaft housing drive shaft or lower case e To select the shims see Chapter 6 Shim ming regular rotation model e To install the pinion nut push down on the drive shaft 4 Install a new O ring to the drive shaft housing and then install the drive shaft housing into the lower case te Fe d ae mm S6AL6110 NOTE Install the drive shaft housing with the cutout in the housing facing forward as shown 6 17 5 Tighten the pinion nut to the specified torque S6AL6150 Drive shaft holder 6 90890 06520 Pinion nut holder amp 90890 06715 Pinion nut 142 Nem 14 2 kgf m 104 7 ft lb Installing the propeller shaft housing 1 Set the shift rod joint and dog clutch to the neutral position as shown Install the propeller shaft shim and propeller shaft assembly into the pro peller shaft housing assembly Apply grease to new O rings and propel ler shaft housing S6AL6120 6AL3 11 Drive shaftand lower case regular rotation model NOTE I TE lt Be sure to select the propeller shaft shim if replacing the propeller shaft forward gear or reverse gear e To select the shims see Cha
262. rks CO o AJ On mn BUN Mm Part name lt Shift rod Oil seal Oil seal housing O ring Bolt Seal Woodruff key Bolt Water pump housing O ring Insert cartridge O ring Impeller Outer plate cartridge Gasket Dowel Dowel Not reusable Not reusable M6 x 20 mm M8 x 45 mm Not reusable Not reusable Not reusable kA FA k RPP RPP k k BPP WP k k Fi 6AL3 11 6 32 Lower unit Removing the lower unit 1 Drain the gear oil S6P26400E 2 Setthe 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 S69J6545 WARNING e Do not hold the propeller with your hands when loosening or tightening it lt Be sure to disconnect the battery cables from the battery and the clip from the engine stop lanyard switch lt Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning lt When removing the lower unit with the power unit installed be sure to Suspend the outboard motor If the outboard motor is not suspended it can fall sud denly and result in severe injury 6 33 3 Mark the trim tab at the area shown and then remove it 4 Remove the bolts and then remove the lower unit from the upper case S6AL6790 Removing the water pump and shift rod 1 Rem
263. rminal Check the battery terminal Discharged battery Check the battery Oil pressure does not increase Manual valve opened Manual function valve mal Check the manual valve Insufficient PTT flu id Add sufficient fluid PTT fluid leakage Check the PTT unit for leakage Clogged filter Clogged fluid pas sage WD See the wiring diagram 6AL3 11 Disassemble and check the PTT unit TRBL w SHTG e Troubleshooting Symptom 1 PTT unit does not hold the outboard motor up Symptom 2 Cause 1 Cause 2 Checking step Manual valve opened Manual valve mal function Check the manual valve Insufficient PTT flu id Add sufficient fluid PTT fluid leakage Check the PTT unit for leakage Clogged fluid pas sage Troubleshooting the lower unit Symptom 1 Shift mechanism of the forward gear and reverse gear does not operate properly Symptom 2 Cause 1 Cause 2 Disassemble and check the PTT unit Checking step 9 25 Remote control box malfunction Check the remote control box Shift cable and shift cable end malfunc tion Check the shift ca ble and shift cable end Adjust the shift ca ble Shift rod operation malfunction Detent malfunction Check the detent Shift rod connec tion malfunction Check the shift rod connection Shift mechanism mal
264. rness hoses and other parts do not interfere with any moving parts 5 20 Removing the timing belt driven sprocket and camshaft CAUTION Do not turn the crankshaft counterclock wise otherwise the water pump impeller may be damaged Do not turn the crankshaft or the driven sprockets when the timing belt is not installed Otherwise the piston and valves or intake and exhaust valves will collide with each other and be damaged Do not turn the crankshaft and cam shafts unless instructions have been given NOTE St Check the valve clearances before removing the parts 1 Check that the A mark on the drive sprocket and the A mark on the cyl inder block are aligned 2 Check that the Il marks on the port driven sprockets are aligned and check that the I marks on the starboard driven sprockets are aligned S6P25430 3 Remove the timing belt guides and cylinder head covers 5 21 S6AL5720 NOTE See the exploded diagram 5 7 4 Make marks through on the timing belt as shown S6P25450E RARE nr JULE UFF LUN t t t of 11 23 60 88 133 160 A S6P25460 Belt teeth number NOTE ee It is not necessary to mark the timing belt when replacing it 6AL3 11 5 Turn the timing belt tensioner gradually clockwise using a hexagon wrench and then insert a 95 0 mm 0 2 in pin into the hole S6AL5A50 NOTE E Leave
265. rque S6AL5G 60 J S6AL5A80 CAUTION Do not turn the exhaust camshaft when tightening the bolt Otherwise the intake and exhaust valves will collide with each other and be damaged NOTE Slight turn the driven sprockets in direction to remove any free play B before tightening the driven sprocket bolt Driven sprocket bolt 60 N m 6 0 kgf m 44 3 ft lb 6AL3 11 Power unit check and adjustment 10 Install the dowel and variable camshaft timing assembly on the intake camshaft 11 Check that the lower edge of the intake and exhaust driven sprockets are aligned 5 28 12 Hold the intake camshaft using a wrench and then tighten the variable camshaft timing bolt to the specified torque S6AL5G70 Bua CAUTION lt Do not hold the driven sprocket when tightening the variable camshaft timing bolt Otherwise the variable camshaft timing assembly could be damaged e Do not turn the intake camshaft when tightening the variable camshaft timing bolt Otherwise the intake and exhaust valves will collide with each other and be damaged S6AL5A90 5 29 NOTE _ _ TT Slight turn the driven sprockets in direction to remove any free play D before
