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F90D Service Manual

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1. S6D85510 NOTE mA NF I 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 Ib 2nd 17 N m 1 7 kgf m 12 5 ft lb 8 Install the cylinder head cover 5 35 A a Ci IT j c 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 lb 9 Install the sprockets and timing belt NOTE E For sprocket and timing belt installation pro cedures see Installing the sprockets and timing belt 6D81G11 Cylinder head Exhaust cover Exhaust cover 25 w 49N m 4 9 kgf m 36 1 ft Ib o 18 N m 1 8 kgf m 13 3 ft Ib MJ 23 N m 2 3 kgf m 17 0 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib S6D85090 Z o ON OA POD Part name Remarks Not reusable 94 x 13 mm Gasket Screw Anode Exhaust cover Gasket Cooling water temperature sensor Holder Bolt Holder Bolt Gasket Grommet Pressure control valve Spring Cover Bolt Gasket Not reusable M6 x 15 mm M6 x 10 mm Not reusable M6 x 20 mm Not reusable OA WwW 6D81G11 5 36 25 KE 26 18 N m 1 8 kgf m 1
2. Dimensions Exterior mm in oy LO D e st L 998 39 3 527 20 7 X 1 115 43 9 gt EU gg 651 25 6 62 2 4 U I 4 5 SV ceo co i Tw F i N nn a em 8 ES TI co cp Y Y sy y a W 1 o Bc o 164 6 5 La IK o zz 88 D Lm TN ns Zo Or J S i0 ot IX N amp 1 00 63 2 u 5 5 X Y 1 i 56 i 3 Te Lo st NN ux 28 14 574 22 6 S6D82010 6D81G11 2 9 Maintenance specification Clamp bracket mm in 180 7 1 180 7 1 163 5 64 163 5 6 4 80 3 1 348 5 13 7 13 0 5 125 4 4 9 125 4 4 9 S6D82020 6D81G11 SPEC um s Specifications Tightening torques Specified torques Tightening torques Part to be tightened Thread size kgf m ft lb Fuel system Fuel filter cup 0 3 2 2 Fuel pump mounting bolt 1 0 7 4 Fuel pump screw 0 4 3 0 Sensor assembly screw i 0 37 2 7 Idle speed control screw 1 0 37 2 7 Fuel rail mounting bolt 0 8 5 9 Throttle body mounting bolt 0 8 5 9 Fuel cooler screw 0 3 2 2 Float chamber screw 0 3 2 2 Vapor separator drain screw 1 1 Pressure regulator bolt 0 5 3 7 Fuel hose joint 0 4 3 0 Plate screw 0 2 1 5 Wiring harness holder screw Pressure check valve Power unit Power unit mounting bolt Apron screw Flywheel magnet
3. n 6 8 Removing the water pump and shift r0d n 6 9 Disassembling the oil seal housing i 6 9 Checking the water pump and shift F0d ii 6 9 Propeller shaft housing um Mipggannnnnnnnnnnnnnnnnnnnnnnnnnnsnsnnnnnnnnnnnn 6 10 Removing the propeller shaft housing assembly 6 11 Disassembling the propeller shaft assembly 6 11 Disassembling the propeller shaft housing seeseeeees 6 11 Checking the propeller shaft housing ei 6 12 Checking the propeller shaft ei 6 12 Assembling the propeller shaft assembly sees 6 12 Assembling the propeller shaft housing 4 ue 6 13 Drive shaft and lower 6ase 7 4 aa 6 15 Removing the drive haft f HE 6 17 Disassembling the drive shaftz amp F 5 ERR 6 17 Disassembling the forward gear PF A 6 17 Disassembling the lower case 999 5 c ER 6 17 Checking the pinion and forward gear eese 6 18 eum bghrings LLL MEN 6 18 G heckingkiheldyive shah Aaeeei RR 6 18 CENE lower cg6o nn Ma 6 18 AsSembmegngiower case 00 0 ff 6 19 Assembling the forward gear
4. f RED 6 19 Assembling theidrivtsiaa tl B EE eese 6 20 Installing the drive shaft ff 6 20 Installing the propeller shaft h usingu eZ 6 20 Installing the water pump and shift r0d 6 21 Installing the lowerWYynit f M mme 6 22 Sa dg eo M O EE EE 6 25 STG ee 6 26 Selecting the PINION SHIMS an passe 6 26 Selecting the forward gear ShIMS i 6 27 Backlash tas 6 28 Measuring the forward gear backlash i 6 28 Lower unit Special service tools Gland nut wrench Bearing housing needle bearing remover YB 34447 YB 06112 YB 06153 Bearing housing puller Driver handle large YB 06207 YB 06071 Universal puller Propeller shaft oil seal installer YB 06117 YB 06269 Slide hammer Drive shaft needle bearing depth stop YB 06096 YB 34473 C Bearing puller legs Bearing outer race attachment YB 06523 YB 06109 6 1 6D81G11 Drive shaft holder YB 06151 gt Drive shaft needle bearing remover and installer YB 06155 Drive shaft seal installer YB 06244 0 Forward gear bearing cup installer YB 06276 B e Forward gear outer race installer YB 06085 6D81G11 Special service tools s Shift rod push arm YB 06052 Pinion shim selecting tool YB 34432 9 YB 34432 10A YB 34432 11A YB 34432 17 Forward gear shi
5. 7 21 After test run eerie nter 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 Assembling the power trim and tilt motor 7 29 Assembling the power trim and tilt unit 7 41 Assembling the power unit 5 49 Assembling the propeller shaft assembly mmm d MM 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 16 Backlash Mme ee 6 28 Bleeding the power trim and tilt unit 7 43 Bleeding the power trim and tilt unit built in een P s 7 44 Bottom cowling ff fana 7 3 Bow view BP RR 8 5 Bracket UNIt na 3 11 9 13 Break ini saisa Eee 1 9 C Canister ciency 4 18 Changing the engine oil by draining it 3 4 Changing the engine oil using an oil Changer 3 4 Changing the gear oil ane 3 12 Charging system 8 16 Checking th
6. 6D81G11 Upper case Removing the upper case Checking the oil pump 1 Place a drain pan under the drain hole 1 Check the gear teeth for cracks or wear and then remove the drain bolt 1 and let and the oil pump case for scratches the oil drain completely Replace the oil pump assembly if neces sary d 2 Check the shaft for cracks or wear Replace if necessary 3 Check the oil passage for dirt or residue Clean if necessary Assembling the oil pump S63P7140 1 Install a new oil seal into the oil pump cover to the specified depth 2 Remove the oil pump assembly and mount covers 3 Disconnect the ground lead and speed SI ometer hose 4 Remove the upper and lower mounting nuts and then remove the upper case Disassembling the oil pump S6D87100 1 Remove the screws and disassemble the oil pump Z Bearing installer YB 41446 Driver handle large YB 06071 Depth 8 0 5 0 3 mm 0 02 0 01 in 2 Install a new oil seal into the oil pump housing ec S6D87110 S6D87070 Bearing cup installer YB 06167 Driver handle large YB 06071 6D81G11 7 12 Bracket unit 3 Install new oil seals into the oil seal hous ing S6D87140 T m S6D87120 Oil seal installer YB 06023 Driver handle small YB 06229 Roller
7. S69J3370 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 S60C1200 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 6D81G11 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 an Ge
8. ER A eee 8 5 Top view C sem 8 6 Ignition and ignition control system esee 8 7 Checking the ignition sparks Mg 8 7 Checkingthe spark plug wires P MP 8 7 Checking the ignition Coils 4 sss ua assesses 8 7 cg BA ae ae 8 8 Checking the pulsemcoils 34 A 8 8 Checking the sensolassembly f nennen 8 8 Checking the cooling water temperature sensor in 8 9 Checking the oil pressure switch ml sanan en RAM 8 9 Checking the shift position switch QP An Kuren EEE 8 9 Checking the main and fuel pump relay main control 8 10 A eee 8 10 Oo ei at Ak MY 8 10 Checking the electri fuel pump AN Wenn 8 10 Checking the main and fuel pump relay fuel control 8 11 Starting system amp f fanne 8 11 Checking the fus g EE 8 11 Checking the starter relay ii 8 11 Starter MOtOTF dt 8 13 Disassembling the starter MOtor nenn 8 15 Checking the starter motor pinion 8 15 Checking the armature u en 8 15 Checking the DUS ESRA 8 16 Checking the magnet switch ii 8 16 Checking the starter motor opera
9. dg 9 7 21 Power trim and tilt unit fl A iena 7 23 Removing the power trim and tilt UN t i 7 24 Power trim and tilt moWer Riiie een nna nnn nra nan annnm una e eg auam a muuunkk xin 7 25 Disassembling the power trim and tilt MOtor 7 27 Checking the power trim and tilt motor 7 27 Assembling the power trim and tilt motor in 7 29 Gear PUND cici C M 7 30 Disassembling the gear pump ii 7 33 Checking he gear pumps u tma coU uisa D ond 7 33 Assembling the gear pump i 7 33 6D81G11 Tilt cylinder and trim cylinder rruannnvvnnnnnnnnnnnnnnnnvnnnnnnvnnnnnnnnnvnnnnnnnvnnnnnnnnnene 7 35 Disassembling the trim Cylinder ii 7 38 Disassembling the tilt cylinder rrrrnnnnnnnvnnnnnnnnnnnnnvnnnnnnnnnennnnennnnnnerennnnn 7 38 Checking the tilt cylinder and trim cylinder ii 7 39 Checking the valves E 7 39 Assembling the tilt cylinder 7 39 Assembling the power trim and tilt UNIt 7 41 Bleeding the power trim and tilt unit 7 43 Installing the power trim and tilt unit 7 44 Bleeding the power trim and tilt unit built in nenn 7 44 Power trim and tilt electrical SYStem rire 7 45 Checking the fuse fR BEI reeeo eeraa 7 45 Checking the power tri
10. S6D85470 S6D85460 Cylinder head warpage limit 0 1 mm 0 0039 in 5 32 Installing the valves 1 Install a new valve seal 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 S60C5670 NOTE Ti The valve spring can be installed in any direction 2 Valve spring compressor 4 YM 01253 Valve spring compressor attachment YB 06320 5 33 3 Compress the valve spring and then install the valve cotters using a thin screwdriver with a small amount of grease applied to it S6005680 4 Lightly tap the valve spring retainer with a plastic hammer to set the valve cotters securely SITE COSE AS 12 Ya Oy ep 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 6D81G11 o o WW o o oo WY 9 El 0 OO qpe La El El o bo Jo Ro Rap MO SBL dg io o OEC Oo e o S6D85480 CAUTION Do not reuse the cylinder head gasket always replace it with a new one NOTE fs ee S Apply engine oil to the cyl
11. anana nana 2 13 Good working practices 1 4 H Hose routing arsaa sia ANA rea GAN GAGE 4 2 How to use this Manual 1 1 6D81G11 J L M Identification NE ENE NANG KANGEN KAKANGE 1 5 Ignition and ignition control system 8 7 Installing the clamp brackets 7 21 Installing the cylinder head 5 33 Installing the drive shaft 6 20 Installing the exhaust cover 5 38 Installing the fuel hose clamp 4 15 Installing the lower unit 6 22 Installing the power trim and tilt unit 7 44 Installing the power unit 5 51 Installing the pressure control valve 5 38 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 esses 4 7 Introduction 1 9 2 Junction DOX en un A 5 22 Lower unit D 2 6 3 12 6 4 Lubricating the outboard motor 3 15 Mainte
12. 4 S6D85080 Part name Remarks Z o o I CO CI BE o ND 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 N ON OO M10 x 143 mm o M8 x 40 mm M6 x 22 mm DDDDDPRH o 6D81G11 5 24 15 N m 1 5 kgf e m 11 1 ft Ib 30 N m 3 0 kgf m 22 1 ft Ib Part name o AG I 8 AR WA 4 Remarks S6D85080 Valve lifter Valve cotter Valve spring retainer Valve spring Valve spring seat Valve seal Valve guide 5 25 Not reusable Not reusable 6D81G11 Removing the cylinder head 1 Remove the cylinder head cover 2 Remove camshaft caps and in the sequence shown ERE a ro o A El MU S6D85420 3 Remove the camshaft intake 3 cam shaft exhaust 2 and oil seals 5 S6D85430 4 Remove the valve shims from the valve lifters S60C5380 6D81G11 Cylinder head NOTE Do not mix the valve train parts Keep them organized in their proper groups 5 Remove the c
13. Clean or replace the filters No Check the fluid passages for clogs or debris Clogs or debris Clean the passages Check the internal parts valves pistons gears etc 6D81G11 Bracket unit 9 14 TRBL 1 SHTG e Troubleshooting Symptom Power trim and tilt unit does not hold the outboard motor up Check that the manual valve is closed Is it closed Close the valve Yes Check the power trim and tilt fluid level At specified level Add fluid to the correct level Disassemble the power trim and tilt unit and then check the filters for debris or dirt Stuck foreign substance or lam Clean or replace the filters clogs No Check the fluid passages for clogs or debris Clogs or debris Clean the passages Check the internal parts valves pistons gear etc 9 15 6D81G11 Bracket unit Symptom Shift mechanism of the forward gear and reverse gear does not operate properly Check the shift cable operation Check the shift cables and links of the remote control box Good operat ing condition Check the operation of the shift rod Check the detent of the bottom cowling Good operat ing condition Check the condition of the shift rod connection between the lower case and upper case C
14. 5 45 3 Check the crankpin mark on the crank shaft I 2 3 OD I wa DA ren S6D85670 4 Subtract the crankpin diameters 1 4 from the connecting rod big end inside diameters 1 4 NOTE c E 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 Select the suitable color for the con necting rod bearing from the table below according to the calculated values S6D85710 6D81G11 Connecting rod bearing selection table 20 C 68 F Connecting rod big end inside diameters crankpin diameters mm Upper Lower bearing bearing 3 025 3 027 Yellovv Yellow 3 028 3 034 Yellow Green 3 035 3 041 Green Green 3 042 3 049 Green Blue 3 050 3 057 Blue Blue 3 058 3 063 Blue Red 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 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
15. Check the fuel system using the Yamaha Diagnostic System 9 9 6D81G11 Power unit Ignition system Check the ignition spark using A WARNING the spark checker Do not touch any of the connections of the spark checker leads Do not let sparks leak out of the removed spark plug caps Keep flammable gas or liquids away since this test can produce sparks Check the ignition system out k Good spar put peak voltage Check the ignition system using the Yamaha Diagnostic System Within Replace the spark plug spegififation Check the ignition coils resis tance Within Check the ignition specification system using the Yamaha Diagnostic System Replace the ignition coil Compression pressure S Check that there is no secondary air intake on the contact surfaces of the intake manifold and cylinder head Is there air intake Replace the defective seals Check the compression pres sure of the combustion chamber 6D81G11 9 10 TRBL 1 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 Check the engine using the diagnostic flash indicator or the Yamaha Diagnostic System Symptom Engine can run but engine speed will not inc
16. ii 1 6 CCS ger oil levo AR 1 7 ol lic battery ee 1 7 Checking the outboard motor mounting height 1 7 Checking the remote control Cables udtzzasssssnannnnnnnnnannnnnnnenennnnnnn 1 7 Checking the steering system eene 1 8 Checking the gear shift and throttle operation ssessssse 1 8 Checking the power trim and tilt SyStem i 1 8 Checking the engine start switch and engine stop lanyard switch 1 8 Checking the cooling water pilot hole i 1 9 E up M to c Apr E 1 9 Bei OAHU PLC T T atacs 1 9 After test run 7 mcm 1 9 General information How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under stand Use the information below as a guide for effective and quality service 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 Symbols are used to indicate important aspects of a procedure such as the grade of lubricant and lubrication point 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 ind
17. Segment Armature shaft No continuity 6D81G11 Power trim and tilt motor 5 Check the circuit breaker for continuity Replace if there is no continuity S62Y7930 6 Measure the brush length Replace if below specification S62Y7940 Brush length wear limit 3 5 mm 0 14 in 7 Check the base for cracks or damage Replace if necessary 8 Check the bushing and oil seal for damage or wear Replace if necessary r S62Y7950 7 28 Bracket unit Assembling the power trim and tilt motor 1 Install a new oil seal and the bushing into the motor base as shown S6D87330 2 Attach the circuit breaker onto the brush 5 together with the brush holder and connect the wire lead S62Y7970 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 S6D87350 NOTE ee 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 6D81G11 Gear pump sho P 5 N m 0 5 kgf m 3 7 ft Ib DE SI X 5 N m 0 5 kgf m 3 7 ft Ib Z o Part name A Power trim and tilt motor Gear pump 33 MI2N m 0 2 kgf m 1
18. 1 Install the throttle position sensor 1 in a position where the output voltage is within specification x S6D84170 NOTE e f the throttle position sensor output voltage is out of specification reinstall the throttle position sensor e Measure the throttle position sensor output voltage using the Yamaha Diagnostic Sys tem e 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 Yamaha Diagnostic System 4 9 6D81G11 Intake manifold Vapor separator Vapor separator Noir S6D84070 Z o NOD IA WU N Part name 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 Not reusable Not reusable UU a AAA on 2 2 iD WW 6D81G11 4 10 rue BY Fuel system 411 5 N m 0 15 kgf m 1 1 ft Ib Sg 3 N m 0 3 kgf m 2 2 ft Ib 1 3 N m 0 3 kgf m 2 2 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib S6D84080 No Part name Qty Remarks 1 Screw 6 5 x 14 mm 2 Gasket 1 3 Float chamber 1 4 Damper 1 5 Drain screw 1 6 O ring 1 7 Joint screw 1 8 O ring 1 9 Fuel hose 1 10 F
19. Changing the engine oil using an oil changer 1 Start the engine warm it up and then turn it off 2 Remove the oil dipstick and oil filler cap S60C3060 3 Insert the tube of the oil changer 2 into the dipstick hole 3 6D81G11 Top cowling Fuel system Power unit S6D83040 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 qt 6 Install the oil filler cap and oil dipstick and then start the engine and warm it up for 5 minutes 7 Turn the engine off and then check the oil level and 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 mac ADJ Periodic checks and adjustments 2 Remove the oil dipstick and oil filler cap S60C3060 3 Place a drain pan under the drain hole and then remove the drain bolt and let the oil drain completely l 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 rec
20. Intake A i 36 48 36 58 1 4362 1 4402 Exhaust A i 36 90 37 06 1 4528 1 4591 Intake B i 29 95 30 05 1 1791 1 1831 5 Exhaust B i i 29 92 30 08 1 1780 1 1842 Camshaft journal diameter i 24 960 24 980 0 9827 0 9835 Camshaft runout limit i 0 03 0 0012 Valves Valve clearance cold Intake i 0 20 0 03 0 008 0 001 Exhaust i 0 34 0 03 0 013 0 001 Head diameter A Intake i 29 0 29 2 1 14 1 15 Exhaust 24 0 24 2 0 94 0 95 Face width B Intake NB i 1 99 2 44 0 0783 0 0961 Exhaust A i 2 27 2 72 0 0894 0 1071 Seat contact width C Intake i 1 20 1 60 0 0472 0 0630 Exhaust i 1 20 1 60 0 0472 0 0630 Margin thickness D Intake i 0 80 1 20 0 0315 0 0472 Exhaust i 1 00 1 40 0 0394 0 0551 Stem diameter Intake i 5 975 5 990 0 2352 0 2358 Exhaust i 5 960 5 975 0 2346 0 2352 Guide inside diameter Intake and exhaust i 6 000 6 018 0 2362 0 2369 Stem to guide clearance Intake i 0 010 0 043 0 0004 0 0017 Exhaust i 0 025 0 058 0 0010 0 0023 Stem runout limit i 0 01 0 0004 Valve springs Free length i 53 20 2 0945 Tilt limit i 2 6 0 10 The figure is for reference only 6D81G11 2 4 SPEC um s Specifications Item Model F90TR Valve lifters Valve lifter outside diameter 27 965 27 980 1 1010 1 1016 Valve lifter to cylinder head i 0 020 0 056 0 0008 0 0022 cl
