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Yamaha F200B Service Manual

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Table of Contents

Quick Links

See also: Owner's Manual
F200B
FL200B
F250G
FL250G
SERVICE MANUAL
6DX-28197-5P-11
Table of Contents
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Summary of Contents for Yamaha F200B

  • Page 1 F200B FL200B F250G FL250G SERVICE MANUAL 6DX-28197-5P-11...

  • Page 2: Important Information

    Preface This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have the Bronze Technical Certificate of the YTA...
  • Page 3 Contents General information INFO Specification SPEC TECH Technical features and description Rigging information GING TRBL Troubleshooting SHTG Electrical system ELEC Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT Maintenance Index Appendix...

  • Page 5: Table Of Contents

    INFO General information Safety while working ............. 0-1 Rotating part................0-1 Hot part..................0-1 Electric shock ................0-1 Propeller ..................0-1 Handling of gasoline..............0-1 Ventilation................... 0-1 Self-protection ................0-2 Working with crane..............0-2 Handling of gas torch ..............0-2 Part, lubricant, and sealant............

  • Page 6: Safety While Working

    INFO General information Safety while working Handling of gasoline • Gasoline is highly flammable. Keep gaso- To prevent an accident or injury and to pro- line and all flammable products away from vide quality service, observe the following heat, sparks, and open flames. safety procedures.

  • Page 7: Self-Protection

    Yamaha, when servicing or repairing the out- • If the outboard motor does not have three board motor. or more points to be suspended, support it...

  • Page 8: Special Service Tool

    INFO General information Special service tool Disassembly and assembly Use the recommended special service tools • Use compressed air to remove dust and dirt to work safely, and to protect parts from dam- during disassembly. age. • Apply engine oil to the contact surfaces of moving parts before assembly.

  • Page 9: How To Use This Manual

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

  • Page 10: Abbreviation

    INFO General information Abbreviation The following abbreviations are used in this service manual. Abbreviation Description ABYC American Boat and Yacht Council Aft end American Petroleum Institute Accelerator Position Sensor Automatic Transmission Fluid American Wire Gauge Bow end BTDC Before Top Dead Center Check Engine Centerline Cold Cranking Ampere...
  • Page 11 How to use this manual Abbreviation Description Throttle Position Sensor Upside Variable Camshaft Timing Water in Fuel YDIS Yamaha Diagnostic System...

  • Page 12: Lubricant, Sealant, And Thread Locking Agent

    Lubricant, sealant, and thread locking agent Symbol Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication points. Symbol Name Application Yamaha 4-stroke motor oil Lubricant Gear oil Lubricant Water resistant grease Lubricant (Yamaha grease A)
  • Page 13 Lubricant, sealant, and thread locking agent Symbol Name Application ThreeBond 1386B Sealant ThreeBond 1401 Thread locking agent ThreeBond 1530D Sealant LOCTITE 242 (blue) Thread locking agent LOCTITE 271 (red) Thread locking agent LOCTITE 572 (white) Sealant Silicone sealant Sealant...

  • Page 14: Special Service Tool

    INFO General information Special service tool For all markets except U.S.A. and Canada Special service tools with Yamaha part numbers (90890/60V-*****) are distributed by the Parts Divi- sion. Drilling plate Peak voltage adapter 90890-06783 90890-03172 YDIS (CD-ROM, Ver. 1.33) Test harness (3 pins)
  • Page 15 Special service tool Fuel pressure gauge adapter B Flywheel magnet holder 90890-06942 90890-06522 Fuel pressure gauge Flywheel puller 90890-06786 90890-06521 Leakage tester Sheave holder 90890-06840 90890-01701 Compression gauge Valve spring compressor 90890-03160 90890-04019 Compression gauge extension Valve spring compressor attachment 90890-06563 90890-06320 0-10...
  • Page 16 INFO General information Valve guide remover/installer Valve seat cutter 30° (intake) 90890-06801 90890-06817 Valve guide installer Valve seat cutter 30° (exhaust) 90890-06810 90890-06326 Valve guide reamer Valve seat cutter 45° (intake) 90890-06804 90890-06816 Valve lapper Valve seat cutter 45° (exhaust) 90890-04101 90890-06325 Valve seat cutter holder...
  • Page 17 Special service tool Oil filter wrench Needle bearing attachment 90890-06830 90890-06653 Driver rod L3 Shift rod socket 90890-06652 90890-06679 Needle bearing attachment Bearing housing puller claw L 90890-06613 90890-06502 Needle bearing attachment Stopper guide plate 90890-06607 90890-06501 Piston ring compressor Center bolt 90890-05158 90890-06504...
  • Page 18 INFO General information Slide hammer handle Needle bearing attachment 90890-06531 90890-06611 Bearing outer race puller assembly Driver rod SS 90890-06523 90890-06604 Bearing separator Needle bearing attachment 90890-06534 90890-06610 Stopper guide stand Bearing depth plate 90890-06538 90890-06603 Bearing puller assembly Bearing inner race attachment 90890-06535 90890-06640 0-13...
  • Page 19 Special service tool Needle bearing attachment Bearing inner race attachment 90890-06654 90890-06658 Drive shaft holder 6 Bearing inner race attachment 90890-06520 90890-06659 Pinion nut holder Bearing outer race attachment 90890-06715 90890-06628 Ball bearing attachment Driver rod LS 90890-06655 90890-06606 Driver rod LL Backlash indicator 90890-06605 90890-06706...
  • Page 20 INFO General information Magnet base plate Ring nut wrench 90890-07003 90890-06578 Dial gauge set Ball bearing attachment 90890-01252 90890-06557 Magnet base B PTT oil pressure gauge assembly 90890-06844 90890-06580 Pinion height gauge Cylinder-end screw wrench 90890-06672 90890-06568 Puller head PTT piston vice attachment 90890-06514 90890-06572 0-15...
  • Page 21 Special service tool Tilt rod wrench 90890-06569 0-16...
  • Page 22 SPEC Specification Model features ..............1-1 General feature ................1-1 Model designation ..............1-2 Serial number ................1-3 Model data ................1-4 Dimension and weight ..............1-4 Performance................1-4 Power unit .................. 1-4 Lower unit................... 1-5 Bracket unit ................1-5 Fuel and oil requirement.............
  • Page 23 Lower unit (counter rotation model).......... 1-19 Bracket unit ................1-19 PTT unit..................1-20 General tightening torque ..........1-21...

  • Page 24: Model Features

    SPEC Specification Model features General feature F200B, FL200B, F250G, and FL250G Overall feature • Electronic fuel injected, 60° V6, DOHC, 24-valves, VCT, 3352.0 cm (204.5 cu. in) engine • 6Y8 Multifunction Meter for easy rigging and precision engine information • Low emission in compliance with EU regulation a Power unit •...

  • Page 25: Model Designation

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

  • Page 26: Serial Number

    F200BET 1002876– bracket. FL200BET 1001074– F250GET 1000001– FL250GET 1000001– YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON 1 Model name 2 Approved model code 3 Transom height 4 Serial number...

  • Page 27: Model Data

    Model features / Model data Model data Dimension and weight Model Item Unit F200BET FL200BET F250GET FL250GET Overall length mm (in) 868.0 (34.2) Overall width mm (in) 634.0 (25.0) Overall height mm (in) 1829.0 (72.0) mm (in) 1956.0 (77.0) Outboard motor transom height mm (in) 643.0 (25.3) mm (in)

  • Page 28: Lower Unit

    SPEC Specification Lower unit Model Item Unit F200BET FL200BET F250GET FL250GET 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 Clock- Counter- Clock- Counter- Propeller direction (rear view) wise clockwise wise...

  • Page 29: Battery Requirement

    Model data Battery requirement Model Item Unit F200BET FL200BET F250GET FL250GET Minimum cold cranking amps CCA/EN 711.0 Minimum rated capacity 20HR/IEC 100.0 PTT fluid requirement Model Item Unit F200BET FL200BET F250GET FL250GET Fluid type ATF Dexron II...

  • Page 30: Electrical System Technical Data

    SPEC Specification Electrical system technical data Ignition timing control system Model Item Unit F200BET FL200BET F250GET FL250GET Spark plug mm (in) 1.0–1.1 (0.039–0.043) Ignition coil Input voltage 12.0 Pulser coil Air gap mm (in) 1.4–1.6 (0.055–0.063) Resistance (*1) Ω At 20 °C (68 °F) 396.0–594.0 Output peak voltage At cranking (unloaded)

  • Page 31: Fuel Injection Control System

    Electrical system technical data Fuel injection control system Model Item Unit F200BET FL200BET F250GET FL250GET Fuel line Pressure (*1) Within 5 seconds after engine start switch (kgf/cm 290.0 (2.90, 42.1) turned to ON psi) At engine idle speed (kgf/cm 260.0 (2.60, 37.7) psi) Fuel injector Resistance (*1)

  • Page 32: Ptt System

    SPEC Specification Model Item Unit F200BET FL200BET F250GET FL250GET With remote control lever fully closed APS 1 0.550–0.850 APS 2 0.400–1.000 With remote control lever fully open APS 1 and APS 2 Above 3.250 Output voltage (*1) With throttle valve fully closed TPS 1 0.500–0.700...

  • Page 33: Charging System

    Electrical system technical data Charging system Model Item Unit F200BET FL200BET F250GET FL250GET Lighting coil Resistance (*1) Ω At 20 °C (68 °F) 0.11–0.17 Output peak voltage At cranking (unloaded) At 1500 r/min (unloaded) 44.7 At 3500 r/min (unloaded) 97.7 Fuse Rectifier Regulator Output peak voltage...

  • Page 34: Gauge/Sensor

    SPEC Specification Gauge/sensor Model Item Unit F200BET FL200BET F250GET FL250GET Water pressure sensor Input voltage 4.75–5.25 Output voltage (*1) At 392.0 kPa (3.92 kgf/cm , 56.8 psi) At 784.0 kPa (7.84 kgf/cm , 113.7 psi) Speed sensor Input voltage 4.75–5.25 Output voltage (*1) At 392.0 kPa (3.92 kgf/cm...

  • Page 35: Power Unit Technical Data

    Electrical system technical data / Fuel system technical data / Power unit technical data Power unit technical data Power unit Model Item Unit F200BET FL200BET F250GET FL250GET Cylinder Minimum compression (kgf/cm 630.0 (6.30, 91.4) pressure (*1) psi) Engine oil Oil pressure (*2) At 60 °C (140 °F) with SL 10W-30 engine oil and at (kgf/cm...

  • Page 36: Crankcase Assembly

    SPEC Specification Model Item Unit F200BET FL200BET F250GET FL250GET Valve spring Free length mm (in) 48.1 (1.89) Tilt mm (in) 1.7 (0.07) Valve lifter Outside diameter mm (in) 30.970–30.980 (1.2193–1.2197) Valve lifter clearance mm (in) 0.020–0.055 (0.0008–0.0022) Camshaft Cam lobe height Intake mm (in) 46.311–46.411 (1.8233–1.8272)
  • Page 37 Power unit technical data Model Item Unit F200BET FL200BET F250GET FL250GET Piston ring Top ring Type Barrel Dimension height (B) mm (in) 1.200 (0.0472) Dimension width (T) mm (in) 2.800–3.000 (0.1102–0.1181) End gap (*1) mm (in) 0.200–0.300 (0.0079–0.0118) Side clearance mm (in) 0.030–0.050 (0.0012–0.0020) 2nd ring...

  • Page 38: Lower Unit Technical Data

    SPEC Specification Lower unit technical data Lower unit assembly (regular rotation model) Model Item Unit F200BET F250GET Lower unit Holding pressure (kgf/cm 68.6 (0.686, 9.9) psi) Forward gear backlash (*1) mm (in) 0.26–0.65 (0.0102–0.0256) Reverse gear backlash (*1) mm (in) 0.23–0.88 (0.0091–0.0346) Pinion shim (T3) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50...

  • Page 39: Bracket Unit Technical Data

    Lower unit technical data / Bracket unit technical data Bracket unit technical data PTT system Model Item Unit F200BET FL200BET F250GET FL250GET Hydraulic pressure (*1) Down (kgf/cm 6.7–8.7 (67.0–87.0, 971.5–1261.5) psi) (kgf/cm 13.0–15.0 (130.0–150.0, 1885.0–2175.0) psi) Motor brush Standard length mm (in) 11.5 (0.45) Wear limit...

  • Page 40: Specified Tightening Torque

    SPEC Specification Specified tightening torque Specified tightening torques are provided for specific nuts, bolts, and screws. When tightening these fasteners, follow the tightening torque specifications indicated throughout the manual to meet the design aims of the outboard motor. Rigging information Tightening torques Part to be tightened Screw size...
  • Page 41 Specified tightening torque Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb PTT relay terminal nut — Engine ECM bolt Timing belt tensioner bolt — 28.8 Pulley bolt 28.8 Cylinder head cover bolt Ignition coil bolt Spark plug —...

  • Page 42: Lower Unit (Regular Rotation Model)

    SPEC Specification Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb 10.3 Crankcase bolt (length: 55 mm) 20.7 Anode bolt Anode — Thermostat cover plug 17.0 Connecting rod bolt 17.0 90° Lower unit (regular rotation model) Tightening torques Part to be tightened Screw size N·m...

  • Page 43: Ptt Unit

    Specified tightening torque Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb Upper mounting nut 53.1 — Lower mounting nut — 53.1 Upper mount bracket bolt 39.8 Engine oil drain bolt 20.7 Baffle plate screw Apron stay — 14.8 Oil pan assembly bolt 31.0...

  • Page 44: General Tightening Torque

    SPEC Specification General tightening torque This chart indicates the tightening torques for standard fasteners with a standard ISO thread pitch. General torque Width Screw specifications across size (B) flats (A) N·m kgf·m ft·lb 8 mm 10 mm 12 mm 13.3 14 mm 26.6 17 mm...
  • Page 45 TECH Technical features and description Electronic control system ..........2-1 Engine control system component ..........2-2 Actuator, sensor, and switch ............2-3 Electronic fuel injection control........... 2-4 Digital ignition control ..............2-5 VCT control ................2-6 Knock control................2-7 Over-rev control and alert control..........2-8 ETV control.................

  • Page 46: Tech Fea

    TECH Technical features and description Electronic control system These models use electronic fuel injection control, digital ignition control, VCT control, knock con- trol, over-rev control, alert control, ETV control, and fail-safe control. The engine ECM performs these controls according to the signals sent from various sensors and switches. In addition, the engine ECM has a self-diagnosis function to perform troubleshooting using the YDIS.

  • Page 47: Engine Control System Component

    Electronic control system Engine control system component 1 OCV (STBD) D Engine temperature sensor 2 Thermoswitch (STBD) E Thermoswitch (PORT) 3 APS F OCV (PORT) 4 Neutral switch G Cam position sensor (PORT IN) 5 Shift cut switch H Fuel injector (PORT) 6 Fuel injector (STBD) I High-pressure fuel pump 7 Cam position sensor (STBD IN)

  • Page 48: Actuator, Sensor, And Switch

    TECH Technical features and description Actuator, sensor, and switch Engine ECM Determines the engine operating conditions according to the input signals from the sensors, which are installed at various locations on the engine, and sends output signals to operate the actuators to perform the various control functions.

  • Page 49: Electronic Fuel Injection Control

    Electronic control system Electronic fuel injection control In electronic fuel injection control, the engine ECM calculates the precise air and fuel mixture required in each combustion chamber depending on the load and engine speed in order to increase combustion efficiency. The fuel injection amount is controlled by the fuel injector actuation time. There are 2 types of fuel injection timing control: synchronous fuel injection and asynchronous fuel injection.

  • Page 50: Digital Ignition Control

    TECH Technical features and description Digital ignition control In digital ignition control, the engine ECM determines the optimum ignition timing according to the signals from the sensors and sends the primary current to the ignition coils. According to the engine operating conditions, the basic ignition timing and ignition coil energization time are determined.

  • Page 51: Vct Control

    Electronic control system VCT control In VCT control, the engine ECM determines the appropriate intake valve opening timing according to the signals from the sensors. According to the engine operating conditions, the OCVs are oper- ated and the VCT assemblies advance and retard the intake valve opening timing in order to increase the intake and exhaust efficiency at low and mid-range engine speeds and obtain greater acceleration.

  • Page 52: Knock Control

    TECH Technical features and description Knock control In knock control, the engine ECM receives the knock signal from the knock sensor, which is installed on the cylinder block between the cylinder banks. The engine ECM retards the ignition tim- ing and decreases the engine speed according to the amount of knocking to protect the engine from damage.

  • Page 53: Over-Rev Control And Alert Control

    Electronic control system Over-rev control and alert control In over-rev control and alert control, the engine ECM decreases the engine speed to protect the engine from damage. Pulser coil Fuel injector Engine temperature sensor Oil pressure sensor Engine Ignition coil Thermoswitch Shift cut switch 6Y8 Multifunction...

  • Page 54: Etv Control

    TECH Technical features and description ETV control In ETV control, the engine ECM determines the appropriate throttle valve opening according to the signals from the sensors, and controls the throttle valve. The engine ECM is equipped with a learn- ing function that records all of the compensations made by the control to the throttle valve opening for the operating conditions up to that point.

  • Page 55: Fail-Safe Control

    Electronic control system Fail-safe control In fail-safe control, the engine ECM enters the fail-safe mode when an electrical component mal- functions. The fail-safe control system records the trouble codes according to the engine trouble conditions. Trouble Item gauge Trouble conditions to be detected code display Pulser coil...

  • Page 56: Power Unit System

    TECH Technical features and description Power unit system These models are equipped with a V6, 4-stroke engine that has 60° cylinder banks. The power unit features shimless valve lifters, a blowby gas reburning system, a vapor gas treatment system, a sin- gle electronic throttle body, long intake manifolds, large diameter intake valve heads, and an in- bank exhaust system.

  • Page 57: Fuel System Fuel

    Power unit system / Fuel system Fuel system Fuel diagram Primer pump Boat fuel filter (optional) Boat fuel tank Fuel filter (with water separator and water detection switch) Check valve Low-pressure Atmosphere (cowl inside) fuel pump Check valve Canister Atmosphere (cowl outside) Check valve Filter Surge tank...
  • Page 58 TECH Technical features and description È È From the fuel tank 1 Primer pump 2 Fuel filter assembly (with water separator) 3 Low-pressure fuel pump 4 Vapor separator 5 Fuel cooler 6 High-pressure fuel pump 7 Pressure regulator 8 Fuel rail (PORT) 9 Fuel rail (STBD) 0 Fuel injector 2-13...

  • Page 59: Fuel System

    Fuel system Blowby gas reburning system A blowby gas reburning system removes any unburned fuel from the blowby gases and sends it to the combustion chambers to be burned. È É È Blowby gas flow É Engine oil 1 Intake silencer 2 Blowby gas separator (integrated with cylinder head cover) 2-14...

  • Page 60: Vapor Gas Treatment

    TECH Technical features and description Vapor gas treatment Vapor gases from the vapor separator are collected in the canister, and then gradually discharged into the atmosphere after being absorbed and cleaned by the activated charcoal. After the engine is started, the vapor gases in the canister are drawn into the surge tank through the vapor shut-off valve, which is controlled by the engine ECM, and then sent to the intake manifolds and combustion chambers.

  • Page 61: Lubrication System

    Fuel system / Lubrication system Lubrication system Lubrication diagram Piston Camshaft VCT assembly passage hole Crankpin (connecting rod big end) Cylinder head Camshaft journal Crankshaft main journal Valve and related parts Main gallery Oil pressure sensor Oil filter Oil pump with relief valve Oil strainer Oil pan...

  • Page 62: Cooling System

    TECH Technical features and description Cooling system Cooling diagram Thermostat (PORT) Thermostat (STBD) Cylinder block Exhaust cover (PORT) Exhaust cover (STBD) Cylinder head (PORT) Cylinder head (STBD) Cylinder block É Flushing device Upper Exhaust guide Muffler Fuel cooler Rectifier Regulator Lower Exhaust guide Upper case...
  • Page 63 Cooling system É Ê È È Cooling water flow É F(L)200B Ê F(L)250G 1 Water inlet 2 Water pump 3 Oil pan 4 Exhaust guide 5 PCV 6 Thermostat 2-18...
  • Page 64 TECH Technical features and description G C D È È Cooling water flow A Cooling water hose (joint to Rectifier Regulator) 1 Cooling water hose (cylinder block to joint) B Cooling water hose (Rectifier Regulator to 2 Cooling water hose (joint to joint) joint) 3 Cooling water hose (joint to joint) C Cooling water hose (joint to fuel cooler)
  • Page 65 Cooling system G C D È I Flushing hose (joint to cooling water passage cover) J Speedometer hose a Fuel cooler b Rectifier Regulator c Cooling water pilot hole (on the bottom cowling) d Adapter (water pressure sensor) e Water passage cover (on the cylinder block) 2-20...

  • Page 66: Intake And Exhaust System

    TECH Technical features and description Intake and exhaust system The single electronic throttle valve, which is operated by the engine ECM, enables precise control of the intake air. The intake air is smoothly routed into each combustion chamber through the surge tanks and the long intake manifolds for greater power.

  • Page 67: Lower Unit

    Intake and exhaust system / Lower unit Lower unit The outer plate cartridge and insert cartridge of the water pump are hard chromeplated for durability and to protect the parts from abrasion due to muddy water. The lower case and propeller shaft housing are anodized. Drive shaft spring (F250G and FL250G) The spring pushes the drive shaft toward the water pump and stabilizes the thrust free play of the shaft.

  • Page 68: Propeller Damper Cooling (F250G And Fl250G)

    TECH Technical features and description Propeller damper cooling (F250G and FL250G) The water pipe for cooling the propeller damper is incorporated in the lower case. The water intake is located in front of the trim tab to drawn in the water by the dynamic pressure, and the propeller damper is cooled without disturbing the exhaust gas flow.
  • Page 69 GING Rigging information Outboard motor installation ..........3-1 External dimensions ............3-2 F200BET, FL200BET, F250GET, FL250GET......3-2 Clamp bracket ................3-3 Crate top cover pictograph description ......3-4 Uncrating procedure ............3-5 Outboard motor mounting..........3-6 Outboard motor mounting height........3-8 Rigging grommet mounting ..........