266. s and oil control valve couplers 12 Route and fasten the wiring harness in its original position NOTE EE To route and fasten the wiring harness see Chapter 8 Wiring harness routing 13 Install the flywheel magnet cover Checking the cooling water passage 1 Check the cooling water inlet covers and cooling water inlet Clean if clogged es E lt F S6AL3140 2 Place the lower unit in water and then start the engine 3 10 CHK Q ADJ Periodic check and adjustment 3 Check for water flow atthe cooling water pilot hole If there is no water flow check the cooling water passage inside the out board motor S6AL3180 Control system Checking the engine idle speed 1 Startthe engine and warm it up for 5 min utes 2 Check the engine idle speed using the Selva genuine tachometer on board meter or using the YDIS NOTE To connect and operate the YDIS see Chap ter 9 YDIS and the YDIS Ver 1 23a or later Instruction Manual ul Engine idle speed 600 700 r min Adjusting the throttle cable 1 Set the remote control lever to the neu tral position and fully close the throttle lever 2 Loosen the locknut remove the clip and then disconnect the throttle cable joint 3 11 S 6P 23330 3 Check that the accelerator lever con tacts the fully closed stopper CJ 1 S6AL3190 4 Adjust the posit
267. s check that they move smoothly 4 Install the upper bearing into the con necting rod and the lower bearing into the connecting rod cap 6AL3 11 Cylinder block S6AL5810 NOTE ee e Install the connecting rod bearings in their original positions e Insert the projections of the bearings into the slots on the connecting rod cap and connecting rod 5 Install half of the main bearings into the cylinder block 9 S6AL5820 NOTE e Install the bearings in their original posi tions lt Insert the projection of each bearing into the slots in the cylinder block 5 70 6 Set the crankshaft new oil seal and thrust bearings and new O rings and into the cylinder block as shown S6AL5500 CAUTION Do not damage the oil seal when installing it by contacting the edge of the drive sprocket NOTE eege Apply engine oil to the oil seal lip thrust bearings and the O rings and before installation Do not get any engine oil to the drive sprocket e Install each thrust bearing with its grooves facing outward as shown 7 Install half of the main bearings and the thrust bearing into the crankcase 8 Apply sealant to the mating surface of the crankcase 5 71 S6AL5830 NOTE ee e Install the main bearings in their original positions e Insert the projection of each bearing into the slots in the crankcase Do
268. se joint Clamp Grommet Not reusable 96 x 20 mm A k k RP PNP RPP k k k k k NFP PH 6AL3J 11 7 2 Bracket unit S6AL7020 Remarks a CO CDJ On Un P DI NN Hm Part name Bottom cowling Rubber seal Cowling lock lever Bushing Plate Bolt Bolt Wave washer Lever Bolt Spring Hook Bracket Bracket Rivet Bolt Plate M6 x 20 mm M6 x 30 mm M6 x 20 mm M6 x 25 mm OD SNA ee an S 7 3 6AL3J 11 Shift rod and bottom cowling S6AL7020 Part name i Remarks Collar Grommet Bolt Cooling water pilot hole Wire lead extension Holder PTT switch Bracket Bracket Cover Gasket Bolt Bracket Clamp Holder Grommet Holder M8 x 35 mm Counter rotation model M6 x 20 mm R egular rotation model Counter rotation model kA OD k k k k 4 k k k RN k k Ab BB Regular rotation model 6AL3 11 7 4 Bracket unit Disassembling the bottom cowling 1 Remove the shift bracket assembly and then remove the flushing hose joint adapter LS S6AL7030 4 NOTE SSS e If the power unit is installed remove the starboard intake manifold and dipstick guide and then remove the shift bracket assembly e See the exploded diagrams 4 9 5 33 2 Remove the shift rod assembly S6AL7040 NOTE The shift rod assembly cannot be removed when the power unit is installed
269. sensor coupler Checking the engine start switch 1 Disconnect the 10 pin main harness cou pler 2 Check the engine start switch for continu ity at the 10 pin main harness coupler engine start switch end Check the wir ing harness or replace the engine start Switch if there is no continuity OFF aed START ON START Op DE Z YAMAHA S6AL8890 6AL3 11 Ignition and ignition control system ECM and electronic throttle valve control system Lead color Switch Black Red Yellow position B R Y OFF O ON O START O 3 Connect the 10 pin main harness cou pler Checking the engine stop lanyard switch 1 Disconnectthe 10 pin main harness cou pler 2 Turn the engine start switch to ON and then check the engine stop lanyard switch for continuity at the 10 pin main harness coupler engine stop lanyard switch end Check the wiring harness or replace the engine stop lanyard switch if out of specification opt ON START ON START Ge DIE S6AL8540 Switch Lead color position White W Black B Clip removed OQ t O Clip installed 3 Turn the engine start switch to OFF 4 Connect the 10 pin main harness cou pler 6AL3 11 ECM and electronic throttle valve control system Checking the throttle valve operation 1 Remove the flywheel magnet cover a
270. sher Bracket Pinion shaft Planetary gear Outer gear Plate Armature Stator M6 x 35 mm Not reusable A k k RP DI k k k HN k bk kb 6AL3J 11 8 42 evec E ELEC ES Electrical system P Al lA i WE TN Wl ty UU 16 Sai AFER GER Part name DR S6AL8181 Remarks 8 43 Brush assembly Brush spring Plate Plate Bracket Screw Bolt Rubber seal Shift lever Spring Magnet switch assembly Nut Pinion stopper set Washer set Starting motor gear assembly Brush holder assembly Lever assembly A k k RPP RPP RPP RPNNPFP k k RH 4 x 15 mm M6 x 120 mm 6AL3 11 Removing the starter motor 1 Remove the starboard intake manifold and intake silencer NOTE To remove the intake manifold see Chapter 4 Intake manifold 2 Remove the starter motor from the power unit NOTE ee lt Check the engine start switch starter relay and starter relay fuse before removing the starter motor e To remove the starter motor see Chapter 5 Starter motor Checking the starter motor operation 1 Hold the starter motor in a vise using alu minum plates on both sides 2 Connect the positive battery cable to the magnet switch terminal and con nect the negative battery cable to the starter motor body as shown 3 Connect the starter motor lead brown white to the posi