21. 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 Disconnect an ignition coil coupler 2 Connect the test harness 2 pins to the ignition coil 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 S6D88070 CZ Digital multimeter YU 34899 A Peak volt meter adapter YU 39991 Test harness 2 pins YB 06792 ECM output peak voltage Black red B R Ground Black white B W Ground Loaded Cranking 1 500 3 500 210 290 290 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 coil 6D81G11 Ignition and ignition control system 3 Measure the pulser coil output peak volt age Replace the stator assembly if below specification S6D88080 NOTE Do not loosen the pulser coil screw A Digital multimeter YU 34899 A Peak volt meter adapter YU 39991 Test harness 3 pins YB 06791 Pulser coil output peak voltage White red W R Black B White black W B Black B Unloaded Loaded Cranking 1 500 3 500 3 6 3 4 18 2 34 3 Pulser coil resistance reference data 459 561 Q Checking the sensor assem
22. S60C3710 NOTE e c wQ Apply grease to the grease nipple until it flows from the bushings 2 Apply low temperature resistant grease to the area shown S6D83190 3 Apply corrosion resistant grease to the area shown S68F3190C 6D81G11 6D81G11 Fuel system Special Service 10015 M 4 1 HOSE FUNG ME 4 2 Fuel and blowby hoses nee 4 2 Fuel filter and fuel pump iii 4 3 Checking the fuel pump ii nen 4 5 Disassembling the fuel Pump u 4 5 Checking the diaphragm and valves nn 4 6 Assembling the fu fpump BR 4 6 Intake manifold NT aao 4 7 Checking the throttle position sensor dieere 4 9 Installing the throttle position sensor 44 ee aal 4 9 Ch cking he idle speed control g Pn 4 9 VENT 0 AE ee 9 ll 4 10 Reducing the fuel pilpssuroe 4 4 hhv 4 13 Disconnecting the quick connector S EEES eeeeee eens 4 13 Measuringithe fuel pressured a Sen ERR 4 13 Checking the pressure regulator 5 uen 4 14 Drain fuel Z 4 P VL ENG 4 15 Removing the fuel hose clamps ee ERR 4 15 ugs fuel hose clap al A 4 15 Disassembling the vapor separator Am 4 15 Cheekingki
23. S69J3370 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 ation 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 4 Remove the clip S6D83140 6D81G11 Control system 5 Align the alignment mark 8 on the bush ing and alignment mark on the bracket S6D81040 6 Install the clip N Adjust the position of the shift cable joint until its hole is aligned with the set pin S69J3370 d 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 Check the gear shift for smooth operation and if necessary repeat steps 2 8 3 10 mac 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 powe
24. 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 port RS232C Dsub 9 pin port USB port Printer Compatible with the operating systems mentioned above NOTE EM The amount of memory and the amount of free space on the hard disk differs depending on the computer Using this software while there is not enough free space on the hard disk could cause errors and result in insufficient memory This software will not run properly on some computers When starting up this program do not start other software applications Do not use the screen saver function or the energy saving feature when using this program 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 The USB adapter cannot be used with Windows 95 For operating instructions of the Yamaha Diagnostic System refer to the Yamaha Diagnostic Sys tem Instruction Manual 9 3 6D81G11 Yamaha Diagnostic System Connecting the communication ca
25. YAMAHA F90D SERVICE MANUAL AA LIT 18616 02 86 6D8 28197 1G 11 NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use Because Yamaha has a policy of continuously improving its products models may differ in detail from the descriptions and illustrations given in this publication Use only the latest edition of this manual Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures and these are incorporated in successive editions of this manual Important information Particularly important information is distinguished in this manual by the following notations A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the outboard motor CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the out board motor NOTE A NOTE provides key info
26. and then remove the cross pin dog clutch slider and shift plunger i M Disassembling the propeller shaft S62Y6635 housing 1 Remove the reverse gear and thrust washer S62Y6610 S68S6090 CAUTION Do not reuse the bearing always replace it with a new one 6D81G11 Propeller shaft housing Z Slide hammer YB 06096 Bearing puller legs YB 06523 3 Remove the oil seals and needle bear ing S68S6100 K Bearing housing needle bearing remover 2 YB 06153 Driver handle large YB 06071 Checking the propeller shaft housing 1 Clean the propeller shaft housing using a soft brush and cleaning solvent and then check it for cracks Replace if necessary 2 Check the teeth and dogs of the reverse gear for cracks or wear Replace the gear if necessary 3 Check the bearings for pitting or 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 S6D56510 6D81G11 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 shown 6C16750 NOTE Su 2 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 b
27. 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 and fuel cooler 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 2 and pressure regulator for leaks or deterioration Replace if necessary Checking the fuel filter 1 Check the fuel filter element D 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 IN oF c amp S6D83030 NOTE o Be sure not to spill any fuel when removing the fuel filter cup 6D81G11 Power unit Checking the engine oil 1 Place the outboard motor in an upright position 2 Remove the oil dipstick wipe it clean and then insert it back into the dipstick hole 3 Remove the oil dipstick again to check the oil level and to check the oil for dis coloration and its viscosity f 2 SA S60C1150 NOTE Change the oil if it appears milky or dirty If the engine oil is below the minimum level mark add sufficient oil until the level is between and
28. the cooling water passage inside the out board motor lever 6D81G11 3 8 CHK ADJ 3 6 Loosen the locknut remove the clip and then disconnect the throttle cable joint Loosen the locknut and then discon nect the throttle link rod joint from the ball joint of the throttle body S6D83090 Check that the stopper on the throttle cam contacts the fully closed stopper 7 on the cylinder block S6D83100 Check that the throttle valve fully close NOTE Do not turn the throttle stop screw 3 9 Push the throttle link rod toward the cylinder head and check that the throttle cam roller 9 contacts the side of the throttle cam Q Periodic checks and adjustments S6D83110 8 Adjust the throttle link rod joint to align its hole with the ball joint O on the throttle body 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 6 on the throttle lever and fully open stopper 2 on the throttle body is less than 5 mm 0 20 in when the throttle cam is in the fully open position S6D83130 11 Adjust the position of the throttle cable joint until its hole is aligned vvith the set pin on the throttle cam 6D81G11 LER
29. turn it clock wise 90 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 necessary 2 Check the impeller and insert cartridge for cracks or wear Replace if necessary 3 Check the Woodruff key and the groove 8 on the drive shaft for wear Replace if necessary od di fo P S6D86050 4 Check the shift rod for cracks or wear Replace if necessary 6D81G11 Lower unit Propeller shaft housing Propeller shaft housing S6D86060 Z o ON OA BE WIN Part name Remarks Slider Shift plunger Dog clutch Spring Propeller shaft Shim Washer Reverse gear Thrust washer Ball bearing O ring Propeller shaft housing Straight key Needle bearing Oil seal Claw washer Ring nut Not reusable Not reusable Not reusable LA SM oa oa oa 6D81G11 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 S68S6070 2 Pull out the propeller shaft housing assembly S68S6080 Z Bearing housing puller YB 06207 Universal puller 3 YB 06117 3 Remove the propeller shaft assembly Disassembling the propeller shaft assembly 1 Remove the spring
30. 3 9 kgf m 28 8 ft Ib S6D85030 No Part name Q ty Remarks 1 Timing belt 1 2 Bolt 2 M10 x 35 mm 3 Dowel 2 4 Driven sprocket 2 5 Bolt 2 M6 x 15 mm 6 Bracket 1 7 Bolt 1 M10 x 45 mm 8 Timing belt tensioner 1 9 Spring 1 10 Plastic tie 1 11 Hose 1 12 Clamp 1 13 Nut 1 14 Drive sprocket 1 15 Plate 1 16 Woodruff key 1 6D81G11 5 6 4129 N m 2 9 kgf m 21 4 ft Ib Q ARP x Q OX 2 gt DX m 0 9 kgf m 6 6 ft Ib S6D85040 Z o o NOD OI BE o ND Part name Remarks Screw 86 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 Not reusable M6 x 25 mm M8 x 45 mm DO N DS N Nanananananana BE lt 9 7 6D81G11 Power unit 4129 N m 2 9 kgf m 21 4 ft Ib Q ARP x Q OX 2 gt DX S6D85040 Part name Remarks Nut 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 A A AA l l l c c c c a cl c 6D81G11 5 8 S6D85070 Z o ON OA
31. 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 trim cylinder Vee e 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 46 Checking the valve clearance 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 iii 3 8 Cylinder block i 5 39 Cylinder head 5 24 Diagnosing the electronic control SYSTEM ran 9 18 Dimensions eese 2 9 Disassembling the cylinder block 5 40 Disassembling the drive shaft 6 17 Disassembling the forward gear 6 17 Disassembling the fuel pump 4 5 Disassembling the gear pump 7 33 Disa
32. Joint Nut Cooling water inlet cover Screw Seal Plate Forward gear shim Taper roller bearing Needle bearing Forward gear assembly Needle bearing Not reusable LL 4 I Not reusable Not reusable a 6 15 6D81G11 Drive shaft and lower case ED S6D86080 Part name Remarks Pinion Nut Lower case 6D81G11 6 16 Lower unit Removing the drive shaft 1 Remove the drive shaft assembly and pinion and then pull out the forward gear S68S6150 Disassembling the drive shaft 1 Install the pinion nut D tighten it finger tight and then remove the drive shaft bearing using a press S6C16140 CAUTION Do not press the drive shaft threads 8 directly When removing the drive shaft bearing do not damage the drive shaft collar 4 Do not reuse the bearing always replace it with a new one Bearing splitter plate commercially available 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 splitter plate D commercially available 2 Remove the needle bearing from the for ward gear CIWS S68S6160 CAUTION Do not reuse the bearing always replace it with a new one Disassembling the lower case 1 Remove the taper roller bearing outer
33. Measure the valve stem runout Replace if above specification S60C5440 AS Valve stem runout limit 0 01 mm 0 0004 in Checking the valve guides NOTE n Before checking the valve guide make sure that the valve stem diameter is within specifi cation 1 Measurethe valve guide inside diameter 3 6D81G11 Cylinder head S60C5450 Valve guide inside diameter 8 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 valve guide inside diameter valve stem diameter Intake 0 010 0 043 mm 0 0004 0 0017 in Exhaust 0 025 0 058 mm 0 0010 0 0023 in Replacing the valve guides Remove the valve guide D by striking the special service tool from the combus tion chamber side S60C5470 Valve guide remover installer YM 04064 A 5 28 2 Install the new valve guide Q by striking the special tool from the camshaft side to the specified position S60C5480 NOTE ww Before installing the valve guide mark its installation position b as shown Apply engine oil to the surface of the new valve guide Cz Valve guide remover installer YM 04064 A AS Valve guide position amp 11 5 0 2 mm 0 45 0 01 in 3 Insert the special service tool into the valve guide and then
34. Unloaded Cranking 1 500 12 4 45 3 Stator coil resistance reference data White W White W 0 24 0 36 Q at 20 C 68 F Checking the Rectifier Regulator 1 Disconnect the stator coil coupler 2 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 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 6D81G11 TRBL 6D81G11 Troubleshooting Special service 1001 uu 9 1 Yamaha Diagnostic System rswvnnnnnnnvnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 9 2 Hode ON Mer M 9 2 Power UNI nee 9 5 Bracket UN ee rematat tim ma 9 13 Electrical syste En nanana nanan nannan annan nann aanns 9 17 Self diagnosis AMP aaen nanen nanne ag iii 9 18 Diagnosing the electronic control System 9 18 TRBL 1 SHTG e Troubleshooting Special service tools Yamaha Diagnostic System 60V 85300 02 YAMAHA INSTALLATION MANUAL Yamaha Diagnostic System 60V WS853 02 Diagnostic test lead YB 06795 9 1 6D81G11 Special service tools Yamaha Diagnostic System Yamaha Diagnostic System Introduction Features The newly developed Yamaha Diagnosti
35. V Vapor separator i 4 10 Ventilation i 1 3 Y Yamaha Diagnostic System 9 2 6D81G11 F90TR Q 1234567 8 9101112131415161718192021222324 1234567 8 910111213 14151617 18192021 222324 mmmmmm m mn9999599900 BES F352 RO 00 om mom E mcd I Sn TE Hehe alee O I3 ale da li amim ic E uL E M IO i plac ad I dE TES Fr Per ole ger imus D v Ev OG ADOND ROPO DIO TTT MIETTA E i ar KE hi hi T T 1 1 AQQQQQQQQQQO 63555858358 GE an ODOOOOOO GE an QDOGOOOOHO S6D8VVD01 Wiring diagram F90TR Q Ignition coil Spark plug Power trim and tilt switch tiller handle optional 4 Power trim and tilt switch bottom cowling 6 Battery Cooling water temperature sensor Starter motor Fuse 30 A Fuse 20 A Neutral switch optional Starter relay 2 Power trim and tilt relay 3 Trim sensor Power trim and tilt motor 5 Electric fuel pump Main an
36. Water Propeller boss Wet sump 6D81G11 Item General specifications Model F9OTR 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 RON PON API SAE L US at Imp qt L US qt Imp qt SAE cm US oz Imp oz Regular unleaded gasoline 91 86 4 stroke motor oil SE SF SG SH or SJ 10W 30 or 10W 40 4 3 4 55 3 78 4 5 4 76 3 96 GEAR CASE LUBE 90 670 22 7 23 6 Bracket unit Trim angle at 12 boat transom Tilt up angle Steering angle Degree Degree Degree 70 35 35 Drive unit Gear shift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction rear view Propeller mark F N R 2 31 30 13 Spiral bevel gear Dog clutch Spline Clockwise K Electrical Battery minimum capacity CCA SAE MCA ABYC RC SAE 1 RON Research Octane Number PON Pump Octane Number RON Motor Octane Number 2 2 CCA Cold Cranking Ampere MCA Marine Cranking Ampere A A Minute ABYC American Boat and Yacht Council SAE Society of Automotive Engineers RC Reserve Capacity 6D81G11 2 2 SPEC um s Specifications Maintenance specification Power unit Item Unit Model F90TR Power unit Minimum compression pressure C
37. m 9 0 kgf m 66 4 ft Ib 80 N m 8 0 kgf m 59 0 ft Ib Part name Remarks Free piston Circlip Cylinder base Spring Washer Circlip Trim cylinder 7 37 6D81G11 Disassembling the trim cylinder 1 Hold the power trim and tilt unit ina vise using aluminum plates on both sides S62Y7500 2 Loosen the trim cylinder end screw and then remove it S60C7765 A WARNING Make sure that the ram is fully extended before removing the end screw dl Trim cylinder wrench YB 06175 2B 3 Drain the power trim and tilt fluid Disassembling the tilt cylinder 1 Hold the tilt cylinder in a vise using aluminum plates 8 on both sides 6D81G11 Tilt cylinder and trim cylinder NOTE n Place the tilt cylinder in the vise horizontally 2 Loosen the tilt cylinder end screw and then remove it S6C17840 CAUTION Do not damage the check valve when loosening the end screw Z Trim cylinder wrench YB 06175 2B 3 Hold the tilt ram end in a vise using alu minum plates on both sides 7 38 Bracket unit 4 Remove the bolt 3 then the tilt piston se ON o E po e S6D87400 Checking the tilt cylinder and trim cylinder 1 Check the power trim and tilt unit for cracks or corrosion Replace if neces sary Check the inner walls of the trim cylinder and tilt cylinder for scratche
38. race and shim s S6C16700 6D81G11 NOTE Install the claws as shown Slide hammer D YB 06096 4 Bearing puller legs YB 06523 2 Remove the drive shaft bearing outer race shim s and drive shaft sleeve S6C16710 NOTE Install the claws as shown S68S6180 Drive shaft needle bearing remover E and installer YB 06155 Driver handle large YB 06071 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 6D81G11 Drive shaft and lower case 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 opp S6D86210 ox Runout limit 0 5 mm 0 020 in Checking the lower case 1 Check the skeg and torpedo for cracks 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 NOTE Install the needle bearing with the manufac ture identification mark facing upward Driver handle large D YB 06071 A Drive shaft needle bearing remover and installer 2 YB 06155 Drive shaft needle bearing depth stop 9 YB 34473 aN Depth 188 1 0 5 mm 7 41 0 02 in 2
39. tion S69J8370 S69J8400 NOTE Commutator diameter wear limit Remove the clip with a thin screwdriver 28 0 mm 1 10 in 3 Measure the commutator undercut Replace the armature if below specifica tion 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 EN I PA Turn the pinion counterclockwise to check that it operates smoothly and turn it clockwise 69J8410 to check that it locks in place Tu 4 Commutator undercut wear limit 8 0 2 mm 0 01 in Checking the armature 1 Check the commutator for dirt Clean 4 Check the armature for continuity with 600 grit sandpaper and com Replace if out of specifications pressed air if necessary S69J8420 S69J8390 8 15 6D81G11 Armature continuity Commutator segments Continuity Segment Armature core Segment Armature shaft No continuity No continuity Checking the brushes 1 Measure the brush length Replace the brush assembly if below specification S69J8430 AS Brush length wear limit amp 9 5 mm 0 37 in 2 Check the brush holder assembly for continuity Replace if out of specification S69J8440 Brush Brush No continuity Checking the magnet switch 1 Connect the tester leads between the magnet sw
