Home

Marlin 100 EFI English

1.
2. 6 22 Installing the power trim and tilt unit 7 44 Installing the power unit 5 52 Installing the pressure control valve 5 39 Installing the propeller shaft housing 6 20 Installing the sprockets and timing belt 5 18 Installing the steering arm 7 18 Installing the throttle position sensor 4 9 Installing the upper case 7 15 Installing the valves 5 33 Installing the water pump and shift rod 6 21 Intake MaNIfold nennen 4 7 AtFOdUelOn tests 9 2 Junction DOX cc ccecececcecccececececececaceeneners 5 22 LOWER UDIT sis 2 6 3 12 6 4 Lubricating the outboard motor 3 15 Maintenance interval chatt 3 2 Maintenance specification 2 3 Manual formalei 1 1 Measuring the forward gear backlash 6 28 Measuring the fuel pressure 4 13 Measuring the lower resistance 8 2 Measuring the peak voltage 8 2 Parts lubricants and sealants 1 3 POR VIEW ail aaa 8 3 Power trim and tilt electrical system 7 45 Power trim and tilt motor 7 25 Power trim and tilt unit 7 23 Power UMM io 2 3 3 4 5 3 9 5 Predelivery CHECKS
3. ii 3 12 Ghanging NE gear Ole 3 12 Checking the lower unit for air leakage nennen 3 13 Checking the propeller nn a a ica 3 13 Generale eek 3 14 Ghecking ING NOU av 3 14 Ghecking Ihe Dallery Kaas 3 14 Lubricating the outboard Motor nennen nennen 3 15 IC ADJ Periodic checks and adjustments Special service tools Digital tachometer 90890 06760 Leakage tester 90890 06840 Oil filter wrench 64 90890 01426 3 1 6D93G11 Special service tools Maintenance interval chart Maintenance interval chart Use the following chart as a guideline for general maintenance Adjust the maintenance intervals according to the operating conditions of the outboard motor Initial Every Refer to Item Remarks 10 E er 50 hours 100 Em 200 hours See 1 month 3 months i months 1 EE pag Anodes extemal Chealreplace 34 Anis ema Greskepass I tofu Battery Oehage O I I 814 e _ E Top cowling cowling Top cowling Check Fuel filter che de can be disassembled Fuel system Fuel system Check O O O o Ci ile ELEME ne E Lubrication points Lubrication points Lubricate MESE 15 Engine idle speed EC 2 8 EFI Piece POV Pressure Control Valve Check O 539 em Se I 1 T FA Propeller and cotter pn Chedkreplace O O 18 gt EM e ES Thermostat Check LU link thrott
4. 25 49 N m 4 9 kgf m 36 1 ft Ib DEP 26 x18 N m 1 8 kgf m 13 3 ft Ib Q O O WER Dg OS di 29 gt 22 3 271 Ny LO 16N m 0 6 kgf m 4 4 ft Ib Q 12N m 1 2 kgf 2 kgf m 8 9 ft Ib S6D85090 Gasket Screw 94 x 13 mm Anode Exhaust cover Gasket Cooling water temperature sensor Holder Bolt Holder Bolt Gasket Grommet Pressure control valve Spring Cover Bolt Gasket Not reusable CO N DU Bb DON M6 x 15 mm M6 x 10 mm Not reusable M6 x 20 mm Not reusable WO A N Dy 0 QQ aA 5 37 6D93G11 Exhaust cover 25 49 N m 4 9 kgf m 36 1 ft Ib DEP 26 x18 N m 1 8 kgf m 13 3 ft Ib Q O O WER E di 29 gt 271 Ny LO 16N m 0 6 kgf m 4 4 ft Ib 12N m 1 2kgf 2 kgf m 8 9 ft Ib S6D85090 18 Plug M18x 17mm Grommet Anode Cover Bolt Bolt Bolt Joint Oil filter Gasket Not reusable Plug M14 x 12 mm Plastic tie Not reusable Hose 6D93G11 5 38 Power unit Removing the exhaust cover 1 Remove the exhaust cover bolts in the sequence shown T O M AT 9 OTO S6D85530 2 Remove the exhaust cover Checking the pressure control valve 1 Remove the pressure control valve 2 Check the pressure control valve for wear or damage Replace if necessary 3 Check the grommet for deformation Replace
5. S60C5A30 Crankpin oil clearance 0 024 0 044 mm 0 0009 0 0017 in Selecting the connecting rod bearing NOTE Use a metric gauge in this procedure 1 When replacing the connecting rod bear ing select the suitable bearing as fol lows 2 Measure the connecting rod big end inside diameter S60C5980 NOTE Reuse the removed connecting rod bolts Connecting rod big end inside diameter a 47 025 47 045 mm 6D93G11 Cylinder block 3 Check the crankpin mark on the crank shaft 1 S6D85670 4 Subtract the crankpin diameters 1 4 from the connecting rod big end inside diameters 1 4 NOTE AAA The crankpin diameters 1 4 can be determined by the stamped value as described below Crankpin diameter 43 900 stamped value 1 000 Example 1 92 43 992 5 46 Power unit 5 Select the suitable color for the con necting rod bearing from the table below according to the calculated values 56D85710 Connecting rod bearing selection table 20 C 68 F Connecting rod big end inside i Upper Lower MENES bearin bearin crankpin diameters d J mm CAUTION The mark indicates that the colors of the upper and lower bearings are differ ent Example If the Connecting rod big end inside diame ter is 47 050 mm and the Crankpin mark is 92 then the Calculated value 47 050
6. If the grooves in the propeller nut 2 do not align with the cotter pin hole tighten the nut until they are aligned Propeller nut 4 34 N m 3 4 kgf m 25 1 ft lb 6D93G11 6 24 Lower unit Shimming 11B1 32 0 A1 S6D86290 6 25 6D93G11 Shimming NOTE e Shimming is not required when assembling the original lower case and inner parts e Shimming is required when assembling the original inner parts and a new lower case Shimming is required when replacing the inner part s Selecting the pinion shims 1 Install the special service tool onto the drive shaft 1 and drive shaft bearing f A 13 l I Ww L S62Y6905 56056500 NOTE e Select the shim thickness T3 by using the specified measurement s and the calcula tion formula Install the special service tool to the drive shaft so that the shaft is at the center of the hole e Tighten the wing nuts another 1 4 of a turn after they contact the plate Pinion height gauge 3 90890 06710 2 Install the pinion and pinion nut and then tighten the nut to the specified torque 6D93G11 Shimming Pinion nut 93 N m 9 3 kgf m 68 6 ft lb 3 Measure the distance M between the special service tool and the pinion as shown 562Y6915 NOTE ee I Measure the pinion at three points to find the clearance average Digital caliper 4 90890 06704 6 26 Lower unit 4 Calcula
7. Install the bearings in their original posi tions Do not get any sealant on the main bear ings 10 Install the crankcase onto the cylinder block and apply engine oil onto the threads of the crankcase bolts 11 Tighten the crankcase bolts to the speci fied torques in two stages and in the sequence shown 6D93G11 CAUTION The oil seals must be installed before tightening the crankcase bolts NOTE e Tighten the M10 bolts to 19 N m 1 9 kgf m 14 0 ft lb first and then tighten the M8 bolts to 14 N m 1 4 kgf m 10 3 ft lb Make a mark d on the M10 bolts and the crankcase and then tighten the bolts 60 from the mark e Tighten the M8 bolts to 28 N m 2 8 kgf m 20 7 ft lb Crankcase bolt M10 1st 19 N m 1 9 kgf m 14 0 ft lb 2nd 60 Crankcase bolt M8 1st 14 N m 1 4 kgf m 10 3 ft lb 2nd 28 N m 2 8 kgf m 20 7 ft lb 12 Install the cylinder head NOTE For cylinder head installation procedure see Installing the cylinder head 13 Install all parts removed during disas sembly 6D93G11 Cylinder block Installing the power unit 1 Clean the power unit mating surface and install the dowels 1 and a new gasket 2 2 Install the power unit 3 by installing bolts and then tightening them to the specified torques in two stages and in the sequence shown 3 Install the apron S6D85630 S6D85310 Power unit mounting bolt 4 1st 42
8. 6D93G11 Propeller shaft housing S6C16470 ve Bearing inner race attachment 0 90890 06661 6D93G11 Lower unit Drive shaft and lower case i S6D86080 Remarks 1 Drive shaft Taper roller bearing 1 Pinion shim Sleeve Hose Plastic tie Joint Nut Cooling water inlet cover Screw Seal Plate Forward gear shim Taper roller bearing Needle bearing Forward gear assembly Needle bearing Not reusable CO N DU AS DN Not reusable Not reusable a nn n 6 15 6D93G11 Drive shaft and lower case S6D86080 No Pertname av Remarks Pinion Nut Lower case 6D93G1 1 6 16 Lower unit Removing the drive shaft 1 Remove the drive shaft assembly and pinion and then pull out the forward gear S68S6360J Drive shaft holder 5 90890 06519 ___ Pinion nut holder New 90890 06715 Current 90890 06505 Disassembling the drive shaft 1 Install the pinion nut D tighten it finger tight and then remove the drive shaft bearing using a press 56616390 CAUTION Do not press the drive shaft threads 3 directly e When removing the drive shaft bearing do not damage the drive shaft collar 4 e Do not reuse the bearing always replace it with a new one vz Bearing inner race attachment 3 90890 06639 Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear using a press 6 17
9. On Z Bearing outer race attachment 90890 06628 56D87610 Driver rod LS 90890 06606 7 12 BRKT Bracket unit 3 Install new oil seals into the oil seal hous ing WR No 2 S6D97030 42 Needle bearing attachment i 90890 06612 Driver rod LS 90890 06606 4 Install new o rings and the gasket and then tighten the screws to the specified torque 56D97040 Oil pump cover screw 4 N m 0 4 kgf m 3 0 ft lb Disassembling the upper case 1 Remove the muffler assembly from the upper case 2 Remove the circlip then the drive shaft bushing 7 13 e D CEL 56D87140 ve Ball bearing attachment Q 90890 06638 Driver rod LL 2 90890 06605 Checking the drive shaft bushing 1 Check the drive shaft bushing for wear or cracks Replace if necessary Disassembling the oil pan 1 Remove the muffler 1 and plate 2 from the oil pan 3 2 Remove the exhaust manifold from the oil pan 3 3 Remove the oil pan 3 from the exhaust guide 4 Remove the oil strainer S6D87540 6D93G11 Checking the oil strainer 1 Check the oil strainer for dirt or residue Clean if necessary Assembling the oil pan 1 Install a new gasket onto the exhaust guide 1 Install a new gasket and the oil strainer onto the exhaust guide and then tighten the bolts to the specified torque S6D87150 Oil strainer bolt 10 N m 1 0 kgf m
10. To diagnose a malfunctioning sensor or switch use the diagnostic flash indicator to determine the cause Power unit Symptom Engine does not crank Check the starting system e Check the power unit Check that the gearshift is in the neutral position Is the gearshift in No neutral Set it to the neutral position Yes Check the engine start switch for continuity Is there continuity Replace the engine start switch Yes Check the engine stop lanyard switch for continuity with lock plate Is there continuity Replace the engine stop lan yard switch Yes Check the fuse for continuity Continued on next page 9 5 6D93G 11 Power unit Is there continuity Replace the fuse Yes Check the wiring harnesses for continuity Is there continuity Replace the wiring harnesses Yes Listen for the operation sound of the starter relay Can the operation sound be heard No Replace the starter relay Yes Check the starter motor opera tion No Disassemble and check the starter motor 8 15 8 16 Good operating condition Yes Check the power unit 6D93G 11 9 6 SHTG e Troubleshooting Symptom Engine cranks but will not start engine stop lanyard switch is operating nor mally Check the ignition system e Check the fuel system e Check the compression pressure of the power unit
11. BRKT Bracket unit Tilt cylinder and trim cylinder sein pi 80 N m 8 0 kgf m 59 0 ft Ib Part name Remarks Power trim and tilt assembly Dust seal Backup ring Not reusable Not reusable O ring Trim cylinder end screw O ring Tilt cylinder end screw assembly Backup ring O ring O ring Washer Filter O ring Trim piston Backup ring O ring Ball Not reusable Not reusable Not reusable Not reusable ol gt x c c c oo 7 35 6D93G11 Tilt cylinder and trim cylinder 56D87390 4 34 80 N m 8 0 kgf m 59 0 ft Ib 90 N m 9 0 kgf m 66 4 ft Ib Not reusable rr IJ NNN CN QU r Tilt piston assembly Tilt cylinder Backup ring Tilt piston u p D CC O o E G G al O Z Not reusable 7 36 6D93G11 gt x DC eo Bracket unit 90 N m 9 0 kgf m 66 4 ft Ib 56D87390 34 80 N m 8 0 kgf m 59 0 ft Ib c O EL oa D D Sa LL dp p CC O o E G o O Z Cylinder base Trim cylinder 6D93G11 7 37 Disassembling the trim cylinder 1 Hold the power trim and tilt unit in a vise using aluminum plates on both sides 562Y7500 2 Loosen the trim cylinder end screw 2 and then remove it 56D87630 A WARNING Make sure that the ram is fully extended before removing the end screw gt Cylinder end s
12. Check that the spark plugs pro WARNING duce sparks Do not touch any of the connections of the ignition tester leads e Do not let sparks leak out of the removed spark plug caps e Keep flammable gas or liquids away since this test can produce sparks Yes Check the ignition spark using Are there sparks i the ignition tester 8 7 Yes Check the pulser coil output peak voltage 8 8 Check the condition of the spark plugs Good spark No Check the ignition coil resis tance 8 7 Within Replace the ignition specification coil Yes Check the spark plug wire resis tance and check the spark plug cap for corrosion or rust 8 7 Good condition No Replace the spark plug wire Yes Check the ECM output peak Continued on next page voltage 8 8 9 7 6D93G11 Power unit No Check the main and fuel pump Wet k plugs et spark plugs relay for continuity 8 11 Yes Is there Replace the main continuity and fuel pump relay Start the engine using dried or new spark plugs Check the fuel system Does the engine Check the compression pres start sure of the combustion chamber 5 3 Within specification Check the condition of the spark plugs again Failure in starting operation Check the valve Wet spark plugs i park plug Failure in starting operation clearance 5 10 Adjust the valve No Within
13. Check the fuel system M clearance specification Yes Check the cylinder head cylin der block and piston assembly 6D93G11 9 8 SHTG e Troubleshooting Symptom Engine can be started but does not remain on e Check the fuel system Check the ignition system Check the compression pressure of the power unit Fuel system Check that the fuel vent screw of the fuel tank is open Is the vent screw open Open the fuel vent screw Yes Check for water or residue in the fuel filter No Check the fuel hose for kinks or fuel leakage Water or residue Yes Clean the fuel system from the Kinks or fuel Yes Replace the fuel tank to the fuel filter leakage defective parts Check the fuel pressure 4 13 Check the pressure regulator Within Yes Check the fuel 8 10 Check the fuel system using the Yes Within Diagnostic System specification No Replace the fuel injector Good operating condition Replace the pressure regulator Check the fuel system using the Diagnostic System 9 9 6D93G11 Power unit Ignition system A WARNING e Do not touch any of the connections of the ignition tester leads e Do not let sparks leak out of the removed spark plug caps e Keep flammable gas or liquids away since this test can produce sparks Check the ignition spark using the ignition tester 8 7 Check the p
14. IM 8 N m 0 8 kgf m 5 9 ft Ib IX 8 N m 0 8 kgf m 5 9 ft Ib S6D84050 Remarks Intake manifold sensor assembly Screw O ring Idle speed control O ring Throttle body assembly Bolt Gasket Throttle position sensor Screw O ring Fuel injector O ring set Fuel rail Bolt g5 x 13 mm Not reusable Not reusable M6 x 16 mm Not reusable CON OOF UN Not reusable Not reusable M6 x 38 mm 1 1 4 1 1 1 1 3 1 1 2 1 4 4 1 2 6D93G11 4 8 ue Y Fuel system Checking the throttle position sensor 1 Check the throttle position sensor output voltage using the Selva Diagnostic System If the output voltage is out of specification replace the throttle posi tion sensor Throttle position sensor output voltage at engine idle speed 0 8 1 2 V Installing the throttle position sensor 1 Install the throttle position sensor 1 in a position where the output voltage is within specification S6D84170 NOTE e f the throttle position sensor output voltage is out of specification reinstall the throttle position sensor Measure the throttle position sensor output voltage using the Selva Diagnostic Sys tem Do not turn the throttle stop screw 8 Throttle position sensor output voltage at engine idle speed 0 8 1 2 V Checking the idle speed control 1 Check the operation of the idle speed control using the Selva Diagnostic System 4
15. S62Y6740K CAUTION Do not reuse the bearing always replace it with a new one Bearing separator 1 90890 06534 2 Remove the needle bearing from the for ward gear 56856160 CAUTION Do not reuse the bearing always replace it with a new one Disassembling the lower case 1 Remove the taper roller bearing outer race and shim s 56856370 6D93G11 NOTE Install the claws as shown Z Bearing outer race puller assembly 1 90890 06523 2 Remove the drive shaft bearing outer race shim s and drive shaft sleeve o ss TE 2 So Ky 56016490 NOTE Install the claws as shown 2 Stopper guide plate 90890 06501 7 1 Stopper guide stand 90890 06538 Bearing puller assembly 4 90890 06535 3 Remove the needle bearing 56856390 Needle bearing attachment 90890 06611 Driver rod L3 90890 06652 6D93G11 Drive shaft and lower case Checking the pinion and forward gear 1 Check the teeth of the pinion and the teeth and dogs of the forward gear for cracks or wear Replace if necessary Checking the bearings 1 Check the bearings for pitting or rum bling Replace if necessary Checking the drive shaft 1 Check the drive shaft for bends or wear Replace if necessary 2 Measure the drive shaft runout IA IBI LI 56D86210 Runout limit 0 5 mm 0 020 in Checking the lower case 1 Check the skeg and torpedo for crack
16. Valve seat cutter 90890 06312 90890 06315 90890 06324 90890 06326 90890 06328 90890 06555 e Piston slider 90890 06530 Oil filter wrench 64 90890 01426 6D93G11 5 2 Power unit Power unit Checking the compression pressure 1 Start the engine warm it up for 5 min utes and then turn it off 2 Remove the engine stop lanyard from the engine stop lanyard switch on the remote control box 3 Remove the spark plug wire cover and all spark plugs and then install the special service tools into a spark plug hole S6D85110 CAUTION Before removing the spark plugs blow compressed air in the spark plug well to clear out any dirt or dust that may fall into the cylinder Compression gauge i 90890 03160 Compression gauge extension M14 2 90890 06563 4 Fully open the throttle crank the engine until the reading on the compression gauge stabilizes and then check the compression pressure Minimum compression pressure reference data 860 kPa 8 6 kgf cm 124 7 psi 5 If the compression pressure is below specification and the compression pres sure for each cylinder is unbalanced add a small amount of engine oil to the cylin der and then check the pressure again 5 3 NOTE A e If the compression pressure increases check the pistons and piston rings for wear Replace if necessary e If the compression pressure does not increase check the valve clearance valve
17. solu Brush length wear limit 8 3 5 mm 0 14 in Commutator undercut wear limit a 1 0 mm 0 04 in 7 Check the base for cracks or damage Replace if necessary 4 Check the armature for continuity Replace if out of specifications 8 Check the bushing and oil seal for damage or wear Replace if necessary f 56948420 562Y7950 6D93G1 1 7 28 BRKT Bracket unit Assembling the power trim and tilt motor 1 Install a new oil seal 1 and the bushing 2 into the motor base 3 as shown 56087330 2 Attach the circuit breaker onto the brush together with the brush holder 6 and connect the wire lead 562Y7970 3 Install the springs 8 into the motor base then the brush holder into the motor base together with the brushes and circuit breaker S6D87340 4 Push the brushes into the brush holder and then install the armature 5 Install the stator onto the base 7 29 56D87350 NOTE Place a clean cloth over the end of the arma ture shaft hold it with a pair of pliers and then carefully slide the stator over the arma ture 6D93G11 Power trim and tilt motor Gear pump Gear pump yx 12 N m 0 2 kgf m 1 5 ft Ib y 5 N m 0 5 kgf m 3 7 ft Ib 3 5 N m 0 5 kgf m 3 7 ft Ib S6D87360 Part name Remarks Gear pump assembly Spacer Pin Lever Bolt Bolt Spring Shuttle piston Backup ring Down relief valve seat
18. 0 0276 0 0354 in Oil ring 0 20 0 70 mm 0 0079 0 0276 in Measuring point 20 mm 0 8 in Checking the piston ring grooves 1 Measure the piston ring grooves Replace the piston if out of specification S63P5720 5 43 Piston ring groove Top ring 1 23 1 25 mm 0 048 0 049 in Second ring 1 52 1 54 mm 0 060 0 061 in Oil ring 2 51 2 53 mm 0 099 0 100 in Checking the piston ring side clearance 1 Measure the piston ring side clearance Replace the piston and piston rings as a set if out of specification S63P5730 Piston ring side clearance Top ring 0 04 0 08 mm 0 0016 0 0031 in Second ring 0 03 0 07 mm 0 0012 0 0028 in Oil ring 0 03 0 15 mm 0 0012 0 0059 in Checking the connecting rod big end side clearance 1 Measure the connecting rod big end side clearance Replace the connecting rod or crankshaft or both if out of specifi cation 6D93G 11 Cylinder block Crankshaft journal diameter 4 985 48 000 mm 1 8892 1 8898 in Crankpin diameter b 43 982 44 000 mm 1 7316 1 7323 in Crankpin width 21 00 21 07 mm 0 8268 0 8295 in 2 Measure the crankshaft runout Replace the crankshaft if above specification S6D85580 Connecting rod big end side clearance 8 0 14 0 28 mm 0 0055 0 0110 in Checking the crankshaft KO 1 Measure the crankshaft journal diameter 7 a crankp
19. 30 N m 3 0 kgf m 22 1 ft Ib Y OA Y ON O V jt CI ENN 5 ON NY DAS px 24 271 22 A 190 y 27 e 18 18 28 N m 2 8 kgf m 20 7 ft Ib ar Q 47 17 5 S6D85080 Remarks 18 16 Valve lifter Valve cotter 32 Valve spring retainer 16 Valve spring 16 Valve spring seat 16 Valve seal 16 Valve guide 16 5 25 6D93G11 Removing the cylinder head 1 Remove the cylinder head cover 2 Remove camshaft caps 1 and in the sequence shown S6D85420 3 Remove the camshaft intake S cam shaft exhaust 2 and oil seals 56D85430 4 Remove the valve shims 6 from the valve lifters S60C5380 6D93G11 Cylinder head NOTE S Do not mix the valve train parts Keep them organized in their proper groups 5 Remove the cylinder head bolts in the sequence shown om oF ei3 O 4 O O Oly El CAUTION Do not scratch or damage the mating sur faces of the cylinder head and cylinder block 56D85440 5 26 Power unit 6 Remove the intake and exhaust valves 560C5390 NOTE Be sure to keep the valves springs and other parts in the order as they were removed 2 Valve spring compressor 90890 04019 Valve spring compressor attachment 9 90890 06320 Checking the valve lifters 1 Check the valve lifters for damage scratches or wear Replace if necessary Che
20. 4 S60C5A80 6D93G11 Cylinder block NOTE Install the bearings in their original positions 4 Install the piston with the UP mark on the piston crown facing towards the fly wheel magnet 560C5A90 DUDE NOTE Apply engine oil to the side of the pistons and piston rings before installation Piston slider 90890 06530 5 Install half of the bearings into the cyl inder block S60C5B10 NOTE AAA e Install the bearings in their original posi tions Install the unified thrust bearing at the posi tion shown 5 50 Power unit 6 Set the crankshaft 8 and oil seals 9 and into the cylinder block as shown 56D85700 7 Install the connecting rod cap to the connecting rod and then tighten the new connecting rod bolts to the specified torques in two stages S60C5B30 CAUTION Do not reuse the connecting rod bolts always replace them with new ones 9 51 NOTE ER Make sure that the large flat side of the connecting rod faces towards the flywheel magnet side of the crankshaft Apply engine oil to the connecting rod caps and connecting rod bolts before installation Connecting rod bolt 63 1st 18 N m 1 8 kgf m 13 3 ft lb 2nd 80 8 Install half of the bearings 42 into the crankcase 9 Apply sealant to the mating surface of the crankcase ANSA ATI VAT AZ P E S6D85620 NOTE
21. Bolt Dowel Driven sprocket Bolt Bracket Bolt Timing belt tensioner Spring Plastic tie Hose Clamp Nut Drive sprocket Plate Woodruff key M10 x 35 mm M6 x 15 mm M10 x 45 mm CO N DU POD Not reusable h az MN DD Na 6D93G11 5 6 Power unit 29 Y 8 spe SETEICIT CE PINS 2 lt A STAN m 0 4 kgf m 3 0 ft Ib EE feno CA 21 9 OS X lt gt DE S6D85040 Part name pena Screw 96 x 30 mm Cover Spark plug wire Holder Holder Bolt Holder Clamp Hose Plastic tie Ignition coil Bracket Bolt Holder Starter motor Bolt Terminal M6 x 12 mm CO N DU AS DN Not reusable M6 x 25 mm M8 x 45 mm ud 6D93G11 Power unit 29 8 429 N m 2 9 kgf m 21 4 ft Ib i STAN m 0 4 kgf m 3 0 ft Ib a I S6D85040 Part name Bono Cap Positive battery lead Nut Negative battery lead Bolt Junction box cover Bolt Cap Oil pressure switch Bolt Holder Bolt Clamp M6 x 20 mm M6 x 10 mm M4 x 8 mm M6 x 25 mm Aa l l a LA do ll do l 1 LJ 6D93G11 5 8 Power unit N 8 N m 0 8 kgf m 5 9 ft Ib 17 N m 1 7 kgf m 12 5 ft lb ie 12 N m 0 2 kgf m 1 5 ft lb TAO 8 N m 0 8 kgf m 5 9 ft Ib N 8N m 0 8 kgf m 5 9 ft lb m 0 8 kgf m 5 S6D85070 Oil filler cap O ring Cylinder head cover S