271. side down 5 27 Ber g RG 0 rap Ber ESA d V R ei CC USD 0 O SX d 0 st SC g K d 2 O 2 O i I O of Wa LO S6P25E20 7 Tighten the camshaft cap bolts to the specified torques in 2 stages and in the sequence shown PORT STBD Go Ie P Orr Ei 3 e 1 3 er S ek eo ees Oe THON 3 dh us 4 Er 9 VE S6AL5290 CAUTION Do not reuse the bolts with seal washers always replace them with new ones NOTE ee Apply engine oil to the camshaft caps and camshaft cap bolts before installation e Tighten the camshaft cap bolt M6 x 30 mm to the general torque only Do not tighten it to 17 Nem 1 7 kgf m 12 5 ftlb Camshaft cap bolt 1st 8 N m 0 8 kgf m 5 9 ft lb 2nd 17 Nem 1 7 kgf m 12 5 ft lb 6AL3 11 8 Install the dowel and exhaust driven sprocket on the exhaust camshaft 9 Hold the exhaust camshaft using a wrench and then tighten the driven sprocket bolt to the specified to
272. sitive battery cable bolt 6AL3J 11 2 14 sreo Specification P art to be tightened Thread size Tightening torques N m kgf m Negative battery cable nut 13 1 3 Negative terminal bolt 26 2 6 PTT relay lead nut 4 0 4 Rectifier Regulator bolt M6 6 0 6 12 1 2 Anode screw M4 3 0 3 ECM bolt M6 7 0 7 Engine hanger bolt M6 12 1 2 M8 14 1 4 28 2 8 Cylinder head bolt 23 2 3 45 4 5 Loosen comple tely 23 253 45 4 5 90 Knock sensor 32 3 2 Cooling water passage cover bolt 12 1 2 Anode bolt 7 0 7 Exhaust cover bolt 6 0 6 12 1 2 Exhaust cover plug 14 1 4 28 2 8 55 5 5 Oil filter 18 1 8 Oil pressure sensor 18 1 8 Oil filter joint 34 3 4 Crankcase cover bolt 14 1 4 28 2 8 Connecting rod cap bolt 23 25 43 4 3 90 Engine temperature sensor 15 1 5 14 1 4 28 2 8 Crankcase bolt 25 2 5 90 4 0 90 Oil pump cover screw 0 4 Thermostat cover plug 2 3 Anode bolt 0 7 Lower unit regular rotation model Gear oil check screw 2 15 0 9 6AL3
273. stoppers are installed before installing the power unit otherwise the fuel rails could be dam aged 5 78 2 Clean the power unit mating surface and install the dowels and a new gasket 3 Install the power unit by installing the bolts and and then tightening them to the specified torque S6AL5900 Apron bolt and upper case cover bolt 8 N m 0 8 kgf m 5 9 ft lb 5 Install the speed sensor coupler to the bracket 6 Connect the flushing hose NOTE a Be sure to install the shift rod assembly onto the bottom cowling before installing the power unit C CA CN Power unit mounting bolt and S6AL5540 42 N m 4 2 kgf m 31 0 ft lb 7 Connect the warning indicator coupler 4 Install the upper case cover and trim sensor coupler isolator cou aprons pler water detection switch coupler blue PTT switch coupler 49 10 pin main harness coupler LAN communi cation coupler white and then install them onto the brackets 5 79 6AL3J 11 S6AL5550 8 Connect the cooling water pilot hose 49 9 Connectthe neutral switch coupler blue and shift cut switch coupler 4 and then install them onto the bracket 10 Install the dipstick guide and oil dip stick S6AL5560 NOTE Apply engine oil to the O ring before installing the dipstick guide
274. t 3 Measure the input voltage between the terminals and ground and the termi nals and ground as shown NOTE Eng Measure the voltage with the battery con nected and the engine start switch turned to OFF 8 27 006 00 ro Le TE HAH 119 S6AL8550 Terminal Ground Terminal Ground 12 V battery voltage 4 Turn the engine start switch to ON and then measure the input voltage between terminals and as shown S6AL8560 Terminal Terminal 12 V battery voltage 5 Turnthe engine start switch to OFF 6 Install the main relay and electronic throt tle valve relay and then install all parts removed during disassembly Checking the ECM circuit 1 Disconnect the ECM couplers and 2 Check for continuity between the ECM coupler terminals 46 68 69 75 76 and 84 wiring harness end and ground Check the wiring harness and ground if there is no continuity 6AL3 11 ECM and electronic throttle valve control system DCV AD er IS CI Beat de CEs AN Jl medl ONS r S6AL8910
275. t it with the tilt stop lever S69J3500 6AL3 11 WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the PTT unit should lose fluid pressure 2 Remove the reservoir cap and then check the fluid level in the reservoir WARNING Make sure that the trim and tilt rams are fully extended when removing the reser voir cap otherwise fluid can spurt out from the unit due to internal pressure NOTE If the fluid is at the correct level a small amount of fluid should overflow out of the filler hole when the reservoir cap is removed 3 If necessary add sufficient fluid of the recommended type until it overflows out of the filler hole AC Recommended PTT fluid ATF Dexron II 4 Install a new O ring and the reservoir cap and then tighten the reservoir cap to the specified torque Reservoir cap 7 N m 0 7 kgf m 5 2 ftlb 6AL3 11 Control system Bracket unit Lower unit Lower unit Checking the gear oil level 1 Fully tilt the outboard motor down 2 Remove the gear oil check screw a and then check the gear oil level in the lower case S60V3320 NOTE EE If the oil is at the correct level a small amount of oil should overflow out of the check hole when the gear oil check screw is removed 3 If necessary add sufficient gear oil of the recommended type until it over
276. t turn the crankshaft or the driven sprockets when the timing belt is not installed Otherwise the pistons and valves or intake and exhaust valves will collide with each other and be damaged Do not turn the crankshaft and cam shafts unless instructions have been given 1 Check that the A mark on the drive sprocket is aligned with the mating sur face of the crankcase and cylinder block STBD Port SZR S6P25570 2 Install the valve lifters onto the cylinder S6AL5250 heads NOTE SE NOTE When applying the sealant be sure not to e Apply engine oil to the valve shims and block the oil passages or oil holes and do not valve lifters before installation apply it to the cylinder head journals Install the valve shims and valve lifters in their original positions 6AL3J 11 5 26 4 Install the camshafts with the oil seals NOTE e Apply molybdenum disulfide grease to the cam lobes e Be sure to install the camshafts in the proper positions e See the exploded diagram 5 7 5 Check that the camshaft dowel holes are in the position shown in the illustration S6AL5280 6 Install the camshaft caps in their proper positions as shown and with the stamped numbers up