  • Page 70: Rigging Information

    • Improper mounting of the outboard motor could result in hazardous conditions, such as poor handling, loss of control, or fire hazards. Consult your dealer or have a Yamaha trained person experienced in proper rigging mount the outboard motor.

  • Page 71: External Dimensions

    Outboard motor installation / External dimensions External dimensions F200BET, FL200BET, F250GET, FL250GET mm (in) X: 1155 (45.5) 619 (24.4) U: 1272 (50.1) 219 (8.6) 651 (25.6) 75 (3.0) 230 (9.1) X: 52 (2.0) U: 59 (2.3) 673 (26.5) (*1) Minimum distance between the outboard motors in twin or triple installation (*2) Transom height TIP: The dimension values may include reference values.

  • Page 72: Clamp Bracket

    GING Rigging information Clamp bracket mm (in) 180 (7.1) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 79 (3.1) 20 (0.8) 13 (0.5) 13 (0.5) 102 (4.0) 102 (4.0) 125.4 (4.9) 125.4 (4.9) TIP: The dimension values may include reference values.

  • Page 73: Crate Top Cover Pictograph Description

    External dimensions / Crate top cover pictograph description Crate top cover pictograph description The following pictographs are important when handling the crate. Read the notice and understand what each pictograph means to prevent damage to the outboard motor when handling, transporting, and storing the crate. Stack limit: Maximum units for storage Upward Handle with care...

  • Page 74: Uncrating Procedure

    GING Rigging information Uncrating procedure 1. Check the crate for shipping damage. 2. Remove the top cover. 3. Remove all of the bolts from the bottom plate, and then remove the frame. NOTICE: Be careful not to damage the outboard motor. 4.

  • Page 75: Outboard Motor Mounting

    Uncrating procedure / Outboard motor mounting Outboard motor mounting Proper mounting of the outboard motor pro- vides better performance, maximum reliabil- ity, and the highest customer satisfaction. This chapter contains the specifications nec- essary to mount the outboard motor, and may vary slightly depending on applications.
  • Page 76 GING Rigging information TIP: TIP: • Make sure that the distance g is equal to This mounting height information is for refer- distance h. ence only. It is impossible to provide com- • If the boat has a V shape hull, the center plete instructions for every possible boat and outboard motor should have longer tran- outboard motor combination.

  • Page 77: Outboard Motor Mounting Height

    Outboard motor mounting / Outboard motor mounting height 5. Apply sealant to the mounting holes and secure the outboard motor using the included mounting bolts 2, small wash- ers 3, large washers 4, and nuts 5. NOTICE: Make sure that there is no clearance between the surfaces of the boat transom and the clamp brackets.

  • Page 78: Rigging Grommet Mounting

    GING Rigging information Rigging grommet mounting Rigging grommet description 3. Remove the rigging grommet 3. a Throttle cable b Extension wiring harness c Water temperature sensor harness (optional) or water pressure sensor hose (optional) d Isolator lead (optional) e Battery cable f Conventional gauge lead (optional) or 6Y8 Multifunction Meter harness (optional) g Fuel hose...
  • Page 79 Rigging grommet mounting 7. Fully screw in the shift cable joint 6 to 12. Adjust the shift cable joint 6, and then install the shift cable joint 6 to the pin h. the shift cable 5. WARNING! The shift cable joint must be screwed in 8.0 mm (0.31 in) or more.

  • Page 80: Installing The Wiring Harness

    GING Rigging information 16. Fully screw in the throttle cable joint B to Throttle cable locknut D: the throttle cable A. 4 N·m (0.4 kgf·m, 3.0 ft·lb) 17. Pull the inner cable so that there is no 21. Check the shift cable and throttle cable free play (backlash).

  • Page 81: Installing The Battery Cable

    Rigging grommet mounting 3. Connect the isolator coupler a. 2. Cut off the tip a of the nipple 2. Installing the battery cable 1. Route the battery cable through the bot- tom cowling. 2. Connect the negative battery cable a, and then tighten the negative battery cable nut 1 to the specified torque.

  • Page 82: Installing The Water Pressure Sensor (Optional)

    GING Rigging information TIP: Cut the tube 5 to 600 mm (23.6 in). 5. Remove the bracket 6. Speed sensor adapter bolt A: 10 N·m (1.0 kgf·m, 7.4 ft·lb) 9. Connect the extension hose 3 to the speed sensor adapter 0, and then fas- ten the extension hose using the plastic 6.

  • Page 83: Installing The Rigging Grommet

    Rigging grommet mounting 1. Remove the engine ECM cover 1, and then remove the plug 2. 5. Install the engine ECM cover. Installing the rigging grommet 2. Install the water pressure sensor 3 to the water pressure sensor adapter 4, 1.

  • Page 84: Remote Control Box And Switch Panel Installation

    GING Rigging information 5. Install the rigging tube retainer 3, and then fasten it using the plastic tie 4. Remote control box and switch panel installation See the Remote Control Box Operation Man- ual or Rigging Guide for the installation pro- cedures.

  • Page 85: Battery Installation

    Remote control box and switch panel installation / Battery installation Battery installation • Make sure to connect the battery properly and select the proper cable sizes. Otherwise, a fire could result. • When installing an isolator lead to the positive battery terminal or battery switch, over-cur- rent protection in compliance with ABYC (E-11) must be provided.
  • Page 86 GING Rigging information STBD PORT Outboard Outboard motor motor Isolator lead Black Red Black Black Outboard motor Isolator lead Black Battery switch ON/OFF STBD PORT Outboard Outboard motor motor Isolator lead Isolator lead Black Black ON/OFF ON/OFF Battery switch Battery switch Black 3-17...

  • Page 87: Battery Cable Routing With House (Accessory) Battery

    Battery installation STBD PORT Outboard Outboard motor motor Battery switch Battery switch Navigation systems Boat systems Black Black ON/OFF ON/OFF Black Black Black Battery cable routing with house (accessory) battery • When only one battery is used for one engine, connect the positive battery cable and isola- tor lead to the positive battery terminal.
  • Page 88 GING Rigging information Outboard motor Isolator lead Battery switch Battery switch ON/OFF Black House battery Outboard motor Isolator lead Black Black House battery Outboard motor Isolator lead Black Battery switch Black House battery 3-19...
  • Page 89 Battery installation STBD PORT Outboard Outboard motor motor Isolator lead Isolator lead Black Black Battery switch Battery switch ON/OFF ON/OFF Black Black Battery switch House battery STBD PORT Outboard Outboard motor motor Isolator lead Isolator lead Black Black Battery switch Battery switch ON/OFF Black...
  • Page 90 GING Rigging information STBD PORT Outboard Outboard motor motor Isolator lead Isolator lead Black Black Battery switch Battery switch House battery Black Black STBD PORT Outboard Outboard motor motor Isolator lead Isolator lead Battery switch Battery switch Black ON/OFF ON/OFF ON/OFF Black Black...
  • Page 91 Battery installation / System diagram 3-22...
  • Page 92 GING Rigging information P B P/B É Ê Ë (*1) Hub 1 (*1) È (*1) (*1) 3-23...

  • Page 93: System Diagram

    System diagram 3-24...
  • Page 94 GING Rigging information P B P/B (*1) (*1) È É (*1) Hub 3 Hub 2 (*1) Hub 1 3-25...
  • Page 95 System diagram 3-26...
  • Page 96 GING Rigging information P B P/B È É Hub 3 (*1) (*1) Hub 2 (*1) (*1) (*1) Hub 1 (*1) Hub 4 3-27...

  • Page 97: Rigging Recommendation

    System diagram / Rigging recommendation Rigging recommendation Extension length recommendation for battery cable Do not exceed the recommended extension length for the battery cable. Otherwise, the elec- trical system could be damaged or operate improperly. To extend the length of battery cables, follow the requirements in the tables for your battery capac- ity, cable size, and ambient temperature.

  • Page 98: Propeller Selection

    GING Rigging information Propeller selection The propeller sizes listed in the propeller list indicate the following information: The size and type of propeller that is used will affect the performance of a boat and out- board motor critically. Propellers greatly affect boat speed, acceleration, engine life, fuel economy, and even boating and steering capabilities.
  • Page 99 S-Steel 6D0-45970-00 15 1/2 S-Steel 6D0-45978-00 15 3/4 S-Steel 6G5-45932-00 15 3/4 S-Steel 6D0-45976-00 13 1/2 Aluminum 6G5-45949-00 F200B only 13 3/4 Aluminum 6G5-45943-01 F200B only Aluminum 6G5-45945-01 F200B only 14 1/2 Aluminum 6G5-45947-01 F200B only 14 5/8 Aluminum 6G5-45952-00...
  • Page 100 GING Rigging information Counter rotation model Dia. (in) Pitch (in) Mark Material Part number Remarks 13 3/8 S-Steel 6K1-45976-00 13 3/4 S-Steel 6K1-45978-02 13 3/4 S-Steel 68G-45974-00 13 3/4 S-Steel 6K1-45974-02 13 3/4 S-Steel 6K1-45972-01 13 3/4 S-Steel 68G-45976-00 14 1/4 S-Steel 68G-45972-00 14 1/4...
  • Page 101 TRBL SHTG Troubleshooting YDIS ..................4-1 Feature ..................4-1 Hardware requirement..............4-1 Function..................4-2 Connecting the communication cable to the outboard motor ..4-5 Outboard motor troubleshooting........4-6 Troubleshooting procedure ............4-6 Troubleshooting the power unit using the YDIS ......4-6 Trouble code and checking step ..........

  • Page 102: Troubleshooting

    TRBL SHTG Troubleshooting YDIS This manual contains the model-specific information. See the YDIS Instruction Manual for detailed information. Feature The YDIS provides quicker detection and analysis of engine malfunctions. By connecting your computer to the engine ECM of an outboard motor using the communication cable, this software can be used to display sensor data and data stored in the engine ECM on the computer monitor.

  • Page 103: Function

    YDIS TIP: • The amount of memory and the amount of free space on the hard disk differs depending on the computer. • Using this software while there is not enough free space on the hard disk could cause errors and result in insufficient memory.
  • Page 104 TRBL SHTG Troubleshooting • Stationary test Operation tests can be performed while the engine is stopped. Oil ctrl. valve drive (STBD) Operate electric fuel pump Ignite ignition coil (#1–#6) (*1) (*3) Oil ctrl. valve drive (PORT) Operate elect. fuel feed Operate injector (#1–#6) (*2) pump (*4)
  • Page 105 YDIS (*1) Intake air pressure (*2) This item shows the target output voltage of the TPS. This value is the control voltage that the engine ECM requires to set the target opening angle of the throttle valve. (*3) Reference TPS voltage This item shows the criterion output voltage of the TPS.

  • Page 106: Connecting The Communication Cable To The Outboard Motor

    TRBL SHTG Troubleshooting Connecting the communication cable to the outboard motor a YDIS coupler (gray) YDIS (CD-ROM, Ver. 1.33) 1: 60V-WS853-06 YDIS USB adapter and cable 2: 60V-WS850-00...

  • Page 107: Outboard Motor Troubleshooting

    YDIS / Outboard motor troubleshooting Outboard motor troubleshooting Troubleshooting procedure 1. Before troubleshooting the outboard motor, check that fresh fuel of the specified type has been used. 2. Check that all electrical connections are secure and free from corrosion, and that the battery is fully charged.
  • Page 108 TRBL SHTG Troubleshooting Trouble code table : Indicated — : Not indicated Trouble Diagnostic YDIS diagno- Item YDIS diagnosis code flash indicator sis record Normal — — Pulser coil malfunction Engine temp sensor malfunction (*1) Knock sensor malfunction Battery voltage malfunction Intake temp sensor malfunction (*2) Cam position sensor (EXH) malfunction Water in fuel...
  • Page 109 Outboard motor troubleshooting Trouble Diagnostic YDIS diagno- Item YDIS diagnosis code flash indicator sis record 131, 132, 133, Accelerator position sensor malfunction 134, (*1) Engine temperature sensor malfunction (*2) Air temperature sensor malfunction (*3) Neutral switch malfunction (*4) Air pressure sensor malfunction (*5) Oil pressure sensor malfunction (*6) Engine shut-off switch ON...
  • Page 110 TRBL SHTG Troubleshooting...
  • Page 111 Outboard motor troubleshooting 4-10...
  • Page 112 TRBL SHTG Troubleshooting 4-11...
  • Page 113 Outboard motor troubleshooting 4-12...
  • Page 114 TRBL SHTG Troubleshooting 4-13...
  • Page 115 Outboard motor troubleshooting 4-14...
  • Page 116 TRBL SHTG Troubleshooting 4-15...
  • Page 117 Outboard motor troubleshooting 4-16...
  • Page 118 TRBL SHTG Troubleshooting 4-17...

  • Page 119: Trouble Code And Checking Step

    Outboard motor troubleshooting Troubleshooting the power unit using the diagnostic flash indicator 1. Remove the flywheel magnet cover. 2. Connect the special service tool 1. b b b b e b 5. If trouble code is detected, see “Trouble code and checking step” (4-9). TIP: a Diagnostic test lead (Blue/White) When more than 1 trouble code is detected,...

  • Page 120: Troubleshooting The Power Unit (Trouble Code Not Detected)

    TRBL SHTG Troubleshooting Troubleshooting the power unit (trouble code not detected) Troubleshooting consists of the following 3 items: Symptom 1: Specific trouble conditions Symptom 2: Trouble conditions of an area or individual part Cause: Trouble causes of symptom 2 — : Not applicable Symptom 1: Engine does not crank.
  • Page 121 Outboard motor troubleshooting Symptom 1: Engine will not start (engine cranks). Symptom 2 Cause Checking step page Engine ECM does not Blown fuse Check the fuse. operate Main relay malfunction Check the main relay. 5-27 Short, open, or loose Check for wiring continuity between 5-28 connection in engine ECM the main relay and the engine ECM.
  • Page 122 TRBL SHTG Troubleshooting Symptom 2 Cause Checking step page Fuel not supplied (all — Measure the fuel pressure. cylinders) Pinched or kinked fuel hose Check the fuel hose. Fuel leakage Check for fuel leakage. Clogged fuel filter element Check the fuel filter element for dirt 6-14 and obstructions.
  • Page 123 Outboard motor troubleshooting Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited engine speed. Symptom 2 Cause Checking step page Spark plug does not Spark plug malfunction Check the ignition spark. 5-53 spark (some cylinders) Check the spark plug. 7-44 Short, open, or loose Measure the ignition coil input voltage.
  • Page 124 TRBL SHTG Troubleshooting Symptom 1: High engine idle speed. Symptom 2 Cause Checking step page Air leakage (throttle valve– Check the gaskets of the intake 6-15 cylinder head) manifolds, surge tank, and throttle 6-26 body. — Throttle cable is not adjusted Adjust the throttle cable.
  • Page 125 Outboard motor troubleshooting Symptom 1: Discharged battery. Symptom 2 Cause Checking step page Battery performance Check the battery capacity and specific 10-4 decrease gravity. Check that the battery cables and — terminals are connected properly. Short, open, or loose Check the charging circuit for proper connection in charging circuit connections and damage.

  • Page 126: Troubleshooting The Ptt Unit

    TRBL SHTG Troubleshooting Troubleshooting the PTT unit Troubleshooting consists of the following 3 items: Symptom 1: Specific trouble conditions Symptom 2: Trouble conditions of an area or individual part Cause: Trouble causes of symptom 2 — : Not applicable Symptom 1: PTT unit does not operate. Symptom 2 Cause Checking step...

  • Page 127: Troubleshooting The Lower Unit

    Outboard motor troubleshooting Symptom 1: PTT unit does not hold the outboard motor up. Symptom 2 Cause Checking step page Decrease in PTT fluid Manual valve open Check the manual valve. 9-40 pressure in lower Insufficient PTT fluid Add sufficient PTT fluid. 10-14 chamber of PTT PTT fluid leakage...
  • Page 128 ELEC Electrical system Electrical component ............5-1 Port..................... 5-1 Starboard..................5-2 Fuse holder ................5-3 Rear.................... 5-4 Top ..................... 5-5 Wiring harness routing ............5-6 Port..................... 5-6 Starboard..................5-9 Rear..................5-12 Top ................... 5-15 Bottom cowling ................. 5-18 Circuit diagram ..............5-22 ECM coupler layout............
  • Page 129 Checking the lighting coil............5-50 Checking the Rectifier Regulator..........5-51 Ignition unit and component ........... 5-53 Checking the ignition spark ............5-53 Checking the ignition coil............5-53 Checking the pulser coil ............5-55 Checking the air temperature sensor ........5-56 Checking the air pressure sensor..........

  • Page 130: Electrical System

    ELEC Electrical system Electrical component Port 1 Air temperature sensor 7 Water detection switch (in fuel cup 2 YDIS coupler assembly) 3 Fuel injector 8 Air pressure sensor 4 High-pressure fuel pump 9 ETV 5 Low-pressure fuel pump 6 Condenser (connect to the air pressure sensor)

  • Page 131: Starboard

    Electrical component Starboard 1 PTT relay 2 Fuse holder 3 Starter motor 4 Diode (connect to the PTT relay) 5 Oil pressure sensor 6 APS 7 Rectifier Regulator 8 Fuel injector...

  • Page 132: Fuse Holder

    ELEC Electrical system Fuse holder 1 Fuse (10 A) (ETV, engine ECM) 9 Starter relay 2 Fuse (30 A) (ignition coil, fuel injector, 0 Main relay VCT, engine ECM) A ETV motor relay 3 Fuse (20 A) (engine start switch, PTT B High-pressure fuel pump relay switch) 4 Fuse (30 A) (starter relay)

  • Page 133: Rear

    Electrical component Rear 1 Cam position sensor (PORT IN) 8 Water pressure sensor coupler 2 Cam position sensor (PORT EX) 9 Joint coupler 2 3 Condenser (connect to the cam position 0 Knock sensor coupler sensor [PORT EX]) 4 Engine ECM 5 Ignition coil 6 Cam position sensor (STBD IN) 7 Knock sensor...

  • Page 134: Top

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

  • Page 135: Wiring Harness Routing

    Electrical component / Wiring harness routing Wiring harness routing Port È É Ê Ë Ì Í Î Ï Ô Ó Ñ Ò × × Õ Ù È Install the low-pressure fuel pump coupler Ì Fasten the wiring harness using the holder onto the wiring harness guide.
  • Page 136 ELEC Electrical system È É Ê Ë Ì Í Î Ï Ô Ó Ñ Ò × × Õ Ù Î Fasten the wiring harness (to fuel injector Ò Fasten the wiring harness in the order Ñ, [#2]) and wiring harness (to fuel injector Ï, and Î.
  • Page 137 Wiring harness routing È É Ê Ë Ì Í Î Ï Ô Ó Ñ Ò × × Õ Ù Õ Before installing the intake silencer, fasten the wiring harness (to air temperature sen- sor) at the white tape using the holder on the oil filler neck.

  • Page 138: Starboard

    ELEC Electrical system Starboard Û È É Ú Ê Ù Ô × Ë Ì Í Î Õ Ï Ñ Ó Ò È Fit the stator assembly lead into the 1 Wiring harness groove in the junction box. 2 Stator assembly lead É...
  • Page 139 Wiring harness routing Û È É Ú Ê Ù Ô × Ë Ì Í Î Õ Ï Ñ Ó Ò Ë Fasten the starter motor lead and junction Î Route the wiring harnesses and PTT box wiring harness extension using the motor lead through the guide on the termi- holder.
  • Page 140 ELEC Electrical system Û È É Ú Ê Ù Ô × Ë Ì Í Î Õ Ï Ñ Ó Ò Ó Install the junction box wiring harness Ù Fasten the wiring harness (to fuel injector extension ground lead terminal so that it [#1]) and wiring harness (to fuel injector contacts the stopper.

  • Page 141: Rear

    Wiring harness routing Rear È É Ê Ë × Ì Õ Í Ô Ó Ò Ñ Ï Î È Fasten the wiring harness using the Ê Place the condenser between the engine holder. ECM bracket and the wiring harness, and É...
  • Page 142 ELEC Electrical system È É Ê Ë × Ì Õ Í Ô Ó Ò Ñ Ï Î Í Fasten the wiring harness at the white Ñ Fasten the knock sensor lead using the tape using the holder. holder. Make sure that the end of the cor- Î...
  • Page 143 Wiring harness routing È É Ê Ë × Ì Õ Í Ô Ó Ò Ñ Ï Î Ó Fit the protrusion on the knock sensor Õ Make sure that the slot in the joint coupler coupler into the hole in the engine ECM bracket fits over the rib on the engine bracket.

  • Page 144: Top

    ELEC Electrical system È Ò É Ñ Ï Ì Ê Î Í Ì Ë Ô Õ Ó È Fit the protrusion on the plastic tie into the 1 Stator assembly lead 2 Thermoswitch connector hole in the wiring harness guide. É...
  • Page 145 Wiring harness routing È Ò É Ñ Ï Ì Ê Î Í Ì Ë Ô Õ Ó Ë Install the pulser coil coupler to the Ï Fasten the wiring harness and vapor gas bracket. hose using the holder. Ì Install the plastic ties to the wiring harness Ñ...
  • Page 146 ELEC Electrical system È Ò É Ñ Ï Ì Ê Î Í Ì Ë Ô Õ Ó Ó Make sure that the wiring harness (to fuel injector) does not protrude above the ribs on the wiring harness guide. Ô Point the end of the plastic tie to star- board.