40. 3 11 Lower unit acer a 3 12 Checking the gear oil level L i 3 12 Changing the gear OI BP 3 12 Checking the lower unit for air leakage i 3 13 Checking the propeller 3 13 clu 3 14 Checking the anod688 sanken 3 14 Checking the bale 3 14 Lubricating the outboard motor sseen nn 3 15 ER ADJ Periodic checks and adjustments Special service tools Digital tachometer YU 39951 B Battery powered timing light YM 33277 A Oi Pressure vacuum tester YB 35956 A IN Oil filter wrench YU 38411 6D81G11 3 1 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 Item Remarks Initial Every 50 hours 3 months 10 hours 1 month 100 hours 200 hours 6 months 1 year Refer to page Anodes external Check replace O O 3 14 Anodes internal Check replace O 3 14 Battery Check charge 3 14 Cooling water passages Clean 3 8 Top cowling Check 3 3 Fuel filter can be disassembled Check replace 3 3 Fuel system Check 3 3 Gear oil Change 3 12 Lubrication points Lubricate 3 15 Engine idle speed EFI models Check
41. 5 ft Ib Remarks X 5 N m 0 5 kgf m 3 7 ft Ib S6D87360 Gear pump assembly Spacer Pin Lever Bolt Bolt Spring Shuttle piston Backup ring Down relief valve seat Washer Spring Pin Cap Bolt Bolt Cap ON OA POD 6D81G11 AND Li LL Ni SO M3 x 16 mm M3 x 35 mm M5 x 30 mm M4 x 30 mm 7 30 Bracket unit 5a Dar S SK 5 N m 0 5 kgf m 3 7 ft Ib P 5 N m 0 5 kgf m 3 7 ft Ib 5 N m 0 5 kgf m 3 7 ft Ib 33 MI2N m 0 2 kgf m 1 5 ft Ib S6D87360 No Part name Q ty Remarks 18 Holder 1 19 Spring 1 20 Washer 1 21 Up relief valve seat 1 22 Bolt 2 M5 x 25 mm 23 O ring 1 24 Shuttle piston 1 25 Bolt 2 M5 x 45 mm 26 Bolt 2 M5 x 50 mm 27 Filter 1 28 Plate 1 29 O ring 2 30 Filter 2 31 O ring 1 32 Manual valve 1 33 Circlip 1 7 31 6D81G11 Gear pump 2N m 0 2 kgf m 1 5 ft Ib 4 N m 0 4 kgf m 3 0 ft Ib 16 S6D87550 No Part name Qty Remarks 1 Manual release spring 1 2 Ball 2 3 Bracket 1 4 Bolt 1 M3 x 5 mm 5 Bolt 2 M5 x 6 mm 6 Washer 2 7 O ring 2 8 Adapter 2 9 Spring 2 10 Ball 2 11 Gear 2 12 Drive shaft 1 13 Pin 2 14 Driven shaft 1 15 Ball 2 16 Pin 2 6D81G11 7 32 Bracket unit Disassembling the gear pump 1 Remove the manual valve then the g
42. 9 ft lb 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 6D81G11 5 38 Cylinder block LO 19 N m 1 9 kgf m 14 0 ft Ib 60 28N m 2 8 kgf m 20 7 ft Ib ORTE 18 N m 1 8 kgf m 13 3 ft Ib 80 S6D85100 Z o o I CO OI BE o ND Part name Remarks Bolt M6 x 20 mm Dowel Bolt M10 x 135 mm Crankcase Bolt Cylinder block Main bearing Main bearing Main bearing Oil seal Crankshaft Oil seal Connecting rod bearing Piston connecting rod assembly Bolt o M8 x 55 mm Not reusable Not reusable OS CO AA Ro ea Not reusable M8 x 38 mm Piston ring set Stud bolt 5 39 6D81G11 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 Oil filter wrench YU 38411 2 Remove the crankcase bolts in the sequence shown and then remove the crankcase S6D85560 NOTE ag 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 6D81G11 Cylinder block e S6D85570 NOTE ___ e Be sure to keep the bearings in the orde
43. Apply LOCTITE 271 red Apply silicon sealant Apply LOCTITE 242 blue 6D81G11 1 2 an 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 S69J1010 Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous If inhaled in large quantities they may cause loss of consciousness and death within a short time When test running an engine indoors e g in a water tank be sure to do so where ade quate ventilation can be maintained S69J1020 Self protection Protect your eyes by vvearing 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 S69J1030 Parts lubricants and sealants Use only genuine Yamaha parts lubricants and sealants or those recommended by Yamaha vvhen servicing or repairing the out board motor S69J1040 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
44. BE o NN Part name Remarks Oil filler cap O ring Cylinder head cover Screw 94 x 8 mm Plate Grommet Gashet Bolt M6 x 30 mm Camshaft cap Camshaft cap Bolt M7 x 48 mm Bolt M7 x 37 mm Oil seal Not reusable Camshaft 5 9 6D81G11 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 Ms 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 OD filler and spark plug wire cover disconnect the spark plug wires fuel hoses and blowby hose and then remove all spark plugs S6D85130 2 Turn the flywheel magnet clockwise and align the TDC mark on the flywheel magnet with the pointer D and check that a marks and on the driven sprockets are aligned 6D81G11 Power unit S6D85140 Loosen the tensioner bolt and then remove the spring 8 timing belt 9 driven sprockets 9 and cylinder head cover i S6D85150 5 10 4 Install the driven sprockets 9 timing bel
45. 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 a bench 3 Install half of the bearings and the crankshaft into the cylinder block 6D81G11 Cylinder block S60C5910 NOTE ge Install the bearings in their original posi tions Install the unified thrust bearing at the posi tion 8 shown 4 Put a piece of Plastigauge PG 1 on each crankshaft journal parallel to the crankshaft S60C5920 NOTE gt Do not put the Plastigauge PG 1 over the oil hole in the main journals of the crankshaft 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 5 46 7 Tighten the crankcase bolts to the speci fied torques in two stages and in the sequence shown S60C5950 Crankshaft journal oil clearance 0 024 0 044 mm 0 0009 0 0017 in Selecting the main bearing 1 When replacing the main bearing select the suitable bearing as follows 2 Check the crankshaft journal mark on the S6D85600 crankshaft and the cylinder block mark on the cylinder block 2 NOTE Eg sy 4 Do not move the crankshaft until the crank shaft journal oil clearance meas
46. EL YS NM H LL HH HSH PN 6D81G11 6 6 Lower unit S1104J S6D86040 Part name Remarks Gasket Outer plate cartridge Gasket Oil seal housing O ring Gasket Oil seal 6 7 6D81G11 Removing the lower unit 1 Drain the gear oil S66T6370 2 Set the gear shift to the neutral position and place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then remove the propeller nut and propeller S62Y6485 WARNING e Do not hold the propeller with your hands when loosening or tightening it Be sure to disconnect the battery leads from the battery and the clip from the engine stop lanyard switch Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning 3 Disconnect the speedometer hose 4 Mark the trim tab Q at the area shown and then remove it 6D81G11 Lower unit S6D86020 5 Loosen the bolts nuts and then remove the lower unit from the upper case S6D86030 X transom model 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 M at S60C6405 NOTE Pull up the shift rod assembly a little to dis connect it from the shift slider
47. Remove the oil pressure switch and then install an oil pressure gauge 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 5 f 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 engine idle speed 6D81G11 Power unit 42 N m 4 2 kgf m 31 0 ft Ib 42N m 4 2 kgf m 31 0 ft Ib S6D85010 o co E o be x o A E Z t Remarks Not reusable M6 x 16 mm M10 x 130 mm 96 x 40 mm M8 x 35 mm Part name Grommet Grommet Flywheel magnet cover Power unit Oil dipstick 2 3 4 5 6 5 4 6D81G11 Z o Part name S6D85020 Remarks Nut Washer Flywheel magnet Screw Screw Stator coil Bolt Stator assembly Collar Bolt Woodruff key Bolt Holder Grommet ON OA BE WUN A Mu as o N R SS St 94 x 10 mm 086 x 30 mm M6 x 30 mm M6 x 15 mm M6 x 15 mm 6D81G11 Power unit 3265 N m 26 5 kgf m 195 5 ft Ib xn 39 N m
48. 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 anana 8 11 Checking the gear oil level 1 7 8 12 Checking the gear pump 7 33 Checking the gear shift and throttle Operazione EN 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 fuel control 8 11 Checking the main and fuel pump relay main control sees 8 10 Checking the oil pressure 5 3 Checking the oil pressure switch 8 9 Checking the oil pump une 7 12 Checking the oil strainer 7 14 Checking the outboard motor mounting GIG
49. 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 6D81G11 Safety while working 6 Keep a supply of clean lint free cloths for Disassembly and assembly wiping up spills etc 1 Good working practices Special service tools Use the recommended special service tools to protect parts from damage Use the right tool in the right manner do not improvise 69J1050 3 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 4 in the center and moving outvvard Non reusable parts Always use new gaskets seals O rings cot ter pins circlips etc when installing or assembling parts S69J1060 6D81G11 m Use compressed air to remove dust and dirt during disassembly Apply engine oil to the contact surfaces of moving parts before assembly iG S69J1070 Install bearings with the manufacture identification mark in the direction indi cated in the installation proced
50. nut Starter motor bolt Spark plug wire cover screw Starter relay lead bolt Starter relay holder screw Main and fuel pump relay screw Oil pressure switch Oil pressure switch lead bolt PTT relay lead nut PTT motor lead bolt Positive battery lead nut Timing belt tensioner bolt Drive sprocket nut Driven sprocket bolt Camshaft cap bolt Cylinder head cover plate screw Cylinder head cover bolt 2 11 6D81G11 Tightening torques Tightening torques N m kgf m 14 1 4 28 2 8 Cylinder head bolt 15 1 5 30 3 0 90 Spark plug 25 2 5 Cylinder block plug 23 2 3 Oil filter joint 49 4 9 Oil filter 18 1 8 6 0 6 12 1 2 Anode screw 2 0 2 Exhaust cover plug 95 5 5 14 1 4 28 2 8 19 1 9 60 18 1 8 80 Part to be tightened Thread size M8 Exhaust cover bolt Crankcase bolt Connecting rod cap bolt Lower unit Gear oil drain screw 0 9 Gear oil check screw 0 9 Lower case mounting bolt L transom model 3 9 Lower case mounting nut X transom model 3 9 Propeller nut 3 4 Ring nut Cooling water inlet cover screw 0 5 Pinion nut 9 3 Bracket unit Shift rod detent bolt 1 8 Shift position switch screw 0 1 Flushing hose adapter screw 0 2 Oil pump bolt 1 0 Upper mounting nut 5 1 Lower mounting nut 5 1 Grease nipple 0 3 Oil pump cover screw 0 4 Oil seal h
51. o A x M6 x 20 mm M6 x 25 mm M6 x 20 mm 96 x 19 mm Part name Bottom cowling Grommet Power trim and tilt switch Grommet Grommet Grommet 18 19 27 28 29 32 7 4 6D81G11 BRKT bo 5 BP d a N Vo ong 7 7 N amp X a pL E e o r co RES N ANTA x SEG UR e Np TI Pe NS I NE r A b a Bracket unit S6D87020 2 a E E o E y E z N Es Remarks Not reusable M6 x 20 mm M6 x 25 mm M6 x 20 mm Part name Plastic tie Retaining plate Grommet Rubber seal 39 43 46 47 6D81G11 7 5 Bottom cowling Upper case Upper case x 10 N m 1 0 kgf m 7 4 ft Ib 3 N m 0 3 kgf m 2 2 ft Ib S6D87030 Z o ON OA BE WU N Part name Remarks 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 M6 x 45 mm Not reusable M10 x 40 mm M8 x 16 mm A NNN N HAN ANN HOF 6D81G11 7 6 Bracket unit S6D87040 Z o ON OA BE WU N Part name Remarks 86 x 10 mm Oil seal Screw Gasket O ring Shaft O ring Oil seal Oil seal O ring Oil seal housing Screw Oil pump assembly 96 x 10 mm
52. oil level S60C1140 Checking the battery 1 Check the capacity electrolyte level and specified gravity of the battery Recommended battery capacity CCA SAE 380 A MCA ABYC 502 A RC SAE 124 Minute 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 low water resistance will increase and reduce engine efficiency i S69J1160 1 7 NOTE The optimum mounting height is affected by the combination of the boat and the outboard motor To determine the optimum mounting height test run the outboard motor at differ ent heights 2 Check that the clamp brackets are secured with the clamp bolts Checking the remote control cables 1 Set the remote control lever to the neu tral position and fully close the throttle lever 2 Check that the stopper on the throttle cam contacts the fully closed stopper on the cylinder block S6D81030 3 Check that the alignment mark on the bushing is aligned with the alignment mark on the bracket S6D81040 6D81G11
53. 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 e 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 S6D87310 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 off of the arma ture 7 27 3 Remove the armature from the PTT motor base CAUTION Do not allow grease or oil to contact the commutator 4 Remove the screws 2 and then disas semble the PTT motor base S6D87320 Checking the power trim and tilt motor 1 Check the commutator for dirt Clean with 600 grit sandpaper and com pressed air if necessary S69J8390 2 Measure the commutator diameter Replace the armature if below specifica tion 6D81G11 S69J8400 AS Commutator diameter wear limit 21 0 mm 0 83 in 3 Measure the commutator undercut 8 Replace the armature if below specifica tion S69J8410 AS Commutator undercut wear limit amp 1 0 mm 0 04 in 4 Check the armature for continuity Replace if out of specifications S69J8420 Commutator segments B Continuity Segment Armature core No continuity
54. ream the valve guide S60C5490 NOTE e 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 YM 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 lapper commercially avail able as shown S69J5820 4 Measure the valve seat contact width where the blueing dye is adhered to the valve face Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification Replace the valve guide if the valve seat contact is uneven X 69J5830 6D81G11 S69J5840 AS Valve seat contact width 8 1 20 1 60 mm 0 0472 0 0630 in Refacing the valve seat 1 Reface the valve seat with the valve seat cutters S69J5845 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 6D81G11 Cylinder head S69J5870 Slag or rough surface CAUTION Do not over cut the valve seat Be sure to turn the cutter evenly downward at
55. room temperature 69J2150 2 13 6D81G11 CHK ADJ 6D81G11 Periodic checks and adjustments Special service L00018 3 1 Maintenance interval chart srrrrnnnnnnnnnnvnnnnnnnnnnnnnnvnnnenennnnnnnnnnnnnnnnnnnnnnnnnnennnnr 3 2 TOP COMING dimarts je 3 3 Checking the top COWling i 3 3 Fuel Systemi P 3 3 Checking the fuel joint and fuel hoses fuel joint to fuel injector 3 3 Checking the fugi gm e 3 3 Power unit N fff eere D 3 4 Checking thef ngine Oil ee ce Au 3 4 Changing the engine oil using an oil changer ei 3 4 Changing the engine oil by draining it i 3 4 pp sf 7 I 3 5 CIECHE timinglbelt 97 v 3 6 Checking the spark plugs 4B QR 3 6 Checking the therm stat 4 4 FS I 3 7 Checking the cooling water passage li 3 8 uk JA EEE AES 3 8 Checking the engine idle speed eese 3 8 Adjusting the throttle link and throttle cable sr 3 8 Checking the gear shijl operation A 3 10 Bracket Unit ee oa Aare 3 11 Checking the power trim and tilt operation n 3 11 Checking the power trim and tilt fluid level gt
56. several times to make sure that the pin does not come out S60C4110 NOTE er NG Make sure thatthe gasket and diaphragm are kept in place through the assembly process 6D81G11 4 6 ve Fuel system Intake manifold 1 VG or S6D84040 Part name y Remarks No 1 2 3 4 5 6 7 8 Intake silencer Bolt Bushing Collar Intake manifold assembly Bolt Collar Bolt Spacer Bolt Collar Holder Gasket Pin Joint M6 x 80 mm M8 x 30 mm M8 x 100 mm M6 x 45 mm Not reusable A ND 4 200220 BAN AD 4 7 6D81G11 Intake manifold 3 7 N m 0 37 kgf m 2 7 ft Ib MJ 8 N m 0 8 kgf m 5 9 ft Ib IX 8N m 0 8 kgf m 5 9 ft Ib S6D84050 Z o ON OA POD Part name Remarks Intake manifold Sensor assembly Screw g5 x 13 mm O ring Idle speed control O ring Throttle body assembly Bolt M6 x 16 mm Gasket Throttle position sensor Screw O ring Fuel injector O ring set Fuel rail Bolt M6 x 38 mm 6D81G11 4 8 Zu Fuel system Checking the throttle position sensor 1 Check the throttle position sensor output voltage using the Yamaha 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
57. 0 16 0 02 in 6D81G11 3 Install a new O ring onto the oil seal housing 4 Install a new gasket the oil seal hous ing a new gasket 8 the outer plate cartridge and a new gasket 0 S6D86140 5 Install the Woodruff key into the drive shaft 6 Align the groove on the impeller AD with the Woodruff key 2 and then install the impeller onto the drive shaft S6D86260 7 Install the insert cartridge 3 into the water pump housing 3 6D81G11 Drive shaft and lower case S1104J S6D86150 NOTE i ij Align the insert cartridge projection with the hole in the water pump housing 8 Install the dowels 5 and the water pump housing onto the lower case 9 Install and tighten the bolts 9 a ar o3 aco DO TO S6D86160 NOTE TT e Apply grease to the inside of the water pump housing before 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 on the bush ing with the alignment mark on the bracket S6D81040 S6D86170 Lower case mounting bolt nut 39 N m 3 9 kgf m 28 8 ft lb S6D86190 5 Install the trim tab to its original posi tion and then connect the speedometer hose 3 Inst
58. 016 5 1 x dl e 5 3 Checking the compression pressure i 5 3 Checking the oil pressure 5 3 Checking the valve clearance ii 5 10 Replacing the timing bell 5 13 Removing the power UNit nenn 5 16 Removing the timing belt and sprockets sseeseeeeeeees 5 17 Checking the timing belt and sprockets sseeeesseee 5 18 Installing the sprockets and timing bell 22444444444 24000 5 18 Throttle link AE IP a u s A 5 20 ECM A Eina Rees af 5 21 TTE EO EE EA A 5 22 Cylinder i i a A anana nn NR 5 24 Removingithe cylinder head P ff BREL 5 26 Checking the valve lifters 99 on RO 5 27 Checking the valve sprihgs 99 S Esse 5 27 anc uw vafves L PP LLL O 5 27 ence We NE areas 5 28 Henn valve gl des ARR 5 28 checking the valve sbatto 5 29 Refacing th amp jvalve Bat 5 7 7 EEE nena 5 30 Checking the c ams ais ED Lo E 5 31 Checking the cylinder head A AE A 5 32 Installing the valles fi i 5 33 Installing the cylinder head Z BMP 5 33 Exhaust COVEr acli 5 36 Removing the exhaust COVef een 5 38 Checking the pressure control valve i 5 38 Installing the pres
59. 1 Install the forward gear then the drive shaft assembly pinion and pinion nut and then tighten the nut to the specified torque S68S6410 Pinion nut 93 N m 9 3 kgf m 68 6 ft Ib Install the washer and propeller shaft assembly 2 into the propeller shaft housing assembly 3 Apply grease to a new O ring S62Y6705 6 20 Lower unit 3 Install the shim and propeller shaft housing assembly into the lower case and then install the straight key claw washer 2 and ring nut 4 Tighten the ring nut to the specified torque S63P6320 S63P6330 NOTE i 4 To secure the ring nut bend one tab of the claw washer into a slot in the ring nut Bend all other tabs toward the propeller shaft housing assembly Gland nut wrench YB 34447 Ring nut 8 103 N m 10 3 kgf m 76 0 ft lb Installing the water pump and shift rod 1 Install the shift rod assembly 6 21 S60C6430 NOTE J J 2 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 S6D86130 NOTE MEME Install an oil seal halfway into the oil seal housing then the other oil seal Propeller shaft oil seal installer 3 YB 06269 Driver handle large 2 YB 06071 Depth 4 0 0 5 mm