277. tall the cross pin and spring 49 S6AL6440 6 41 6AL3 11 Propeller shaft housing Counter rotation model Drive shaftand lower case Counter rotation model Drive shaftand lower case counter rotation model 142 N m 14 2 kgf m 104 7 ft Ib S6AL6450 Remarks a CO OANA mn BUN Mm Part name lt Drive shaft Thrust bearing Spring Washer Cover Oil seal Bolt Drive shaft housing Needle bearing O ring Pinion shim Thrust bearing Lower case Needle bearing Pinion Washer Nut Not reusable M8 x 25 mm A k k P A k k RPP ob Not reusable ken nb 6AL3J 11 6 42 Lower unit 2142 N m 14 2 kgf m 104 7 ft Ib S6AL6450 Part name Remarks Reverse gear shim Retainer Needle bearing Thrust bearing Circlip Needle bearing Reverse gear lt Not reusable Not reusable Goart 6 43 6AL3 11 Drive shaftand lower case Counter rotation model Removing the drive shaft 1 Remove the pinion nut S6AL6070 US Drive shaft holder 6 90890 06520 Pinion nut holder 90890 06715 2 Remove the drive shaft drive shaft hous ing pinion thrust bearing spring and washer 3 Remove the reverse gear Disassembling the drive shaft housing 1 Remove the cover oil seals and needle bearing L Ze S6AL6990 v Needle bearing attachment 90890 06610
278. tch to OFF 11 Connect the electronic throttle valve cou pler Variable camshaft timing control system Checking the cam position sensor 1 Disconnect the cam position sensor cou plers 8 34 evec ELEC Electrical system 2 Turn the engine start switch to ON and 5 Connect the wire leads between cam then measure the input voltage at the position sensor and cam position sensor cam position sensor coupler wiring har coupler wiring harness end as ness end Check the wiring harness if shown below specification NOTE Be sure to connect the wire leads to the cor PORT EX responding terminals STBD IN 6 Connect the tester leads to the wire leads S6AL8710 S6AL8730 PORT EX STBD IN S6AL8720 Cam position sensor input voltage Red yellow RAY Black B 12 V battery voltage Cam position sensor output voltage White blue W L Black B PORT EX Mi IEC B St y W B S6AL8740 White black W B Black B STBD IN White green W G amp Black B PORT IN 4 75 5 25 V reference data 3 Turn the engine start switch to OFF 4 Remove the cam position sensors S6AL8750 8 35 6AL3J 11 7 Turn the engine start switch to ON and then measure the output voltage when moving the screwdriver close to the sen sor Replace the cam position sensor if out of specification
279. tch to OFF 7 Remove the intake air temperature sen Sor 8 Place the intake air temperature sensor in a container of water and slowly heat the water 000000000 S6AL8460 9 Measure the intake air temperature sen sor resistance Replace if out of specifi cation Intake air temperature sensor resistance at 20 68 F 2 21 2 69 kQ 8 20 evec ELEC ES Electrical system 10 Install the intake air temperature sensor and then connect the intake air tempera ture sensor coupler Checking the intake air pressure sensor 1 Disconnect the intake air pressure sen sor coupler N Turn the engine start switch to ON and then measure the input voltage at the intake air pressure sensor coupler wiring harness end Check the wiring harness if out of specification I Oo 2 Aan ag Intake air pressure sensor input voltage reference data Orange 0 Black B 4 75 5 25 V 3 Turn the engine start switch to OFF 4 Remove the intake air pressure sensor and then connect the coupler 5 Connect the special service tool S6AL8480 Vacuum pressure pump gauge set 90890 06756 8 21 6 Check the intake air pressure using the YDIS NOTE EE To connect and operate the YDIS see Chap ter 9 YDIS and the YDIS Ver 1 23a or later Instruction Ma
280. tected Troubleshooting when a trouble code is not available consists of the following 4 items Symptom 1 Specific trouble conditions Symptom 2 Trouble conditions of an area or individual part Cause 1 The content considered as the trouble factors of symptom 2 Cause 2 The content considered as the trouble causes of cause 1 described if necessary Symptom 1 Engine does not crank Symptom 2 Starter motor does not operate Cause 1 Discharged battery Cause 2 Checking step Check the battery Loose connection of battery terminal Short open or loose connection in starter motor circuit Check the battery ter minal Check the wiring har ness continuity Starter relay malfunc tion Check the starter relay Blown fuse Check the fuse Starter motor malfunc tion Disassemble and check the starter motor Engine start switch malfunction Gear shift not in the neutral position Check the engine start switch Shift the remote control lever to the neutral position Starter motor operates but the engine does not crank Stuck piston Piston lock due to water or oil in the combustion chamber Disassemble and check the power unit Salt buildup on the drive shaft and bushing Disassemble and check the upper case Starter motor malfunc tion WD See the wiring diagram 9 19 Disassemble and check the starter motor Troubleshooti
281. ter low pressure fuel pump filter check valve and fuel cooler Replace the low pressure fuel hose con nections if there is leakage or deteriora tion 3 Check the high pressure fuel hose con nections Also check the vapor separa tor pressure regulator D fuel rails and fuel injectors Replace the high pressure fuel hose connections if there is leakage or deterioration S6AS3030 6AL3 11 4 Install the port intake manifold fuel rail covers and flywheel magnet cover NOTE EE To install the intake manifold see Chapter 4 Installing the intake manifold Checking the fuel filter 1 Disconnect the water detection switch coupler blue 2 Remove the clamp from the water detection switch lead isolator lead oil pressure sensor lead and PTT switch lead SN 9 Sat D sr 4 A 4 NN 3 Remove the fuel filter cup assembly S6AS 3010 NEIE Do not twist the water detection switch lead when removing the fuel filter cup assem bly e Be sure not to spill any fuel when removing the fuel filter cup assembly 4 Check the fuel filter element Replace the fuel filter element if there is dirt or residue 5 Check the fuel filter cup assembly Clean with straight gasoline if there are foreign substance or replace if cracked 6AL3 11 Top cowling Fuel system S6AS3021 NOTE _ I lt When cleaning the fuel filte