  • Page 147: Bottom Cowling

    Wiring harness routing Bottom cowling È Ê Ë Ì Í Ó Î Ò Ñ Ï É Ï Õ Í Ô Î Ñ 1 Shift cut switch 9 Isolator coupler 2 Neutral switch 0 Water detection switch coupler 3 PTT switch A PTT switch wiring harness extension 4 Trim sensor coupler B Wiring harness...
  • Page 148 ELEC Electrical system È Ê Ë Ì Í Ó Î Ò Ñ Ï É Ï Õ Í Ô Î Ñ È Regular rotation model Ë Fasten the flushing hose, cooling water É Counter rotation model hose, trim sensor lead, and speedometer Ê...
  • Page 149 Wiring harness routing È Ê Ë Ì Í Ó Î Ò Ñ Ï É Ï Õ Í Ô Î Ñ Í If the 6Y8 Multifunction Meter is selected, Ñ If analog meters are selected, connect the remove the caps and connect the coupler. alert indicator coupler, and then install the Î...
  • Page 150 ELEC Electrical system È Ê Ë Ì Í Ó Î Ò Ñ Ï É Ï Õ Í Ô Î Ñ Ó Make sure that the white paint mark on the Õ Fasten the flushing hose, cooling water flushing hose and the white tape on the hose, trim sensor lead, and PTT switch PTT motor lead are aligned with the edge lead using the holder.

  • Page 151: Circuit Diagram

    Wiring harness routing / Circuit diagram Circuit diagram TIP: The circled numbers in the illustration indicate the engine ECM terminal numbers. Fuel injector #1 Pulser coil Fuel injector #2 Fuel injector #3 Fuel injector #4 Fuel injector #5 Cam position sensor (PORT EX) Fuel injector #6 Cam position sensor...
  • Page 152 ELEC Electrical system OCV (STBD) Water pressure sensor æ OCV (PORT) • Speed sensor High-pressure High-pressure fuel pump relay fuel pump Air temperature sensor Engine temperature sensor Low-pressure fuel pump Trim sensor Thermoswitch Vapor shut-off valve Thermoswitch º Water detection switch Oil pressure alert indicator Shift cut switch ç...

  • Page 153: Ecm Coupler Layout

    Circuit diagram / ECM coupler layout ECM coupler layout Connecting part Color Connecting part Color Cam position sensor White/Black Battery power Red/Yellow (STBD IN) Cam position sensor White/Green source YDIS White/Black (PORT IN) Cam position sensor White/Blue (PORT EX) APS 2 Pink/White Water detection Blue/White...
  • Page 154 ELEC Electrical system Connecting part Color Connecting part Color Ignition coil #6 Black/Brown ETV power source Red/Green Ignition coil #5 Black/Blue ETV power source Red/Green Fuel injector #6 Purple/White ETV motor (close) Green/Black Fuel injector #5 Purple/Blue Fuel injector #4 Purple/Green ETV motor (open) Green/Red...

  • Page 155: Checking The Electrical Component

    ECM coupler layout / Checking the electrical component Checking the electrical component When measuring peak voltage Using the YDIS between the terminals of an electrical When checking the ETV, TPS, OCV, ignition component using the digital tester, make spark, APS, high-pressure fuel pump, fuel sure that the leads do not contact any injector, or each sensor, use the YDIS.

  • Page 156: Using The Digital Tester

    ELEC Electrical system Using the digital tester The electrical technical data apply to the measurements taken using the Yamaha-rec- ommended tester. The resistance values shown are the values taken before the engine is started. The actual resistance may vary depending on the envi- ronmental conditions and ambient tempera- ture.

  • Page 157: Checking The Engine Ecm Circuit

    Checking the electrical component / Engine control system and component 5. Turn the engine start switch to ON, and then measure the input voltage between the terminals e and g. 69 68 Main relay input voltage: Terminal e–Terminal g 12.0 V (battery voltage) 6.

  • Page 158: Checking The Aps

    ELEC Electrical system 11. Install the engine ECM, and then tighten the engine ECM bolts to the specified torque. Engine ECM bolt: 7 N·m (0.7 kgf·m, 5.2 ft·lb) 12. Install the engine ECM cover. Checking the APS APS 1 and APS 2 are a single unit, which 7.

  • Page 159: Checking The Aps Circuit

    Engine control system and component F200B and FL200B: È É APS output voltage (reference data): Fully closed c Fully open d Item APS 1 0.550–0.850 V Above 3.250 V APS 2 0.400–1.000 V F250G and FL250G: APS output voltage (reference data):...

  • Page 160: Checking The Etv And Tps

    ELEC Electrical system Wiring harness continuity: a Terminal 1–b Terminal 40 a Terminal 2–b Terminal 44 a Terminal 3–b Terminal 38 a Terminal 6–b Terminal 31 a Terminal 7–b Terminal 41 a Terminal 8–b Terminal 49 8. Connect engine coupler. NOTICE: Make sure that the rubber seal is installed properly in the engine ECM coupler.

  • Page 161: Checking The Etv Motor Relay

    Engine control system and component 3. Turn the engine start switch to ON, and then measure the TPS output voltages and throttle valve opening angles when the remote control lever is at the fully closed position a and fully open position TPS input voltage: Orange (O)–Black (B) TPS output voltage and throttle valve...

  • Page 162: Checking The Etv And Tps Circuit

    ELEC Electrical system ETV motor relay input voltage: 3. Remove the engine ECM cover. Terminal a–Ground Terminal b–Ground 4. Remove the engine ECM, and then dis- connect the engine ECM couplers b and 12.0 V (battery voltage) 5. Turn the engine start switch to ON, and then measure the input voltage between the terminals a and c.

  • Page 163: Checking The Cam Position Sensor

    Engine control system and component 7. Install the intake silencer. See “Installing 11. Connect the fuse holder couplers, and the intake silencer” (6-19). then install the fuse holder. 8. Remove the intake manifold (STBD). 12. Install the intake manifold (STBD). See See “Removing the intake manifold”...
  • Page 164 ELEC Electrical system 8. Connect the tester probes to the test PORT EX leads. NOTICE: Make sure that the test leads do not contact each other and cause a short circuit. Otherwise, the fuse could blow when the engine start switch is turned to ON.
  • Page 165 Engine control system and component 14. Remove the engine ECM, and then dis- connect the engine ECM coupler n. Cam position sensor output voltage: White/Black (W/B)–Black (B) (STBD IN) White/Blue (W/L)–Black (B) (PORT EX) Position Voltage g, k More than 4.8 Less than 1.0 15.

  • Page 166: Checking The Ocv

    ELEC Electrical system TIP: Make sure that there is continuity between terminals 1 and 3 of the cam position sensor couplers a and b and one of the terminals of the fuse holder coupler m. 5 4 3 2 1 16.
  • Page 167 Engine control system and component 3. Turn the engine start switch to ON, and then measure the input voltage at the OCV coupler. PORT 8. Disconnect the battery leads. 9. Install the OCVs. See step 4 in “Installing the cylinder head” (7-68). STBD 10.

  • Page 168: Checking The Oil Pressure Sensor

    ELEC Electrical system Checking the oil pressure sensor 1. Disconnect the oil pressure sensor cou- pler a. 5 4 3 2 1 22 21 20 19 18 17 16 2. Turn the engine start switch to ON, and then measure the input voltage at the oil pressure sensor coupler.

  • Page 169: Checking The Water Pressure Sensor (Optional)

    Engine control system and component Oil pressure sensor output voltage Wiring harness continuity: (reference data): a Terminal 1–c Terminal 48 Pink/White (P/W)–Black (B) a Terminal 2–b Terminal 18 2.5 V at 392.0 kPa a Terminal 3–c Terminal 37 (3.92 kgf/cm , 56.8 psi) 10.

  • Page 170: Checking The Speed Sensor (Optional)

    ELEC Electrical system 5. Apply positive pressure to the water 9. Check the wiring harness for continuity. pressure sensor slowly, and then mea- sure the output voltage at the specified pressures. Wiring harness continuity: a Terminal 1–c Terminal 48 a Terminal 2–b Terminal 18 Pressure pump 1: a Terminal 3–c Terminal 42 (commercially available)
  • Page 171 Engine control system and component 6. Turn the engine start switch to OFF, and then disconnect the special service tool and pressure pump. 7. Install the speed sensor. See steps 7 and “Installing speed sensor (optional)” (3-12). 8. Remove the engine ECM, and then dis- connect the engine ECM couplers b and Speed sensor input voltage: Orange (O)–Black (B)

  • Page 172: Fuel Control Unit And Component

    ELEC Electrical system É Engine ECM bolt: 7 N·m (0.7 kgf·m, 5.2 ft·lb) 12. Connect the speed sensor coupler. 13. Install the engine ECM cover. Fuel control unit and component Checking the water detection switch 1. Disconnect the water detection switch coupler a.

  • Page 173: Checking The Fuel Injector

    Engine control system and component / Fuel control unit and component Wiring harness continuity: STBD a Terminal 1–e Terminal 5 a Terminal 2–e Terminal 18 10. Connect engine coupler. NOTICE: Make sure that the rubber seal is installed properly in the engine ECM coupler.
  • Page 174 ELEC Electrical system Wiring harness continuity: Fuel injector #1 a Terminal 1– b Terminals 1–10 and 16–22 a Terminal 2–c Terminal 59 Fuel injector #2 a Terminal 1– b Terminals 1–10 and 16–22 a Terminal 2–c Terminal 60 Fuel injector #3 10.

  • Page 175: Checking The Low-Pressure Fuel Pump And High-Pressure Fuel Pump

    Fuel control unit and component 15. Install the intake manifold (STBD). See “Installing the intake manifold” (6-18). 16. Connect the fuel injector couplers, and then install the fuel rail covers. Checking the low-pressure fuel pump and high-pressure fuel pump 1. Check the operation of the low-pressure fuel pump and high-pressure fuel pump using the YDIS “Stationary test”...

  • Page 176: Checking The High-Pressure Fuel Pump Relay

    ELEC Electrical system 15. Connect engine coupler. NOTICE: Make sure that the rubber seal is installed properly in the engine ECM coupler. 16. Install the engine ECM, and then tighten the engine ECM bolts to the specified torque. Engine ECM bolt: 7 N·m (0.7 kgf·m, 5.2 ft·lb) 12.

  • Page 177: Checking The Vapor Shut-Off Valve

    Fuel control unit and component 4. Turn the engine start switch to ON, and 2. Disconnect the throttle body assembly wiring harness extension coupler a. then measure the input voltage between the terminal a and ground, and the ter- 3. Turn the engine start switch to ON, and minal b and ground.
  • Page 178 ELEC Electrical system 13. Connect the fuse holder coupler, and then install the fuse holder. 14. Measure the vapor shut-off valve resis- tance. G/B R/Y 9. Check the wiring harness for continuity. 5 4 3 2 1 22 21 20 19 18 17 16 Vapor shut-off valve resistance (reference data): Red/Yellow (R/Y)–Green/Black (G/B)

  • Page 179: Charging Unit And Component

    Fuel control unit and component / Charging unit and component 3. Move the stator assembly leads away from the area covered by the intake man- ifold, and then install the intake manifold (STBD). See “Installing the intake mani- fold” (6-18). 4.

  • Page 180: Checking The Rectifier Regulator

    ELEC Electrical system 8. Install the intake manifold (STBD). See 5. Remove the fuse holder, and then dis- “Installing the intake manifold” (6-18). connect the Rectifier Regulator couplers and ground lead. Checking the Rectifier Regulator Do not connect the battery cables in reverse.
  • Page 181 Charging unit and component 7. Check the Rectifier Regulator for conti- nuity. Rectifier Regulator continuity (testing diode mode): Tester probe Display value (reference data) 0.420 V 0.422 V 0.426 V 0.421 V 0.425 V 0.424 V 0.756 V 0.755 V 0.416 V 0.417 V 0.417 V...

  • Page 182: Ignition Unit And Component

    ELEC Electrical system Ignition unit and component Checking the ignition coil 1. Remove the engine ECM cover. Checking the ignition spark 2. Disconnect the ignition coil couplers a. • Make sure to install the special service 3. Turn the engine start switch to ON, and tool to the ignition coil so that sparks do then measure the input voltage at the not leak out.
  • Page 183 Ignition unit and component Wiring harness continuity: Ignition coil #1 a Terminal 1–b Terminal 71 a Terminal 2–Ground a Terminal 3– c Terminals 1–10 and 16–22 Ignition coil #2 a Terminal 1–b Terminal 70 a Terminal 2–Ground a Terminal 3– 8.

  • Page 184: Checking The Pulser Coil

    ELEC Electrical system 12. Install the engine ECM, and then tighten Pulser coil output peak voltage: the engine ECM bolts to the specified White/Red (W/R)–Black (B) torque. Unloaded Loaded r/min Engine ECM bolt: Cranking 1500 3500 7 N·m (0.7 kgf·m, 5.2 ft·lb) DC V 14.5 17.8...

  • Page 185: Checking The Air Temperature Sensor

    Ignition unit and component Wiring harness continuity: a Terminal 1–b Terminal 15 a Terminal 2–b Terminal 16 10. Connect engine coupler. NOTICE: Make sure that the rubber seal is installed properly in the engine ECM coupler. 11. Install the engine ECM, and then tighten the engine ECM bolts to the specified Air temperature sensor input voltage: torque.

  • Page 186: Checking The Air Pressure Sensor

    ELEC Electrical system 3. Turn the engine start switch to ON, and then measure the input voltage at the throttle body assembly wiring harness extension coupler. 14. Check the wiring harness for continuity. Air pressure sensor input voltage: Orange (O)–Black (B) 4.75–5.25 V 4.
  • Page 187 Ignition unit and component Wiring harness continuity: a Terminal 1–c Terminal 36 a Terminal 2–b Terminal 18 a Terminal 3–c Terminal 48 8. Connect the engine ECM couplers. NOTICE: Make sure that the rubber seal is installed properly in each engine ECM coupler.

  • Page 188: Checking The Engine Temperature Sensor

    ELEC Electrical system Checking the engine temperature Engine temperature sensor resistance sensor (reference data): 1. Remove the flywheel magnet cover. Black/Yellow (B/Y)–Black/Yellow (B/Y) 54.2–69.0 kΩ at 20 °C (68 °F) 2. Disconnect the engine temperature sen- 3.12–3.48 kΩ at 100 °C (212 °F) sor coupler a.

  • Page 189: Checking The Thermoswitch

    Ignition unit and component 6. Place the thermoswitches in a container Engine ECM bolt: of water and heat the water slowly. 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7. Check the thermoswitches for continuity 15. Install the engine ECM cover. at the specified temperatures. Replace if out of specification.

  • Page 190: Checking The Shift Cut Switch

    ELEC Electrical system 2. Connect the special service tool 1 to the 11. Check the wiring harness for continuity. shift cut switch coupler a. 3. Turn the engine start switch to ON, and then measure the input voltage. Wiring harness continuity: Pink (P)–m Terminal 52 Black (B)–k Terminal 18 12.
  • Page 191 Ignition unit and component Lead color Switch position Free c Pushed d 8. Disconnect the special service tool. 9. Remove the engine ECM cover. 10. Remove the engine ECM, and then dis- connect the engine ECM coupler e. Test harness (2 pins) 1: 90890-06867 Shift cut switch resistance (reference data): 11.

  • Page 192: Checking The Neutral Switch

    ELEC Electrical system 15. Connect the shift cut switch coupler. 6. Check the neutral switch for continuity. Replace if out of specification. Checking the neutral switch 1. Disconnect the neutral switch coupler a. STBD 2. Connect the special service tool 1 to the neutral switch coupler a.

  • Page 193: Checking The Knock Sensor

    Ignition unit and component Knock sensor resistance (reference data): Wiring harness continuity: 504.0–616.0 kΩ at 20 °C (68 °F) a Terminal 1–e Terminal 12 a Terminal 2–e Terminal 18 4. Remove the engine ECM, and then dis- connect the engine ECM coupler b. 11.

  • Page 194: Checking The Engine Shut-Off Switch

    ELEC Electrical system 8. Connect the knock sensor coupler. 2. Remove the fuse cover and relay cover, and then remove the starter relay 1. 9. Install the engine ECM cover. NOTICE: Be careful not to damage the relay. Checking the engine shut-off switch 1.

  • Page 195: Checking The Engine Start Switch

    Ignition unit and component / Starting unit and component Starter relay input voltage: Terminal b–Terminal c 12.0 V (battery voltage) 6. Install the starter relay, and then install the relay cover and fuse cover. 7. Install the intake manifold (STBD). See “Installing the intake manifold”...
  • Page 196 ELEC Electrical system Starter motor Part name Q’ty Remarks Stator Armature Brush holder assembly Brush spring Brush assembly Starting motor gear assembly Washer set Bracket M4 × 15 mm Screw M6 × 117 mm Bolt M6 × 35 mm Bolt Cover assembly Clutch assembly Bracket...
  • Page 197 Starter motor Part name Q’ty Remarks Washer Pinion shaft Planetary gear Plate Starter motor pinion Pinion stopper set Lever assembly Seal set Magnet switch Washer 5-68...

  • Page 198: Removing The Starter Motor

    ELEC Electrical system 2. Push the pinion stopper c down, and Removing the starter motor then remove the clip d. Before removing the starter motor, make sure to disconnect the negative battery terminal. 1. Remove intake silencer. “Removing the intake silencer” (6-17). 2.
  • Page 199 Starter motor 5. Remove the rubber seal m, lever n, and pinion shaft assembly p. 9. Remove the E-clip 0, and then remove the clutch assembly A from the pinion 6. Remove the stator 6. NOTICE: Do not shaft B. disassemble stator.

  • Page 200: Checking The Armature (Starter Motor)

    ELEC Electrical system Checking the armature (starter motor) 1. Check the commutator. Clean using 600- grit sandpaper and compressed air if dirty. Armature continuity: Checking the brush holder and brush 2. Measure the commutator diameter a. 1. Check the brush holder assembly for Replace the armature if below specifica- continuity.

  • Page 201: Assembling The Starter Motor

    Starter motor Brush standard length f: 15.5 mm (0.61 in) Wear limit g: 9.5 mm (0.37 in) Assembling the starter motor • Do not apply grease or oil to the com- mutator of the armature. TIP: • Do not reuse a gasket or seal set, Align the holes c and d in the plate b with always replace it with a new one.
  • Page 202 ELEC Electrical system TIP: TIP: Align the protrusion u on the stator assem- Make sure that the clutch assembly 7 does bly t with the slot v in the cover assembly not come out from the pinion shaft 8. 7. Install the pinion shaft assembly n, the lever p, a new rubber seal r, the plane- 9.

  • Page 203: Installing The Starter Motor

    Starter motor / PTT electrical system Installing the starter motor 1. Install the starter motor to the power unit. See “Installing the starter motor” (7-28). 2. Install the intake manifold (STBD). See “Installing the intake manifold” (6-18). 3. Install the intake silencer. See “Installing the intake silencer”...

  • Page 204: Checking The Ptt Switch (Bottom Cowling)

    ELEC Electrical system 7. Connect the positive battery lead to the È connector f, connect the negative bat- tery lead to the terminal b, and then check the PTT relay for continuity. Replace if out of specification. É PTT relay continuity: È...

  • Page 205: Checking The Trim Sensor

    PTT electrical system 5. Remove the fuse holder 2, and then dis- 11. Connect the PTT switch coupler. connect the fuse holder coupler e. Checking the trim sensor 1. Remove the trim sensor, and then dis- connect the trim sensor coupler a. 6.
  • Page 206 ELEC Electrical system 4. Remove the engine ECM cover. 12. Adjust the trim sensor. See “Adjusting the trim sensor” (9-34). 5. Remove the engine ECM, and then dis- connect the engine ECM coupler f. 6. Check the wiring harness for continuity. Wiring harness continuity: a Terminal 1–e Terminal 2 a Terminal 2–f Terminal 18...
  • Page 207 PTT electrical system — MEMO — 5-78...
  • Page 208 FUEL Fuel system Hose routing ............... 6-1 Fuel hose and blowby hose............6-1 Vapor gas hose ................6-3 Cooling water hose..............6-5 Fuel system ................ 6-7 Reducing the fuel pressure ............6-7 Disconnecting the quick connector..........6-7 Connecting the quick connector ..........6-8 Measuring the fuel pressure............
  • Page 209 Checking the primer pump ............6-32 Installing the low-pressure fuel pump........6-33 Vapor separator..............6-34 Draining the fuel ............... 6-35 Removing the vapor separator ..........6-35 Installing the vapor separator ........... 6-35 Vapor separator and high-pressure fuel pump ..... 6-37 Disassembling the vapor separator..........

  • Page 210: Fuel System

    FUEL Fuel system Hose routing Fuel hose and blowby hose 1 Fuel hose (primer pump to fuel filter 8 Blowby hose (cylinder head cover [STBD] assembly) to intake silencer) 2 Fuel hose (fuel filter assembly to joint) 9 Blowby hose (cylinder block to joint) 3 Fuel hose (joint to low-pressure fuel a Primer pump pump)
  • Page 211 Hose routing k Fuel rail (STBD) m Fuel rail (PORT) n Joint...

  • Page 212: Vapor Gas Hose

    FUEL Fuel system Vapor gas hose Ë È Ê É È Í Ì Ì Ê Ë Í STBD É 1 Vapor gas hose (vapor separator to joint) 9 Vapor gas hose (check valve to joint) 2 Vapor gas hose (canister atmospheric port 0 Vapor gas hose (intake silencer to check to joint) valve)
  • Page 213 Hose routing Ë È Ê É È Í Ì Ì Ê Ë Í STBD É d Pressure regulator e Canister f Vapor shut-off valve g Air pressure sensor h Intake silencer...

  • Page 214: Cooling Water Hose

    FUEL Fuel system Cooling water hose 1 Cooling water hose (Rectifier Regulator to 9 Cooling water hose (joint to joint) joint) 0 Flushing hose (joint to cooling water 2 Cooling water hose (joint to Rectifier passage cover) A Flushing hose (flushing hose adapter to Regulator) 3 Cooling water hose (joint to joint) joint)
  • Page 215 Hose routing H Cooling water pilot hose (joint to cooling water pilot hole) I Cooling water hose (joint to joint) a Fuel cooler (vapor separator) b Rectifier Regulator c Cooling water pilot hole (on the bottom cowling) d Adapter (water pressure sensor) e Cooling water passage cover (on the cyl- inder block)

  • Page 216: Fuel System

    FUEL Fuel system Fuel system 2. Remove the flywheel magnet cover. Reducing the fuel pressure 3. Wrap a rag around the quick connector Before servicing the high-pressure fuel 4. Spread apart the ends of the locking line or vapor separator, make sure to slider a, and then move the locking reduce the fuel pressure in the fuel line.

