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Aruana 40 EFI English

1. 2 BTDC 10 3 BTDC 10 1 BTDC 10 Convexo concave shape conex segmen LT LLL ULL Concave segment Crankshaft angle 120 180 240 300 360 420 480 540 600 660 0 60 degree Normal operating BTDC 36 ATDC 12 BTDC 36 ATDC 12 Ignition tS Injection BH l S A Cylinder 1 Combustion Exhaust Intake Compression Ignition e Injection La S l se Cylinder 42 Compression Exhaust Intake Ignition k AS SS Injection La Ka l S Cylinder 3 Exhaust Intake Compression Eeo K Exhaust 2 5 Engine control system Ignition timing control The CDI system of the engine ECM controls the ignition timings It determines the optimum ignition timing using the signals transmitted from the sensors and sup plies the primary current to the ignition coils Air pressure sensor Ignition coil 1 Air temperature sensor Ignition coil 2 TPS Ignition coil 3 Thermo sensor Pulser coil Engine ECM Engine start switch Engine shut off switch Oil pressure switch Neutral switch The ignition timing control includes the start up normal operating and engine speed control modes and automatically shifts between these modes depending on the engine operating conditions In the start up mode the engine ECM fixes the ignition timing until the engine is started Start up mode ignition timing BTDC 10 In the normal operating mode the engine ECM picks up the optimum ignition timing from the map
2. 8 15 Checking the lower unit anode 8 3 Checking the lower unit for air Ec TE TC re 8 19 Checking the magnet switch 5 35 Checking the main relay 5 15 Checking the neutral switch 5 29 Checking the neutral switch tiller handle MOdel id dE 5 32 Checking the oil pan and exhaust A nn er 9 33 Checking the oil pressure 7 1 Checking the oil pressure switch 5 18 Checking the oil strainer 9 33 Checking the outboard motor mounting HEN es Dt ri 10 6 Checking the pinion e ee eee eee 8 14 Checking the piston diameter 0 0 7 54 Checking the piston pin 7 55 Checking the piston pin boss inside TEAMET 7 55 Checking the piston mg 7 54 Checking the piston ring end gap 7 55 Checking the piston ring groove 7 55 Checking the piston ring side clearance 7 55 Checking the pressure regulator 6 5 Checking the primer pDump 6 16 Checking the propeller 8 3 10 13 Checking the propeller shaft 8 8 Checking the propeller shaft housing 8 8 Checking the PTT cylinder and piston 9 59 Checking the PTT fluid level 10 13 Checking the PTT motor 9 50 Checking the PTT operation 10 13 Checking the PTT relay 5 42
3. 8 19 Installing the wiring hammess 7 24 Installing the wiring harness remote control MOAN ee 3 16 Intake and exhaust system 2 18 LOCKING operation 2 14 LOWer UN etat nur are 1 4 1 14 8 1 Lower unit assembly 1 12 Lower unit technical data 1 12 Lubricating the outboard motor 10 12 Lubrication system 2 16 Maintenance interval chart 10 1 Manual format 0 4 R Index Measuring the forward and reverse gear N O backlash before disassembly 8 25 Measuring the forward gear alen WE 8 34 Measuring the fuel pressure 6 4 Measuring the peak voltage 5 14 Measuring the reverse gear backlash uses 8 37 Mechanism and operation o o o o 2 13 Model data 1 3 Model designation eee 1 2 Model features 1 1 Mounting the outboard motor 3 9 Mounting the rigging grommet 3 11 Non reusable part 0 3 Operation in case of malfunctions 2 22 Optional equipment 1 15 3 16 Outboard motor installation 3 1 Outline 2 1 2 13 2 15 2 19 10 1 Part lubricant and eealant 0 2 Performance see eee ee ee e e e eee 1 3 Pinion shim T3 selection table 8 32 EON VEN re 5 1 Power unt
4. 8 22 Special service tool 0 3 0 7 Special tightening torque 1 12 Starboard view 5 3 5 8 5 9 Starter mob avsa 5 33 7 27 Staring SSE een 1 7 Starting units and components 5 30 SVMDOL ee 0 6 System diagram 2 16 2 17 2 18 3 19 TES TUN erain iedera aaa 10 7 TONG sele EE 2 4 Throttle link rod 6 21 Tightening Ioroue lies 0 3 Tiller handle tiller handle model 5 10 Tiller handle model 1 14 Tilt down operation eee eee ee 2 21 Tilt up operation 2 20 TOP VEN Luke 5 7 Trouble code and checking step 4 6 Troubleshooting procedure 4 4 Troubleshooting the power unit 4 4 Troubleshooting the povver unit trouble code not deiected 4 9 Troubleshooting the power unit using the diagnostic flash indicator 4 8 Troubleshooting the power unit using Me DIS rss dla 4 4 Troubleshooting the PTT unit 4 12 4 13 U Uncrate procedure 3 8 Unlocking operation 2 14 Vapor gas DO SE semana mada ade 6 2 Vapor gas hose and cooling water hose 6 3 Vapor separator 6 25 Vapor separator disassembly 6 29 Variable trolling speed control 2 12 EHNEN EEE ie sous 0 1 VV Water UMP acia 8 4 When the outboard motor hits something in the
5. 5 38 9 50 Checking the Camshaft 7 41 Checking the clamp bracket anode 9 40 Checking the compression pressure 7 1 Checking the connecting rod big end side Clear aNG nn A de ie 7 56 Checking the connecting rod small end and big end inside diameter 7 56 Checking the cooling water passage 10 8 Checking the cooling water pilot hole 10 3 Checking the crankpin oil clearance 7 57 Checking the crankehatt 7 56 Checking the crankshaft journal oil EE Ee ad 7 58 Checking the cylinder bore 7 54 Checking the cylinder head 7 36 Checking the cylinder head anode 7 42 Checking the diaphragm and valve 6 14 Checking the dog clutch 8 8 Checking the drive shaft 8 14 Checking the drive shaft bushing 9 28 Checking the electrical component 5 14 Checking the engine ECM 5 26 Checking the engine ECM circuit 5 16 Checking the engine idle speed 10 9 Checking the engine oil level 10 4 10 10 Checking the engine shut off switch 5 30 Checking the engine start switch 5 31 Checking the engine start switch and engine Shut off switch 10 4 10 11 Checking the exhaust cover anode 7 49
6. Throttle link rod 6 Remove the bolt O the collar 40 the spring AD the cotter pin 42 and the roller 3 Installing the throttle link 1 Install the roller a new cotter pin the spring the collar 4 and the bolt 6 2 Install the throttle lever assembly 6 to the crankcase Make sure to fit the end a of the spring into the hole of the crankcase 6 22 vet py Fuel system 3 Install the wave washer 7 the collar 8 and the bolt 9 4 Install the throttle cam assembly 0 5 Adjust the throttle link rod OD and then install it WT y DR MI LSC Reg SI 7 z SS AV INN 6 Install the throttle cable and the clip See Installing the shift cable and throttle cable remote control model 3 14 Adjusting the throttle link rod 1 Loosen the locknut CA and then remove the throttle link rod 2 from the throttle cam 8 6 23 2 Make sure that the protrusion on the throttle lever 4 and the protrusion on the shift bracket are aligned 3 Set the throttle cam until it slightly contacts the roller 6 AA Be 4 Adjust the throttle link rod length so that it fits onto the protrusion of the throttle cam and then install the throttle link rod to the throttle cam TIP Adjust the throttle link rod length with the pro trusions 8 and aligned 5 Tighten the link rod locknut to the specifie
7. 4 Remove the oil strainer OU the relief valve 2 and the gaskets 3 and 2 Remove the rubber seal the exhaust manifold G and the gasket 5 Remove the anode 5 oO O FO os D D vo C OO Oo C O o O ee 2 o o o W 6 O oe gt ge Os og ros fap 9 32 BRKT Bracket unit 6 Remove the oil seal 5 Checking the oil pan and exhaust manifold 1 Clean the removed parts 2 Check the exhaust guide the exhaust manifold and the muffler Replace if cor roded or cracked 3 Check the oil pan Replace if corroded or cracked Checking the oil strainer 1 Check the oil strainer Clean if there is dirt or residues Checking the exhaust guide anode 1 Check the anode Clean if there is grease oil or scales NOTICE Do not grease oil or paint the anode Assembling the oil pan and exhaust manifold 1 Install a new oil seal into the exhaust guide 2 to the specified depth 8 Driver rod L3 8 90890 06652 Needle bearing attachment 4 90890 06613 9 33 Installation depth 8 0 5 1 0 mm 0 02 0 04 in Install new gaskets 6 and 6 onto the exhaust guide Install the relief valve and the oil strainer 8 Install the gasket 9 the cooling water pipe a new rubber seal 4 and the oil pan 42 and then tighten the oil pan bolts 3 temporarily Install a new gasket
8. 8 08 22 PTT unit ERIN torques Part to be tightened Screw size Nm kim ft lb PTT motor assembly bolt M 7 07 52 Valve lock screw gt 1 8 1 08 44 Main valve Manual valve Gear pump bolt Gear pump housing bolt Tilt piston bolt Cylinder end screw E wee Reservoir cap 7 07 a Optional equipment Part to be tightened Screw size HAS ORNE ft lb C H gt 28 vo Water pressure sensor 18 18 e Speed sensor e 18 133 EC Specification General tightening torque This chart specifies the tightening torques for standard fasteners with a standard ISO thread pitch Tightening torque specifications for special components or assemblies are provided in the applicable sections of this manual To avoid warpage tighten the multi fastener assemblies in a crisscross fashion and progressive stages until the specified torque is reached Unless otherwise speci fied torque specifications require clean dry threads Components should be at room temperature Width General torque barz across moin LE at a 7S Kul TECH ar FEA Technical features and description Engine control system 2 1 JUNE PRET E ER E 2 1 MEL a a 2 4 PUST e ii 2 5 OO iles Be eu go EEE EE 2 6 Fuel injection control sse see eee ee eee 2 7 EE Need 2 8 oo 2 10 Electronic control system nvrrrrnnnnnvnnnnnnnnvnnnnnnnnnvn
9. 00000000000000800 00000000840 00900000 Wiring harness continuity Terminal 1 Terminal 26 Terminal 2 Terminal 29 Terminal 3 Terminal 12 5 Connect the engine ECM coupler 8 and the trolling switch coupler 8 Fuel control units and components Checking the water detection switch 1 Disconnect the water detection switch coupler 8 2 Turn the engine start switch to ON and then measure the input voltage at the water detection switch coupler 5 20 Float height reference data 19 4 mm 0 76 in 6 Disconnect the engine ECM coupler PAN OO CLC n ss a dl IN Water detection switch input voltage Blue White L W Black B TH i 4 75 5 25 V NI 3 Turn the engine start switch to OFF and then remove the filter cup assembly 4 Check that the float D moves smoothly 5 Check the water detection switch for conti nuity with the float in positions A and B NOTICE Do not remove the clip and the float 0O0000000000000 000 L T E COC EC L L E OOOO Wiring harness continuity Terminal 1 Terminal 14 Terminal 2 Ground 8 Connect the engine ECM coupler e 9 Install the filter cup assembly See Fuel filter assembly 6 7 10 Connect the water detection switch cou pler 8 Checking the fuel injector 1 Check the fuel injector operation using the YDIS Stationary test and check the operating sound 2
10. 3 Apply the specified positive pressure Replace the fuel joint if the specified pressure cannot be maintained for at least 10 seconds Vacuum pressure pump gauge set 2 90890 06756 Specified positive pressure 50 0 kPa 0 50 kgf cm 7 3 psi Checking the fuel filter assembly 1 Connect the special service tool D to the fuel inlet 8 2 Cover the fuel outlet with a rubber plug 2 and then apply the specified positive pressure Replace the O ring fuel cup assembly or fuel filter assembly if the specified pressure cannot be maintained for at least 15 seconds Leakage tester 1 90890 06840 Specified positive pressure 200 0 kPa 2 00 kgf cm 29 0 psi 3 Connect the special service tool to the fuel outlet Cover the fuel inlet with a rubber plug 2 and then apply the specified negative pressure Replace the O ring the fuel cup assembly or the fuel filter assembly if the specified pressure cannot be maintained for at least 15 seconds Vacuum pressure pump gauge set 8 90890 06756 Specified negative pressure 80 0 kPa 0 80 kgf cm 11 6 psi Fuel filter assembly Disassembling the fuel filter assembly Remove the fuel cup assembly Q the O ring the fuel filter element and the clamp 4 1 Checking the fuel filter element ds Check the fuel filter element Replace the fuel filter element if there is dirt or resi dues Checking the fuel cup
11. 3 Measure the camshaft journal diameters d and and the cylinder head journal inside diameter Replace the camshaft or cylinder head assembly or Rocker arm inside diameter both if out of specifications 16 000 16 018 mm 0 6299 0 6306 in Rocker arm shaft outside diameter C 15 9 1 15 991 mm 0 6288 0 6296 in 7 41 Camshaft and valve Specified spark plug DPR6EB 9 NGK Spark plug gap 0 8 0 9 mm 0 032 0 035 in Camshaft journal diameter 1 C 36 925 36 945 mm 1 4537 1 4545 in Camshaft journal diameter 2 A 3 36 935 36 955 mm 1 4541 1 4549 in Cylinder head journal inside diameter f 3 000 3 025 mm 1 4567 1 4577 in Checking the spark plug 1 Clean the electrodes 8 with a spark plug cleaner 2 Check the spark plug Replace if the electrodes are eroded there is excessive carbon or other deposits 3 Check the spark plug gap Replace if out of specification Checking the cylinder head anode 1 Check the anodes Clean if there is grease oil or scales NOTICE Do not grease oil or paint the anodes Assembling the cylinder head 1 Install a new valve seal D onto the valve guide 2 9 Vo 2 Install the valve Q the valve spring seat 4 the valve spring and the valve spring retainer 6 in this order and then attach the special service tools and 7 42 Power unit Valve spri
12. 4 Install the through tube 9 and the bolt to the clamp bracket PORT 4 5 Install the bushings 42 to the swivel bracket 8 6 Install the swivel bracket 8 the trim sensor cam 3 remote control model with PTT and the clamp bracket STBD 4 and then tighten the self locking nut 5 and the trim sensor cam screw remote control model with PTT to the specified torque 7 Install the stoppers 7 9 40 BRKT Bracket unit 8 Install the ground lead hydro tilt model Install the ground leads 49 and PTT model 9 Install the grease nipples and then tighten them to the specified torque remote control model Remote control model with PTT PTT model Hydro tilt model Self locking nut 5 22 N m 2 2 kgf m 16 2 ft lb Trim sensor cam screw 6 2 N m 0 2 kgf m 1 5 ft lb Grease nipple 3 N m 0 3 kgf m 2 2 ft lb 10 Apply grease into the grease nipples until grease comes out from the bushings 8 remote control model 9 41 Adjusting the trim sensor cam remote control model with PTT 1 Tilt the outboard motor to the fully down position 2 Loosen the trim sensor cam screw 1 3 Adjust the trim sensor cam 2 so that the trim sensor setting resistance is within specification Digital circuit tester 90890 03174 Trim sensor setting resistance Terminal Terminal 9 0 11 0Q TIP e To decrease the resistance turn the trim sens
13. 9 4 Installing the fuel hose clambp 6 26 Installing the fuel injector 6 39 Installing the hydro tilt assembly 9 43 Installing the lower unit coonccccc co 8 20 Installing the oil filter 7 49 Installing the oil pressure switch 7 50 Installing the power unt 7 9 Installing the propeller shaft housing A 8 18 Installing the PTT motor 9 51 Installing the PTT unit 9 45 Installing the remote control box and tachometer remote control model 3 16 Installing the shift cable and throttle cable remote control model 3 14 Installing the shift rod drive shaft and oil seal MOUS ING BEEN 8 17 Installing the speed sensor 3 17 Installing the sprocket and timing belt 7 16 Installing the starter motor 5 40 7 29 Installing the stator assembhy 7 17 Installing the steering arm 9 36 Installing the thermo sensor 7 50 Installing the throttle body 6 19 Installing the throttle link 6 22 Installing the tiller handle 3 11 Installing the upper case 9 24 Installing the vapor separator 6 27 Installing the water pressure sensor 3 16 Installing the water pump
14. 10119 UOILDIUNLULUO SD 19Z1JIQOLULUI eubis Jejnbal Bulj009 198240 uonounypeuw opes ye j y sed 11e aye u bai o UOI UOIDUNYJLLU JOS P51j198dS JO mo u8s ssald aye ul 67 i Z uol OUNJJEW UOJMS eubis Immo UOINSOd JIUS On Ul JOTEAA lant ul D 9P09 UOINPUOD we Ee sc st Troubleshooting the power unit using the diagnostic flash indicator 1 Connect the special service tool NA XU Adra IE A RE a Diagnostic test lead Blue White Diagnostic flash indicator B 1 90890 06865 YDIS connecting harness 2 90890 06882 TIP When performing this diagnosis all the elec trical wires must be properly connected 2 Start the engine and let it idle 3 Check the flash patterns that indicate a trouble code Example the flash pattern below is for the trouble code 23 2 3 mA A WAI Li aa 0 GG Troubleshooting the power unit a Light on 0 33 second Light off 4 95 seconds C Light off 0 33 second 9 Light off 1 65 seconds 4 lf a trouble code is detected see Trouble code and checking step 4 6 TIP When more than one trouble code is detected the diagnostic flash indicator B flashes in the pattern of the lowest trouble code After that trouble code is corrected the indicator flashes in the pattern of the next lowest trouble code This continues until all the trouble codes are detected and corrected 4 8 TRBL d SHTG e Troublesho
15. 6 Connect the water pressure sensor coupler 3 17 7 Install the extension hose and corrugated tube OD to the nipple 8 and the water pressure sensor adapter TIP Cut the extension hose D and corrugated tube to 320 0 mm 12 6 in Installing the speed sensor See 6Y8 Multifunction Meter set up manual for details of the components 1 Remove the speedometer hose 1 from the rigging grommet and then cut off the tip of the nipple 2 Install the extension hose 8 to the nipple 2 and then fasten it with a plastic tie 4 TIP Cut the extension hose 8 to 425 0 mm 16 7 in 3 Remove the black tape and then remove the cap 6 4 Install the speed sensor 6 to the speed sensor adapter 7 and then tighten the speed sensor 6 to the specified torque D Speed sensor 6 18 N m 1 8 kgf m 13 3 ft lb 5 Install the speed sensor assembly 8 to the cylinder head cover Optional equipment 7 Run the extension hose 8 from the port side 8 Connect the extension hose 8 to the speed sensor adapter 7 and then install the extension hose 8 to the clamp O 9 Install the rubber seal in the area 3 18 wh Rigging information TIP Cut the rubber seal to 30 0 mm 1 2 in Installing the battery Improper battery connections or cable size selection may result in a fire NOTICE If battery connections are revers
16. 7 22 Power unit 10 Disconnect the main relay coupler and then remove the main relay ST RE DE REL NN ant i GA LE IEF RF si r NG AS 11 Remove the terminal lead and then remove the terminal 8 V2 Cl e ar N De A See NE 7 23 13 Remove the YDIS coupler and then disconnect the plastic ties the diode u the clamp V and the fuse holders W 14 Remove the PTT relay coupler PTT model EKA Bo Le Ke NA RO Installing the wiring harness To install all the wiring harnesses see Elec trical component and wiring harness routing 5 1 1 2 et GF RK Install the camp 8 ES ge N L 4 MS Install the PTT relay coupler b PTT model Lee LA 3 Connect the fuse holders the camp 9 the diode and the plastic ties and then install the YDIS coupler Tighten the YDIS coupler screw to the specified torque Wiring harness YDIS coupler screw 2 3 N m 0 3 kgf m 2 2 ft lb 5 Install the bracket 9 6 Install the terminal and then install the terminal lead 7 Tighten the terminal bolt amp to the specified torque Power unit Terminal bolt 4 N m 0 4 kgf m 3 0 ft lb 8 Install the main relay and then tighten the main relay screw 7 to the specified torque 9 Connect the main relay coupler hi Main relay screw D 3 N m 0 3 kgf m 2 2