22. Check the water pump impeller for cracks or wear Check the water Check the thermostat operation passage for clogs or Good condition 3 7 debris No Replace the impeller Good condition Replace the thermostat Yes Check the cooling water tem perature sensor 8 9 Good condition No Replace the cooling water tem perature sensor Yes Check the engine using the Diagnostic System 9 11 6D93G11 Power unit Lubrication system Check the engine oil level No Add engine oil to the correct level At specified level Yes Check the oil pressure 5 3 Within specification Check the oil pump for debris or oil leaks Yes No Check the oil Debris or leaks passage Yes Check the oil pressure switch Clean or replace the defective 8 9 parts No Good condition Replace the oil pressure switch Yes Check the engine using the Diagnostic System 6D93G11 9 12 TRBL e SHTG e Troubleshooting Bracket unit Symptom Power trim and tilt unit does not operate Listen for the operation sound of the power trim and tilt relay Can the operation sound be heard No Yes Listen for the operation sound of the power trim and tilt motor Can the operation sound be heard No Yes Check that the manual valve is closed Continued on next page 9 13 Che
23. ness 11 as shown in the examples below 6D93G11 56856260 NOTE F is the deviation of the lower case dimen sion from standard The F mark is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark unreadable assume that F is zero and check the backlash when the unit is assembled Forward gear shim thickness T1 24 42 F 100 M Example If M is 24 00 mm and F is 5 then T1 24 42 5 100 24 00 mm 0 42 0 05 mm 0 47 mm If M is 24 00 mm and F is 5 then T1 24 42 5 100 24 00 mm 0 42 0 05 mm 0 37 mm 3 Select the forward gear shim s T1 as follows Calculated numeral Rounded numeral at 1 100 pace Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 6D93G11 Shimming Backlash Example If T1 is 0 47 mm then the forward gear shim is 0 45 mm If T1 is 0 50 mm then the forward gear shim is 0 48 mm Backlash Measuring the forward gear backlash 1 Removethe water pump assembly NOTE Do not remove the oil seal housing in this procedure 2 Set the gear shift to the neutral position at the lower unit S6D86280 6 28 Lower unit 3 Install the special service tool so that it pushes against the propeller shaft S60X6370 NOTE Tighten the center bolt whi
24. 56065670 NOTE The valve spring can be installed in any direction Z Valve spring compressor 7 90890 04019 Valve spring compressor attachment o 90890 06320 3 Compress the valve spring and then install the valve cotters using a thin screwdriver with a small amount of grease applied to it 6D93G11 S60C5680 4 Lightly tap the valve spring retainer with a plastic hammer to set the valve cotters securely y S60C5690 Installing the cylinder head 1 Check that the piston of cylinder 1 is at TDC 2 Install a new gasket and the cylinder head and then tighten the bolts to the specified torques in the sequence shown 6D93G11 Cylinder head O E O a MoL O O E S6D85480 CAUTION Do not reuse the cylinder head gasket always replace it with a new one NOTE AAA e Apply engine oil to the cylinder head bolts before installation e Tighten the M10 bolts to the specified torques in two stages first and then tighten the M8 bolts to 14 Nm 1 4 kgf m 10 3 ft lb Make a mark on the M10 bolts and the cylinder head and then tighten the bolts 90 from the mark e Tighten the M8 bolts to 28 N m 2 8 kgf m 20 7 ft lb Cylinder head bolt M10 1st 15 N m 1 5 kgf m 11 1 ft lb 2nd 30 N m 3 0 kgf m 22 1 ft lb 3rd 90 Cylinder head bolt M8 1st 14 N m 1 4 kgf m 10 3 ft lb 2nd 28 N m 2 8 kgf m 20 7 ft lb 0 3
25. 7 4 ft lb Install the dowels and oil pan 3 onto the exhaust guide and then tighten the oil pan bolts finger tight Install a new gasket and the exhaust manifold onto the oil pan and then tighten the exhaust manifold bolts to the specified torque Tighten the oil pan bolts 4 to the speci fied torque Tighten the exhaust manifold bolts 6 again to the specified torque 6D93G11 f 8 Upper case 56D87160 Oil pan bolt 4 11 N m 1 1 kgf m 8 1 ft lb Exhaust manifold bolt 11 N m 1 1 kgf m 8 1 ft lb Install new gaskets the plate and the muffler 8 onto the oil pan Install the water pipe 56D87170 7 14 BRKT Bracket unit Assembling the upper case 1 Install the drive shaft bushing into the upper case and then install the circlip Needle bearing attachment 90890 06653 Driver rod L3 2 90890 06652 2 Install the muffler assembly 3 by insert ing the tip of the water pipe 4 into the joint hole 8 of the upper case 3 Install the muffler assembly bolts and then tighten them to the specified torque S6D87190 Muffler assembly bolt 20 N m 2 0 kgf m 14 8 ft lb Installing the upper case 1 Install the upper mount G and bolts 2 into the upper case 7 15 2 Install the bolts 3 and then tighten them to the specified torque 56D87590 Upper mount bolt 28 N m 2 8 kgf m 20 7 ft lb 3 Instal
26. Bolt Collar Grommet Bolt ECM Rectifier Regulator Bolt Bolt Bracket Bolt M6 x 15 mm M6 x 12mm CO N DU POD M6 x 20 mm M6 x 30 mm M6 x 25 mm M6 x 20 mm IU DU Q RRB DH AA A PD M6 x 30 mm 5 21 6D93G11 ECM Junction box Junction box N g A q Q Q Q CA DE Part name Remarks Screw 96 x 25 mm Main and fuel pump relay Power trim and tilt relay Washer Nut Cap Bolt Ground lead Fuse Fuse Cap Cap otarter relay Holder Screw Bolt Cap M6 x 20 mm 30A 20A 96 x 20 mm M6 x 10 mm A GQ A QQ PO DD PO KD 6D93G11 5 22 Power unit I Part name Remarks Holder Junction box Collar Grommet Bolt M6 x 10mm Clamp Grommet 5 23 6D93G11 Junction box Cylinder head Cylinder head 15N m 1 5 kgf m 11 1 ft Ib 30 N m 3 0 kgf m 22 1 ft Ib o z o o VID LT N Y ON o NO y O 14 N m 1 4 kgf m 10 3 ft Ib 21 48 28 N m 2 8 kgf m 20 7 ft Ib 20 Y S6D85080 Remarks Cylinder head Exhaust valve Intake valve Gasket Collar Bolt Bolt Cover Thermostat Bolt Spark plug Bolt Bolt Anode cover Anode Grommet Valve shim Not reusable M8 x 55 mm M6 x 25 mm CO N DU Bb UN DO N 00 CO Li E O M10 x 143 mm M8 x 40 mm M6 x 22 mm N NNNNA O 6D93G11 5 24 Power unit OM 15N m 1 5 kgf m 11 1 ft Ib
27. Intake 0 20 0 03 mm 0 008 0 001 in Exhaust f 0 34 0 03 mm 0 013 0 001 in 6 Turn the flywheel magnet 360 clock wise 7 Check the intake valve clearance for cyl inders 3 and 4 and the exhaust valve clearance for cylinders 2 and 4 Adjust if out of specification 8 Turn the flywheel magnet clockwise and align the TDC mark on the flywheel magnet with the pointer and check that the A marks on the driven sprockets are aligned S6D85160 9 Loosen the tensioner bolt and then Check the intake valve clearance for cyl inders 1 and 2 and the exhaust valve clearance for cylinders 1 and 3 Adjust remove the spring 8 timing belt 9 driven sprockets 9 camshaft caps 1 and camshafts 2 If out of specification S6D85180 S6D85170 NOTE AAA NOTE Do not mix the valve train parts Keep them Check the valve clearance when the engine organized in their proper groups is cold Note the measurement 10 Remove the valve lifters from the cylinder head 5 11 6D93G11 11 Remove the valve shim 3 from the valve lifter 9 using a thin screwdriver 56D85190 12 Measure the valve shim thickness with a micrometer and then note the measure ment 13 Select the necessary valve shim by cal culating its thickness with the following formula Necessary valve shim thickness Removed valve shim thickness Measured valve clearance Specified valve
28. Replace the gear pump assembly if necessary Assembling the gear pump 1 Install the drive gear I and driven gear into the gear pump housing O 2 Install the balls into the gear pump housing S6D87560 4 Remove the gear pump bracket then the adapters 5 Remove the pins 2 then the drive gear and driven gear 56C17610 3 Install the gear pump cover 4 then the pins 6 7 33 6D93G11 Gear pump Lever bolt M3 2 63 2 N m 0 2 kgf m 1 5 ft lb 9 Install the up relief valve seat and down relief valve seat 5 10 Install the relief valve seat caps by installing bolts 47 and 8 then tightening SSA OO them to the specified torques 4 Install the adapters into the gear pump 11 Tighten the bolts to the specified cover torque 5 Install the balls into the gear pump cover with the manual release spring 8 6 Install the gear pump bracket by installing the bolts then tightening them to the specified torques 56D87380 Relief valve cap bolt M4 7 4 N m 0 4 kgf m 3 0 ft lb Relief valve cap bolt M5 8 5 N m 0 5 kgf m 3 7 ft lb Gear pump housing bolt 9 un 5 N m 0 5 kgf m 3 7 ft lb Gear pump bracket bolt M3 2 N m 0 2 kgf m 1 5 ft lb Gear pump bracket bolt M5 4 N m 0 4 kgf m 3 0 ft lb 7 Install the shuttle pistons 9 then the lever AD 8 Tighten bolts 42 and 43 to the specified torque 56C17640 6D93G11 7 34
29. Washer Spring Pin Cap Bolt Bolt Cap M3 x 16 mm M3 x 35 mm CO N DU Bb UN M5 x 30 mm M4 x 30 mm 6D93G11 7 30 BRKT Bracket unit yx 12 N m 0 2 kgf m 1 5 ft Ib y 5 N m 0 5 kgf m 3 7 ft Ib 3 5 N m 0 5 kgf m 3 7 ft Ib S6D87360 Part name Remarks Holder Spring Washer Up relief valve seat Bolt O ring Shuttle piston Bolt Bolt Filter Plate O ring Filter O ring Manual valve Circlip M5 x 25mm Not reusable M5 x 45 mm M5 x 50 mm Not reusable Not reusable 1 31 6D93G11 Gear pump 12 N m 0 2 kgf m 1 5 ft Ib x 4 N m 0 4 kgf m 3 0 ft Ib 56D87550 Remarks Manual release spring Ball Bracket Bolt Bolt Washer O ring Adapter Spring Ball Gear Drive shaft Pin Driven shaft Ball Pin M3 x 5 mm M5 x 6 mm Not reusable CO N DU POD PONMHIANHI NDNNNNNYNP A HAYDN 6D93G11 7 32 BRKT Bracket unit Disassembling the gear pump 1 Remove the manual valve then the gear pump and filters S6C 1 600 Checking the gear pump S6D87370 1 Clean all the pistons and balls and then check them for damage or wear Replace 2 Remove the relief valve seat caps then if necessary the up relief valve seat 1 and down relief valve seat 2 Check the filters for damage or clogs Replace if necessary 3 Remove the lever then the shuttle pistons 2 3 Check the drive gear and driven gear for damage or wear
30. be sure to do so where ade quate ventilation can be maintained 56941020 Self protection Protect your eyes by wearing safety glasses or safety goggles during all operations involv ing drilling and grinding or when using an air compressor Protect your hands and feet by wearing pro tective gloves and safety shoes when neces sary 1 3 56941030 Parts lubricants and sealants Use only genuine Selva parts lubricants and sealants or those recommended by Selva when servicing or repairing the out board motor 56941040 Under normal conditions the lubricants men tioned in this manual should not harm or be hazardous to your skin However you should follow these precautions to minimize any risk when working with lubricants 1 Maintain good standards of personal and industrial hygiene 2 Change and wash clothing as soon as possible if soiled with lubricants 3 Avoid contact with skin Do not for example place a soiled rag in your pocket 4 Wash hands and any other part of the body thoroughly with soap and hot water after contact with a lubricant or lubricant soiled clothing has been made 5 To protect your skin apply a protective cream to your hands before working on the outboard motor 6D93G11 6 Keepasupplyofclean lint free cloths for Wiping up spills etc Good working practices Special service tools Use the recommended special service tools to protect parts from damage Use
31. ene 1 6 Propeller selection 1 5 6D93G1 1 R Propeller shaft housing 6 10 Propeller SIZO niona 1 5 Reducing the fuel pressure 4 13 Refacing the valve seat 5 30 Removing the clamp brackets 7 21 Removing the cylinder head 5 26 Removing the drive shaft 6 17 Removing the exhaust cover 0 39 Removing the fuel hose clamp 4 16 Removing the lower unit 6 8 Removing the power trim and tilt unit 7 24 Removing the power unit 5 16 Removing the propeller shaft housing SSN iaia 6 11 Removing the steering arm 7 18 Removing the timing belt and sprockets 5 17 Removing the upper case 7 12 Removing the water pump and shift rod 6 9 Replacing the oil filter 3 5 Replacing the timing belt 5 13 Replacing the valve guides 5 28 S Safety while working 1 3 selecting the connecting rod bearing 5 46 Selecting the forward gear shims 6 27 selecting the main bearing 5 48 Selecting the pinion shims 6 26 SECCIONS El 1 6 SEIECIAGNOSIS israe 9 1
32. low water resistance will increase and reduce engine efficiency S69J1 160 1 NOTE ee The optimum mounting height is affected by the combination of the boat and the outboard motor To determine the optimum mounting height test run the outboard motor at differ ent heights 2 Check that the clamp brackets are secured with the clamp bolts Checking the remote control cables 1 Set the remote control lever to the neu tral position and fully close the throttle lever 2 Check that the stopper 1 on the throttle cam contacts the fully closed stopper Q on the cylinder block 56D81030 3 Check that the alignment mark on the bushing is aligned with the alignment mark on the bracket 56D81040 6D93G11 jun dope 56943370 A WARNING The shift throttle cable joint must be screwed in a minimum of 8 0 mm 0 31 in Checking the steering system 1 Check the steering friction for proper adjustment 2 Check that the steering operates smoothly 560C1200 3 Check that there is no interference with wires or hoses when the outboard motor is steered Checking the gear shift and throttle operation 1 Check that the gear shift operates smoothly when the remote control lever is shifted from neutral to forward or reverse 2 Check that the throttle operates smoothly when the remote control lever is shifted from forward or reverse to the fully open position 8
33. minum plates on both sides 12 Install the tilt piston to the tilt ram by installing the bolt 60 then tightening it to the specified torque 6D93G11 7 40 BRKT Bracket unit 15 Install the tilt cylinder end screw 8 and then tighten it to the specified torque 56D87650 CAUTION Do not damage the check valve when tightening the end screw vz Cylinder end screw wrench New 90890 06568 Current 90890 06544 Tilt cylinder end screw 8 80 N m 8 0 kgf m 59 0 ft lb 16 Install the free piston G into the tilt cylin der 47 by installing the circlip 62 sL 17 Install the cylinder base 63 springs 64 and washer 65 into the tilt cylinder with the circlip 69 S6D87420 7 41 S6D87430 Assembling the power trim and tilt unit 1 Hold the trim cylinder in a vise using alu minum plates on both sides 2 Install the filters and gear pump assem bly by installing the bolts then tight ening them to the specified torques 3 Install the manual valve and reservoir cap 4 56D87440 Gear pump bolt 2 5 N m 0 5 kgf m 3 7 ft lb Reservoir cap 2 7 N m 0 7 kgf m 5 2 ft lb 4 Fill the reservoir with the recommended fluid to the correct level as shown 6D93G11 56D87450 Recommended power trim and tilt fluid ATF Dexron II 5 Install a new O ring the joint and the power trim and tilt motor by installing the bolts then tightening them
34. vere FPS Starting model code serial No F80BET 1000001 F100DET 6D9 1000001 1 5 Propeller selection The performance of a boat and outboard motor vvill be critically affected by the size and type of propeller you choose Propellers greatly affect boat speed acceleration engine life fuel economy and even boating and steering capabilities An incorrect choice could adversely affect performance and could also seriously damage the engine Use the following information as a guide for selecting a propeller that meets the operating conditions of the boat and the outboard motor Propeller size The size of the propeller is indicated on the propeller boss end on the side of the propel ler boss S69J1100 000x0 0 9 7 DE DO S60C1120 a Propeller diameter in inches b Propeller pitch in inches Propeller type propeller mark 6D93G11 Identification Propeller selection Predelivery checks Selection When the engine speed is at the full throttle operating range 5 000 6 000 r min the ideal propeller for the boat is one that pro vides maximum performance in relation to boat speed and fuel consumption Propeller size in 12 5 8 x 21 K 13x 19 R 13 x 23 R 13x 25 R 13 1 4x 17 R 13 1 2x 15 R 13 5 8 x 13 R 14x11 K 13x17 K 13x19 K 13x21 K 13x23 K 13x25 K 13 1 2x 14 K 13 1 2x 16 K Aluminum Stainless Predelivery checks To make the delivery proc
35. 100 EF 0 24 0 36 10 1 9 378 8 ATF Dexron II 10 0 0 39 3 5 0 14 22 0 0 87 21 0 0 83 2 8 SPEC ye Specifications Dimensions Exterior mm in 35 240 9 4 405 15 9 L 527 20 7 X 857 33 7 L 917 36 1 X 1 044 41 1 on re LO Y NN dos 56D82010 2 9 6D93G11 Maintenance specification Clamp bracket mm in 180 7 1 163 5 6 4 180 7 1 02 8 0S C D SN RE Ww y Ne iu D T QopDvse gt vSc 20 S 81 L EL S 8v o m Y LO AN re S6D82020 2 10 6D93G 11 SPEC O nom Specifications Tightening torques Specified torques Tightening torques EN EL Fuel system Fuel system 000 Fuel fiter cup T 3 22 Fuel pump mounting bolt 7 4 Fuel pump screw 4 3 0 Sensor assembly screw 27 Fuelral mounting bot me 8 os 59 Totte body mouningbot me 8 08 53 22 Vapor separator dain sorew 18 048 14 Fuehosjim pf 4 94 88 Pressure checkvave 30 40 74 Power unt mouningb t Poggi MO tas 5 9 Oil pressure switch lt 8 08 59 Positive battery lead nu m 9 09 66 Driven sprocket bt mo 60 60 443 r 8 08 59 We 8 os so NO 11 6D93G11 Tightening torques ae torques UE E V jr Cylinder head bol EE Ea rer
36. 2 N m 0 2 kgf m 1 5 ft lb 4 Fully tilt the outboard motor up and then support it with the tilt stop lever 3 56D87530 WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure 5 Check the trim sensor resistance If the resistance is out of specification adjust the trim sensor cam position and check the trim sensor Trim sensor resistance Pink P Black B 238 8 378 8 Q at 20 C 68 F 6D93G11 Clamp brackets and swivel bracket 7 22 BRKT Bracket unit Power trim and tilt unit S6D87270 Remarks Power trim and tilt unit Circlip Shaft Circlip Shaft Bushing Bushing Ground lead Bolt Bushing Bushing Collar Holder Bolt CON OOF DN M6 x 10 mm MN MD N PO a amp NA PO a da M6 x 10 mm 1 23 6D93G11 Removing the power trim and tilt unit 1 Fully tilt the outboard motor up and then support it with the tilt stop lever 1 56D83150 N 86007745 WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure NOTE e If the power trim and tilt does not operate loosen the manual valve and tilt the out board motor up manually e If the manual valv
37. 2346 0 2352 6 000 6 018 0 2362 0 2369 0 010 0 043 0 0004 0 0017 0 025 0 058 0 0010 0 0023 0 01 0 0004 53 20 2 0945 2 6 0 10 2 4 SPEC mM Specifications Valve lifters Valve lifter outside diameter Valve lifter to cylinder head clearance Valve shims Valve shim thickness in 0 025 mm increments Connecting rods Big end inside diameter Big end side clearance Crankpin oil clearance Big end bearing thickness Yellow Green Blue Red Crankshaft Crankshaft journal diameter Crankpin diameter Crankpin width Runout limit Crankcase Crankshaft journal oil clearance Upper crankcase main bearing thickness Green Blue Red Upper crankcase main bearing 3 thickness Green Blue Red Lower crankcase main bearing thickness Yellow Green Blue Red 2 5 Model 27 965 27 980 1 1010 1 1016 0 020 0 056 0 0008 0 0022 2 0 3 3 0 08 0 13 47 025 47 045 1 8514 1 8522 0 14 0 28 0 0055 0 0110 0 024 0 044 0 0009 0 0017 1 499 1 506 0 0590 0 0593 1 506 1 513 0 0593 0 0596 1 513 1 520 0 0596 0 0598 1 520 1 527 0 0598 0 0601 47 985 48 000 1 8892 1 8898 43 982 44 000 1 7316 1 7323 21 00 21 07 0 8268 0 8295 0 03 0 0012 0 024 0 044 0 0009 0 0017 2 992 2 999 0 1178 0 1181 2 999 3 006 0 1181 0 1183 3 006 3 013 0 1183 0 1186 2 992 2 999 0 1178 0 1181 2 999 3 006 0 1181 0 1183 3 006 3 013 0 1183 0 1186 3 010 3 017 0 1185 0 1188 3 017 3 024 0 11
38. 25 eee ie SE 29 MI 4 49 361 Olffr am Lele 1st Exhaust cover bolt me o cu D eas Anode sorew JM 2 02 18 Exhaust cover plug me 55 55 406 m 20 7 qs gt d ii Lower unit Gear oildrain serew 9 09 66 Gear oil check serew I 9 09 66 Lower case mounting nut Xtransom model 39 39 288 Rngnt 103 108 760 Cooling water inlet cover screw 5 08 37 Bracket unit Shift rod detentbot gt 18 18 183 Upermow ngnt 81 81 376 lowemow ngnt BA 376 Grease mipple 3 08 22 6D93G11 D A N SPEC Specifications udi torques n ees n Exhaust manifold bolt W n 4 Steering arm stud bol mo 20 20 148 Self locking nut dq deci dee D We Trim sensor cam screw Power trim and tilt unit Reservoir cap PTT motor bolt Gear pump housingbo f w 5 05 37 Herb ms 08 15 MEA ELA EN OOC e Eee mw 80 sd Tilt cylinder end seem 80 80 590 General torques This chart specifies tightening torques for sene OLE standard fasteners with a standard ISO MG POE pe thread pitch Tightening torque specifications for special components or assemblies are provided in applicable sections of this man ual To avoid warpage tighten multi fastener assemblies in a crisscross fashion and pro gressive stages until the specified torque is reached Unless
39. 3 7 8 9 kQ 4 4 3 10 2 RQ Checking the ignition coils 1 Remove the spark plug wires from the ignition coils 2 Disconnect the ignition coll coupler 3 Measure the ignition coil resistance Replace if out of specification S63P8100 6D93G11 Ignition coil resistance Primary coll Red R Black white B W 1 53 2 07 Q at 20 C 68 F Secondary coil 12 495 16 905 kQ at 20 C 68 F Checking the ECM 1 Disconnectan ignition coll coupler 2 Connect the test harness 2 pins to the ignition coll 3 Measure the ECM output peak voltage If below specification measure the pulser coil output peak voltage Replace the ECM if the output peak voltage of the pulser coil is above specification Peak voltage adapter B 90890 03172 Test harness 2 pins 90890 06792 ECM output peak voltage Black red B R Ground Black white B W Ground Loaded nl Loaded gt suli Cranking 1 500 3 500 DEV 210 290 20 Checking the pulser coils 1 Remove the junction box cover Discon nect the pulser coil coupler 2 Connect the test harness 3 pins to the pulser coll 6D93G11 Ignition and ignition control system 3 Measure the pulser coil output peak volt age Replace the stator assembly if below specification 56D88080 NOTE Do not loosen the pulser coil screw Digital circuit tester 90890 03174 1 Peak voltage adapter B 90890 03172 Test harness
40. 3 pins 90890 06791 Pulser coil output peak voltage White red W R Black B White black W B Black B se Ua Toaded i Pulser coil resistance reference data 459 561 Q Checking the sensor assembly 1 Measure the ambient temperature 8 8 ELEC 7 ELEC m Electrical systems 2 Connect a computer to the outboard motor and use the Diagnostic System to display the intake air tempera ture S6D88160 3 If the ambient temperature and the dis played intake air temperature differ by more than 5 C 9 F replace the sensor assembly NOTE Check the sensor assembly when the engine is cold Checking the cooling water temperature sensor 1 Placethe cooling water temperature sen sor in a container of water and slowly heat the water 00 0 d ba 56948230 2 Measure the cooling water temperature sensor resistance Replace if out of spec ification Cooling water temperature sensor resistance at 0 C 32 F 5 21 6 37 KQ at 80 C 176 F 0 290 0 354 kQ 8 9 Checking the oil pressure switch 1 Check the oil pressure switch for continu ity Replace if there is no continuity 2 Connect the special service tool to the oil pressure switch 3 Slowly operate the special service tool 56068180 4 Check the oil pressure switch for no con tinuity at the specified pressure Replace if there is continuity Vacuum pressure pump gauge set 9089
41. 6D93G11 Predelivery checks S69J1210 Checking the power trim and tilt system 1 Check that the outboard motor tilts up and down smoothly when operating the power trim and tilt unit 2 Check that there is no abnormal noise produced when the outboard motor is tilted up or down 3 Check that there is no interference with wires or hoses when the tilted up out board motor is steered 4 Check that the trim meter points down when the outboard motor is tilted all the way down Checking the engine start switch and engine stop lanyard switch 1 Check that the engine starts when the engine start switch is turned to START 2 Check that the engine turns off when the engine start switch is turned to OFF S60V1070 1 8 eum General information 3 Check that the engine turns off when the engine stop lanyard is pulled from the engine stop lanyard switch 569J1220 Checking the cooling water pilot hole 1 Check that cooling water is discharged from the cooling water pilot hole IN 4 do S63P3120 Test run 1 Start the engine and then check that the gear shift operates smoothly 2 Check the engine idle speed after the engine has been warmed up 3 Operate at trolling speed 4 Run the outboard motor for 1 hour at 2 000 r min or at half throttle then for another hour at 3 000 r min or at 3 4 throttle 5 Check that the outboard motor does not tilt up when shifting into rever