282. ter 40 um Paper Yellow Fuel filter 10 um Paper Green S6AL1060 Float red A In Water detection switch black B Out 2 pin coupler blue Interchangeability The new and previous parts are not interchangeable Previous parts previous engine New parts new engine When the water detection switch is on the water detection warnings are given according to the con ditions as listed in the following table Warning condition table Shift position Buzzer Indicator Neutral Yes Yes Forward Reverse No Yes 6AL3J11 1 14 aa General information Injector The injector for the 2007 models was improved in order to reduce the amount of soot after combus tion compared to the injector used for the 2006 model F L 250A Due to the change in the injector spray angle the ECM fuel injection mapping was also changed Therefore be sure to use the 2007 model injector together with the 2007 model ECMs 2006 model F L 250A 2007 model F L 200C F L 225B F L 250A S6AL1070 Identification table Injector body color 2006 model 2007 model Light gray Violet 6P2 13761 00 6P2 13761 10 Interchangeability The new and previous parts are not interchangeable Previous parts previous engine New parts new engine 1 15 6AL3J11 ECM Feature and benefit The ECM changes due to the yearly modifications are listed in
283. ter of the hole e Tighten the wing nuts another 1 4 of a turn after they contact the plate e Make sure that the special service tool and drive shaft are parallel CZ Pinion height gauge 90890 06710 6AL3 11 Shimming counter rotation model 2 Install the pinion and pinion nut and then tighten the nut to the specified torque Pinion nut 142 N m 14 2 kgf m 104 7 ft lb 3 Measure the distance M4 between the Special service tool and the pinion as shown S6AL6260 NOTE a Measure the pinion at 4 points to find the dis tance average Digital caliper 90890 06704 4 Turn the thrust bearing 2 or 3 times to seat the drive shaft housing and then measure the housing height M3 as shown S6AL6270 NOTE SS Measure the thrust bearing at 4 points to find the height average Z Digital caliper 90890 06704 Shimming plate 90890 06701 6 54 Lower unit 5 Calculate the pinion shim thickness T3 as shown in the examples below S69J6555 NOTE _ gt y P is the deviation of the lower case dimen sion from standard The P mark 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 Pinion shim thickness T3 82 00 P 100 M3 M4 Example If M3 is 50 75 mm
284. ter relay 6AL3 11 Electrical component Aft view S6P28860C ECM Cam position sensor PORT EX Cam position sensor PORT IN GO Ignition coil Cam position sensor STBD IN Knock sensor Condenser assembly connect to the cam position sensor PORT EX Coupler knock sensor white 6AL3 11 8 6 evec ELEC ES Electrical system Top view Oil control valve STBD Oil control valve PORT Thermoswitch STBD Thermoswitch PORT Engine temperature sensor Crank position sensor Vapor shut off valve Stator assembly Neutral switch Shift cut switch 8 7
285. terclockwise and measure the back lash when the drive shaft stops in each direction S6AL6950 6AL3 11 Backlash regular rotation model NOTE Measure the backlash at 4 points to find the average Reverse gear backlash 0 32 0 65 mm 0 0126 0 0256 in 14 Add or remove shim s if out of specifica tion Er Shim thickness Less than To be decreased by 0 32 mm 0 0126 in 0 49 M x 0 71 More than To be increased by 0 65 mm 0 0256 in M 0 49 x 0 71 M Measurement Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 15 Remove the special service tools and then install the water pump assembly 16 Fill the gear oil to the correct level 6 30 Lower unit Lower unit Counter rotation model JON m 0 9 kgf m 6 6 ft Ib 47 N m 4 7 kgf m 34 7 ft Ib Part name CO 4IN m E JON m 0 9 kgf m 6 6 ft Ib lt 54 N m 5 4 kgf m 39 8 ft Ib 4 7 kgf m 34 7 ft Ib S6AL6770 Remarks Lower unit Plate Rubber seal Check screw Gasket Bolt Drain screw Grommet Bolt Bolt Spacer Propeller Spacer Washer Cotter pin Propeller nut Trim tab LO ON DU P GA NN Hm 6 31 Not reusable M10 x 45 mm M10 x 45 mm M10 x 70 mm Not reusable A k k k k k k k k k k ANGRE bk kb 6AL3 11 Lower unit Counter rotation model S6AL6780 Rema
286. the propeller shaft housing 6 17 6 48 Installing the PTT motor 7 54 Installing the PTT unit 7 27 Installing the reservoir vo eee eee 7 55 Installing the starter motor seee 8 50 Installing the steering arm uu eee 7 20 Installing the throttle body 4 17 Installing the tilt cylinder ee 7 53 Installing the tilt ram 7 55 Installing the trim ram 7 53 Installing the upper case 7 19 Installing the valve sesescserrren 5 52 Installing the water pump and shift rod 6 18 6 49 Installing the wiring harness 0 5 76 Intake manifold eccerre 4 9 Introduction 9 1 J L Junction box ainiin naina 5 36 L n Lower UNIK sab Dada aga Mann a SUDA 2 7 3 14 Lower unit counter rotation model 6 31 Lower unit regular rotation model 6 1 Low pressure fuel PUMP seer 4 21 Lubricating the outboard motor 3 18 Index M Maintenance interval chart 3 1 Maintenance spechflcation 2 3 Manual format 1 1 Measuring the forward and reverse gear backlash 6 28 6 60 Measuring the fuel pressure 111 4 6 Measuring the peak voltage cce 8 1 Mod lisme TAR nant 1 6 P Part lubricant and sealant 1 4 POE VIEW Linde rt nn sen 8 3 8 8 Power Unit 2 3 3 5 5 33 Power unit check and adjustment 5 1 Power unit assembly 5 33 Predelivery check 1 22 Propeller selection saranane anenanan 1 21 Propelle