17. 90890 06535 2 Remove the ball bearing Stopper guide plate 4 90890 06501 Stopper guide stand 6 90890 06538 Bearing puller assembly 90890 06535 3 Remove the oil seals 8 with the needle bearing 9 L Driver rod L3 40 90890 06652 Needle bearing attachment D 90890 06614 Checking the propeller shaft 1 Check the propeller shaft Replace if damaged or worn 2 Measure the propeller shaft runout Replace if above specification Propeller shaft runout 0 02 mm 0 0008 in Checking the dog clutch 1 Check the dog clutch the shift plunger the slider the cross pin and the spring Replace if cracked or worn Checking the propeller shaft housing 1 Check the propeller shaft housing Replace if cracked or damaged Checking the reverse gear 1 Check the teeth and dogs of the reverse gear Replace if cracked or worn Assembling the propeller shaft assembly 1 Install the dog clutch D onto the propel ler shaft with the F mark a facing toward the forward gear 2 Install the spring Q and the slider 4 into the propeller shaft 2 Propeller shaft housing TIP Align the hole in the dog clutch 1 with the hole in the propeller shaft 3 Install the cross pin 6 and the spring TP AAA When installing the cross pin align the hole in the dog clutch with the hole in the slider 4 Check that the dog clutch operates smoothly
18. Crankcase bolt 43 1 8 M8 1st 15 N m 1 5 kgf m 11 1 ft lb 2nd 30 N m 3 0 kgf m 22 1 ft lb Crankcase bolt 44 9 16 M6 1st 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 N m 1 2 kgf m 8 9 ft lb TIP After tightening the crankcase bolts check that the crankshaft rotates smoothly 7 63 Cylinder block MEMO 7 64 Lower unit Bee UN E 8 1 Removing the lower unit ese eee ee ee eee 8 3 Checking the tele EE 8 3 Checking the lower unit anode sees eee eee eee 8 3 Water DUMD hp 8 4 Removing the water PUMP sse eee eee ee e ee ee ee eee 8 5 Checking the water pump cccooccccccccncccncnnonocononanonononcnnnnnnnnnoncnnnnons 8 5 Propeller shaft housing rrnnnnnvvnnennnnnnennnnnnnnennennnnnnenesnnnnnennenn 8 6 Removing the propeller shaft housing assembly 8 7 Disassembling the propeller shaft assembly o 8 7 Disassembling the propeller shaft housing assembly 8 7 Checking the propeller shaft sse eee 8 8 Checking the dog AMEN EE 8 8 Checking the propeller shaft housing esse eee eee eee 8 8 Checking the reverse gear see eee eee 8 8 Assembling the propeller shaft assembly 8 8 Assembling the propeller shaft housing assembly 8 8 Drive shaft and lower case 8 11 Removing the oil seal housing drive shaft and shift rod 8 13 Disassembling the oil seal housing esse
19. 10 5 Checking the outboard motor mounting height 10 6 Checking Ne PIT system WEE 10 6 Checking the Steering system c e eee eee ee eee 10 6 Checking the throttle cable and shift cable 10 6 Checking the hydro tilt system 10 7 TEN e oo 10 7 Bier T o 0 NE 10 7 AE EST iio een iaa 10 8 General Periodic Maintenance rerrnrnvrnnnnvnnnnvvnnnnvrennnvrennnnn 10 8 A 10 8 Checking the battery sees eee eee 10 8 Checking the cooling water passage sse eee eee 10 8 Checking the engine idle Speed sse sees eee 10 9 Changing the engine oil 10 9 Checking the engine oil level eee eee eee 10 10 Replacina NE ON TE save 10 10 Checking the engine start switch and engine shut off VU 10 11 Checking the fuel filter ooccccoccococononocononoconononnonos 10 11 Checking the fuel joint and fuel hoses fuel joint to fuel NET re 10 11 Changing the gear oil eee 10 11 Checking the gear oil level eee 10 12 Lubricating the outboard motor sss eee eee 10 12 Checking the propeller sese eee 10 13 Checking the PTT fluid level ooocccccoccnccccnnconononononos 10 13 Checking the PTT operation occccoocnccccccncoconnnocanononencncnnanoss 10 13 AQJUSUNG the SMUT CADIS vasset 10 13 Checking the spark plug e see eee 10 14 Checking the timing belt 10 14 Replacing the timing belt esse eee eee eee 10 14 Checking the thermostat see eee eee eee 10 14 Adju
20. 2 Remove the balls the absorber valve pins 8 and the filter 4 6 Remove the main valves S and the shuttle piston 6 3 Remove the gear pump assembly 4 Remove the spring the valve pin the valve seal 8 and the filters 7 Remove the valve lock screw 7 and the relief valve assembly 8 8 Remove the lock screw 9 the spring ol A T the valve pin and the valve pin seal 2 e l from the relief valve 3 5 Remove the circlip and then remove the manual valve the manual valve Bech TE seats 2 the spring 3 and the adapter E 9 55 TIP When disassembling the relief valve assem bly 489 make sure to note down the number of turns the lock screw is turned out from its original position Checking the gear pump 1 Check the operation of the gear pump shafts Replace the gear pump assembly if the shafts do not rotate smoothly Checking the gear pump housing 1 Check the gear pump housing Replace if corroded or cracked Checking the valve seal 1 Check the main valve seal assembly and the absorber valve pin assemblies Replace if damaged 2 Check the main valves and the shuttle piston Replace if damaged 3 Check the relief valve assembly Replace if damaged 4 Check the manual valve and the spring Replace if damaged Checking the filter 1 Check the filters Clean if there is dirt or residues Assembling the
21. 8 13 Disassembling the oil pan and exhaust Mamo lira Pee 9 32 Disassembling the oil seal housing 8 13 Disassembling the propeller shaft A a a a 8 7 Disassembling the propeller shaft housing ass Das 8 7 Disassembling the PTT cylinder 9 59 Disassembling the PTT motor 9 49 Disassembling the shift rod 9 17 Disassembling the starter motor 5 36 Disassembling the tiller handle 9 8 Disassembling the Upper case 9 28 Disassembling the vapor separator 6 32 Disassembly and assembly 0 3 Disconnecting the quick connector 6 4 Draining the fuel ses eee eee eee 6 26 Drive shaft and lower ca8e 8 11 ECM coupler layout 5 13 ElECMIC SNOCK T 0 1 Electrical component and vviring harness OU Te ecos del 5 1 Electrical system 1 12 Electrical technical data 1 5 Electronic control system 2 11 Engine control system 2 1 Engine control units and components 5 15 Engine ECM 7 19 Engine speed Control 2 8 Engine speed control system 1 6 XHAUS I COV Cl dene 7 46 EX ENOrE E 3 4 EXMenorE SR A EE 3 5 ES EH 2 10 Feature eee eee 4 1 Flywheel magnet and timing belt 7 12 Forward gear shim T1 selection chart 8 36 FOM VI Wal tn 5 5 Fuel and oil reguremen
22. Bracket unit Removing the flushing hose 1 Remove the adapter and the hose joints and 8 NA pr o o Installing the flushing hose 1 Install the flushing hose adapter and then tighten the flushing hose adapter screws 2 to the specified torque 2 Pass the flushing hose 8 through the hose joint 4 and install it to the hose joint amp and then fasten the flushing hose 8 with a new plastic tie 6 3 Install them to the adapter with the gasket O se P 2x S E a Flushing hose adapter screw 2 5 Nm 0 5 kgf m 3 7 ft lb 9 21 Bottom cowling Upper case and mounts Upper case and mounts 24 N m 2 4 kgf m 17 7 ft lb Part name Remarks Self locking nut Nut Washer Ground lead Bolt Cover Washer Lower mount Washer Rubber washer Washer Bolt Cap Bolt Bolt Upper mount Plate CON OOF M M12 x 170 mm M6 x 7 mm M8 x 30 mm A 210 K M M M M ON ND AA D M KM 9 22 BRKT Bracket unit Remarks M8 x 175 mm 2 Part name Bolt 18 9 23 Removing the upper case 1 Drain the remaining engine oil 2 Remove the ground lead 1 3 Loosen the upper mount bolts 2 and the lower mount cover bolts PORT and STBD 4 Remove the upper mounting nuts 4 and the lower mounting nuts and then remove the upper case assembly 6 5 Remove the upper mount bolts 2 the upper mount 7 the plate 8 and the upper mounting bolt
23. 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 Valve stem diameter 6 Intake 5 475 5 490 mm 0 2156 0 2161 in Exhaust 5 460 5 4 5 mm 0 2150 0 2156 in 4 Measure the valve stem runout Replace if above specification 1 37 Valve stem runout 0 01 mm 0 0004 in Checking the valve guide Before checking the valve guides make sure that the valve stem diameter is within specifi cation 1 Measure the valve guide inside diameter a Replace if out of specification Valve guide inside diameter 8 5 500 5 512 mm 0 2165 0 2170 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 0 037 mm 0 0004 0 0015 in Exhaust 0 025 0 052 mm 0 0010 0 0020 in Replacing the valve guide After replacing a valve guide check the valve seat contact area 1 Remove the valve guide D from the com bustion chamber side using the special service tool 2 Valve guide remover installer 90890 06801 2 Install a new valve guide 8 from the camshaft side to the specified position amp using the special service tool 2 Valve guide position 8 16 3 16 7 mm 0 64 0 66 in 3 I
24. WARNING Do not touch any of the special service tool connections Y COW NM Q CET SS SN Ke L AN QUE TT Y LAG Ignition tester spark gap tester 1 90890 06754 4 Remove the special service tool and then connect the spark plug caps Checking the engine ECM 1 Disconnect the ignition coil couplers 8 and then connect the test harness 2 pins 2 Measure the engine ECM output peak voltage Test harness 2 pins D 90890 06861 Engine ECM output peak voltage 1 Black Orange B O Black B 2 Black White B W Black B 3 Black Yellow B Y Black B 100 0 V at cranking unloaded 3 Disconnect the test harness 1 4 Disconnect the engine ECM coupler 5 26 PSN DOG TH slet Ges E I E GH P Alo EE NIE A D 5 Check the wiring harness for continuity a Be OO 00000000 0000060000 Wiring harness continuity Ignition coll 1 Terminal 1 Ground Terminal 2 Terminal 43 Ignition coll 2 Terminal 1 Ground Terminal 2 Terminal 42 Ignition coil 3 Terminal 1 Ground Terminal 2 Terminal 41 6 Connect the engine ECM coupler 7 Connect the ignition coil couplers 8 Checking the spark plug cap 1 Remove the spark plug caps from the spark plug wires by turning the caps counterclockwise IV 5 27 2 Measure the spark plug cap resistance Spark plug cap resistance reference data 5 0 RO at 20 C
25. into the lower unit T Install the lower unit to the upper case and then tighten the lower case mounting bolts amp and 6 to the specified torque Installing the lower unit A WARNING GE Gin an 5 Install the trim tab to its original Do not hold the propeller with your nstall the trim tab to i igi hands when loosening or tightening it paruen e Make sure to disconnect the battery 6 Install the anode cables from the battery and the clip from the engine shut off switch e When installing the lower unit with the power unit installed make sure to sus pend the outboard motor If the outboard motor is not suspended it can fall sud denly and result in severe injuries 1 Check that the pin is aligned with the alignment mark on the shift bracket D aq oe Zz EP VE Lower case mounting bolt 6 and 2 Set the gear shift to the N position 40 N m 4 0 kgf m 29 5 ft lb 8 20 Lower unit 7 Install the propeller and the propeller nut 40 Place a block of wood between the anti cavitation plate and the propeller to keep the propeller from turning and then tighten the propeller nut D to the specified torque Propeller nut 40 35 N m 3 5 kgf m 25 8 ft lb 8 Install a new cotter pin AD TIP If the grooves in the propeller nut do not align with the cotter pin hole tighten the nut until they are aligned 9 Fill the gear oil to the correct level See Changi
26. magnet cover 1 TIP Put a rag between the flywheel magnet the lifting harness and the shackle 8 Carefully lift up the outboard motor together with the bottom frame NOTICE Do not allow the lifting harness to damage any parts of the outboard motor 6 Install the shackles 2 to the engine hangers Q and then install the lifting harnesses 4 to the shackles 7 Tension the lifting harnesses 4 3 8 N T Rigging information 10 Remove the bolts UE SE 11 Remove the steering retainer and then install a hydraulic steering cylinder or steering cable following the manufactures recommendation before the outboard motor is mounted remote control model Mounting the outboard motor Proper mounting of the outboard motor will mean better performance maximum reliabil ity and highest customer satisfaction This chapter contains the specifications neces Sary to mount the outboard motor and may vary slightly depending on the applications When mounting the outboard motor also make sure the outboard motor has the clear ance to provide full movement from both PORT to STBD as well as during trim and tilt functions See Dimensions 3 2 1 Set the outboard motor on the vertical centerline of the boat transom C L 3 9 No strakes hull Strakes hull C L Centerline of the transom TIP Double check the measurement distance to verify that the vertical centerli
27. the bracket the bushing 8 the washer 4 the cotter pin 6 and the bushing 2 Install the spring into the shift rod detent bolt 8 and then tighten the shift rod detent bolt 8 temporarily 3 Install the ball and then tighten the shift rod detent bolt 8 to the specified torque 9 1 Bottom cowling 5 N m 0 5 kgf m 3 7 ft lb Shift rod and shift bracket Bottom cowling CON OOF M Bolt Bracket Clamp Clamp Bracket Plate Grommet Grommet Cap Adapter Gasket Hose joint Hose joint Plastic tie Hose Hose joint Bolt KR N sch amp po k 009 M6 x 20 mm Not reusable M6 x 30 mm E A 23 Lis au Remarks 9 18 BRKT Bracket unit 27 28 10 lt Sc G 34 CM D el p toe RE O DE A Haga L JJ AN Remarks 18 Holder Screw Hose Hose Holder Collar Grommet Grommet Hook Spring Lever Bushing Bolt Bushing Wave washer Washer Cowling lock lever M6 x 14 mm Bottom cowling 5 Num 0 5 kgfm 3 7 ft lb o7 28 S g ee 29 SES lt 3 13 y ZA Remarks 35 Hose Bottom cowling Holder Bolt Bracket Grommet Collar Water outlet Clamp Bracket Cover Gasket PTT switch Gasket Rubber seal M6 x 20 mm Remote control model with PTT Remote control model with PTT M sch sch sch sch nm sch A A M 9 20 BRKT
28. 1 2 3 Remove the rocker arm shaft bolts 4 the washers 6 the stoppers 6 and the tensioners D and then remove the washers 8 and the rocker arms 9 and 0 7 35 TIP Make sure to keep the parts in their original groups 4 Remove the retaining bolt 4D and then remove the camshaft 42 and the oil seal Sy Remove the intake and exhaust valves I NK IT booooo O o oy Valve spring compressor 4 90890 04019 Valve spring compressor attachment 5 90890 06320 TIP Make sure to keep the parts in their original groups Ch 1 ecking the cylinder head Eliminate any carbon deposits from the combustion chambers and check for deterioration Check the cylinder head warpage using a straightedge D and a thickness gauge in 7 directions Replace the cylinder head assembly if above specification Camshaft and valve Cylinder head warpage limit 0 10 mm 0 0039 in Checking the valve spring 1 Measure the valve spring free length 8 Replace if below specification Valve spring free length 8 39 85 mm 1 57 in 2 Measure the valve spring tilt Replace if above specification 7 36 Power unit Valve spring tilt 1 7 mm 0 07 in Checking the valve 1 Check the valve face Replace if pitted or worn 2 Measure the valve margin thickness Replace if out of specification E Gin Valve margin thickness 8
29. 2 with a plastic tie 3 TIP Before fastening the extension wiring har ness O to the clamp OD and the bracket 2 pull it to prevent loosening 10 Remove the cap lt A XJ Mounting the rigging grommet 11 Run the alert indicator harness 5 into the bottom cowling and then connect the alert indicator harness coupler CA 12 Remove the cap 6 Va tS LNG Z oP LN A A 13 Run the trolling switch harness 2 into the bottom cowling and then connect the trolling switch harness coupler 9 14 Install the shift cable and the throttle cable See Installing the shift cable and throttle cable remote control model 3 14 3 12 wh Rigging information 18 UU TIP The shape identifies the shift cable 8 15 Install each harness and cable in the corresponding position on the rigging grommet See Rigging grommet description 3 11 16 Install the battery cable with the positive battery cable up aligning the white tape 9 on the battery cable with the outer end of the rigging grommet 17 Install the rigging grommet and grommet holder into the bottom cowling 18 Fasten the extension wiring harness O the battery cables 0 the alert indicator harness 45 the trolling switch harness 7 the shift cable and the throttle cable with the plastic tie QD 3 13 19 Check the steering friction plate assembly T
30. 230 0 2 30 33 4 50 0 0 50 7 3 200 0 2 00 29 0 80 0 0 80 11 6 50 0 0 50 7 3 30 0 0 30 4 4 50 0 0 50 7 3 170 0 1 70 24 7 42 1 2 0 1 66 0 08 30 7 1 21 200 0 2 00 29 0 Fuel system technical data Power unit technical data Power unit technical data Power unit Cylinder Minimum compression pres kPa kgf sure 1 cm2 psi Engine oil Oil pressure 2 at 60 C 140 F with SL 10W 30 engine oil and at 800 r min at 61 C 142 F with SL 10W 30 engine oil and at 3000 r min Thermostat Valve opening temperature 58 62 136 144 Fully open temperature 70 158 Fully open stroke 3 0 0 12 840 0 8 40 121 8 kPa kgf cm2 psi 230 0 2 30 33 4 kPa kgf s al 480 0 4 80 69 6 1 Measuring conditions Ambient temperature 20 C 68 F fully open throttle and the spark plugs removed from all cylinders The figures are for reference only 2 For details of the checking method see Checking the oil pressure 7 1 The figures are for reference only Cylinder head assembly 2 Ji E RSE Valve Clearance Intake 0 20 0 05 0 008 0 002 Exhaust 0 30 0 05 0 012 0 002 Seat contact width i 1 30 1 50 0 051 0 059 Margin thickness Intake 0 80 1 20 0 0315 0 0472 Exhaust i 1 00 1 40 0 0394 0 0551 0 10 0 0039 Valve spring Free length 39 85 1 57 Tilt 1 7 0 07 Valve stem Diameter Intake 5 475 5 490 0 2156 0 2
31. Assembling the propeller shaft housing assembly NOTICE Do not reuse the bearing Always replace it with a new one 8 8 Lower unit 1 Install a new needle bearing into the propeller shaft housing to the specified depth Driver rod L3 2 90890 06652 Needle bearing attachment 8 90890 06614 Installation depth 8 3 0 3 5 mm 0 118 0 138 in TIP Install the needle bearing with the manufac ture identification mark b facing toward the propeller side 2 Install new oil seals into the propeller shaft housing to the specified depth Driver rod L3 2 90890 06652 Needle bearing attachment 6 90890 06653 Installation depth 4 0 4 5 mm 0 157 0 177 in TIP Install an oil seal halfway into the propeller shaft housing and then install the other oil seal 8 9 3 Install the original shim s T2 amp and a new ball bearing CO onto the reverse gear Bearing inner race attachment 9 90890 06639 UP ee a Install the ball bearing with the manufacture identification mark facing toward the pro peller side 4 Install the reverse gear assembly 0 into the propeller shaft housing Needle bearing attachment 90890 06608 5 After installing the reverse gear assembly check that the reverse gear rotates smoothly Propeller shaft housing 6 Install new O rings 42 and 63 PAN 8 10 Lower unit Drive shaft and lower case 1 E lt ye 1 lt
32. Neutral switch Intake press sensor Air pressure sensor Short or open in the air pressure sensor circuit Sets a tentative air pressure value based on the engine speed and TPS signals 2 Neutral switch is at OFF throttle is fully closed ISC valve is fully closed and engine speed is above 1100 r min Cranks when the clip is not inserted Cooling water temperature lower than 40 C 104 F and engine speed above 3000 r min Intake air passage CO N CO Engine stop lanyard svvitch Engine shut off switch 44 9 4 for more than 2 minutes Battery voltage and low battery voltage alert are displayed Control mode in case of malfunction PAG N gt gt Technical features and description Electronic control system Digital network system The features a digital network system The 6Y8 Multifunction Meter can also be installed as an option In this system the signals cannot be detected with a circuit tester as data exchange between con nected computers and the meters is being carried out continuously using their built in ICs Data 0 or 1 are repeatedly written or registered into the specified address of a frame When any trouble occurs trouble code information will also be written into the frame The data communication wiring consists of a pair of cables which are out of phase with each other to be free from external impacts 1 frame Voltage Electronic control system