  • Page 217: Connecting The Quick Connector

    Fuel system TIP: • If the quick connector 1 is not installed completely onto the fuel rail or vapor sepa- rator, the locking slider a cannot be moved to the lock position. • Confirm that the quick connector is installed properly by making sure there is a small amount of free play when the quick connec- tor is pulled and pushed.
  • Page 218 FUEL Fuel system Fuel pressure gauge 4: 90890-06786 8. Turn the engine start switch to ON, and then measure the fuel pressure within 5 seconds. Fuel pressure (reference data): 290.0 kPa (2.90 kgf/cm , 42.1 psi) TIP: • The fuel pressure decreases 5 seconds after the engine start switch is turned to •...

  • Page 219: Checking The Pressure Regulator

    Fuel system Checking the pressure regulator 9. Reduce the fuel pressure. See “Reduc- ing the fuel pressure” (6-7). 1. Reduce the fuel pressure. See “Reduc- ing the fuel pressure” (6-7). 10. Disconnect the special service tool from the pressure regulator, and then connect 2.

  • Page 220: Fuel Filter Assembly

    FUEL Fuel system Fuel filter assembly 5 N m (0.5 kgf m, 3.7 ft lb) 12 mm (0.47 in) 12 mm 12 mm 9 mm (0.47 in) (0.47 in) (0.35 in) Part name Q’ty Remarks Hose Plastic tie Bracket M6 × 25 mm Bolt Grommet Collar...
  • Page 221 Fuel filter assembly 5 N m (0.5 kgf m, 3.7 ft lb) 12 mm (0.47 in) 12 mm 12 mm 9 mm (0.47 in) (0.47 in) (0.35 in) Part name Q’ty Remarks Holder 6-12...

  • Page 222: Removing The Fuel Filter Assembly

    FUEL Fuel system Removing the fuel filter assembly Cover the fuel components using a rag to prevent fuel from spilling out. 1. Remove the intake manifold (PORT). See “Removing the intake manifold” (6- 17). 2. Disconnect the water detection switch coupler a.

  • Page 223: Disassembling The Fuel Filter Assembly

    Fuel filter assembly Disassembling the fuel filter assembly 1. Remove the fuel cup assembly 1, O-ring 2, and fuel filter element 3, and then remove the clip 4 and float 5. Fuel cup assembly 3: 5 N·m (0.5 kgf·m, 3.7 ft·lb) Installing the fuel filter assembly 1.
  • Page 224 FUEL Fuel system Intake manifold 7 N m (0.7 kgf m, 5.2 ft lb) 10 N m (1.0 kgf m, 7.4 ft lb) Part name Q’ty Remarks M6 × 25 mm Bolt Intake silencer Grommet Air temperature sensor Grommet Flywheel magnet cover Grommet M6 ×...
  • Page 225 Intake manifold 7 N m (0.7 kgf m, 5.2 ft lb) 10 N m (1.0 kgf m, 7.4 ft lb) Part name Q’ty Remarks M6 × 40 mm Bolt Intake manifold assembly (STBD) Gasket 6-16...

  • Page 226: Intake Manifold

    FUEL Fuel system Removing the intake silencer 1. Remove the flywheel magnet cover. 2. Disconnect the air temperature sensor coupler a, and then remove the air tem- perature sensor 1. Removing the intake manifold 1. Remove the fuel drain hose 1 from the intake manifold (PORT) 2.

  • Page 227: Checking The Intake Manifold

    Intake manifold 3. Remove the blowby hose 4. 2. Install new gaskets onto the intake mani- Checking the intake manifold folds. Make sure to fit the protrusion on each gasket into its corresponding slot in 1. Check the intake manifolds. Replace if the intake manifolds.

  • Page 228: Installing The Intake Silencer

    FUEL Fuel system PORT ² ± & STBD & ± ² Intake manifold bolt 5: TIP: 10 N·m (1.0 kgf·m, 7.4 ft·lb) When the protrusions on the gaskets contact the fuel rail cover, make sure that the gaskets TIP: remain installed properly. Make sure to tighten the intake manifold bolts in the order 1, 2, and so on.
  • Page 229 Intake manifold Intake silencer bolt 2: 8. Install the flywheel magnet cover. 7 N·m (0.7 kgf·m, 5.2 ft·lb) 3. Connect the blowby hose 4 into the intake silencer 1 and cylinder head cover (STBD), and then connect the blowby hose 5 into the joint 6. 4.
  • Page 230 FUEL Fuel system Throttle body Part name Q’ty Remarks Joint Plastic tie M8 × 40 mm Bolt Throttle body assembly M6 × 16 mm Bolt Holder Hose Holder Hose Joint ø5 mm Hose Holder Hose Holder Hose Hose Hose 6-21...
  • Page 231 Throttle body Part name Q’ty Remarks Joint ø3 mm Dowel Holder Joint Hose Check valve Hose Hose Hose Joint Hose 6-22...

  • Page 232: Removing The Throttle Body Assembly

    FUEL Fuel system 5. Remove the plastic tie 6, and then Removing the throttle body remove the joint 7. assembly 1. Disconnect the throttle body assembly 6. Remove the throttle body assembly 8. wiring harness extension coupler a and ETV coupler b. 2.

  • Page 233: Checking The Vacuum Hose

    Throttle body Vacuum/pressure pump gauge set 1: 90890-06756 3. Connect the special service tool 1 to the opposite canister check valve port. 4. Apply positive pressure and check that no air comes out of the opposite end of the canister check valve. Replace the 2.
  • Page 234 FUEL Fuel system 6. Fasten the wiring harness 0 using the holders. 7. Connect the throttle body assembly wir- ing harness extension coupler a and ETV coupler b. 6-25...
  • Page 235 Throttle body / Canister, throttle body, and surge tank Canister, throttle body, and surge tank 13 N m (1.3 kgf m, 9.6 ft lb) 5 N m (0.5 kgf m, 3.7 ft lb) 13 N m (1.3 kgf m, 9.6 ft lb) 5 N m (0.5 kgf m, 3.7 ft lb) 5 N m (0.5 kgf m, 3.7 ft lb) 5 N m (0.5 kgf m, 3.7 ft lb)
  • Page 236 FUEL Fuel system 13 N m (1.3 kgf m, 9.6 ft lb) 5 N m (0.5 kgf m, 3.7 ft lb) 13 N m (1.3 kgf m, 9.6 ft lb) 5 N m (0.5 kgf m, 3.7 ft lb) 5 N m (0.5 kgf m, 3.7 ft lb) 5 N m (0.5 kgf m, 3.7 ft lb) Part name Q’ty...

  • Page 237: Canister, Throttle Body, And Surge Tank

    Canister, throttle body, and surge tank Removing the canister, throttle body, and surge tank 1. Remove the holder 1 and canister 2. 6. Remove the air pressure sensor 0. 2. Remove the bracket 3. Checking the ETV 1. Turn the throttle valve manually and check that it moves smoothly.

  • Page 238: Installing The Canister, Throttle Body, And Surge Tank

    FUEL Fuel system 2. Connect the special service tool 1 to the 2. Install a new gasket 3 and the throttle atmospheric port a and block the other damper plate 4, and then tighten the ports b with rubber plugs 2. throttle damper plate bolts 5 to the spec- ified torque.
  • Page 239 Canister, throttle body, and surge tank 8. Install the grommets E and collars F to the bracket G. 9. Install the bracket G, and then tighten the canister bracket bolts H to the speci- fied torque. Canister bracket bolt H: 5 N·m (0.5 kgf·m, 3.7 ft·lb) 10.
  • Page 240 FUEL Fuel system Low-pressure fuel pump 5 N m (0.5 kgf m, 3.7 ft lb) Part name Q’ty Remarks Hose Clamp Clamp Joint Bushing Low-pressure fuel pump Hose Holder Cover M6 × 15 mm Bolt 6-31...

  • Page 241: Low-Pressure Fuel Pump

    Low-pressure fuel pump Removing the low-pressure fuel pump Cover the fuel components using a rag to prevent fuel from spilling out. 1. Disconnect the low-pressure fuel pump coupler a. 2. Remove the holders 1 from the fuel hose 2, and then disconnect the fuel hose 2.

  • Page 242: Installing The Low-Pressure Fuel Pump

    FUEL Fuel system Installing the low-pressure fuel 6. Connect the low-pressure fuel pump cou- pler b. pump 1. Install the low-pressure fuel pump 1 and cover 2, and then tighten the low-pres- sure fuel pump cover bolts 3 to the specified torque.
  • Page 243 Low-pressure fuel pump / Vapor separator Vapor separator Part name Q’ty Remarks Hose Clamp Bolt M6 × 16 mm Bolt M6 × 35 mm Collar Vapor separator assembly Grommet Bracket Bracket Vapor separator wiring harness extension Plastic tie Hose Clamp Hose Joint 6-34...

  • Page 244: Draining The Fuel

    FUEL Fuel system Draining the fuel 1. Remove the flywheel magnet cover. 2. Remove intake silencer. “Removing the intake silencer” (6-17). 3. Disconnect the fuel hose 1 from the vapor separator assembly. 4. Loosen the vapor separator drain screw 2 to drain the fuel into a drain pan. 3.
  • Page 245 Vapor separator 5. Connect the vapor separator wiring har- ness extension 9. 6. Connect the quick connector. See “Con- necting the quick connector” (6-8). 6-36...

  • Page 246: Vapor Separator And High-Pressure Fuel Pump

    FUEL Fuel system Vapor separator and high-pressure fuel pump 2 N m (0.2 kgf m, 1.5 ft lb) 4 N m (0.4 kgf m, 3.0 ft lb) 4 N m (0.4 kgf m, 3.0 ft lb) 2 N m (0.2 kgf m, 1.5 ft lb) 2 N m (0.2 kgf m, 1.5 ft lb) Part name Q’ty...
  • Page 247 Vapor separator and high-pressure fuel pump 2 N m (0.2 kgf m, 1.5 ft lb) 4 N m (0.4 kgf m, 3.0 ft lb) 4 N m (0.4 kgf m, 3.0 ft lb) 2 N m (0.2 kgf m, 1.5 ft lb) 2 N m (0.2 kgf m, 1.5 ft lb) Part name Q’ty...

  • Page 248: Disassembling The Vapor Separator

    FUEL Fuel system 5. Remove the float chamber cover A, gas- Disassembling the vapor separator ket B, high-pressure fuel pump C, and 1. Remove the vapor separator drain screw grommet D. 1 and drain hose 2. 2. Remove the fuel cooler cover 3 and gasket 4.

  • Page 249: Checking The High-Pressure Fuel Pump

    Vapor separator and high-pressure fuel pump Float height a: 67.5 ± 2.5 mm (2.66 ± 0.10 in) TIP: To measure the float height, it should be rest- ing on the needle valve. Do not press the float. Checking the check valve 1.

  • Page 250: Assembling The Vapor Separator

    FUEL Fuel system Assembling the vapor separator 4. Connect the high-pressure fuel pump coupler a, and then install the grommet A and high-pressure fuel pump B. Do not reuse a gasket, always replace it with a new one. 1. Install the needle valve assembly 1, and then tighten the needle valve assembly screw 2 to the specified torque.
  • Page 251 Vapor separator and high-pressure fuel pump Vapor separator drain screw R: 2 N·m (0.2 kgf·m, 1.5 ft·lb) Vapor separator cover bolt J: 2 N·m (0.2 kgf·m, 1.5 ft·lb) 7. Install the pressure regulator K and holder L, and then tighten the pressure regulator holder screw M to the specified torque.

  • Page 252: Fuel Injector

    FUEL Fuel system Fuel injector STBD PORT Part name Q’ty Remarks M6 × 20 mm Bolt Cover (STBD) M6 × 35 mm Bolt Plastic tie Fuel rail assembly (STBD) Fuel rail (STBD) Fuel injector O-ring set Holder Fuel rail assembly (PORT) Fuel rail (PORT) Cover (PORT) Quick connector...
  • Page 253 Fuel injector STBD PORT Part name Q’ty Remarks Fuel hose assembly 6-44...

  • Page 254: Removing The Fuel Injector

    FUEL Fuel system Removing the fuel injector STBD Cover the fuel components using a rag to prevent fuel from spilling out. 1. Disconnect the quick connectors. See steps 3–5 in “Disconnecting the quick connector” (6-7). 2. Remove the fuel hoses 1 and 2. PORT 4.

  • Page 255: Checking The Quick Connector

    Fuel injector 2. Check the fuel injectors. See “Checking PORT the fuel injector” (5-44). Checking the quick connector 1. Check the quick connector 1. Replace if cracked or damaged. 2. Check the O-rings a in the quick con- nector 1. Replace the quick connector if an O-ring is cracked or damaged.
  • Page 256 FUEL Fuel system 6. Fasten the wiring harness using the hold- PORT ers 4, and then fasten the wiring har- ness using the plastic ties 6. See “Wiring harness routing” (5-6). PORT STBD STBD 7. Install the fuel rail covers 7 and 8. PORT STBD 8.
  • Page 257 POWR Power unit Power unit (check and adjustment)........7-1 Checking the compression pressure .......... 7-1 Checking the oil pressure............7-1 Checking the pulser coil air gap ..........7-1 Checking the valve clearance ............ 7-2 Adjusting the valve clearance............. 7-4 Power unit assembly ............7-6 Removing the power unit............
  • Page 258 POWR Checking the spark plug............7-44 Installing the cylinder head cover ..........7-44 Camshaft ................7-46 Removing the driven sprocket and camshaft ......7-48 Checking the sprocket.............. 7-49 Checking the valve lifter ............7-49 Checking the camshaft............. 7-50 Installing the camshaft and driven sprocket ......7-50 Exhaust cover..............
  • Page 259 Checking the piston diameter........... 7-86 Checking the cylinder bore............7-86 Checking the piston ring............7-86 Checking the piston ring end gap (reference) ......7-86 Checking the piston ring groove..........7-87 Checking the piston ring side clearance........7-87 Checking the piston pin boss inside diameter ......7-87 Checking the piston pin ............

  • Page 260: Power Unit

    POWR Power unit Power unit (check and 11. Install the spark plugs, and then tighten them to the specified torque. adjustment) Checking the compression pressure Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb) 1. Start the engine, warm it up for 5–10 min- 12.

  • Page 261: Checking The Valve Clearance

    Power unit (check and adjustment) 2. Turn the flywheel magnet clockwise to TIP: align the protrusion a on the flywheel When measuring or adjusting the valve clear- magnet with the protrusion b on the ances, the fuel line must be disconnected, so pulser coil.
  • Page 262 POWR Power unit Valve clearance (cold): Intake f: 0.205 ± 0.035 mm (0.0081 ± 0.0014 Exhaust g: 0.345 ± 0.035 mm (0.0136 ± 0.0014 TIP: Write down the measurement data. 14. Measure the intake and exhaust valve clearances of the specified cylinders. Adjust if out of specification.

  • Page 263: Adjusting The Valve Clearance

    Power unit (check and adjustment) 2. Check that the “II” marks c on the VCT assembly (PORT) and driven sprocket (PORT) are aligned, and check that the “I” marks d on the VCT assembly (STBD) and driven sprocket (STBD) are aligned.
  • Page 264 POWR Power unit 17. Install the intake manifolds. See in TIP: “Installing the intake manifold” (6-18). Make sure to keep the parts in the order as they were removed. 18. Check the pulser coil air gap. See steps 2–5 in “Checking the pulser coil air gap” 10.

  • Page 265: Power Unit Assembly

    Power unit (check and adjustment) / Power unit assembly Power unit assembly 4 N m (0.4 kgf m, 3.0 ft lb) 42 N m (4.2 kgf m, 31.0 ft lb) Part name Q’ty Remarks Power unit Gasket Dowel M6 × 20 mm Bolt Cable holder M6 ×...
  • Page 266 POWR Power unit 4 N m (0.4 kgf m, 3.0 ft lb) 42 N m (4.2 kgf m, 31.0 ft lb) Part name Q’ty Remarks Apron (STBD) Cover O-ring M6 × 16 mm Bolt Dipstick guide Dipstick Holder M6 × 10 mm Bolt Engine ECM cover M6 ×...

  • Page 267: Removing The Power Unit

    Power unit assembly Removing the power unit Make sure to reduce the fuel pressure before removing the power unit. See “Reducing the fuel pressure” (6-7). It is recommended to loosen the flywheel magnet nut before removing the power unit to improve working efficiency.
  • Page 268 POWR Power unit 10. Remove the 10-pin coupler e from the holders on the bracket A, and then dis- connect the 10-pin coupler. 11. Remove the 6Y8 Multifunction Meter 16. Remove the engine ECM cover D, and coupler f from the tab on the bracket, then remove the speed sensor coupler k and then disconnect the 6Y8 Multifunc- from the bracket E.
  • Page 269 Power unit assembly 21. Disconnect the shift cut switch coupler m, and then remove the wiring harness and neutral switch lead from the holders J and K. 22. Remove the neutral switch coupler n, and then disconnect the neutral switch coupler from the bracket L.

  • Page 270: Installing The Power Unit

    POWR Power unit 28. Remove the power unit mounting bolts V and W, and then remove the power unit STBD U, gasket X, and dowels Y. 2. Clean the power unit mating surface, and then the install the dowels 1 and a new gasket 2.
  • Page 271 Power unit assembly 5. Install the cover 7 and aprons 8. TIP: To fasten the PTT motor lead, see “Wiring harness routing” (5-6). 8. Connect the cooling water hose C, and TIP: then fasten it using the clamp D. Make sure that the ground lead a is routed through the gap between the aprons and is 9.
  • Page 272 POWR Power unit 20. Connect the trim sensor coupler g, and 15. Connect the vapor gas hose K to the housing (STBD), and then fasten it using then install the trim sensor coupler to the the plastic tie L. tab on the bracket. STBD 21.
  • Page 273 Power unit assembly Negative battery cable nut: TIP: 13 N·m (1.3 kgf·m, 9.6 ft·lb) To install the water detection switch coupler and isolator coupler, see “Wiring harness 31. Install the rigging grommet Z and retain- routing” (5-6). ing plate [. 26.
  • Page 274 POWR Power unit Flywheel magnet 240 N m (24.0 kgf m, 177.0 ft lb) 4 N m (0.4 kgf m, 3.0 ft lb) Part name Q’ty Remarks Width across flats: 36 mm Washer Flywheel magnet Stator assembly M6 × 35 mm Bolt Dowel Holder...

  • Page 275: Flywheel Magnet

    Flywheel magnet Removing the flywheel magnet Do not turn the flywheel magnet counter- clockwise. Otherwise, the water pump impeller could be damaged. 1. Loosen flywheel magnet nut. NOTICE: Apply force in the direction of the arrow to prevent the special service tool 1 from slipping off easily.

  • Page 276: Checking The Pulser Coil

    POWR Power unit Checking the pulser coil 1. Check the pulser coil. See step 6 in “Checking the pulser coil” (5-55). Installing the flywheel magnet Do not turn the flywheel magnet counter- clockwise. Otherwise, the water pump impeller could be damaged. 5.
  • Page 277 Flywheel magnet TIP: • Make sure to remove any grease from the tapered portion c of the crankshaft and the inner surface d of the flywheel magnet. • Apply engine oil to the threads e of the fly- wheel magnet nut and upper and lower sur- faces f of the washer before installation.
  • Page 278 POWR Power unit Wiring harness Part name Q’ty Remarks Wiring harness guide Plastic tie Damper M6 × 35 mm Bolt Holder Wiring harness Protector M6 × 30 mm Bolt M6 × 16 mm Bolt 7-19...

  • Page 279: Wiring Harness

    Wiring harness Removing the wiring harness When removing the wiring harness and wir- ing harness guide, the fuel line must be dis- connected. Therefore, make sure to reduce the fuel pressure before performing the dis- assembly procedure. 1. Disconnect the air temperature sensor coupler, and then remove the blowby hose and intake silencer.
  • Page 280 POWR Power unit PORT 17. Remove the low-pressure fuel pump cou- 25. Remove the plastic tie B, and then dis- pler r from the wiring harness guide, connect the thermoswitch connectors (STBD) A. and then disconnect the low-pressure fuel pump coupler. 26.
  • Page 281 Wiring harness 33. Remove the fuse holder J and grommet K, and then disconnect the fuse holder couplers H. 29. Remove the thermoswitch lead and engine temperature sensor lead from the holder E on the wiring harness guide, and then remove the wiring harness guide G.

  • Page 282: Installing The Wiring Harness

    POWR Power unit 2. Install the wiring harness at the white tape c to the holder 1, and then fasten the wiring harness using the plastic tie 3. Connect the APS coupler d. 39. Disconnect the oil pressure sensor cou- pler R and water detection switch cou- 4.
  • Page 283 Wiring harness 12. Fasten the air temperature sensor lead using the holder 0. 13. Install the wiring harness guide A, and then install the thermoswitch lead and engine temperature sensor lead to the holder p on the wiring harness guide. 8.
  • Page 284 POWR Power unit 21. Connect the thermoswitch connectors (PORT) A and vapor separator wiring harness extension coupler B, and then fasten the thermoswitch connectors, vapor separator wiring harness exten- sion, and wiring harness using the holder 22. Fasten the YDIS/diagnostic flash indica- tor connector lead using the holder J.
  • Page 285 Wiring harness 35. Connect ignition coil couplers (PORT) T, cam position sensor coupler (PORT EX) U, and cam position sensor coupler (PORT IN) Y. 36. Connect the engine ECM couplers Z. NOTICE: Make sure that the rubber seal is installed properly in each engine ECM coupler.

  • Page 286: Starter Motor

    POWR Power unit Starter motor 26 N · m (2.6 kgf · m, 19.2 ft · Ib) Part name Q’ty Remarks Starter motor M8 × 45 mm Bolt Holder Plastic tie M8 × 16 mm Bolt Terminal M8 × 20 mm Bolt Terminal stud bolt Collar...