60. 117 Neway valve seat kit YB 91044 Crankshaft holder YB 06552 Piston ring compressor YM 08037 5 1 6D81G11 Special service tools Oil filter wrench YU 38411 6D81G11 5 2 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 YA Compression gauge YU 33223 Compression gauge extension 2 YB 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 NOTE __ f TT e f the compression pressure increases check the pistons and piston rings for wear Replace if necessary e f the compression pressure does not increase check the valve clearance valve 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
61. 3 3 ft Ib MJ 23 N m 2 3 kgf m 17 0 ft Ib 2 N m 0 2 kgf m 1 5 ft Ib S6D85090 No Part name Q ty Remarks 18 Plug 1 M18 x 17 mm 19 Grommet 1 20 Anode 1 21 Cover 1 22 Bolt 1 M8 x 25 mm 23 Bolt 18 M6 x 30 mm 24 Bolt 1 M6 x 20 mm 25 Joint 1 26 Oil filter 1 27 Gasket 1 28 Plug 1 M14 x 12 mm 29 Plastic tie 1 30 Hose 1 5 37 6D81G11 Exhaust cover Removing the exhaust cover Installing the exhaust cover 1 Remove the exhaust cover bolts in the 1 Install a new gasket and the exhaust sequence shown cover 2 Install the bolts and then tighten them to the specified torques in two stages and in the sequence shown BOI U Eg o S6D85530 ced Lii 2 2 Remove the exhaust cover 6 Checking the pressure control valve Or S6D85550 1 Remove the pressure control valve NOTE __ 2 Check the pressure control valve for Apply engine oil to the exhaust cover bolts wear or damage Replace if necessary before installation 3 Check the grommet for deformation Replace if necessary Exhaust cover bolt 1st 6 N m 0 6 kgf m 4 4 ft lb 4 Check the spring for fatigue or deforma 2nd 12 N m 1 2 kgf m 8
62. AL A a ULL COS 7 7 6D81G11 Upper case 20 N m 2 0 kgf m 14 8 ft Ib Sg 28 N m 2 8 kgf m 20 7 ft Ib S6D87050 Z o NOD IA WU 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 M14 x 12 mm Not reusable Not reusable 96 x 15 mm he Se ke dk ee de Jo MPO ck ME lt 6D81G11 7 8 Bracket unit 20 N m 2 0 kgf m 14 8 ft Ib Sg 28 N m 2 8 kgf m 20 7 ft Ib S6D87050 Part name Remarks 2 lt Dowel Upper case Drive shaft bushing Circlip Lower mount Washer Washer Washer Bolt MONNNN D M12 x 200 mm 7 9 6D81G11 Upper case we Ix 11 N m 1 1 kgf m 8 1 ft Ib S6D87060 Z o NOD IA WIN Part name y Remarks Exhaust guide Gasket Dowel Gasket Oil strainer Collar Bolt Bolt Oil pan Gasket Exhaust manifold Bolt Gasket Gasket Plate Dowel Bolt Not reusable Not reusable wow NO a M6 x 25 mm M6 x 25 mm N Not reusable M6 x 70 mm Not reusable Not reusable DO NT NT NA a a 6D81G11 7 10 Bracket unit 11 N m 1 1 kgf m 8 1 ft Ib S6D87060 Part name Remarks Muffler Bolt M6 x 50 mm Grommet Spacer Pipe
63. D81G11 Specifications General specifications 2 1 Maintenance specification ssarnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnenennnnnnnnnnnnnnnnnnnnnnnnnnnene 2 3 POWER UN setantena ri ai 2 3 LOWErUN P a tel ee 2 6 Le 5 TIPP TNT 2 6 DIMENSIONS C ednn 2 9 Tightening torques ugs eoe o gg ccs cc os ax se kde a 2 11 Specified torques m9 BE e 2 11 General torque seem 2 13 SPEC um s Specifications General specifications Item Model F90TR Dimension Overall length Overall width Overall height X Boat transom height L X 817 32 2 479 18 9 1 582 62 3 1 710 67 3 508 20 0 635 25 0 Weight without propeller 168 370 172 379 Performance Maximum output Full throttle operating range Maximum fuel consumption Engine idle speed kW hp r min L US gal Imp gal hr r min 66 2 90 at 5 500 r min 5 000 6 000 33 0 8 72 7 26 at 6 000 r min 700 50 Power unit Type Cylinder quantity Total displacement Bore x stroke Compression ratio Control system Starting system Fuel system Ignition control system Advance type Maximum generator output Spark plug Cooling system Exhaust system Lubrication system 2 1 cm cu in mm in In line 4 stroke DOHC 16 valves 4 1 596 97 39 79 0 x 81 4 3 11 x 3 20 9 6 Remote control Electric Fuel injection TCI Micro computer 12 25 LFR5A 11 NGK
64. F with 10W 30 engine oil Relief valve opening pressure L US gal Imp gal min kPa kgf cm psi kPa kgf cm psi 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 Thermostat Opening temperature Fully open temperature Valve open lower limit Lower unit Item ien C F mm in 58 62 136 144 70 158 4 3 0 17 Model F90TR Gear backlash Pinion to forward gear Pinion shims Forward gear shims Electrical Item 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 Ignition and ignition control system Spark plug gap Ignition coil resistance at 20 C 68 F Primary coil Secondary coil Spark plug wire resistance 1 2 3 4 R B W 6D81G11 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 7 8 9 4 3 10 2 2 6 SPEC um is Specifications Item 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 VV R W B B at 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
65. Fully charge the battery if out of 1 Apply water resistant grease to the areas specification shown WARNING Battery electrolyte is dangerous it con tains sulfuric acid which is poisonous 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 36009660 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 NOTE 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 AS Electrolyte specific gravity 1 280 at 20 C 68 F S60C3695 3 15 6D81G11 General
66. ION Do not rotate the quick connector tab 1 past the stopper position 8 otherwise it could be damaged 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 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 M 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 to fuel pressure gauge adapter B 6D81G11 S6D84110 ds 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 Cz Fuel pressure gauge adapter B YB 06942 Fuel pressure gauge 2 YB 06766 4 Turn the engine start switch to ON and then measure the fuel pressure within 3 seconds NOTE __ WP wa NJ The fuel pressure decreases 3 seconds after the engine start switch is turned to ON AS Fuel pressure reference data 300
67. Install the sleeve original shim s and taper roller bearing outer race S6D86100 6 19 CAUTION Add or remove shim s if necessary if replacing the taper roller bearing or lower case NOTE ee e Apply the gear oil to the inside and outside of the sleeve before installation e Install the sleeve by facing the projection forward Drive shaft seal installer YB 06244 Driver handle large YB 06071 3 Install the original shim s and taper roller bearing outer race 009 CAUTION Add or remove shim s if necessary if replacing the taper roller bearing or lower case Zj Forward gear bearing cup installer 6 YB 06276 B Driver handle large 2 YB 06071 Assembling the forward gear 1 Install a new taper roller bearing into the forward gear using a press 6D81G11 Drive shaft and lower case General pipe 33 mm 1 30 in 28 mm 1 10 in Installing the drive shaft 1 S6C16530 v2 Forward gear outer race installer 1 YB 06085 2 Install a new needle bearing into the for ward gear to the specified depth S6C16540 Z Bearing housing needle bearing remover 1 Driver handle large YB 06071 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 S6C16270 6D81G11 Installing the propeller shaft housing YB 06112
68. NOTE Install the bearings in their original positions 3 Put a piece of Plastigauge PG 1 onto the crankpin parallel to the crankshaft S60C5990 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 6D81G11 Cylinder block S60C5A10 NOTE See _ 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 S62Y5980 NOTE Reuse the removed connecting rod bolts e 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 5 44 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 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 8 S60C5980 NOTE Reuse the removed connecting rod bolts Connecting rod big end inside diameter 8 47 025 47 045 mm
69. ON 8 10 evec 7 ELEC ES Electrical systems 2 Listen for the operating sound of the electric fuel pump Check the fuel sys tem if there is no sound NOTE WENN After the engine start switch is turned to ON the electric fuel pump will operate for 3 sec ondas Checking the main and fuel pump relay fuel control 1 Remove the main and fuel pump relay 7 S6D88090 2 Connect the digital circuit tester leads to the relay terminals and 3 Connect the positive battery terminal to the relay terminal 4 Connect the negative battery terminal to the relay terminal 4 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 and after dis connecting a battery terminal from the relay terminal 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 Chec
70. OTE 5 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 S60C5B30 CAUTION Do not reuse the connecting rod bolts always replace them with new ones 6D81G11 5 50 11 Tighten the crankcase bolts to the speci 13 Install all parts removed during disas fied torques in two stages and in the sembly sequence shown Installing the power unit 1 Clean the power unit mating surface and install the dowels and a new gasket Q 2 Install the power unit 3 by installing bolts Oa and then tightening them to the specified torques in two stages and in the sequence shown 3 Install the apron 6D85680 CAUTION The oil seals must be installed before tightening the crankcase bolts NOTE i BEP ae 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 i e Make a mark on the M10 bolts and the A S6D85630 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 S6D85310 Power unit mount
71. Oil pressure Cylinder head Warpage limit lines indicate straightedge position Camshaft cap inside diameter kPa kgf cm psi kPa kgf cm psi 860 8 6 124 7 510 5 1 74 0 at engine idle speed 0 1 0 0039 25 000 25 021 0 9843 0 9851 Cylinders Bore size Taper limit Out of round limit 79 000 79 020 3 1102 3 1110 0 08 0 0032 0 05 0 0020 Pistons Piston diameter D AE Measuring point H D Piston clearance Over size piston diameter 78 928 78 949 3 1074 3 1082 13 0 0 51 0 070 0 080 0 0028 0 0031 79 178 79 199 3 1172 3 1181 Piston rings Top ring Dimension B Dimension T End gap Side clearance 2nd piston ring Dimension B Dimension T End gap Side clearance JB T CP T 1 Measuring conditions 1 17 1 19 0 0461 0 0469 2 80 3 00 0 1102 0 1181 0 15 0 30 0 0059 0 0118 0 04 0 08 0 0016 0 0031 1 47 1 49 0 0579 0 0587 3 00 3 20 0 1181 0 1260 0 70 0 90 0 0276 0 0354 0 03 0 07 0 0012 0 0028 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 6D81G11 Maintenance specification Model sem FOOTR Oil ring Dimension B i 2 38 2 48 0 0937 0 0976 Dimension TO i 2 40 0 0945 End gap LA i 0 20 0 70 0 0079 0 0276 Side clearance i 0 03 0 15 0 0012 0 0059 Camshafts
72. Oil pressure switch Operating pressure kQ kQ kPa kgf cm psi 3 6 3 4 18 2 34 3 459 561 0 8 1 2 at engine idle speed 5 21 6 37 0 290 0 354 127 5 166 7 1 28 1 67 18 49 24 17 Fuel control system Fuel injector resistance at 21 C 70 F 12 0 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 7 Sliding gear 1 40 30 15 5 0 61 9 5 0 37 29 0 1 14 6D81G11 Item Maintenance specification Charging system Fuse Stator coil output peak voltage VV VV at cranking unloaded at 1 500 r min unloaded at 3 500 r min unloaded Stator coil resistance VV VV at 20 C 68 F Rectifier Regulator output peak voltage R Ground at 1 500 r min unloaded at 3 500 r min unloaded 0 24 0 36 Povver trim and tilt system Trim sensor Setting resistance P B Resistance P B Fluid type Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit The figure is for reference only 6D81G11 10 1 9 378 8 ATF Dexron H 10 0 0 39 3 5 0 14 22 0 0 87 21 0 0 83 2 8 SPEC Cal Specifications
73. 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 qt 6 Install the oil filler cap and oil dipstick and then start the engine and warm it up for 5 minutes 7 Turn the engine off and then check the oil level and 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 6D81G11 Remove the spark plug wire cover Disconnect the spark plug wires and then remove the spark plugs Clean the electrodes with a spark plug cleaner or wire brush Replace the spark plug if necessary S69J3190 Check the electrodes for erosion and excessive carbon or other deposits and the gasket for damage Replace the spark plug if necessary 3 6 mac ADJ Periodic checks and adjustments 5 Check the spark plug gap Adjust if out of specification 69J3200 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 cov
74. 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 C je n 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 S63P4110 2 Push down on the plunger and the dia phragm turn fuel pump body 1 approximately 90 to a position where the pin can be removed easily and then remove the pin S60C4070 S60C4080 6D81G11 Fuel filter and fuel pump 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 u__ m_mve 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 and then install the plunger into the diaphragm 2 Push down on the plunger and the dia phragm and then install the pin S60C4100 3 Turn fuel pump body 1 approximately 90 and then push down on the plunger
75. TG 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 oper No Check the voltage between each terminal of the PTT relay ation sound coupler when pushing the power trim and tilt switch be heard Between the sky blue Sb lead and black B lead Yes Between the light green Lg lead and black B lead J Can 12 V be Replace the power obtained trim and tilt relay P Listen for the operation sound of the power trim and tilt motor ieh pre fuse for continuity Is there continuity Replace the fuse Check for continuity between the battery relays and power trim and tilt switch S Check the voltage between the Sky blue Sb lead and light green Lg lead MV Can the oper ation sound be heard Can 12 V be obtained Replace the power trim and tilt relay Check that the manual valve is Check the power trim and tilt closed motor Continued on next page 9 13 6D81G11 Is it closed Close the valve Yes Check the power trim and tilt fluid level At specified Add fluid to the correct level level Disassemble the power trim and tilt unit and then check the filter for debris or dirt Stuck foreign substance or clogs
76. 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 6D81G11 7 22 Bracket unit Power trim and tilt unit S6D87270 Z o ON OA BE o N Part name y Remarks Power trim and tilt unit Circlip Shaft Circlip Shaft Bushing Bushing Ground lead Bolt Bushing Bushing Collar Holder Bolt M6 x 10 mm NN NNa a a Na Naaa M6 x 10 mm 7 23 6D81G11 Removing the power trim and tilt unit 1 Fully tilt the outboard motor up and then support it with the tilt stop lever S6D83150 LN S60C7745 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 NOTE 7 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 valve 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 l
77. a pres sure of 40 50 N 4 5 kgf 8 8 11 Ibf to prevent chatter marks 3 Use a 30 cutter to adjust the contact width of the top edge of the valve seat I 30 S69J5880 Previous contact width 4 Use a 60 cutter to adjust the contact width of the bottom edge of the valve seat Previous contact width S69J5890 5 30 5 Use a 45 cutter to adjust the contact width of the valve seat to specification D 45 69J5900 Previous contact width Specified contact width 6 aN A kv 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 p Previous contact width 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 sf A NU X S69J5920 p Previous contact width 5 31 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 x 60 S69J5930 p Previous contact width 9 Apply a thin even layer of lapping com poun
78. ach 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 speed and the total operating time are displayed This allows you to check the operating status of the engine 7 Some files Lets you select and run other applications while continuing to run the diagnostic program Contents 1 Software 1 YAMAHA N nn 2 Adapter 1 DIAGNOSTIC YAMAHA SYSTEM DIAGNOSTIC SYSTEM 3 Communication cable 1 YAMAHA N I gt INSTALLATION MANUAL INSTRUCTION MANUAL 4 Instruction Manual 1 5 Installation Manual 1 6D81G11 9 2 TRBL 1 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
79. adjust 3 8 PCV Pressure Control Valve Check Power trim and tilt unit Check Propeller and cotter pin Check replace Shift link shift cable Check adjust Thermostat Check Throttle link throttle cable throttle pick up timing Check adjust Water pump Check Engine oil Check change Oil filter Change Spark plugs Clean adjust replace Timing belt NOTE Check replace When operating in salt water turbid or muddy water the engine should be flushed with clean water after each use Remarks Every 500 hours 2 5 years 1 000 hours 5 years Refer to page Timing belt Replace O 5 13 Valve clearance DOHC NOTE Check adjust O 5 10 When using lead or high sulfur gasoline checking valve clearance may be required more frequently than every 500 hours 6D81G11 3 2 ER 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 S60C3010 2 Loosen the bolts 3 Move the hook up or down slightly to adjust its position Ca FELD 4 S6D83010 NOTE e To loosen the fitting move the hook in direction 8 To tighten the fitting move the hook in direction 4 Tighten the bolts 5 Check the fitting again and if necessary
80. agnosis J S69J9020 e Trouble code indication Example The illustration indicates code number 23 Light on 0 33 second Light off 4 95 seconds Light off 0 33 second d Light off 1 65 seconds S69J9030 9 18 TRBL 1 SHTG e Troubleshooting 4 If a flash pattern listed in the diagnostic code chart is displayed check the mal functioning part according to the flash pattern NOTE ch 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 Normal Incorrect pulser coil signal Incorrect cooling water temperature sensor signal Incorrect throttle position sensor signal 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 Over cool signal Incorrect memory data signal 9 19 6D81G11 A B Adjusting the float e e 4 17 Adjusting the throttle link and throttle cable 2 uun4 4244 3 8 Adjusting the trim sensor
81. all the dowels 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 S6D86180 6 23 6D81G11 6 Install the propeller and propeller nut 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 S69J6340 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 NOTE If the grooves in the propeller nut do not align with the cotter pin hole tighten the nut until they are aligned Propeller nut 34 N m 3 4 kgf m 25 1 ft lb 6D81G11 Drive shaft and lower case 7 Fill the gear oil to the correct level 6 24 Lower unit Shimming UN T3 H H A y gt to UJ oo DI E EN Fe m N r LX E 510 Eee NN 3Pj E EN je ee A Ray VE T1 B1 32 0 Al S6C16670 6D81G11 6 25 Shimming NOTE a e Shimming is not required when assembling the original lower case and inner parts e Shimming is required when assembling the original i