33. T E O X LO re o E Z N LO T AL A SH TAS o We NY Remarks Q ty 1 1 D E O Cc T d X O O Bn Q v C gt o gt O QO AQ 18 19 7 13 Removing the flywheel magnet 1 Flywheel holder 2 90890 06522 Remove the fuel system See Chapter 6 Fuel system Turn the flywheel magnet clockwise and align the 1 mark on the driven sprocket D with the a mark b on the cylinder head Loosen the flywheel magnet nut NOTICE Apply force in the direction of the arrow to prevent the flywheel holder from slipping off easily 4 Remove the flywheel magnet and the Woodruff key NOTICE To prevent damage to the engine or tools screw in the flywheel puller set bolts evenly and completely so that the flywheel puller is parallel to the flywheel magnet Flywheel magnet and timing belt Flywheel puller 8 90890 06521 Removing the stator assembly 1 Disconnect the pulser coil connectors 8 and then remove the pulser coil 1 2 Disconnect the stator assembly coupler b and then remove the stator assembly 2 and the base assembly Removing the timing belt and sprocket NOTICE Do not turn the crankshaft or the driven sprocket when the timing belt is not installed Otherwise the piston and valves could collide with each other and be damaged 1 Remove the timing belt from the driven sprocket s
34. Terminal 12 0 V battery voltage 2 Disconnect the battery power source the ground lead the PTT motor leads and the PTT relay coupler NOTICE Always disconnect the battery negative termi nal before disconnecting the PTT relay terminals 3 Connect the test harness 2 pins 4 Check the PTT relay for continuity Replace if out of specification Lg Oh Saye ol i 2 ae SO Test harness 2 pins 90890 06867 5 42 PTT relay continuity PTT relay continuity gt oo Connect the positive battery lead to the terminal and the negative battery lead to the terminal and then check the PTT relay for continuity Replace the PTT relay if out of specification 7 Connect the PTT relay coupler the bat tery povver source the ground lead and the PTT motor leads Checking the PTT switch on bottom cowling 1 Disconnect the PTT switch coupler 8 2 Measure the input voltage between the PTT switch coupler terminal and the ground a RI 6 Connect the positive battery lead to the Q terminal and the negative battery lead N to the terminal and then check the att Y PTT relay for continuity Replace the PTT S Y o A relay if out of specification e A L EL PTT switch input voltage Red R Ground 12 0 V battery voltage 3 Check the PTT switch for continuity Replace the PTT switch if out of specifi cation 5 43 PTT electrical s
35. and the cylinder end screw als EF q 5 Remove the absorber valves 9 Checking the PTT cylinder and piston 1 Check the tilt piston and the free pis ton Replace if cracked or scratched Check the cylinder end screw and the cylinder Replace if cracked or scratched Check the tilt ram Polish with 400 600 grit sandpaper if there is light rust or replace if bent or excessively corroded Check the absorber valves di Clean if there is dirt or residues PTT cylinder 3 4 Install the balls the absorber valve pins the springs hi and the balls amp 5 Install the washer and the tilt piston bolt and then tighten the tilt piston bolt n to the specified torque Assembling the PTT cylinder Lubricate the parts with ATF Dexron II during assembly NOTICE e Do not use a rag when assembling the PTT unit because dust and particles on the PTT unit can lead to poor perfor mance e Do not reuse the dust seal and O rings Always replace them with new ones 1 Install a new dust seal D new O rings and and the backup ring to the cyl Tilt piston bolt U inder end screw 61 N m 6 1 kgf m 45 0 ft lb 6 Install the gear pump housing See Assembling the gear pump housing 9 56 2 7 Fill the cylinder with the recommended e PTT fluid to about 60 of the cylinder capacity 2 Install a new O ring 8 and the backup ring to t
36. depending on the engine speed Most retarded Most advanced Ignition timing control range ATDC 12 BTDC 36 The normal operating mode also compensates the ignition timing by advancing or retarding it depending on the engine operating conditions Ignition timing compensations Corresponding sensor Compensation after engine start Thermo sensor Pulser coil die speed stabilizing Compensation at acceleration TPS Air pressure sensor Compensation at deceleration Engine speed feedback The engine speed control mode functions to limit engine speed increases when over revving over heat or low oil pressure is detected 2 6 Technical features and description Fuel injection control The engine ECM determines the optimum injecting timing and fuel volume based on the signals from the sensors Air pressure sensor Fuel injector 1 Air temperature sensor Fuel injector 42 TP Fuel injector 3 Thermo sensor Pulser coil Engine ECM Engine start switch Engine shut off switch Oil pressure switch Neutral switch The fuel injection control system includes the start up normal operating and fuel injection cut modes and automatically shifts between these modes depending on the engine operating condi tions Just after the engine start switch is turned to ON the engine ECM transmits signals once to all the injectors simultaneously before the high pressure fuel pump starts operating to avoid valve sticking of the injectors In t
37. flush the cooling water passages without starting the engine General Periodic Maintenance Checking the anode NOTICE Do not grease oil or paint the anodes or the trim tab Otherwise they will become ineffective Predelivery check General Periodic Maintenance 1 Check the anodes and trim tab See Checking the cylinder head anode 7 42 Checking the exhaust cover anode 7 49 Checking the exhaust guide anode 9 33 Checking the clamp bracket anode 9 40 Checking the hydro tilt anode 9 43 and Checking the lower unit anode 8 3 TIP Replace the anodes or trim tab if excessively eroded In addition check the ground lead Checking the battery 1 Check the battery See Checking the battery 10 3 Checking the cooling water passage 1 Remove the water inlet covers 2 Mark an alignment mark 2 on the trim tab and the lower case and then remove the trim tab 3 Check the water inlet covers and water inlets Clean if clogged 4 Install the water inlet covers D and the trim tab and then tighten the water inlet cover screw 8 to the specified torque 10 8 Maintenance Water inlet cover screw 8 1 N m 0 1 kgf m 0 7 ft lb 4 Remove the oil filler cap Pull out the dipstick 2 and use the oil changer 8 to extract the oil completely 5 Place the lower unit in water and then start the engine 6 Check for water flow at the cooling water pilot
38. handle model 1 Remove the tiller handle cover and then disconnect the alert indicator couplers a and 2 Connect the battery 1 5 V to the alert indicator couplers and Check that the overheat alert indicator or the oil pressure alert indicator comes on Replace the alert indicator if it does not come on NOTICE Do not apply a voltage higher than 1 7 V when checking the LED Lighting up Battery Yellow Y indicator Pink Black P B 5 19 Oil pressure rer yr alert indicator Pink VVhite P W Engine control units and Components Fuel control units and components 3 Connect the alert indicator couplers 8 and and then install the tiller handle cover Checking the alert buzzer 1 Remove the alert buzzer 2 Connect the battery leads to the alert buzzer connectors and then check that the alert buzzer comes on Replace the alert buzzer if it does not come on 3 Install the alert buzzer Checking the trolling switch 1 Disconnect the trolling switch coupler a KA E SADA CSS A I d Vu ons a 2 Check the trolling switch for continuity Replace the trolling switch if out of specification Switch Terminal postion foo UP 3 Disconnect the engine ECM coupler JE UN L T TK ISE f Sy T as 6 B E U Se Mi IG OS a NE l Ph i 4 Check the wiring harness for continuity 9
39. r 2 3 4 5 6 7 8 Not reusable M6 x 30 mm N a mh sch DL JS 6 12 vel py Fuel system Removing the fuel pump assembly Use a rag to catch any spilled gasoline when removing the fuel Components 1 Disconnect the fuel hose D 2 Remove the fuel pump assembly Specified negative pressure 30 0 kPa 0 30 kgf cm 4 4 psi Connect the special service tool D to the fuel pump outlet Cover the fuel pump inlet with a rubber plug Apply the specified positive pressure and Checking the fuel pump assembly check that there is no air leakage 1 Connect the special service tool D to the fuel pump inlet 2 Cover the fuel pump outlet with a rubber plug 2 and then apply the specified positive pressure Check that there is no air leakage Specified positive pressure 50 0 kPa 0 50 kgf cm 7 3 psi Disassembling the fuel pump assembly 1 Remove the cover the diaphragm and the fuel pump body 2 Vacuum pressure pump gauge set 1 90890 06756 Specified positive pressure 50 0 kPa 0 50 kgf cm 7 3 psi 3 Apply the specified negative pressure and check that there is no air leakage Fuel pump assembly te OD 2 Align the groove of the fuel pump body Checking the diaphragm and valve 1 with the hole of the plunger amp by 1 Check the diaphragm Replace if torn turning them 2 Check the valves 8 Repla
40. 1 Side clearance Oil ring Dimension height B Dimension width T End gap 1 Side clearance Power unit technical data Lower unit technical data Teste 10 0 0 39 Barrel 1 17 1 19 0 0461 0 0469 2 30 2 50 0 0906 0 0984 0 15 0 30 0 0059 0 0118 0 02 0 06 0 0008 0 0024 Taper 1 47 1 49 0 0579 0 0587 2 60 2 80 0 1024 0 1102 0 30 0 50 0 0118 0 0197 0 02 0 06 0 0008 0 0024 2 36 2 48 0 0929 0 0976 2 75 0 1083 0 20 0 70 0 0079 0 0276 0 04 0 18 0 0016 0 0071 Connecting rod Small end inside diameter Big end inside diameter Big end side clearance Crankpin oil clearance Crankshaft Journal diameter 15 985 15 998 0 6293 0 6298 36 000 36 024 1 4173 1 4183 0 05 0 22 0 0020 0 0087 0 016 0 040 0 0006 0 0016 42 984 43 000 1 6923 1 6929 Crankpin diameter 32 984 33 000 1 2986 1 2992 Crankpin width 21 00 21 07 0 8268 0 8295 Runout i 0 03 0 0012 Crankcase Crankshaft journal oil clear ance 0 012 0 036 0 0005 0 0014 1 The figures are for reference only Lower unit technical data Lower unit assembly Lower unit kPa kgf cm psi Holding pressure 68 6 0 686 9 9 67 Specification es p Ester Pinion to forward gear Backlash 1 0 18 0 66 0 0071 0 0260 Pinion to reverse gear Backlash 1 0 75 1 23 0 0295 0 0484 Pinion shim T3 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Forward gear shim
41. 1 3 1 9 1 13 2 15 Power unit check and adjustment 7 1 Power unit assembly eee e eee Power unit technical data Predelivery check B rel et NE Propeller selection Propeller shaft housing Propeller etze ee PIT e ale EE PTT electrical system PHT Gear pump gE 01 ION tino a electes PTT requirement PESO Tania A etat tr EE EE VE a Reducing the fuel pressure Refacing the valve seat Index Removing the clamp bracket 9 40 Removing the cylinder head 7 31 Removing the exhaust cover 7 48 Removing the flushing hose 9 21 Removing the flywheel magnet 7 14 Removing the friction plate 9 3 Removing the fuel filter assembly 6 9 Removing the fuel hose clamp 6 26 Removing the fuel injector 6 39 Removing the fuel pump assembly 6 13 Removing the hydro tilt assembly 9 43 Removing the lower unit 8 3 Removing the oil filter 7 48 Removing the oil pressure switch 7 48 Removing the oil seal housing drive shaft and SOC RE EE 8 13 Removing the power unt 7 7 Removing the propeller sha
42. 2 in direction 2 Tighten the valve adjusting locknut to the specified torque and then check the valve clearances Valve adjusting locknut 1 13 5 N m 1 35 kgf m 9 96 ft lb 3 Install a new gasket 8 and the cylinder head cover gt N Power unit check and adjustment Install the clamps to the cylinder head cover 4 Install the ignition coils and then connect the ignition coil couplers Install all the spark plug caps Install the fuel filter assembly the fuel hoses 8 and the blowby hose 7 4 Power unit Power unit assembly 21 N m 2 1 kgf m 15 5 ft lb 21 Num 2 1 kgf m 15 5 ft lb Part name Remarks Bolt M6 x 20 mm Grommet holder Grommet Cable guide Bolt Bracket Collar Neutral switch Plate Screw Rigging grommet Bolt Gasket Dipstick Bolt Screw Nut M6 x 25 mm CON OOF ODD M4 x 16 mm M8 x 80 mm Not reusable M6 x 16 mm M6 x 25 mm 7 5 Power unit assembly 0 3 kgf m 2 2 ft lb 3 N m ola els O O LO LO re TT CIE O O IX T Tr NIN Ses E E Zz re Tri CV AN Remarks d ep Cc Ke SC A E O _ Q lt 18 7 6 Power unit Removing the power unit 1 Remove the grommet holder the grommet 2 and the rigging grommet 8 2 Remove the clips and then disconnect the shift cable 6 and the throttle cable 6 3 Remove the plastic
43. 5VV 30 10W 30 or 10W 40 Replacing the oil filter Replacement engine oil quantity 1 Extract the engine oil with an oil changer with oil filter replacement See Changing the engine oil 10 9 step 1 7 L 1 80 US qt 1 50 Imp ot 1 step 4 5 Install the oil filler cap and dipstick and then start the engine and warm it up for 5 2 Place a rag under the oil filter and then minutes remove the oil filter 6 Turn off the engine and then check the oil level See Changing the engine oil 10 9 step step 10 10 10 Maintenance Checking the engine start switch and engine shut off switch 1 Check the engine start switch and engine shut off switch See Checking the engine start switch and engine shut off switch 10 4 Checking the fuel filter 1 Check the fuel filter See Checking the fuel filter assembly 6 9 Checking the fuel joint and fuel hoses fuel joint to fuel injector 1 Check the fuel joint and fuel hose con nections To check the fuel hose connec tions see Fuel hose 6 1 Changing the gear oil A WARNING Never get under the lower unit while it is tilted 1 Tilt the outboard motor so that the drain screw is at the lowest possible point 2 Place a drain pan under the gear oil drain hole 3 Remove the drain screw 2 and gasket 8 NOTICE If there is an excessive quantity of metal particles on the magnetic gear oil drain screw this can in
44. 6 together with 1 Remove the starter motor lead and the brush holder assembly CO from the the magnet switch 2 bracket 8 6 Remove the armature 6 from the brush holder assembly 3 Remove the bolts and then disassem ble the starter motor 4 Remove the stator amp 5 36 sel ELEC i Electrical system 7 Remove the lever 9 and the pinion shaft assembly 0 o X 8 Remove the rubber seal 8 and the plan Q etary gear P N 3 k Checking the starter motor 1 Check the commutator Clean with 600 grit sandpaper and compressed air if dirty 9 Remove the cap 10 Push down the pinion stopper O using a pipe 2 and then remove the clip 9 2 Measure the commutator diameter 8 b Replace the armature if below specifica tion Pipe 42 commercially available 8 15 5 mm 0 61 in LHD 11 0 mm 0 43 in 11 Remove the pinion stopper clutch assembly 3 and the outer gear Commutator standard diameter 8 29 4 mm 1 16 in Wear limit 28 8 mm 1 13 in 3 Measure the commutator undercut Replace the armature if below specifica tion 5 37 Starter motor Brush holder assembly continuity 2 Measure the length of each brush Replace the brush assembly if below Commutator standard undercut specification 0 5 mm 0 02 in Wear limit 0 2 mm 0 01 in 4 Check the armature for continuity Replace if ou
45. 68 F 3 Install the spark plug caps to the spark plug wires by turning the caps clockwise Checking the ignition coil 1 Disconnect the ignition coil couplers 2 Remove the spark plug caps 3 Measure the ignition coil resistance Ignition coil resistance Primary coil reference data 0 1 89 0 2415 Q at 20 68 F Secondary coil 3 256 4 884 RO at 20 C 68 F 4 Install the spark plug caps 5 Connect the ignition coil couplers Checking the pulser coil 1 Measure the pulser coil output peak volt age Pulser coil output peak voltage White Red W R Black B S Dev so 27 65 98 TIP e When measuring the pulser coil output peak voltage under the unloaded cranking condition disconnect the connectors 8 e When measuring the pulser coil output peak voltage under the loaded cranking condition remove the clip from the engine shut off switch to prevent the engine from starting 2 Disconnect the pulser coil connectors a and then measure the pulser coil resis tance Pulser coil resistance 152 0 228 0 Q at 20 C 68 F 3 Disconnect the engine ECM coupler 4 Check the wiring harness for continuity Ignition units and components W R B ce 6106906069 se ee O0000000 00000006 Wiring harness continuity White Red W R Terminal 34 Black B Terminal 26 5 Connect the engine ECM coupler b and pulser coil connector 8 Checking the air t
46. 7 2 10 14 Checking the valve guide 7 37 Checking the valve seal 9 56 Checking the valve Seat 7 38 Checking the valve Spring 7 36 Checking the vapor separator 6 33 Checking the vapor shut off valve 5 23 6 27 Checking the water detection switch 5 20 Checking the water pressure sensor ODUON et Mir nee Checking the water pump Circuit dagan ee enca CAMO ele EE Connecting the communication cable to the outboard motor 4 3 ele ue RL EE A 7 Index Cooling System esse ee eee eee 2 17 Cooling water NOSE see eee 6 3 Crankcase assembly 1 11 Crate top cover pictograph description 3 Alis ii ei em A amada 7 52 Cylinder head nana 7 30 Cylinder head assembly 1 10 Digital network system 2 11 Dimension and VWeght ee 1 3 DIMENSIONS TE 3 2 Disassembling the cylinder block 7 53 Disassembling the cylinder head 7 35 Disassembling the drive shaft assembly 8 13 Disassembling the electrical components CURA eis 9 14 Disassembling the forward gear 8 13 Disassembling the friction plate 9 3 Disassembling the fuel filter assembly 6 10 Disassembling the fuel pump assembly 6 13 Disassembling the gear pump housing 9 55 Disassembling the lower case
47. AN GIN A N y N pp H N A P 3 Ol Fol SM Valve clearance Intake 0 0 20 0 05 mm 0 008 0 002 in Exhaust 0 30 0 05 mm 0 012 0 002 in TIP Note down the measurement data 7 Measure the intake and exhaust valve clearances of the corresponding cylinder Not applicable 7 3 8 Turn the flywheel magnet an additional 240 clockwise and align the ee mark Y on the driven sprocket with the a mark on the cylinder head 9 Measure the intake and exhaust valve clearances of the corresponding cylinder Not applicable 10 Turn the flywheel magnet an additional 240 clockwise and align the eee mark h on the driven sprocket 7 with the a mark on the cylinder head 11 Measure the intake and exhaust valve clearances of the corresponding cylinder Not applicable 12 Adjust the valve clearances if out of specification Adjusting the valve clearance Adjust the valve clearances when the engine is cold NOTICE Do not turn the flywheel magnet counter clockwise Otherwise the water pump impeller may be damaged 1 Loosen the valve adjusting locknut D and then turn the adjusting screw 2 until the specified valve clearance is obtained DA BE Ty R Y Y OS N TIP e To decrease the valve clearance turn the adjusting screw in direction a e To increase the valve clearance turn the adjusting screw