  • Page 287: Removing The Starter Motor

    Starter motor Removing the starter motor 1. Disconnect the starter motor lead a, and then remove the plastic ties 1 and hold- ers 2. Terminal stud bolt 2: 26 N·m (2.6 kgf·m, 19.2 ft·lb) 3. Connect the starter motor lead c and brown lead of the wiring harness, and 2.

  • Page 288: Fuse Box

    POWR Power unit Fuse box Part name Q’ty Remarks Fuse box assembly Fuse 10 A, Spare is included. Fuse 30 A, Spare is included. Fuse 20 A, Spare is included. Fuse 15 A, Spare is included. ø5 × 20 mm Screw Relay Cover...
  • Page 289 Fuse box / Junction box Junction box 4 N m (0.4 kgf m, 3.0 ft lb) 6 N m (0.6 kgf m, 4.4 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) 3 N m (0.3 kgf m, 2.2 ft lb) 6 N m (0.6 kgf m, 4.4 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) Part name...
  • Page 290 POWR Power unit 4 N m (0.4 kgf m, 3.0 ft lb) 6 N m (0.6 kgf m, 4.4 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) 3 N m (0.3 kgf m, 2.2 ft lb) 6 N m (0.6 kgf m, 4.4 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) Part name Q’ty...

  • Page 291: Removing The Rectifier Regulator

    Junction box Removing the Rectifier Regulator Checking the Rectifier Regulator 1. Remove the Rectifier Regulator protector anode 1. Check the anode. Replace if eroded. Clean if there is grease, oil, or scales. 2. Disconnect the cooling water hoses a NOTICE: Do not apply grease, oil, or and b.

  • Page 292: Installing The Junction Box

    POWR Power unit Installing the junction box PTT relay terminal nut 4: 4 N·m (0.4 kgf·m, 3.0 ft·lb) 1. Install the junction box 1. Installing the Rectifier Regulator 2. Install the holder a on the wiring har- ness to the junction box 1. Do not reuse a gasket, always replace it 3.
  • Page 293 Junction box 4. Install the Rectifier Regulator couplers a to the junction box. 5. Connect the Rectifier Regulator ground lead b. 6. Fasten the Rectifier Regulator leads using the plastic tie 8. 7. Connect the cooling water hoses c and 8.
  • Page 294 POWR Power unit Engine ECM 7 N m (0.7 kgf m, 5.2 ft lb) Part name Q’ty Remarks Engine ECM M6 × 20 mm Bolt Plastic tie Holder Bracket Collar Grommet M6 × 28 mm Bolt Holder Bracket M6 × 16 mm Bolt Holder Bracket...

  • Page 295: Engine Ecm

    Engine ECM Removing the engine ECM 1. Remove the engine ECM 1. 2. Remove the knock sensor lead a from the holder 2. Installing the engine ECM 1. Fasten the knock sensor lead a using the holder 1. 2. Install the engine ECM 2, and then tighten the engine ECM bolts 3 to the specified torque.
  • Page 296 POWR Power unit Timing belt 39 N m (3.9 kgf m, 28.8 ft lb) 39 N m (3.9 kgf m, 28.8 ft lb) Part name Q’ty Remarks Timing belt Timing belt tensioner M10 × 55 mm Bolt Washer Pulley Collar M6 ×...

  • Page 297: Timing Belt

    Timing belt Removing the timing belt • When the timing belt is not installed, do not turn the crankshaft or driven sprock- ets. Otherwise, the pistons and valves or intake and exhaust valves could col- lide with each other and be damaged. •...

  • Page 298: Checking The Timing Belt

    POWR Power unit TIP: • When turning the timing belt tensioner, apply a force of 15 N·m (1.5 kgf·m, 11.1 ft·lb) or less. • Leave the pin inserted into the hole f of the timing belt tensioner until the timing belt is installed again.
  • Page 299 Timing belt 5. Install the washer, and then tighten the TIP: pulley bolt 8 to the specified torque. Before installing the timing belt, make sure that the marks on the crankshaft and cylinder block are aligned. Also, make sure that the marks on the VCT assemblies and driven sprockets are aligned.
  • Page 300 POWR Power unit TIP: • When turning the timing belt tensioner, apply a force of 15 N·m (1.5 kgf·m, 11.1 ft·lb) or less. • Make sure that the belt position marks are aligned with the “ ” marks. See steps 6 and 7 in “Removing the timing belt”...
  • Page 301 Timing belt / Cylinder head cover Cylinder head cover 2 N m (0.2 kgf m, 1.5 ft lb) 8 N m (0.8 kgf m, 5.9 ft lb) 8 N m (0.8 kgf m, 5.9 ft lb) 25 N m (2.5 kgf m, 18.4 ft lb) 7 N m (0.7 kgf m, 5.2 ft lb) 23 N m (2.3 kgf m, 17.0 ft lb) Part name...
  • Page 302 POWR Power unit 2 N m (0.2 kgf m, 1.5 ft lb) 8 N m (0.8 kgf m, 5.9 ft lb) 8 N m (0.8 kgf m, 5.9 ft lb) 25 N m (2.5 kgf m, 18.4 ft lb) 7 N m (0.7 kgf m, 5.2 ft lb) 23 N m (2.3 kgf m, 17.0 ft lb) Part name Q’ty...

  • Page 303: Cylinder Head Cover

    Cylinder head cover Removing the cylinder head cover 1. Remove the ignition coils 1, spark plugs 2, cam position sensors 3 and 4, and adapter 5, and then remove the cylinder head covers 6 and 7. 2. Check the spark plug. Replace if the electrodes are eroded, or there is carbon or other deposits.
  • Page 304 POWR Power unit 4. Install the adapter 8. 5. Install a new gasket 9 and the adapter plug 0, and tighten the adapter plug to the specified torque. 6. Connect the cooling water hose A, and then fasten it using the clamp B. 7.

  • Page 305: Camshaft

    Cylinder head cover / Camshaft Camshaft 32 N m (3.2 kgf m, 23.6 ft lb) 8 N m (0.8 kgf m, 5.9 ft lb) 17 N m (1.7 kgf m, 12.5 ft lb) 60 N m (6.0 kgf m, 44.3 ft lb) 60 N m (6.0 kgf m, 44.3 ft lb) 8 N m (0.8 kgf m, 5.9 ft lb) 17 N m (1.7 kgf m, 12.5 ft lb)
  • Page 306 POWR Power unit 32 N m (3.2 kgf m, 23.6 ft lb) 8 N m (0.8 kgf m, 5.9 ft lb) 17 N m (1.7 kgf m, 12.5 ft lb) 60 N m (6.0 kgf m, 44.3 ft lb) 60 N m (6.0 kgf m, 44.3 ft lb) 8 N m (0.8 kgf m, 5.9 ft lb) 17 N m (1.7 kgf m, 12.5 ft lb) 8 N m (0.8 kgf m, 5.9 ft lb)

  • Page 307: Removing The Driven Sprocket And Camshaft

    Camshaft Removing the driven sprocket and TIP: camshaft Be careful when turning the VCT assemblies and driven sprockets. Depending on the posi- tion of the camshafts, the force of the valve When the timing belt is not installed, do springs may cause the VCT assemblies and not turn the crankshaft or camshafts.

  • Page 308: Checking The Sprocket

    POWR Power unit 6. Secure the exhaust camshaft using a wrench 3, and then remove the driven sprockets 5. NOTICE: When removing the driven sprocket, do not turn the exhaust camshaft. Otherwise, the intake and exhaust valves could col- lide with each other and be damaged. 7.

  • Page 309: Checking The Camshaft

    Camshaft Checking the camshaft 3. Measure the camshaft runout. 1. Check the edge and face of the flange on the camshafts (PORT) and intake cam- shaft (STBD) that is used for the cam position sensor. Replace the camshaft if damaged, rough, or scratched. Camshaft runout: 0.015 mm (0.0006 in) 4.
  • Page 310 POWR Power unit • Do not reuse a gasket, oil seal, or seal washer, always replace it with a new one. • When the timing belt is not installed, do not turn the crankshaft or camshafts. Otherwise, the pistons and valves or intake and exhaust valves could collide with each other and be damaged.
  • Page 311 Camshaft PORT STBD PORT STBD 5. Install the camshaft caps 9, 0, A, and B in their proper positions and with the stamped numbers upside down. 6. Install the camshaft cap bolts C, D, E, Camshaft cap bolt D, E, and F: and F.
  • Page 312 POWR Power unit PORT 13. Secure the intake camshaft using a wrench I, and then tighten the VCT bolts M to the specified torque. NOTICE: When tightening the VCT bolt, do not secure the driven sprocket. Other- wise, the VCT assembly could be damaged.
  • Page 313 Camshaft VCT cap O: 32 N·m (3.2 kgf·m, 23.6 ft·lb) 15. Align the “II” marks h on the VCT assembly (PORT) and driven sprocket (PORT) by turning them counterclock- wise 60° gradually. NOTICE: Do not turn the VCT assembly (PORT) and driven sprocket (PORT) counterclock- wise more than 60°, and do not turn the VCT assembly (STBD) and driven...
  • Page 314 POWR Power unit 17. Check that the “I” marks m on the VCT assembly (STBD) and driven sprocket (STBD) are aligned. STBD 7-55...

  • Page 315: Exhaust Cover

    Camshaft / Exhaust cover Exhaust cover 6 N·m (0.6 kgf·m, 4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·Ib) 55 N·m (5.5 kgf·m, 40.6 ft·Ib) Part name Q’ty Remarks M6 × 50 mm Bolt M18 × 17 mm Plug Gasket Exhaust outer cover (PORT)

  • Page 316: Removing The Exhaust Cover

    POWR Power unit 2. Install new gaskets 4 and the exhaust Removing the exhaust cover covers 5 and 6, and then tighten the 1. Loosen the exhaust cover bolts 1 in the exhaust cover bolts 7 to the specified order 1, 2, and so on, and then remove torques in 2 stages and in the order 1, the exhaust covers 2 and 3.

  • Page 317: Cylinder Head

    Exhaust cover / Cylinder head Cylinder head 7 N m( 0.7 kgf m, 5.2 ft lb) 30 N m (3.0 kgf m, 22.1 ft lb) 60 N m (6.0 kgf m, 44.3 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) (* 1) È...
  • Page 318 POWR Power unit 7 N m( 0.7 kgf m, 5.2 ft lb) 30 N m (3.0 kgf m, 22.1 ft lb) 60 N m (6.0 kgf m, 44.3 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) (* 1) È...
  • Page 319 Cylinder head 7 N m( 0.7 kgf m, 5.2 ft lb) 30 N m (3.0 kgf m, 22.1 ft lb) 60 N m (6.0 kgf m, 44.3 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) (* 1) È...

  • Page 320: Removing The Cylinder Head

    POWR Power unit Removing the cylinder head 1. Remove the fuel rails. See “Removing the fuel injector” (6-45). 2. Remove the engine hangers 1. 3. Remove the OCVs 2 and filters 3. 4. Loosen the cylinder head bolts 4, 5, and 6 in the order 1, 2, and so on, and Disassembling the cylinder head then remove the cylinder heads 7 and...

  • Page 321: Checking The Cylinder Head

    Cylinder head Valve spring compressor 2: 90890-04019 Cylinder head warpage limit: Valve spring compressor attachment 3: 0.10 mm (0.0039 in) 90890-06320 Checking the valve spring 1. Measure the valve spring free length a. TIP: Make sure to keep the parts in the order as they were removed.

  • Page 322: Checking The Valve Guide

    POWR Power unit Valve margin thickness a: Intake: 0.500–0.900 mm (0.0197–0.0354 in) Exhaust: 0.900–1.300 mm (0.0354–0.0512 in) 3. Measure the valve stem diameter b. Replace if out of specification. Valve guide inside diameter a: Intake and exhaust: 5.504–5.522 mm (0.2167–0.2174 in) 2.

  • Page 323: Checking The Valve Seat

    Cylinder head 2. Install a new valve guide 3 using the Valve guide inside diameter: special service tools 2 from the cam- Intake and exhaust: shaft side until the valve guide installer 5.504–5.522 mm (0.2167–0.2174 in) 4 to the specified height a. Checking the valve seat 1.

  • Page 324: Refacing The Valve Seat

    POWR Power unit 2. Cut the surface of the valve seat using a 45° cutter by turning the cutter clockwise until the valve seat face has become smooth. NOTICE: Do not over cut the valve seat. To prevent chatter marks, make sure to turn the cutter evenly using a downward force of 40–50 N (4.0–5.0 kgf, 8.8–11.0 lbf).
  • Page 325 Cylinder head b Previous contact width • If the valve seat contact area is too narrow and situated near the top edge of the valve face, cut the top edge of the valve seat using a 30° cutter to center the area, and then set its width using a 45°...

  • Page 326: Checking The Cylinder Head Anode

    POWR Power unit Valve lapper 1: 90890-04101 8. Recheck the valve seat contact area of the valve. See “Checking the valve seat” (7-64). Checking the cylinder head anode 1. Check the anodes. Replace if eroded. Clean if there is grease, oil, or scales. Valve spring compressor 6: 90890-04019 NOTICE: Do not apply grease, oil, or Valve spring compressor attachment 7:...

  • Page 327: Installing The Cylinder Head

    Cylinder head 2. Install the dowels 2, new gaskets 3, and the cylinder heads 4, and then tighten the cylinder head bolts 5 to the specified torques in 6 stages and in the order 1, 2, and so on. 3. Tighten the cylinder head bolts 6 and 7 to the specified torques in 2 stages and in the order 9, 0, and so on.
  • Page 328 POWR Power unit Tightening procedure when using new cylin- der head bolts: Cylinder head bolt 5 1–8 (M10): 1st: 30 N·m (3.0 kgf·m, 22.1 ft·lb) 2nd: 60 N·m (6.0 kgf·m, 44.3 ft·lb) 3rd: Loosen completely 4th: 30 N·m (3.0 kgf·m, 22.1 ft·lb) 5th: 60 N·m (6.0 kgf·m, 44.3 ft·lb) 6th: 90°...

  • Page 329: Cooling Water Passage Cover

    Cylinder head / Cooling water passage cover Cooling water passage cover 3 N m (0.3 kgf m, 2.2 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) 32 N·m (3.2 kgf·m, 23.6 ft·Ib) 12 mm (0.47 in) 9 mm 7 mm 12 mm (0.35 in)
  • Page 330 POWR Power unit 3 N m (0.3 kgf m, 2.2 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) 32 N · m (3.2 kgf · m, 23.6 ft · Ib) 12 mm (0.47 in) 9 mm 7 mm 12 mm (0.35 in) (0.28 in)

  • Page 331: Removing The Cooling Water Passage Cover

    Cooling water passage cover Removing the cooling water passage Installing the cooling water passage cover cover 1. Remove the knock sensor, and then dis- connect the flushing hose. Do not reuse a gasket, always replace it with a new one. 2.
  • Page 332 POWR Power unit 5. Install the knock sensor 8, and then tighten it to the specified torque. 6. Fasten the knock sensor lead a and flushing hose 6 using the plastic tie 9. Knock sensor 8: 32 N·m (3.2 kgf·m, 23.6 ft·lb) TIP: Fasten the knock sensor lead a so that it is taut.

  • Page 333: Crankcase

    Cooling water passage cover / Crankcase Crankcase 18 N m (1.8 kgf m, 13.3 ft lb) 15 N m (1.5 kgf m, 11.1 ft lb) 4 N m (0.4 kgf m, 3.0 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) 34 N m (3.4 kgf m, 25.1 ft lb) 14 N m (1.4 kgf m, 10.3 ft lb) 28 N m (2.8 kgf m, 20.7 ft lb)
  • Page 334 POWR Power unit 18 N m (1.8 kgf m, 13.3 ft lb) 15 N m (1.5 kgf m, 11.1 ft lb) 4 N m (0.4 kgf m, 3.0 ft lb) 12 N m (1.2 kgf m, 8.9 ft lb) 34 N m (3.4 kgf m, 25.1 ft lb) 14 N m (1.4 kgf m, 10.3 ft lb) 28 N m (2.8 kgf m, 20.7 ft lb) Part name...

  • Page 335: Removing The Oil Filter Bracket

    Crankcase Removing the oil filter bracket Removing the crankcase cover 1. Remove the oil filter 1. 1. Remove the fuel filter assembly. See “Removing the fuel filter assembly” (6- 13). 2. Remove the throttle body assembly. See “Removing the throttle body assembly” (6-23).

  • Page 336: Disassembling The Oil Pump Assembly

    POWR Power unit Disassembling the oil pump Driver rod L3 2: 90890-06652 Needle bearing attachment 3: assembly 90890-06613 1. Remove the screws 1 and disassemble the oil pump. 2. Install a new oil seal 4 into the oil pump housing. Driver rod L3 2: 90890-06652 Needle bearing attachment 5: 90890-06607...

  • Page 337: Installing The Crankcase Cover

    Crankcase Installing the crankcase cover Do not reuse a gasket, always replace it with a new one. 1. Install the washer 1 and engine temper- STBD PORT ature sensor 2, and then tighten the engine temperature sensor to the speci- fied torque.

  • Page 338: Installing The Oil Filter Bracket

    POWR Power unit 3. Install the oil pump assembly 3 by align- ing the oil pump gear with the crankshaft. NOTICE: Before installing the oil pump assembly, make sure to fill it with engine oil through the oil pas- sages a. STBD PORT Oil filter union bolt 4:...
  • Page 339 Crankcase 5. Install the oil filter 7, and then tighten it to the specified torque. Oil filter 7: 18 N·m (1.8 kgf·m, 13.3 ft·lb) Oil filter wrench 8: 90890-06830 7-80...
  • Page 340 POWR Power unit Cylinder block 7 N m (0.7 kgf m, 5.2 ft lb) 23 N m (2.3 kgf m, 17.0 ft lb) 3 N m (0.3 kgf m, 2.2 ft lb) 33 N m (3.3 kgf m, 24.3 ft lb) 44 43 14 N m (1.4 kgf m, 10.3 ft lb) 28 N m (2.8 kgf m, 20.7 ft lb)
  • Page 341 Cylinder block 7 N m (0.7 kgf m, 5.2 ft lb) 23 N m (2.3 kgf m, 17.0 ft lb) 3 N m (0.3 kgf m, 2.2 ft lb) 33 N m (3.3 kgf m, 24.3 ft lb) 44 43 14 N m (1.4 kgf m, 10.3 ft lb) 28 N m (2.8 kgf m, 20.7 ft lb) 13N m (1.3 kgf m, 9.6 ft...
  • Page 342 POWR Power unit 7 N m (0.7 kgf m, 5.2 ft lb) 23 N m (2.3 kgf m, 17.0 ft lb) 3 N m (0.3 kgf m, 2.2 ft lb) 33 N m (3.3 kgf m, 24.3 ft lb) 44 43 14 N m (1.4 kgf m, 10.3 ft lb) 28 N m (2.8 kgf m, 20.7 ft lb) 13N m (1.3 kgf m, 9.6 ft...

  • Page 343: Disassembling The Cylinder Block

    Cylinder block Disassembling the cylinder block 1. Remove the thermoswitches 1. 2. Remove the thermostat covers 2, and then remove the thermostats 3 and anodes 4. TIP: Make sure to keep the parts in the order as 3. Remove the connecting rod caps a, and they were removed.

  • Page 344: Checking The Thermostat

    POWR Power unit STBD PORT Bearing splitter plate G: (commercially available) Gear puller H: (commercially available) General cylindrical tool I: e = 19 mm (0.7 in) 8. Remove the crankshaft B, crankshaft f = 90 mm (3.5 in) journal bearings C, thrust bearings D, and oil seal E.

  • Page 345: Checking The Piston Diameter

    Cylinder block Water Cylinder bore (D –D Valve opening a temperature 94.000–94.017 mm (3.7008–3.7014 58–62 °C Starts opening (136–144 °F) Checking the piston ring above 70 °C 4.3 mm (0.17 in) or above 1. Check the piston ring dimensions B and (158 °F) Checking the piston diameter 1.

  • Page 346: Checking The Piston Ring Groove

    POWR Power unit Measuring point a (reference data): 20.0 mm (0.8 in) Piston ring end gap b (reference data): Top ring: 0.200–0.300 mm (0.0079–0.0118 in) Second ring: 0.300–0.450 mm (0.0118–0.0177 in) Oil ring 0.150–0.600 mm (0.0059–0.0236 in) Piston ring side clearance: TIP: Top ring a: The figures are for reference only.

  • Page 347: Checking The Connecting Rod Small End Inside Diameter And Big End Inside Diameter

    Cylinder block TIP: • When checking the big end inside diame- ter, reuse the removed connecting rod bolt. • Make sure that the protrusions c on the connecting rod and connecting rod cap are aligned. • In the 3rd tightening stage for the connect- ing rod bolts 1, mark the connecting rod bolts and the connecting rod cap with iden- tification marks d, and then tighten the...

  • Page 348: Checking The Crankcase Bolt

    POWR Power unit È É È M10 × 102 mm Crankshaft journal diameter a: É M8 × 93 mm 62.968–62.992 mm (2.4791–2.4800 Crankcase bolt diameter difference limit: Crankpin diameter b: È: a – b = Less than 0.20 mm (0.0079 49.976–50.000 mm (1.9676–1.9685 É: a –...

  • Page 349: Selecting The Crankpin Bearing

    Cylinder block TIP: Do not place the Plastigauge (PG-1) over the oil hole in the crankpin of the crankshaft. Connecting rod bolt 2: 4. Install the connecting rod a and con- 1st: 13 N·m (1.3 kgf·m, 9.6 ft·lb) necting rod cap b onto the crankpin c. 2nd: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 3rd: 90°...

  • Page 350: Checking The Crankshaft Journal Oil Clearance

    POWR Power unit 3. Install the crankshaft journal bearings 1 P1 P2 and crankshaft 2 into the cylinder block P5 P6 TIP: • Install the crankshaft journal bearings 1 in the original positions. P1 P2P3 P4 P5 P6 • Insert the protrusion a of each bearing into the slots in the cylinder block.