42. Assembling the power trim and A rali EA 7 29 Assembling the power trim and A ca 7 41 Assembling the power unit 5 50 Assembling the propeller shaft SS HS 6 12 Assembling the propeller shaft housing 6 13 Assembling the tilt cylinder 7 39 Assembling the upper case 7 15 Assembling the vapor separator 4 17 B SA EE gr 6 28 Bleeding the power trim and tilt unit 7 43 Bleeding the power trim and tilt unit DU IN EE eis 7 44 BOHOM COWING a 7 3 BOW VIEW use 8 5 Bracket ilb usse botas toU a re 3 11 9 13 Break iN eese nennen nnns 1 9 C OU o 4 19 Changing the engine oil by draining it 3 4 Changing the engine oil using AN OL CAT arr 3 4 Changing the gear oil 3 12 Charging System aan aa 8 16 Checking the anodes 3 14 Checking the armature 8 15 Checking the battery 1 7 3 14 Checking the bearings 6 18 Checking the brushes 8 16 Checking the camshatfts 5 32 Checking the Canister 4 20 Checking the compression pressure 5 9 6D93G11 Index Checking the connecting rod big end side cleatatiee on ae 5 43 Checking the cooling water passage 3 8 Checking the
43. Connect the test harness 6 pins between the Rectifier Regulator and sta tor coil coupler 3 Disconnect the test harness coupler and then measure the Rectifier Regulator output peak voltage at the coupler Q If below specification measure the stator coil output peak voltage Replace the Rectifier Regulator if the output peak voltage of the stator coil is above specifi cation 8 17 6D93G11 TRBL dd 6D93G11 Troubleshooting Special Service tools nn ae 9 1 Selva Diagnostic System s2u uu nn 9 2 HAT OCUCTION id 9 2 POWer Unit se 9 5 Bracket nite sisya ae 9 13 Electrical systemsS ila 9 17 SE CIA NOS Siria 9 18 Diagnosing the electronic control SyStem nennen nennen 9 18 TRBL e SHTG e Troubleshooting Special service tools Diagnostic System 60V 85300 02 IT YAMAHA ours 220 EL CS WATERCRAFT Diagnostic System 60V WS853 02 Diagnostic flash indicator B 90890 06865 9 1 6D93G 11 Special tools Diagnostic System Diagnostic System Introduction Features The newly developed Diagnostic System provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods By connecting your computer to the ECM Electronic Control Module of an outboard motor using the communication cable this software can be used to display sensor data and data stored in the ECM on a computer s monitor If this s
44. Cotter pin Bushing Lever M6 x 25 mm CO N DU Bb WN 4 x 16 mm M6 x 50 mm Not reusable 1 1 1 1 2 2 1 1 2 1 1 2 1 1 1 1 1 6D93G1 1 1 2 BRKT Bracket unit Bottom cowling A 2N m 0 2 kgf m 1 5 ft Ib S6D87020 Part name dy Bolt M6 x 16 mm Washer Lever Washer Bushing Bolt Base Lever Spring Bolt Hook Cooling water outlet Canister outlet Bolt Grommet Collar Grommet M6 x 30 mm M6 x 20 mm M8 x 35 mm OI OT A 5 n n n rnc rn zdmgi rsrmmI T 7 3 6D93G11 Bottom cowling 2 N m 0 2 kgf m 1 5 ft Ib S6D87020 Part name Bottom cowling Grommet Collar Bolt Holder Bolt Bracket Bolt Plate Power trim and tilt switch Grommet Grommet Bolt Plate Grommet Screw Bracket M6 x 20 mm M6 x 20 mm M6 x 25 mm M6 x 20 mm 6 x 19 mm 1 4 4 1 1 2 1 3 3 1 1 3 1 1 1 2 1 6D93G1 1 7 4 BRKT Bracket unit 7 9 Part name Adapter Gasket Joint Joint Plastic tie Hose Bolt Bolt Retaining plate Bolt Plate Grommet Rubber seal Clamp A 2N m 0 2 kgf m 1 5 ft Ib S6D87020 gt LL NI gt db o a i i Not reusable M6 x 20 mm M6 x 25 mm M6 x 20 mm 6D93G11 Bottom cowling Upper case Upper case 51 N m 5 1 kgf m 37 6 ft Ib A IX 3 N m 0 3 kgf m 2 2 ft Ib S6D87030 Part name Remarks Not reusable M6 x
45. Hypoid gear oil API GL 4 SAE 90 4 Install the check screw and then tighten it to the specified torque Gear oil check screw 9 N m 0 9 kgf m 6 6 ft lb Changing the gear oil 1 Tilt the outboard motor up slightly 2 Place a drain pan under the drain screw D remove the drain screw then the check screw and let the oil drain com pletely 6D93G11 3 Bracket unit Lower unit S60V3330 Check the oil for metal and discoloration and its viscosity Check the internal parts of the lower case if necessary 3 12 TA ADJ Periodic checks and adjustments 4 Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible S60V3340 S60V3350 Recommended gear oil Hypoid gear oil API GL 4 SAE 90 Gear oil quantity 670 cm 22 7 US oz 23 6 Imp oz 5 Install the check screw and quickly install the drain screw and then tighten them to the specified torque Gear oil check screw and drain screw 9 N m 0 9 kgf m 6 6 ft lb Checking the lower unit for air leakage 1 Remove the check screw 1 and then install the special service tool 3 13 S60V3370 2 Apply the specified pressure to check that the pressure is maintained in the lower unit for at least 10 seconds CAUTION Do not over pressurize the lower unit oth erwise the oil seals can be damaged NO
46. N m 4 2 kgf m 31 0 ft lb 2nd 42 N m 4 2 kgf m 31 0 ft lb Apron screw 4 N m 0 4 kgf m 3 0 ft lb 4 Install the oil dipstick 5 Connect the flushing hose cooling water pilot hose and canister hose 5 52 Power unit 6 Connect the fuel hose and shift position switch coupler 7 Connect the PTT motor leads and PTT switch coupler and then install the junc tion box cover PTT motor lead bolt 4 N m 0 4 kgf m 3 0 ft lb Positive battery lead nut 9 N m 0 9 kgf m 6 6 ft lb 9 Connect the shift cable and throttle cable and then adjust their lengths For adjustment procedures see Chapter 3 Adjusting the throttle link and throttle cable and Checking the gear shift oper ation 10 Install all parts removed during disas sembly 11 Check the engine oil level 9 E S60C1150 NOTE If the engine oil is below the minimum level mark add sufficient oil until the level is between and Recommended engine oil 4 stroke motor oil API SE SF SG SH or SJ SAE 10W 30 or 10W 40 0 93 6D93G11 Lower unit Speelal service TOONS un een 6 1 LEONE UN ua 6 4 REMOVING the lower UNIt e 6 8 Removing the water pump and shift F0d Rennen nennen 6 9 Disassembling the oil seal housing nenne nnenn nennen 6 9 Checking the water pump and shift F0d i 6 9 Propeller shaft housing
47. NN PO I 30 3 30 6 mm 1 19 1 20 in M6 x 10 mm 96 x 15 mm M6 x 10 mm 7 20 BRKT Bracket unit Removing the clamp brackets 1 Remove the power trim and tilt unit For removal procedure see Removing the power trim and tilt unit 2 Remove the anode 1 3 Disconnect the ground lead 4 Remove the trim sensor cam screw 8 5 Loosen the self locking nut amp and the bolt and then remove clamp brackets and 6 Remove the trim sensor 7 Remove the tilt stop lever 56D87510 Installing the clamp brackets 1 Install the trim sensor 1 onto the swivel REL EG P WE UP NOTE Adjust the trim sensor after installing the power trim and tilt unit 2 Assemble the clamp brackets and the swivel bracket by installing the anode 2 bolt and self locking nut 2 then tight ening the nut to the specified torque S6D87520 Self locking nut 4 15 Nm 1 5 kgf m 11 1 ft lb 3 Install the power trim and tilt unit For installation procedure see Installing the power trim and tilt unit Adjusting the trim sensor 1 Fully retract the power trim and tilt unit 2 Loosen the trim sensor cam screw 1 3 Adjust the trim sensor cam where the specified trim sensor setting resistance is obtained 6D93G11 AD RE Ge Trim sensor setting resistance Pink P Black B 10 1 Q at 20 C 68 F Trim sensor cam screw 1
48. according to the flash pattern NOTE When more than one problem is detected the light of the special service tool flashes in the pattern of the lowest numbered problem After that problem is corrected the light flashes in the pattern of the next lowest num bered problem This continues until all of the problems are detected and corrected Symptom Incorrect pulser coil signal 15 Incorrect cooling water temperature sensor signal Incorrect throttle position sensor signal 19 Incorrect battery voltage Incorrect sensor assembly intake air temperature signal Incorrect shift position switch signal Incorrect sensor assembly intake air pressure signal Incorrect idle speed control signal Incorrect engine stop lanyard switch signal 49 Over cool signal 9 19 6D93G11 A Adjusting Metodo cias 4 17 Adjusting the throttle link and throttle cable ases 3 8 Adjusting the trim sensor 7 21 After test run anaren 1 9 Applicable model 1 5 Assembling the drive shaft 6 20 Assembling the forward gear 6 19 Assembling the fuel pump 4 6 Assembling the gear pump 7 33 Assembling the lower case 6 19 Assembling the oil pan 7 14 Assembling the oil pump 7 12
49. and then tighten it to the specified torque NOTE Repeat this procedure until the fluid remains at the correct level Reservoir cap 7 N m 0 7 kgf m 5 2 ft lb Power trim and tilt electrical system Checking the fuse 1 Check the fuse for continuity Replace if there is no continuity Checking the power trim and tilt relay 1 Check the power trim and tilt relay for continuity Replace if out of specification Ne CTC DST oe JOCI ae LS OE B CIA 563P7370 NOTE ____ __ 1 4 14 4 Be sure to set the measurement range 8 shown in the illustration when checking for continuity 6D93G11 Tilt cylinder and trim cylinder Power trim and tilt electrical system LI mi Power trim and tilt relay continuity Sky blue Sb Black B TP Light green Lg Black B Unulty Terminal 1 Terminal 4 Terminal 2 Terminal 4 EY Terminal 1 Terminal 8 Terminal 2 Terminal 3 Bs UG 2 Connect the digital circuit tester between power trim and tilt relay terminals 2 and Q 3 Connect the light green Lg lead to the positive battery terminal and the black B lead to the negative battery terminal as shown 4 Check for continuity between terminals and 3 Replace if there is no continu ity 563P7380 5 Connect the digital circuit tester between power trim and tilt relay terminals 1 and 3 6 Conn
50. and tilt relay 7 45 Checking the power trim and tilt switch 7 46 Checking the power trim and tilt system 1 8 Checking the pressure control valve 5 39 Checking the pressure regulator 4 14 Checking the propeller 3 13 Checking the propeller shaft 6 12 Checking the propeller shaft housing 6 12 Checking the pulser coils 8 8 Checking the Rectifier Regulator 8 17 Checking the remote control cables 1 7 Checking the sensor assembly 8 8 Checking the shift position switch 8 9 Checking the spark plug wires 8 7 Checking the spark plugs 3 6 Checking the starter motor operation 8 16 Checking the starter motor pinion 8 15 Checking the starter relay 8 11 Checking the stator coil 8 16 Checking the steering system 1 8 Checking the thermostat 3 7 Checking the throttle position sensor 4 9 Checking the tilt cylinder and IIA 7 39 Checking the timing belt 3 6 Checking the timing belt and sprockets 5 18 Checking the top cowling 3 3 Checking the trim sensor 7 47 Checking the valve clearance
51. arrows shown to prevent the flywheel holder from slipping off easily NOTE _ Apply engine oil to the flywheel magnet nut before installation Flywheel holder 90890 06522 ES Flywheel magnet nut 215 N m 21 5 kgf m 158 6 ft lb 20 Install the flywheel magnet cover Removing the power unit NOTE It is recommended to loosen the flywheel magnet nut before removing the power unit to improve working efficiency 1 Remove the flywheel magnet cover 2 Disconnect the battery leads 3 Remove the junction box cover and then disconnect the PTT motor leads and PTT switch coupler 4 Disconnect the throttle cable and shift cable 6D93G11 Power unit 5 Disconnect the fuel hose and shift posi tion switch coupler 6 Disconnect the cooling water pilot hose canister hose and flushing hose 7 Remove the oll dipstick 8 Remove the apron 1 and then remove the power unit by removing the bolts S6D85350 9 Remove the flywheel magnet 5 16 Power unit Removing the timing belt and sprockets NOTE 0 0 0 0 0 0 0 0 0 0 0 000 P Use a deep socket 2 for this procedure CAUTION Do not turn the camshaft when loosening eee the drive sprocket nut Do not turn the drive sprocket counter clockwise otherwise the valve system may be damaged Crankshaft holder 20 e Do not turn the drive sprocket or the A 90890 06552 driven sprockets
52. block Renee nenn nennen nennen 5 41 Checking the piston diameter ii 5 41 Checking the cylinder bore aera i e 5 42 Checking the piston clearance i 5 42 Ghecking ine piston TINGS ase ei alain 5 42 Checking the piston ring grooves nennen nn 5 43 Checking the piston ring side clearance nennen een 5 43 Checking the connecting rod big end side clearance 5 43 Ghecking the crankshalk e 2 de 5 44 Checking the crankpin oil clearance 5 44 Selecting the connecting rod bearing nennen nnennnnn een 5 46 Checking the crankshaft journal oil clearance 5 47 Selecting the main bearing E 5 48 Assembling the power UNIT 5 50 Installing the power UML erinnern 5 52 6D93G11 Power unit Special service tools Compression gauge 90890 03160 Compression gauge extension M14 90890 06563 Flywheel holder 90890 06522 Os SD Dy E 2 Flywheel puller 90890 06521 Crankshaft holder 20 90890 06552 5 1 Valve spring compressor 90890 04019 NAO Valve spring compressor attachment 90890 06320 A Valve guide remover installer 5 9 90890 04064 di Valve guide reamer 6 0 90890 04066 R Valve seat cutter holder 90890 06553 6D93G11 Special service tools e
53. cooling water pilot hole 1 9 Checking the cooling water temperature SMS 8 9 Checking the crankpin oil clearance 5 44 Checking the crankshaft 5 44 Checking the crankshaft journal oil clearance nennen 5 47 Checking the cylinder bore 5 42 Checking the cylinder head 5 32 Checking the diaphragm and valves 4 6 Checking the drive shaft 6 18 Checking the drive shaft bushing 7 13 Checking the ECM een 8 8 Checking the electric fuel pump 8 10 Checking the electrical components 8 2 Checking the engine idle speed 3 8 Checking the engine oil 3 4 Checking the engine oil level 1 6 Checking the engine start switch and engine stop lanyard switch 1 8 Checking the fuel filter 3 3 Checking the fuel joint and fuel hoses fuel joint to fuel injector 3 3 Checking the fuel pump 4 5 Checking the fuel system 1 6 Checking the fuse 7 45 Checking the fuses 8 11 Checking the gear oil level 1 7 3 12 Checking the gear pump 33 Checking the gear s
54. e Apply engine oil to the driven sprocket bolts before installation e Do not turn the camshafts when tightening the driven sprocket bolts Flywheel holder 90890 06522 Driven sprocket bolt 2 60 N m 6 0 kgf m 44 3 ft lb 5 18 Power unit 3 Install the retaining plate Woodruff key 4 drive sprocket 5 and nut and then tighten the nut 4 a S60C5240 NOTE e Apply engine oil to the drive sprocket nut before installation Tighten the drive sprocket nut finger tight 4 Check that the hole on the retaining plate is aligned with the projection on the cylinder block S6D85300 5 Install the timing belt and timing belt ten sioner NOTE For timing belt installation procedure see Replacing the timing belt 5 19 6 Tighten the drive sprocket nut to the specified torque BN S6D85410 NOTE Use a deep socket for this procedure v Crankshaft holder 20 8 90890 06552 N Drive sprocket nut 265 N m 26 5 kgf m 195 5 ft lb 6D93G11 Power unit Throttle link Throttle link S6D84140 Part name M6 x 35 mm Throttle cam Bolt Collar Wave washer Washer Spring Washer Throttle lever Bolt Collar Throttle link rod Nut Throttle link rod joint Bracket Bolt M6 x 25 mm M6 x 30 mm 6D93G11 5 20 Power unit ECM S6D85050 Part name Remarks Wiring harness Bracket Bolt Bolt Bracket Bracket Bracket
55. esses 1 8 Checking the engine start switch and engine stop lanyard switch 1 8 Checking the cooling water pilot hole esee 1 9 Ialia 1 9 OT 1 9 NM T T TU MTM 1 9 How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under General information stand Use the information below as a guide for effective and quality service CD Parts are shown and detailed in an exploded diagram and are listed in the components list Tightening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions 3 Symbols are used to indicate important aspects of a procedure such as the grade of lubricant and lubrication point 4 The components list consists of part names and part quantities as well as bolt and screw dimen SIONS Service points regarding removal checking and installation are shown in individual illustrations to explain the relevant procedure NOTE For troubleshooting procedures see Chapter 9 Troubleshooting Lower Lower unit unit 0 N m 4 0 kgf m za y w Z o Part name 8 amp 562Y6480K Remarks Lower unit Plastic tie Hose Check screw Gasket Dowel pin Bolt Drain screw Grommet Bolt Bolt Thrust washer 1 2 9 4 5 6 7 8 Propeller Washer Washer Cotter pin Propeller nut
56. gauge first cover the connection between the gauge and the adapter with a clean dry rag to prevent fuel from leaking out e Gently screw in the gauge until it is firmly connected Fuel pressure gauge adapter B 90890 06942 Fuel pressure gauge 2 90890 06786 4 Turn the engine start switch to ON and then measure the fuel pressure within 3 seconds NOTE The fuel pressure decreases 3 seconds after the engine start switch is turned to ON Fuel pressure reference data 300 kPa 3 0 kgf cm 43 5 psi 5 Measure the fuel pressure 3 seconds after turning the engine start switch to ON Fuel pressure reference data 260 kPa 2 6 kgf cm 37 7 psi Start the engine warm it up for 5 min utes and then measure the fuel pres sure If below specification check the high pressure fuel line and the vapor separator o 6D93G11 Vapor separator Fuel pressure reference data 230 kPa 2 3 kgf cm 33 4 psi ds WARNING Before measuring the fuel pressure make sure that the drain screw is tight ened securely Do not loosen the drain screw while measuring the fuel pressure Loosening the drain screw can cause fuel to spray out creating a fire hazard After measuring the fuel pressure cover the end of the hose with a clean dry rag point the hose downward and then loosen the drain screw to drain the remaining fuel from the hose and gauge When storing the fuel pressure gauge make sure t
57. gt joint 3 4 Loosen the locknut 2 and then discon nect the throttle link rod joint 5 from the ball joint of the throttle body A o N S6D83110 i Adjust the throttle link rod joint to align its 8 ral hole with the ball joint on the throttle TS Ma O 1 S6D83090 5 Check that the stopper amp on the throttle cam contacts the fully closed stopper 7 on the cylinder block en S6D83120 9 Connect the throttle link rod joint and then tighten the locknut 10 Operate the throttle cam to check that the throttle valve fully closes and fully opens and check that the gap between the stopper di on the throttle lever and fully open stopper 2 on the throttle body is less than 5 mm 0 20 in S6D83100 when the throttle cam is in the fully open position 6 Check that the throttle valve fully close NOTE Do not turn the throttle stop screw 7 Push the throttle link rod toward the cylinder head and check that the throttle cam roller contacts the side of the throttle cam S6D83130 11 Adjust the position of the throttle cable joint until its hole is aligned with the set pin on the throttle cam 3 9 6D93G11 jun dope 56943370 A WARNING The throttle cable joint must be screwed in a minimum of 8 0 mm 0 31 in 12 Connect the throttle cable joint install the clip and then tighten the locknut 13 Check the throttle cable for smooth oper atio
58. magnet clock wise check the interior and the exte rior of the timing belt for cracks damage or wear Replace if necessary T Z Ey Hi f S6D83070 NOTE _ _ PPr For replacement procedures see Chapter 5 Replacing the timing belt Checking the spark plugs 1 Removethe spark plug wire cover 2 Disconnect the spark plug wires and then remove the spark plugs 3 Clean the electrodes 1 with a spark plug cleaner or wire brush Replace the spark plug if necessary 56943190 4 Check the electrodes for erosion and excessive carbon or other deposits and the gasket for damage Replace the spark plug if necessary 3 6 TA ADJ Periodic checks and adjustments 5 Check the spark plug gap Adjust if out of specification 569J3200 Specified spark plug LFR5A 11 NGK Spark plug gap 1 0 1 1 mm 0 039 0 043 in 6 Install the spark plugs tighten them fin ger tight then to the specified torque using a spark plug wrench Spark plug 25 N m 2 5 kgf m 18 4 ft lb 7 Install the spark plug wire cover Spark plug wire cover screw 4 N m 0 4 kgf m 3 0 ft lb Checking the thermostat 1 Remove the flywheel magnet cover 2 Disconnect the cooling water hose 1 and then remove the thermostat cover 2 and thermostat 3 3 S6D83080 3 Suspend the thermostat in a container of water A Place a thermometer in th
59. motor 1 Remove the power trim and tilt motor O ring and joint from the power trim and tilt unit S6D87300 CAUTION e Make sure that the tilt ram is fully extended when removing the power trim and tilt motor otherwise fluid can spurt out from the unit due to internal pres sure Do not push the tilt ram down while the power trim and tilt motor is removed from the power trim and tilt unit other wise fluid can spurt out 2 Remove the stator 1 56D87310 NOTE re Place a clean cloth over the end of the arma ture shaft hold it with a pair of pliers and then carefully slide the stator off of the arma ture 1 21 3 Remove the armature from the PIT motor base CAUTION Do not allow grease or oil to contact the commutator 4 Remove the screws Q and then disas semble the PTT motor base 56D87320 Checking the power trim and tilt motor 1 Check the commutator for dirt Clean with 600 grit sandpaper and com pressed air if necessary 69J8390 2 Measure the commutator diameter Replace the armature if below specifica tion 6D93G11 Power trim and tilt motor 5 Check the circuit breaker for continuity Replace if there is no continuity 56948400 Commutator diameter wear limit S62Y7930 21 0 mm 0 83 in 6 Measure the brush length Replace if 3 Measure the commutator undercut below specification Replace the armature if below specifica tion 562Y7940
60. otherwise specified torque specifications require clean dry threads Components should be at room temperature ees O a OT Gear pump bolt C1 Relief valve cap bolt i H Gear pump bracket bolt i 569J2150 213 6D93G11 CHK ADJ 6D93G 11 Periodic checks and adjustments Special Service TOONS ee 3 1 Maintenance interval Chat una 3 2 TOP COWING eee 3 3 Checking the top COWNMG isaac 3 3 A Ao PP ee 3 3 Checking the fuel joint and fuel hoses fuel joint to fuel injector 3 3 Gh cking he Tuel Mera 3 3 POWEL UN ii is 3 4 CHECKING IG SMO MMS Ol een aa 3 4 Changing the engine oil using an oil changer een een 3 4 Changing the engine oil by draining it i 3 4 Replacing Meo Ner ee een 3 5 Checking the TIMING bell rie aaa 3 6 Checking the spark PIUGS sir lai 3 6 Checking the thermostat nenn 3 7 Checking the cooling water passage nennen 3 8 Control VS TEN 3 8 Checking the engine idle speed i 3 8 Adjusting the throttle link and throttle Cable nn 3 8 Checking the gear shift operation nn nenne nnnennnnnnen nenne 3 10 Bracket UNN gem 3 11 Checking the power trim and tilt operation een 3 11 Checking the power trim and tilt fluid level 3 11 LOWEN UNA dai 3 12 Checking the gear oil level
61. pe RR 6 10 Removing the propeller shaft housing assembly 6 11 Disassembling the propeller shaft assembly Rennen 6 11 Disassembling the propeller shaft NOUSINQ nennen 6 11 Checking the propeller shaft housing i 6 12 Checking the propeller shaft sees 6 12 Assembling the propeller shaft assembly ssuueuessse 6 12 Assembling the propeller shaft housing esses 6 13 Drive shaft and lower CaSe r annurnanunnnnnunnnnunnnnnvnnnnuennnnvnnnnnennnnvnnnnnennnnvennnnenen 6 15 Removing the ME ST ae 6 17 Disassembling the drive shaft nennen nennen nennen 6 17 Disassembling the forward gear nennen nenne nenn 6 17 Disassembling the lower case nenne nnnnn nenne nenne nennen 6 17 Checking the pinion and forward gear i 6 18 Checking The bearings os copied tee aan 6 18 Checking the drive shaft nennen nnnnnnnnennennnn nenn 6 18 Ghe ecking ilie lower case u seien 6 18 Assembling the lower case uazusssssnsenennennnnnennnnnnnnnnennnnnnnnnne nennen nennen 6 19 Assembling the forward gear ii 6 19 Assembling the drive shaft iii 6 20 Instaling ihesdgrive shall ae 6 20 Installing the propeller shaft housing nennen 6 20 Insta