82. amber screw 3 N m 0 3 kgf m 2 2 ft Ib Adjusting the float 1 Adjust the stopper 8 of the float by bending it until the float height is within specification S6C 14290 AS Float height 46 6 1 0 mm 1 83 0 04 in 2 Adjust the lever of the float by bending it until the float height is within specifi cation 4 17 S6C14300 Float height 35 0 1 0 mm 1 38 0 04 in NOTE gt I When adjusting the float height do not bend the lever 6D81G11 Vapor separator Canister Canister S6D84150 Part name y Remarks M6 x 16 mm Z o o IJ OO OI BE o ND Bolt Bracket Canister Bolt Grommet Bracket Collar Hose Hose Hose Filter Hose Clamp Bolt Holder Bolt Bracket M6 x 28 mm M6 x 10 mm M6 x 16 mm A ee ee NN A 7 6D81G11 4 18 vel i Fuel system 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 S6D84160 3 Apply the specified positive pressure and check that there is no air leakage Replace the canister if there is air leak age 24 Pressure vacuum tester YB 35956 A AS Specified pressure 19 6 kPa 0 196 kgf cm 2 8 psi 4 19 6D81G11 powe amp Power unit Special Service 10
83. b 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 6D81G11 Power trim and tilt unit 4 Remove the circlips 6 then the lower mounting shaft 5 Remove the circlip 8 then the upper mounting shaft 9 NOTE 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 9 7 24 Bracket unit Power trim and tilt motor 4 N m 0 4 kgf m 3 0 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib S6D87290 Z o ON OA BE o N Part name 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 5x 25 mm Not reusable 94 x 15 mm A us LL ms 7 25 6D81G11 Power trim and tilt motor Sg 4 N m 0 4 kgf m 3 0 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib S6D87290 Part name Remarks Circuit breaker Spring PTT motor base Oil seal Plate Screw 4 x 10 mm 6D81G11 7 26 Bracket unit Disassembling the power trim and tilt motor 1 Remove the power trim and tilt motor O ring and joint from the
84. bearing installer remover 4 YB 06432 Checking the drive shaft bushing Driver handle large YB 06071 1 Check the drive shaft bushing for wear or cracks Replace if necessary 4 Install new o rings and the gasket and then tighten the screws to the specified Disassembling the oil pan torque 1 Remove the muffler and plate 2 from the oil pan 3 2 Remove the exhaust manifold from the oil pan 3 Remove the oil pan 3 from the exhaust guide WR No 1 4 Remove the oil strainer S6D87130 Oil pump cover screvv 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 TARDE bushing 7 13 6D81G11 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 2 Install a new gasket and the oil strainer onto the exhaust guide and then tighten the bolts to the specified torque S6D87150 AS Oil strainer bolt 10 N m 1 0 kgf m 7 4 ft lb 3 Install the dowels and oil pan 3 onto the exhaust guide and then tighten the oil pan bolts 4 finger tight 4 Install a new gasket and the exhaust manifold onto the oil pan and then tighten the exhaust manifold bolts to the specified torque 5 Tighten the oil pan bolts 2 to the speci fied torque 6 Tigh
85. ble to the outboard motor Bow view 3 pin communication coupler S6D89010 6D81G11 9 4 TRBL 1 SHTG e Troubleshooting NOTE 0 Iiili lsdl L Check that all electrical connections are tight and free from corrosion and that the battery is fully charged to 12 V To 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 To diagnose a malfunctioning sensor or switch use the diagnostic test lead to determine the cause Power unit Symptom Engine does not crank Check the starting system Check the power unit Check that the gearshift is in the neutral position Is the gearshift n Set it to the neutral position Check the engine start switch for continuity Is there continuity Replace the engine start switch Check the engine stop lanyard switch for continuity with lock plate Is there continuity Replace the engine stop lan yard switch Check the fuse for continuity Continued on next page 9 5 6D81G11 Power unit Is there continuity Replace the fuse Yes Check the wiring harnesses for continuity Is there continuity Replace the wiring harnesses Listen for the operation soun
86. bly 1 Measure the ambient temperature 8 8 ELEC ELEC a Electrical systems 2 Connect a computer to the outboard motor and use the Yamaha Diagnostic System to display the intake air tempera ture b A q v S6D88160 3 If the ambient temperature and the dis played intake air temperature differ by more than 5 C 4 9 F replace the sensor assembly NOTE ga OO Check the sensor assembly when ihe engine is cold Checking the cooling water temperature sensor 1 Place the cooling water temperature sen sor in a container of water and slowly heat the water 00 0 calici S69J8230 2 Measure the cooling vvater 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 S60C8180 4 Check the oil pressure switch for no con tinuity at the specified pressure Replace if there is continuity Z Pressure vacuum tester 4 YB 35956 A 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
87. bolts then tightening them to the specified torques S6D87380 Relief valve cap bolt M4 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 RES 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 8 Tighten bolts 2 and 3 to the specified torque S6C17640 6D81G11 7 34 Bracket unit Tilt cylinder and trim cylinder 90 N m 9 0 kgf m 66 4 ft Ib 80 N m 8 0 kgf m 59 0 ft Ib Z o ON OA BE o N Part name Remarks Power trim and tilt assembly Dust seal Not reusable Backup ring 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 7 35 6D81G11 Tilt cylinder and trim cylinder 90 N m 9 0 kgf m 66 4 ft Ib 80 N m 8 0 kgf m 59 0 ft Ib Part name Remarks Valve Spring Washer Tilt cylinder Ball O ring Backup ring Tilt piston Ball Ball Valve Spring Pin Dowel Washer Tilt piston assembly O ring 6D81G11 4 N I N N E lt Not reusable Not reusable 7 36 Bracket unit 90 N
88. c 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 computers monitor If this software is run on Microsoft Windows 95 Windows 98 Windows Me Windows 2000 or Windows XP the information can be displayed in colorful graphics Also the software can be oper ated using either a mouse or a keyboard In addition the data for the main functions Diagnosis Diagnosis record Engine monitor and Data logger can be saved on a disk or printed out Functions 1 Diagnosis With the engine main switch ON each sensors 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 e
89. 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 GEAR CASE LUBE 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 Ib Changing the gear oil 1 Tiltthe outboard motor up slightly 2 Place a drain pan under the drain screw remove the drain screw then the check screw 2 and let the oil drain com pletely 6D81G11 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 IQ 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 0 9 S60V3340 S60V3350 Recommended gear oil GEAR CASE LUBE 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 Ib Checking the lower unit for air leakage 1 Remove the check screw D and then install the special service tool 3 13 S60V3360 Pressure vacuum tester YB 35956 A 2 Apply the specified pressure to che
90. ck 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 NOTE l Lzb 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 6D81G11 General Checking the anodes 1 Check the anodes and trim tab for scales grease or oil Clean if necessary S6D83170 S6D83210 d se q S62Y3640 CAUTION Do not oil grease or paint the anodes or the trim tab otherwise they will be ineffec tive 6D81G11 Lower unit General NOTE i 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 add distilled water until the level is between the maximum and minimum level marks S69J3620 3 14 ER ADJ Periodic checks and adjustments 2 Check the specific gravity of the electro Lubricating the outboard motor lyte
91. combustion chamber Within specification x Check the condition of the spark Failure in Station plugs again gog M PA a N Check the valve Wet spark plugs P pug clearance Failure in starting operation A Adjust the valve clearance Within Check the fuel system d specification Check the cylinder head cylin der block and piston assembly 6D81G11 9 8 TRBL 1 SHTG e Troubleshooting Symptom Engine can be started but does not remain on 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 Check the fuel hose for kinks or fuel leakage Water or residue Replace the defective parts Kinks or fuel leakage Clean the fuel system from the fuel tank to the fuel filter Check the fuel pressure Check the fuel injector resistance Within Check the pressure regulator FE P g specification Within specification No Check the fuel system using the Yamaha Diagnostic System Replace the fuel injector Good operat ing condition Replace the pressure regulator
92. d of the starter relay Can the oper ation sound be heard Replace the starter relay Check the starter motor opera tion Good operat ing condition Replace the starter motor Check the power unit 6D81G11 9 6 TRBL 1 SHTG e Troubleshooting Symptom Engine cranks but will not start engine stop lanyard switch is operating nor mally Check the ignition system Check the fuel system Check the compression pressure of the power unit Check that the spark plugs pro WARNING Ba E duce sparks Do not touch any of the connections of the spark checker leads Do not let sparks leak out of the removed spark plug caps Keep flammable gas or liquids away since this test can produce sparks Check the ignition spark using the spark checker Are there sparks Check the ignition system output peak voltage Check the condition of the spark Good spark plugs C ON Check the ignition coil M 2 C OW Check the main and fuel pump relay for continuity NG A Wet spark plugs Replace the main and fuel pump relay Is there continuity Start the engine using dried or new spark plugs Continued on next page Check the fuel system 9 7 6D81G11 Power unit Does the engine start Check the compression pres sure of the
93. d fuel pump relay Diode Oil pressure switch Pulser coil Stator coil Rectifier Regulator ECM 63 Throttle position sensor Shift position switch Sensor assembly Fuel injector Idle speed control Variable trolling RPM switch optional tool A To warning indicator trim meter B To remote control box switch panel C To personal computer for diagnosis D To diagnostic flash indicator special service E To Variable trolling RPM switch Color code B Black Br Brown G Green L Blue Lg Light green O Orange P Pink R Red Sb Sky blue VV 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 LAW Blue white L Y Blue yellow OM 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 R Y Red yellow W B White black W L White blue VV R White red YAMAHA YAMAHA MOTOR CORPORATION USA Printed in USA Jul 2004 x1CR E
94. d onto the valve seat and then lap the valve using a valve lapper commer cially available S69J5820 CAUTION Do not get the lapping compound on the valve stem and valve guide 10 After every lapping procedure be sure to 11 clean off any remaining lapping com pound from the cylinder head and the valve Check the valve seat contact area of the valve again Checking the camshafts 1 Measure the cam lobe Replace if out of specification 6D81G11 69J5950 Cam lobe 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 S6D85450 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 6D81G11 Cylinder head S69J5970 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 2 Check the cylinder head warpage using a straightedge and thickness gauge in the directions shown Replace if above specification
95. 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 6D81G11 Power unit S6D85390 NOTE n Apply engine oil to the driven sprocket bolts before installation e Do not turn the camshafts when tightening the driven sprocket bolts Flywheel magnet holder YB 06139 Driven sprocket bolt 2 60 N m 6 0 kgf m 44 3 ft lb 5 18 3 Install the retaining plate Woodruff key drive sprocket and nut and then tighten the nut D S60C5240 LE NOTE mm HB 32 4 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 TE S6D85410 NOTE Crankshaft holder 8 YB 06552 Drive sprocket nut 265 N m 26 5 kgf m 195 5 ft lb 6D81G11 Power unit Throttle link Throttle link S6D84140 Z o NODO IA WU Part name Remarks 2 lt Throtile cam Bolt Collar Wave washer Washer Spring Washer Throttle lever B
96. e 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 5 41 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 S69J5B80 Piston ring dimensions Top ring 8 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 3 Check the piston ring end gap at the specified measuring point Replace if out of specification 6D81G11 O O TTD MR CD S63P5870 Piston ring end gap Top ring 0 15 0 30 mm 0 0059 0 0118 in Second ring 0 70 0 90 mm 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 Piston ring groove Top ring 8 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 6D81G11 Cylinder block Checking the piston ring side clearance 1 Measure the piston ring
97. e 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 5 Install the lower mounting shaft and then install the circlips 6 Route the PTT motor leads through the hole and then install the holders and plastic ties 7 Connect the ground lead 6D81G11 Tilt cylinder and trim cylinder Bleeding the power trim and tilt unit built in 1 Fully turn the manual valve counterclock wise S6007745 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 Ib 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 7 44 Bracket unit 6 Support the outboard motor with the tilt stop lever S60C7975 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 NOTE a 4 2 If the fluid is at the correct level the fluid should overflow out of
98. e 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 camshafts 5 31 Checking the canister 4 19 Checking the compression pressure 5 3 Checking the connecting rod big end side clearance ii 5 43 Checking the cooling water passage 3 8 6D81G11 Checking the cooling water pilot hole 1 9 Checking the cooling water temperature GE 0 8 9 Checking the crankpin oil clearance 5 43 Checking the crankshaft 5 43 Checking the crankshaft journal oil Clearance it tes einer 5 46 Checking the cylinder bore 5 41 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 nee 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
99. e pinion as shown S62Y6875 NOTE Measure the pinion at three points to find the clearance average 6 Select the pinion shims T3 S62Y6860 NOTE The sum of T3 and MO should be more than M Calculation formula Pinion shim thickness T3 M MO Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Selecting the forward gear shims 1 Calculate the specified value MO as shown in the examples below 6 27 S68S6260 NOTE oe F is the deviation of the lower case dimen sion from standard The F mark is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark is unreadable assume that F is zero and check the backlash when the unit is assembled Specified value MO 1 61 F 100 mm Example If F is 5 then MO 1 61 5 100 mm 1 61 0 05 mm 1 66 mm If F is 5 then MO 1 61 5 100 mm 1 61 0 05 mm 1 56 mm 2 Install the taper roller bearing onto the special service tools S62Y6890 6D81G11 NOTE Tighten the nut four turns after it contacts the spring 2 Forward gear shim selecting tool YB 34446 1 YB 34446 3 YB 34446 5 YB 34446 7 3 Measure the clearance M between the gauge pin and the press plate S62Y6895 4 Select the forward gear shims T1 S62Y6880 NOTE The sum of T1 and M should
100. ear pump and filters i S6C17600 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 and down relief valve seat 2 Check the filters for damage or clogs Replace if necessary 3 Remove the lever 3 then the shuttle pistons 2 3 Check the drive gear and driven gear for damage or wear Replace the gear pump assembly if necessary Assembling the gear pump 1 Install the drive gear and driven gear into the gear pump housing ce 2 Install the balls 3 into the gear pump T housing S6D87560 4 Remove the gear pump bracket then CBS OY o the adapters N 2882 5 Remove the pins 7 then the drive gear ZA and driven gear LI S6C17610 3 Install the gear pump cover 2 then the pins 7 33 6D81G11 Gear pump Lever bolt M3 3 2 N m 0 2 kgf m 1 5 ft lb 9 Install the up relief valve seat and down relief valve seat 10 Install the relief valve seat caps by installing bolts and 8 then tightening 96617620 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 6 Install the gear pump bracket by installing the
101. earance Valve shims Valve shim thickness i 2 0 3 3 0 08 0 13 in 0 025 mm increments Connecting rods Big end inside diameter 47 025 47 045 1 8514 1 8522 Big end side clearance i 0 14 0 28 0 0055 0 0110 Crankpin oil clearance i 0 024 0 044 0 0009 0 0017 Big end bearing thickness Yellow i 1 499 1 506 0 0590 0 0593 Green i 1 506 1 513 0 0593 0 0596 Blue i 1 513 1 520 0 0596 0 0598 Red i 1 520 1 527 0 0598 0 0601 Crankshaft Crankshaft journal diameter 47 985 48 000 1 8892 1 8898 Crankpin diameter 43 982 44 000 1 7316 1 7323 Crankpin width i 21 00 21 07 0 8268 0 8295 Runout limit i 0 03 0 0012 Crankcase Crankshaft journal oil i 0 024 0 044 0 0009 0 0017 clearance Upper crankcase main bearing thickness Green i 2 992 2 999 0 1178 0 1181 Blue i 2 999 3 006 0 1181 0 1183 Red i 3 006 3 013 0 1183 0 1186 Upper crankcase main bearing 3 thickness Green i 2 992 2 999 0 1178 0 1181 Blue i 2 999 3 006 0 1181 0 1183 Red i 3 006 3 013 0 1183 0 1186 Lower crankcase main bearing thickness Yellow i 3 010 3 017 0 1185 0 1188 Green i 3 017 3 024 0 1188 0 1191 Blue i 3 024 3 031 0 1191 0 1193 Red i 3 031 3 038 0 1193 0 1196 2 5 6D81G11 Unit Maintenance specification Model F90TR Oil pump Discharge at 97 103 C 207 217 F with 10W 30 engine oil Pressure at 97 103 C 207 217
102. earing into the connecting rod cap S60C5A80 5 49 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 S6D85610 NOTE SCA TT Apply engine oil to the side of the pistons and piston rings before installation Z Piston ring compressor YM 08037 5 Install half of the bearings into the cyl inder block S60C5B10 NOTE o e Install the bearings in their original posi tions e Install the unified thrust bearing at the posi tion amp shown 6D81G11 Cylinder block 6 Set the crankshaft 8 and oil seals and into the cylinder block as shown NOTE Make sure that the large flat side C 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 2 into the crankcase 9 Apply sealant to the mating surface of the crankcase S6D85700 518 FO O O 7 Install the connecting rod cap to the OF 4 E connecting rod and then tighten the new Nois N 4 connecting rod bolts i to the specified Do o o 9 o torques in tvvo stages di o gt 8 g Q 9 9 O o S6D85620 N