  • Page 351: Selecting The Crankshaft Journal Bearing

    Cylinder block 6. Install the crankcase 4, and then tighten Crankcase bolt 5 1–8 (M8): the crankcase bolts 5 and 6 to the 1st: 28 N·m (2.8 kgf·m, 20.7 ft·lb) specified torques in 2 stages and in the 2nd: 90° order 1, 2, and so on.
  • Page 352 POWR Power unit 1. Check the crankshaft journal mark a on Upper bearing Lower bearing the crankshaft and the cylinder block color color mark b on the cylinder block. Yellow Yellow Green Green Blue Blue J2 J1 2. Select the suitable colors c for the crankshaft journal bearing from the “Crankshaft journal bearing selection table.”...

  • Page 353: Crankshaft Journal Bearing Selection Table

    Cylinder block Example: If the crankshaft journal mark a is “69” g and the cylinder block mark b is “07” h, select the crankshaft journal bearing color in 99 9 06 07 08 09 f. The crankshaft journal bearing color is blue.

  • Page 354: Checking The Cylinder Block Anode

    POWR Power unit Checking the cylinder block anode TIP: 1. Check the anodes. Replace if eroded. • Face the protrusion b on the connecting Clean if there is grease, oil, or scales. rod a in the same direction as the mark c NOTICE: Do not apply grease, oil, or on the piston crown.
  • Page 355 Cylinder block TIP: TIP: Install the crankpin bearings in the original • Do not get any engine oil to the drive positions. sprocket. • Install each thrust bearing with its grooves r facing outward. 6. Install crankshaft journal bearings 6 into the cylinder block 7.
  • Page 356 POWR Power unit TIP: • Install each thrust bearing with its grooves t facing outward. • Fit the protrusion on each thrust bearing into the slot in the crankcase. 11. Install new O-rings C and D and the crankcase E onto the cylinder block, and then tighten the crankcase bolts F and G to the specified torques in 2 stages STBD...
  • Page 357 Cylinder block TIP: • Make sure that the protrusions x on the connecting rod and connecting rod cap w face toward the flywheel magnet end of the crankshaft. • In the 3rd tightening stage for the connect- ing rod bolts K, mark the connecting rod bolts and the connecting rod cap with iden- tification marks y, and then tighten the bolts 90°...
  • Page 358 POWR Power unit 20. Install the thermoswitches T. Anode bolt M: 7 N·m (0.7 kgf·m, 5.2 ft·lb) Anode O: 3 N·m (0.3 kgf·m, 2.2 ft·lb) Thermostat cover plug S: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 7-99...
  • Page 359 Cylinder block — MEMO — 7-100...
  • Page 360 Removing the lower unit............. 8-6 Checking the propeller ............... 8-6 Checking the lower unit anode ........... 8-6 Water pump and shift rod (F200B)........8-7 Removing the water pump and shift rod........8-9 Disassembling the water pump housing........8-9 Checking the water pump and shift rod........8-9 Assembling the water pump housing ........
  • Page 361 Shimming check sheet ............. 8-38 Measuring the forward gear backlash and reverse gear backlash before disassembly ......8-40 Shimming ................. 8-43 Shim location (F200B).............. 8-43 Shim location (F250G) ............. 8-44 Selecting the pinion shim (T3)..........8-45 Pinion shim (T3) selection table ..........8-48 Selecting the propeller shaft shim (T4) (F250G) ......
  • Page 362 LOWR Lower unit (FL200B)............8-59 Removing the lower unit............8-61 Checking the propeller ............. 8-61 Checking the lower unit anode ..........8-61 Lower unit (FL250G) ............8-62 Removing the lower unit............8-64 Checking the propeller ............. 8-64 Checking the lower unit anode ..........8-64 Water pump and shift rod (FL200B) .......
  • Page 363 Installing the shift rod ............... 8-84 Installing the water pump ............8-85 Checking the lower unit for air leakage ........8-85 Installing the lower unit............. 8-85 Drive shaft and lower case (FL250G) ......8-86 Removing the drive shaft............8-88 Disassembling the oil seal housing .......... 8-88 Disassembling the reverse gear..........
  • Page 364 LOWR Lower unit Lower unit (F200B) È 9 N m (0.9 kgf m, 6.6 ft lb) 42 N m (4.2 kgf m, 31.0 ft lb) 55 N m (5.5 kgf m, 40.6 ft Ib) 47 N m (4.7 kgf m, 34.7 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb)
  • Page 365 Lower unit (F200B) È 9 N m (0.9 kgf m, 6.6 ft lb) 42 N m (4.2 kgf m, 31.0 ft lb) 55 N m (5.5 kgf m, 40.6 ft Ib) 47 N m (4.7 kgf m, 34.7 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb)
  • Page 366 LOWR Lower unit Removing the lower unit È • Make sure to disconnect the battery cables from the battery, and remove the clip from the engine shut-off switch. • When removing the lower unit with the power unit installed, make sure to sus- pend the outboard motor.
  • Page 367 Lower unit (F200B) / Lower unit (F250G) Lower unit (F250G) È 42 N m (4.2 kgf m, 31.0 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) 55 N m (5.5 kgf m, 40.6 ft Ib) 47 N m (4.7 kgf m, 34.7 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb)
  • Page 368 LOWR Lower unit È 42 N m (4.2 kgf m, 31.0 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) 55 N m (5.5 kgf m, 40.6 ft Ib) 47 N m (4.7 kgf m, 34.7 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) 47 N m (4.7 kgf m, 34.7 ft lb) Part name...
  • Page 369 Lower unit (F250G) Removing the lower unit 1. Drain the gear oil. See steps 1–5 in “Changing gear oil” (10-11). 2. Remove the propeller, trim tab, lower unit, and extension (U-transom model). See steps 2–6 in “Removing the lower unit” (8-3). TIP: When disassembling the lower unit, measure the backlash before disassembly.
  • Page 370 LOWR Lower unit Water pump and shift rod (F200B) Part name Q’ty Remarks Seal Shift rod M6 × 20 mm Bolt Oil seal Plate O-ring Spring E-clip Woodruff key Dowel Gasket Outer plate cartridge Impeller Washer Wave washer Spacer Collar...
  • Page 371 Water pump and shift rod (F200B) Part name Q’ty Remarks O-ring Water pump housing M8 × 45 mm Bolt Cover Seal Insert cartridge O-ring...
  • Page 372 LOWR Lower unit Removing the water pump and shift 1. Remove the water pump housing 1, col- lar 2, spacer 3, washers 4, wave washer 5, impeller 6, and Woodruff key 2. Remove the outer plate cartridge 8 and gasket 9. Disassembling the water pump housing 1.
  • Page 373 Water pump and shift rod (F200B) TIP: TIP: Fit the protrusions a on the insert cartridge If the engine overheated, the inside of the 4 into the slots b in the water pump housing water pump housing may be deformed.
  • Page 374 LOWR Lower unit Water pump and shift rod (F250G) Part name Q’ty Remarks Seal Shift rod M6 × 20 mm Bolt Oil seal Plate O-ring Spring E-clip Woodruff key Dowel Gasket Outer plate cartridge Impeller O-ring Water pump housing M8 × 45 mm Bolt Cover 8-11...
  • Page 375 Water pump and shift rod (F250G) Part name Q’ty Remarks Seal Insert cartridge O-ring 8-12...
  • Page 376 LOWR Lower unit Removing the water pump and shift 1. Remove the water pump housing 1, impeller 2, and Woodruff key 3. 2. Remove the outer plate cartridge 4 and gasket 5. 3. Set the gear shift to the N position, and then remove the plate, oil seal, O-ring, and shift rod.
  • Page 377 Water pump and shift rod (F250G) / Propeller shaft housing (F200B) Propeller shaft housing (F200B) 20 21 18 19 1 N m (0.1 kgf m, 0.7 ft lb) 29 N m (2.9 kgf m, 21.4 ft lb) 6 N m (0.6 kgf m, 4.4 ft lb) Part name Q’ty...
  • Page 378 LOWR Lower unit 20 21 18 19 1 N m (0.1 kgf m, 0.7 ft lb) 29 N m (2.9 kgf m, 21.4 ft lb) 6 N m (0.6 kgf m, 4.4 ft lb) Part name Q’ty Remarks Washer M8 × 33 mm Bolt O-ring Needle bearing...
  • Page 379 Propeller shaft housing (F200B) Removing the propeller shaft TIP: housing assembly When removing the slider 5, make sure that 1. Remove the cover 1 and bolts 2. the balls 7 do not fall out of position. Disassembling the propeller shaft housing assembly 1.
  • Page 380 LOWR Lower unit 3. Check the dog clutch, shift rod joint, and slider. Replace if cracked or worn. Assembling the propeller shaft assembly 1. Install the shift plunger 1, slider 2, balls 3, and shift rod joint 4 into the propeller shaft 5.
  • Page 381 Propeller shaft housing (F200B) Assembling the propeller shaft housing assembly • Use heat-resistant gloves. Otherwise, burns could result. • To prevent fires, remove any flammable substances, such as gasoline and oil, around the working area. • Keep good ventilation while working.
  • Page 382 LOWR Lower unit 4. Heat the installation area of the ball bear- ing in the propeller shaft housing 9 using a gas torch, and then install the reverse gear assembly 0. NOTICE: When heating the propeller shaft housing, heat the entire installation area evenly.
  • Page 383 Propeller shaft housing (F200B) / Propeller shaft housing (F250G) Propeller shaft housing (F250G) 11 10 24 25 1 N m (0.1 kgf m, 0.7 ft lb) 29 N m (2.9 kgf m, 21.4 ft lb) 6 N m (0.6 kgf m, 4.4 ft lb) Part name Q’ty...
  • Page 384 LOWR Lower unit 11 10 24 25 1 N m (0.1 kgf m, 0.7 ft lb) 29 N m (2.9 kgf m, 21.4 ft lb) 6 N m (0.6 kgf m, 4.4 ft lb) Part name Q’ty Remarks Reverse gear shim (T2) —...
  • Page 385 Propeller shaft housing (F250G) Removing the propeller shaft Disassembling the propeller shaft housing assembly assembly 1. Remove the water pipe 1. 1. Disassemble the propeller shaft assem- bly. See “Disassembling the propeller shaft assembly” (8-16). Disassembling the propeller shaft housing assembly 1.
  • Page 386 LOWR Lower unit 2. Install the rubber seal 1. 8-23...
  • Page 387 Propeller shaft housing (F250G) / Drive shaft and lower case (F200B) Drive shaft and lower case (F200B) 142 N m (14.2 kgf m, 104.7 ft lb) Part name Q’ty Remarks Thrust bearing Pinion shim (T3) — O-ring Needle bearing Oil seal housing M8 ×...
  • Page 388 LOWR Lower unit Removing the drive shaft Needle bearing attachment 3: 1. Remove the pinion nut and washer. 90890-06610 Driver rod L3 4: 90890-06652 Disassembling the forward gear 1. Remove the taper roller bearing. Drive shaft holder 6 1: Bearing separator 1: 90890-06534 90890-06520 Disassembling the lower case Pinion nut holder 2: 90890-06715...
  • Page 389 Drive shaft and lower case (F200B) Checking the drive shaft TIP: 1. Check the drive shaft. Replace if dam- • Since the diameter of the passage in the aged or worn. lower case and the diameter of the special service tool 1 are both 40 mm (1.57 in), 2.
  • Page 390 LOWR Lower unit Ball bearing attachment 6: 90890-06655 Bearing outer race puller assembly 7: 90890-06523 TIP: The needle bearing contains 24 rollers. Assembling the forward gear Do not reuse a bearing, always replace it with a new one. TIP: 1. Install a new taper roller bearing. Do not reuse a shim if deformed or scratched.
  • Page 391 Drive shaft and lower case (F200B) Depth a: 4.25–4.75 mm (0.167–0.187 in) 2. Install new oil seals into the oil seal hous- ing to the specified depth b. 3. Install the pinion and washer, and then tighten the pinion nut temporarily.
  • Page 392 LOWR Lower unit 4. Install the propeller shaft housing assem- bly, and then tighten the propeller shaft housing bolts 6 to the specified torque. 5. Install the cover 7. 6. Install the water inlet covers 8, and then tighten the water inlet cover screw 9 to the specified torque.
  • Page 393 Drive shaft and lower case (F200B) 3. Align the slot a on the impeller 5 with the Woodruff key 4, and then install the impeller 5. 4. Install the washers 6, wave washer 7, spacer 8, and collar 9. TIP: Make sure to fit the tip a of the shift rod 1 into the slot b in the shift rod joint.
  • Page 394 LOWR Lower unit TIP: While turning the drive shaft clockwise, push the water pump housing down to install it. Checking the lower unit for air leakage 1. Remove the check screw 1, and then connect the special service tool 2. 2.
  • Page 395 Drive shaft and lower case (F200B) È Propeller nut A: 55 N·m (5.5 kgf·m, 40.6 ft·lb) 7. Install a new cotter pin B. È U-transom model Lower case mounting bolt 5: 47 N·m (4.7 kgf·m, 34.7 ft·lb) Lower case mounting nut 6: 47 N·m (4.7 kgf·m, 34.7 ft·lb)
  • Page 396 LOWR Lower unit Drive shaft and lower case (F250G) 142 N m (14.2 kgf m, 104.7 ft lb) Part name Q’ty Remarks Thrust bearing Pinion shim (T3) — O-ring Needle bearing Oil seal housing M8 × 25 mm Bolt Oil seal Cover Drive shaft Lower case...
  • Page 397 Drive shaft and lower case (F250G) 142 N m (14.2 kgf m, 104.7 ft lb) Part name Q’ty Remarks Pinion Washer Pinion nut 8-34...
  • Page 398 LOWR Lower unit Removing the drive shaft Installing the drive shaft 1. Remove the pinion nut. See step 1 in 1. Install the forward gear assembly into the “Removing the drive shaft” (8-25). lower case. 2. Install the washer 1, spring 2, thrust 2.
  • Page 399 Drive shaft and lower case (F250G) 3. Install the original propeller shaft shim 3 and propeller shaft assembly 4 into the propeller shaft housing assembly 5. Installing the shift rod 1. Install the shift rod. See “Installing the shift rod” (8-29). Installing the water pump 1.
  • Page 400 Measure the backlash before disassembly. Within specification? Shimming is not required. Disassemble the lower unit. Select the pinion shims (T3). (F200B) Select the pinion shims (T3) and propeller shaft shim (T4). (F250G) Assemble the lower unit. Measure the backlash. Adjust the forward gear shim...
  • Page 401 Shimming (regular rotation model) Shimming check sheet Lower case deviation Serial number Remarks Pinion height (mm) Measurements Measuring point #1 Measuring point #2 Measuring point #3 Measuring point #4 Average Round-down average Forward gear backlash (mm) Measurements Before disassembly After disassembly Measuring point #1 Measuring point #2 Measuring point #3...
  • Page 402 LOWR Lower unit Forward gear shim (T1) thickness measurement in 2 places (mm) Number of shim(s) Subtotal 0.10 0.12 0.15 0.18 0.30 0.40 0.50 Total Reverse gear shim (T2) thickness measurement in 2 places (mm) Number of shim(s) Subtotal 0.10 0.12 0.15 0.18...
  • Page 403 1. Remove the water pump assembly and outer plate cartridge. See steps 1 and 2 in “Removing the water pump and shift rod” (8-9). (F200B) See steps 1 and 2 in “Removing the water pump and shift rod” (8-13). (F250G) 2.
  • Page 404 LOWR Lower unit Backlash indicator 9: 90890-06706 Magnet base plate 0: 90890-07003 Dial gauge set A: 90890-01252 Magnet base B B: 90890-06844 12. Turn the drive shaft slowly clockwise and counterclockwise and measure the back- lash between where the drive shaft stops in each direction.
  • Page 405 Average 0.5425 See “Installing the water pump” (8-30). Round-down average 0.54 (F200B) See steps 1–3 and 5 in “Install- ing the water pump” (8-30). (F250G) 15. Check that the forward gear backlash average is within specification. Forward gear backlash: 0.26–0.65 mm (0.0102–0.0256 in)
  • Page 406 • When assembling the lower unit to measure the backlash after selecting the pinion shims (T3), do not apply gear oil, grease, or sealant to the parts. • When assembling the lower unit after shimming is completed, make sure to apply gear oil, grease, and sealant to the specified areas. Shim location (F200B) 8-43...
  • Page 407 Shimming (regular rotation model) Shim location (F250G) 8-44...
  • Page 408 LOWR Lower unit 2. Tighten the oil seal housing bolts 4. Selecting the pinion shim (T3) • Spray anti-rust lubricant on the gears and bearings before installation. Do not apply gear oil to the parts. Otherwise, correct measurements cannot be obtained. •...
  • Page 409 Shimming (regular rotation model) TIP: If there is no gap, the thrust bearing outer race d may not have been installed. If the gap is 1 mm (0.04 in) or more, the pinion 8. Turn the drive shaft 10 times or more to shims (T3) 8 may not have been removed.
  • Page 410 LOWR Lower unit TIP: • Measure the gap at 4 points: e, f, g, and È P /M 0.16 0.17 0.18 0.19 • Write down the measurement data in the shimming check sheet. É 10. Determine the gap average, and then 1.12 round down the average to the 1/100 place.
  • Page 411 Shimming (regular rotation model) Pinion shim (T3) selection table (mm) È 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 1.32 1.32 1.32 1.30 1.30 1.28 1.28 1.25 1.25 1.25 1.22 1.22 1.22 1.20 1.20 1.32 1.32...
  • Page 412 LOWR Lower unit (mm) È 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 0.39 0.40 0.41 0.42 0.43 0.44 0.45 1.02 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95 0.95 0.92 0.92 0.92 0.90 0.90 1.02 1.02 1.00 1.00 0.98 0.98 0.95 0.95...
  • Page 413 Shimming (regular rotation model) Selecting the propeller shaft shim 5. Select the propeller shaft shim (T4) thick- ness from the following table according (T4) (F250G) to the free play measurement. 1. Install the original propeller shaft shim. (mm) TIP: Free play Shim thickness •...
  • Page 414 “Installing the drive shaft” (8-28). See “Removing the drive shaft” (8-25). (F200B) See steps 2 and 3 in “Installing (F200B) See step 1 in “Removing the the drive shaft” (8-35) and steps 4 and 5 drive shaft”...
  • Page 415 Shimming (regular rotation model) 7. Install the determined forward gear TIP: shims (T1) and taper roller bearing outer • If the shim thickness adjustment value is race. See steps 2 and 3 in “Assembling positive, the current shim thickness must the lower case”...
  • Page 416 LOWR Lower unit 8-53...
  • Page 417 Shimming (regular rotation model) 8-54...
  • Page 418 1. Remove the propeller shaft housing bearings and shims. assembly. See “Removing the propeller shaft housing assembly” (8-16). (F200B) 1. Install the original reverse gear shims See “Removing the propeller shaft hous- and ball bearing. See steps 3 and 4 in ing assembly”...
  • Page 419 Shimming (regular rotation model) Current reverse gear shim thickness = 1.25 0.40 Shim thickness adjustment = –0.20 mm 0.20 New reverse gear shim (T2) thickness = 1.25 mm + (–0.20) mm = 1.05 mm Available shim thicknesses: –0.20 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 –0.40 TIP: È...
  • Page 420 LOWR Lower unit 8-57...
  • Page 421 Shimming (regular rotation model) 8-58...
  • Page 422 LOWR Lower unit Lower unit (FL200B) È 42 N m (4.2 kgf m, 31.0 ft lb) 55 N m (5.5 kgf m, 40.6 ft Ib) 47 N m (4.7 kgf m, 34.7 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) 47 N m (4.7 kgf m, 34.7 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) Part name...
  • Page 423 Lower unit (FL200B) È 42 N m (4.2 kgf m, 31.0 ft lb) 55 N m (5.5 kgf m, 40.6 ft Ib) 47 N m (4.7 kgf m, 34.7 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) 47 N m (4.7 kgf m, 34.7 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) Part name...
  • Page 424 LOWR Lower unit Removing the lower unit 1. Drain the gear oil. See steps 1–5 in “Changing gear oil” (10-11). 2. Remove the propeller, trim tab, lower unit, and extension (U-transom model). See steps 2–6 in “Removing the lower unit” (8-3). TIP: When disassembling the lower unit, measure the backlash before disassembly.
  • Page 425 Lower unit (FL200B) / Lower unit (FL250G) Lower unit (FL250G) È 42 N m (4.2 kgf m, 31.0 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) 55 N m (5.5 kgf m, 40.6 ft Ib) 47 N m (4.7 kgf m, 34.7 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) 47 N m (4.7 kgf m, 34.7 ft lb) Part name...
  • Page 426 LOWR Lower unit È 42 N m (4.2 kgf m, 31.0 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) 55 N m (5.5 kgf m, 40.6 ft Ib) 47 N m (4.7 kgf m, 34.7 ft lb) 9 N m (0.9 kgf m, 6.6 ft lb) 47 N m (4.7 kgf m, 34.7 ft lb) Part name...
  • Page 427 Lower unit (FL250G) Removing the lower unit 1. Drain the gear oil. See steps 1–5 in “Changing gear oil” (10-11). 2. Remove the propeller, trim tab, lower unit, and extension (U-transom model). See steps 2–6 in “Removing the lower unit” (8-3). TIP: When disassembling the lower unit, measure the backlash before disassembly.
  • Page 428 LOWR Lower unit Water pump and shift rod (FL200B) Part name Q’ty Remarks Seal Shift rod M6 × 20 mm Bolt Oil seal Plate O-ring Spring E-clip Woodruff key Dowel Gasket Outer plate cartridge Impeller Washer Wave washer Spacer Collar 8-65...
  • Page 429 Water pump and shift rod (FL200B) Part name Q’ty Remarks O-ring Water pump housing M8 × 45 mm Bolt Cover Seal Insert cartridge O-ring 8-66...
  • Page 430 LOWR Lower unit Removing the water pump and shift 1. Remove the water pump housing, impel- ler, Woodruff key, outer plate cartridge, and gasket, and then set the gear shift to the N position. See steps 1–3 in “Remov- ing the water pump and shift rod” (8-9). 2.
  • Page 431 Water pump and shift rod (FL200B) / Water pump and shift rod (FL250G) Water pump and shift rod (FL250G) Part name Q’ty Remarks Seal Shift rod M6 × 20 mm Bolt Oil seal Plate O-ring Spring E-clip Woodruff key Dowel Gasket Outer plate cartridge Impeller...
  • Page 432 LOWR Lower unit Part name Q’ty Remarks Seal Insert cartridge O-ring 8-69...
  • Page 433 Water pump and shift rod (FL250G) Removing the water pump and shift 1. Remove the water pump housing, impel- ler, Woodruff key, outer plate cartridge, and gasket, and then set the gear shift to the N position. See steps 1 and 2 in “Removing the water pump and shift rod”...
  • Page 434 LOWR Lower unit Propeller shaft housing (FL200B) 12 11 108 N m (10.8 kgf m, 79.7 ft lb) 29 N m (2.9 kgf m, 21.4 ft lb) 1 N m (0.1 kgf m, 0.7 ft lb) 6 N m (0.6 kgf m, 4.4 ft lb) Part name Q’ty Remarks...
  • Page 435 Propeller shaft housing (FL200B) 12 11 108 N m (10.8 kgf m, 79.7 ft lb) 29 N m (2.9 kgf m, 21.4 ft lb) 1 N m (0.1 kgf m, 0.7 ft lb) 6 N m (0.6 kgf m, 4.4 ft lb) Part name Q’ty Remarks...
  • Page 436 LOWR Lower unit Removing the propeller shaft housing assembly 1. Remove the cover and bolts. See step 1 in “Removing the propeller shaft housing assembly” (8-16). 2. Remove the propeller shaft housing assembly. 4. Remove the ring nut 3 and claw washer Slide hammer handle 1: 90890-06531 Puller head 2: 90890-06514 Disassembling the propeller shaft...
  • Page 437 Propeller shaft housing (FL200B) Assembling the propeller shaft housing assembly • Use heat-resistant gloves. Otherwise, burns could result. • To prevent fires, remove any flammable substances, such as gasoline and oil, around the working area. • Keep good ventilation while working. Do not reuse a bearing, always replace it with a new one.
  • Page 438 LOWR Lower unit 4. Heat the installation area of the taper TIP: roller bearing outer race in the propeller If a high-pitched metallic sound is produced shaft housing 3 using a gas torch, and when the special service tool is struck, the then install the propeller shaft 4 and a taper roller bearing outer race is installed new taper roller bearing 5.
  • Page 439 Propeller shaft housing (FL200B) TIP: • Do not reuse a shim if deformed or scratched. • Face the “F” mark a on the dog clutch toward the forward gear. 8. Install the shift plunger B, slider C, balls D, and shift rod joint E. TIP: When installing the slider C, make sure that the balls D do not fall out of position.