48. Fuel control units and Components Charging units and components Wiring harness continuity Terminal 1 Terminal 49 Terminal 2 Terminal 7 10 Install the vapor shut off valve and then connect the vapor shut off valve coupler a 11 Connect the engine ECM coupler and the main relay coupler Vacuum pressure pump gauge set 1 90890 06756 Charging units and components Checking the lighting coil stator Specified negative pressure assembly 67 0 kPa 0 67 kgf cm 9 7 psi 1 Disconnect the Rectifier Regulator cou pler and then connect the test har 6 Remove the special service tool ness 3 pins 7 Measure the resistance between the 2 Measure the lighting coil output peak vapor shut off valve terminals voltage between all combinations of the Vapor shut off valve resistance terminals Replace the stator assembly if 30 0 34 0 Q at 20 C 68 F below specification 8 Disconnect the engine ECM coupler b and the main relay coupler 0 9 Check the wiring harness for continuity Test harness 3 pins D 90890 06870 Lighting coil output peak voltage Green G Green G Unloaded r min OOO O OOOO 000006000 TIP To prevent the engine from starting when cranking it make sure to remove the clip from the engine shut off switch 9 24 sel ELEC i Electrical system 3 Measure the lighting coil resistance Lighting coil resistance refere
49. See Installing the tiller handle 3 11 Installing the 6Y8 Multifunction Meter harness remote control model 1 Remove the cap SARA DX SAN KINN De SNS T 2 Run the 6Y8 Multifunction Meter harness 2 into the bottom cowling and then connect the 6Y8 Multifunction Meter harness coupler 8 A 4 Remove the each cap and then connect the couplers and RNA Installing the remote control box and tachometer remote control model See Remote control box operation manual or Rigging guide for the installation proce dures Optional equipment Installing the water pressure sensor See 6Y8 Multifunction Meter set up manual for details of the components 1 Remove the plug SES BR A O A 2 Install a new gasket 2 and the nipple 8 and then tighten the nipple to the specified torque S FN Or IX EE KE Nipple 8 23 Nm 2 3 kgf m 17 0 ft lb _ wh Rigging information 3 Install the water pressure sensor 4 to the water pressure sensor adapter 6 and then tighten the water pressure sensor to the specified torque Water pressure sensor 4 18 N m 1 8 kgf m 13 3 ft lb 4 Install the water pressure sensor assembly 6 to the bottom cowling with a tapping screw D Dr ex sl 5 Remove the water pressure sensor harness 8 from the clamp 8 and then remove the cap 9 LE TR D Tr
50. T h Increase the friction k Decrease the friction TIP OS Check that the hoses the harness the lead and the cables do no interfere with the steer ing friction plate assembly 20 Adjust the friction adjusting nut until steering operation works properly WARNING Do not overtighten the friction adjuster If there is too much resistance it could be difficult to steer which could result in an accident L 2 Mounting the rigging grommet TIP e Tighten or loosen the friction adjusting nut at the steering lock lever in the position 6 e To increase the friction tighten the friction adjusting nut in direction M e To decrease the friction loosen the friction adjusting nut in direction Installing the shift cable and throttle cable remote control model 5 Make a mark on the fully retracted AWARNING inner cable and then make a mark on Always perform the cable adjustment in the fully extended inner cable advance following the procedures in the remote control operation manual 6 Make a mark in the middle point EE between marks 9 and 8 and then align 1 Install the cable guide to the grooves the mark f with the outer cable edge O a of the shift cable and the throttle cable 8 and then install the bottom cowling 7 Adjust the shift cable joint 4 and then install the shift cable joint 4 to the pin WARNING The shift cable joint must 2 Full
51. WEE 2 22 Wiring h sas 7 20 7 21 Working with crane 0 2 Index Index MEMO Appendix WING diagr ali WEE A 2 How to use the wiring diagram e eee eee ee eee A 2 Fuel unit and ignition unit T A 3 Charging unit and starting unt A 5 Gea ide UIE SEENEN A 7 MEMO Wiring diagram How to use the wiring diagram Composition of the wiring diagrams The wiring diagram consists of three categories The fuel unit and ignition unit the charging unit and starting unit and the control unit Legend symbols in the wiring diagrams 1 Double colors wire 2 No wire connector 3 A wire is not included in the selected wiring unit 4 Alert buzzer 6 Option parts Color Code B Black L G Blue Green Br Brown L R Blue Red G Green L W Blue White L Blue O W Orange VVhite Lg Light green P B Pink Black O Orange P G Pink Green P Pink P W Pink White R Red Pu B Purple Black Sb Sky blue PU R Purple Red VV White Pu Y Purple Yellovv Y Yellow R B Red Black B O Black Orange R G Red Green B W Black White R Y Red Yellow B Y Black Yellow VV B White Black Gy Gray W G White Green G B Green Black W R White Red G R Green Red W L White Blue G Y Green Yellow Y G Yellow Green L B Blue Black A 2 Fuel unit and ignition unit a Fuse 20A engine start switch PTT switch b Fuse 30A main re
52. and then check that cooling water is discharged from the cooling water pilot hole Checking the engine oil level 1 Put the outboard motor in an upright position NOTICE If the motor is not level the oil level indicated on the dip stick may not be accurate Start the engine and warm it up for 5 10 minutes Stop the engine and leave it at OFF for 5 10 minutes Remove the top cowling Remove the dipstick and wipe it clean with a rag Insert the dipstick completely for accurate measurement and remove it again Check the oil level using the dipstick to make sure the level falls at the center between the upper level 2 and the lower level Fill with oil if it is below the lower level or extract to the center level if it is above the upper level 8 gt NG I EA LL SCH Checking the engine start switch and engine shut off switch 1 Check that the engine starts when the engine start switch is turned to START Check that the engine turns off when the engine start switch is turned to OFF Predelivery check ON Sie ER Tiller handle model 704 remote control model 703 remote control model 10 4 Maintenance 3 Check that the engine turns off when the clip is pulled from the engine shut off switch Check that the engine turns off when the engine shut off switch is pushed tiller handle model GYAMAHA Tiller handle model 704 remote control mod
53. e Keep good ventilation while working NOTICE Do not reuse the bearing Always replace it with a new one 1 Install the original shim s T1 2 Heat the installation area of the taper roller bearing outer race in the lower case with a gas torch and then install a new taper roller bearing outer race 2 NOTICE When heating the lower case heat the entire installation area evenly Otherwise the paint on the lower case could be burned 8 15 TIP Do not reuse a shim if deformed or scratched 3 While holding the special service tool 8 strike the tool to check that the taper roller bearing outer race is installed properly If a high pitched metallic sound is produced when the special service tool is struck the outer race is installed properly SE Driver rod LL 8 90890 06605 Bearing outer race attachment 4 90890 06622 4 Install a new needle bearing into the lower case to the specified depth Driver rod SL 6 90890 06602 Needle bearing attachment 90890 06614 Bearing depth plate amp 90890 06603 Installation depth 8 182 5 183 0 mm 7 19 7 20 in TP e Install a new needle bearing with the identi fication mark facing toward the water pump side e When using the driver rod do not strike the special service tool in a manner that will force the stopper out of place Sl Heat the installation area of the taper roller bearing outer race in the lower ca
54. le Fuel hose ow pressure Oheckireplace 0 le Fuelpump orere o rm Fuelileakage Toe folof E Gerd r nn en Greasing points Lubie e 17 me Impeller Check replace 8 5 water pump housing Impeller Replace 8 5 water pump housing 8 19 Pilot water water Check 103 3 ol Te cotter pin PTT unit unit Check replace 10 13 13 beer i RRE 10 5 Spark plug s plug s Check replace 7 42 42 ES link throttle cable Check adjust replace ES 6 21 Thermostat Check replace Check replace O 7 7 49 Tmingoet Checkeplace me 7 4 DI EE m Wiring harness connec Check replace tions wiring coupler con nections Selva meterigauge Not applicable Item to page 1000 1000hous o Exhaust guide Check replace 9 33 exhaust manifold Timing bet C 0 78 TIP When using lead high sulfur gasoline checking the valve clearance may be required more fre quently than every 500 hours 10 2 Maintenance Predelivery check To make the delivery process smooth and efficient the predelivery checks should be completed as explained below Checking the battery 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 injuries e Wear protective eye gear when ha
55. lower chamber of the cylinder to force the free piston and the tilt ram assembly OD to move upward The relief valve 3 of the fluid pressure circuit will open when the fluid pressure exceeds the limit while the relief valve Q in the upstream will not work in its trim range because the passage is closed with the free piston rubber seal 9 The up relief valve opens at 5 4 MPa 54 0 kgf cm 783 0 psi h Fluid pressure circuit k Return circuit M Relief circuit 2 20 Technical features and description Tilt down operation When the PTT switch is pressed to DN fluid pressure created by the gear pump flows into the down side of the shuttle piston and pushes the down valve allowing it to open At this point the fluid pressure forces the shuttle piston to slide to the up valve The protrusion of the shuttle piston C opens the up valve 2 which opens the return circuit Then the PTT fluid flows into the upper chamber of the cylinder to force the tilt ram assembly OD to move downward The relief valve of the fluid pressure circuit will open when the fluid pressure exceeds the limit The down relief valve opens at 2 0 MPa 20 0 kgf cm 290 0 psi h Fluid pressure circuit k Return circuit Relief circuit 2 21 PTT unit Operation in case of malfunctions When the fluid pressure in the PTT cylinder exceeds the specified limit the protection valves absorber valve pins 6 and 6 will open to f
56. ml EY DN Disassembling the PTT motor 1 Remove the stator M 9 49 Checking the PTT motor 1 Check the commutator Clean with 600 grit sandpaper and compressed air if dirty 2 Measure the commutator diameter 8 Replace the armature assembly if below specification Motor commutator standard diameter 8 16 3 mm 0 64 in Wear limit 14 9 mm 0 59 in Check the armature continuity Replace the armature assembly if out of specification PTT motor Digital circuit tester 90890 03174 4 Check the bearing Replace the armature assembly if damaged Checking the brush 1 Measure the length of each brush Replace if below specification Brush standard length 8 7 5 mm 0 30 in Wear limit 5 1 mm 0 20 in Assembling the PTT motor NOTICE e Do not reuse the oil seal and O rings Always replace them with new ones e Do not allow grease or oil to contact the armature commutator 1 Install a new oil seal 1 Driver rod L3 2 90890 06652 Needle bearing attachment 8 90890 06617 9 50 BRKT Bracket unit 2 Install the PTT motor lead 4 the springs the circuit breaker the brush holder and the brushes 8 and PTT motor assembly bolt 6 7 N m 0 7 kgf m 5 2 ft lb 3 Push the brushes and 9 into the brush holder and then install the armature assembly 0 4 Install the stator 4D and then tighten the screws 2 Installing the
57. p D lt 1 of wf lt lt eT S 1 of ser af 1 Pad gt af ve E r E lt D 1 of lt 1 lt wf Le DN p Ge 22 amp amp 08 e M 21 1 N m 0 1 kgf m 0 7 ft lb Remarks O ring Oil seal Plate O ring E clip Shift rod Cover Oil seal housing assembly Oil seal housing O ring Not reusable Oil seal Not reusable Washer Drive shaft Taper roller bearing Shim T3 Sleeve Nut 8 11 Drive shaft and lower case E 1 E WW D ka lt 1 of wf lt lt eT S 1 of ser af 1 Pad gt af ve E r E lt D 1 of lt 1 lt wf Le DN p Ge 22 amp amp 08 e M 21 1 N m 0 1 kgf m 0 7 ft lb Part name Remarks Water inlet cover STBD Lower case Water inlet cover PORT Screw Shift cam Shim T1 Taper roller bearing Not reusable Forward gear Needle bearing Not reusable Pinion Nut 8 12 Lower unit Removing the oil seal housing drive shaft and shift rod 1 Remove the cover the oil seal hous ing assembly 2 and the washer 2 Remove the shift rod assembly 4 3 Remove the pinion nut and then remove the drive shaft and the pinion Drive shaft holder 3 6 90890 06517 Pinion nut holder 6 90890 06715 4 Pull out the forward gear assembly Disassembling the oil seal housing 1 Remove the oil seals and the O ring Q 8 13 Disassembling the drive shaft assemb
58. specified torque 4 Tighten the exhaust cover anode plug to the specified torque 7 50 Power unit 5 Install a new gaskets 42 and the exhaust cover plugs 43 and then tighten the exhaust cover plugs 4 to the specified torque 6 Install a new gasket 4 and the exhaust cover plug 3 and then tighten the exhaust cover plug 45 to the specified torque Exhaust cover anode screw 2 N m 0 2 kgf m 1 5 ft lb Exhaust cover anode plug 0 18 N m 1 8 kgf m 13 3 ft lb Exhaust cover plug 4 M14 23 N m 2 3 kgf m 17 0 ft lb Exhaust cover plug 5 M18 56 N m 5 6 kgf m 41 3 ft lb 7 Install the bracket 6 7 51 Cylinder block D 15 Num 1 5 kgf m 11 1 ft lb 30 N m 3 0 kgf m 22 1 ft lb o sous en 3 L O 12 13 14 15 16 Part name Bolt Bolt Crankcase Crankshaft journal bearing Oil seal Crankshaft Dowel Cylinder block Oil seal Crankpin bearing Bolt Connecting rod assembly Piston pin Clip Piston Piston ring set Oo p OS Exhaust cover Cylinder block 6 N m 0 6 kgf m 4 4 ft lb 17 N m 1 7 karm 12 5 feb Remarks Not reusable 7 52 Power unit Disassembling the cylinder block 1 Loosen the crankcase bolts and in the sequence numbers 1 2 2 Remove the crankcase bolts D and 2 and then remove the crankcase 3 3 Remove the connecting rod bolts and the connecting rod caps 2 and t
59. the retaining plate and the drive sprocket nut Check that the 1 mark on the driven sprocket is aligned with the a mark on the cylinder head and the hole on the retaining plate is aligned with the a mark on the cylinder block 7 16 Installing the stator assembly 1 Install the base assembly D and the sta tor assembly 2 and then connect the stator assembly coupler 8 C ge o ELT 8 Sie EI I 5 Install the timing belt with its part 2 Install the pulser coil and then connect the pulser coil connectors Di Installing the flywheel magnet 1 Install the Woodruff key and then install the flywheel magnet 2 and the fly wheel magnet nut TIP Make sure to remove any grease from the tapered portion of the crankshaft and the flywheel magnet 2 Tighten the flywheel magnet nut 8 to the specified torque NOTICE Apply force in the direction of the arrow to prevent the flywheel holder from slipping off easily e Le Le Le LC L Lop qa Flywheel holder 4 90890 06522 Flywheel magnet nut 8 157 N m 15 7 kgf m 115 8 ft lb Flywheel magnet and timing belt 7 18 Power unit Engine ECM Remarks Xn TN NEN ZE Q ANO Ga LEIA VERE OE IV A NI e RL M6 x 25 mm Q ty 9 1 1 3 3 6 2 2 1 Part name Ben O o a 2 Q DO D EE O Oo L
60. upper case 5 Install the upper case assembly 8 inserting the tip of the water pipe 0 into the rubber seal 8 and then tighten the upper case bolts D temporarily 9 29 TP AAA When tightening the upper case bolts AD tighten the power unit mounting bolts at the same time to the specified torque See Installing the power unit 7 9 step 3 and step 4 6 Install a new gasket 42 and the engine oil drain bolt 43 and then tighten the engine oil drain bolt 43 to the specified torque Engine oil drain bolt 43 27 N m 2 7 kgf m 19 9 ft lb Exhaust manifold and oil pan E o CO JO GQ Bb ON Gasket Cover Bolt Bolt Oil strainer Gasket Pipe Rubber seal Oil seal Exhaust guide Gasket Dowel Bolt Grommet Oil pan Grommet Anode Part name N A sch k ND wo k k ee O Upper case Exhaust manifold and oil pan Not reusable M6 x 25 mm M6 x 16 mm Not reusable Not reusable Not reusable M6 x 25 mm 11 N m 1 1 kgf m 8 1 ft lb Remarks 9 30 sj E Q Q D 11 N m 1 1 kgf m 8 1 ft lb OU Fe o D OC 6 o E o CC e A O Z M5 x 12 mm 20 mm reusable M6 Not Exhaust manifold reusable Not reusable Not M6 x 25 mm 9 31 Exhaust manifold and oil pan Disassembling the oil pan and exhaust manifold Remove the muffler the gaskets and the plate 1
61. 12 sel ELEC i Electrical system ECM coupler layout 1 2 6Y8 Multifunction Meter 6Y8 Multifunction Meter TPS Sensor power Source Pink Orange N Blue Black Yellow Black Yellow Speed sensor Air temperature sensor 0 Thermo sensor 12 13 14 15 Trolling switch DN Engine shut off switch White Blue White Blue White Green Water detection switch ISC ISC Ground YDIS Green Yellovv Black White Black 1 23 Air pressure sensor Pink Green 5 13 EA KN KA En EM EE KIN NN KI EN 17161914181211101918171615 4 3 2111 8483323 13029282 2629242322 2 1201918 remote control 35 Engine start switch Yellow 37 Diagnostic flash indi Blue White cator 38 Oil pressure alert indi Pink White Calor Ground Black Alert buzzer Ignition coil 3 Black Yellow 42 Ignition coil 2 Black White Main relay high pres sure fuel pump Overheat alert indica Pink Black tor ECM coupler layout Checking the electrical component Checking the electrical component Checking by use of YDIS When checking the TPS ISG high pressure fuel pump fuel injector or each sensor use the YDIS When deleting the diagnosis record in the YDIS be sure to check the time that the trou ble codes were detected When checking the input voltage of a part the coupler or connector must be discon nected As a result the engine ECM deter mines that the part is
62. 2 Trim sensor coupler AD Trolling switch lead 8 6Y8 Multifunction Meter communication cou 2 Neutral switch lead pler 3 Alert indicator harness 4 Alert indicator coupler Water pressure sensor lead 6 Trolling switch coupler 5 Sub wiring harness 6 Neutral switch coupler 7 Water pressure sensor coupler Fuel hose 9 Speedometer hose 5 8 sel ELEC i Electrical system Bottom cowling remote control model Jo d es 1 Neutral switch 2 Trim sensor coupler 3 6Y8 Multifunction Meter communication cou pler 4 Alert indicator coupler 6 Trolling switch coupler 6 Neutral switch coupler 7 Water pressure sensor coupler PTT switch coupler PTT model 9 PTT switch PTT model 5 9 Fuel hose D Speedometer hose 2 PTT motor lead PTT model 3 Trim sensor lead PTT model Alert indicator harness 5 Neutral switch lead Water pressure sensor lead D PTT switch lead PTT model Sub wiring harness Electrical component and wiring harness routing Tiller handle tiller handle model D PTT switch D Alert indicator 2 Trolling switch 8 Neutral switch Run the neutral switch leads blue and black 4 Alert buzzer under the control link assembly 6 Engine start switch coupler 6 Extension wiring harness 7 Engine shut off switch Engine start switch 9 Grommet Alert indicator harness Run the neutral switch leads brown under the buzzer 5 10 sel ELEC i Electric
63. 20 A engine start switch 3 Fuse 30 A main relay 4 Fuse 20 A starter relay 6 Lighting coll lead 6 Wiring harness 7 Ignition coil Water pressure sensor option 5 1 PTT switch Q Rectifier Regulator Oil pressure switch OD YDIS coupler 2 Diode connect to the PTT relay 3 Joint connector 2 Joint connector 1 5 Trim sensor lead Flash indicator connector Electrical component and wiring harness routing D PTT motor lead Pass the lighting coil lead amp through the Starter relay lead groove of the magnet base Extension wiring harness Pass the wiring harness 6 between the Rectifier Regulator lead engine hanger and the cylinder head 2 Thermo sensor lead Connect the ignition coil coupler marked with 22 Oil pressure connector white tape to the 1 cylinder ignition coil sel ELEC i Electrical system Starboard view C 1 Fuel injector Install the injector leads 1 and 2 into the 2 Blowby hose positions 8 and then install the wiring har 3 Wiring harness ness into the positions 4 Vapor gas hose Clamp the fuel hose 8 and the wiring harness 5 Throttle body lead 3 at the position marked with white tape Throttle body Install the wiring harness holders to the holes High pressure fuel pump of the intake manifold Fuel hose 9 Vapor shut off valve lead 5 3 Electrical component and wiring harness routing D Clamp the holder to the wiring h