103. earing into the propel ler shaft housing to the specified depth S63P6090 NOTE es Install the needle bearing with the manufac ture identification mark facing toward the oil seal propeller side Driver handle large YB 06071 A Bearing housing needle bearing remover 2 YB 06153 AS Depth 25 25 0 25 mm 0 99 0 01 in Apply grease to the new oil seals and then install them into the propeller shaft housing to the specified depth N S69J6145 NOTE 0 Install an oil seal halfway into the propeller shaft housing then the other oil seal 6 13 Propeller shaft oil seal installer 3 YB 06269 Driver handle large 2 YB 06071 Depth 5 0 0 5 mm 0 20 0 02 in 3 Install the thrust washer and new ball bearing to the reverse gear 7 using a press S6D86070 NOTE NEM S Install the ball bearing with the manufacture identification mark d facing outward propel ler side Z Drive shaft needle bearing depth stop 8 YB 34473 4 Install the reverse gear assembly into the propeller shaft housing using a press 6D81G11 Propeller shaft housing S6D86220 2 Bearing outer race attachment YB 06109 6D81G11 6 14 Lower unit Drive shaft and lower case 0 S6D86080 Z o ON OA BE WU N Part name Remarks Drive shaft Taper roller bearing Pinion shim Sleeve Hose Plastic tie
104. em may be damaged e Do not turn the drive sprocket or the driven sprockets when the timing belt is not installed Otherwise the piston and valves will interfere with each other and be damaged 1 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 S6D85220 S6D85360 NOTE _ __ EEE REIFEN Use a deep socket 2 for this procedure e Do not turn the camshaft when loosening the drive sprocket nut Crankshaft holder YB 06552 3 Disconnect the cooling water hose and remove the bracket 4 Remove the spring and timing belt ten sioner and then remove the timing belt from the driven sprockets then from the drive sprocket 5 Loosen the driven sprocket bolts and then remove the driven sprockets S6D85370 NOTE _ _ _ Do not turn the camshafts when loosening the driven sprocket bolts Flywheel magnet holder YB 06139 6 Remove the nut D drive sprocket retaining plate and Woodruff key 8 6D81G11 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
105. en terminals and Replace if there is no continu ity S63P7380 5 Connect the digital circuit tester between power trim and tilt relay terminals 1 and 6 Connect the sky blue Sb lead to the positive battery terminal and the black B lead to the negative battery terminal as shown 7 Check for continuity between terminals and Replace if there is no continu ity aes ABE zu S63P7390 Checking the power trim and tilt switch 1 Check the power trim and tilt switch for continuity Replace if out of specification 6D81G11 S62Y7A70 Lead color Switch Sky blue position Sb Up OLA Free Down O Lightgreen Red R Lg Checking the trim sensor 1 Measure the trim sensor resistance Replace if out of specification S63P7290 NOTE Turn the lever 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 7 46 6D81G11 Electrical systems Special Service 10016 8 1 Checking the electrical components eese 8 2 Measuring the peak voltage i 8 2 Measuring the lower resistance 8 2 Electrical COMPONGING mee 8 3 POHL VIEW Tr L 8 3 Starboard view cea nmm 8 4 Bow view
106. ent marks are aligned S6D85280 17 Install the brachet and connect the cool ing vvater hose 6D81G11 18 Install the stator assembly and Woodruff key 19 Install the flywheel magnet S63P5360 CAUTION Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily NOTE EM eee Apply engine oil to the flywheel magnet nut before installation Flywheel magnet holder YB 06139 N 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 a 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 and trim sensor coupler 3 Remove the junction box cover and then disconnect the PTT motor leads and PTT switch coupler 6D81G11 Power unit 4 Disconnect the throttle cable and shift cable 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 oil dipstick 8 Remove the apron 1 and then remove the power unit by removing the bolts S6D85350 9 Remove the flywheel magnet 5 16 Removing the timing belt and sprockets CAUTION e Do not turn the drive sprocket counter clockwise otherwise the valve syst
107. ep 1 7 Checking the pinion and forward gear 6 18 Checking the piston clearance 5 41 Checking the piston diameter 5 40 Checking the piston ring grooves 5 42 i 1 Index Checking the piston ring side clearance 5 42 D Checking the piston rings 5 41 Checking the power trim and tilt fluid EV p 3 11 Checking the power trim and tilt motor 7 27 Checking the power trim and tilt Operation 3 11 Checking the power trim 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 38 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
108. er 2 Disconnect the cooling water hose D and then remove the thermostat cover 2 and thermostat 3 S6D83080 3 Suspend the thermostat in a container of water 4 Place a thermometer in the water and slowly heat the water S69J5E40 5 Check the thermostat valve opening at the specified water temperatures Replace if out of specification S69J5E50 6D81G11 Power unit Control system Water Valve lift temperature 9 0 05 mm 0 0020 in valve begins to lift 58 62 C IM C ie S63P3120 Control system Checking the engine idle speed 1 Start the engine and warm it up for 5 min Checking the cooling water passage utes 1 Check the cooling water inlet cover and cooling water inlet for clogs Clean if necessary 136 144 F 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 2 Attach the special service tool to spark plug wire 1 and then check the engine idle speed Engine idle speed 700 50 r min S62Y3320 Adjusting the throttle link and 2 Place the lower unit in water and then throttle cable start the engine 1 Remove the intake silencer 3 Check for water flow at the cooling water 2 Set the remote control lever to the neu pilot hole If there is no water flow check tral position and fully close the throttle
109. ew 4 N m 0 4 kgf m 3 0 ft lb 5 12 Replacing the timing belt CAUTION e Do not turn the drive sprocket counter clockwise otherwise the valve system may be damaged e Do not remove the ignition timing pointer e Do not turn the drive sprocket or the driven sprockets 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 S63P5250 CAUTION Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily S63P5270 5 13 S69J5180 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 y TT Apply force to the crankshaft end until the fly wheel magnet comes off the tapered portion of the crankshaft Universal puller YB 06117 4 Remove the Woodruff key and stator assembly 2 S6D85210 NOTE Do not loosen the pulser coil screw 5 Turn the drive sprocket clockwise and align the hole 8 on the retaining plate with the projection on the cylinder block and check that A marks and on the driven sprockets are aligned 6D81G11 Power unit 9 Check that A marks and on the driven sprockets are aligned S6D85220 6 Disconnect the cooling
110. g Besembly asana anganani KANA an nen aa ga naa niens 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 filterd 3 5 Replacing the timing belt 5 13 Replacing the valve guides 5 28 Safety while working 1 3 Selecting the connecting rod bearing 5 45 Selecting the forward gear shims 6 27 Selecting the main bearing 5 47 Selecting the pinion shims 6 26 Selection A 1 6 Self diagi osi mmm 9 18 Self protection i 1 3 Serial number i 1 5 SM rol n 7 2 Smin lae EEE 6 25 6 26 Special service tools 9 1 4 1 5 1 6 1 7 1 8 1 9 1 Specified torques eenen 2 11 Starboard VIeW iii 8 4 Starter MOtor ii 8 13 Starting SYStem ii 8 11 Steering arm ii 7 17 SYMDOIS ii 1 2 NEN ME 1 9 Throttle link eicere 5 20 Tightening torques ssses 2 11 Tilt cylinder and trim cylinder 7 35 Top cowling i 3 3 TOP VIEW nenne ein 8 6 i 3 Index U Upper CaSe ikiii aaa agak aa aga naga NAGA aa aa 7 6
111. he Vapor separator 22222220 AERE 4 16 Assembling the vapor separator 4 e 4 16 Adjusting the flBat W sn dIi mm 4 17 Canister A ccce 4 18 Checking the CarWeter EE 4 19 vel D Fuel system Special service tools OG I c m Pressure vacuum tester YB 35956 A Fuel pressure gauge YB 06766 Fuel pressure gauge adapter B YB 06942 4 1 6D81G11 Special service tools Hose routing Hose routing Fuel and blowby hoses Eri GE S6D84010 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 High pressure fuel hose vapor separator to fuel rail Fuel hose pressure regulator to fuel cooler Fuel hose fuel cooler to vapor separator Canister hose vapor separator to canister Canister hose canister to idle speed control 5 Canister hose canister to filter 2 Canister hose filter to bottom cowling 6D81G11 4 2 rue D Fuel system Fuel filter and fuel
112. il Cooling water temperature sensor Starter motor Junction box 6 Spark plug 6D81G11 8 4 eLec 7 ELEC ES Electrical systems Bow view S6D88030 ECM Fuse 20A Sensor assembly ECM ignition coil electric fuel pump and fuel intake air temperature and intake air injector pressure Fuse 20A Idle speed control main switch and power trim and tilt switch Throttle position sensor Fuse 20 A 6 Rectifier Regulator Rectifier Regulator Power trim and tilt relay Fuse 30 A Starter relay starter relay Main and fuel pump relay 8 5 6D81G11 Electrical components Top view S6D88040 Fuel injection Shift position switch Sensor assembly intake air temperature and intake air pressure Idle speed control 6 Stator coil Power trim and tilt switch Starter motor 6D81G11 8 6 evec 7 ELEC ES Elec
113. in each direction AS Forward gear backlash 0 28 0 63 mm 0 0110 0 0248 in 6 Add or remove shim s if out of specifica tion Forward gear backlash Less than To be decreased by Shim thickness 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 M Measurement 6 29 6D81G11 Bracket unit Special Service COONS M 7 1 lt 1 isa 7 2 Bottom Coves ama aa ae 7 3 UPPer COSE eso T 7 6 Removing the upper Case un niment 7 12 Disassembling the oil pump Em 7 12 Checking the oia umpan LAE 7 12 Assembling H RT MERE cr ee 7 12 Disassembling the upper case s c gat esee Den 7 13 Checking the drive shaft bushing 2424444 2244er nnnnnnennnnnnhenn 7 13 Disassembling the oil pan ca rien fe 7 13 era JJ ursus 7 14 Assembling the oil pan Rw 7 14 Assembling the upper Case a a nh 7 15 I mmu upper Baso 4 4 ARR 7 15 Steering BB ey a ee aana 7 17 Removing the steering arm P RO anenun ena EU oe 7 18 Installiieuslle steering am oa I 7 18 Clamp brackets and swivel bracket eene 7 19 Henn damp b f ckets nn AM 7 21 Instaliga e Clamp rackets 2000 ST 7 21 Adj geng tit tim sensor
114. inches Propeller pitch in inches Propeller type propeller mark 6D81G11 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 Material 12 5 8 x21 K 13x19 K 13 x 23 R 13x 25 R 13 1 4x 17 K 13 1 2x 15 K 13 5 8 x 13 K 14x11 K 13x17 K 13x 19 R CAUTION 13x21 K This is a 4 stroke engine Never use pre mixed fuel Aluminum S6D81020 13x23 R Stainless 13x25 K 13 1 2x14 K Checking the engine oil level 13 12x 16 R 1 Check the engine oil level Predelivery checks To make the delivery process 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 y S60C1150 with fuel NOTE E If the engine oil is below the minimum level mark add sufficient oil until the level is between 8 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 qt 6D81G11 1 6 an General information Checking the gear oil level 1 Check the gear
115. inder head bolts before installation Tighten the M10 bolts to the specified torques in two stages first and then tighten the M8 bolts to 14 N m 1 4 kgf m 10 3 ft lb e 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 3 Install the valve shims and valve lifters 6D81G11 Cylinder head NOTE LU Apply engine oil to the valve shims and valve lifters before installation 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 S6D85490 NOTE m 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 5 34 6 Install the camshaft caps in the proper position as shown and with the stamped numbers facing upside down 7 Tighten the camshaft cap bolts to the specified torques in two stages and in the sequence shown
116. ing bolt 4 1st 42 N m 4 2 kgf m 31 0 ft lb 12 Install the cylinder head 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 NOTE BEE ee For cylinder head installation procedure see Installing the cylinder head 4 Install the oil dipstick 5 51 6D81G11 5 Connect the flushing hose cooling water pilot hose and canister hose 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 8 Connect the trim sensor coupler and bat tery leads Positive battery lead nut 9 N m 0 9 kgf m 6 6 ft Ib 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 NA S60C1150 NOTE If the engine oil is below the minimum level mark b add sufficient oil until the level is between 8 and Recommended engine oil 4 stroke motor oil API SE SF SG SH or SJ SAE 10W 30 or 10W 40 6D81G11 Cylinder block 5 52 6D81G11 Lower unit Special Service 10016 M nn 6 1 Eo gn tee 6 4 Removing the lower unit
117. itch terminals as shown 2 Connect the positive battery lead to the brown Br lead 6D81G11 Starter motor Charging system 3 Connect the negative battery lead to the starter motor body S6D88130 CAUTION Do not connect the battery for more than one second otherwise the magnet switch can be damaged 4 Check that there is continuity between the magnet switch terminals Replace if there is no continuity 5 Check that there is no continuity after the negative battery terminal is removed Replace if there is continuity NOTE pu 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 Disconnect the stator coil coupler 2 Connect the test harness 6 pins to the stator coil coupler 8 16 eLec 7 ELEC ES Electrical systems 3 Measure the stator coil output peak volt age Replace the stator coil if below specification S6D88150 Digital multimeter YU 34899 A or S6D88140 Test harness 6 pins YB 06848 Digital multimeter YU 34899 A Peak volt meter adapter YU 39991 Test harness 6 pins YB 06848 Rectifier Regulator output peak voltage Red R Ground Unloaded 1 500 3 500 13 0 13 0 Stator coil output peak voltage White W White W
118. ividual illustrations to explain the relevant procedure NOTE For troubleshooting procedures see Chapter 9 Troubleshooting LOWR t Lower unit Lower unit 35 N m 3 5 kgf m 25 fta Ib LOWR Removing the drive shaft 1 Remove the drive shaft assembly and pinion and then pull out the forward Lower unit XITN m 0 7 kgf m 5 1 ft Ib S62Y6740K 2140 N m 4 0 kgf m 29 ft Ib CAUTION Do not reuse the bearing always replace S62YG850K it with a new one SS2YG480K p Drive shaft holder 4 1 90890 06518 Remarks Pinion nut holder 2 90890 06505 Vag Lower unit Socket adapter 2 90890 06507 des u Disassembling the drive shaft 2 Remove the needle bearing from the for lose Chack screw 1 Install the pinion nut D tighten it finger ward gear tight and then remove the drive shaft Gasket bearing using a press Dowel pin Bolt M10 x 40 mm Drain screw Bearing separator 1 90890 06534 Grommet Bolt M10 x 45 mm Bolt M8 x 60 mm Thrust washer hi Propeller GENE CAUTION Washer Do not reuse the bearing always replace Washer CAUTION it with a new one Cotter pin Do not press the drive shaft threads 8 Propeller nut directly Stopper guide plate 2 90890 06501 Do not reuse the bearing always Stoppe
119. k 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 black B lead Replace if there is continuity 6D81G11 Fuel control system Starting system S60V8265 6D81G11 8 12 evec 7 ELEC ES Electrical systems Starter motor gt u e 3 amp 1 amp gt i Ann N nmm us UI 16 S63P8050 Z o ON OA BE WU Part name Remarks 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 Not reusable 1 1 1 1 2 1 1 1 1 1 1 1 3 1 1 1 1 8 13 6D81G11 11 nmm us UI 16 Part name Starter motor S63P8050 Remarks Brush assembly Brush spring Brush holder Plate Washer Bracket Screw Bolt Rubber seal Shift lever Spring Magnet switch assembly Washer Nut 6D81G11 A o ANN 4 x 15 mm M6 x 120 mm 8 14 eLec 7 ELEC aa Electrical systems Disassembling the starter motor 2 Measure the commutator diameter 1 Slide the pinion stopper D down as Replace the armature if below specifica shown and then remove the clip
120. kPa 3 0 kgf cm 43 5 psi 5 Measure the fuel pressure 3 seconds after turning the engine start switch to ON AS Fuel pressure reference data 260 kPa 2 6 kgf cm 37 7 psi o Start the engine vvarm 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 6D81G11 Vapor separator Fuel pressure reference data 230 kPa 2 3 kgf cm 33 4 psi Checking the pressure regulator 1 Disconnect the quick connector from the fuel rail NOTE 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 Disconnect the pressure regulator hose and then connect the special service tools to the pressure regulator S6D84120 d 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 Z Fuel pressure gauge YB 06766 Fuel pressure gauge adapter B YB 06942 Pressure vacuum tester YB 35956 A 5 Start the engine and let it idle 4 14 ve Fuel system 6 Check that the fuel pressure reduces when vacuum pressure is applied to the pressure regulator If the fuel p
121. linder block journal inside diameters crankshaft journal Bearing cylinder side thrust bearing Bearing crankcase side diameters mm 6 023 6 026 Green Yellow 6 027 6 034 Blue Green 6 035 6 042 Blue Blue 6 043 6 049 Red Blue 6 050 6 058 Red Red 6D81G11 Cylinder block 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 8 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 blue Bearing crankcase side blue 5 f the calculated value is more than the maximum value 6 058 mm replace the crankshaft 5 48 Assembling the power unit 1 Install the oil ring D second ring 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 45 40 5 S60C5A70 CAUTION Do not scratch the piston or break the pis ton rings NOTE S J 7 After installing the piston rings check that they move smoothly 3 Install the upper bearing into the con necting rod and the lower b
122. m and tilt relay i 7 45 Checking the power trim and tilt switch 7 an 7 46 Checking the tr mmus B 7 46 6D81G11 Bracket unit Special service tools Bearing installer Drive shaft needle bearing installer and YB 41446 remover Bearing cup installer YB 06196 YB 06167 Trim cylinder wrench Driver handle large YB 06175 2B YB 06071 Driver handle small YB 06229 Roller bearing installer remover YB 06432 Oil seal installer YB 06023 7 1 6D81G11 Special service tools Shift rod Shift rod Ix 1 N m 0 1 kgf m 0 7 ft Ib S6D87010 Z o o I CO OI BE WIN Part name Remarks Bolt Spring Ball Washer Bushing Bolt Bracket Shift rod Screw Plate Shift position switch Bolt Bushing Bracket Cotter pin Bushing Lever M6 x 25 mm 94 x 16 mm M6 x 50 mm Not reusable A I Ny li NN dir 6D81G11 7 2 o9 Y 3 5 NL o u a 5 S z o o CIS cs Ola LS NENGGE N N Pa aa De TIA 1 e NS loro Aa To te S6D87020 2 Io Te E s D Es ed E a N Ei Remarks M6 x 16 mm M6 x 30 mm M6 x 20 mm M8 x 35 mm Part name Cooling water outlet Canister outlet Grommet Grommet 6D81G11 7 3 Bottom cowling S6D87020 X 2N m 0 2 kgf m 1 5 ft Ib Remarks E E