  • Page 440 LOWR Lower unit Propeller shaft housing (FL250G) 15 14 108 N m (10.8 kgf m, 79.7 ft lb) 29 N m (2.9 kgf m, 21.4 ft lb) 1 N m (0.1 kgf m, 0.7 ft lb) 6 N m (0.6 kgf m, 4.4 ft lb) Part name Q’ty Remarks...
  • Page 441 Propeller shaft housing (FL250G) 15 14 108 N m (10.8 kgf m, 79.7 ft lb) 29 N m (2.9 kgf m, 21.4 ft lb) 1 N m (0.1 kgf m, 0.7 ft lb) 6 N m (0.6 kgf m, 4.4 ft lb) Part name Q’ty Remarks...
  • Page 442 LOWR Lower unit Removing the propeller shaft Checking the propeller shaft housing assembly 1. Check the propeller shaft. See “Checking the propeller shaft” (8-74). 1. Remove the water pipe, cover, and bolts. See steps 1 and 2 in “Removing the pro- Assembling the propeller shaft peller shaft housing assembly”...
  • Page 443 Propeller shaft housing (FL250G) / Drive shaft and lower case (FL200B) Drive shaft and lower case (FL200B) 142 N m (14.2 kgf m, 104.7 ft lb) Part name Q’ty Remarks Thrust bearing Pinion shim (T3) — O-ring Needle bearing Oil seal housing M8 ×...
  • Page 444 LOWR Lower unit 142 N m (14.2 kgf m, 104.7 ft lb) Part name Q’ty Remarks Needle bearing Pinion Washer Pinion nut 8-81...
  • Page 445 Drive shaft and lower case (FL200B) Removing the drive shaft 2. Heat the installation area of the retainer in the lower case using a gas torch, and 1. Remove the oil seal housing and drive then remove the retainer 1 and reverse shaft.
  • Page 446 LOWR Lower unit Checking the pinion and reverse 3. Heat the installation area of the retainer in the lower case using a gas torch, and gear then install the retainer 5. NOTICE: 1. Check the pinion and reverse gear. When heating the lower case, heat the Replace if cracked or worn.
  • Page 447 Drive shaft and lower case (FL200B) Assembling the reverse gear Installing the propeller shaft housing assembly Do not reuse a bearing or circlip, always replace it with a new one. Do not reuse an O-ring, always replace it with a new one. 1.
  • Page 448 LOWR Lower unit TIP: Make sure to fit the tip a of the shift rod 1 into the slot b in the shift rod joint. Installing the water pump 1. Install the water pump. See “Installing the water pump” (8-30). Checking the lower unit for air leakage 1.
  • Page 449 Drive shaft and lower case (FL200B) / Drive shaft and lower case (FL250G) Drive shaft and lower case (FL250G) 142 N m (14.2 kgf m, 104.7 ft lb) Part name Q’ty Remarks Thrust bearing Pinion shim (T3) — O-ring Needle bearing Oil seal housing M8 ×...
  • Page 450 LOWR Lower unit 142 N m (14.2 kgf m, 104.7 ft lb) Part name Q’ty Remarks Reverse gear Needle bearing Circlip Needle bearing Pinion Washer Pinion nut 8-87...
  • Page 451 Drive shaft and lower case (FL250G) Removing the drive shaft Assembling the lower case 1. Remove the pinion nut. See step 1 in 1. Install a new needle bearing, the original “Removing the drive shaft” (8-25). reverse gear shim, and retainer. See steps 1–4 in “Assembling the lower case”...
  • Page 452 LOWR Lower unit Checking the lower unit for air leakage 1. Check the lower unit for air leakage. See “Checking the lower unit for air leakage” (8-31). Installing the lower unit 1. Install the extension (U-transom model), lower unit, trim tab, and propeller. See steps 1–7 in “Installing the lower unit”...
  • Page 453 Drive shaft and lower case (FL250G) / Shimming (counter rotation model) Shimming (counter rotation model) Shimming workflow Remove the water pump assembly. Measure the backlash before disassembly. Within specification? Shimming is not required. Disassemble the lower unit. Select the pinion shims (T3) and propeller shaft shims (T4).
  • Page 454 LOWR Lower unit Shimming check sheet Lower case deviation Serial number Remarks Pinion height (mm) Measurements Measuring point #1 Measuring point #2 Measuring point #3 Measuring point #4 Average Round-down average Forward gear backlash (mm) Measurements Before disassembly After disassembly Measuring point #1 Measuring point #2 Measuring point #3...
  • Page 455 Shimming (counter rotation model) Forward gear shim (T2) thickness measurement in 2 places (mm) Number of shim(s) Subtotal 0.10 0.12 0.15 0.18 0.30 0.40 0.50 Total Reverse gear shim (T1) thickness measurement in 2 places (mm) Number of shim(s) Subtotal 0.10 0.12 0.15...
  • Page 456 LOWR Lower unit 5. Tighten the center bolt 4 to the specified Measuring the forward gear backlash torque while holding the drive shaft not to and reverse gear backlash before turn. disassembly Two pieces of washers (90201-31M00) are required to measure the reverse gear back- lash for the shim adjustment on the counter rotation model.
  • Page 457 Shimming (counter rotation model) Backlash indicator 9: 90890-06706 Magnet base plate 0: 90890-07003 Dial gauge set A: 90890-01252 Magnet base B B: 90890-06844 11. Turn the drive shaft slowly clockwise and counterclockwise and measure the back- lash between where the drive shaft stops in each direction.
  • Page 458 LOWR Lower unit 16. Remove the propeller shaft housing assembly. See step 1 in “Removing the propeller shaft housing assembly” (8-16) and step 2 in “Removing the propeller shaft housing assembly” (8-73). (FL200B) See steps 1 and 2 in “Remov- ing the propeller shaft housing assembly”...
  • Page 459 Shimming (counter rotation model) 20. Repeat steps 12 and 13 to measure the reverse gear backlash. 21. Check that the reverse gear backlash average is within specification. Reverse gear backlash: 0.43–0.96 mm (0.0169–0.0378 in) TIP: Adjust the shim thicknesses if the reverse gear backlash is out of specification.
  • Page 460 LOWR Lower unit Shimming • Before selecting the forward gear shims (T2) and reverse gear shims (T1), make sure to select the pinion shims (T3). • When assembling the lower unit to measure the backlash after selecting the pinion shims (T3), do not apply gear oil, grease, or sealant to the parts.
  • Page 461 Shimming (counter rotation model) Shim location (FL250G) 8-98...
  • Page 462 LOWR Lower unit Selecting the pinion shim (T3) Propeller shaft shim (T4) thickness adjust- ment = 0.15 mm b See “Selecting the pinion shim (T3)” (8-45). current shim thickness must Pinion shim (T3) selection table increased by 0.15 mm. See “Pinion shim (T3) selection table” (8-48). È...
  • Page 463 Shimming (counter rotation model) Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 TIP: Use up to 3 shims to obtain the required shim thickness. 5. Remove the dog clutch. See “Disassem- bling the propeller shaft assembly” (8- 16). 6.
  • Page 464 LOWR Lower unit Propeller shaft shim (T4) selection table The shim thickness does not have to be adjusted for the gray-colored cell. (mm) È 0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 É –0.28 –0.25 –0.25 –0.22 –0.20 –0.18 –0.15 –0.15 –0.12...
  • Page 465 Shimming (counter rotation model) Measuring the forward gear backlash Adjusting the forward gear shim (T2) • Spray anti-rust lubricant on the gears and thickness bearings before installation. Do not apply 1. Remove the propeller shaft housing gear oil to the parts. Otherwise, correct assembly.
  • Page 466 LOWR Lower unit Current forward gear shim thickness = 1.12 0.20 Shim thickness adjustment = –0.20 mm New forward gear shim (T2) thickness = 1.12 mm + (–0.20) mm = 0.92 mm Available shim thicknesses: –0.20 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 –0.40 TIP: –0.60...
  • Page 467 Shimming (counter rotation model) 8-104...
  • Page 468 LOWR Lower unit 8-105...
  • Page 469 Shimming (counter rotation model) Measuring the reverse gear backlash 7. Measure the reverse gear backlash. See steps 12, 13, and 21 in “Measuring the • Spray anti-rust lubricant on the gears and forward gear backlash and reverse gear bearings before installation. Do not apply backlash before disassembly”...
  • Page 470 LOWR Lower unit Current reverse gear shim thickness = 0.65 0.20 Shim thickness adjustment = –0.23 mm New reverse gear shim (T1) thickness = 0.65 mm + (–0.23) mm = 0.42 mm Available shim thicknesses: –0.20 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 –0.40 TIP: –0.60...
  • Page 471 Shimming (counter rotation model) 8-108...
  • Page 472 LOWR Lower unit 8-109...
  • Page 473 Shimming (counter rotation model) — MEMO — 8-110...
  • Page 474 BRKT Bracket unit Shift rod and shift bracket..........9-1 Removing the shift rod and shift bracket ........9-3 Disassembling the shift bracket..........9-3 Assembling the shift bracket ............9-4 Installing the shift rod and shift bracket ........9-4 PTT switch and cowling lock lever ........9-6 Removing the PTT switch ............
  • Page 475 Bleeding the PTT unit............... 9-40 Installing the PTT unit............... 9-41 PTT motor ................. 9-43 Removing the reservoir ............9-45 Removing the PTT motor ............9-45 Disassembling the PTT motor ..........9-45 Checking the armature (PTT motor)......... 9-46 Checking the brush ..............9-46 Assembling the PTT motor............
  • Page 476 BRKT Bracket unit Shift rod and shift bracket 18 N · m (1.8 kgf · m, 13.3 ft · Ib) 2 N · m (0.2 kgf · m, 1.5 ft · Ib) 2 N · m (0.2 kgf · m, 1.5 ft · Ib) 1 N ·...
  • Page 477 Shift rod and shift bracket 18 N·m (1.8 kgf·m, 13.3 ft·Ib) 2 N·m (0.2 kgf·m, 1.5 ft·Ib) 2 N·m (0.2 kgf·m, 1.5 ft·Ib) 1 N·m (0.1 kgf·m, 0.7 ft·Ib) 19 N·m (1.9 kgf·m, 14.0 ft·Ib) Part name Q’ty Remarks Shift lever Washer Bushing M6 ×...
  • Page 478 BRKT Bracket unit Removing the shift rod and shift bracket 1. Remove the shift cut switch coupler a. 2. Remove the clip 1 and bushing 2, and then remove the shift bracket assembly b, holder 3, and washer 4. Disassembling the shift bracket 1.
  • Page 479 Shift rod and shift bracket Assembling the shift bracket 1. Install the neutral switch 1 and plate 2, and then tighten the neutral switch screws 3 to the specified torque. 2. Fasten the neutral switch lead a using the plastic tie 4. 7.
  • Page 480 BRKT Bracket unit Shift rod detent bolt 7: 18 N·m (1.8 kgf·m, 13.3 ft·lb) 3. Install the bushing 8 and shift lever 9, and then install the clip 0. 4. Install the grommet A and shift rod assembly a. TIP: Align the center of the pin b on the shift lever 9 with the mark c on the bottom cowling.
  • Page 481 Shift rod and shift bracket / PTT switch and cowling lock lever PTT switch and cowling lock lever m (0.5 kgf m, 3.7 ft lb) È È Part name Q’ty Remarks Gasket PTT switch Cover Holder M6 × 20 mm/Regular rotation model Bolt M6 ×...
  • Page 482 BRKT Bracket unit m (0.5 kgf m, 3.7 ft lb) È È Part name Q’ty Remarks Cowling lock lever (PORT) Cowling lock lever (STBD) Cowling lock lever (BOW) Plastic tie Grommet Hose Joint Joint Gasket Adapter Hose Joint Hose Clamp M6 ×...
  • Page 483 PTT switch and cowling lock lever m (0.5 kgf m, 3.7 ft lb) È È Part name Q’ty Remarks Holder PTT switch wiring harness extension Counter rotation model Holder Counter rotation model Holder Regular rotation model È Counter rotation model...
  • Page 484 BRKT Bracket unit Removing the PTT switch 1. Remove the holder 1 (regular rotation model) or holder 2 (counter rotation model) and holder 3, and then remove the PTT switch 4 and gasket 5. È STBD Removing the flushing hose and É...
  • Page 485 PTT switch and cowling lock lever TIP: Align the white paint mark c on the flushing hose 1 and the white tape d on the PTT motor lead b with the inner end of the grom- met 2. 2. Install the cooling water pilot hose 4, cooling water hose 5, and joint 6, and then fasten the hoses 4 and 5 using the clamp 7 and plastic ties 8.
  • Page 486 BRKT Bracket unit Installing the PTT switch Do not reuse a gasket, always replace it with a new one. Flushing hose adapter screw C: 5 N·m (0.5 kgf·m, 3.7 ft·lb) 1. Install a new gasket 1, the PTT switch Installing the cowling lock lever 2, and the holder 3.
  • Page 487 PTT switch and cowling lock lever / Bottom cowling Bottom cowling Part name Q’ty Remarks Bracket M6 × 30 mm Bolt Bracket M6 × 20 mm Bolt Bracket Bracket Bracket Rivet Water outlet M8 × 35 mm Bolt Grommet Collar Rubber seal Grommet Grommet...
  • Page 488 BRKT Bracket unit Part name Q’ty Remarks Grommet Bottom cowling 9-13...
  • Page 489 Bottom cowling / Upper case and mounts Upper case and mounts 54 N m (5.4 kgf m, 39.8 ft lb) 72 N m (7.2 kgf m, 53.1 ft lb) È 72 N m (7.2 kgf m, 53.1 ft lb) Part name Q’ty Remarks Upper mounting nut...
  • Page 490 BRKT Bracket unit 54 N m (5.4 kgf m, 39.8 ft lb) 72 N m (7.2 kgf m, 53.1 ft lb) È 72 N m (7.2 kgf m, 53.1 ft lb) Part name Q’ty Remarks M14 × 190 mm Upper mounting bolt M6 ×...
  • Page 491 Upper case and mounts Removing the upper case Installing the upper case 1. Drain the remained engine oil. 1. Install the upper mounts 1 and upper mounting bolts 2. 2. Disconnect the ground lead 1 and adapter 2 (X-transom model). 2.
  • Page 492 BRKT Bracket unit 5. Install the upper and lower mounting bolts into the bracket assembly b simul- taneously. 6. Install the washers 9, upper mounting nuts 0, and lower mounting nuts A, and then tighten the upper mounting nuts 0 and lower mounting nuts A to the speci- fied torque.
  • Page 493 Upper case and mounts / Upper case Upper case 4 N m (0.4 kgf m, 3.0 ft lb) 8 N m (0.8 kgf m, 5.9 ft lb) 42 N m (4.2 kgf m, 31.0 ft lb) 28 N·m (2.8 kgf·m, 20.7 ft·Ib) 20 N m (2.0 kgf m, 14.8 ft lb) 8 N m (0.8 kgf m, 5.9 ft lb) Part name...
  • Page 494 BRKT Bracket unit 4 N m (0.4 kgf m, 3.0 ft lb) 8 N m (0.8 kgf m, 5.9 ft lb) 42 N m (4.2 kgf m, 31.0 ft lb) 28 N · m (2.8 kgf · m, 20.7 ft · Ib) 20 N m (2.0 kgf m, 14.8 ft lb) 8 N m (0.8 kgf m, 5.9 ft lb) Part name...
  • Page 495 Upper case Disassembling the upper case Bearing puller assembly 9: 90890-06535 1. Remove the engine oil drain bolt 1, Stopper guide stand 0: 90890-06538 cover 2, and damper 3. Stopper guide plate A: 90890-06501 Checking the drive shaft bushing 1. Check the drive shaft bushing. Replace if cracked or worn.
  • Page 496 BRKT Bracket unit 3. Install the dowels 6. Baffle plate screw 8: 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4. Install the baffle plate 7, and then Oil pan assembly bolt (M8) B: tighten the baffle plate screws 8 to the 20 N·m (2.0 kgf·m, 14.8 ft·lb) specified torque.
  • Page 497 Upper case / Oil pan and exhaust manifold Oil pan and exhaust manifold 42 N m(4.2 kgf m, 31.0 ft lb) 20 N m(2.0 kgf m, 14.8 ft lb) 12 N m(1.2 kgf m, 8.9 ft lb) Part name Q’ty Remarks M10 ×...
  • Page 498 BRKT Bracket unit 42 N m(4.2 kgf m, 31.0 ft lb) 20 N m(2.0 kgf m, 14.8 ft lb) 12 N m(1.2 kgf m, 8.9 ft lb) Part name Q’ty Remarks M8 × 90 mm Bolt Rubber seal Gasket Plate Water pipe Rubber seal Gasket...
  • Page 499 Oil pan and exhaust manifold Disassembling the oil pan and exhaust manifold 1. Remove the oil pan assembly bolt 1. 2. Remove the muffler 2, plate 3, and then remove the exhaust manifold 4. Checking the oil pan and exhaust manifold 1.
  • Page 500 BRKT Bracket unit 4. Install a new gasket B, the exhaust man- ifold C, and a new rubber seal D, and then tighten the exhaust manifold bolts E temporarily. 5. Tighten the exhaust manifold bolts E first, and then tighten the oil pan bolts 0 Oil strainer bolt 6: and A to the specified torque.
  • Page 501 Oil pan and exhaust manifold 8. Tighten the muffler bolts M to the speci- fied torque. Muffler bolt M: 20 N·m (2.0 kgf·m, 14.8 ft·lb) 9. Tighten the oil pan assembly bolt N to the specified torque. Oil pan assembly bolt N 42 N·m (4.2 kgf·m, 31.0 ft·lb) 9-26...
  • Page 502 BRKT Bracket unit Steering arm Part name Q’ty Remarks Steering arm Washer Bushing O-ring Bushing Steering yoke Circlip Grommet 9-27...
  • Page 503 Steering arm Removing the steering arm 1. Remove the circlip 1, and then remove the steering yoke 2 by striking it with a copper hammer. 4. Install the steering yoke 9 so that the steering arm and steering yoke 9 are both facing in the same direction (a and b are aligned).
  • Page 504 BRKT Bracket unit 7. Inject grease into the grease nipple A until it comes out from both the upper and lower bushings d. 9-29...
  • Page 505 Steering arm / Clamp bracket and swivel bracket Clamp bracket and swivel bracket 22 N m (2.2 kgf m, 16.2 ft lb) 4 N m (0.4 kgf m, 3.0 ft lb) 4 N m (0.4 kgf m, 3.0 ft lb) 3 N m (0.3 kgf m, 2.2 ft lb) 24 26 24 Part name...
  • Page 506 BRKT Bracket unit 22 N m (2.2 kgf m, 16.2 ft lb) 4 N m (0.4 kgf m, 3.0 ft lb) 4 N m (0.4 kgf m, 3.0 ft lb) 3 N m (0.3 kgf m, 2.2 ft lb) 24 26 24 Part name Q’ty Remarks...
  • Page 507 Clamp bracket and swivel bracket Removing the clamp bracket 1. Remove the PTT unit. See “Removing the PTT unit” (9-37). 2. Remove the anode 1. 3. Remove the ground leads 2 and 3. 4. Remove the self-locking nut 4 and through tube 5, and then disassemble the clamp brackets 6 and 7.
  • Page 508 BRKT Bracket unit 2. Install the bushings 1, collar 2, distance collar assembly b, and tilt stop levers 3 and 4. 6. Install the through tube A with its flat cor- ner d pointing down. 7. Tighten the self-locking nut B tempo- rarily.
  • Page 509 Clamp bracket and swivel bracket Self-locking nut B: 22 N·m (2.2 kgf·m, 16.2 ft·lb) Grease nipple D: 3 N·m (0.3 kgf·m, 2.2 ft·lb) Friction plate screw G: 4 N·m (0.4 kgf·m, 3.0 ft·lb) 12. Inject grease into the grease nipples until grease comes out from the bushings f.
  • Page 510 BRKT Bracket unit Trim sensor setting resistance: Terminal c –Terminal d 9.0–11.0 Ω 6. Fully tilt the swivel bracket up, and then support it using the tilt stop lever. 7. Tighten the trim sensor screws 2 to the specified torque. Trim sensor screw 2: 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8.
  • Page 511 Clamp bracket and swivel bracket / PTT unit PTT unit 42 N m (4.2 kgf m, 31.0 ft lb) Part name Q’ty Remarks Shaft Circlip Plastic tie Bushing Bushing PTT unit Ground lead M6 × 10 mm Bolt M10 × 45 mm Bolt 9-36...
  • Page 512 BRKT Bracket unit Removing the PTT unit When removing the PTT unit with the power unit installed, make sure to sus- pend the outboard motor. 1. Fully tilt the swivel bracket up, and then support it using the tilt stop lever 1. 3.
  • Page 513 PTT unit 6. Remove the PTT unit 7. TIP: If the fluid is at the proper level, a small amount of fluid should flow out of the filler hole. 4. If the fluid is below the proper level, add the recommended fluid. Recommended PTT fluid: ATF Dexron II 5.
  • Page 514 BRKT Bracket unit Pipe joint 2: 15 N·m (1.5 kgf·m, 11.1 ft·lb) 12. Connect the PTT motor leads to the bat- tery terminals to fully retract the PTT rams. 13. Loosen the pipe joints 4, and then remove the pipe joint at end b. 14.
  • Page 515 PTT unit Battery PTT motor lead terminal Sky blue (Sb) Light green (Lg) Hydraulic pressure (up) (reference data): 13.0–15.0 MPa (130.0–150.0 kgf/cm , 1885.0–2175.0 psi) 16. Reverse the PTT motor leads between the battery terminals to fully retract the trim rams. 20.
  • Page 516 BRKT Bracket unit Battery PTT motor lead terminal Light green (Lg) Down Sky blue (Sb) 2. Fully tilt the swivel bracket up, and then support it using the tilt stop lever 1. Battery PTT motor lead terminal Light green (Lg) Down Sky blue (Sb) Sky blue (Sb)
  • Page 517 PTT unit 9. Fasten the PTT motor lead a and trim sensor lead using the plastic ties 9. PTT unit bolt 5: 42 N·m (4.2 kgf·m, 31.0 ft·lb) 5. Pass the PTT motor lead a through the hole b in the clamp bracket (STBD). 6.
  • Page 518 BRKT Bracket unit PTT motor 7 N m (0.7 kgf m, 5.2 ft lb) 19 N m (1.9 kgf m, 14.0 ft lb) Part name Q’ty Remarks Spacer Filter Sheet O-ring Reservoir cap O-ring Reservoir M8 × 20 mm Bolt PTT motor assembly O-ring Joint...
  • Page 519 PTT motor 7 N m (0.7 kgf m, 5.2 ft lb) 19 N m (1.9 kgf m, 14.0 ft lb) Part name Q’ty Remarks Spring O-ring Motor base assembly Oil seal 9-44...
  • Page 520 BRKT Bracket unit Removing the reservoir Disassembling the PTT motor 1. Remove the PTT motor bolts 1, and then remove the stator 2. NOTICE: Before removing the reservoir, make sure Secure the end of the armature shaft that the PTT rams are fully extended. Oth- using a pair of pliers, and then remove erwise, fluid could be expelled forcefully the armature 3 along with the motor...
  • Page 521 PTT motor Bearing splitter 7: (commercially available) TIP: Before removing the bearing, measure and write down the bearing depth a. 5. Remove the bearing 8. Motor commutator standard diameter a: 23.0 mm (0.91 in) Wear limit: 22.0 mm (0.87 in) 3.
  • Page 522 BRKT Bracket unit 2. Check the motor base assembly for con- tinuity. Replace the motor base assembly if there is no continuity. 2. Install the brushes 3 and springs 4. Sb: Sky blue Lg: Light green Motor base assembly continuity: Terminal c–Terminal e Terminal c–Terminal g 3.
  • Page 523 PTT motor 7. Install the stator 0, and then tighten the bolts A. NOTICE: Secure the end of the armature shaft using a pair of pli- ers, and then install the armature along with the motor base assembly. Otherwise, the armature could sepa- rate from the motor base assembly due to the magnetic force of the stator 0 and damage the brushes.
  • Page 524 BRKT Bracket unit Reservoir bolt 6: 19 N·m (1.9 kgf·m, 14.0 ft·lb) Reservoir cap 8: 7 N·m (0.7 kgf·m, 5.2 ft·lb) Installing the PTT motor • When assembling the PTT unit, do not use a rag. Otherwise, dust and particles could get on the PTT unit components, PTT motor bolt 4: causing poor performance.
  • Page 525 PTT motor / PTT gear pump PTT gear pump 7 N m (0.7 kgf m, 5.2 ft lb) 7 N m (0.7 kgf m, 5.2 ft lb) 2 N m (0.2 kgf m, 1.5 ft lb) Part name Q’ty Remarks M5 ×...
  • Page 526 BRKT Bracket unit 7 N m (0.7 kgf m, 5.2 ft lb) 7 N m (0.7 kgf m, 5.2 ft lb) 2 N m (0.2 kgf m, 1.5 ft lb) Part name Q’ty Remarks Up-shuttle piston Ball Relief valve seat O-ring Ball Manual release plate...
  • Page 527 PTT gear pump 7 N m (0.7 kgf m, 5.2 ft lb) 7 N m (0.7 kgf m, 5.2 ft lb) 2 N m (0.2 kgf m, 1.5 ft lb) Part name Q’ty Remarks O-ring Spacer Filter O-ring Manual valve Circlip 9-52...
  • Page 528 BRKT Bracket unit 4. Remove the bracket 6, and then remove Disassembling the gear pump the balls 7 and 8. assembly 1. Remove the PTT motor assembly. See “Removing the PTT motor” (9-45). 2. Remove the manual valve 1, and then remove the gear pump assembly 2.
  • Page 529 PTT gear pump 3. Install the balls 8 and 9, manual release plate 0, and bracket A, and then tighten the gear pump bracket bolts B temporarily. 4. Check that gear pump turns smoothly, and then tighten the gear pump bracket bolts B to the specified torque.
  • Page 530 BRKT Bracket unit 11. Check the hydraulic pressure. See Down-relief screw depth a “Checking the hydraulic pressure” (9-38). (reference data): 1.07–1.27 mm (0.042–0.050 in) TIP: Up-relief screw height b If the hydraulic pressure is out of specifica- (reference data): tion, adjust the relief lock screws to adjust the 1.95–2.45 mm (0.077–0.096 in) pressure.