64. 5 22 sel ELEC ik Electrical system High pressure fuel pump input voltage Blue L Black B 12 0 V battery voltage 4 Turn the engine start switch to OFF 5 Measure the resistance of the high pres sure fuel pump motor q High pressure fuel pump resistance reference data 1 4 1 Q at 20 C 68 F 6 Disconnect the engine ECM coupler and the main relay coupler ODO ODO T OOO COO O O 00000000800000000 Wiring harness continuity Terminal 1 Terminal 26 Terminal 2 Terminal 8 5 23 8 Connect the engine ECM coupler b and the main relay coupler 9 Connect the high pressure fuel pump coupler 8 Checking the vapor shut off valve 1 Disconnect the vapor shut off valve cou pler 2 Turn the engine start switch to ON and then measure the input voltage between the vapor shut off valve coupler terminal and ground Vapor shut off valve input voltage Red Yellow R Y Ground 12 0 V battery voltage 3 Remove the vapor shut off valve and then connect the special service tool D to the vapor shut off valve 4 Apply the specified negative pressure to the vapor shut off valve 5 Check that the vapor shut off valve opens and the negative pressure is released when the battery voltage is applied to the vapor shut off valve terminals NOTICE Apply the battery voltage to the vapor shut off valve terminals for only a few seconds
65. Checking the PTT switch on bottom cowling 5 43 Checking the PTT switch tiller handle model 5 44 Checking the PTT system 10 6 Checking the pulser Coil 5 27 Checking the pulser coil air gap 7 1 Checking the Rectifier Regulator 5 25 Checking the reverse dear 8 8 Checking the rocker arm and rocker ARMA SGM enia oie hale ea ais 7 41 Checking the shift rod 8 14 Checking the spark plug 7 42 10 14 Checking the spark plug Cap 5 27 Checking the speed sensor option 5 41 Checking the starter motor 5 37 Checking the starter motor operation 5 35 Checking the starter motor pinion 5 35 Checking the starter relay 5 30 Checking the steering system 10 6 Checking the thermo Sensor 5 29 Checking the thermostat 7 49 10 14 Checking the throttle body 5 17 6 19 Checking the throttle cable and shift A a 10 6 Checking the timing belt 10 14 Checking the timing belt and sprocket 7 15 Checking the top cowling 10 14 Checking the TP Suc 5 18 Checking the trim sensor 5 45 Checking the trolling switch 5 20 Checking the valve eee eee 7 37 Checking the valve clearance
66. Drive shaft bushing Holder Hose Dovvel Upper case and mounts Upper case 27 N m 2 7 kgf m 19 9 ft lb Remarks Ms x 30 mm Not reusable L transom model M14 x 12 mm L transom model L transom model L transom model L transom model 9 26 BRKT Bracket unit D 21 Num 2 1 kgf m 15 5 ft lb 2 21 Num 2 1 kgf m 15 5 ft lb 4 Remarks Gasket Not reusable Drain bolt Rubber seal Rubber seal Not reusable 9 27 Disassembling the upper case 1 Remove the engine oil drain bolt 2 Remove the upper case bolts Q and then remove the oil pan assembly Q from the upper case IS Ss TNS AG CH Ee f late o H C Ne 3 Remove the guide 4 and the baffle plate 6 i S om PAs SS d 4 Remove the circlip 6 and the collar M L transom model Upper case 5 Remove the drive shaft bushing L transom model Stopper guide plate 90890 06501 Bushing installer center bolt 0 90890 06601 Checking the drive shaft bushing 1 Check the bushing Replace if cracked or worn Assembling the upper case 1 Install the drive shaft bushing into the upper case L transom model Driver rod L3 90890 06652 Needle bearing attachment 90890 06614 9 28 BRKT Bracket unit 2 Install the collar and the circlip amp L transom model 3 i S gt Ao Ws d 4 Install a new rubber seal into the
67. N m 0 3 kgf m 2 2 ft lb Remarks Hydro tilt model M5 x 22 mm Not reusable PTT model M4 x 10 mm PTT model M6 x 30 mm M6 x 15 mm 9 6 BRKT Bracket unit 9 7 Part name Plastic tie Neutral switch Shift link Throttle lever Screw E clip Drive gear Shift cable Clip Throttle cable Holder Bolt Cap Not reusable M3 x 15 mm M6 x 30 mm 3 N m 0 3 kgf m 2 2 ft lb Remarks Tiller handle Disassembling the tiller handle 1 Remove the bracket 1 2 Remove the cover 2 and then disconnect the alert indicator couplers a and b EE Cart NO _ G 5 Disconnect the connectors d of the PTT switch Red R lead the Sky blue Sb lead and the Light green Lg lead PTT model 3 Remove the clips 8 and then remove 6 Remove the holders 9 PTT model the cable clamps 8 the shift cable and the throttle cable 6 LP NO IE VS 5 E N a N AG C2 eg N QI U 7 Remove the cap 0 the throttle grip AD the bushing 42 and the shift lever 3 4 Remove the bracket and the cable hydro tilt model holders 8 and then disconnect the Remove the PTT switch 4 the throttle connectors C of the neutral switch grip D the bushing and the shift lever Brown Br leads 3 PTT model 9 8 BRKT Bracket unit 10 Remove the neutral switch 9 the throttle arm 0 and the bushing 23 11 Remove the cotter pin the washers 3 the
68. PTT motor 1 Install a new O ring the shaft connec tor 2 the spring Q and the PTT motor assembly 4 to the gear pump housing and then tighten the PTT motor assembly bolts to the specified torque 9 51 PTT gear pump 3 N m 0 3 kgf m 2 2 ft lb 1 Bolt 4 2 Gear pump assembly 1 3 O ring 2 4 Spring 1 5 Valve pin 1 6 Valve seal 1 7 Filter 2 8 O ring 2 9 Bolt 3 10 Gear pump housing 1 11 Girclip 1 12 Manual valve 1 13 O ring 1 14 O ring 1 15 Manual valve seat 2 16 Spring 1 17 Adapter 1 6 N m 0 6 kgf m 4 4 ft lb gn DJ PTT motor PTT gear pump Remarks M4 x 25 mm Not reusable Not reusable Not reusable Not reusable 9 52 BRKT Bracket unit 3 N m 0 3 kgf m 2 2 ft lb 6 N m 0 6 kgfm 4 4 ft lb gn DJ Remark 18 Main valve assembly Main valve O ring O ring O ring Shuttle piston O ring O ring Ball Absorber valve pin Spring O ring Filter O ring Relief valve assembly Lock screw Spring Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable 2 2 2 2 1 1 2 2 2 2 4 1 1 1 1 1 9 53 PTT gear pump 3 N m 0 3 kgf m 2 2 ft lb Remarks Valve pin Valve seal O ring Not reusable Relief valve O ring Not reusable Valve lock screw 9 54 BRKT Bracket unit Disassembling the gear pump housing 1 Remove the gear pump housing 0
69. Trouble Diagnostic YDIS diagno Intake press sensor malfunction Air pressure sensor malfunction ME EE Intake air passage Air leakage ME MN D Engine stop lanyard switch ONT Engine shut off switch ONT 49 Over cooling Over cooling 4 5 INO3 u pu au Troubleshooting the power uni LI G pue poq 81044 eu ueemjeq Aununuo9 GUUIM 10 989 LA LVS indu Apog 8 n014 ou eunsegiy 92 SICA eu Buisn ainyesedwe die eu Y99490 AlNUNUOI 369 10 J03ejn694 19111984 ou eu aBeyon yead indino Gc q JoyeinBbay 1811994 O 91NSE9N da eon yeod indino 109 BunyBbi y eunseoyy INO3 9u16u9 au pue poq ajnolyj ou usam jaq ununuoo Bulim 10 peu 9GLJJOA indu Apog 8 1014 eu eunsegiy SICA ou Guisn eue Buluado pue o6e110A dino Sd ou SJNSBAN INO3 eulfus eu pue JOSUSS OUIJSUY ay uSam aq ynunuo9 Bulim JO peu 99UB SIS9 J y 3INSEIN aBeyyon indu y NSLE NW JOSUSS OWJI9U JOSUSS OUWIJSU sda s Bulyoouy abed 0 19 04 peeds opt yBIH j eWJOU s8jeuedo aulbuy AUEULLIOU sejelado aulbuy suompuos lsyeq uo spuedeg 111591 jou saop 9UI6U7 S9uURWJOMSd uoneJejaooe papelbaq pasds opt yBIH JLSUJ9MAO pasds 9ui6u9 wnwixew Bululjoeq GOOUEULIOUGO Uu0e2191999e papelbaq peeds opt yBIH ejdsip abneb NVI uol eonoads jo mo o6e110A peiji98ds mojeg uol P51j198dS jo mo uol 671UO90S jo mo UONIPUOS U
70. a new gasket and the cylinder head cover Cylinder head Install a new gasket 8 and the oil pump assembly aligning the slot in the oil pump drive shaft with the camshaft pin NOTICE Before installing the oil pump assembly make sure to fill it with engine oil through the oil passage 9 7 32 Power unit Camshaft and valve 18 N m 1 8 kgf m 13 3 ft lb yal G a 16 Nut 17 Rocker arm Part name Q ty Remarks 1 Intake valve 3 2 Exhaust valve 3 3 Oil seal 1 4 Gasket 1 5 Retaining bolt 1 6 Valve guide 6 7 Valve spring seat 6 8 Valve seal 6 9 Valve spring 6 10 Valve spring retainer 6 11 Valve cotter 12 12 Rocker arm D 13 Adjusting screw 5 14 Nut 5 15 Adjusting screw 1 1 1 7 33 Camshaft and valve 18 N m 1 8 kgf m 13 3 ft lb 18 N m 1 8 kgf m 13 3 ft lb yal G a Hart name Remarks Washer Bolt Tensioner Stopper Rocker arm shaft Washer Camshaft Screw O ring Anode Anode plug Spark plug Cylinder head Bolt Engine hanger Ms x 22 mm M5 x 24 mm Not reusable M6 x 20 mm N AY CD CD ON M M E MN 7 34 Power unit Disassembling the cylinder head 1 Remove the cylinder head anodes the spark plugs and the engine hanger 2 Gradually loosen the rocker arm shaft bolts in several stages and in the sequence numbers
71. and starting unit Joint coupler 2 Joint coupler 1 19 H mme WM MIL of CH Starter motor Starter relay EE Rectifier Regulator CH It ml Ka minn ti l HM mn ft IL TIP Tt NI Lun Engine ECM i mA HESA IT ds FE nm 67 5 tt 111 i z E aoe S IL TT S Es E A Z Sim WW Ej m I a gt ia i i L O d a 1 E 52 43 Water pressure Speed sensor PTT motor PTT switch Trim sensor sensor A 6 Control unit A Tiller handle PTT switch Engine start switch Engine shut off 704 remote control Y 703 remote control W JB R Y Br D To power unit To gauge Trolling switch DSQ lt T Woh UN r Engine start switch Engine shut off PTT switch switch Neutral switch KES ne ee ee ss e See see is ee SSE ee EN ee SETE E Eee SEE Se SES SSRS ee demes me de me eue site L ss die nu SES as R GC start switch Engine shut off PTT switch
72. case 4 Heat the installation area of the taper roller bearing outer race in the lower case with a gas torch and then remove the taper roller bearing outer race the shim s T3 D and the drive shaft sleeve 8 NOTICE When heating the lower case heat the entire installation area evenly Otherwise the paint on the lower case could be burned or the drive shaft sleeve could be damaged TIP e Before removing the taper roller bearing outer race place some cushioning mate rial under the lower case to catch the outer race when it falls out e If the taper roller bearing outer race does not come out lightly tap the lower case with a plastic hammer Checking the shift rod 1 Check the shift rod Replace if bent or worn Checking the pinion 1 Check the pinion teeth Replace if cracked or worn Checking the forward gear 1 Check the teeth and dogs of the forward gear Replace if cracked or worn Checking the drive shaft 1 Check the drive shaft Replace if dam aged or worn 8 14 Lower unit 2 Measure the drive shaft runout Replace if above specification Drive shaft runout 0 5 mm 0 0197 in Checking the lower case 1 Check the lower case Replace if cracked or damaged Assembling the lower case A WARNING e Use heat resistant gloves Otherwise burns could result e To avoid the risk of fire remove any flammable substances such as gasoline and oil around the working area
73. cover pictograph description The following pictographs are important signs to handle the crate Read the notices and understand what the pictographs mean to avoid damage to the product when handling transporting and or keeping the crate A WARNING Lifting fork insert position EE Stack limit Maximum units for storage Such as gloves and eye protection when handling and opening crate Handle with care 4 Y UK ES ES Avoid water Product barycentric position NOTICE Use forklifts with forks that are at least 1m 40 in length Only stack with crates of the same size Be sure unit is stacked securely all four corners fit securely on unit below it Stack Limit 2 units at handling IMPORTANT This unit delivered to carrier in a good condition For protection against loss due to damage inspect thoroughly If damage is noted make note on freight bill Shipper assumes no further liability to the transportation company Your claim should be filed against carrier for damage of any nature 3 Crate top cover pictograph description Uncrate procedure Uncrate procedure 1 Check for any shipping damage 2 Remove the top cover 3 Remove all bolts from the bottom plate and remove the frame NOTICE Be careful not to cause any damage to the outboard motor 4 Remove the wrapping and check the outboard motor for concealed damage 5 Remove the top cowling and the flywheel
74. disconnected and a trouble code is detected Therefore be sure to delete the diagnosis record after checking the input voltage YDIS CD ROM Ver 1 32 60V WS853 05 YDIS KIT 60V 85300 05 TIP e Before checking the electrical components make sure that the battery is fully charged Install the proprietary YDIS software in CD ROM to your computer Always use the exclusive communication cable for connect ing the engine ECM to the computer For a description of the communication cable and CD ROM to be used see YDIS 4 1 Also be sure to check the CD ROM version before using it To connect and operate the YDIS see the YDIS Ver 1 32 or later Instruction Man ual Measuring the peak voltage A WARNING When checking the peak voltage do not touch any of the connections of the digital tester probes NOTICE When testing the voltage between the ter minals of an electrical component with the digital tester do not allow any of the leads to touch any metal parts If touched the electrical component can be short cir cuited and damaged To check the electrical components or mea sure the peak voltage use the special ser vice tools A faulty electrical component can be easily checked by measuring the peak voltage The specified engine speed when measuring the peak voltage is affected by many factors such as fouled spark plugs or a weak battery If one of these factors is present the peak vol
75. eee eee ee eee 8 13 Disassembling the drive shaft assembly 8 13 Disassembling the forward gear sse eee eee 8 13 Disassembling the lower case ese ee eee e 8 13 Ce ES Ares 8 14 Checking The DINION WEE 8 14 Checking the forward gear sss sees eee 8 14 Checking NE AVE EE 8 14 Checking the lower case TT 8 15 Assembling the lower case cesses eee ee eee eee 8 15 Assembling the forward gear sese eee eee eee 8 16 Assembling the drive shaft esse sese 8 17 Assembling the oil seal housing css eee eee ee eee 8 17 Installing the shift rod drive shaft and oil seal housing 8 17 Installing the propeller shaft housing assembly 8 18 Installing the water pump esse eee eee eee eee eee ee eee 8 19 Checking the lower unit for air leakage sse eee ee eee ee 8 19 Installing the lower unit sa agere 8 20 SANN NNN 8 22 SAI WOKIOW EE 8 22 SAIMAN CHECK NEE 8 23 Measuring the forward and reverse gear backlash before SIE E ue asar eee ramener 8 25 SAO TTT 8 28 Shim localo WEE 8 28 Selecting the pinion shim T3 occococcnccnccnnoncnnnononcncnnacnnonanonoss 8 29 Pinion shim T3 selection table KEREN eee 8 32 Measuring the forward gear backlash 8 34 Adjusting the forward gear shim thickness T1 8 34 Forward gear shim T1 selection chart eee eee 8 36 Measuring the reverse gear backlash 8 37 Adjusting t
76. ft lb 10 Install the starter relay 8 and the plate 9 and then connect the starter relay connectors 9 11 Tighten the starter relay screw 0 to the specified torque Starter relay screw 0 3 N m 0 3 kgf m 2 2 ft lb 7 25 12 Install the starter relay leads M and then tighten the starter relay lead bolts to the specified torque 13 Install the caps 42 Starter relay lead bolt 4 4 N m 0 4 kgf m 3 0 ft lb 14 Install the PTT relay 49 and then connect the PTT relay coupler M PTT model 15 Install the PTT relay leads and then tighten the PTT relay lead nuts D to the specified torque PTT model 16 Install the caps PTT model PTT relay lead nut 4 N m 0 4 kgf m 3 0 ft lb 17 Install the ground leads Wiring harness 19 Install the wiring harness to the clamps 20 Install the Rectifier Regulator coupler V to the bracket 4 and then connect the thermo sensor coupler W and the oil pressure switch connector 9 et NR SSL Weg dg TALE eae d LB JEG E SN EN o ea TEZRO DI Y SI ka NMP A AA HE d i 0 ID L NO AS o 21 Install the ground lead Y and the clamps A 7 26 Power unit Starter motor 7 27 Bolt Bushing Washer Clip Shift rod lever Bolt Bracket Engine hanger Dowel Bracket Bolt Starter motor Bolt Terminal Starter motor lead Bolt Cap nn mn DA A BHR PO WH N
77. grommet and then install them Install the engine shut off switch and then tighten the engine shut off switch nut to the specified torque Install the buzzer and then connect the engine shut off switch connectors and the buzzer connectors Cf Connect the engine start switch coupler Align the white tapes h on the extension wiring harness and the alert indicator harness with the inner end of the grommet 9 14 BRKT Bracket unit aer ay GA o Li SE GU 4 Engine start switch nut 5 Nm 0 5 kgf m 3 7 ft lb Engine shut off switch nut 2 5 N m 0 25 kgf m 1 84 ft lb 7 Install the alert indicator and then tighten the alert indicator screws 8 to the specified torque Alert indicator screw 8 2 N m 0 2 kgf m 1 5 ft lb 9 15 Electrical components multifunction Shift rod and shift bracket Shift rod and shift bracket Remarks Cotter pin Washer Bushing Bracket Ball Spring Detent bolt Bushing Bolt M5 x 14 mm Shift rod Grommet CO CO NOORA M wesch O 9 16 BRKT Bracket unit Disassembling the shift rod 1 Remove the shift rod detent bolt D the spring and the ball Shift rod detent bolt 8 18 N m 1 8 kgf m 13 3 ft lb 2 Remove the cotter pin and then remove the washer 6 the bushings 6 the bracket 7 and the bushing 8 Assembling the shift rod 1 Install the bushing
78. ground 0000 0000 000590000 DO DO PO 0 PO La PO DOC OC OO OC EE OY ODO OOOO OOU OO CO OO LC Wiring harness continuity Terminal 39 Ground Terminal 48 Ground Terminal 1 Ground 3 Measure the input voltage between the engine ECM coupler terminal 45 and the ground 5 16 sel ELEC ik Electrical system Engine ECM input voltage Terminal 45 Ground 12 0 V battery voltage 4 Turn the engine start switch to ON and then measure the input voltage between the engine ECM coupler terminal 36 and the ground 200000000 on of 20000000 BIR Engine ECM input voltage Terminal 36 Ground 12 0 V battery voltage 5 Turn the engine start switch to OFF 6 Disconnect the main relay coupler 3 7 Check the wiring harness for continuity MOO OU OOD 0O0G000000 Wiring harness continuity Terminal 46 Terminal 6 5 1 y 8 Connect the main relay coupler C and the engine ECM couplers and Checking the throttle body The TPS the air pressure sensor the air temperature sensor and the ISC are the components of the throttle body 1 Disconnect the throttle body coupler 8 2 Turn the starter switch to ON and then measure the throttle body input voltage Throttle body input voltage Orange O Ground 4 75 V 5 25 V 3 Turn the engine start switch to OFF 4 Disco