123. m selecting tool YB 34446 1 YB 34446 3 YB 34446 5 YB 34446 7 Backlash indicator rod YB 06265 Backlash adjustment plate YB 07003 6 2 Lower unit Dial indicator gauge YU 03097 YU A8438 6 3 6D81G11 Special service tools Lower unit Lower unit 34 N m 3 4 kgf m 25 1 ft Ib Sx 9 N m 0 9 kgf m 6 6 ft Ib S6D86010 Z o ON OA POD Part name Remarks 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 M10 x 45 mm M8 x 60 mm L transom model Not reusable Es Es CE CO OI OS NN km 6D81G11 6 4 Lower unit 34 N m 3 4 kgf m 25 1 ft Ib Sx 9 N m 0 9 kgf m 6 6 ft Ib S6D86010 Part name Remarks Dowel X transom model Extension X transom model Stud bolt M10 x 180 mm X transom model Washer X transom model Spring washer X transom model Nut X transom model Bolt M8 x 190 mm X transom model 6 5 6D81G11 Lower unit S1104J S6D86040 Z o ON OA BE WIN Part name Remarks Q lt Bolt O ring Oil seal Oil seal housing O ring Circlip Shift rod Woodruff key Screw Bolt Cover Bolt Seal Water pump housing Insert cartridge Impeller Dowel M6 x 16 mm Not reusable Not reusable Not reusable SL LL I
124. n 3 Remove the reservoir cap and then check the fluid level in the reservoir NOTE 8 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 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 Ib 6 Connect the PTT motor leads to the bat tery terminals to fully retract the tilt ram S6D87570 Battery terminal Light green Lg e Sky blue Sb O PTT motor lead ai Reverse the PTT motor leads between the battery terminals to fully extend the tilt ram S6D87580 Battery terminal Sky blue Sb Light green Lg O PTT motor lead 6D81G11 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 e 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 S60C7975 CAUTION After tilting the outboard motor up b
125. nance interval chart 3 2 Maintenance specification 2 3 Manual format eh nawan saa awa asa 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 Port VIEW iet aa 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 unit 2 3 3 4 5 3 9 5 Predelivery ChECKS i 1 6 Propeller selection 1 5 Propeller shaft housing 6 10 Propeller size 1 5 6D81G11 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 5 38 Removing the fuel hose clamp 4 15 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 housin
126. neral information 3 Check that the engine turns off when the Break in engine stop lanyard is pulled from the During the test run perform the break in engine stop lanyard switch operation in the following three stages 1 One hour at 2 000 r min or at approxi mately half throttle 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 69J1220 5 minutes Checking the cooling water pilot hole 1 Check that cooling water is discharged 6 from the cooling water pilot hole _ mum A o 1 2 10 S69J1240 a J A Hour IR i After test run 1 Check for water in the gear oil en S63P3120 i 2 Check for fuel leakage in the cowling Test run 3 Flush the cooling water passage with 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 reverse and that water does not flow in over the transom NOTE 1k1 nlnk1 The test run is part of the break in operation 1 9 fresh water using the flushing kit and with the engine running at idle 6D81G11 6
127. nner parts and a new lower case e Shimming is required when replacing the inner part s Selecting the pinion shims 1 Calculate the specified value MO as shown in the examples below S68S6250 NOTE 7 7 O P is the deviation of the lower case dimen sion from standard The P mark 8 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 Specified value MO 0 20 P 100 mm Example If P is 5 then MO 0 20 5 100 mm 0 20 0 05 mm 0 25 mm If P is 5 then MO 0 20 5 100 mm 0 20 0 05 mm 0 15 mm 2 Install the drive shaft and drive shaft bearing to the special service tools 3 Attach the clamp to the gauge base using the bolts of an appropriate size 6D81G11 Shimming NOTE _ _m _m Tighten the clamp bolts another 1 4 of a turn after they contact the clamp 4 Install the pinion and pinion nut and then tighten the nut to the specified torque S6C16730 NOTE me Install the special service tools onto the drive shaft so that the shaft is at the center of the hole 42 Pinion shim selecting tool YB 34432 9 YB 34432 10A YB 34432 11A YB 34432 17 Pinion nut 93 N m 9 3 kgf m 68 6 ft Ib 6 26 Lower unit 5 Measure the clearance M between the shim selecting tool and th
128. not be more than MO Calculation formula Forward gear shim thickness T1 MO M Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Shimming Backlash Backlash Measuring the forward gear backlash 1 Remove the water pump assembly NOTE i nn Do not remove the oil seal housing in this procedure 2 Set the gear shift to the neutral position at the lower unit S6D86190 3 Install the special service tools so that it pushes against the propeller shaft S60X6390 NOTE Tighten the universal puller while turning the drive shaft until the drive shaft can no longer be turned Z Bearing housing puller YB 06207 Universal puller YB 06117 6D81G11 6 28 Lower unit 4 Install the backlash indicator onto the drive shaft 20 mm 0 79 in in diameter Available shim thicknesses then the dial gauge onto the lower unit 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 S6C16550 NOTE MM 7 Install the dial gauge so that the plunger 8 contacts the mark b on the backlash indica tor 5 Backlash indicator rod 3 YB 06265 Backlash adjustment plate 2 YB 07003 Dial indicator gauge 6 YU 03097 Magnetic base stand 6 YU A8438 5 Slowly turn the drive shaft clockwise and counterclockwise and measure the back lash when the drive shaft stops
129. olt Collar Throttle link rod Nut Throttle link rod joint Bracket Bolt M6 x 35 mm M6 x 25 mm LL S NN Li NN PD A HS M6 x 30 mm 6D81G11 5 20 ECM S6D85050 Z o o NOD OI BE o ND Part name Remarks Wiring harness Bracket Bolt Bolt Bracket Bracket Bracket Bolt Collar Grommet Bolt ECM Rectifier Regulator Bolt Bolt Bracket Bolt M6 x 15 mm M6 x 12 mm M6 x 20 mm M6 x 30 mm M6 x 25 mm M6 x 20 mm CG N INT HRA RPS BSB SB NN M6 x 30 mm 5 21 6D81G11 ECM Junction box Junction box 4 N m 0 4 kgf m 3 0 ft Ib Mg 4 N m 0 4 kgf m 3 0 ft Ib Z o o IJ CO CI BE o ND Part name Remarks 96 x 25 mm Screw Main and fuel pump relay Power trim and tilt relay Washer Nut Cap Bolt Ground lead Fuse Fuse Cap Cap Starter relay Holder Screw Bolt Cap M6 x 20 mm 30A 20A 96 x 20 mm M6 x 10 mm A A Q 0 ii DS NON DNDN 6D81G11 5 22 4 N m 0 4 kgf m 3 0 ft Ib Mg 4 N m 0 4 kgf m 3 0 ft Ib Part name Remarks Holder Junction box Collar Grommet Bolt M6 x 10 mm Clamp Grommet 5 23 6D81G11 Junction box Cylinder head Cylinder head 15 N m 1 5 kgf m 11 1 ft Ib 30 N m 3 0 kgf m 22 1 ft Ib o AG I 8 AR I
130. om 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 qt 6 Install the oil filler cap and oil dipstick and then 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 S OEBE e Wait more than 5 minutes after turning the engine off to replace the oil filter e Be sure to clean up any oil spills Oil filter wrench YU 38411 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 6D81G11 Power unit 2 While turning the flywheel magnet clock wise check the interior and the exte rior of the timing belt for cracks damage or wear Replace if necessary S6D83070 NOTES For replacement procedures see Chapter 5 Replacing the timing belt Oil filter Checking the spark plugs 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
131. onnected properly Replace the shift rod Disassemble the lower case and then check the operation of the dog clutch Good operat ing condition Replace the defective parts Yes Check the forward gear and reverse gear 6D81G11 9 16 TRBL 1 SHTG e Troubleshooting Electrical systems Symptom Battery becomes weaker quickly Check the charging system Measure the output peak voltage of the stator coil Within specification Replace the stator coil Measure the Rectifier Regulator output peak voltage Within specification Replace the Rectifier Regulator Replace the battery and then check the voltage of all electri cal equipment on your boat 9 17 6D81G11 Self diagnosis Diagnosing the electronic control system 1 Connect the special service tool to the outboard motor as shown S6D89020 NOTE Eun 7 7 gt When performing this diagnosis all of the electrical wires must be properly connected Diagnostic test lead YB 06795 2 Startthe engine and let it idle 3 Check the flash pattern of the special service tool to determine if there are any malfunctions Normal condition no defective part or irregular process ing is found Single flash is given every 4 95 sec onds 8 Light on 0 33 second b Light off 4 95 seconds 6D81G11 Electrical systems Self di
132. ousing screw 0 4 Upper mount bolt 2 8 Muffler assembly bolt 2 0 Engine oil drain bolt 2 7 Oil strainer bolt 1 0 Oil pan bolt 1 1 Exhaust manifold bolt 1 1 6D81G11 2 12 SPEC um s Specifications TE Part to be tightened Thread size tignteningAerques N m kgf m Steering arm stud bolt M10 20 2 0 Self locking nut 15 15 Trim sensor cam screw M6 2 0 2 Povver trim and tilt unit Reservoir cap PTT motor bolt Gear pump bolt Gear pump housing bolt 0 7 0 4 0 5 0 5 0 4 0 5 0 2 0 2 0 2 0 4 Trim cylinder end screw 9 0 Tilt cylinder end screw 8 0 Tilt piston bolt 8 5 Relief valve cap bolt Lever bolt Manual valve BPO PO PO ON A OF U SIN Gear pump bracket bolt General torques This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch Tightening torque specifications for special components or assemblies are General torque specifications N m kgf m ft lb 5 0 5 3 6 provided in applicable sections of this man 8 0 8 5 8 ual To avoid warpage tighten multi fastener 18 1 8 13 assemblies in a crisscross fashion and pro 36 3 6 25 gressive stages until the specified torque is 43 4 3 31 reached Unless otherwise specified torque specifications require clean dry threads Components should be at
133. pump Ix 10 N m 1 0 kgf m 7 4 ft Ib Ne 3N m O3kg m 22f Ib Se S6D84020 No Part name Remarks 1 2 3 4 5 6 7 8 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 M6 x 12 mm CW Ss Cs Ad Ad AL Aa Not reusable 4 3 6D81G11 Fuel filter and fuel pump Sg 4 N m 0 4 kgf m 3 0 ft Ib S6D84030 Z o 0 CO IJ OA A ON Part name 2 lt Remarks Screw Cover Gasket Fuel pump body 2 assembly Diaphragm 96 x 35 mm Not reusable Pin Spring Fuel pump body 1 Spring Plunger Nut ow da oa oa oa 4 4 9 b O 6D81G11 4 4 Zu 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 24 Pressure vacuum tester YB 35956 A AS 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 AS
134. r as they were removed e Mark each piston with an identification number 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 S60C5820 Piston diameter 8 78 928 78 949 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 5 40 Checking the cylinder bore 1 Measure the cylinder bore D D at measuring points and and in direction D D3 Ds which is parallel to the crankshaft and direction Dz D De 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 Replace or rebore the cylinder block if above specifi cation Taper limit D1 Ds direction 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 Ds Ds 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 bor
135. r guide stand Trim tab S62Y6750K replace it with a new one 90890 06538 Bearing puller 90890 06535 nei F Bearing puller claw 1 Bearing inner race attachment 3 62Y5A11 E 90890 06639 90890 06536 Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear using a press 62Y5A11 1 1 6D81G11 How to use this manual Symbols The symbols below are designed to indicate the content of a chapter General information Fuel system Bracket unit am T FUEL BRRT Specifications Power unit Electrical systems Periodic checks and adjustments Lower unit Troubleshooting CHK Q TRBL ADJ Bonn sure 2 Special tool Specified measurement Specified oil or fluid Specified electrical value Specified engine speed resistance voltage electric current Specified tightening torque Symbols 7 to 3 in an exploded diagram indicate the grade of lubricant and the lubrication point Apply Yamaha 4 stroke motor oil Apply corrosion resistant grease Apply gear oil Yamaha grease D Apply water resistant grease Yamaha grease A d Apply low temperature resistant grease Apply molybdenum disulfide grease Yamaha grease C 3 Apply injector grease Symbols to 8 in an exploded diagram indicate the type of sealant or locking agent and the appli cation point Apply Gasket Maker Apply LOCTITE 572 9
136. r trim and tilt fluid level if necessary S6C13220 NOTE m Be sure to listen to the vvinding sound of the povver trim and tilt motor for smooth opera tion 2 Fully tilt the outboard motor up and then support it with the tilt stop lever to check the lock mechanism of the lever Checking the power trim and tilt fluid level 1 Fully tilt the outboard motor up and then support it with the tilt stop lever ds 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 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 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 6D81G11 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 e If the oil is at the correct level the oil should overflow out of the check hole when the
137. re tightening the lower mounting nut be sure to connect the ground lead to the lower mounting bolt 6 Install the mount covers 8 7 Install the oil pump assembly and the bolts 9 and then tighten them to the specified torque S6D87210 NOTE re 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 51 N m 5 1 kgf m 37 6 ft lb Oil pump bolt 49 10 N m 1 0 kgf m 7 4 ft lb Grease nipple 3 N m 0 3 kgf m 2 2 ft lb 6D81G11 Upper case 7 16 Bracket unit Steering arm Z o Part name 20 N m 2 0 kgf m 14 8 ft Ib Co NOOA S6D87220 Remarks Nut Steering hook Stud bolt Steering arm Washer Bushing O ring Bushing Washer Steering yoke Damper Circlip ON OA POD maaana a Nu EE lt M10 x 40 mm Not reusable 6D81G11 Removing the steering arm 1 Remove the circlip 2 Remove the steering yoke 2 by striking it with a plastic hammer S6D87230 3 Remove the steering arm from the svvivel 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 on
138. rease Overheat warning indicator is on Oil pressure warning indicator is on Warning indicator is on and buzzer is sounding Check the cooling system Check the lubrication system Cooling system Check the cooling water inlet for clogs or debris Check that cooling water is discharged from the cooling Clogs or debris water pilot hole Is water Clean the cooling water inlet g discharged Check the water pump impeller Pro Vel Good condition Check the thermostat operation passage No Replace the Good condition impeller Replace the thermostat Check the cooling water tem perature sensor Replace the cooling water tem perature sensor Good condition Check the engine using the Yamaha Diagnostic System 9 11 6D81G11 Power unit Lubrication system Check the engine oil level Add engine oil to the correct level At specified level Check the oil pressure Within specification Check the oil pump for debris or oil leaks Check the oil passage Debris or leaks Clean or replace the defective Check the oil pressure switch parts Good condition Replace the oil pressure switch Check the engine using the Yamaha Diagnostic System 6D81G11 9 12 TRBL 1 SH
139. ressure does not reduce replace the pressure regulator NOTE NG 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 using a thin screwdriver to release the fuel pressure WARNING Always reduce the fuel pressure in the high pressure fuel line before servicing the line or the vapor separator If the fuel pressure is not released pressurized fuel may spray out 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 S6D84100 4 15 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 Sal LA CAUTION If the fuel hose clamp is removed without cutting the crimp first the fuel hose will be damaged S69J4030 Installing the fuel hose clamp 1 Crimp the fuel hose clamp properly to securely fasten it d 69J4040 A WARNING Do not reuse the fuel hose clamp always replace it with a new one Disassembling the vapor separator 1 Remove
140. rmation to make procedures easier or clearer F90D SERVICE MANUAL 2004 by Yamaha Motor Corporation USA 1st Edition June 2004 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation USA is expressly prohibited Printed in USA LIT 18616 02 86 Contents General information muh Specifications o 5 LU 0 Od Periodic checks and adjustments Q Li A gt I c Fuel system I Tl cC m r Ol Lower unit o Bracket unit m Electrical systems CO m UJ JIN y O 4 Hg HZ H4 0 JJ JJ Ww r Troubleshooting de o Q ESRI 6D81G11 General information How to use this Manual 1 1 Manual TOrmat 5 saa T 1 1 jns rime RR Hm 1 2 Safety while WOT pde 1 3 Fire DOCU Qr T 1 3 VE Pe aae EEEE EAEE TERA 1 3 Self protection ara n 1 3 Parts lubricants and sealants eese 1 3 Good working practices Em 1 4 Disassembly and assembly oom P LL 1 4 Identification UP EET oa Is 1 5 Applicable medom comm anae Issues 1 5 JENS JE EE ca 1 5 Propelenselecton enn AE I A 1 5 TE ED 1 5 ee MH EE JE ree sss 1 6 ce Cle il a ee 1 6 Checkingiihe fuelfsystem d Nenn EEE 1 6 Checking the engine oil level at
141. s 1 Remove the power trim and tilt unit For removal procedure see Removing the power trim and tilt unit Remove the anode Disconnect the ground lead Remove the trim sensor cam screw 3 Loosen the self locking nut and the bolt and then remove clamp brackets and Remove the trim sensor Remove the tilt stop lever S6D87510 Installing the clamp brackets 1 Install the trim sensor onto the swivel bracket 7 21 NOTE IM Adjust the trim sensor after installing the power trim and tilt unit m 3 Assemble the clamp brackets and the swivel bracket by installing the anode 2 bolt and self locking nut then tight ening the nut to the specified torque S6D87520 Self locking nut 4 15 N m 1 5 kgf m 11 1 ft lb Install the power trim and tilt unit For installation procedure see Installing the power trim and tilt unit Adjusting the trim sensor 1 2 3 Fully retract the power trim and tilt unit Loosen the trim sensor cam screw 1 Adjust the trim sensor cam 2 where the specified trim sensor setting resistance is obtained 6D81G11 Clamp brackets and swivel bracket Trim sensor setting resistance Pink P Black B 10 1 Q at 20 C 68 F Trim sensor cam screw 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 S6D87530