  • Page 531: Ptt Cylinder

    PTT gear pump / PTT cylinder PTT cylinder 65 N m (6.5 kgf m, 47.9 ft lb) 90 N m (9.0 kgf m, 66.4 ft lb) 160 N m (16.0 kgf m, 118.0 ft lb) 15 N m (1.5 kgf m, 11.1 ft lb) 7 N m (0.7 kgf m, 5.2 ft lb) 20 N m (2.0 kgf m, 14.8 ft lb) Part name...
  • Page 532 BRKT Bracket unit 65 N m (6.5 kgf m, 47.9 ft lb) 90 N m (9.0 kgf m, 66.4 ft lb) 160 N m (16.0 kgf m, 118.0 ft lb) 15 N m (1.5 kgf m, 11.1 ft lb) 7 N m (0.7 kgf m, 5.2 ft lb) 20 N m (2.0 kgf m, 14.8 ft lb) Part name Q’ty...
  • Page 533 PTT cylinder 65 N m (6.5 kgf m, 47.9 ft lb) 90 N m (9.0 kgf m, 66.4 ft lb) 160 N m (16.0 kgf m, 118.0 ft lb) 15 N m (1.5 kgf m, 11.1 ft lb) 7 N m (0.7 kgf m, 5.2 ft lb) 20 N m (2.0 kgf m, 14.8 ft lb) Part name Q’ty...
  • Page 534 BRKT Bracket unit Removing the tilt ram 7. Cover the tilt cylinder opening using a rag 8, and then blow compressed air through the hole a to remove the free Before removing the tilt cylinder, make piston 9. WARNING! When removing sure that the PTT rams are fully extended.
  • Page 535 PTT cylinder Checking the tilt cylinder and PTT body 1. Check the PTT body 1 and tilt cylinder 2. Replace if cracked or corrosion. 2. Check the inner surface of the PTT body 1 and tilt cylinder 2. Replace if scratched.
  • Page 536 BRKT Bracket unit 4. Tighten the tilt ram 0 to the specified torque. Assembling the tilt ram • When assembling the PTT unit, do not use a rag. Otherwise, dust and particles could get on the PTT unit components, causing poor performance. PTT piston vice attachment 9: •...
  • Page 537 PTT cylinder Installing the tilt cylinder • When assembling the PTT unit, do not use a rag. Otherwise, dust and particles could get on the PTT unit components, causing poor performance. • Do not reuse an O-ring, always replace it with a new one.
  • Page 538 BRKT Bracket unit 3. Install the trim ram assemblies into the PTT body 1, and then tighten the trim cylinder end screws 2 to the specified torque. Cylinder-end screw wrench 3: 90890-06568 Trim cylinder end screw 2: Pipe joint adapter 6: 160 N·m (16.0 kgf·m, 118.0 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) Pipe joint 9 and 0:...
  • Page 539 PTT cylinder Recommended PTT fluid: ATF Dexron II 4. Install the tilt piston assembly into the tilt cylinder, and then tighten the tilt cylinder end screw 1 to the specified torque. Cylinder-end screw wrench 2: 90890-06568 Tilt cylinder end screw 1: 90 N·m (9.0 kgf·m, 66.4 ft·lb) 5.
  • Page 540 Maintenance Outline ................10-1 Maintenance chart 1..............10-1 Maintenance chart 2..............10-3 Predelivery check............. 10-4 Checking battery (for electric start models)......10-4 Checking the cooling water pilot hole........10-4 Checking the engine oil level............ 10-5 Checking the engine start switch and engine shut-off switch...............
  • Page 541 Checking the top cowling ............10-15 Checking the valve clearance ..........10-16 Checking the water pump............10-16...
  • Page 542 Maintenance Outline • To obtain long product life, Yamaha strongly recommends that the specified periodic checks and maintenance be performed according to the maintenance interval charts. • If replacement parts are necessary, use only genuine Yamaha parts of equivalent design and quality.
  • Page 543 Outline Initial Every Item Actions 20 hours 100 hours 300 hours 500 hours page (3 months) (1 year) (3 years) (5 years) Engine oil filter (car- Replacement 10-10 tridge) Fuel filter (can be disas- Inspection or replace- 6-14 sembled) ment as necessary Fuel line (High pressure) Inspection Inspection or replace-...
  • Page 544 Wire harness connec- Inspection or replace- tions/wire coupler con- — ment as necessary nections (Yamaha) Meter/gauge Inspection (*1) — : Not applicable (*1): See “6Y8 Multifunction Meter set up manual” for the check of 6Y8 Multifunction Meter. Maintenance chart 2...

  • Page 545: Predelivery Check

    Outline / Predelivery check Predelivery check To make the delivery process smooth and efficient, complete the predelivery checks as explained in the following procedures. Checking battery (for electric start models) Battery electrolyte is dangerous; it con- tains sulfuric acid, which is poisonous 2.
  • Page 546 Maintenance Checking the engine oil level Checking the engine start switch and 1. Place the outboard motor in an upright engine shut-off switch position. NOTICE: If the outboard 1. Check that the engine starts when the motor is not level, the oil level indi- engine start switch is turned to START.
  • Page 547 Predelivery check É Check screw 1: 9 N·m (0.9 kgf·m, 6.6 ft·lb) START Checking the gear shift and throttle operation 1. Check that the gear shift operates smoothly when the remote control lever is moved from the N position to the F or R position.
  • Page 548 Maintenance Checking the PTT system 1. Check that the outboard motor tilts up and down smoothly when the PTT switch is operated. 2. Check that there is no abnormal noise produced when the outboard motor is tilted up or down. 3.
  • Page 549 Predelivery check / General periodic maintenance 3. For the remaining 8 hours c of opera- TIP: tion: • Replace the anodes or trim tab if eroded. In Operate the engine at any engine speed. addition, check the ground lead. However, do not operate the engine at •...
  • Page 550 1. Start the engine and warm it up for 5–10 minutes. 2. Check the engine idle speed using the Yamaha genuine tachometer (on-board meter) or the YDIS. To connect and operate the YDIS, see the “YDIS (Ver. 1.33 or later) Instruction Manual.”...
  • Page 551 General periodic maintenance 6. Fill the engine with the specified amount 11. Start the engine and check that the oil of the recommended engine oil through pressure alert indicator does not come the oil filler hole. Install the oil filler cap 1 on.
  • Page 552 Maintenance Checking the fuel joint and fuel hose (fuel joint to fuel injector) 1. Check the fuel joint and fuel hose con- nections. See “Fuel hose and blowby hose” (6-1). Checking the fuel filter 1. Check the fuel filter. See “Checking the fuel filter assembly”...
  • Page 553 General periodic maintenance Recommended gear oil: Hypoid gear oil API: GL-4 SAE: 90 Oil quantity: Regular rotation model: 1.150 L (1.216 US qt, 1.012 lmp qt) Counter rotation model: 1.000 L (1.057 US qt, 0.880 lmp qt) Check screw 3: 9 N·m (0.9 kgf·m, 6.6 ft·lb) 8.
  • Page 554 Maintenance Greasing 1. Apply water resistant grease to the spec- ified lubrication points. È 10-13...
  • Page 555 Do not reuse an O-ring, always replace it with a new one. È F200B and FL200B 1. Fully tilt the outboard motor up, and then É F250G and FL250G support it using the tilt stop lever 1.
  • Page 556 Maintenance 4. Install a new O-ring and the reservoir cap 6. Remove the wiring harness guide. See 2, and then tighten the reservoir cap 2 steps 5–29 in “Removing the wiring har- to the specified torque. ness” (7-20). Reservoir cap 2: 7.
  • Page 557 General periodic maintenance 3. Move the hook 2 up or down slightly to TIP: adjust its position. When measuring or adjusting the valve clear- ances, the fuel line must be disconnected, so make sure to reduce the fuel pressure before performing the disassembly procedure.
  • Page 558 Index Bracket unit........1-5 1-19 Bracket unit technical data ....... 1-16 Abbreviation ..........0-5 Break-in ............ 10-7 Actuator, sensor, and switch.......2-3 Adjusting the forward gear shim (T1) thickness .........8-51 Camshaft ..........7-46 Adjusting the forward gear shim Canister, throttle body, and surge tank..6-26 (T2) thickness ........8-102 Changing engine oil........
  • Page 559 Index Checking the electrical component ...5-26 Checking the outboard motor Checking the engine ECM circuit....5-28 mounting height ........10-6 Checking the engine oil level ..10-5 10-10 Checking the PCV ......9-20 10-14 Checking the engine shut-off switch ..5-65 Checking the pinion and Checking the engine start switch ....5-66 forward gear ........8-26 8-35...
  • Page 560 Disconnecting the quick connector..... 6-7 Circuit diagram..........5-22 Draining the fuel ........6-35 Clamp bracket..........3-3 Drive shaft and lower case (F200B) ..8-24 Clamp bracket and swivel bracket ....9-30 Drive shaft and lower case (F250G)..8-33 Cleaning and adjusting spark plug..10-15 Drive shaft and lower case (FL200B) ..
  • Page 561 2-22 Installing the flywheel magnet....7-17 Lower unit (counter rotation model)..1-19 Installing the fuel filter assembly ....6-14 Lower unit (F200B) ........8-1 Installing the fuel injector ......6-46 Lower unit (F250G)........8-4 Installing the intake manifold.....6-18 Lower unit (FL200B) ......... 8-59...
  • Page 562 (F250G and FL250G) ......2-23 Lower unit assembly Propeller selection ........3-29 (regular rotation model)......1-15 Propeller shaft housing (F200B) ....8-14 Lower unit technical data ......1-15 Propeller shaft housing (F250G) ....8-20 Low-pressure fuel pump ......6-31 Propeller shaft housing (FL200B)..... 8-71 Lubricant, sealant, Propeller shaft housing (FL250G) ....
  • Page 563 Self-protection..........0-2 Vapor separator........6-34 Serial number..........1-3 Vapor separator and Shift rod and shift bracket ......9-1 high-pressure fuel pump......6-37 Shim location (F200B) ......8-43 VCT control..........2-6 Shim location (F250G) ......8-44 VCT system ..........1-9 Shim location (FL200B) ......8-97 Ventilation........... 0-1 Shim location (FL250G) ......8-98...
  • Page 564 Index Water pump and shift rod (F200B)....8-7 Water pump and shift rod (F250G) ...8-11 Water pump and shift rod (FL200B)..8-65 Water pump and shift rod (FL250G) ..8-68 Wiring diagram........... A-2 Wiring harness ..........7-19 Wiring harness routing ........5-6 Working with crane ........0-2...
  • Page 565 Appendix Wiring diagram ................A-2 How to use the wiring diagram ........... A-2 Engine control unit..............A-3 Fuel unit..................A-5 Ignition unit ................. A-7 Charging unit and starting unit ........... A-9 PTT unit and control unit ............A-11...
  • Page 566 — MEMO —...

  • Page 567: Wiring Diagram

    Wiring diagram How to use the wiring diagram Composition of the wiring diagrams The wiring diagram consists of five categories. Engine control unit, Fuel unit, Ignition unit, Charging and starting unit, and PTT unit and control unit. Legend symbols in the wiring diagrams 1 Double colors wire 2 No wire connector 3 A wire is not included in the selected wiring unit.
  • Page 568 Engine control unit (*1) Depending on the outboard motor, the locations of terminals 1-10 and 16-22 may vary. a Fuse (60 A) (house [accessory] battery) b Fuse (60 A) (starting battery) c Fuse (30 A) (ignition coil, fuel injector, VCT, engine ECM) d Fuse (10 A) (ETV, engine ECM) e Fuse (30 A) (starter relay) f Fuse (10 A) (low-pressure fuel pump)
  • Page 570 Jul. 2011 – ** × 1 CR...
  • Page 571 Engine control unit 53 62 70 78 È Joint coupler 1 24 12 Fuse box Battery 61 69 77 86 Pulser coil Engine ECM 13 1 (*1) 27 34 40 46 33 39 45 52 8 14 20 24 12 7 13 19 26 Air pressure sensor...
  • Page 572 Fuel unit (*1) Depending on the outboard motor, the locations of terminals 1-10 and 16-22 may vary. a Fuse (60 A) (house [accessory] battery) b Fuse (60 A) (starting battery) c Fuse (30 A) (ignition coil, fuel injector, VCT, engine ECM) d Fuse (10 A) (ETV, engine ECM) e Fuse (30 A) (starter relay) f Fuse (10 A) (low-pressure fuel pump)
  • Page 573 Fuel unit È 53 62 70 78 Fuse box Pu/W Pu/L Pu/G Pu/Y Pu/R Pu/B Battery Pulser coil 24 12 61 69 77 86 Engine ECM (*1) 13 1 Joint coupler 1 24 12 27 34 40 46 13 1 Joint coupler 2 33 39 45 52 8 14 20...
  • Page 574 Ignition unit (*1) Depending on the outboard motor, the locations of terminals 1-10 and 16-22 may vary. a Fuse (60 A) (house [accessory] battery) b Fuse (60 A) (starting battery) c Fuse (30 A) (ignition coil, fuel injector, VCT, engine ECM) d Fuse (10 A) (ETV, engine ECM) e Fuse (30 A) (starter relay) f Fuse (10 A) (low-pressure fuel pump)
  • Page 575 Ignition unit È 53 62 70 78 B/Br Fuse box Battery 61 69 77 86 Pulser coil Engine ECM (*1) 24 12 13 1 Joint coupler 1 27 34 40 46 24 12 33 39 45 52 13 1 Joint coupler 2 8 14 20 7 13 19 26 Air temperature sensor...
  • Page 576 Charging unit and starting unit (*1) Depending on the outboard motor, the locations of terminals 1-10 and 16-22 may vary. a Fuse (60 A) (house [accessory] battery) b Fuse (60 A) (starting battery) c Fuse (30 A) (ignition coil, fuel injector, VCT, engine ECM) d Fuse (10 A) (ETV, engine ECM) e Fuse (30 A) (starter relay) f Fuse (10 A) (low-pressure fuel pump)
  • Page 577 Charging unit and starting unit È Rectifier Regulator Fuse box 53 62 70 78 Battery House (accessory) battery 61 69 77 86 Starter motor Engine ECM (*1) 24 12 27 34 40 46 13 1 Joint coupler 1 33 39 45 52 24 12 8 14 20 13 1...
  • Page 578 PTT unit and control unit (*1) Depending on the outboard motor, the locations of terminals 1-10 and 16-22 may vary. a Fuse (60 A) (house [accessory] battery) b Fuse (60 A) (starting battery) c Fuse (30 A) (ignition coil, fuel injector, VCT, engine ECM) d Fuse (10 A) (ETV, engine ECM) e Fuse (30 A) (starter relay) f Fuse (10 A) (low-pressure fuel pump)
  • Page 579 PTT unit and control unit Ê Engine start switch PTT switch Engine shut-off switch Sb R Lg Y Br È Free START Pull Fuse box 53 62 70 78 Battery Starter motor Í PTT relay Ì 61 69 77 86 Engine ECM (*1) Neutral switch...

This manual is also suitable for:

Fl200bF250gFl250g

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