62. r min 5 000 6 000 Maximum fuel consumption L US gal 28 0 7 40 6 16 at 35 0 9 2 7 7 at Imp gal hr 6 000 r min 6 000 r min Engine idle speed min Power unit Type In line 4 stroke DOHG 16 valves Cylinder quantity 4 Total displacement cm cu in 1 596 97 39 Bore x stroke mm in 79 0 x 81 4 3 11 x 3 20 Compression ratio 9 6 Control system Remote control Starting system Electric Fuel system Fuel injection Ignition control system TCI Advance type Micro computer Maximum generator output 12 25 Spark plug LFR5A 11 NGK Cooling system Water Exhaust system Propeller boss Lubrication system Wet sump 2 1 6D93G11 Item e Te Fuel and oil Fuel type Fuel minimum rating Engine oil Engine oil grade Engine oil quantity without oil filter replacement with oil filter replacement Gear oil type Gear oil grade Gear oil quantity Bracket unit Trim angle at 12 boat transom Tilt up angle Steering angle Drive unit Gear shift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction rear view Propeller mark Electrical Battery minimum capacity CCA EN 20HR IEC 1 RON Research Octane Number RON PON API SAE L US at Imp at L US at Imp at API SAE cm US oz Imp oz General specifications Model Marin 100 ER Regular unleaded gasoline 91 86 4 stroke motor oil SE SF SG SH or SJ 10W 30 or 10W 40 4 3
63. the hose with a clean dry rag point the hose downward and then loosen the drain screw to drain the remaining fuel from the hose and gauge When storing the fuel pressure gauge make sure that the drain screw is tight ened securely NOTE A When the vacuum pressure reaches the specified level the fuel pressure reduces Draining the fuel 1 Remove the cap 2 Cover the pressure check valve of the vapor separator with a rag and then press in the pressure check valve a using a thin screwdriver to release the fuel pressure ds WARNING Always reduce the fuel pressure in the high pressure fuel line before servicing the line or the vapor separator If the fuel pressure is not released pressurized fuel may spray out 3 Place a container under the vapor sepa rator drain hose and then loosen the drain screw 4 Drain the fuel from the vapor separator drain hose by pressing the pressure check valve using a thin screwdriver 6D93G11 tj 56D84100 A WARNING Reduce the fuel pressure before loosen ing the vapor separator drain screw or pressurized fuel will spray out and may result in serious injury Removing the fuel hose clamp 1 Remove the fuel hose clamp by cutting the crimped section of the clamp LIP 56944030 CAUTION If the fuel hose clamp is removed without cutting the crimp first the fuel hose will be damaged Installing the fuel hose clamp 1 Crimp the fuel hose clamp proper
64. to the specified torque 56D87460 PIT motor bolt 4 N m 0 4 kgf m 3 0 ft lb 6 Add fluid of the recommended type to the first level at the bottom of the trim cylin der 7 Install the balls 6 into the tilt cylinder and then insert the tilt cylinder into the trim cylinder 6D93G11 Tilt cylinder and trim cylinder 56017760 NOTE A AAA Apply grease to the balls from falling out of the cylinder installation 8 Install the trim cylinder end screw 8 and then tighten it to the specified torque 56D87660 Cylinder end screw wrench New 90890 06568 Current 90890 06544 Trim cylinder end screw 8 90 N m 9 0 kgf m 66 4 ft lb 9 Fully extend the tilt rod and then add suf ficient fluid of the recommended type to the correct level 7 42 BRKT Bracket unit 10 Install the reservoir cap S6C17780 Bleeding the power trim and tilt unit 1 Tighten the manual valve 1 by turning it clockwise Manual valve 1 2 N m 0 2 kgf m 1 5 ft lb 2 Place the power trim and tilt unit in an upright position 3 Remove the reservoir cap and then check the fluid level in the reservoir NOTE If the fluid is at the correct level the fluid should overflow out of the filler hole when the reservoir cap is removed 4 If necessary add sufficient fluid of the recommended type until it overflows out of the filler hole Recommended power trim and tilt fluid ATF
65. valve seat cylinder head gasket and cylin der head Adjust or replace if necessary Checking the oil pressure 1 Remove the flywheel magnet cover 2 Place a rag under the oil pressure switch 3 Remove the oil pressure switch and then install an oil pressure gauge D to the oil pressure switch installation hole NOTE Use a general pressure gauge 4 Start the engine and warm it up for 5 min utes 5 Check the oil pressure Check the oil pump oil leakage and oil strainer if below specification Oil pressure reference data 510 kPa 5 1 kgf cm 74 0 psi at engine idle speed 6D93G11 Power unit i 42 N m 4 2 kgf m 31 0 ft Ib P 42 N m 4 2 kgf m 31 0 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib S6D85010 Remarks Damper Grommet Grommet Flywheel magnet cover Power unit Oil dipstick Gasket Dowel Bolt Bolt Screw Nut Apron Bolt Holder Not reusable M6 x 16 mm M10 x 130 mm 6 x 40 mm CO N DU Bb OND M8 x 35 mm 6D93G11 5 4 Power unit 56D85020 Nut Washer Flywheel magnet Screw Screw Stator coil Bolt Stator assembly Collar Bolt Woodruff key Bolt Holder Grommet 4 x 10 mm 6 x 30 mm M6 x 30 mm CO N DU AS DN M6 x 15 mm M6 x 15 mm LL a DD CC FR HSH WHO aaa 5 5 6D93G11 Power unit 265 N m 26 5 kgf m 195 5 ft Ib 39 N m 3 9 kgf m 28 8 ft Ib S6D85030 Timing belt
66. 0 06756 Operating pressure 127 5 166 7 kPa 1 28 1 67 kgf cm 18 49 24 17 psi Checking the shift position switch 1 Check the shift position switch for conti nuity Replace if there is no continuity 56948270 6D93G11 Ignition and ignition control system Fuel control system Switch position uio Black B Checking the main and fuel pump relay main control 1 Remove the main and fuel pump relay Im SS 56D88090 2 Connect the digital circuit tester leads to the relay terminals 2 and 3 3 Connect the positive battery terminal to the relay terminal 4 4 Connect the negative battery terminal to the relay terminal 5 5 Check for continuity between the relay terminals and Replace if there is no continuity 6 Check that there is no continuity between the relay terminals 2 and 3 after dis connecting a battery terminal from the relay terminal 4 or Replace if there is continuity 6D93G11 56D88100 Fuel control system Checking the injectors 1 Measure the resistance of the fuel injec tors 56C14170 Fuel injector resistance reference data 12 0 Q at 21 C 70 F NOTE e e Check the operation of the fuel injectors using the Stationary test of the Selva Diagnostic System Checking the electric fuel pump 1 Turn the engine start switch to ON 8 10 ELEC 7 ELEC m Electrical systems 2 Listen for th
67. 10 Digital caliper 90890 06704 Shimming plate 90890 06701 6 3 Backlash indicator 90890 06706 lt gt Magnet base plate 90890 07003 Dial gauge set 90890 01252 Magnetic base B 90890 06844 6D93G11 Special service tools Lower unit Lower unit 56D96010 Part name Lower unit Hose Check screw Gasket Dowel Bolt Drain screw Grommet Bolt Bolt Spacer Propeller Washer Washer Cotter pin Nut Trim tab Not reusable M10 x 40 mm L transom model CO N DU Bb UN M10 x 45 mm M8 x 60 mm L transom model Not reusable LALA ld do My a 6D93G11 6 4 Lower unit 56D96010 Part name Dowel 2 X transom model Extension 1 X transom model Stud bolt 4 M10 x 180 mm X transom model Washer 4 X transom model Spring washer 4 X transom model Nut 4 X transom model Bolt 1 M8 x 190 mm X transom model 6 5 6D93G11 Lower unit S1104J S6D86040 No Partname Qty Remake Bolt M6 x 16 mm O ring i Oil seal Oil seal housing O ring Circlip Shift rod Woodruff key Screw Bolt Cover Bolt Seal Water pump housing Insert cartridge Impeller Dowel CON DU AS DUNN 94 x 12 mm M8 x 75 mm M8 x 50 mm 4 4 4 4 4 1 2 2 1 2 1 1 1 1 2 6D93G11 6 6 Lower unit S1104J S6D86040 18 Gasket Outer plate cartridge Gasket Oil seal housing O ring Gasket Oil seal 6 6D93G 11 Lower un
68. 4 Power unit 3 Install the valve shims and valve lifters NOTE 0 e Apply engine oil to the valve shims and valve lifters before installation e Install the valve shims and valve lifters in their original positions 4 Install the camshaft intake 1 and cam shaft exhaust with the new oil seals Q 56D85490 NOTE e Apply molybdenum disulfide grease to the cam lobes e Be sure to install the camshaft with the fuel pump drive cam on the intake side 5 Check that the camshaft dowel holes are in the position shown in the illustra tion Adjust if necessary S6D85500 0 35 6 Install the camshaft caps in their proper positions as shown with the stamped numbers upside down 7 Tighten the camshaft cap bolts to the specified torques in two stages and in the sequence shown OO Y NT AA2I I 56D85510 NOTE a Apply engine oil to the camshaft caps and camshaft cap bolts before installation Camshaft cap bolt 1st 8 N m 0 8 kgf m 5 9 ft lb 2nd 17 N m 1 7 kgf m 12 5 ft lb 8 Install the cylinder head cover 6D93G11 S6D85520 Cylinder head cover bolt 1st 8 N m 0 8 kgf m 5 9 ft lb 2nd 8 N m 0 8 kgf m 5 9 ft Ib 9 Install the sprockets and timing belt NOTE For sprocket and timing belt installation pro cedures see Installing the sprockets and timing belt 6D93G11 Cylinder head 0 36 Power unit Exhaust cover
69. 4 55 3 78 4 5 4 76 3 96 Hypoid gear oll GL 4 90 670 22 7 23 6 F N R 2 31 30 13 Spiral bevel gear Dog clutch Spline Clockwise K PON Pump Octane Number RON Motor Octane Number 2 2 Meeting both API and SAE requirements 3 CCA Cold Cranking Ampere EN European Norm European standard IEC International Electrotechnical Commission 6D93G 11 2 2 SPEC UE Specifications Maintenance specification Power unit Power unit Minimum compression kPa 860 8 6 124 7 pressure kgf cm psi Oil pressure kPa 510 5 1 74 0 at engine idle speed kgf cm psi Cylinder head Warpage limit 0 1 0 0039 lines indicate straightedge position Camshaft cap inside diameter 25 000 25 021 0 9843 0 9851 Cylinders Bore size 79 000 79 020 3 1102 3 1110 Taper limit 0 08 0 0031 Out of round limit 0 05 0 0020 Pistons H Piston diameter D pa 78 928 78 949 3 1074 3 1082 Measuring point H 457 j 13 0 0 51 Piston clearance 0 070 0 080 0 0028 0 0031 Over size piston diameter 79 178 79 199 3 1172 3 1181 Piston rings Top ring Dimension B i 1 17 1 19 0 0461 0 0469 Dimension T 2 80 3 00 0 1102 0 1181 End gap 0 15 0 30 0 0059 0 0118 Side clearance 0 04 0 08 0 0016 0 0031 2nd piston ring Dimension B 1 47 1 49 0 0579 0 0587 Dimension T 3 00 3 20 0 1181 0 1260 End gap 0 70 0 90 0 0276 0 0354 Side clearance 0 03 0 07 0 0012 0 0028 1 Me
70. 43 992 3 058 mm Suitable colors Upper bearing gt blue Lower bearing red 6 If the calculated value is more than the maximum value 3 063 mm replace the connecting rod or crankshaft or both 9 4 Checking the crankshaft journal oil clearance 1 Clean the bearings the crankshaft jour nals the bearing portions of the crank case and the cylinder block 2 Place the cylinder block upside down on abench 3 Install half of the bearings and the crankshaft into the cylinder block S60C5910 NOTE e Install the bearings in their original posi tions Install the unified thrust bearing at the posi tion Q shown 4 Put a piece of Plastigauge PG 1 on each crankshaft journal parallel to the crankshaft 56065920 NOTE M Do not put the Plastigauge PG 1 over the oil hole in the main journals of the crankshaft 6D93G11 5 Install the remaining half of the bearings into the crankcase 6 Install the crankcase onto the cylinder block and apply engine oil onto the threads of the crankcase bolts 7 Tighten the crankcase bolts to the speci fied torques in two stages and in the sequence shown NOTE Do not move the crankshaft until the crank shaft journal oil clearance measurement has been completed e Tighten the M10 bolts to 19 N m 1 9 kgf m 14 0 ft lb first and then tighten the M8 bolts to 14 N m 1 4 kgf m 10 3 ft lb Make a mark on the M10 bolts and
71. 45 mm Oil seal Bolt Oil pump assembly Dowel O ring Upper case assembly Cover Bolt Grommet Grommet Nut Nut Washer Washer Grease nipple Bolt Ground lead Not reusable CO N DU AS WN M10x40mm M8 x 16mm NNNN SN SM Q Q 05 6D93G11 7 6 BRKT Bracket unit 1 1 Oil seal Screw Gasket O ring Shaft O ring Oil seal Oil seal O ring Oil seal housing Screw Oil pump assembly gt bh N A ao Not reusable 96 x 10 mm Not reusable Not reusable 6 X 10 mm Remarks 56D97010 6D93G 11 Upper case 4 N m 0 4 kgf m 3 0 ft Ib 20 N m 2 0 kgf m 14 8 ft Ib E DS 28 N m 2 8 kgf m 20 7 ft Ib S6D97020 Part name Remarks Bolt Upper mount Plate Washer Washer Bolt Bolt Muffler assembly Gasket Drain bolt Damper Rubber seal Gasket Gasket Screw Baffle plate Grommet M8 x 45 mm M12 x 194 mm M8 x 40 mm CO N DU BE ON M14 x 12 mm Not reusable Not reusable 96 x 15 mm 3 1 1 2 2 2 4 1 1 1 1 1 1 1 2 1 1 6D93G11 7 8 BRKT Bracket unit a 20 N m 2 0 kgf m 14 8 ft gt Ib A 28 N m 2 8 kgf m 20 7 ft Ib S6D97020 Part name Remarks Dowel Upper case Drive shaft bushing Circlip Lower mount Washer Washer Washer Bolt 2 1 1 1 2 2 2 2 2 M12 x 200 mm 7 9 6D93G11 Upper case 11N m 56D87060 Remarks
72. 5 10 Checking the valve guides 5 28 Checking the valve lifters 5 27 Checking the valve seat 5 29 Checking the valve springs 5 27 Checking the valves 5 27 7 39 Checking the vapor separator 4 16 Checking the water pump and shift rod 6 9 Clamp brackets and swivel bracket 7 19 Control system 3 8 Cylinder block RR 0 5 40 Cylinder lead auc De rco pen ect ont 5 24 D Diagnosing the electronic control G SV SIC IN aa 9 18 DIMENSIONS Lee 2 9 Disassembling the cylinder block 5 41 Disassembling the drive shaft 6 17 Disassembling the forward gear 6 17 Disassembling the fuel pump 4 5 Disassembling the gear pump 7 33 Disassembling the lower case 6 17 Disassembling the oil pan 7 13 Disassembling the oil pump 7 12 Disassembling the oil seal housing 6 9 Disassembling the power trim and Ulmo pare 7 27 Disassembling the propeller shaft asSsemDIY nas 6 11 Disassembling the propeller shaft housing nennen 6 11 Disassembling the starter motor 8 15 Disassembling the tilt cylinder 7 38 Disassembling the trim cylinder
73. 7 Adjusting ING Tlodl 32 oi nt pd e oct ese nisus atrets er 4 17 Canisius eiat Tati Eee aa 4 19 Gheeking NE ANSEES 4 20 ver i Fuel system Special service tools Vacuum pressure pump gauge set 90890 06756 Fuel pressure gauge 90890 06786 Fuel pressure gauge adapter B 90890 06942 4 1 6D93G11 Hose routing Fuel and blowby hoses 1 Blowby hose Fuel hose primary pump to fuel filter Fuel hose fuel filter to fuel pump Fuel hose fuel pump to strainer 6 Fuel hose strainer to vapor separator amp High pressure fuel hose vapor separator to fuel rail Fuel hose pressure regulator to fuel cooler Fuel hose fuel cooler to vapor separator 9 Canister hose vapor separator to canister Canister hose canister to idle speed control AD Canister hose canister to filter 2 Canister hose filter to bottom cowling NN 6D93G11 Special service tools Hose routing 56D84010 vel D Fuel system Fuel filter and fuel pump 10 N m 1 0 kgf m 7 4 ft Ib 13 N m 0 3 kgf m 2 2 ft Ib Jor a i Sim ae III S6D84020 Remarks Nut Fuel filter assembly O ring Fuel filter element O ring Float Cup Fuel hose Fuel pump Bolt Fuel hose Strainer Bolt Bracket O ring Not reusable Not reusable CO N DU AS DN M6 x 30 mm M6 x 12 mm 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 Not reusable 4 3 6D93G11 Fuel filter and fuel pump M14 N
74. 7 38 Disassembling the upper case 7 13 Disassembling the vapor separator 4 16 Disassembly and assembly 1 4 Disconnecting the quick connector 4 13 Draining the fuel suus 4 15 Drive shaft and lower case 6 15 FOM 5 21 FEN a eli 2 6 Electrical components 8 3 Electrical Systems an nina 9 17 Exhaust COVEr nennen 5 37 Fire prevention iii 1 3 Fuel and blowby hoses 4 2 Fuel control system 8 10 Fuel filter and fuel pump 4 3 Fuel system i 3 3 Gear PUMP dci 7 30 A a 3 14 General specifications 2 1 General torques eeeeeseeeeeees 2 13 Good working practices 1 4 6D93G11 H J L Hose ION ae 4 2 How to use this manual 1 1 Identification iata een 1 5 Ignition and ignition control system 8 7 Installing the clamp brackets 7 21 Installing the cylinder head 5 34 Installing the drive shaft 6 20 Installing the exhaust cover 5 39 Installing the fuel hose clamp 4 16 Installing the lower unit
75. 8 Self protection nia 1 3 Serial MUNDO assalire 1 5 MIL TOO ee 7 2 SHIMMINd A DO 6 25 6 26 Special service Olsen 3 1 4 1 5 1 6 1 7 1 8 1 9 1 Specified torques 2 11 Starboard VIEW a 8 4 Starter MOtOr a 8 13 Starting SYStem ii 8 11 Steering arm ii 7 17 SVITDOIlS te laica 1 2 Lest tina 1 9 Trote Mk eures 5 20 Tightening torques 2 11 Tilt cylinder and trim cylinder 7 35 TOP COMING a een 3 3 TOO VOW en 8 6 Index U Upper Svene 7 6 V Vapor separator usa 4 10 iare een 1 3 Y Diagnostic System 9 2 6D93G11 Index MEMO 6D93G11 1 5 Wiring diagram CD Ignition coil 2 Spark plug 3 Power trim and tilt switch tiller handle optional Power trim and tilt switch bottom cowling Battery Cooling water temperature sensor 7 Starter motor Fuse 30 A 9 Fuse 20 A Neutral switch optional AD Starter relay Power trim and tilt relay d3 Trim sensor Power trim and tilt motor 5 Electric fuel pump Main and fuel pump relay 2 Diode Oil pressure switch Pulser coil 6 Stator coil 0 Rectifier Regulator ECM 3 Throttle position sensor 4 Shift position switch Sensor assembly Fuel injector Idle speed control Variable trolling R
76. 88 0 1191 3 024 3 031 0 1191 0 1193 3 031 3 038 0 1193 0 1196 Marlin 100 Er 6D93G11 o mm sn Oil pump Discharge at 97 103 C 207 217 F with 10W 30 engine oil L US gal Imp gal min kPa kgf cm psi Pressure at 97 103 C 207 217 F with 10W 30 engine oil Relief valve opening pressure kPa kgf cm psi Thermostat Opening temperature Fully open temperature Valve open lower limit Lower unit Unit Gear backlash Pinion to forward gear mm in Pinion shims mm Forward gear shims mm Electrical e Te Ignition and ignition control system Spark plug gap Ignition coil resistance at 20 C 68 F Primary coll R B W Secondary coil Spark plug wire resistance 1 2 3 4 6D93G11 Maintenance specification Model Marin 100 EF 5 9 1 559 1 298 at 1 000 r min 118 0 1 18 17 1 at 1 000 r min 441 539 4 41 5 39 63 9 78 2 58 62 136 144 70 158 4 3 0 17 Model F80BET F100DET 0 28 0 63 0 0110 0 0248 0 10 0 12 0 15 0 18 0 30 0 40 0 50 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Model F80BET F100DET 1 0 1 1 0 039 0 043 1 53 2 07 12 495 16 905 4 5 10 7 3 3 8 0 3 8 9 4 3 10 2 2 6 SPEC O nom Specifications Item e ECM output peak voltage B R B W Ground at cranking loaded at 1 500 r min loaded at 3 500 r min loaded Pulser coil output peak voltage W R W B B a
77. 890 5 Use a 45 cutter to adjust the contact width of the valve seat to specification hi b Previous contact width Specified contact width 56945900 6 If the valve seat contact area is too wide and situated in the center of the valve face use a 30 cutter to cut the top edge of the valve seat a 60 cutter to cut the bottom edge to center the area and set its width S69J5910 b Previous contact width 5 31 7 If the valve seat contact area is too nar row and situated near the top edge of the valve face use a 30 cutter to cut the top edge of the valve seat If necessary use a 45 cutter to center the area and set its width 30 u 7 69J5920 D Previous contact width 8 If the valve seat contact area is too nar row and situated near the bottom edge of the valve face use a 60 cutter to cut the bottom edge of the valve seat If neces sary use a 45 cutter to center the area and set its width e 3 7 a 56945930 b Previous contact width 9 Apply a thin even layer of lapping com pound onto the valve seat and then lap the valve using a valve lapper commer cially available 5695820 6D93G11 CAUTION Do not get the lapping compound on the valve stem and valve guide 10 After every lapping procedure be sure to clean off any remaining lapping com pound from the cylinder head and the valve 11 Check the valve seat contact area of the valve ag
78. 9 6D93G 11 Intake manifold Vapor separator Vapor separator S6D84070 Remarks Vapor separator Bolt Grommet Collar Fuel hose Fuel inlet hose Hose Joint Hose Hose Hose Hose Clamp Clamp Quick connector Clamp Plastic tie M6 x 30 mm CO N DU Bb OD Not reusable Not reusable O A hv SA ld ld DDD 6D93G11 4 10 ru Fuel system 3 N m 0 3 kgf m 2 2 ft Ib 1 4 N m 0 4 kgf m 3 0 ft Ib S6D84080 Remarks 6 Screw 5x 14 mm Gasket 1 Float chamber Damper Drain screw O ring Joint screw O ring Fuel hose Fuel cooler Screw Fuel hose Hose Hose Hose Plastic tie Not reusable Not reusable CON OOF corn 96 x 15 mm O a N Sa FS de Not reusable 4 11 6D93G11 Vapor separator Ae 5 N m 0 5 kgf m 3 7 ft Ib S6D84090 Cover Pressure regulator Bolt O ring Joint screw O ring Electric fuel pump Grommet Collar Filter Screw Wiring harness Float Needle valve Pin Cap M6 x 12 mm Not reusable Not reusable CO N OOF WN 4 x 6 mm Not reusable A l dl TA Aa U R x a 6D93G11 4 12 ver Fuel system Reducing the fuel pressure 1 Remove the cap 1 2 Cover the pressure check valve of the vapor separator with a rag and then press in the pressure check valve using a thin screwdriver to release the fuel pressure 56D84180 A WARNING Always
79. AE VS 56D83040 4 Operate the oil changer to extract the oil NOTE Be sure to clean up any oil spills 5 Pour the specified amount of the recom mended engine oil into the oil filler hole Recommended engine oil 4 stroke motor oil API SE SF SG SH or SJ SAE 10W 30 or 10W 40 Engine oil quantity Without oil filter replacement 4 3 L 4 55 US qt 3 78 Imp at 6 Install the oil filler cap and oil dipstick and then start the engine and warm it up for 5 minutes 7 Turn the engine off and then check the oil level and correct it if necessary Changing the engine oil by draining It 1 Start the engine warm it up and then turn it off 3 4 TA ADJ Periodic checks and adjustments 2 Remove the oil dipstick and oil filler cap DI Al o EL ah S60C3060 3 Place a drain pan under the drain hole and then remove the drain bolt and let the oil drain completely S63P3080 NOTE Be sure to clean up any oil spills 4 Install the drain bolt and then tighten it to the specified torque Engine oil drain bolt 27 N m 2 7 kgf m 20 0 ft lb 5 Pour the specified amount of the recom mended engine oil into the oil filler hole Recommended engine oil 4 stroke motor oil API SE SF SG SH or SJ SAE 10W 30 or 10W 40 Engine oil quantity Without oil filter replacement 4 3 L 4 55 US at 3 78 Imp ot 6 Install the oil filler cap and oil dipstick and t
80. Apply corrosion resistant grease to the area shown S68F3190C 6D93G 11 General 3 16 CHK ADJ O Periodic checks and adjustments MEMO 6D93G11 6D93G11 Fuel system Special service tools an een 4 1 A as 4 2 Fuel and blowby NOSES S E 4 2 Fuel filter and fuel pump eese eere rere eee 4 3 Checking The T el PIMP Lae 4 5 Disassembling the fuel pump re 4 5 Checking the diaphragm and valves 4 6 Assembling the fuel pump iii 4 6 MAKE MANOR eee 4 7 Checking the throttle position sensor een nnnnnnnnnnnnnennnnnnn 4 9 Installing the throttle position sensor nennen nennen 4 9 Checking the idle speed control een nnnnnnnnnnn nn nnennnnnnnn 4 9 vepser EE 4 10 Reducing the fuel pressure bovactitehat gene eitaas ia 4 13 Disconnecting the quick CONNECHO 4 13 Measuring the fuel preSSUre ii 4 13 Checking the pressure regulator i 4 14 praning NE TUE aci atac ns 4 15 Removing the fuel hose clamp nennen nennen 4 16 Installing the fuel hose clamp iii 4 16 Disassembling the vapor separator nennen 4 16 Checking the vapor separator i 4 16 Assembling the vapor separator nenne nnnnn nennen 4 1
81. Dexron II 5 Install the reservoir cap and then tighten it to the specified torque Reservoir cap 7 N m 0 7 kgf m 5 2 ft lb 6 Connect the PTT motor leads to the bat tery terminals to fully retract the tilt ram m sii fa UN NLr pg yl 56D87570 Ram PIT motor lead Battery terminal own Sky blue Sb Light green Lg Tre 7 Reverse the PTT motor leads between the battery terminals to fully extend the tilt ram 6D93G11 56D87580 R PTT motor lead battery terminal Light green Lg am ES Sky blue Sb o NOTE e Repeat this procedure so that the ram goes up and down four or five times be sure to wait a few seconds before switching the leads If the ram does not move up and down eas ily push and pull on the ram to assist oper ation 8 Check the fluid level when the tilt ram is fully extended Add sufficient fluid if nec essary Installing the power trim and tilt unit 1 Fully tilt the outboard motor up and then support it with the tilt stop lever 1 560C7975 6D93G11 Tilt cylinder and trim cylinder CAUTION ee After tilting the outboard motor up be sure to support it with the tilt stop lever 2 Install the collars and bushings 3 Lift the power trim and tilt unit up and then install the upper mounting shaft 4 Install the circlip 3 5 Install the lower mounting shaft 2 and then install the circlips 6 Ro