142. s Replace if necessary Check the outer surface of the tilt piston and free piston for scratches Replace if necessary 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 8 of the tilt cylinder end screw and check the valve for dirt or residue Clean if necessary S62Y7610 7 39 2 Check the operation 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 Install the O ring 3 onto the trim cylinder end screw Install the tilt ram 2 into the trim cylinder end screw 4 5 S60C7860 Install the backup ring and new O rings and into the tilt cylinder end screw 8 60C7865 Install the tilt cylinder end screw onto the tilt ram S60C7870 6D81G11 Tilt cylinder and trim cylinder 6 Install the new O rings and and backup ring onto the trim piston 2 7 Install the balls valves 9 and springs 5 into the trim piston and then install the washer 6 and trim piston to the tilt cylin der 2 8 Install the filter and washer to the trim piston S6D87410 Tilt piston bolt 69 85 N m 8 5 kgf m 62 7 ft lb 13 Install the tilt ram into the til
143. side clearance Replace the piston and piston rings as a set if out of specification S63P5730 Piston ring side clearance Top ring 8 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 5 42 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 S6D85580 Connecting rod big end side clearance 8 0 14 0 28 mm 0 0055 0 0110 in Checking the crankshaft 1 Measure the crankshaft journal diameter crankpin diameter and crankpin width Replace the crankshaft if out of specification S63P5750 63P5760 5 43 Crankshaft journal diameter 47 985 48 000 mm 1 8892 1 8898 in Crankpin diameter 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 S6D85590 Crankshaft runout limit 0 03 mm 0 0012 in Checking the crankpin oil clearance 1 Clean the bearings and the connecting rod N Install the upper bearing into the con necting rod and the lower bearing into the connecting rod cap 6D81G11 S60C5960
144. ss 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 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 6D81G11 Power unit 19 Check that the TDC mark on the fly wheel magnet is aligned with the pointer b and that A marks and on the driven sprockets are aligned 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 scr
145. ssembling 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 tilt MOTOT DMH 7 27 Disassembling the propeller shaft assembly sina ie ebrei Reds 6 11 Disassembling the propeller shaft MOBBING Li 6 11 Disassembling the starter motor 8 15 Disassembling the tilt cylinder 7 38 Disassembling the trim cylinder 7 38 Disassembling the upper case 7 13 Disassembling the vapor separator 4 15 Disassembly and assembly 1 4 Disconnecting the quick connector 4 13 Draining tr fuel pm 4 15 Drive shaft and lower case 6 15 E ON eese 5 21 Electrical AFFI 2 6 Electrical components 8 3 Electrical Systems sss 9 17 ES IS COVES 5 36 F Fire prevention ii 1 3 Fuel and blowby hoses 4 2 Fuel control system 8 10 Fuel filter and fuel pump 4 3 F el system entree 3 3 G Gear pump coder nene vede 7 30 General ente re etti tend 3 14 General specifications 2 1 General torQues
146. sure control valve umnsusssnnnannnnnnnnnnnnnnnnnnnnnnn nenn 5 38 Installing the exhaust COVEr in 5 38 6D81G11 Cylinder Block qM 5 39 Disassembling the cylinder block 5 40 Checking the piston diameter sese 5 40 Checking the cylinder bore sseeeeeem e 5 41 Checking the piston clearance rnnnnnnnnvnnnvrnrrnnnnnnnnnnnnnnannnnnrrnrnnnnennnnnnnnn 5 41 Checking the piston rings i 5 41 Checking the piston ring grooves i 5 42 Checking the piston ring side clearanCe i 5 42 Checking the connecting rod big end side clearance 5 43 Checking the crankshaft fee ea 5 43 Checking the crankpin oil clearance ii 5 43 Selecting the connecting rod bearing 5 45 Checking the crankshaft journal oil clearance 5 46 Selecting the main bearing b eese 5 47 Assembling M nenti 5 49 Installing the powem ge M 5 51 6D81G11 Special service tools cm Compression gauge Valve spring compressor YU 33223 YM 01253 Valve spring compressor attachment YB 06320 Compression gauge extension YB 06563 Valve guide remover installer YM 04064 A Flywheel magnet holder YB 06139 Valve guide reamer YM 04066 Universal puller YB 06
147. t 9 and spring 8 and then tighten the tensioner bolt S6D85160 5 Check the intake valve clearance for cyl inders 1 and 2 and the exhaust valve clearance for cylinders 1 and 3 Adjust if out of specification n SUSA m NOTE e Check the valve clearance when the engine is cold e Note the measurement Valve clearance cold 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 4 marks on the driven sprockets are aligned 9 Loosen the tensioner bolt 2 and then remove the spring 8 timing belt 9 driven sprockets 0 camshaft caps and camshafts S6D85180 NOTE n Do not mix the valve train parts Keep them organized in their proper groups 10 Remove the valve lifters from the cylinder head 6D81G11 11 Remove the valve shim 3 from the valve lifter using a thin screwdriver S6D85190 12 Measure the valve shim thickne
148. t cylinder 14 Hold the tilt cylinder in a vise using aluminum plates on both sides S60C7875 9 Install the backup ring and new O ring to the tilt piston 10 Install balls and 63 valves 65 springs amp pins 6 dowels and washer 8 NOTE into the tilt piston Place the tilt cylinder in the vise horizontally ri 11 Hold the tilt ram end in a vise using alu minum plates on both sides 12 Install the tilt piston to the tilt ram by installing the bolt 69 then tightening it to the specified torque 6D81G11 7 40 Bracket unit 15 Install the tilt cylinder end screw 8 and then tighten it to the specified torque S60C 7890 CAUTION Do not damage the check valve when tightening the end screw Trim cylinder wrench YB 06175 2B Tilt cylinder end screw 8 80 N m 8 0 kgf m 59 0 ft lb 16 Install the free piston into the tilt cylin der by installing the circlip 62 e e c S6D87420 17 Install the cylinder base 63 springs 63 and washer 8 into the tilt cylinder with the circlip G9 7 41 x d A 2 9 Assembling the power trim and tilt unit 1 Hold the trim cylinder in a vise using alu minum plates on both sides ED S6D87430 2 Install the filters and gear pump assem bly CD by installing the bolts 2 then tight ening them to the specified torques 3 Install the manual valve 3 and reservoir cap Gear p
149. t the positive pin on the peak volt age adapter to the positive terminal of the digital circuit tester 6D81G11 Measuring the lower resistance When measuring 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 IL 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 ELEC EX 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 6 Fuel injector Electric fuel pump 8 3 6D81G11 Electrical components Starboard view S6D88020 Ignition co
150. ten the exhaust manifold bolts 6 again to the specified torque 6D81G11 Upper case S6D87160 Oil pan bolt 2 11 N m 1 1 kgf m 8 1 ft Ib Exhaust manifold bolt 11 N m 1 1 kgf m 8 1 ft Ib 7 Install new gaskets the plate and the muffler 8 onto the oil pan 8 Install the water pipe 9 S6D87170 7 14 Bracket unit Assembling the upper case 1 2 Install the drive shaft bushing into the upper case and then install the circlip S6D87180 Drive shaft needle bearing installer and remover 1 YB 06196 Driver handle large YB 06071 Install the muffler assembly 3 by insert ing the tip of the water pipe 2 into the joint hole of the upper case Install the muffler assembly bolts and then tighten them to the specified torque S6D87190 AS Muffler assembly bolt amp 20 N m 2 0 kgf m 14 8 ft Ib Installing the upper case 1 3 Install the upper mount and bolts into the upper case Install the bolts 3 and then tighten them to the specified torque S6D87590 Upper mount bolt 8 28 N m 2 8 kgf m 20 7 ft lb Install the lower mounts onto the upper case S6D87200 Install the upper and lower mounting bolts into the bracket simultaneously Install the upper mounting nut and lower mounting nut and then tighten them to the specified torques 6D81G11 NOTE EE Befo
151. 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 and then tighten it to the specified torque 7 45 NOTE s 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 AS Em X oe On poe S63P7370 NOTE __ _ Be sure to set the measurement range shown in the illustration when checking for continuity Power trim and tilt relay continuity Sky blue Sb Black B Light green Lg Black B Terminal Terminal 4 Terminal 2 Terminal 4 Terminal Terminal Terminal 2 Terminal 3 Continuity Continuity No continuity 2 Connect the digital circuit tester between power trim and tilt relay terminals 2 and 6D81G11 Tilt cylinder and trim cylinder Power trim and tilt electrical system 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 betwe
152. the float chamber float pin and float 6D81G11 S6C14220 NOTE Remove the float pin in the direction of the arrow 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 2 Check the 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 6D81G11 Vapor separator S6C14210 NOTE LL Do not reuse the float pin always replace it with a new one Install the float pin in the direction of the arrow 8 shown nstall the float pin with its tapered end towards the punch mark b on the vapor separator cover 2 Check the float height O as shown Adjust the float height if out of specifica A N m Float height 46 6 1 0 mm 1 83 0 04 in 4 16 ve Fuel system 3 Check the float height as shown Adjust the float height if out of specifica be HI Come e The float should be resting on the needle valve but not compressing it e Take measurements at the position shown opposite the float pivot Float height d 35 0 1 0 mm 1 38 0 04 in 4 Install the float chamber Float ch
153. there is no continuity S69J8270 6D81G11 Ignition and ignition control system Fuel control system Lead color Blue green L G Switch position Black B Free Push C 0 Checking the main and fuel pump relay main control 1 Remove the main and fuel pump relay ff S6D88090 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 Check for continuity between the relay terminals and 3 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 6D81G11 S6D88100 Fuel control system Checking the injectors 1 Measure the resistance of the fuel injec tors S6C14170 Fuel injector resistance reference data 12 0 Q at 21 C 70 F NOTE Check the operation of the fuel injectors using the Stationary test of the Yamaha Diagnostic System Checking the electric fuel pump 1 Turn the engine start switch to
154. tion i 8 16 Gliarditig system nee ee 8 16 Checking the Stator Cleaner ee 8 16 Checking the Rectifier Regulator 8 17 ELEC ELEC ES Electrical systems Special service tools Spark checker Test harness 6 pins YM 34487 YB 06848 Digital multimeter Pressure vacuum tester YU 34899 A YB 35956 A Peak volt meter adapter YU 39991 Test harness 2 pins YB 06792 Test harness 3 pins YB 06791 8 1 6D81G11 Special service tools Checking the electrical components Checking the electrical components Measuring the peak voltage NOTE _ r 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 S69J8010 A WARNING When checking the peak voltage do not touch any of the connections of the digital tester leads NOTE e Use the peak voltage adapter with the digi tal circuit tester e When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode e Connec
155. to the swivel bracket S6D87240 3 Install the bushing O ring 8 and washer 9 onto the swivel bracket 6D81G11 Steering arm S6D87250 4 Install the steering yoke 9 to the steer ing arm by aligning the center 8 of the yoke with the center of the steer ing arm 5 Install the circlip S6D87260 6 Inject grease into the grease nipple until grease comes out from both the upper and lower bushings S60C7255 7 18 Bracket unit Clamp brackets and swivel bracket Z o Ix 15 N m 1 5 kgf m 11 1 ft Ib Part name S6D87490 Remarks ON OA BE WU 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 4 1 1 1 1 2 1 1 96 x 25 mm M6 x 14 mm M6 x 16 mm M8 x 20 mm 6D81G11 Clamp brackets and swivel bracket 4 16 415 Ix 3N m 0 3 kgf m 2 2 ft Ib S6D87500 No Part name Q ty Remarks 1 Swivel bracket 1 2 Tilt stop lever 1 3 Bushing 4 4 Distance collar 2 8 30 3 30 6 mm 1 19 1 20 in 5 Pin 2 6 Hook 1 7 Bolt 1 M6 x 10 mm 8 Spring 1 9 Tilt stop lever 1 10 Trim sensor 1 11 Screw 2 96 x 15 mm 12 Bolt 1 M6 x 10 mm 13 Clamp 2 14 Grease nipple 2 15 Ground lead 1 16 Pin 1 6D81G11 7 20 Bracket unit Removing the clamp bracket
156. trical 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 WARNING Do not touch any of the connections of the spark checker leads e Do not let sparks leak out of the removed spark plug caps Keep flammable gas or liquids away since this test can produce sparks NOTE TT The ignition spark can also be checked using the Stationary test of the Yamaha 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 r gt S60C8100 Spark plug wire resistance 1 4 5 10 7 KQ 2 3 3 8 0 kQ 3 3 8 9 KQ 4 4 3 10 2 kQ Checking the ignition coils 1 Remove the spark plug wires from the ignition coils 2 Disconnect the ignition coil coupler 3 Measure the ignition coil resistance Replace if out of specification S63P8100 6D81G11 Ignition coil resistance Primary coil
157. uel cooler 1 11 Screw 2 96 x 15 mm 12 Fuel hose 1 13 Hose 1 14 Hose 1 15 Hose 1 16 Plastic tie 8 4 11 6D81G11 x 5N m 0 5 kgf m 3 7 ft Ib Vapor separator Sx 2N m 0 2 kgf m 1 5 ft Ib S6D84090 No Part name Q ty Remarks 1 Cover 1 2 Pressure regulator 1 3 Bolt 2 M6 x 12 mm 4 O ring 1 5 Joint screw 1 6 O ring 1 7 Electric fuel pump 1 8 Grommet 1 9 Collar 1 10 Filter 1 11 Screw 3 94 x 6 mm 12 Wiring harness 1 13 Float 1 14 Needle valve 1 15 Pin 1 16 Cap 1 6D81G11 4 12 vel I Fuel system Reducing the fuel pressure 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 using a thin screwdriver to release the fuel pressure S6D84180 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 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 S6C14240 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 CAUT
158. ump bolt 2 5 N m 0 5 kgf m 3 7 ft lb Reservoir cap 7 N m 0 7 kgf m 5 2 ft Ib 4 Fill the reservoir with the recommended fluid to the correct level as shown 6D81G11 S6D87450 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 to the specified torque S6D87460 PTT 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 into the tilt cylinder and then insert the tilt cylinder into the trim cylinder 6D81G11 Tilt cylinder and trim cylinder S6C17760 NOTE n Apply grease to the balls from falling out of the cylinder installation 8 Install the trim cylinder end screw and then tighten it to the specified torque S6D87480 Trim cylinder wrench i YB 06175 2B 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 10 Install the reservoir cap S6C17780 7 42 Bracket unit Bleeding the power trim and tilt unit 1 Tighten the manual valve by turning it clockwise S62Y7840 Manual valve 2 N m 0 2 kgf m 1 5 ft lb 2 Place the power trim and tilt unit in an upright positio
159. ure In addition be sure to lubricate the bearings liberally Apply a thin coat of water resistant grease to the lip and periphery of an oil seal before installation Check that moving parts operate nor mally after assembly 1 4 an General information Identification Applicable model This manual covers the following model Applicable model F90TR 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 S69J1090N Model name Approved model code Transom height Serial number Approved Starting model code serial No F90TR 61P 1007790 Model name 1 5 Propeller selection The performance of a boat and outboard motor will be critically affected by the size and type of propeller you choose Propellers greatly affect boat speed acceleration engine life fuel economy and even boating and steering capabilities An incorrect choice could adversely affect performance and could also seriously damage the engine Use the following information as a guide for selecting a propeller that meets the operating conditions of the boat and the outboard motor Propeller size The size of the propeller is indicated on the propeller boss end on the side of the propel ler boss 000x0 0 S69J1100 000x0 0 9 7 S60C 1120 Propeller diameter in
160. urement 1 2 43 4 5 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 4 e Make a mark on the M10 bolts and the crankcase and then tighten the bolts 60 from the mark S60C5A40 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 Ib 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 8 Remove the crankcase and then mea 3 Subtract crankshaft journal diameters sure the width of the compressed Plasti 1 5 from cylinder block journal inside gauge PG 1 on each crankshaft diameters 1 5 journal Replace the main bearing if out of specification 5 47 6D81G11 NOTE TT Cylinder block journal inside diameters 1 5 and crankshaft journal diameters 1 5 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 gt 54 032 4 Select the suitable color for the main bearing from the table below according to the calculated values S6D85720 Main bearing selection table 20 C 68 F Cy
161. water hose 3 S6D85240 and remove the bracket 7 Remove the spring and timing belt tensioner 6 and then remove the timing belt 7 from the driven sprockets then from the drive sprocket S6D85230 8 Check that the hole 8 on the retaining plate and the projection on the cylin der block are aligned 6D81G11 5 14 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 by turning it counterclockwise S6D85290 S6D85250 CAUTION e 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 e Do not get oil or grease on the timing belt NOTE 0 The lower edge of the timing belt should be 2 mm 0 08 in 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 S6D85260 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 Ib 16 Turn the drive sprocket two full turns and then check that the alignm
162. ylinder head bolts in the sequence shown S6D85440 CAUTION Do not scratch or damage the mating sur faces of the cylinder head and cylinder block 5 26 6 Remove the intake and exhaust valves S60C5390 NOTE Be sure to keep the valves springs and other parts in the order as they were removed 4 Valve spring compressor YM 01253 Valve spring compressor attachment YB 06320 Checking the valve lifters 1 Check the valve lifters for damage scratches or wear Replace if necessary Checking the valve springs 1 Measure the valve spring free length 8 Replace if below specification S60C5400 5 27 Valve spring free length 53 20 mm 2 0945 in 2 Measure the valve spring tilt Replace if above specification VILL LL 7 A 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 8 Replace if out of specification e S60C5420 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 Replace if out of specification 6D81G11 S60C5430 Valve stem diameter Intake 5 975 5 990 mm 0 2352 0 2358 in Exhaust 5 960 5 975 mm 0 2346 0 2352 in 4

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