287. the following table according to the model for the F L 200C F L 225B F L 250A Due to the change in the injector spray angle the ECM fuel injection mapping was also changed ECM identification Identification table Model 6AL 00 ECM identification Description S6AL1080 F L 200C 6AL 00 2007 model F L 225B 6AS 00 2007 model F L 250A 6AL3 11 6P 2 02 2006 model 6P 2 03 Interchangeability The new and previous parts are not interchangeable Previous parts previous engine New parts new en gine 2007 model an General information ECM coupler layout F L 200C F L 225B Connecting part Color code Cam position sensor STBD IN White black Connecting part S6P21150 Color code YDIS White black Cam position sensor PORT IN White green Cam position sensor PORT EX White blue Accelerator position sensor 1 main P ink white Water detection switch Blue white Shift cut switch Blue yellow Battery power source Red yellow Main relay Yellow green Knock sensor Green Intake air pressure sensor
288. tive battery terminal and then check the starter motor operation S6AL8190 6AL3 11 Starter motor WARNING The pinion moves slightly away from the starter motor body and rotates at high speed so do not place any objects near the pinion or touch it NOTE E lt Check the starter motor operation for a few seconds e If the starter motor is disassembled for maintenance be sure to check the opera tion again after assembling it 4 Disconnect the negative battery cable and positive battery cable from the bat tery terminals 8 44 ELE E ELEC Re Electrical system Checking the magnet switch 1 Connect the tester leads between the magnet switch terminals and as shown 2 Connect the negative battery cable to the starter motor body 3 Connect the positive battery cable to the starter motor lead brown white and then check the magnet switch continuity S6AL8200 CAUTION Do not connect the starter motor lead brown white to the battery for more than 1 second otherwise the magnet switch can be damaged 4 Check that there is continuity between the magnet switch terminals and Replace if there is no continuity Magnet switch terminal No Connect CC Disconnect 5 Checkthatthere is no continuity between the magnet switch terminal and starter motor body when the negative battery terminal is removed from the starter mo
289. tle position sensor 1 Engine temperature Overheat thermoswitch Throttle valve opening Intake temperature Main switch 0 90 Throttle position sensor 2 Oil pressure Main relay 10 Accelerator position Intake cam timing Electronic throttle sensor 1 STBD Y relay Accelerator position Intake cam timing Fuel pump relay 2 sensor 2 PORT Atmospheric pressure Engine stop lanyard Switch Battery voltage 12 16 Shift position switch Intake air pressure Intake air temperature IL Engine oil pressure 1 Intake cam timing starboard 1 Intake cam timing port 6 Neutral switch 1 Shift cut switch 1 Thermoswitch IL Engine start switch 0 Main relay ignition coil fuel injector variable camshaft timing ECM low pressure fuel pump high pressure fuel pump 11 Electronic throttle valve relay 12 High pressure fuel pump relay 6AL3 11 9 2 TRBL 1 SHTG e Troubleshooting 4 Stationary test Operation tests can be performed with the engine off Items For F L 200C F L 225B Ignite ignition coil Oil ctrl valve drive Operate electric fuel 1 6 STBD pump Operate injector Oil ctrl valve drive Operate elect fuel feed 1 6 PORT pump D Oil control valve drive starboard TZ Oil control valve drive port 3 Operate high pressure fuel pump 4 Operate low pressure fuel pump 5 Data logger Displays 13 minutes of recorded data for 2 o
290. to the parts when install ing the propeller shaft housing assembly in the reverse direction use flangeless bolts M8 x 30 mm without washers 5 Remove the ring nut and claw washer DQ S6AL6380 6 Remove the bearing outer race 0 taper roller bearing thrust bearing and propeller shaft shim s using a press 6AL3 11 Propeller shaft housing counter rotation model S6AL6390 CAUTION lt Do not press the propeller shaft threads Q directly lt Do not reuse the taper roller bearing always replace it with a new one 7 Remove the oil seals and needle bear ing JE e ta S6AL6400 Needle bearing attachment 90890 06611 Driver rod L3 90890 06652 Checking the propeller shaft housing 1 Check the water pipe Replace the water pipe if corrosion deformation or cracked 2 Clean the propeller shaft housing and then check it Replace the propeller shaft housing if cracked or damaged 6 38 Lower unit 3 Check the teeth and dogs of the forward gear Replace the forward gear if cracked or worn gt Check the bearings Replace the bear ings if pitted or if there is rumbling Checking the propeller shaft 1 Check the propeller shaft Replace the propeller shaft if bent or worn N Measure the propeller shaft runout Replace the propeller shaft if above specification S6P26220C AS Propeller shaft runout limit 0 02 mm 0 0008 in 3 Check the
291. too low water resistance will increase and reduce engine efficiency A t S69J1160 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 differ ent heights 2 Check that the clamp brackets are secured with the clamp bolts Checking the remote control cable 1 Set the remote control lever to the neu tral position and fully close the throttle lever 2 Check that the accelerator lever D con tacts the fully closed stopper 1 23 S6P 21030 NOTE SS To adjust the throttle cable see Chapter 3 Adjusting the throttle cable 3 Check that the center of the set pin is aligned with the alignment mark on the bracket S6P21040 jam O co CT S6AL3120 A WARNING The shift throttle cable joint must be screwed in a minimum of 8 0 mm 0 31 in 6AL3 11 Predelivery check Checking the steering system 3 Check that there is no interference with 1 Check that the steering operates wires or hoses when the tilted up out smoothly board motor is steered 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 2 S69J1200 Check that there is no interference with