82. Exhaust guide Gasket Dowel Gasket Oil strainer Collar Bolt Bolt Oil pan Gasket Exhaust manifold Bolt Gasket Gasket Plate Dowel Bolt M6 x 25 mm M6 x 25 mm CON OOF WD N Not reusable M6 x 70 mm Not reusable Not reusable o MO YO A hi ai da 6D93G1 1 7 10 BRKT Bracket unit S6D87060 Remarks Muffler Bolt M6 x 50 mm Grommet Spacer Pipe 7 11 6D93G11 Removing the upper case 1 Place a drain pan under the drain hole and then remove the drain bolt 1 and let the oil drain completely S63P7140 2 Remove the oil pump assembly and mount covers 3 Disconnect the ground lead and speed ometer hose 4 Remove the upper and lower mounting nuts and then remove the upper case Disassembling the oil pump 1 Remove the screws and disassemble the oil pump 56D87070 6D93G11 Upper case Checking the oil pump 1 1 2 Check the gear teeth for cracks or wear and the oil pump case for scratches Replace the oil pump assembly if neces sary Check the shaft for cracks or wear Replace if necessary Check the oil passage for dirt or residue Clean if necessary Assembling the oil pump Install a new oil seal into the oil pump cover to the specified depth 56087600 Bearing outer race attachment 1 90890 06625 Driver rod LS 2 90890 06606 0 5 0 3 mm 0 02 0 01 in Install a new oil seal into the oil pump housing
83. Is it closed Close the valve Yes Check the power trim and tilt fluid level At specified No level Add fluid to the correct level Yes Disassemble the power trim and tilt unit and then check the fil ters for debris or dirt Stuck foreign substance or clogs Yes Clean or replace the filters Check the fluid passages for clogs or debris Clogs or debris Clean the passages Check the internal parts valves pistons gear etc 9 15 6D93G11 Bracket unit Symptom Shift mechanism of the forward gear and reverse gear does not operate properly Check the shift cable operation Good operating No condition Yes Check the operation of the shift rod No Good operating condition Yes Check the shift rod connection between the lower case and upper case and check the shift rod for bends and wear Good condition Disassemble the lower case and then check the operation of the dog clutch Good operating condition Check the dogs of the forward gear and reverse gear for cracks and wear 6D93G 11 Check the shift cables and links of the remote control box Check the shift mechanism on the bottom cowling detent spring ball Replace the shift rod Check the dog clutch and slider for cracks and wear 9 16 TRBL e SHTG e Troubleshooting Electrical systems Symptom Battery be
84. Marlin 100 EFI SERVICE MANUAL SELVA NOTICE This manual has been prepared by Selva primarily for use by Selva dealers and their trained mechanics when performing maintenance procedures and repairs to Selva equipment It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use Because Selva has a policy of continuously improving its products models may differ in detail from the descriptions and illustrations given in this publication Use only the latest edition of this manual Authorized Selva dealers are notified periodically of modifications and significant changes in specifications and procedures and these are incorporated in successive editions of this manual Important information Particularly important information is distinguished in this manual by the following notations N The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the outboard motor CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the out board motor NOTE A NOTE provides key information to make procedures easier
85. PM switch optional To warning indicator To remote control box switch panel To personal computer for diagnosis D To diagnostic flash indicator special service tool To Variable trolling RPM switch To trim meter Color code B Black Br Brown G Green L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Yellow B R Black red B W Black white B Y Black yellow Br W Brown white G B Green black G R Green red G Y Green yellow L G Blue green L W _ Blue white L Y Blue yellow O W Orange white P B Pink black P G Pink green P W Pink white Pu B Purple black Pu R Purple red R B Red black RN Red yellow W B White black W L White blue W R White red RRR CEUTA 11d _ iii mme mum 9 ole Til DM ei I De e Ul B i i ESS TT nu LL V se NR P P Eje OS lt UW v Il mo EST ies HI gt gt eer aro TE H i Ce rt lt rar OONOUARWM EE a caca ca caca OSO O14 C9 O i El 27 R oo Br W I I I I E I z l ml l I H gr Br i B l I o P l laol I I um 8 do ste o R das R 3 en DODO ODO S6D9WDO1
86. TE EMEN Cover the check hole with a rag when remov ing the tester from the lower unit Lower unit holding pressure 100 kPa 1 0 kgf cm 14 5 psi 3 If pressure drops below specification check the drive shaft and propeller shaft oil seals for damage Checking the propeller 1 Check the propeller blades and splines for cracks damage or wear Replace if necessary 6D93G11 General Checking the anodes 1 Check the anodes and trim tab for scales grease or oil Clean if necessary S6D83170 S6D83210 LY cues S62Y3640 CAUTION Do not oil grease or paint the anodes or the trim tab otherwise they will be ineffec tive 6D93G 11 Lower unit General NOTE S If itis necessary to disassemble the outboard motor to check an anode refer to the applica ble disassembly procedure in this manual 2 Replace the anodes or trim tab if exces sively eroded Checking the battery 1 Check the battery electrolyte level If the level is at or below the minimum level mark a add distilled water until the level is between the maximum and minimum level marks 569J3620 3 14 TA ADJ Periodic checks and adjustments 2 Check the specific gravity of the electro Lubricating the outboard motor lyte Fully charge the battery if out of 1 Apply water resistant grease to the areas specification shown A WARNING Battery electrolyte is dangerous it con tains sulfuric acid which is poisonou
87. Trim tab 1 1 A Lo ko Aa HL cO nm NN DOS o n n Not reusable Not reusable M10 x 40 mm M10 x 45mm M8 x 60 mm Not reusable 62Y5A11 KONE Lower unit Removing the drive shaft 1 Remove the drive shaft assembly and pinion and then pull out the forward S62Y6850K Drive shaft holder 4 90890 06518 Pinion nut holder 2 90890 06505 Socket adapter 2 90890 06507 Disassembling the drive shaft 1 Install the pinion nut tighten it finger tight and then remove the drive shaft bearing using a press S62Y6735K CAUTION S Do not press the drive shaft threads directly Do not reuse the bearing always replace it with a new one Bearing inner race attachment 3 90890 06639 Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear using a press S62Y6740K CAUTION Do not reuse the bearing always replace it with a new one Bearing separator 1 90890 06534 2 Remove the needle bearing from the for ward gear S82Y6750K CAUTION Do not reuse the bearing always replace it with a new one Stopper guide plate 2 90890 06501 Stopper guide stand 3 90890 06538 Bearing puller 4 90890 06535 Bearing puller claw 1 90890 06536 62Y5A11 6D93G11 How to use this manual Symbols The symbols below are designed to indicate the content of a chapter General information Fuel system Bracket unit Specificatio
88. UMP i 7 12 Checking ne ODUM PS 7 12 ASSEMDINNG heoil PUMP rioni ira iii 7 12 Disassembling the upper case nennen nenn ennnnn nennen nen 7 13 Checking the drive shaft bushing i 7 13 Disassembling the oil pan i 7 13 CGheoking MEOS TANE Fi tes sa urn 7 14 Assembling the oil palio 7 14 Assembling th Upper case eate ER ie 7 15 Installing the upper case ii 7 15 Steering AN 7 17 REMOVING the steering arm iii 7 18 installing the steering arises ec aan 7 18 Clamp brackets and swivel bracket nnnrnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnennnnnnnr 7 19 Removing the clamp brackets ieri 7 21 installing tne lamp brackets crinali 7 21 AQJUStNQ the um Sel OE aS 7 21 Power trim nd Ull UNN a een 7 23 Removing the power trim and tilt unit aa 7 24 Power ttim and HIEWMol ca rina 7 25 Disassembling the power trim and tilt MOtor Rennen 7 27 Checking the power trim and tilt Motor i 7 27 Assembling the power trim and tilt motor i 7 29 Gear PIN o APA Po TR MS 7 30 Disassembling the gear pump e 7 33 Gheeking Ne gear PP aars 7 33 Assembling the gear pump neuen ener 7 33 6D93G11 Tilt cylinder and trim cylinder sss 7 35 Disassembling the trim cylin
89. ack B lead Replace if there is continuity 6D93G11 Fuel control system Starting system S60V8265 6D93G11 9 12 ELEC 7 ELEC m Electrical systems Starter motor sel S__2 ie 3 4 Um S63P8050 Clip Pinion stopper Starter motor pinion Spring Bolt Housing Bearing Clutch assembly E clip Washer Bracket Pinion shaft Planetary gear Outer gear Plate Armature Stator M6 x 35 mm CO N DU AS DUNN Not reusable A U A A A A AA AA pO im os 8 13 6D93G11 Starter motor oT E 4 S63P8050 lr ee or e a Brush assembly Brush spring Brush holder Plate Washer Bracket Screw Bolt Rubber seal Shift lever Spring Magnet switch assembly Washer Nut 4 x 15 mm M6 x 120 mm A A NN NNO I bh 6D93G11 9 14 ELEC 77 ELEC ui Electrical systems Disassembling the starter motor 1 Slide the pinion stopper down as shown and then remove the clip 2 S69J8370 NOTE Remove the clip with a thin screwdriver 2 Remove the bolts and then disassemble the starter motor Checking the starter motor pinion 1 Check the teeth of the pinion for cracks or wear Replace if necessary 2 Check for smooth operation Replace if necessary NOTE ___ Turn the pinion counterclockwise to check that it operates smoothly and turn it clockwise to check that it locks in place Checking the armature 1 Check the comm
90. ain Checking the camshafts 1 Measure the cam lobe Replace if out of specification O p 8695950 Cam lobe 3 Intake 36 48 36 58 mm 1 4362 1 4402 in Exhaust 36 90 37 06 mm 1 4528 1 4591 in Cam lobe Intake 29 95 30 05 mm 1 1791 1 1831 in Exhaust 29 92 30 08 mm 1 1780 1 1842 in 2 Measure the camshaft runout Replace if above specification 6D93G11 Cylinder head 56D85450 Camshaft runout limit 0 03 mm 0 0012 in 3 Measure the camshaft journal diameter and cylinder head journal inside diam eter Replace the camshaft and cylin der head if out of specification 569J5970 Camshaft journal diameter 24 960 24 980 mm 0 9827 0 9835 in Camshaft cap inside diameter 25 000 25 021 mm 0 9843 0 9851 in Checking the cylinder head 1 Eliminate carbon deposits from the com bustion chambers and check for deterio ration 9 32 Power unit 2 Check the cylinder head warpage using a straightedge D and thickness gauge 2 in the directions shown Replace if above specification S6D85470 S6D85460 Cylinder head warpage limit 0 1 mm 0 0039 in Installing the valves 1 Install a new valve seal 1 onto the valve guide S60C5660 2 Install the valve 2 valve spring seat 3 valve spring 2 and valve spring retainer in the sequence shown and then attach the special service tools 9 33
91. asuring conditions Ambient temperature 20 C 68 F wide open throttle with spark plugs removed from all cylinders The figures are for reference only 2 The figures are for reference only 2 3 6D93G 11 Maintenance specification Model en Oom isis NODER Oil ring Dimension B Dimension TO End gap Side clearance Camshafts Intake A Exhaust A Intake B Exhaust B Camshaft journal diameter Camshaft runout limit Valves Valve clearance cold Intake Exhaust Head diameter A Intake Exhaust Face width B Intake Exhaust Seat contact width C Intake Exhaust Margin thickness D Intake Exhaust Stem diameter Intake Exhaust Guide inside diameter Intake and exhaust Stem to guide clearance Intake Exhaust Stem runout limit Valve springs Free length Tilt limit The figure is for reference only 6D93G11 2 38 2 48 0 0937 0 0976 2 40 0 0945 0 20 0 70 0 0079 0 0276 0 03 0 15 0 0012 0 0059 36 48 36 58 1 4362 1 4402 36 90 37 06 1 4528 1 4591 29 95 30 05 1 1791 1 1831 29 92 30 08 1 1780 1 1842 24 960 24 980 0 9827 0 9835 0 03 0 0012 0 20 0 03 0 008 0 001 0 34 0 03 0 013 0 001 29 0 29 2 1 14 1 15 24 0 24 2 0 94 0 95 1 99 2 44 0 0783 0 0961 2 27 2 72 0 0894 0 1071 1 20 1 60 0 0472 0 0630 1 20 1 60 0 0472 0 0630 0 80 1 20 0 0315 0 0472 1 00 1 40 0 0394 0 0551 5 975 5 990 0 2352 0 2358 5 960 5 9 5 0
92. ck the voltage between each terminal of the PTT relay coupler when pushing the power trim and tilt switch Between the sky blue Sb lead and black B lead Between the light green Lg lead and black B lead Can the specified battery voltage be obtained Yes Replace the power trim and tilt relay Check the fuse for continuity Is there continuity Replace the fuse Yes Check for continuity between the battery relays and power trim and tilt switch Check the voltage between the Sky blue Sb lead and light green Lg lead Can the specified battery voltage be obtained Replace the power trim and tilt relay Disassemble and check the power trim and tilt motor 7 27 6D93G11 Bracket unit No Is it closed Close the valve Yes Check the power trim and tilt fluid level At specified No Add fluid to the correct level level Yes Disassemble the power trim and tilt unit and then check the filter for debris or dirt Stuck foreign substance or clogs Yes Clean or replace the filters Check the fluid passages for clogs or debris Clogs or debris Clean the passages Check the internal parts valves pistons gears etc 6D93G11 9 14 TRBL e SHTG e Troubleshooting Symptom Power trim and tilt unit does not hold the outboard motor up Check that the manual valve is closed No
93. cking the valve springs 1 Measure the valve spring free length 3 Replace if below specification 560C5400 5 2 Valve spring free length 8 53 20 mm 2 0945 in 2 Measure the valve spring tilt D Replace if above specification S60C5410 Valve spring tilt limit 2 6 mm 0 10 in Checking the valves 1 Check the valve face for pitting or wear Replace if necessary 2 Measure the valve margin thickness Replace if out of specification 56065420 Valve margin thickness 8 Intake 0 80 1 20 mm 0 0315 0 0472 in Exhaust 1 00 1 40 mm 0 0394 0 0551 in 3 Measure the valve stem diameter b Replace if out of specification 6D93G11 96005430 Valve stem diameter b Intake 5 975 5 990 mm 0 2352 0 2358 in Exhaust 5 960 5 975 mm 0 2346 0 2352 in 4 Measure the valve stem runout Replace if above specification 56005440 Valve stem runout limit 0 01 mm 0 0004 in Checking the valve guides NOTE Before checking the valve guide make sure that the valve stem diameter is within specifi cation 1 Measure the valve guide inside diameter 6D93G11 Cylinder head S60C5450 Valve guide inside diameter Intake and exhaust 6 000 6 018 mm 0 2362 0 2369 in 2 Calculate the valve stem to valve guide clearance as follows Replace the valve guide if out of specification Valve stem to valve guide clearance val
94. clearance Example If the Removed valve shim thickness is 2 10 mm the Measured valve clearance is 0 30 mm and the Specified valve clearance is 0 20 mm then the necessary valve shim thickness 2 10 0 30 0 20 2 20 mm 14 Install the necessary valve shim into the valve lifter and then install the valve lift ers into the cylinder head 15 Install the camshafts camshaft caps driven sprockets and timing belt and then tighten the tensioner bolt 16 Check the valve clearance Adjust if nec essary 17 Loosen the tensioner bolt and then remove the timing belt and driven sprock ets 18 Install the cylinder head cover and driven sprockets 6D93G11 Power unit 19 Check that the TDC mark on the fly wheel magnet is aligned with the pointer D and that A marks and on the driven sprockets are aligned IN d LD Gr OG LO S6D85200 20 Install the timing belt 21 Install the spark plugs and then connect the spark plug wires fuel hoses and blowby hose Spark plug 25 N m 2 5 kgf m 18 4 ft lb 22 Install the spark plug wire cover filter and flywheel magnet cover Spark plug wire cover screw 4 N m 0 4 kgf m 3 0 ft lb 9 12 Power unit Replacing the timing belt CAUTION clockwise otherwise the valve system may be damaged Do not remove the ignition timing pointer Do not turn the drive sprocket or the driven sprockets
95. comes weaker quickly Check the charging system Measure the output peak voltage of the stator coil Within specification Replace the stator coil Yes Measure the Rectifier Regulator output peak voltage Within specification Replace the Rectifier Regulator Yes Replace the battery and then check the voltage of all electri cal equipment on your boat 9 17 6D93G1 1 Self diagnosis Diagnosing the electronic control system 1 Connect the special service tool to the outboard motor as shown S6D89030 NOTE When performing this diagnosis all of the electrical wires must be properly connected Z Diagnostic flash indicator B 90890 06865 2 Start the engine and let it idle 3 Check the flash pattern of the special service tool to determine if there are any malfunctions e Normal condition no defective part or irregular process ing is found e Single flash is given every 4 95 sec onds 8 Light on 0 33 second D Light off 4 95 seconds 6D93G11 Electrical systems Self diagnosis e e Trouble code indication Example The illustration code number 23 8 Light on 0 33 second Light off 4 95 seconds C Light off 0 33 second d Light off 1 65 seconds 56949020 indicates 56949030 9 18 TRBL e SHTG e Troubleshooting 4 f a flash pattern listed in the diagnostic code chart is displayed check the mal functioning part
96. crew 94 x 8 mm Plate Grommet Gasket Bolt M6 x 30 mm Camshaft cap Camshaft cap Bolt M7 x 48 mm Bolt M7 x 37 mm Oil seal Not reusable Camshatt CO N DU AS DON 5 9 6D93G11 Checking the valve clearance CAUTION e Do not turn the flywheel magnet coun terclockwise otherwise the valve sys tem may be damaged e Do not remove the ignition timing pointer e Do not turn the flywheel magnet or the driven sprockets when the timing belt is not installed Otherwise the piston and valves will interfere with each other and be damaged NOTE A For removal and installation procedures of the timing belt driven sprockets and cam shafts see the applicable procedures in this manual 1 Remove the flywheel magnet cover filter and spark plug wire cover 3 disconnect the spark plug wires 4 fuel hoses and blowby hose and then remove all spark plugs 3 OD A O 56D85130 2 Turn the flywheel magnet clockwise and align the TDC mark 8 on the flywheel magnet with the pointer and check that A marks and on the driven sprockets are aligned 6D93G11 Power unit 56D85140 Loosen the tensioner bolt and then remove the spring 8 timing belt driven sprockets do and cylinder head cover 1 56D85150 5 10 Power unit 4 Install the driven sprockets 9 timing belt and spring and then tighten the Valve clearance cold tensioner bolt
97. crew wrench i New 90890 06568 Current 90890 06544 3 Drain the power trim and tilt fluid Disassembling the tilt cylinder 1 Hold the tilt cylinder in a vise using aluminum plates on both sides 6D93G11 Tilt cylinder and trim cylinder 2 ID S60C7770 NOTE _ r T_T1T Place the tilt cylinder in the vise horizontally 2 Loosen the tilt cylinder end screw and then remove it 56087640 CAUTION Do not damage the check valve when loosening the end screw Cylinder end screw wrench New 90890 06568 Current 90890 06544 3 Hold the tilt ram end in a vise using alu minum plates on both sides 7 38 BRKT Bracket unit 4 Remove the bolt 8 then the tilt piston 4 j f O o do Checking the tilt cylinder and trim cylinder 1 Check the power trim and tilt unit for cracks or corrosion Replace if neces sary 2 Check the inner walls of the trim cylinder and tilt cylinder for scratches Replace if necessary 3 Check the outer surface of the tilt piston and free piston for scratches Replace if necessary 4 Check the tilt ram for bends or excessive corrosion Polish with 400 to 600 grit sandpaper if there is light rust or replace if necessary Checking the valves 1 Check the operation of the check valve a of the tilt cylinder end screw and check the valve for dirt or residue Clean if necessary 562Y7610 7 39 2 Check the operatio
98. der nn nenn nnnnnn nennen nennen 7 38 Disassembling the tilt cylinder iii 7 38 Checking the tilt cylinder and trim cylinder Rennen 7 39 CRECKINO TE Vales tesina 7 39 Assembling INS NIECYINdEr eek 7 39 Assembling the power trim and tilt UNIt i 7 41 Bleeding the power trim and tilt unit nenne iaia 7 43 Installing the power trim and tilt unit nen nnnnnn nennen nennen 7 44 Bleeding the power trim and tilt unit built in Rennen 7 44 Power trim and tilt electrical system suu 7 45 Checking Me USC odos 7 45 Checking the power trim and tilt relay rrenen 7 45 Checking the power trim and tilt switch oooonnccnncccononnnnnnnnnnnonnnnnos 7 46 Checking the trim SEnSor ii 7 47 6D93G11 BRKT Bracket unit Special service tools Bearing outer race attachment Cylinder end screw wrench 90890 06625 90890 06628 New 90890 06568 Current 90890 06544 Driver rod LL 90890 06605 Driver rod L3 90890 06652 y Driver rod LS 90890 06606 O Ball bearing attachment 90890 06638 Needle bearing attachment 90890 06612 90890 06653 7 1 6D93G11 Special service tools Shift rod Shift rod 56D87010 Part name dy Bolt Spring Ball Washer Bushing Bolt Bracket Shift rod Screw Plate Shift position switch Bolt Bushing Bracket
99. e is loosened be sure to tighten it to the specified torque after tilting the outboard motor up Manual valve 2 N m 0 2 kgf m 1 5 ft lb 2 Remove the holders and plastic ties and then pull out the PTT motor leads 3 3 Remove the bolt and disconnect the ground lead 6 6D93G11 Power trim and tilt unit 4 Remove the circlips then the lower mounting shaft 5 Remove the circlip then the upper mounting shaft NOTE A Y Hold the power trim and tilt unit with one hand and pull the upper mount shaft out at a downward angle with the other 6 Remove the power trim and tilt unit 0 a op 7 24 BRKT Bracket unit Power trim and tilt motor Py 4 N m 0 4 kgf m 3 0 ft Ib X7 N m 0 7 kgf m 5 2 ft Ib S6D87290 Remarks Power trim and tilt motor Bolt O ring Joint O ring Reservoir cap Screw Stator O ring Armature Washer Bushing Wire lead Screw Brush Brush Brush holder M6 x 20 mm Not reusable Not reusable 65x25 mm 1 2 3 4 5 6 7 8 Not reusable 4 x 15 mm A A A N oo A QQ ELL bh 7 25 6D93G11 Power trim and tilt motor 4 N m 0 4 kgf m 3 0 ft Ib X7 N m 0 7 kgf m 5 2 ft Ib 56D87290 Remarks Circuit breaker Spring PTT motor base Oil seal Not reusable Plate Screw 94 x 10 mm 6D93G11 7 26 BRKT Bracket unit Disassembling the power trim and tilt
100. e operating sound of the electric fuel pump D Check the fuel sys tem if there is no sound S6D881 10 NOTE After the engine start switch is turned to ON the electric fuel pump will operate for 3 sec onds Checking the main and fuel pump relay fuel control 1 Remove the main and fuel pump relay E 56D88090 2 Connect the digital circuit tester leads to the relay terminals 2 and 3 Connect the positive battery terminal to the relay terminal 2 4 Connect the negative battery terminal to the relay terminal 4 5 Check for continuity between the relay terminals 2 and 3 Replace if there is no continuity 8 11 6 Check that there is no continuity between the relay terminals 2 and after dis connecting a battery terminal from the relay terminal 2 or Replace if there is continuity S6D88120 Starting system Checking the fuses 1 Check the fuses for continuity Replace if there is no continuity Checking the starter relay 1 Connect the digital circuit tester leads to the starter relay terminals 2 Connect the positive battery terminal to the brown Br lead 3 Connect the negative battery terminal to the black B lead 4 Check for continuity between the starter relay terminals Replace if there is no continuity 5 Check that there is no continuity between the starter relay terminals after discon necting a battery terminal from the brown Br or bl