79. handle bracket nut to the specified torque Tiller handle Grease nipple Gs 3 N m 0 3 kgf m 2 2 ft lb Tiller handle bracket bolt 88 32 Nm 3 2 kgf m 23 6 ft lb Tiller handle bracket nut 89 32 N m 3 2 kgf m 23 6 ft lb 9 12 BRKT Bracket unit Electrical components multifunction Part name Remarks Trolling switch Engine shut off switch Engine start switch Tiller handle Bracket Bolt Alert indicator harness Extension wiring harness Grommet Buzzer Grommet Gasket Plate Screw Clamp Alert indicator Cover M6 x 15 mm CON OOF ODD 9 13 Disassembling the electrical components multifunction 1 Remove the alert indicator 1 Remove the buzzer Gi and then disconnect the buzzer connectors 8 and the engine shut off switch connectors Remove the engine shut off switch Disconnect switch coupler 0 the engine start Remove the extension wiring harness 4 the alert indicator harness 6 the trolling switch and the grommet Remove the engine start switch 8 AS o r ERT E ei EA gm L3 e Electrical components multifunction Assembling the electrical components multifunction 1 Install the engine start switch D with the hole facing upward and then tighten the start switch nut to the specified torque Pass the extension wiring harness the alert indicator harness Q and the trolling switch lead through the
80. hole If there is no water flow check the cooling water passage inside the outboard motor Checking the engine idle speed 1 Start the engine and warm it up until the idle speed gets stable at 750 850 r min 2 Check the engine idle speed using the Selva genuine tachometer on board meter or the YDIS To connect and operate the YDIS see the YDIS Ver 5 Add the correct amount of oil through the filler hole Put back the filler cap D and the dipstick 2 NOTICE Overfilling the oil could cause leakage or damage If the oil level is above the upper level mark extract until the level meets the specified capacity 1 32 or later Instruction Manual Changing the engine oil The engine oil should be extracted with an oil changer NOTICE Change the engine oil after the first 20 hours of operation or 3 months and every 100 hours or at 1 year intervals thereafter Recommended engine oil 4 stroke motor oil with combinations of the following SAE and API oil classifica tions 1 Put the outboard motor in an upright API SE SF SG SH SJ or SL position NOTICE If the outboard motor is not level the oil level indi cated on the dipstick may not be accu SAE 5W 30 10W 30 or 10W 40 Replacement engine oil quantity without oil filter replacement rate 1 5 L 1 59 US at 1 32 Imp at 2 Start the engine and warm it up for 5 10 Leave the outboard motor OFF for 5 10 minutes minutes 3 St
81. if out of specification El Piston ring dimensions Top ring 8 B 1 17 1 19 mm 0 0461 0 0469 in T 2 30 2 50 mm 0 0906 0 0984 in Second ring B 1 47 1 49 mm 0 0579 0 0587 in T 2 60 2 80 mm 0 1024 0 1102 in Oil ring B 2 36 2 48 mm 0 0929 0 0976 in T 2 75 mm 0 1083 in 7 54 Power unit Checking the piston ring end gap 1 Level the piston ring in the cylinder with a piston crown 2 Check the piston ring end gap at the specified measuring point Piston ring end gap 8 reference data Top ring 0 15 0 30 mm 0 0059 0 0118 in Second ring 0 30 0 50 mm 0 0118 0 0197 in Oil ring 0 20 0 70 mm 0 0079 0 0276 in Measuring point 10 0 mm 0 39 in Checking the piston ring groove 1 Measure the piston ring grooves Replace if out of specification Piston ring groove Top ring 8 1 21 1 23 mm 0 0476 0 0484 in Second ring 1 51 1 53 mm 0 0594 0 0602 in Oil ring 2 52 2 54 mm 0 0992 0 1000 in 55 Checking the piston ring side clearance 1 Measure the piston ring side clearance Replace the piston and piston ring set if out of specification Piston ring side clearance Top ring 8 0 02 0 06 mm 0 0008 0 0024 in Second ring 0 02 0 06 mm 0 0008 0 0024 in Oil ring 0 04 0 18 mm 0 0016 0 0071 in Checking the piston pin boss inside diameter 1 Measure the piston pin bo
82. lubricant and the lubrication points Application 4 stroke motor oil Lubricant _ Symbols in an exploded diagram or illustration indicate the type of sealant or thread locking agent and the application points Application Gasket Maker Sealant ThreeBond 1104J Sealant ThreeBond 1322 Sealant ThreeBond 1377B Thread locking agent ThreeBond 1401 Thread locking agent LOCTITE 271 red Thread locking agent LOCTITE 242 blue Thread locking agent General information Symbo Applicaton LOCTITE 572 white Sealant Silicone sealant Sealant Special service tool For all markets except U S A and Canada Special tools with parts number 90890 are distributed by the Parts Division Drilling plate Diagnostic flash indicator B 90890 06783 90890 06865 EG SSS SS YDIS CD ROM Ver 1 32 Digital circuit tester 60V WS853 05 90890 03174 YDIS KIT Peak voltage adapter B 60V 85300 05 90890 03172 YDIS connecting harness Test harness 8 pins 90890 06882 90890 06879 0 7 Sealant and locking agent Special service tool Leakage tester Ignition tester Spark gap tester 90890 06840 90890 06754 Test harness 3 pins Test harness 2 pins 90890 06869 90890 06861 Vacuum pressure pump gauge set Test harness 2 pins 90890 06756 90890 06867 Test harness 3 pins Fuel pressure gauge adapter 90890 06870 90890 06842 Test harness 2 pins Fuel pressure gauge 90890 0688
83. not touch the starter motor pinion TIP e Check the starter motor operation for a few seconds e If the starter motor is disassembled for maintenance make sure to check the oper ation again after assembling it 3 Disconnect the negative and the positive battery cables from the battery terminals Checking the magnet switch 1 Connect the tester probes to the magnet switch terminals 8 and 2 Connect the negative battery cable to the starter motor body 5 35 3 Connect the positive battery cable to the starter motor Brown Br lead and then check the magnet switch continuity NOTICE Do not connect the starter motor Brown Br lead to the battery for more than 1 second 4 Check that there is continuity between the magnet switch terminals and Replace the magnet switch if out of specification Vag Se Magnet switch Battery lead e DA NE Connect Disconnect f TIP The starter motor pinion should be pushed out while the magnet switch is ON Checking the starter motor pinion WARNING Make sure to disconnect the battery cables before checking the starter motor pinion 1 Check the pinion teeth Replace the pin ion if cracked or worn 2 Check for smooth operation Turn the pinion counterclockwise to check that it operates smoothly and turn it clockwise to check that it locks in place Starter motor Disassembling the starter motor 5 Remove the armature
84. o lt len Intake air flow Exhaust gas flow 2 18 Technical features and description PTT unit Outline The PTT unit consists of the motor unit the gear pump unit the valve unit and the cylinder unit The main valve OU which is a component of the valve unit consists of the up valve a the down valve P and the shuttle piston C The motor driven gear pump 2 changes its rotating directions to move the main valve D and control the PTT fluid flow directions The relief valves and the protection valves 6 and 6 are installed at both the upstream and downstream fluid passages to control the fluid pressure The manual valve opens and closes both passages to enable manual operation of the tilt function The piston absorbers and 9 are incorporated into the cylinder unit piston to absorb crash impacts and prevent damage to the PTT unit in case the outboard motor collides with objects while operating d Upstream passage Downstream passage f Reservoir 2 19 PTT unit Tilt up operation When the PTT switch is pressed to UP fluid pressure created by the gear pump flows into the up side of the shuttle piston C and pushes the up valve 8 allovving it to open At this point the fluid pressure forces the shuttle piston to slide to the down valve The protrusion of the shuttle pis ton opens the down valve which opens the return circuit Then the PTT fluid flows into the
85. plate and the collar Hydro tilt model PTT model 8 Remove the cotter pin 5 the throttle friction adjuster 6 and the bolts 47 GEN 99 S 3 Ya le IS d xi kd 12 Remove the retainers the spring and the bushing 88 D 13 Remove the friction piece and the 9 Pull out the control link assembly 3 and throttle shaft then move it upwards Assembling the tiller handle 1 Pass the throttle shaft D through the fric tion piece 2 and the tiller handle 2 Install the bushing the retainers and the spring 9 9 Tiller handle 3 Install the collar the washers 8 the plate and a new cotter pin 0 TIP o Run the neutral switch lead under the control link assembly 4 See Tiller handle tiller handle model 5 10 6 Install the nut 45 the throttle friction adjuster and a new cotter pin 7 4 Install the neutral switch 4D the throttle arm 2 and the bushing 03 7 Set the plate to the direction shown install the bushing 48 and the throttle grip 9 and then tighten the throttle grip screw 0 to the specified torque 8 Install the cap Q and the shift lever hydro tilt model 5 Align the marks and and the cut Install the PTT switch 3 and the shift aways and and then install the lever and then tighten the PTT switch control link assembly screw to the specified
86. relay 1 Disconnect the main relay coupler 2 Measure the input voltage between the terminals and the ground 9 15 Main relay input voltage Red R Ground Red R Ground 12 0 V battery voltage 3 Turn the engine start switch to ON and then check the wiring harness for continuity Wiring harness continuity Terminal 1 Ground 4 Turn the engine start switch to OFF 5 Remove the main relay and then connect the test harness 8 pins 6 Connect the positive battery lead to the terminal b and the negative battery lead to the terminal and then check for continuity between the terminals and Replace the relay if out of specification NOTICE Do not reverse the battery leads Checking the electrical component Engine control units and Components 7 Connect the positive battery lead to the terminal and the negative battery lead to the terminal and then check for continuity between the terminals h and Replace the relay if out of specification NOTICE Do not reverse the battery leads Terminal Battery lead Terminal N A Connect o Disconnect 8 Disconnect the test harness 9 Install the main relay and then connect the main relay coupler 8 Checking the engine ECM circuit 1 Disconnect the engine ECM couplers 8 and UE gm OL 2 Check for continuity between the engine ECM coupler terminals and the
87. the clamp bracket OD STBD with a plastic tie 2 SKI L Sal Au a EF ih 12 i IF Do SE If EN 7 6 Fasten the PTT motor lead 40 and the speedometer hose 3 with a plastic tie 7 Install the corrugated tube 5 and then fasten it with the plastic ties 6 9 46 BRKT Bracket unit PTT motor Part name PTT motor assembly Stator Screw PTT motor lead Armature Screw Brush Brush Circuit breaker Bolt Spring Brush holder PTT motor base Oil seal O ring Spring Shaft connector M4 x 14 mm CON OOF M Not reusable Not reusable A ld Mi P ND ND 9 47 PTT motor 7 N m 0 7 kgf m 5 2 ft lb 7 N m 0 7 kgf m 5 2 ft lb 1 Not reusable Reservoir cap O ring H xX U E D C gt O D E Cc A 18 19 9 48 BRKT Bracket unit Removing the PTT motor A WARNING Make sure that the tilt ram is fully extended before removing the PTT motor Otherwise fluid can spurt out from the unit due to internal pressure 1 Fully extend the tilt ram and then open the manual valve by turning it clock wise 2 Remove the PTT motor base bolts Gi and then remove the PTT motor 3 Remove the brushes 4 the circuit assembly 8 the O ring the spring breaker the brush holder the and the shaft connector springs 7 and the PTT motor lead 8 4 Remove the oil seal O 9 OS
88. the valve clearance See Check ing the valve clearance 7 2 Checking the water pump 1 Check the water pump housing and impeller See Checking the water pump 8 5 10 14 Index Numerics 6Y8 Multifunction Meter sensor 5 40 A Abbreviation 0 5 Adjusting the float height 6 34 Adjusting the forward gear shim thickness TN pare 8 34 Adjusting the pulser coil air gap 7 2 Adjusting the reverse gear shim thickness KEE 8 37 Adjusting the shift cable 10 13 Adjusting the throttle link rod 6 23 Adjusting the throttle link rod and throttle cable 10 14 Adjusting the trim sensor cam remote control Medel With PTT T 9 41 Adjusting the valve clearance 7 4 After TORT UN tas 10 8 Assemble the fuel filter assembly 6 11 Assembling the cylinder Dlock 7 60 Assembling the cylinder head 7 42 Assembling the drive shaltt 8 17 Assembling the electrical components MANUNEUON E 9 14 Assembling the forward gear 8 16 Assembling the friction plate 9 3 Assembling the fuel pump assembly 6 15 Assembling the gear pump housing 9 56 Assembling the lower case 8 15 Assembling the oil pan an
89. to the drive shaft spline and hold the special service tool 5 Tighten the pinion nut to the specified torque Drive shaft holder 3 90890 06517 Pinion nut 74 N m 7 4 kgf m 54 6 ft lb 6 Place the pinion facing upward and hold it in the upright position 7 Rotate the drive shaft 10 turns or more to seat the taper roller bearing 8 Tighten the pinion height gauge bolts in 4 stages to the specified torque so that the distance between the upper part and the lower part of the special service tools 1 become equal Pinion height gauge bolt 1st 1 N m 0 1 kgf m 0 7 ft lb 2nd 2 N m 0 2 kgf m 1 5 ft lb 3rd 3 N m 0 3 kgf m 2 2 ft lb 4th 4 N m 0 4 kgf m 3 0 ft lb 9 Check again the gap between the pinion and the special service tool OU LAN MP OOOO If there is no gap the shim s T3 may not have been removed Shimming 10 Measure the gap between the pinion 2 and the special service tool When measuring the gap insert the end of the thickness gauge straight into the gap at the measurement point Do not insert the thickness gauge at an angle X TIP e Measure the gap at the 4 points OD O h and k e Note down the measurement data in the shimming check sheet 11 Determine the gap average value and then truncate the number by dropping the figures after the 1 100 place without rounding Example Measurement point M
90. 0 06326 Valve seat cutter 45 90890 06312 Valve seat cutter 60 90890 06323 Exhaust Valve seat cutter 30 90890 06328 Valve seat cutter 45 90890 06325 Valve seat cutter 60 90890 06315 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 NOTICE Do not overcut the valve seat Make sure to turn the cutter evenly downward at a pressure of 40 50 N 4 0 5 0 kgf 8 8 11 0 Ibf to prevent chatter marks IA 25 SCI F SN a Slag or rough surface 3 Use a 30 cutter to adjust the contact width of the valve seat top edge b Previous contact width 4 Use a 60 cutter to adjust the contact width of the valve seat bottom edge b Previous contact width 5 Use a 45 cutter to adjust the contact width of the valve seat to specification Gel 45 b Previous contact width C Specified contact width 6 Check the valve seat contact area of the valve See Checking the valve seat 7 38 Example Camshaft and valve 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 valve seat top edge and then use a 60 cutter to cut the bottom edge to center the area and set its width b Previous contact width If the valve seat contact area is too narrow and situated near the top edge of the valve face use a 302 cutter to cut the valve seat
91. 0 58 058 0 60 060 0 62 062 065 065 0 65 055 058 058 0 58 0 60 060 062 0 62 0 65 065 065 0 68 058 058 0 58 0 60 060 062 062 0 65 065 065 0 68 068 for 0 42 0 45 0 45 0 45 0 48 0 48 050 0 50 0 48 050 052 0 48 052 052 055 0 55 055 058 058 0 58 0 60 0 50 052 055 055 0 55 058 058 0 58 0 60 0 60 055 055 055 0 58 058 058 060 0 60 0 6 055 055 058 0 58 058 080 060 0 62 062 055 058 058 0 58 0 60 0 60 062 0 62 068 0 58 0 58 0 58 0 60 0 60 0 62 062 0 65 065 0 60 0 60 0 62 062 0 65 0 65 065 0 60 0 62 062 065 0 65 0 65 0 68 062 0 0 58 0 58 0 58 0 58 0 58 0 58 060 0 60 0 6 0 62 0 50 0 60 062 082 6 0 65 NO 0 62 0 65 0 65 0 65 0 65 0 62 0 65 0 62 0 65 0 65 0 68 0 65 0 68 0 65 0 68 0 68 0 70 0 68 0 70 0 68 0 72 0 68 0 68 0 70 0 70 0 72 0 72 0 65 0 68 O N Value stamped on the lower case P 8 32 Lower unit 0 55 0 55 058 0 58 0 58 0 60 0 60 062 062 0 65 0 65 0 65 0 55 0 58 0 58 0 58 0 60 0 60 0 62 062 065 065 0 65 068 058 0 58 0 58 0 60 060 0 62 0 62 065 065 0 65 068 0 68 P M 058 0 60 060 0 62 0 62 065 065 0 65 0 68 0 68 068 0 60 062 062 065 0 65
92. 0 6 215 4 a Maximum output KW HP 29 2 40 at 5500 r min Full throttle operating range r min 5000 6000 L US gal 13 6 3 6 3 0 at 5500 r min Imp gal hr Engine idle speed r min 750 850 Maximum fuel consumption Power unit Type 4 stroke SOHC L Cylinder quantity 3 Total displacement cm cu in 747 0 45 6 Bore x stroke mm in 65 0 x 75 0 2 56 x 2 95 Compression ratio 9 40 1 Control system Starting system Electric Fuel system Fuel injection Ignition control system CDI built in to the engine ECM Advance type Microcomputer Maximum generator output 12 0 17 0 Spark plug DPRGEB 9 NGK Firing order 1 23 Cooling system Water 1 3 Item Exhaust system Lubrication system Model data Model Lower unit Gear shift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction rear view Propeller mark Bracket unit Trim angle at 122 boat transom Tilt up angle Steering angle Trim and tilt system Fuel type Fuel minimum rating Engine oil Engine oil grade 1 SAE Total engine oil quantity L US at Imp at L US at Imp at without oil filter replacement with oil filter replacement Gear oil type API SAE L US at Imp at Gear oil grade 2 Gear oil quantity Propeller boss Wet sump 2 00 26 13 Spiral bevel gear Dog clutch Spline Clockwise Regular unleaded gasoline 91 4 stroke motor oil with c
93. 065 068 0 68 0 68 070 0 60 0 60 06 062 0 62 082 0 65 0 65 0 68 0 68 0 70 13 12 11 10 7 5 l 0 65 0 68 3 2 i 0 68 0 70 0 68 0 72 0 70 0 72 0 65 0 68 0 70 0 75 0 72 0 75 0 72 0 75 0 75 0 78 075 075 0 78 7 107 075 0 78 3 07 078 0 80 9 Tor 078 0 80 0 78 0 82 0 85 080 080 0 82 082 085 085 085 088 088 088 0 90 080 082 082 085 085 085 0 88 0 88 0 88 090 090 os 080 082 0 82 085 085 085 088 088 088 080 080 092 0 72 0 75 0 75 0 75 0 78 0 78 0 82 0 78 0 82 N P M 0 80 0 85 0 80 0 85 0 82 0 85 0382 0 88 0 85 0 88 0 85 0 88 0 85 088 088 0 88 0 90 088 088 090 0 90 0 92 088 090 090 0 92 0 92 0 90 082 092 0 95 088 088 090 0 95 088 0 0 32 0 O N 9 0 95 000 0 92 0 98 0 90 082 0 95 0 98 0 95 0 98 0 95 1 00 Value stamped on the lower case P 8 33 Measuring the forward gear backlash e Spray anti rust lubricant on the gear and bearings before installation Do not apply gear oil to the parts Otherwise correct measurements cannot be obtained e Keep the parts free from foreign materials such as dirt or lint e When measuring the forward or the reverse gear backlash use the original bearings and shims A WARNING e Use heat resistant gloves Otherwise burns could result e To avoid the risk of fire remo
94. 12 0 15 0 18 0 30 0 40 and 0 50 mm TIP e Use the lowest number of shims to achieve the required shim thickness If the calculated shim thickness cannot be obtained with a combination of the available shims increase or decrease the shim thick ness by 0 01 mm 5 Install the shim s 11 and the taper roller bearing outer race 8 35 Shimming SSSUXYDIU WIYS JO BUISL8199P Jo Bulsea ou fa 119 Juswesnseew ysepyoeg v eee E E pos ss foe oe fos e oz so o ss os e or se CI se oe sr fos ww Q0 L L VI oot 86 06 S8 08 GI OL S9 09 GG OG Sr OP SE OF Ge O0 GL OL G Up 0 Uc Ur S wu TR TT TT TT EG ES 9 SEAN ET EE TT CT CT SS 11ey9 U01399 J9S LL wys 1896 piemio EE Ds DE TE DE TE e O 00 O 8 36 Lower unit Measuring the reverse gear backlash e Spray anti rust lubricant on the gear and bearings before installation Do not apply gear oil to the parts Otherwise correct measurements cannot be obtained e Keep the parts free from foreign materials such as dirt or lint e When measuring the forward or the reverse gear backlash use the original bearing and shims 1 Install the ball bearing and the original shim s T2 onto the reverse gear and then install the reverse gear assembly into the propeller shaft housing See Assembling the propeller shaft housing assembly 8 8 step 3 step 5 TIP e If the original shim s are missing install new s