292. tor body Replace ifthere is continuity 8 45 NOTE __ __ e The starter motor pinion should be pushed out while the magnet switch is ON e If the starter motor is disassembled for maintenance be sure to check the magnet switch again after assembling it 6 Disconnect the negative battery cable and positive battery cable from the bat tery terminals Checking the starter motor pinion CAUTION Be sure to disconnect the battery cables before checking the starter motor pinion 1 Check the pinion teeth Replace the pin ion if cracked or worn 2 Check for smooth operation NOTE _ Turn the pinion counterclockwise to check that it operates smoothly and turn it clockwise to check that it locks in place Disassembling the starter motor 1 Remove the bolts and then disassem ble the starter motor body S6AL8230 6AL3 11 2 Remove the stator 3 Remove the armature with the brush holder assembly from the bracket S6AL8260 4 Remove the plate and then remove the armature from the brush holder assembly ATI TT Wl ri S6AL8270 NOTE Do not scratch or damage the brushes when removing the armature 5 Remove the magnet switch and spring 6AL3 11 Starter motor S6AL8210 6 Slide the pinion stopper down as shown and then remove the clip 49 S6AL8220 NOTE Remove the clip with a screwdriver 7
293. ts and timing belt NOTE To install the camshafts driven sprockets and timing belt see Chapter 5 Installing the camshaft driven sprocket and timing belt 6AL3 11 Cylinder head 5 56 Cylinder block Crankcase 23 N mi2 3kgi m 17 0f 1b MI O 43 N m 4 3 kgf m 31 7 ft Ib PJ 15N m 1 5 kgf m 11 1 ft Ib 28N m 2 8 kgf m 20 7 ft Ib S6AL5460 Part name 4 Remarks Oil filter Oil pressure sensor O ring Bolt M6 x 45 mm Joint Oil filter bracket Gasket Bolt M6 x 20 mm Crankcase cover Bolt M8 x 45 mm Oil filler cap O ring Gasket Dowel O ring Bolt M6 x 20 mm Blowby hose joint 5 57 6AL3J 11 Cylinder block 23 N mi2 3kgi m 17 0f 1b 43 N m 4 3 kgf m 31 7 ft Ib 90 N 14N m 1 4 kgf m 10 3 ft Ib YO 28 N m 2 8 kgf m 20 7 ft Ib s6a15460 Partname i Remarks Engine stopper STBD Bolt Engine stopper PORT Washer Engine temperature sensor Piston ring set Clip Piston pin Piston Connecting rod Connecting rod bearing Bolt Not reusable kb m KA bi OO OO Ou On i i Pr M9 x 42 mm Bolt M6 x 12 mm Holder Cooling water hose Vapor gas hose Check valve 6AL3 11 5 58 Cylinder block 27 d i 33 34 i Rx J7 N m 0 7 kgf m 5 2 ft Ib ee 40 N m 4 0 kgf m 29 5 ft Ib 90
294. ttom cowling the bracket and the spring end into 1 Install the PTT switch o holder and the cutout in the bracket holder regular rotation model a D E KD STBD S6AL7100 S6AL7140 3 Turn the bracket to the position as shown push it down and then tempo rarily install the shift bracket bolt N abid N A Regular rotation model B Counter rotation model 4 Tighten the shift bracket bolt to the specified torque S6AL7A40 NOTE EE Fasten the PTT switch lead with the holder I S6AL7110 2 Pass the flushing hose trim sensor lead and PTT motor leads through the grommet and then secure them by fastening the plastic ties around the grommet as shown CAUTION Move the shift cut switch lever in direc tion when pushing the shift bracket down otherwise the lever may be dam aged 3 Install the grommet to the bottom Shift bracket bolt cowling 19 N m 1 9 kgf m 14 0 ft lb 7 7 6AL3 11 Shift rod and bottom cowling NOTE ay E e Fasten the flushing hose and trim sensor TN lead with the plate 09 Y L e Fasten the flushing hose trim sensor EN lead and speedometer hose on with the plate e Fasten the flushing hose trim sensor lead and PTT switch lead counter SC rotation model with the clamp T gi a s Eni eee a lt PE 6 I
295. unt housings Gm S6AL7370 NOTE Make sure that the ground lead is not dam aged Installing the upper case 1 Install the washers onto the lower mounting bolts Install the upper and lower mounting bolts into the bracket assembly simul taneously Install the washers upper mounting nuts and lower mounting nuts and then tighten them to the specified torques Pass the speedometer hose through the steering arm and then connect it to the speedometer hose adapter Connect the ground lead 6AL3 11 Upper case and steering arm S6AL7410 Needle bearing attachment 90890 06612 b Gear puller HO commercially available 0 3 Remove the steering arm from the swivel 4 bracket by pulling the arm off the bracket SES Installing the steering arm 1 Install the washer and bushing onto Upper mounting nut the steering arm 72 N m 7 2 kgf m 53 1 ftlb Lower mounting nut 2 Place the swivel bracket in an upright 72 N m 7 2 kgfm 53 1 ftilb position and then install the steering arm onto the swivel bracket Removing the steering arm 1 Remove the circlip S69J7080 S6AL7400 2 Remove the steering yoke as shown 6AL3J 11 7 20 Bracket unit 3 Install the bushing a new O ring the bushing and the washer onto the swivel bracket 4 5 TAN GA fi gt S6AL7430 7 Inject gr
296. utput Diagnosis code output YDIS Ver 1 23a Diagnosis record YDIS Ver 1 23a 1 Normal O 13 Pulser coil malfunction 15 Engine temp sensor malfunction 17 Knock sensor malfunction 19 Battery voltage malfunction 23 Intake temp sensor malfunction 24 Cam position sensor EXH malfunction 0101001010 O O O O O O 28 Shift position switch malfunction 29 Intake press sensor malfunction 37 Intake air passage malfunction 39 Oil press sensor malfunction O O O O 44 Engine stop lanyard switch malfunction 01010010 45 Shift cut off switch malfunction O 46 Overheat thermoswitch malfunction O 71 Cam position sensor STBD INT malfunction O 72 Cam position sensor PORT INT malfunction 73 Oil control valve STBD 14 Oil control valve PORT 112 113 114 115 116 117 118 119 121 122 123 129 136 137 138 139 141 142 143 144 145 Electronic throttle system malfunction 124 125 126 127 128 Throttle position sensor malfunction 131 132 133 134 135 9 7 Accelerator position sensor malfunction 6AL3 11 Troubleshooting the power unit Symptoms table Engine Engine idle Maximum engine speed Acceleration Symptom startability speed Starts Normal Normalt Normal 4 Decreases Poor Increases Normal Normal stea