101. e retaining plate and the projection on the cylin der block are aligned 6D93G11 5 14 Power unit 10 Install a new timing belt 8 onto the drive sprocket with its part number in the upright position and then install the belt onto the driven sprockets in a counter clockwise direction IS is I IM S6D85290 C S6D85250 CAUTION Do not twist turn inside out or bend the timing belt beyond the maximum limit of 25 mm 1 0 in otherwise it can be dam aged Do not get oil or grease on the timing belt NOTE The lower edge of the timing belt should be 2 mm 0 08 in 8 from the bottom of the driven sprockets 11 Install the timing belt tensioner and finger tighten the bolt until the bolt seat contacts the timing belt tensioner 12 Loosen the timing belt tensioner bolt 90 5 15 13 Install the spring 4 56D85260 14 Take up the timing belt slack by turning the drive sprocket clockwise at least two full turns 15 Tighten the timing belt tensioner bolt to the specified torque Timing belt tensioner bolt 39 N m 3 9 kgf m 28 8 ft lb 16 Turn the drive sprocket two full turns and then check that the alignment marks are aligned 56D85280 17 Install the bracket and connect the cool ing water hose 6D93G 11 18 Install the stator assembly and Woodruff Key 19 Install the flywheel magnet 563P5370 CAUTION Apply force in the direction of the
102. e water and slowly heat the water S69J5E40 5 Check the thermostat valve opening at the specified water temperatures Replace if out of specification S69J5E50 6D93G11 Water i Valve lif temperature alve lift en 0 05 mm 136 144 F 0 0020 in valve begins to lift above more than 70 C 158 F 4 3 mm 0 17 in 6 Install the thermostat and cover 7 Connect the cooling water hose and then install the flywheel magnet cover Checking the cooling water passage 1 Check the cooling water inlet cover and cooling water inlet for clogs Clean if necessary S S62Y3320 2 Place the lower unit in water and then start the engine 3 Check for water flow at the cooling water pilot hole If there is no water flow check the cooling water passage inside the out board motor 6D93G11 Power unit Control system YR dr S63P3120 Control system Checking the engine idle speed 1 Startthe engine and warm it up for 5 min utes 2 Attach the special service tool to spark plug wire 1 and then check the engine idle speed Engine idle speed 650 750 r min Adjusting the throttle link and throttle cable 1 Remove the intake silencer N Set the remote control lever to the neu tral position and fully close the throttle lever TA ADJ Periodic checks and adjustments 3 Loosen the locknut D remove the clip and then disconnect the throttle cable
103. ect the sky blue Sb lead to the positive battery terminal and the black B lead to the negative battery terminal as shown 7 Check for continuity between terminals CD and 9 Replace if there is no continu ity 6D93G11 563P7390 Checking the power trim and tilt switch 1 Check the power trim and tilt switch for continuity Replace if out of specification S62Y7A70 BI ee Switch Sky blue Lightgreen O POS Up 7 46 BRKT Bracket unit Checking the trim sensor 1 Measure the trim sensor resistance Replace if out of specification S63P7280 NOTE Turn the lever 1 and measure the resistance as it gradually changes Trim sensor resistance Pink P Black B 238 8 378 8 Q at 20 C 68 F 8 9 11 Q at 20 C 68 F 1 41 6D93G11 6D93G11 Electrical systems Special service tools an een 8 1 Checking the electrical componentS rrrasnnuvunnrnnnnnnnnnnvnnnnnnnnnnnnnnnnnnnunernnnnnnn 8 2 Measuring the peak voltage nenn ennnnn nenn ennennenennn nenn enennennen 8 2 Measuring the lower resistaNCe i 8 2 Electrical cComponenis iz 8 3 OE alici 8 3 o o mei 8 4 PN A thandet saeco actin di 8 5 TOP VI m 8 6 Ignition and ignition control system ecce eee 8 7 Checking the ignition spark i 8 7 Checking the spark plug WIT8S o
104. ed and the total operating time are displayed This allows you to check the operating status of the engine 7 Some files Lets you select and run other applications while continuing to run the diagnostic program Contents e amp YAMAHA OUTBOARDS 2 Adapter 1 YAMAHA n dr EN STEM 3 Communication cable 1 IE INSTALLATION MANUAL 4 Instruction Manual 1 5 Installation Manual 1 6D93G11 9 2 TRBL e SHTG e Troubleshooting Hardware requirements Make sure that your computer meets the following requirements before using this software Computer IBM compatible computer Operating system Microsoft Windows 95 Windows 98 Windows Me Windows 2000 or Windows XP English version CPU Windows 95 98 i486X 100 MHz or higher Pentium 100 MHz or higher recommended Windows Me 2000 Pentium 166 MHz or higher Pentium 233 MHz or higher recommended Windows XP Pentium 300 MHz or higher Pentium 500 MHz or higher recommended Memory Windows 95 98 16 MB or more 32 MB or more recommended Windows Me 32 MB or more 64 MB or more recommended Windows 2000 64 MB or more 128 MB or more recommended Windows XP 128 MB or more 256 MB or more recommended Hard disk free space 20 MB or more 40 MB or more recommended Drive CD ROM drive Display VGA 640 x 480 pixels SVGA 800 x 600 pixels or more recommended 256 or more colors Mouse Compatible with the operating systems mentioned above Communication po
105. een 5 1 PO WOM UMI aan 5 3 Checking the compression pressure nennen 5 3 Ghecking heder 5 3 Checking the valve clearanCe nenn 5 10 Replacing the timing Delt sic a ae tenia eddie 5 13 Removing the power UNIt ie 5 16 Removing the timing belt and SprocketS nennen 5 17 Checking the timing belt and sprocketS 5 18 Installing the sprockets and timing DElt nn nennen nenn 5 18 TInrotlelinki 424 5 20 EM iii ale ri 5 21 JUNCUON box ran 5 22 alegre eee tc 5 24 Removing the cylinder head eese 5 26 Checking the valve lifters nennen 5 27 Checking the valve Springs sees 5 27 Gheecking the VAVE ee 5 27 Checking the valve guides een 5 28 Replacing the valve guides i 5 28 Checking the valve seat a E 5 29 RetacingineValve SEA na 5 30 GheckingithecamshaflSia ee cidade dic 5 32 Checking the cylinder Ti amp ad c areale 5 32 LEE Ua ERE EEE EE tambe 5 33 Installng tne cylinger Neadizici lalla 5 34 EXMAUSE Cover ae ee 5 37 Removing the exhaust COVEN nisse 5 39 Checking the pressure control valve i 5 39 Installing the pressure control Valve ara aane 5 39 Installing the exhaust COVEr ii 5 39 6D93G11 Cnder DIO CR sara 5 40 Disassembling the cylinder
106. efore installation e To install the water pump housing push down on the pump housing and then turn the drive shaft clockwise Installing the lower unit 1 Set the gear shift to the neutral position at the lower unit 6 22 Lower unit 2 Align the alignment mark 8 on the bush ing with the alignment mark on the bracket S6D81040 56D96020 Lower case mounting bolt nut 39 N m 3 9 kgf m 28 8 ft lb 56D86280 5 Install the trim tab to its original posi tion and then connect the speedometer hose 3 3 Install the dowels 1 into the lower unit 4 Install the lower unit into the upper case and then tighten the lower case mounting bolts nuts to the specified torque 56D86180 6 23 6D93G11 Drive shaft and lower case 6 Install the propeller and propeller nut 7 Fill the gear oil to the correct level and then tighten the nut finger tight Place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then tighten the nut to the specified torque S6C 16660 56946340 A WARNING e Do not hold the propeller with your hands when loosening or tightening it e Be sure to disconnect the battery leads from the battery and the clip from the engine stop lanyard switch e Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning NOIE
107. ess smooth and efficient the predelivery checks should be completed as explained below Checking the fuel system 1 Check that the fuel hoses are securely connected and that the fuel tank is full with fuel 6D93G11 56D81020 CAUTION This is a 4 stroke engine Never use pre mixed fuel Checking the engine oil level 1 Check the engine oil level T FR a E S60C1150 NOTE If the engine oil is below the minimum level mark add sufficient oil until the level is between a and Recommended engine oil 4 stroke motor oil API SE SF SG SH or SJ SAE 10W 30 or 10W 40 Engine oil quantity Without oil filter replacement 4 3 L 4 55 US qt 3 78 Imp at 1 6 eum General information Checking the gear oil level 1 Check the gear oil level S60C1140 Checking the battery 1 Check the capacity electrolyte level and specified gravity of the battery Recommended battery capacity CCA EN 430 A 20HR IEC 70 Ah Electrolyte specified gravity 1 280 at 20 C 68 F 2 Check that the positive and negative bat tery leads are securely connected Checking the outboard motor mounting height 1 Check that the anti cavitation plate is aligned with the bottom of the boat If the mounting height is too high cavitation will occur and propulsion will be reduced Also the engine speed will increase abnormally and cause the engine to overheat If the mounting height is too
108. hat the drain screw is tight ened securely Checking the pressure regulator 1 Disconnect the quick connector from the fuel rail NOTE A _ uu 1 Before disconnecting the quick connector release the fuel pressure 2 Connect fuel pressure gauge adapter B between the quick connector and fuel rail 3 Connect the fuel pressure gauge to fuel pressure gauge adapter B 4 14 vel D Fuel system 4 Disconnect the pressure regulator hose and then connect the special service tools to the pressure regulator VET NTG IQ GER 56D84200 WARNING e When connecting the fuel pressure gauge first cover the connection between the gauge and the adapter with a clean dry rag to prevent fuel from leaking out e Gently screw in the gauge until it is firmly connected Fuel pressure gauge 90890 06786 Fuel pressure gauge adapter B 90890 06942 Vacuum pressure pump gauge set 90890 06756 5 Start the engine and let it idle 6 Check that the fuel pressure reduces when vacuum pressure is applied to the pressure regulator If the fuel pressure does not reduce replace the pressure regulator 4 15 A WARNING Before measuring the fuel pressure make sure that the drain screw is tight ened securely e Do not loosen the drain screw while measuring the fuel pressure Loosening the drain screw can cause fuel to spray out creating a fire hazard After measuring the fuel pressure cover the end of
109. hen start the engine and warm it up for 5 minutes 3 5 7 Turn the engine off and then check the oil level and correct it if necessary Replacing the oil filter 1 Extract the engine oil with an oil changer or drain it 2 Place a rag under the oil filter and then remove the oil filter using the oil filter wrench S6D83050 NOTE AA Wait more than 5 minutes after turning the engine off to replace the oil filter Be sure to clean up any oil spills Oil filter wrench 64 90890 01426 3 Apply a thin coat of engine oil to the O ring of the new oil filter 4 Install the oil filter and then tighten it to the specified torque using the oil filter wrench 6D93G11 S6D83060 Oil filter 18 N m 1 8 kgf m 13 3 ft lb 5 Pour the specified amount of the recom mended engine oil into the oil filler hole Recommended engine oil 4 stroke motor oil API SE SF SG SH or SJ SAE 10W 30 or 10W 40 Engine oil quantity With oil filter replacement 4 5 L 4 76 US qt 3 96 Imp at 6 Install the oil filler cap and oil dipstick and then start the engine and warm it up for 5 minutes 7 Turn the engine off and then check the oil level and correct it if necessary Checking the timing belt CAUTION Do not turn the flywheel magnet counter clockwise otherwise the valve system may be damaged 1 Remove the flywheel magnet cover 6D93G11 Power unit 2 While turning the flywheel
110. hift and throttle operation ui 1 8 Checking the gear shift operation 3 10 Checking the idle speed control 4 9 Checking the ignition coils 8 7 Checking the ignition spark 8 7 Checking the injectors 8 10 Checking the lower case 6 18 Checking the lower unit for air leakage 3 13 Checking the magnet switch 8 16 Checking the main and fuel pump relay PCI COMMON er 8 11 Checking the main and fuel pump relay Mal CONTO mariana 8 10 Checking the oil pressure 5 3 Checking the oil pressure switch 8 9 Checking the oil pump 7 12 Checking the oil strainer 7 14 Checking the outboard motor mounting height rennen 1 7 Checking the pinion and forward gear 6 18 i 1 Index Checking the piston clearance 5 42 Checking the piston diameter 5 41 Checking the piston ring grooves 5 43 Checking the piston ring side clearance 5 43 Checking the piston rings 5 42 Checking the power trim and tlt Tug levels us susanne 3 11 Checking the power trim and tilt motor 7 27 Checking the power trim and tilt operation nenne nennen 3 11 Checking the power trim
111. if necessary 4 Check the spring for fatigue or deforma tion Replace if necessary Installing the pressure control valve 1 Install a new gasket and the pressure control valve and then tighten the bolts S6D85540 5 39 Installing the exhaust cover 1 Install a new gasket and the exhaust cover 2 Install the bolts and then tighten them to the specified torques in two stages and in the sequence shown Y OFA BE Oo S6D85550 NOTE gt Apply engine oil to the exhaust cover bolts before installation Exhaust cover bolt 1st 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 N m 1 2 kgf m 8 9 ft lb 6D93G11 Exhaust cover Cylinder block Cylinder block x 19N m 1 9 kgf m 14 0 ft Ib O60 14N m 1 4 kgf m 10 3 ft lb KS i 28 N m 2 8 kgf m 20 7 ft Ib S6D95010 Remarks 4 Bolt M6 x 20 mm Dowel 10 Bolt M10 x 135 mm Crankcase Bolt M8 x 55 mm Cylinder block Main bearing Main bearing Main bearing Oil seal Crankshaft Oil seal Connecting rod bearing Piston connecting rod assembly Bolt CON DOF WN Not reusable Not reusable o DS 0 Ao Not reusable M8 x 38 mm Piston ring set Stud bolt 6D93G11 5 40 Power unit Disassembling the cylinder block 1 Place a rag under the oil filter and then remove the filter using the oil filter wrench NOTE Be sure to clean up any oil spills O
112. il filter wrench 64 90890 01426 2 Remove the crankcase bolts in the sequence shown and then remove the crankcase h Op IN 00 Off NOTE Do not remove the ignition timing pointer from the crankcase 3 Remove the connecting rod bolts and the connecting rod caps and then remove the crankshaft oil seals and the piston assemblies 5 41 Nar gt 56D85570 NOTE A e Be sure to keep the bearings in the order as they were removed e Mark each piston with an identification number 8 of the corresponding cylinder e Do not mix the connecting rods and caps Keep them organized in their proper groups Checking the piston diameter 1 Measure the piston outside diameter at the specified measuring point Replace if out of specification 56005820 Piston diameter a 18 928 8 949 mm 3 1074 3 1082 in Measuring point 13 0 mm 0 51 in up from the bottom of the piston skirt Oversize piston diameter 79 178 79 199 mm 3 1172 3 1181 in 6D93G11 Checking the cylinder bore 1 Measure the cylinder bore D D at measuring points 8 and and in direction D D3 Ds which is parallel to the crankshaft and direction D D4 Dg which is at a right angle to the crankshaft S60C5830 20 mm 0 8 in 50 mm 2 0 in 80 mm 3 1 in Cylinder bore D D 79 000 79 020 mm 3 1102 3 1110 in 2 Calculate the taper limit Re
113. in diameter and crankpin N Jj e width Replace the crankshaft if out of specification q S6D85590 GN Crankshaft runout limit 0 03 mm 0 0012 in Checking the crankpin oil clearance 1 Clean the bearings and the connecting rod N 563P5750 S63P5760 6D93G11 5 44 Power unit 2 Install the upper bearing into the con necting rod D and the lower bearing into the connecting rod cap S60C5960 NOTE Install the bearings in their original positions 3 Put a piece of Plastigauge PG 1 onto the crankpin parallel to the crankshaft 56065990 NOTE Be sure not to put the Plastigauge PG 1 over the oil hole in the crankpin of the crank shaft 4 Install the connecting rod to the crankpin Q 5 45 S60C5A10 NOTE A Make sure that the large flat side on the connecting rod faces towards the flywheel magnet side of the crankshaft 5 Tighten the connecting rod bolts to the specified torques in two stages 562Y5980 NOTE P P_r Reuse the removed connecting rod bolts Do not turn the connecting rod until the crankpin oil clearance measurement has been completed Connecting rod bolt 1st 18 N m 1 8 kgf m 13 3 ft lb 2nd 80 6D93G11 6 Remove the connecting rod cap and measure the width of the compressed Plastigauge PG 1 on each crankpin Replace the connecting rod bearing if out of specification
114. ing attachment 1 90890 06607 2 Install a new needle bearing into the for ward gear to the specified depth S6C 16540 Needle bearing attachment 2 90890 06614 Driver rod L3 S 90890 06652 ye Depth 8 1 20 0 25 mm 0 05 0 01 in Assembling the drive shaft 1 Install a new drive shaft bearing into the drive shaft using a press S6D56240 6D93G11 Installing the propeller shaft housing 1 Drive shaft and lower case Bearing inner race attachment 1 90890 06643 Installing the drive shaft 1 Install the forward gear then the drive shaft assembly pinion and pinion nut and then tighten the nut to the specified torque 56856400 Drive shaft holder 5 D 90890 06519 Pinion nut holder 2 New 90890 06715 Current 90890 06505 Pinion nut 93 N m 9 3 kgf m 68 6 ft lb Install the washer 1 and propeller shaft assembly 2 into the propeller shaft housing assembly 3 Apply grease to a new O ring 562Y6705 6 20 Lower unit 3 Install the propeller shaft housing assem bly into the lower case and then install the straight key claw washer 6 and ring nut 4 Tighten the ring nut to the specified torque 562Y6710 562Y6715 NOTE rn To secure the ring nut bend one tab of the claw washer into a slot in the ring nut e Bend all other tabs toward the propeller shaft housing assembly Ring nut wrench 3 90890 0651 1 R
115. ing nut wrench extension 9 90890 06513 Ring nut 103 N m 10 3 kgf m 76 0 ft lb S60C6430 NOTE MEE Install the shift rod assembly into the lower case turn it counterclockwise 90 8 and then push it down to connect it to the shift slider 2 Install new oil seals into the oil seal hous ing as shown S6C16560 NOTE E Install an oil seal halfway into the oil seal housing then the other oil seal Ball bearing attachment 90890 06655 Installing the water pump and shift rod 1 Install the shift rod assembly 6 21 Driver rod LS 4 90890 06606 4 0 0 5 mm 0 16 0 02 in 6D93G11 f Install a new O ring 5 onto the oil seal housing Install a new gasket 7 the oil seal hous ing a new gasket 8 the outer plate cartridge 9 and a new gasket 0 56D86140 Install the Woodruff key into the drive shaft Align the groove on the impeller with the Woodruff key 2 and then install the impeller onto the drive shaft 56D86260 Install the insert cartridge 3 into the water pump housing A 6D93G11 Drive shaft and lower case S1104J S6D86150 NOTE Te Align the insert cartridge projection with the hole in the water pump housing 8 Install the dowels 45 and the water pump housing 9 onto the lower case 9 Install and tighten the bolts 0 56D86160 NOTE ee e Apply grease to the inside of the water pump housing b
116. it Removing the lower unit 1 Drain the gear oil N S66T6370 2 Set the gear shift to the neutral position S6D86020 and place a block of wood between the anti cavitation plate and propeller to keep 5 Loosen the bolts nuts and then remove the propeller from turning and then the lower unit from the upper case remove the propeller nut and propeller 562Y6485 WARNING e Do not hold the propeller with your hands when loosening or tightening it e Be sure to disconnect the battery leads from the battery and the clip from the engine stop lanyard switch S6D86030 e Put a block of wood between the anti X transom model cavitation plate and propeller to keep the propeller from turning 3 Disconnect the speedometer hose 1 4 Mark the trim tab 2 at the area shown and then remove it 6D93G 11 6 8 Lower unit Removing the water pump and shift rod 1 Remove the water pump housing and impeller 2 Remove the Woodruff key 3 Remove the outer plate cartridge and oil seal housing 4 Remove the shift rod assembly 1 S60C6405 NOTE Pull up the shift rod assembly a little to dis connect it from the shift slider 2 turn it clock wise 902 p and then remove it Disassembling the oil seal housing 1 Remove the oil seals using a flat head screw driver S6D86240 6 9 Checking the water pump and shift rod 1 Check the water pump housing for defor mation Replace if
117. l the lower mounts onto the upper case S6D87200 4 Install the upper and lower mounting bolts into the bracket simultaneously 5 Install the upper mounting nut and lower mounting nut 7 and then tighten them to the specified torques NOTE AAA Before tightening the lower mounting nut be sure to connect the ground lead to the lower mounting bolt 6 Install the mount covers 8 6D93G11 7 Install the oil pump assembly 9 and the bolts 40 and then tighten them to the specified torque 56D87210 NOTE When installing the oil pump assembly onto the upper case pour a small amount of engine oil into the oil inlet or oil outlet of the oil pump assembly Upper mounting nut 51 N m 5 1 kgf m 37 6 ft lb Lower mounting nut 7 51 N m 5 1 kgf m 37 6 ft lb Oil pump bolt 0 10 N m 1 0 kgf m 7 4 ft lb Grease nipple 3 N m 0 3 kgf m 2 2 ft lb 6D93G11 Upper case 7 16 BRKT Bracket unit Steering arm CO N DU AS WD 7 17 Nut Steering hook Stud bolt Steering arm Washer Bushing O ring Bushing Washer Steering yoke Damper Circlip 20 N m 2 0 kgf m 14 8 ft Ib LS CO N O VI 56D87220 Part name Remarks M10 x 40 mm Not reusable 2 TA N N N 6D93G11 Steering arm Removing the steering arm 1 Remove the circlip 2 Remove the steering yoke 2 by striking it with a plastic hammer 56D87250 4 Insta
118. lay 2 Fuse 30 A Starter relay starter relay Main and fuel pump relay 8 5 6D93G1 1 Electrical components Top view 56088040 D Fuel injection Shift position switch Sensor assembly intake air temperature and intake air pressure ldle speed control Stator coll Power trim and tilt switch Starter motor 6D93G11 8 6 ELEC 7 ELEC m Electrical systems Ignition and ignition control system Checking the ignition spark 1 Remove the spark plug wire cover 2 Disconnect the spark plug caps from the spark plugs 3 Connect a spark plug cap to the special service tool S6D88050 4 Crank the engine and observe the spark through the discharge window of the spe cial service tool Check the ignition sys tem if the spark is weak S6D88060 A WARNING e Do not touch any of the connections of the ignition tester leads e Do not let sparks leak out of the removed spark plug caps e Keep flammable gas or liquids away since this test can produce sparks 8 NOTE ee The ignition spark can also be checked using the Stationary test of the Selva Diagnos tic System Checking the spark plug wires 1 Remove the spark plug wires from the spark plugs 2 Remove the spark plug wires from the ignition coils 3 Measure the spark plug wire resistance Replace if out of specification S60C8100 Spark plug wire resistance 1 4 5 10 7 KQ 2 3 3 8 0 RO 3
119. le cable Cn throttle pick up timing Water pump LE REM ras Spark plugs Clean adjust s replace Timing belt Check replace NOTE When operating in salt water turbid or muddy water the engine should be flushed with clean water after each use Every Refer to Item Remarks 500 L Puno 1 000 hours Sue 2 5 ES 5 Ti Pag Timing belt 548 Valve clearance DOHC Check adjust od i NOTE b b When using lead or high sulfur gasoline checking valve clearance may be required more frequently than every 500 hours 6D93G11 3 2 TA ADJ Periodic checks and adjustments Top cowling Checking the top cowling 1 Check the fitting by pushing the cowling with both hands Adjust if necessary I L EE a A M S60C3010 2 Loosen the bolts 3 Move the hook up or down slightly to adjust its position S6D83010 NOTE e To loosen the fitting move the hook in direction e To tighten the fitting move the hook in direction 4 Tighten the bolts 5 Check the fitting again and if necessary repeat steps 2 4 Fuel system Checking the fuel joint and fuel hoses fuel joint to fuel injector 1 Remove the flywheel magnet cover 3 3 2 Check the low pressure fuel hose con nections and fuel joint for leaks Replace if necessary Also check the fuel filter 1 fuel pump strainer 3 and fuel coo
120. le turning the drive shaft until the drive shaft can no longer be turned K Bearing housing puller claw L 90890 06502 Stopper guide plate 2 90890 06501 Center bolt 3 90890 06504 4 Install the backlash indicator onto the drive shaft 20 mm 0 79 in in diameter then the dial gauge onto the lower unit 56016760 NOTE SS Install the dial gauge so that the plunger a contacts the mark b on the backlash indica tor 6 29 Backlash indicator 4 90890 06706 Magnet base plate 6 90890 07003 Dial gauge set 6 90890 01252 Magnetic base B 7 90890 06844 5 Slowly turn the drive shaft clockwise and counterclockwise and measure the back lash when the drive shaft stops in each direction Forward gear backlash 0 28 0 63 mm 0 0110 0 0248 in 6 Add or remove shims if out of specifica tion Forward gear backlash Less than To be decreased by 0 28 mm 0 0110 in 0 46 M x 0 56 More than To be increased by 0 63 mm 0 0248 in M 0 46 x 0 56 Shim thickness M Measurement Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 7 Remove the special service tools and then install the water pump assembly 6D93G11 Backlash MEMO 6D93G11 6 30 Bracket unit Special Service tools sva 7 1 SM OG 7 2 BOHOM COMING iii 7 3 Upper CaSe tS 7 6 Removing the upper case ii 7 12 Disassembling the oil P