95. 161 Exhaust 5 460 5 475 0 2150 0 2156 Runout 0 01 0 0004 07 Specification Valve guide Inside diameter 5 500 5 512 0 2165 0 2170 Stem to guide clearance Intake 0 010 0 037 0 0004 0 0015 Exhaust 0 025 0 052 0 0010 0 0020 Position 16 3 16 7 0 64 0 66 ROCKET arm Hocker arm shaft Cam shaft Cam lobe height Intake 30 737 30 837 1 2101 1 2141 Exhaust 30 933 31 033 1 2178 1 2218 Cam lobe width 25 950 26 050 1 0217 1 0256 Runout 0 007 0 0003 Journal diameter 1 36 925 36 945 1 4537 1 4545 Journal diameter 2 3 36 935 36 955 1 4541 1 4549 Cylinder head journal inside 37 000 37 025 1 4567 1 4577 diameter Piston Diameter 64 950 64 965 2 5571 2 5577 Measuring point 5 0 0 20 Oversize diameter 1st 65 200 65 215 2 5669 2 5675 2nd 65 450 65 465 2 5768 2 5774 Piston clearance 0 035 0 065 0 0014 0 0026 Ring groove Top 1 21 1 23 0 0476 0 0484 Ring groove 2nd 1 51 1 53 0 0594 0 0602 Ring groove Oil i 2 52 2 54 0 0992 0 1000 Pin boss inside diameter 15 974 15 985 0 6289 0 6293 Pin outside diameter 15 965 15 970 0 6285 0 6287 Cylinder Bore mm in 65 000 65 015 2 5591 2 5596 Model on gt Nada S Piston ring End gap measuring point Top ring Type Dimension height B Dimension width T End gap 1 Side clearance 2nd ring Type Dimension height B Dimension width T End gap
96. 2 Turn the engine start switch to ON and TPS and the throttle valve opening angle then measure the oil pressure switch when the remote control lever is at the input voltage fully closed position and the fully open E position xe ZF 7 8 E Oil pressure switch input voltage Pink White P W Ground 12 0 V battery voltage 3 Turn the engine start switch to OFF 4 Remove the oil pressure switch 5 Connect the special service tool 2 to the oil pressure switch 5 18 sel ELEC i Electrical system 6 Apply positive pressure to the oil pressure switch slowly and then check that continuity changes to no continuity in the range of the working pressure Replace the oil pressure switch if the continuity does not change to no continuity in the working pressure range Leakage tester 2 90890 06840 Working pressure 29 4 58 8 kPa 0 294 0 588 kgf cm 4 3 8 5 psi 7 Disconnect the special service tool 2 8 Disconnect the engine ECM coupler wr LI EE l or ch Vire ee 9 Check the wiring harness for continuity P W O O O53 O VOS CC CCC 000000000068000000 Wiring harness continuity Pink White P W Terminal 28 10 Connect the engine ECM coupler 11 Install the oil pressure switch D and the oil pressure switch lead Gi See Installing the oil pressure switch 7 50 Checking the alert indicator tiller
97. 2 ft lb 37 N m 3 7 kgf m 27 3 ft lb e 32 N m 3 2 kgf m 23 6 ft lb Cap 4 N m 0 4 kgf m 3 0 ft Ib 8 N m 0 8 kgf m 5 9 ft lb Cap Friction piece Collar Friction plate Spring vvasher Bolt M6 x 12 mm Nut Steering lock washer Friction adjusting nut 9 2 BRKT Bracket unit Removing the friction plate 1 Remove the friction plate bolts and then remove the friction plate assembly 2 Turn the steering lock shaft until the thread side faces toward the surface C of the bracket 2 Disassembling the friction plate SS 1 Remove the friction plate nut and the S Fo friction adjusting nut and then remove the steering lock washer the friction pieces the collar the washers L the steering lock lever the collar 8 the bracket 9 the steering lock shaft D e Q and the bolt AD TIP Do not turn the steering lock shaft more than 90 3 Assemble the bolt the bracket assembly 4 the collar amp the steering lock lever the washers 7 the collar 8 the friction pieces and the steering lock washer 0 and then install the friction adjusting nut D and the friction plate nut 42 temporarily 4 Tighten the friction plate nut 2 to the specified torque Assembling the friction plate 1 Screw in the steering lock shaft D until its top surface comes level with the top surface of the nut 9 3 Friction plate nut 2 7 N m 0 7
98. 4 the exhaust manifold 45 and the rubber seal 6 and then tighten the exhaust manifold bolts D temporarily Exhaust manifold and oil pan 8 E le AO 572 6 Tighten the exhaust manifold bolts to the specified torque and then tighten the oil pan bolts 43 Exhaust manifold bolt 47 11 Nm 1 1 kgf m 8 1 ft lb 7 Install new gaskets 9 the plate 9 and the muffler and then tighten the bolts 8 Install the anode 9 34 BRKT Bracket unit Steering arm 20 N m 2 0 kgf m 14 8 ft lb 2 Bushing O ring Bushing Washer Steering arm Stud bolt Steering hook Washer Self locking nut Bolt Grommet Friction piece Bushing Steering yoke Circlip Not reusable Remote control model Remote control model Remote control model M6 x 22 mm 0 JO O1 Bb ND sch mn ld k ND WH ND N 9 35 Steering arm Removing the steering arm Installing the steering arm 1 Remove the circlip D and then remove 1 Install the friction piece D and the rubber the steering yoke 2 by striking it with a seal 2 and then tighten the friction piece EES hammer bolt 8 temporarily o ye 6 amp SH 2 Remove the bushing the O ring 8 2 Install the washer 4 the bushing a and the bushing new O ring and the bushing onto the steering arm and then install the 3 Remove the steering arm 6 the vvasher steering arm to the swivel bracket 9
99. 605 Bearing outer race attachment 90890 06622 L Bearing depth plate 90890 06603 gt Bearing outer race attachment 90890 06627 Bearing inner race attachment 90890 06644 Ball bearing attachment 90890 06634 H 0 12 a General information Shift rod push arm Dial gauge set 90890 06052 90890 01252 Bearing housing puller claw S Magnet base B 90890 06564 90890 06844 Ke D ei UY Center bolt Pinion height gauge 90890 06504 90890 06668 Backlash indicator Bushing installer center bolt 90890 06706 90890 06601 Magnet base plate Needle bearing attachment 90890 07003 90890 06613 0 13 Needle bearing attachment 90890 06617 Cylinder end screw wrench 90890 06568 Special service tool 0 14 Specification Model E 1 1 General feature ooonccconnccccncccccnnccnnnconnnnoncnnonnnnnnonnnoncnnnnnnnnnnnnnnns 1 1 WOCElCESIGNATION sa 1 2 SMN Se ns nr con ten 1 2 Model d ta Le 1 3 Dimension and Weight sss sese eee eee 1 3 P MOFMANC He 1 3 FO SET EE na ec ec a 1 3 Beie at dE 1 4 OL ELEN oros EEE 1 4 Fuel and oil requirement see eee ee eee eee eee eee 1 4 Battery T QUIT NL vasre 1 5 PT e EI E EE 1 5 Electrical technical data 1 5 Ignition timing control system ess eee eee ee eee 1 5 Fuel injection control system e eee eee ee ee eee 1 6 Engine speed control system eee eee eee eee 1 6 PLUSS EN Var 1 7 EEN TT 1 7 SE
100. 7 the bushing 8 the O ring O and the bushing 0 3 Install the bushing 40 a new O ring AD and the bushing 42 4 Remove the rubber seal OD and the friction piece 2 el op E RA 9 36 BRKT Bracket unit 4 Install the steering yoke 43 making sure that it is facing the same direction as the steering arm 8 aligning with Friction piece bolt 3 9 N m 0 39 kgf m 2 88 ft lb 9 Apply grease into the grease nipple until it comes out from both the upper and lower bushings 9 5 Hold the steering arm 8 and then strike the steering yoke with a copper hammer until the groove for installing the circlip is visible o Install the circlip 49 SH Install the steering arm stud bolts 5 and then tighten them to the specified torque Steering arm stud bolt 45 20 N m 2 0 kgf m 14 8 ft lb 8 Tighten the friction piece bolt to the specified torque 9 37 Steering arm Clamp bracket and swivel bracket Clamp bracket and swivel bracket 22 N m 2 2 kgf m 16 2 ft lb Part name Remarks M6 x 14 mm Remote control model with PTT Remote control model with PTT Bolt Holder Pin Stopper shaft Stopper knob self locking nut Bolt Bushing Clamp bracket STBD Bushing Stopper Bolt Anode Ground lead Bolt Grease nipple Ground lead M10 x 50 mm CON OOF WD M6 x 25 mm PTT model M6 x 14 mm PTT model Remote control model Hydro tilt model
101. 7 90890 06786 0 8 mn f General information Compression gauge Valve spring compressor attachment 90890 03160 90890 06320 v0 L e Flywheel holder Valve guide remover installer 5 4 90890 06522 90890 06801 Flywheel puller Valve guide reamer 5 5 90890 06521 90890 06804 Crankshaft holder 16 Valve lapper 90890 06355 90890 04101 Valve spring compressor Valve seat cutter holder 5 5 90890 04019 90890 06316 0 9 Special service tool Valve seat cutter 30 Valve seat cutter 60 90890 06326 90890 06315 Q Valve seat cutter 45 Driver rod LS 90890 06312 90890 06606 Valve seat cutter 60 Bearing outer race attachment 90890 06323 90890 06626 D L Valve seat cutter 30 Oil filter wrench 64 90890 06328 90890 01426 Q Valve seat cutter 45 Piston slider 70 90890 06325 90890 06529 O 0 10 mn General information Bearing separator Needle bearing attachment 90890 06534 90890 06614 Stopper guide plate Needle bearing attachment 90890 06501 90890 06653 Stopper guide stand Bearing inner race attachment 90890 06538 90890 06639 Bearing puller assembly Needle bearing attachment 90890 06535 90890 06608 Driver rod L3 Drive shaft holder 3 90890 06652 90890 06517 0 11 Pinion nut holder 90890 06715 Special service tool Driver rod SL 90890 06602 Bearing inner race attachment 90890 06641 Needle bearing attachment 90890 06612 Driver rod LL 90890 06
102. 9 and then tighten the gear pump bolts to the specified torque Gear pump bolt 4 N m 0 4 kgf m 3 0 ft lb 9 57 11 Install new O rings QD the filter 63 the springs 4 the absorber valve pins the balls new O rings 62 and the gear pump housing 43 and then tighten the gear pump housing bolts to the specified torque Gear pump housing bolt 89 9 N m 0 9 kgf m 6 6 ft lb PTT gear pump PTT cylinder HIT cylinder lt f LO om Je PUDO SN om m ye Voy om oo 61 N m 6 1 kgf m 45 0 ft lb 90 N m 9 0 kgf m 66 4 ft lb 9 58 uN X Be O E D oc ojoje o Kol Bel Ke le fw Rv Mi Q DN ul BI NH ua Reel fem On MO Ko D FES EUR Sa A EEN sj ogolo O 21212 Zz gt SV Ir Se UN UN re O Part name Tilt ram assembly gt O D del Y O Z O o oa D D U LL Dust seal Backup ring Cylinder BRKT Bracket unit Disassembling the PTT cylinder Loosen the cylinder end screw 8 and then remove the tilt ram assembly 1 Cylinder end screw wrench 2 90890 06568 2 3 Drain the PTT fluid Cover the PTT cylinder opening with a rag 8 and then blow compressed air through the hole b to remove the free piston 4 WARNING Never look into the PTT cylinder opening while removing the free piston because the free piston and PTT fluid could be forcefully expelled out 4 Remove the tilt piston
103. 9 38 BRKT Bracket unit 22 N m 2 2 kgf m 16 2 ft lb Part name Remarks M6 x 15 mm Remote control model with PTT Remote control model with PTT M6 x 24 mm Remote control model with PTT Remote control model with PTT Screw Trim sensor Screw Trim sensor cam Swivel bracket Through tube Bolt Clamp bracket PORT Ground lead M8 x 20 mm i l l i sch N PTT model 9 39 Removing the clamp bracket 1 Remove the trim sensor remote con trol model with PTT 2 Remove the ground lead 2 hydro tilt model Remove the ground leads Q and PTT model 3 Remove the self locking nut 4 Remove the clamp the bracket STBD the swivel bracket and the trim sensor cam remote control model with PTT and then remove the bolt and the through tube D IE 6 Remote control model with PTT PTT model Hydro tilt model 5 Remove the pin OD the stopper knob 2 the stopper shaft 43 and the bushing s 6 Remove the anode 5 Clamp bracket and swivel bracket Checking the clamp bracket anode 1 Check the anode Clean if there is grease oil or scales NOTICE Do not oil grease or paint the anode Installing the clamp bracket 1 Install the anode Q and then tighten the anode bolt 2 2 Install the bushing the stopper shaft 4 the stopper knob 6 and the pin 6 3 Install the trim sensor to the swivel bracket remote control model with PTT
104. AT SVEEN er 1 8 EE Tn aT ee 1 8 Fuel system technical data 1 9 FINSEN NE 1 9 Power unit technical data rnvrnnnvnnnnvnnnvrnnvrnnnvnnnvnnnnvnnnnvnnnenn 1 10 POWER UN gas 1 10 Cylinder head as le EE 1 10 Grankcase ASS MDIV EE 1 11 Lower unit technical data rnnnnnnnrnnnvrnnnvrnnnvnnnvnnnvvnnnvnnnnvnnnne 1 12 Lower unt ASSEMD persere 1 12 Bracket unit technical data sees 1 13 ES SO ret 1 13 Special tightening torque rrrnvrnnnvnnnnvnnnnvnnnnvnnnnvnnnnvnnnnnnnnnnen 1 13 Sele SVEN eee 1 13 EUT TOTI iorn 1 13 POWer EE EES 1 14 KONE HS 1 15 Tiller handle model rrannnnnonnnnnnanennnnnnannnnnnnnnnnnnanennnnenanennnnen 1 15 Bracket LIMIT EE ee antes aliades aen tata ds 1 15 FI 1 16 Optional ef Wel CT EE 1 16 General tightening torque rnnrrrrnvvnrnnnvennnnnvnnnnnvennnnnvrnsnnnenennn 1 17 EO Specification Model features General feature Overall features e Electronic fuel injected 4 stroke L3 SOHC 6 valve 747 0 cm 45 6 cu in engine e Low emission in compliance with EU regulations e 6Y8 Multifunction Meter option Power unit e Multipoint electronic fuel injection Single throttle body S SN e Long intake manifold e Blowby gas reburning system 1 VAR H Parana rl a e Fuel cooler MN e Closed fuel vapor gas system AY e One piece top cowling with water draining air intake duct e Speed sensor and water pressure sensor
105. Aruana 40 EFI SERVICE MANUAL SELVA Preface This manual has been prepared by Selva primarily for use by Selva dealers and their trained mechanics when performing maintenance procedures and repairs to equipment lt has been written to suit the needs of persons who have basic understanding of the mechanical and electrical concepts and procedures inherent in the work for without such knowledge attempted repairs or ser vice to the equipment could render it unsafe or unfit for use Because Selva has a policy of continuously improving its products models may differ in detail from the descriptions and illustrations given in this publication Use only the latest edition of this manual Authorized Selva dealers are notified periodically of modifications and significant changes in specifications and procedures and these are incorporated in successive editions of this manual Important information Particularly important information is distinguished in this manual by the following notations A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A WARNING A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury NOTICE A NOTICE indicates special precautions that must be taken to avoid damages to the out board motor or other property TIP A TIP provides key information to make procedures easier or clearer Contents General information App
106. Check the hydro tilt unit Replace if there is gas leakage oil leakage or damage or if the rod is bent WARNING Do not disassemble the hydro tilt 9 43 Hydro tilt PTT unit PTT unit Part name Remarks Shaft Bushing Bushing Plastic tie Bolt M8 x 15 mm Washer Shaft Bushing Bushing PTT unit Bolt M6 x 10 mm BRKT Bracket unit Removing the PTT unit A WARNING When removing the PTT unit with the power unit installed make sure to sus pend the outboard motor 1 Tilt the swivel bracket to the fully up posi tion and then support it with the tilt stop lever 1 2 Remove the plastic ties and then remove the corrugated tube 3 Remove the plastic ties 2 from the clamp bracket STBD 9 4 Remove the ground leads from the PTT unit 5 Remove the PTT unit bolt the lower mount shaft D and the bushings amp and O 6 Remove the E clips D the upper mount shaft D the PTT unit and the bushings 42 and 43 9 45 K e TA G L Mo d Installing the PTT unit 1 Install the bushings and 9 2 Install the PTT unit the upper mount shaft and the E clips 3 Install the lower mount shaft 8 and then tighten the PTT unit bolts Install the ground leads 0 PTT unit 5 Pass the PTT motor lead 0 through the hole in the clamp bracket STBD and then fasten the PTT motor lead 0 to
107. Checking the exhaust guide anode 9 33 Checking the filter 9 56 Checking the forward gear 8 14 Checking the fuel cup assembly 6 10 Checking the fuel filter 10 11 Checking the fuel filter assembly 6 9 Checking the fuel filter element 6 10 Checking the fuel miechor 5 21 Checking the fuel ont 6 9 Checking the fuel joint and fuel hoses fuel joint to fuel injector 10 11 Checking the fuel pump assembly 6 13 Checking the fuel rail 6 39 Checking the fuel system 10 5 Checking the gear oil level 10 5 10 12 Checking the gear Dump 9 56 Checking the gear pump housing 9 56 Checking the gear shift and throttle OD rAlON iniciats 10 5 Checking the high pressure fuel pump 6 33 Checking the high pressure fuel ai pa EEE 5 22 Checking the hydro tilt 9 43 Checking the hydro tilt anode 9 43 Checking the hydro tilt system 10 7 Checking the ignition coil 5 27 Checking the ignition spark 5 26 Checking the intake manifold 6 19 Checking the ISC see 5 18 Checking the lighting coil stator assembly 5 24 Checking the lower CaSe
108. Checking the fuel filter element A 6 10 Checking the fuel cup assembly see eee ee eee eee 6 10 Assemble the fuel filter assembly eee eee ee eee 6 11 Installing the fuel filter assembly 6 11 Fuel DUMP EE le E 6 12 Removing the fuel pump assembly 6 13 Checking the fuel pump assembly 6 13 Disassembling the fuel pump assembly 6 13 Checking the diaphragm and valve sse 6 14 Assembling the fuel pump assembly 6 15 Installing the fuel pump assembly 6 15 Checking the primer PUMP sss sees eee eee eee 6 16 RA cere reece searere 6 17 Removing the throttle body sss sese eee eee eee 6 18 Checking the intake manifold sese eee eee eee 6 19 Checking the throttle body sss sese eee 6 19 Installing the throttle body 6 19 deet CR IMKTOOA ses 6 21 Removing the throttle link 6 22 Installing the throttle link 6 22 Adjusting the throttle link rod sse sees eee eee 6 23 Vapor separator nosnou nn 6 25 DANN NE UG Hare 6 26 Removing the fuel hose clamp esse ee ee eee e eee eee 6 26 Installing the fuel hose clamp see eee eee e ee ee eee ee eee 6 26 Removing the vapor separator ese ee ee ee ee ee eee 6 26 Checking the vapor shut off Valve see eee eee eee 6 27 Installing the vapor separator eee eee e ee ee 6 27 Vapor separator disassembly rrnvrrnnnnvnnnnvvrnnnnvrnnnnnvnennn 6 29 Disassembling the vapor separator eee ee ee eee eee 6 32 Checking the fuel strainer esse eee eee e eee 6 33 Checking the high pressure fue
109. D M6 x 25 mm M6 x 20 mm M8 x 45 mm M8 x 45 mm M6 x 10 mm Remarks Starter motor 9 N m 0 9 kgf m 6 6 ft lb 4 N m 0 4 kgf m 3 0 ft lb Remarks 18 Spring washer 1 19 Nut 1 Power unit Removing the starter motor 1 Remove the starter motor 1 Starter motor lead nut 9 N m 0 9 kgf m 6 6 ft lb Starter motor lead bolt 8 2 Remove the terminal 2 and the starter motor lead 3 4 N m 0 4 kgf m 3 0 ft lb Starter motor bolt 6 30 N m 3 0 kgf m 22 1 ft lb I OA Q DA N Installing the starter motor 1 Install the starter motor lead and then tighten the starter motor lead nut 2 and the starter motor lead bolt 8 to the spec ified torque 2 Install the starter motor 4 and then tighten the starter motor bolt amp to the specified torque ht en C INZG LIA SH 0 qe 7 29 Starter motor Cylinder head Cylinder head 6 N m 0 6 kgf m 4 4 ft lb 12 N m 1 2 kgf m 8 9 ft lb 12 N m 1 2 kgf m 8 9 ft lb 2 23 N m 2 3 kgf m 17 0 ft lb OR S EA 12 gt 3 EL 13 DAT EN 207 y C S Q QC Km i 15 14 O G O 4 eu Remarks Dowel Not reusable Gasket Bolt M6 x 25 mm Bolt M9 x 93 mm Cylinder head assembly Gasket Oil pump assembly Bolt Gasket Screw Plate Grommet Bolt Oil filler cap O ring Cylinder head cover Not reusable 0 JO O1 Bb ND M6 x 45 mm