297. valve 1 Connect the special service tool to the vapor shut off valve as shown 2 Apply the specified negative pressure to the vapor shut off valve 3 Check that the vapor shut off valve opens and the negative pressure is released when the battery voltage is applied to the vapor shut off valve termi nals QD NOTE 0 Apply the battery voltage to the vapor shut off valve terminals for a few seconds only other wise the vapor shut off valve may be dam aged 6AL3 11 S6AL8650 CZ Vacuum pressure pump gauge set 90890 06756 Specified negative pressure 67 kPa 0 7 kgf cm 9 7 psi 4 Measure the resistance between the vapor shut off valve terminals Vapor shutoff valve resistance reference data 30 0 34 0 Q at 20 68 F Starting system Checking the fuse 1 Check the fuses for continuity Replace if there is no continuity NOTE For the location of the fuse see Chapter 8 Fuse holder 8 40 evec E ELEC E Electrical system Checking the starter relay 1 Remove the starter relay and check it O 0 0 ON d B R ruse a EEE SS FUSE BIGLE 9 gt Net a TOL el S6P28190 NOTE The high pressure fuel pump relay and m
298. vapor shut off valve WD See the wiring diagram 6AL3 11 Check the vapor shut off valve TRBL D SHTG e Troubleshooting Symptom 1 Unstable engine idle speed poor acceleration poor performance or limited engine speed Symptom 2 Cause 1 Cause 2 Checking step Spark plug does not spark some cylinders Spark plug malfunc tion Check the ignition spark Check the spark plugs Short open or loose connection in ignition coil circuit Check the wiring harness continuity Ignition coil mal function Change the ignition coil and check the ignition spark ECM malfunction Change the ignition coil and check the ignition spark High pressure fuel line malfunction fuel pressure is low Pressure regulator malfunction Check the pressure regulator High pressure fuel pump malfunction Check the high pressure fuel pump continuity Fuel not supplied Some cylinders Fuel injector mal function Check the fuel injector operation Measure the fuel injector resistance Short open or loose connection in fuel injector circuit Check the wiring harness continuity ECM malfunction Change the fuel injector and check the fuel injector operation Clogged fuel injec tor filter Replace the fuel injector Low compression pressure Scratched piston Damaged valve Valve stuck to valve guide WD
299. ve shaft or lower case e To select the shims see Chapter 6 Shim ming counter rotation model e To install the pinion nut push down on the drive shaft 4 Install a new O ring to the drive shaft housing and then install the drive shaft housing into the lower case te S ES Wa CT NG E S6AL6110 NOTE er Install the drive shaft housing with the cutout in the housing facing forward as shown 5 Tighten the pinion nut to the specified torque S6AL6150 Cz Drive shaft holder 6 90890 06520 Pinion nut holder 90890 06715 Pinion nut 142 N m 14 2 kgfm 104 7 ft lb 6AL3 11 Installing the propeller shaft housing 1 Setthe shift rod joint and dog clutch to the neutral position as shown 2 Apply grease to new O rings and propel ler shaft housing 3 Install a new dowel and the propeller shaft housing assembly into the lower case S6AL6510 4 Install the washer and propeller shaft housing bolts and then tighten the bolts to the specified torque 5 Install the ring and bolts S6AL6A20 Propeller shaft housing bolt 30 N m 3 0 kgf m 22 1 ft lb 6 Install the water pipe and rubber seals 6 48 Lower unit Installing the water pump and shift rod 1 Install the shift rod assembly S6AL6880 NOTE dd e Set the gear shift to the neutral position when installing the
300. vnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 4 12 Throte TUE 4 13 Checking the electronic throttle valve system eerren 4 16 CHECKING the canister ss sautant esenes 4 16 Checking the canister check valve NN 4 16 Installing the throttle body nssunsjunvanmedndsdriksvisvjasiner 4 17 Fuel filter asasaran anana a angayangan ES NAN EE 4 19 Checking the fuel filter assembly anane a nenen nana ananeng 4 20 Low pressure fuel PUMP sms 4 21 Checking the low pressure fuel pump ENEE 4 22 Checking the fuel filter 4 22 Checking the dealer 4 22 FUG JOC TN 4 23 CHECKING Wie Med ras saa aaa nn ete a Geer 4 24 Installing the fuel miechor AAA 4 24 Vapor Separator sssssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnannnnnnnnnnnnnnnnnnnnnnnnnnnn nannan nananana 4 26 Removing the fuel hose camp 4 29 Installing the fuel hose clamp vannst ieeeeniensunie 4 29 Checking the high pressure fuel pump REENEN 4 29 CHECKING the vapor separator sienne anana anana aana anana 4 29 6AL3 11 el D Fuel system Hose routing Fuel hose and blowby hose Fuel hose Fuel hose Fuel hose Fuel hose Fuel hose Fuel hose Fuel hose Fuel hose tor Fuel hose Fuel hose Fuel hose Fuel hose fuel joint to fuel filter fuel filter to joint joint to low pressure fuel pump low pressure fuel pump to filter filter to joint joint to check valve check valve to joint PE JE EE quick connector to joint joint to quick connector pressure
301. with the A mark on the cyl inder block by turning the crankshaft clockwise 60 gradually Ng S6P25670 CAUTION Do not turn the crankshaft clockwise more than 60 Otherwise the piston and valves will collide with each other and be damaged 16 Check that the I marks on the star board driven sprockets are aligned 6AL3 11 5 30 17 Install the timing belt onto the drive sprocket with the arrow mark facing upward and align the timing belt mark with the mark on the drive sprocket S6AL5370 i IDODI 2 FU UVA RAR YURI t oi t t 60 88 133 160 E S6P 25460E Belt teeth number CAUTION Do not twist turn inside out or bend the timing belt beyond the maximum limit of 25 mm 1 0 in otherwise it can be dam aged Do not get oil or grease on the timing belt 18 Install the timing belt onto the driven sprockets by aligning belt position marks through with the A marks on the driven sprockets 5 31 S6P25700E 19 Adjust the timing belt to the specified installation height AA 2 EN 6P2 46241 xx IN D A Cap TT IN S6P25710 Timing belt installat

Grey Whale 200 EFI Fin Whale 225 EFI

Contents

Download Pdf Manuals

Related Search

Related Contents