121. ler 4 for leaks or deterioration Replace if necessary 3 Check the high pressure fuel hose con nections for leaks Replace if necessary Also check the vapor separator fuel rail fuel injectors and pressure regulator for leaks or deterioration Replace if necessary Checking the fuel filter 1 Check the fuel filter element for dirt and residue and check the fuel filter cup for foreign substances and cracks Clean the cup with straight gasoline and replace the element if necessary D S6D83030 NOTE Be sure not to spill any fuel when removing the fuel filter cup 6D93G 11 Power unit Checking the engine oil 1 Place the outboard motor in an upright position 2 Remove the oll dipstick wipe it clean and then insert it back into the dipstick hole 3 Remove the oil dipstick again to check the oil level and to check the oil for dis coloration and its viscosity ARE Il Bes f E E S60C1150 NOTE Change the oil if it appears milky or dirty e If the engine oil is below the minimum level mark add sufficient oil until the level is between 8 and Changing the engine oil using an oil changer 1 Start the engine warm it up and then turn it off 2 Remove the oll dipstick and oil filler cap CD UCET e S60C3060 3 Insert the tube of the oil changer 2 into the dipstick hole 6D93G11 Top cowling Fuel system Power unit FIL F
122. ll the steering yoke 0 to the steer ing arm by aligning the center of the yoke with the center of the steer ing arm 5 Install the circlip 5 56D87230 3 Remove the steering arm from the swivel bracket by pulling the arm off the bracket Installing the steering arm 1 Install the washer D bushing O ring 3 and bushing onto the steering arm 5 2 Place the swivel bracket 6 in an upright position and then install the steering arm onto the swivel bracket S6D87260 6 Inject grease into the grease nipple until grease comes out from both the upper and lower bushings S6D87240 3 Install the bushing O ring 8 and washer 9 onto the swivel bracket 560C7255 6D93G1 1 7 18 BRKT Bracket unit Clamp brackets and swivel bracket X 15 N m 1 5 kgf m 11 1 ft Ib 56D87490 CO N DU POD 7 19 Swivel bracket Clamp bracket Clamp bracket Self locking nut Screw Washer Bushing Trim sensor cam Screw Plate Anode Bolt Bolt Through tube Bolt 1 1 1 1 1 2 2 1 1 1 1 1 2 1 1 96 x 25 mm M6 x 14 mm M6 x 16 mm M8 x 20 mm 6D93G11 CO N DU POD Part name Swivel bracket Tilt stop lever Bushing Distance collar Pin Hook Bolt Spring Tilt stop lever Trim sensor Screw Bolt Clamp Grease nipple Ground lead Pin 6D93G11 Clamp brackets and swivel bracket 5 14 16 4 5 56D87500 A N Na FM I 4 ZA
123. lling the water pump and shift F0d nennen nennen 6 21 Installing the lower UNIt i 6 22 Shining ai E EE 6 25 DIMMI 6 26 Seleciing ine pinion ShIMSsi aa 6 26 Selecting the forward gear shims i 6 27 A e iii 6 28 Measuring the forward gear backlash nina 6 28 6D93G11 Lower unit Special service tools Ring nut wrench 3 90890 06511 Ring nut wrench extension 90890 06513 Bearing housing puller clavv L 90890 06502 a Stopper guide plate 90890 06501 Center bolt 90890 06504 6 1 Bearing separator 90890 06534 Stopper guide stand 90890 06538 Bearing puller assembly 90890 06535 Needle bearing attachment 90890 06607 90890 06611 90890 06612 90890 06614 Driver rod L3 90890 06652 6D93G11 Driver rod SS 90890 06604 gt Bearing depth plate 90890 06603 M Driver rod LS 90890 06606 Ball bearing attachment 90890 06655 Bearing inner race attachment 90890 06639 90890 06643 90890 06661 6D93G11 Special service tools Drive shaft holder 5 90890 06519 A Pinion nut holder New 90890 06715 Current 90890 06505 Bearing outer race puller assembly 90890 06523 Driver rod SL 90890 06602 Bearing outer race attachment 90890 06621 90890 06626 6 2 Lower unit Driver rod LL 90890 06605 Shift rod push arm 90890 06052 Pinion height gauge 90890 067
124. ly to securely fasten it 6D93G11 Vapor separator LJ e P S69J4040 A WARNING Do not reuse the fuel hose clamp always replace it with a new one Disassembling the vapor separator 1 Remove the float chamber float pin and float 56C14220 NOTE 2 Remove the float pin in the direction of the arrow Q shown 2 Remove the needle valve and other com ponents Checking the vapor separator 1 Check the needle valve for bends or wear Replace if necessary S6D54200 4 16 vel D Fuel system 2 Checkthe float for deterioration Replace if necessary 3 Check the filter for dirt or residue Clean if necessary Assembling the vapor separator 1 Install the needle valve float and float pin and then check the float for smooth operation 56C14210 NOTE Do not reuse the float pin always replace it with a new one e Install the float pin in the direction of the arrow shown e Install the float pin with its tapered end towards the punch mark on the vapor separator cover 2 Check the float height as shown Adjust the float height if out of specifica tion MM a Float height 46 6 1 0 mm 1 83 0 04 in 3 Check the float height as shown Adjust the float height if out of specifica tion 4 17 56C14200 NOTE e The float should be resting on the needle valve but not compressing it e Take measurements at the position shown opp
125. m 0 4 kgf m 3 0 ft Ib D SD gt 56D84030 Part name Screw 96 x 35 mm Cover Gasket Fuel pump body 2 assembly Diaphragm Not reusable Pin Spring Fuel pump body 1 Spring Plunger Nut CO ON D I On OD O 6D93G11 4 4 ru Fuel system Checking the fuel pump 1 Place a drain pan under the fuel hose connections and then disconnect the fuel hoses from the fuel pump 2 Connect the special service tool to the fuel pump inlet 3 Cover the fuel pump outlet with a finger and then apply the specified positive pressure Check that there is no air leak age S63P4090 Vacuum pressure pump gauge set 90890 06756 Specified pressure 50 kPa 0 5 kgf cm 7 3 psi 4 Apply the specified negative pressure and check that there is no air leakage S63P4100 Specified pressure 30 kPa 0 3 kgf cm 4 4 psi 5 Connect the special service tool to the fuel pump outlet 6 Apply the specified positive pressure and check that there is no air leakage Disas semble the fuel pump if necessary S63P4110 NOTE L_z Assemble the fuel pump valve to the fuel pump body and moisten the inside of the fuel pump with gasoline to ensure a good seal Specified pressure 50 kPa 0 5 kgf cm 7 3 psi Disassembling the fuel pump 1 Disassemble the fuel pump 2 Push downon the plunger and the dia phragm turn fuel pump b
126. n and if necessary repeat steps 2 12 14 Install the intake silencer Checking the gear shift operation 1 Check that the gear shift operates smoothly when shifting it from neutral to forward or reverse Adjust the shift cable length if necessary 2 Setthe gear shift to the neutral position 3 Loosen the locknut D remove the clip and then disconnect the shift cable joint 3 4 Remove the clip 9 S6D83140 6D93G 11 Control system e Align the alignment mark 8 on the bush ing and alignment mark on the bracket 56D81040 6 Install the clip p Adjust the position of the shift cable joint until its hole is aligned with the set pin Tr eM 56943370 WARNING The shift cable joint must be screwed in a minimum of 8 0 mm 0 31 in 8 Connect the cable joint install the clip and then tighten the locknut 9 Checkthe gear shift for smooth operation and if necessary repeat steps 2 8 3 10 IC ADJ Periodic checks and adjustments Bracket unit Checking the power trim and tilt operation 1 Fully tilt the outboard motor up and down a few times and check the entire trim and tilt range for smooth operation Check the power trim and tilt fluid level if necessary S6C 13220 NOTE Be sure to listen to the vvinding sound of the power trim and tilt motor for smooth opera tion 2 Fully tilt the outboard motor up and then support it with
127. n of the absorber valve and check for dirt or residue Clean if necessary Assembling the tilt cylinder Install a new O ring the backup ring and a new dust seal 1 into the trim cylinder end screw Q 2 Install the O ring onto the trim cylinder end screw 3 Install the tilt ram into the trim cylinder end screw S60C 7860 4 Install the backup ring and new O rings and into the tilt cylinder end screw 8 56007865 5 Install the tilt cylinder end screw onto the tilt ram S60C7870 6D93G11 Tilt cylinder and trim cylinder 6 Install the new O rings and 0 and backup ring 1 onto the trim piston 2 7 Install the balls 43 valves 2 and springs 5 into the trim piston and then install the washer 46 and trim piston to the tilt cylin der 7 8 Install the filter and washer 9 to the trim piston MT S 56D87410 Tilt piston bolt 69 85 N m 8 5 kgf m 62 7 ft lb 13 Install the tilt ram into the tilt cylinder 14 Hold the tilt cylinder 49 in a vise using aluminum plates on both sides gt T 8 o Y Ri S60C7875 OG 9 Install the backup ring and new O ring fe 0 gt ds y to the tilt piston 62 56007885 a rm 10 Install balls 3 and 63 valves 65 springs 68 pins dowels 68 and washer amp NOTE into the tilt piston Place the tilt cylinder in the vise horizontally f 11 Hold the tilt ram end in a vise using alu
128. necessary 2 Check the impeller and insert cartridge for cracks or wear Replace if necessary 3 Check the Woodruff key and the groove on the drive shaft for wear Replace if necessary ANGA P S6D86050 4 Check the shift rod for cracks or wear Replace if necessary 6D93G11 Lower unit Propeller shaft housing Propeller shaft housing 10 3 kgf m 76 0 ft Ib S6D76010 Remarks Slider Shift plunger Cross pin Dog clutch Spring Propeller shaft Washer Reverse gear Thrust washer Ball bearing O ring Propeller shaft housing Straight key Needle bearing Oil seal Claw washer Ring nut CO N Dv BE Co Tn Not reusable Not reusable Not reusable 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 6D93G1 6 10 Lower unit Removing the propeller shaft housing assembly 1 Straighten the claw washer tabs and then remove the ring nut and claw washer S62Y6595 Ring nut wrench 3 90890 0651 1 Ring nut wrench extension 2 90890 06513 2 Pul out the propeller shaft housing assembly 56856310 Bearing housing puller claw L 3 90890 06502 Stopper guide plate 4 90890 06501 Center bolt 90890 06504 3 Remove the propeller shaft assembly 6 11 Disassembling the propeller shaft assembly 1 Remove the spring D and then remove the cross pin dog clutch 3 slider and shift plunger S62Y6635 Disassembling the p
129. ns Power unit Electrical systems Troubleshooting TRBL SITO D Special tool Specified measurement 2 Specified oil or fluid 6 Specified electrical value 3 Specified engine speed resistance voltage electric current Specified tightening torque Symbols 7 to 43 in an exploded diagram indicate the grade of lubricant and the lubrication point Apply Selva 4 stroke motor oil AD Apply corrosion resistant grease Apply gear oil Selva grease D 9 Apply water resistant grease Selva grease A 42 Apply low temperature resistant grease Apply molybdenum disulfide grease Selva grease C 3 Apply injector grease Symbols 9 to 8 in an exploded diagram indicate the type of sealant or locking agent and the appli cation point Apply Gasket Maker 7 Apply LOCTITE 572 5 Apply LOCTITE 271 red Apply silicon sealant Apply LOCTITE 242 blue 6D93G1 1 1 2 des General information Safety while working To prevent an accident or injury and to ensure quality service follow the safety pro cedures provided below Fire prevention Gasoline is highly flammable Keep gasoline and all flammable products away from heat sparks and open flames 569J1010 Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous If inhaled in large quantities they may cause loss of consciousness and death within a short time When test running an engine indoors e g in a water tank
130. ody 1 approximately 90 to a position where the pin can be removed easily and then remove the pin S60C40 0 S60C4080 6D93G11 3 Slowly let up on the plunger and dia phragm and then remove them Checking the diaphragm and valves 1 Check the diaphragm for tears and the valves for cracks Replace if necessary Assembling the fuel pump NOTE Clean the parts and soak the valves and the diaphragm in gasoline before assembly to obtain prompt operation of the fuel pump when starting the engine 1 Align the plunger and diaphragm installa tion holes 8 and then install the plunger into the diaphragm 2 Push down on the plunger and the dia phragm and then install the pin 1 56004100 3 Turn fuel pump body 1 2 approximately 90 and then push down on the plunger several times to make sure that the pin does not come out 56004110 NOTE ____ Make sure that the gasket and diaphragm are kept in place through the assembly process 6D93G11 Fuel filter and fuel pump 4 6 cu Fuel system Intake manifold 56D94010 Part name M6 x 80 mm Intake silencer Bolt Bushing Collar Intake manifold assembly Bolt Collar Bolt Spacer Bolt Collar Holder Gasket Pin Joint Intake silencer M8 x 30 mm M8 x 100 mm M6 x 45 mm Not reusable D 00 0 2 DP D Marlin 100 EFI 4 7 6D93G11 Intake manifold 3 7 N m 0 37 kgf m 2 7 ft Ib
131. oftware is run on Microsoft Windows 95 Windows 98 Windows Me Windows 2000 or Windows XP the information can be displayed in colorful graphics Also the software can be oper ated using either amouse or a keyboard In addition the data for the main functions Diagnosis Diagnosis record Engine monitor and Data logger can be saved on a disk or printed out Functions 1 Diagnosis With the engine main switch ON each sensor s status and each ECM diagnosis code or item is displayed This enables you to find malfunctioning parts and controls quickly 2 Diagnosis record Sensors that had been activated and ECM diagnostic codes that have been recorded are displayed This allows you to check the outboard motor s record of malfunctions 3 Engine monitor Each sensor status and the ECM data are displayed while the engine is run ning This enables you to find malfunctioning parts quickly 4 Stationary test With the engine off the ignition fuel injection electric fuel pump and ISC valve are checked These tests can be performed quickly 5 Active test With the engine running each firing cylinder has dropped and the engine speed is checked for changes to determine whether the cylinder is malfunctioning and the ISC valve is checked as well These tests can be performed quickly 6 Data logger Displays 13 minutes of recorded data for two or more of the items stored in the ECM In addition the operating time as compared to the engine spe
132. ooccccccccnconcccconconcconanononononnnnconnnncnncnnoncnns 8 7 Checking the ignition COllS nn 8 7 Checking Ihe EOM uo itus ee dette id aia 8 8 Checking the pulser collS 25 22 ee 8 8 Checking the sensor assemDIY nnne 8 8 Checking the cooling water temperature sensor 8 9 Checking the oil pressure SWItCh 2 Rnnennnnneennnnnnnnnnnnnnnnnnnnnnnn 8 9 Checking the shift position SWItCh i 8 9 Checking the main and fuel pump relay main control 8 10 mieeniplELicieee ila 8 10 Checking tMeInjectorS asensi E 8 10 Checking the electric fuel pump i 8 10 Checking the main and fuel pump relay fuel control 8 11 Starting sysiema ssac D ELE 8 11 GHECKNG NE CURES sei 8 11 Checking the starter relay a 8 11 Starter motor ua 8 13 Disassembling the starter MOtor nennen nnennn nennen nennen 8 15 Checking the starter motor pinion nennen 8 15 Checking the armature cociente 8 15 CHECKING the DIUS DES Lutsk 8 16 Checking the magnet SWitCh oooncccccccooonccnnccnccnnnnnnnnonononarennnnnnonanenoss 8 16 Checking the starter motor operation nennen nnennennnee nenne 8 16 Charging ciem 8 16 Checking ME Stator Colorada 8 16 Checking the Rectifier Regulator ii 8 17 ELEC 77 ELEC l Electrical systems Special
133. or clearer Contents 1 General information N Specifications GO Periodic checks and adjustments gt I c Fuel system m C m r ie 7 8 O Lower unit O 7 Bracket unit CO NI Electrical systems i n o y m x O JJ UJ Lo Troubleshooting D L G Wo Y 6D93G11 General information How to use this Manlal aria 1 1 MENA 1 1 SI MDO SS rr Rai 1 2 Safety while WOKING 1 3 Fire ENE tT 1 3 Venta OM 1 3 je DIOTECUO EE mames 1 3 Parts lubricants and sealants nennen nenn 1 3 3004 WOKING Praslices ars near 1 4 Disassembly and assembly nennen 1 4 laentificalio NN 1 5 Applicable Model punte ad 1 5 Sena number Aer 1 5 isla e arca 1 5 FOC G12 e 1 5 A DU E A 1 6 PTEAEIIVErV CHEcKSs ansvar 1 6 Checking tlie uel SVSEBITI aot tvi a 1 6 Checking the engine oil IEVel iaia 1 6 Checking the gear oil level i 1 7 Checking tlie Dalla issues a Rute recta utc d ete tuens 1 7 Checking the outboard motor mounting height 1 7 Checking the remote control cables i 1 7 Checking the steering system nnn 1 8 Checking the gear shift and throttle operation esses 1 8 Checking the power trim and tilt system
134. osite the float pivot Float height 35 0 1 0 mm 1 38 0 04 in 4 Install the float chamber xy Float chamber screw 3 N m 0 3 kgf m 2 2 ft lb Adjusting the float 1 Adjust the stopper of the float by bending it until the float height is within specification S6C14290 Float height 46 6 1 0 mm 1 83 0 04 in 2 Adjust the lever 0 of the float by bending it until the float height is within specifi cation 6D93G 11 56014300 Float height 9 35 0 1 0 mm 1 38 0 04 in NOTE When adjusting the float height do not bend the lever 6D93G11 Vapor separator 4 18 ru Fuel system Canister 56D84150 Remarks Bolt M6 x 16 mm Bracket Canister Bolt Grommet Bracket Collar Hose Hose Hose Filter Hose Clamp Bolt Holder Bolt Bracket M6 x 28 mm CON OOF WN M6 x 10 mm M6 x 16 mm 4 19 6D93G11 Checking the canister 1 Check the canister for cracks Replace if necessary 2 Connect the special service tool to the atmospheric port 1 and cover the other ports each with a finger 56D84160 3 Apply the specified positive pressure and check that there is no air leakage Replace the canister if there is air leak age vz Vacuum pressure pump gauge set 90890 06756 Specified pressure 19 6 kPa 0 196 kgf cm 2 8 psi 6D93G11 Canister 4 20 Power unit Special service LOOMS an
135. place or rebore the cylinder block if above specifi cation Taper limit D D direction d D D direction 0 08 mm 0 0031 in 3 Calculate the out of round limit Replace or rebore the cylinder block if above specification Out of round limit D D measuring point D D measuring point 0 05 mm 0 0020 in Checking the piston clearance 1 Calculate the piston clearance using the piston outside diameter and the cylinder bore Replace the piston and piston rings as a set or the cylinder block or all parts or rebore the cylinder if out of specifica tion 6D93G11 Cylinder block Piston clearance 0 070 0 080 mm 0 0028 0 0031 in Checking the piston rings 1 Check the piston ring dimensions of B and T Replace if out of specification 569J5B80 Piston ring dimensions Top ring B 1 17 1 19 mm 0 0461 0 0469 in T 2 80 3 00 mm 0 1102 0 1181 in Second ring B 1 47 1 49 mm 0 0579 0 0587 in T 3 00 3 20 mm 0 1181 0 1260 in Oil ring B 2 38 2 48 mm 0 0937 0 0976 in T reference data 2 40 mm 0 0945 in 2 Level the piston ring in the cylinder with a piston crown 9 42 Power unit 3 Check the piston ring end gap at the specified measuring point Replace if out of specification Ar Dr Dl S63P5B70 Piston ring end gap 9 Top ring 0 15 0 30 mm 0 0059 0 0118 in Second ring 0 0 0 90 mm
136. r commercially avail able as shown 5695820 4 Measure the valve seat contact width a where the blueing dye is adhered to the valve face Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification Replace the valve guide if the valve seat contact is uneven X 569J5830 6D93G11 Cylinder head 56945840 Valve seat contact width 1 20 1 60 mm 0 0472 0 0630 in Refacing the valve seat 1 Reface the valve seat with the valve seat cutters 5695870 Slag or rough surface CAUTION Do not over cut the valve seat Be sure to turn the cutter evenly downward at a pres EN sure of 40 50 N 4 5 kgf 8 8 11 Ibf to 30 i y v prevent chatter marks 3 Use a 30 cutter to adjust the contact width of the top edge of the valve seat 569J5850 Lo Valve seat cutter holder gt 6 90890 06553 Valve seat cutter 30 intake 90890 06326 30 exhaust 90890 06328 45 exhaust 90890 06312 30 intake 90890 06324 S69J5880 exhaust 90890 06315 Previous contact width 45 intake 90890 06555 60 60 2 Cut the surface of the valve seat with a 45 cutter by turning the cutter clockwise until the valve seat face has become smooth 6D93G11 5 30 Power unit 4 Use a 60 cutter to adjust the contact width of the bottom edge of the valve seat b b Previous contact width 56945
137. reduce the fuel pressure in the high pressure fuel line before servicing the line or the vapor separator If the fuel pressure is not released pressurized fuel may spray out Disconnecting the quick connector 1 Wrap the quick connector with a cloth and then rotate the quick connector tab D to the stopper position 8 D S6C 14240 WARNING If the quick connector is removed sud denly pressurized fuel could spray out To gradually release the fuel pressure be sure to remove the quick connector slowly 4 13 CAUTION e Do not rotate the quick connector tab 1 past the stopper position otherwise it could be damaged e When the fuel hose is disconnected quickly remove the retainer 2 from the quick connector otherwise the retainer could be lost 2 Disconnect the quick connector 3 from the fuel rail 4 directly o S6C14250 A WARNING Always reduce the fuel pressure in the fuel line before servicing the line or the fuel pipe If the fuel pressure is not released pressurized fuel could spray out Measuring the fuel pressure 1 Disconnect the quick connector from the fuel rail NOTE mm Before disconnecting the quick connector release the fuel pressure 2 Connect fuel pressure gauge adapter B D between the quick connector and fuel rail 3 Connect the fuel pressure gauge Q to fuel pressure gauge adapter B 6D93G 11 A WARNING e When connecting the fuel pressure
138. ropeller shaft housing 1 Remove the reverse gear and thrust washer S6C 16440 Bearing separator 1 90890 06534 Stopper guide plate 2 90890 06501 Stopper guide stand 8 90890 06538 Bearing puller assembly 4 90890 06535 2 Remove the ball bearing Ud y ty N T AG ENN AS TN ol IT nio ey S6C16450 6D93G11 CAUTION Do not reuse the bearing always replace it with a new one 2 Stopper guide plate 90890 06501 1 Stopper guide stand 90890 06538 Bearing puller assembly 90890 06535 3 Remove the oil seals and needle bear ing 56856350 Z Needle bearing attachment 7 90890 06612 Driver rod L3 9 90890 06652 Checking the propeller shaft housing 1 Clean the propeller shaft housing using a soft brush and cleaning solvent and then check it for cracks Replace if necessary 2 Check the teeth and dogs of the reverse gear for cracks or wear Replace the gear if necessary 3 Check the bearings for pitting or rum bling Replace if necessary Checking the propeller shaft 1 Check the propeller shaft for bends or wear Replace if necessary 2 Measure the propeller shaft runout 6D93G11 Propeller shaft housing 56D56510 Runout limit 0 02 mm 0 0008 in 3 Check the dog clutch and slider for cracks or wear Replace if necessary Assembling the propeller shaft assembly 1 Install the dog clutch as
139. rt RS232C Dsub 9 pin port USB port Printer Compatible with the operating systems mentioned above NOTE o dt e The amount of memory and the amount of free space on the hard disk differs depending on the computer e Using this software while there is not enough free space on the hard disk could cause errors and result in insufficient memory his software will not run properly on some computers e When starting up this program do not start other software applications Do not use the screen saver function or the energy saving feature when using this program e If the ECM is changed restart the program e Windows XP is a multiuser operating system therefore be sure to end this program if the login user is changed e The USB adapter cannot be used with Windows 95 For operator instructions of the Diagnostic System refer to the Diagnostic Sys tem Instruction Manual 9 3 6D93G11 Diagnostic System Connecting the communication cable to the outboard motor Bow view 3 pin communication coupler 56D89010 6D93G1 1 9 4 TRBL e SHTG e Troubleshooting NOTE e Check that all electrical connections are tight and free from corrosion and that the battery is fully charged to 12 V e o diagnose a mechanical malfunction use the troubleshooting charts pertaining to the trouble located in this chapter Also when checking and maintaining the outboard motor see Chapters 3 8 for safe maintenance procedures
140. s and highly caustic Always follow these preventive measures e Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury e Wear protective eye gear when handling or working near batteries Antidote EXTERNAL e SKIN Wash with water e EYES Flush with water for 15 minutes and get immediate medical attention Antidote INTERNAL e Drink large quantities of water or milk followed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries generate explosive hydrogen gas Always follow these preventive mea sures e Charge batteries in a well ventilated area e Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes e DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN S60C3670 NOTE A Batteries vary per manufacturer The pro cedures mentioned in this manual may not always apply therefore consult the instruc tion manual of the battery Disconnect the negative battery lead first then the positive battery lead Electrolyte specific gravity 1 280 at 20 C 68 F S60C3695 3 15 6D93G 11 560C3710 NOTE JJ h B Apply grease to the grease nipple until it flows from the bushings 8 2 Apply low temperature resistant grease to the area shown TARRRRR 56D83190 3
141. s or damage Replace the lower case if nec essary 6 18 Lower unit Assembling the lower case 1 Install the needle bearing into the lower case to the specified depth S6C 16500 NOTE A aa Install the needle bearing with the manufac ture identification mark facing upward e When using the driver rod do not strike the special tool in a manner that will force the stopper out of place Z Driver rod SL 90890 06602 1 Needle bearing attachment 90890 0661 1 Bearing depth plate 3 90890 06603 Depth 188 1 0 5 mm 7 41 0 02 in 2 Install the sleeve original shim s and taper roller bearing outer race S6C16510 6 19 CAUTION Add or remove shim s if necessary if replacing the taper roller bearing or lower case NOTE an ri e Apply the gear oil to the inside and outside of the sleeve before installation e Install the sleeve by facing the projection forward Bearing outer race attachment 4 90890 06626 Driver rod LL 6 90890 06605 3 Install the original shim s and taper roller bearing outer race m Y 56016520 CAUTION Add or remove shim s if necessary if replacing the taper roller bearing or lower case Bearing outer race attachment 6 90890 06621 Driver rod LL 90890 06605 Assembling the forward gear 1 Install a new taper roller bearing into the forward gear using a press 6D93G11 S6C16530 Needle bear
142. se and that water does not flow in over the transom NOTE The test run is part of the break in operation 1 9 Break in During the test run perform the break in operation in the following three stages 1 One hour at 2 000 r min or at approxi mately half throttle 2 One hour at 3 000 r min or 3 4 throttle and 1 minute out of every 10 at full throt tle 3 Eight hours at any speed however avoid running at full speed for more than 5 minutes 56941240 Hour After test run 1 Checkfor water in the gear oil 2 Check for fuel leakage in the cowling 3 Flush the cooling water passage with fresh water using the flushing kit and with the engine running at idle 6D93G11 6D93G11 Specifications General specifications ua 2 1 Maintenance specification nn rrnnnunnnnvennnnnnnnnvennnuvnnnnnevnnnennnnnevnnvennnnvennnuennnnner 2 3 mgl m M 2 3 Mo c PUNEO O Meine P TII 2 6 EEE 2 6 DIMENSIONS Lellis 2 9 TONEN torge S aa 2 11 Specified IGUS SE 2 11 General ter ques er 2 13 SPEC a Specifications General specifications i Marin 100 ERA Dimension Overall length Overall width Overall height X Boat transom height L X Weight with aluminum propeller L X with stainless propeller Performance Maximum output KW hp 58 8 80 at 73 6 100 at 5 500 r min 5 500 r min Full throttle operating range
143. service tools Ignition tester 90890 06756 Test harness 6 pins 90890 06848 Digital circuit tester Vacuum pressure pump gauge set 90890 03174 90890 06756 Peak voltage adapter B 90890 03172 Test harness 2 pins 90890 06792 Test harness 3 pins 90890 06791 8 1 6D93G11 Special service tools Checking the electrical components Checking the electrical components Measuring the peak voltage NOTE e ri Before troubleshooting the peak voltage check that all electrical connections are tight and free from corrosion and that the battery is fully charged to 12 V The condition of the ignition system can be determined by measuring the peak voltage Cranking speed is effected by many factors such as fouled or weak spark plugs or a weak battery If one of these factors is present the peak voltage will be lower than specification In addition if the peak voltage is lower than specification the engine will not operate properly 56948020 A WARNING When checking the peak voltage do not touch any of the connections of the digital tester leads NOTE Use the peak voltage adapter with the digi tal circuit tester When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode e Connect the positive pin on the peak volt age adapter to the positive terminal of the digital circuit tester 6D93G11 Measuring the lower resistance When mea
144. shown 56C16750 NOTE ee Install the dog clutch with the F mark facing toward the slider 6 12 Lower unit Assembling the propeller shaft housing 1 Install the needle bearing into the propel ler shaft housing to the specified depth S63P6100 NOTE e Install the needle bearing with the manufac ture identification mark facing toward the oil seal propeller side e When using the driver rod do not strike the special tool in a manner that will force the stopper out of place Driver rod SS 90890 06604 Needle bearing attachment 2 90890 06612 Bearing depth plate 9 90890 06603 Depth b 25 25 0 25 mm 0 99 0 01 in 2 Apply grease to the new oil seals and then install them into the propeller shaft housing to the specified depth NOTE Install an oil seal halfway into the propeller shaft housing then the other oil seal 6 13 Ball bearing attachment 90890 06655 Driver rod LS 90890 06606 Depth 5 0 0 5 mm 0 20 0 02 in 3 Install the thrust washer 6 and new ball bearing to the reverse gear 8 using a press 3 La I AA TT 777 A S6D86270 NOTE Install the ball bearing with the manufacture identification mark 8 facing outward propel ler side qe Bearing inner race attachment 90890 06639 4 Install the reverse gear assembly into the propeller shaft housing using a press
145. suring a resistance of 10 Q or less with the digital circuit tester the correct mea surement cannot be obtained due to the internal resistance of the tester To obtain the correct value subtract the internal resistance from the displayed measurement NOTE 5 To obtain the internal resistance of the digital circuit tester connect both of its probes and check the display Correct value displayed measurement internal resistance 8 2 ELEC 7 ELEC m Electrical systems Electrical components Port view S6D88010 CD Idle speed control Throttle position sensor Sensor assembly intake air temperature and intake air pressure Pulser coil 4 Oil pressure switch 5 Fuel injector 6 Electric fuel pump 8 3 6D93G11 Electrical components Starboard view FLL SU lo Y REIS ff AMI IH IG KL La Br Pa A DD 3 G C PE i 5 4 Gap tas MAG CILE VILE 3 g 3 O D5X 33589 ES Ca 256 585368 000060 8 4 ELEC 7 ELEC m Electrical systems Bow view S6D88030 D ECM 9 Fuse 20A Sensor assembly ECM ignition coil electric fuel pump and fuel intake air temperature and intake air injector pressure Fuse 20A 3 Idle speed control main switch and power trim and tilt switch Throttle position sensor AD Fuse 20 A 5 Rectifier Regulator Rectifier Regulator 6 Power trim and tilt re
146. t cranking unloaded at cranking loaded at 1 500 r min loaded at 3 500 r min loaded Pulser coil resistance W R W B B Throttle position sensor Output voltage P B Cooling water temperature sensor resistance at 0 C 32 F at 80 C 176 F Oil pressure switch Operating pressure Fuel control system Fuel injector resistance at 21 C 70 F Starter motor Type Output Cranking time limit Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit The figures are for reference only 2 KO KO kPa kgf cm psi kW Second Model Marlin 100 ER 3 6 3 4 18 2 34 3 459 561 0 8 1 2 at engine idle speed 5 21 6 3 0 290 0 354 127 5 166 7 1 28 1 67 18 49 24 17 Sliding gear 1 40 30 15 5 0 61 9 5 0 37 6D93G11 A Charging system Fuse Stator coil output peak voltage W W at cranking unloaded at 1 500 r min unloaded at 3 500 r min unloaded Stator coil resistance W W at 20 C 68 F Rectifier Regulator output peak voltage R Ground at 1 500 r min unloaded at 3 500 r min unloaded Power trim and tilt system Trim sensor Setting resistance Resistance Fluid type Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit P B P_B The figure is for reference only 6D93G11 Maintenance specification Model Marin
147. te the pinion shim thickness T3 as shown in the examples below 56856250 NOTE P is the deviation of the lower case dimen sion from standard The P mark is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the P mark unreadable assume that P is zero and check the backlash when the unit is assembled Pinion shim thickness T3 M 31 50 mm P 100 Example If M is 32 10 mm and P is 5 then T3 32 10 31 50 5 100 mm 0 60 0 05 mm 0 55 mm If M is 32 10 mm and P is 5 then T3 32 10 31 50 5 100 mm 0 60 0 05 mm 0 65 mm 5 Select the pinion shim s 13 as follows Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Example If T3 is 0 55 mm then the pinion shim is 0 58 mm If T3 is 0 64 mm then the pinion shim is 0 65 mm Selecting the forward gear shims 1 Turn the taper roller bearing outer race D two or three times to seat the rollers and then measure the bearing height M as shown 562Y6925 562Y6930 NOTE a e Select the shim thickness T1 by using the specified measurement s and the calcula tion formula Measure the bearing outer race at three points to find the height average Z Shimming plate 90890 06701 Digital caliper 90890 06704 6 27 2 Calculate the forward gear shim thick
148. ted values 5 49 56D85720 Main bearing selection table 20 C 68 F Cylinder block journal inside diameters crankshaft journal Bearing cylinder side thrust bearing Bearing crankcase side diameters mm 6 023 6 026 Green 6 043 6 049 Red Blue 608 5058 med Rei CAUTION e The mark indicates that the colors of the upper and lower bearings are differ ent e Be sure to install the main bearings in the middle of the cylinder block and crankcase journal so they do not block the oil holes NOTE Main bearing 3 is a thrust bearing Example If the Crankshaft journal mark is 92 and the Cylinder block mark is 32 then the Calcu lated value 54 032 47 992 6 040 mm Suitable colors Bearing cylinder side thrust bearing gt blue Bearing crankcase side blue 5 If the calculated value is more than the maximum value 6 058 mm replace the crankshaft 6D93G11 Assembling the power unit 1 Install the oil ring D second ring 2 and top ring onto the pistons with the T marks on the piston rings facing upward 2 Offset the piston ring end gaps as shown S60C5A70 CAUTION Do not scratch the piston or break the pis ton rings NOTE After installing the piston rings check that they move smoothly 3 Install the upper bearing into the con necting rod and the lower bearing into the connecting rod cap 5
149. the crankcase and then tighten the bolts 60 from the mark e Tighten the M8 bolts to 28 N m 2 8 kgf m 20 7 ft lb Crankcase bolt M10 1st 19 N m 1 9 kgf m 14 0 ft lb 2nd 60 Crankcase bolt M8 1st 14 N m 1 4 kgf m 10 3 ft lb 2nd 28 N m 2 8 kgf m 20 7 ft lb 6D93G11 Cylinder block Remove the crankcase and then mea sure the width of the compressed Plasti gauge PG 1 on each crankshaft journal Replace the main bearing if out of specification 56065950 Crankshaft journal oil clearance 0 024 0 044 mm 0 0009 0 0017 in Selecting the main bearing When replacing the main bearing select the suitable bearing as follows 5 48 Power unit 2 Check the crankshaft journal mark on the crankshaft 1 and the cylinder block mark on the cylinder block 1 2 3 4 5 3 Subtract crankshaft journal diameters 1 5 from cylinder block journal inside diameters 1 5 NOTE Cylinder block journal inside diameters 1 5 and crankshaft journal diameters 311 525 can be determined by the stamped value as described below Crankshaft journal diameter 47 900 stamped value 1 000 Example 1 92 gt 47 992 Cylinder block journal inside diameter 54 000 stamped value 1 000 Example 1 32 54 032 4 Select the suitable color for the main bearing from the table below according to the calcula
150. the right tool in the right manner do not improvise 56941050 Tightening torques Follow the tightening torque specifications provided throughout the manual When tight ening nuts bolts and screws tighten the large sizes first and tighten fasteners starting in the center and moving outward Non reusable parts Always use new gaskets seals O rings cot ter pins circlips etc when installing or assembling parts 56941060 6D93G11 Safety while working Disassembly and assembly 1 Use compressed air to remove dust and dirt during disassembly 2 Apply engine oil to the contact surfaces of moving parts before assembly 56941070 3 Install bearings with the manufacture identification mark in the direction indi cated in the installation procedure In addition be sure to lubricate the bearings liberally 4 Apply a thin coat of water resistant grease to the lip and periphery of an oll seal before installation 5 Check that moving parts operate nor mally after assembly 1 4 eum General information Identification Applicable model This manual covers the following model Applicable model F80BET F100DET Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket S6D81010 YAMAHA MOTOR CO LTD MADE IN JAPAN PAYS D ORIGINE JAPON 69J1090N Y Model name 2 Approved model code 3 Transom height 4 Serial number
151. the tilt stop lever 1 to check the lock mechanism of the lever 56D83150 Checking the power trim and tilt fluid level 1 Fully tilt the outboard motor up and then support it with the tilt stop lever 1 3 11 56D83150 A WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure 2 Remove the reservoir cap 2 and then check the fluid level in the reservoir E Da N wy O J Y 56D83160 NOTE If the fluid is at the correct level the fluid should overflow out of the filler hole when the reservoir cap is removed 3 If necessary add sufficient fluid of the recommended type until it overflows out of the filler hole Recommended power trim and tilt fluid ATF Dexron II 4 Install the reservoir cap and then tighten it to the specified torque Reservoir cap 7 N m 0 7 kgf m 5 2 ft lb 6D93G11 Lower unit Checking the gear oil level 1 Fully tilt the outboard motor down 2 Remove the check screw D and then check the gear oil level in the lower case S60C3540 NOTE If the oil is at the correct level the oil should overflow out of the check hole when the check screw is removed 3 If necessary add sufficient gear oil of the recommended type until it overflows out of the check hole Recommended gear oil
152. ulser coil output Good spark P peak voltage 8 8 Check the ignition coil resis tance 8 7 Within specification Replace the ignition coil Check the spark plug wire resis tance and check the spark plug cap for corrosion or rust 8 7 Good condition Replace the spark plug wire Check the ECM output peak voltage 8 8 Compression pressure Check that there is no secondary air intake on the contact surfaces of the intake manifold and cylinder head Is there air Yes intake Replace the defective seals Check the compression pres sure of the combustion chamber 6D93G1 9 10 TRBL e SHTG e Troubleshooting Symptom Engine does not accelerate when the throttle is opened quickly The engine turns off when the throttle is opened quickly Acceleration is tardy and the engine is likely to stop at any moment e Check the engine using the diagnostic flash indicator or the Diagnostic System Symptom Engine can run but engine speed will not increase Overheat warning indicator is on Oil pressure warning indicator is on Warning indicator is on and buzzer is sounding e Check the cooling system e Check the lubrication system Cooling system Check the cooling water inlet for clogs or debris 3 8 Check that cooling water is No discharged from the cooling water pilot hole Clogs or debris Yes Clean the cooling water inlet Is water No discharged
153. utator for dirt Clean with 600 grit sandpaper and com pressed air if necessary 56948390 8 15 2 Measure the commutator diameter Replace the armature if below specifica tion 56948400 Commutator diameter wear limit 28 0 mm 1 10 in 3 Measure the commutator undercut a Replace the armature if below specifica tion 56938410 Commutator undercut wear limit 8 0 2 mm 0 01 in 4 Check the armature for continuity Replace if out of specifications 56948420 6D93G11 C mi Armature continuity Commutator segments amp Continuity Segment Armature core Segment No continuit Armature shaft y Checking the brushes 1 Measure the brush length Replace the brush assembly if below specification No continuity 569J8430 Brush length wear limit amp 9 5 mm 0 37 in 2 Check the brush holder assembly for continuity Replace if out of specification 569J8440 i Brush continuity Brush D Brush No continuity Checking the magnet switch 1 Connect the tester leads between the magnet switch terminals as shown 2 Connect the positive battery lead to the brown white Br W lead 6D93G11 Starter motor Charging system 3 Connect the negative battery lead to the starter motor body 56D98010 CAUTION Do not connect the battery for more than one second otherwise the magnet switch can be damaged 4 Check that there is continuit
154. ute the PTT motor leads through the hole and then install the holders and plastic ties 7 Connect the ground lead 56D87470 Bleeding the power trim and tilt unit built in 1 Fully turn the manual valve counterclock wise S60C7745 7 44 BRKT Bracket unit 2 Fully tilt the outboard motor up and then release it to let it lower by its own weight four to five times 3 Tighten the manual valve by turning it clockwise Reservoir cap 7 N m 0 7 kgf m 5 2 ft lb 4 Letthe fluid settle for 5 minutes 5 Push and hold the power trim and tilt switch in the up position to check that the outboard motor is fully tilted up 6 Support the outboard motor with the tilt stop lever 1 560C7975 A WARNING After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure 7 Remove the reservoir cap and then check the fluid level in the reservoir LIMITI 17777777 11177777 LIL VE HEG FJ S6D83160 1 45 NOTE SSS If the fluid is at the correct level the fluid should overflow out of the filler hole when the reservoir cap is removed 8 If necessary add sufficient fluid of the recommended type to the correct level Recommended power trim and tilt fluid ATF Dexron II 9 Install the reservoir cap
155. ve guide inside diameter valve stem diameter Intake 0 010 0 043 mm 0 0004 0 001 7 in Exhaust 0 025 0 058 mm 0 0010 0 0023 in Replacing the valve guides 1 Remove the valve guide 1 by striking the special service tool from the combus tion chamber side 56005470 t Valve guide remover installer 5 9 4 90890 04064 5 28 Power unit 2 Install the new valve guide by striking the special tool from the camshaft side to the specified position 8 560C5480 NOTE ___ Before installing the valve guide mark its installation position as shown e Apply engine oil to the surface of the new valve guide vz Valve guide remover installer 5 9 90890 04064 Valve guide position 11 5 0 2 mm 0 45 0 01 in 3 Insert the special service tool into the valve guide and then ream the valve guide 56065490 NOTE e Turn the valve guide reamer clockwise to ream the valve guide e Do not turn the reamer counterclockwise when removing the reamer Valve guide reamer 6 0 90890 04066 5 29 4 Measure the valve guide inside diameter Valve guide inside diameter Intake and exhaust 6 000 6 018 mm 0 2362 0 2369 in Checking the valve seat 1 Eliminate carbon deposits from the valve with a scraper 2 Apply a thin even layer of Mechanic s blueing dye Dykem onto the valve seat 3 Lap the valve slowly on the valve seat with a valve lappe
156. when the timing belt is not installed Otherwise the piston and valves will interfere with each other and be damaged 1 Remove the flywheel magnet cover 2 Loosen the flywheel magnet nut S6D55B30 CAUTION Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily S63P5280 9 13 Do not turn the drive sprocket counter 563P5290 CAUTION To prevent damage to the engine or tools screw in the puller set bolts evenly and completely so that the puller plate is par allel to the flywheel magnet NOTE o Apply force to the crankshaft end until the fly wheel magnet comes off the tapered portion of the crankshaft Flywheel puller 90890 06521 4 Remove the Woodruff key 1 and stator assembly 56D85210 NOTE Do not loosen the pulser coil screw 5 Turn the drive sprocket clockwise and align the hole on the retaining plate with the projection on the cylinder block and check that A marks and on the driven sprockets are aligned 6D93G11 Power unit 9 Check that A marks and on the driven sprockets are aligned EV DE 56D85220 6 Disconnect the cooling water hose Q S6D85240 and remove the bracket 4 7 Remove the spring and timing belt tensioner 6 and then remove the timing belt from the driven sprockets then from the drive sprocket S6D85230 8 Check that the hole on th
157. when the timing belt is not installed Otherwise the piston and 3 Disconnect the cooling water hose and valves will interfere with each other and remove the bracket be damaged 4 Remove the spring and timing belt ten 1 Turn the drive sprocket clockwise and sioner and then remove the timing belt align the hole on the retaining plate from the driven sprockets then from the with the projection on the cylinder drive sprocket block and check that A marks and on the driven sprockets are aligned 5 Loosen the driven sprocket bolts and then remove the driven sprockets 5 56D85730 NOTE AA Do not turn the camshafts when loosening the driven sprocket bolts S6D85220 Flywheel holder 90890 06522 2 Loosen the drive sprocket nut 1 6 Remove the nut D drive sprocket 6 retaining plate and Woodruff key 8 S6D85360 5 17 6D93G11 S6D85380 Checking the timing belt and sprockets 1 Check the interior and exterior of the tim ing belt for cracks damage or wear Replace if necessary 2 Check the drive sprocket and driven sprockets for cracks damage or wear Replace if necessary Installing the sprockets and timing belt 1 Install the dowels and driven sprockets D and check that A marks and on the driven sprockets are aligned S6D85660 2 Tighten the driven sprocket bolts to the specified torque 6D93G11 Power unit 56D85740 NOTE
158. y between the magnet switch terminals Replace if there is no continuity 5 Checkthat there is no continuity after the negative battery terminal is removed Replace if there is continuity NOTE e The starter motor pinion should be pushed out while the magnet switch is on Checking the starter motor operation 1 Check the operation of the starter motor after installing it onto the power unit Charging system Checking the stator coil 1 Disconnectthe stator coil coupler 2 Connect the test harness 6 pins to the stator coil coupler 8 16 ELEC 77 ELEC m Electrical systems 3 Measure the stator coil output peak volt age Replace the stator coil if below El Sl specification T RN 6 H i i FIA d I WATTE IV 0 X SV ie UE SJ ER PE Fron Man NEAR 1 ji i y MELONS i P4 QI N NY LE Sw S6D88150 GA Digital circuit tester 90890 03174 3 S6D88140 7 1 Test harness 6 pins 90890 06848 SN v DS S LA a Cs Digital circuit tester 90890 03174 A Peak voltage adapter B 90890 03172 voltage Test harness 6 pins 90890 06848 Red R Ground Unloaded r min Stator coil output peak voltage 1 500 3 500 nn Unloaded Rectifier Regulator output peak Unloaded Stator coil resistance reference data 0 24 0 36 Q at 20 C 68 F Checking the Rectifier Regulator 1 Disconnect the stator coil coupler 2

Marlin 100 EFI English

Contents

Download Pdf Manuals

Related Search

Related Contents