110. Disconnect the fuel injector couplers a Float position 3 Turn the engine start switch to ON and then measure the input voltage between the fuel injector coupler terminal and the ground 5 21 Fuel injector input voltage Red Yellow R Y Ground 12 0 V battery voltage 4 Turn the engine start switch to OFF 5 Measure the fuel injector resistance Fuel injector resistance reference data 12 0 Q at 20 C 68 F 6 Disconnect the engine ECM coupler b and the main relay coupler 0 Y AL NE 19 F ARCS Y 8 PRI YIM 7 Check the wiring harness for continuity Fuel control units and components es EO CO OO CO 000000066 Wiring harness continuity Fuel injector 1 Terminal 1 Terminal 7 Terminal 2 Terminal 52 Fuel injector 2 Terminal 1 Terminal 7 Terminal 2 Terminal 51 Fuel injector 3 Terminal 1 Terminal 7 Terminal 2 Terminal 50 8 Connect the engine ECM coupler b and the main relay coupler 9 Connect the fuel injector couplers 8 Checking the high pressure fuel pump 1 Check the operation of the high pressure fuel pump using the YDIS Stationary test and check the operating sound 2 Disconnect the high pressure fuel pump coupler 8 Ge Connect the tester probes to the high pressure fuel pump coupler terminals and then measure the input voltage within 3 seconds after turning the engine start switch to ON
111. EMPING Tn d e e 9 17 BOHOM COMING ME 9 18 Removing the flushing NOSE sse see eee ee ee ee ee eee eee 9 21 Installing the flushing NOSE A 9 21 Upper case and mounts rmeenennvvnnnnnnennnnnnennnnnennnnnnenennnnnnnnnnnr 9 22 Removing the upper case esse eee ee eee e eee 9 24 Installing the upper Case ese ee eee eee 9 24 DCS ner E 9 26 Disassembling the upper case sees eee ee eee 9 28 Checking the drive shaft bushing sss sees eee 9 28 Assembling the upper case cesse ee eee eee 9 28 Exhaust manifold and oil pan 9 30 Disassembling the oil pan and exhaust manifold 9 32 Checking the oil pan and exhaust manifold 9 33 Checking the oil strainer eee ee ee eee ee 9 33 Checking the exhaust guide anode sss sees 9 33 Assembling the oil pan and exhaust manifold 9 33 Steering AM vea 9 35 Removing the steering arm eee eee eee eee eee eee ee eee eee eee 9 36 Installing the Steering arm c e eee eee ee eee eee eee 9 36 Clamp bracket and swivel bracket cmoocoomo oom 9 38 Removing the clamp bracket VU 9 40 Checking the clamp bracket anode sese eee eee eee 9 40 Installing the clamp bracket esse eee eee eee eee eee 9 40 Adjusting the trim sensor cam remote control model with PIT a RE Aa 9 41 RY CAO CLR cee cst eee eee eco 9 42 Removing the hydro tilt assembly 9 43 Checking ne AY GO EE 9 43 Checking the
112. ER 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Reverse gear shim T 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Propeller shaft Drive shaft Runout mm in 5 0 0197 1 Figures obtained using the special service tools Bracket unit technical data PTT system Motor commutator Standard diameter Wear limit Motor brush Standard length Wear limit Special tightening torque Electrical system Part to be tightened Screw size EE i ft lb add Fuel system Part to be tightened Screw size Nm karn p Fuel cup assembly ll 5 05 37 Link rod logknut O 5 05 87 gt Vapor separator drain sorew 15 045 1 ene A 04 30 Lower unit technical data Bracket unit technical data Special tightening torque Power unit Part to be tightened nm LIC TI Lie Ce Pe E EE a 21 15 Aron agar OOS RENE PTT motor lead boit mM 4 04 30 Drive sprodket t 150 150 mos Fiywheel magnetnut IST 167 1158 YDIS coupler srew H Ps 22 Terminal bot M6 4 04 50 Main relay see 06 3 08 22 Starter relay sorew ee 8 03 22 Starter relay lead bolt me 4 04 30 PTT relay lead nul P 04 30 Shift cable locknut 5 os 8 Throttle cable ot 9 5 05 37 Starter motor lead mut 9 09 ee is 12 89 Mg 3rd ara wo o Ce os 44 12 12 89 Cylinder head bolt Cyinder head anode plug 18 18 185 aim
113. Le connectors 8 CODO Wl WM SUR LA TK ENS M Ier QUE PA 8 Install the fuse 1 Checking the trim sensor 1 Disconnect the trim sensor coupler and then remove the trim sensor 5 Remove the fuse 1 5 45 PTT electrical system 2 Measure the trim sensor resistance 7 Connect the gauge harness coupler a and the trim sensor coupler 8 3 Turn the trim sensor lever from the position to the position and then measure the resistance as it gradually changes Trim sensor resistance reference data 238 8 378 8 Q at 9 0 11 0 Q at setting resistance 4 Disconnect the alert indicator harness coupler L 5 Check the wiring harness for continuity O1 Wiring harness continuity a Terminal 1 Terminal 2 a Terminal 2 Ground 6 Install the trim sensor 5 46 Fuel system NOSE TOUNO W 6 1 St nie 6 1 Vap g s NOSE ve 6 2 Cooling water NOSE ses 6 3 1B a esco neeen eee nner ener nee enter a ieee stl rete cee 6 4 Reducing the fuel pressure sees eee eee eee 6 4 Disconnecting the quick connector ENEE 6 4 Measuring the fuel pressure sese ee ee eee eee eee 6 4 Checking the pressure regulator sse eee eee 6 5 F elfihter assembly inicia ss 6 7 Removing the fuel filter assembly 6 9 CHECKING NE VEL ONAL EE 6 9 Checking the fuel filter assembly eee eee ee eee ee ee 6 9 Disassembling the fuel filter assembly 6 10
114. Maintenance Checking the propeller 1 Check the propeller See Checking the propeller 8 3 Checking the PTT fluid level WARNING Never get under the outboard motor while it is tilted 1 Tilt the outboard motor to the fully up position and then support it with the tilt stop lever R 2 Remove the reservoir cap 2 and the O ring and then check the fluid level in the reservoir WARNING Make sure that the tilt ram is fully extended when removing the reservoir cap DE e Er NG x se 10 13 TIP If the fluid is at the correct level a small amount of fluid should overflow out of the filler hole when the reservoir cap is removed 3 If the fluid is below the correct level add the recommended fluid to bring it up to the correct level Recommended PTT fluid ATF Dexron II 4 Install a new O ring and the reservoir cap 2 and then tighten the reservoir cap 2 to the specified torque Reservoir cap 7 N m 0 7 kgf m 5 2 ft lb eae the PTT operation Tilt the outboard motor to the fully up and down positions a few times and check the entire tilt range for smooth operation Check the PTT fluid level if the tilt opera tion is not smooth TIP Make sure that the PTT motor makes a wind ing sound when it is operating smoothly N Tilt the outboard motor to the fully up position and then support it with the tilt stop lever to check that the lock mechanism of the tilt
115. Not reusable M4 x 10 mm M6 x 20 mm 2 gt NI CI bb D bh PO 7 30 Power unit Removing the cylinder head 4 Remove the cylinder head bolts 8 and 1 Remove the oil pump assembly 4 and then remove the cylinder head 6 NOTICE Do not scratch or damage the mating surfaces of the cylinder head and cylinder block Installing the cylinder head 1 Install a new gasket D the cylinder head 2 and the cylinder head bolts and EN xo 2 AR A FA SAN MO Ye ne 3 Loosen the cylinder head bolts 8 and 4 in the sequence numbers O 2 A SA 4 2 Tighten the cylinder head bolts Q and 4 to the specified torque in the sequence numbers 1 2 NOTICE Do not reuse the cylinder head gasket Always replace it with a new one av 7 31 gt PAS QLE DNS ER S R Cylinder head bolt 11 18 M9 1st 12 N m 1 2 kgf m 8 9 ft lb end 23 N m 2 3 kgf m 17 0 ft lb 3rd 90 Cylinder head bolt 4 9 M M6 1st 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 N m 1 2 kgf m 8 9 ft lb TIP s Tighten the M9 bolts 8 11 18 to the speci fied torque in 3 stages In the 3rd stage make a mark on the M9 bolts and the cylinder head and then tighten the M9 bolts 90 from the mark e After tightening the M9 bolts 8 11 88 has been completed tighten the M6 bolts amp o Oo the specified torque in 2 stages 3 Install the plate amp
116. ONOUNJ eW JOS USS due syeju g UONDUNJ EUI sPeyon Aoneg 6L 7 uon DUNJ BUI JOSUSS uonIsod 8J40JU L UOIJUNYJELU JOS U9S due Ion SL po ojanou ojqeoidde oN ue days fuiy2ou2 pue 9p09 9JqnoJL 4 6 O c O O Y 2 3 O Den pajoauuos Ajuedoud SI JSZIIQOUILI y Jey 399849 R1SOWISU SU Y90949 pejeedde jou seu GL 8P00 sajqnol ou JEU YOOYD SICA ou BUISN aA eA OSI 94 pue SdL JO uonIpuo9 Buluado out peu pasds sulbue unuwixeu Bululjoeq yeuwou sejeuedo aulbuy SYOBJO JO pjopuew exejui ay Y00490 poq 811044 eu pue pjojiueLu 9ye u ay JO SJ YSE out Y99049 Sp le 1d99X9 A pew Jou sajelado aulbuy pasds opt yBIH INO3 eulfus au pue y9lims jelneu sy usSamisq ynunuo9 Bulim JO peu Anu UO9 YOUMS jemneu OU Dou oGLJJOA indu YOUMs e1neu au a nsea n ont uonelado ys 1806 ou yooUD WD3 suibua ay pue yms ov uoloejep Jajem O usamisq 0673 ynunuo9 Bulim 10 M99y UNUNUO9 JO YOUMS OGS uonoejep JOJEM out YyooUuyd 02 S aBeyon indul yoyms sa dca M NO O Deum SI YOJMS LES 1 9 Jet NJ Ul JSJEM 10 peu QUIBUS USYM UO S9WOD J9ZZNQ Waly abed peuwou sajeado aulbuy p31 8 S 9UIBUS usym sdo s 197Znq 119 y W03 eulfus au pue poq 8 11014 ou usam jaq ununuoo BUHIM 10 M99y LA indu Apog 8 n014 eu INSLE N SICA ay Buisn ainssaid 11e ay Y29949 pasds op y6IH abneb NVI
117. SY EH Ga oi D y yA i O 272 OA 17 and the exhaust cover anode 4 JE CE NK 3 Loosen the exhaust cover bolts 6 in the sequence numbers 1 2 K L 2 D O 10 CUS ACS Q ls e bes CN 4 Remove the exhaust cover bolts 6 the thermostat cover the thermostat 7 and the exhaust cover 8 Exhaust cover a Removing the thermo sensor 1 Remove the thermo sensor 1 ae A Removing the oil pressure switch 1 Remove the oil pressure switch TL e Us e ed Removing the oil filter 1 Remove the oil filter 7 48 add E Power unit A HU ia eared 0 Oil filter wrench 2 90890 01426 2 Remove the oil filter union bolt 3 Checking the exhaust cover anode 1 Check the anodes Clean if there is grease oil or scales NOTICE Do not grease oil or paint the anodes Checking the thermostat 1 Suspend the thermostat in a container with water 2 Place a thermometer in the water and slowly heat the water 3 Measure the thermostat valve opening 8 at the specified water temperatures Replace if out of specification 7 49 CGS v eaeoe 58 62 C starts opening 136 144 F above 0 C 3 9 mm 0 12 in or above 158 F Installing the oil filter 1 Install the oil filter union bolt and then Oil filter union bolt 1 40 N m 4 0 kgf m 29 5 ft lb 2 Install the oil filt
118. U D QG E O O D acg XL CC o 20 Engine ECM Bolt Plate Clamp Plate grvoroorea 7 19 Wiring harness Bolt Grommet Collar Bracket Plastic tie Plastic tie Wiring harness Holder Fuse Fuse Cap Cap Plastic tie Holder Screw Bolt NO DD FH fH ag OC DD 05 Engine ECM Wiring harness Remarks M6 x 28 mm 20A 30A Yellow Green 7 20 Power unit Remarks 18 Grommet Clamp Clamp Clamp Bracket Bolt Hydro tilt model M6 x 16 mm Cap Bolt Cap Plate Starter relay Main relay Bolt Bolt Cap PTT relay M6 x 10 mm M6 x 20 mm M6 x 10 mm PTT model PTT model 7 21 Removing the wiring harness 1 Remove the clamps 2 and the ground lead 2 Disconnect the oil pressure switch connector and the thermo sensor coupler and then remove the Rectifier Regulator coupler from the bracket 1 I 2 3 Remove the wiring harness from the Nut clamp EEE sam Aa ik atlas A 6 L Rica I ND YO S ms o BG o S Y o VViring harness 5 Remove the ground leads O 6 Remove the caps hi and then remove the PTT relay leads PTT model 7 Disconnect the PTT relay coupler M and then remove the PTT relay PTT model 8 Remove the caps and then remove the starter relay leads 9 Disconnect the starter relay connectors P and then remove the plate 6 and the starter relay 6
119. Variable trolling speed control The Multifunction tiller handle model or the 6Y8 Multifunction Meter Tachometer allows the trolling speed to be adjusted within a certain range Control range 650 900 r min Revolutions per step The trolling speed can be adjusted when shifting to the trolling mode by turning on the switch on the tiller handle or operating the mode button 1 For details of the operation of the mode button see OWNER S MANUAL The engine ECM changes the target engine speed in accordance with the switch operation and then moves the ISC valve The variable trolling mode will be canceled when the engine speed exceeds the limit after opening the throttle Trolling mode canceled at 3000 r min Multifunction tiller handle model Throttle body ISC valve Engine Trolling switch Remote control model Throttle body Tachometer ISC valve Engine ECM 2 12 Technical features and description Power unit Outline This model has been developed to feature a compact power unit while maintaining the basic layout of the in line 3 cylinder and the SOHC Most components such as the cylinder block or the cylinder head have been newly designed to respond to the latest fuel injection control system The single valve throttle body D with various built in sen
120. akage tester 1 90890 06840 Specified positive pressure 170 0 kPa 1 70 kgf cm2 24 7 psi 6 16 ve Ki Fuel system Throttle body Part name Remarks Gasket Not reusable Intake manifold Gasket Bolt M8 x 40 mm Bolt M6 x 35 mm Throttle body Bolt M6 x 16 mm O ring Intake silencer Bolt M6 x 12 mm Plastic tie Cover 6 17 Removing the throttle body 1 Disconnect the 10 pin coupler 8 and then remove the cover OI RO O EG S ap DZ X NTA 2 Disconnect the throttle body coupler and the blowby hose 2 AOD LE n a ATA Lite 3 Remove the intake silencer and the O ring 4 qi 4 Disconnect the vapor gas hose 6 5 Remove the wiring harness clamps BD and from the intake manifold Throttle body 6 Disconnect the pressure regulator hose and then remove the drain hose from the intake manifold T Geen E i Wi Si L Da 7 Remove the throttle link rod from the throttle body side O Ss 8 Remove the intake manifold assembly and the gasket OD 6 18 R Fuel system 9 Remove the throttle body 42 and the 2 Install the throttle body 4 to the intake gasket 3 manifold 8 Checking the intake manifold 3 Install the intake manifold assembly 1 Check the intake manifold Replace if cracked or deformed Checking the throttle body 1 Check manually that the throttle valve operat
121. al system NERE LL Y ON VA gt Cd d gl M di OG O a OG co hr ger SN Bend the extension wiring harness 6 and Install the engine start switch 8 with the hole then connect the harness coupler This har of the switch facing upward ness bending position must be 10 0 mm 0 39 in or more away from the engine start switch coupler The bend radius should be 10 0 mm 0 39 in or more D Align the tape ends of the extension wiring harness 6 and the alert indicator harness with the end of the grommet O 5 11 Electrical component and wiring harness routing Circuit diagram Circuit diagram TIP The circled numbers in the illustration indicate the engine ECM terminal numbers o gt a Pulser coil Air pressure sensor Speed sensor Water pressure sensor 25 Thermo sensor ND 10 Air temperature sensor EMS 9 Oil pressure switch Engine shut off switch Fuel injection 1 UU 62 Fuel injection 2 UU GY Fuel injection 3 UU i Vapor shut off valve 00 Trolling switch UP Trolling switch DN Neutral switch Ignition coil 1 Water detection switch 43 ES 12 29 2 20 14 ES 45 46 44 86 Ge Ignition coil 2 Ground 42 als S nen E Main relay 41 Tie L r g Es E LAS 4 i AO A E Battery 48 High de coon 89 12 Engine start svvitch e D The same marks are connected to each other 5
122. and the engine ECM A 3 Check for wiring continuity between the A E engine ECM and ground Spark plug does not Pulser coil malfunction Measure the pulser coil output peak volt S spark all cylinders age Check the pulser coil airgap the Check the pulser coil airgap coll a air gap tion in pulser coil circuit pulser coil and the engine ECM age 4 9 Troubleshooting the power unit Refer to al Fuel not supplied all Check the fuel pressure cylinders Clogged filter Check the fuel filter for clog and dirt Fuel leakage Check the fuel line for leakage High pressure fuel pump mal Check the high pressure fuel pump oper 5 22 function ation using the YDIS Check the high pressure fuel pump 5 22 resistance Main relay malfunction Check the main relay Short open or loose connec Check the high pressure fuel pump input 5 22 tion in high pressure fuel pump voltage circuit Check for wiring continuity between the 5 22 high pressure fuel pump and the main A 3 relay high pressure fuel pump and ground A 3 Fuel pump malfunction Check the rocker arm Compression pressure Improper valve timing Check the timing belt is low Compression leakage Check the compression pressure Check the valve for bend or stuck Check the piston and piston ring for 7 52 damage Check the cylinder for damage Intake air passage malfunction Check the ISC valve for stuck Check the intake manifold and throttle 6 17 b
123. and throttle cable remote control MOL EE 3 14 Installing the wiring harness remote control model 3 16 Installing the 6Y8 Multifunction Meter harness remote control model sss sese 3 16 Installing the remote control box and tachometer remote control model sss sese eee 3 16 Optional equipment nr 3 16 Installing the water pressure sensor eee eee ee eee 3 16 Installing the speed Sensor eee eee ee eee ee eee 3 17 Installing the battery sss sss sees esse esse eee eee 3 19 System AA tastat emet esment 3 19 Outboard motor application sese ee eee eee eee 3 19 Rigging recommendations evrrrnnnnnvnnnnnnnnnnnnnnnnnnnennnnnnnnnnnn 3 21 Battery requirement ese ee ee eee ee ee eee 3 21 Propeller ole H 3 21 POPE SIZE e nn 3 21 A E E 3 21 N T Rigging information Outboard motor installation 44 WARNING e Overpowering a boat could cause severe instability Do not install an outboard motor with more horsepower than the maximum rating on the capacity plate of the boat If the boat does not have a capacity plate consult the boat manufacturer e Improper mounting of the outboard motor could result in hazardous conditions such as poor handling loss of control or fire hazards Consult your dealer or a trained per son experienced in proper rigging should mount the motor A WARNING Too much weight on the transom can change the boats center of gravity buoyancy operat ing balance or performance which could caus
124. arness Q at the position marked with white tape and then install the vapor gas hose 4 and the blowby hose 2 to the holder Fasten the throttle body leads to the blowby hose 2 with a plastic tie 5 4 sel ELEC i Electrical system Front view TA RK SG VAIER E gt Ss WEL Y S 1 Negative battery cable 2 Positive battery cable 3 PTT relay 4 PTT motor lead blue 6 PTT motor lead green 6 Main relay 7 Starter relay lead red Starter relay 9 Neutral switch Starter relay lead brown 5 5 ds J OD 10 pin coupler Install the negative battery cable 1 into the slots of the bracket After fastening the 10 pin coupler OD fold the end of plastic tie inward so that it does not come out The PTT motor leads 7 and 0 must be installed within 30 Electrical component and wiring harness routing Rear view Her nr Zp ie LES E la 1 Speed sensor option 2 Water detection switch 3 Fuel hose 4 Water detection switch lead Wind the water detection switch lead securing it with a clamp sel ELEC i Electrical system Top view 1 Vapor shut off valve 2 Spark plug 8 Thermo sensor 4 Pulser coil 6 Lighting coil stator assembly 6 Starter motor D Electrical component and wiring harness routing Bottom cowling tiller handle model 1 Neutral switch PTT motor lead PTT model
125. asket 9 and the high pressure fuel pump 0 5 Remove the fuel hoses OD and 2 ve py Fuel system 9 Remove the pin in the direction of the arrow 8 10 Remove the float 2 the needle valve and the plates and amp Checking the fuel strainer 1 Connect the special service tool D to the fuel inlet a 2 Cover the fuel outlet with a rubber plug 2 and then apply the specified positive pressure Replace the fuel strainer if the specified pressure cannot be maintained for at least 15 seconds Leakage tester 1 90890 06840 12 Remove the filter holder 22 the nipple 88 Specified positive pressure and the O ring 9 200 0 kPa 2 00 kgf cm2 29 0 psi Checking the high pressure fuel pump 1 Check the high pressure fuel pump elec trical performance See Checking the high pressure fuel pump 5 22 Checking the vapor separator 1 Check the needle valve Replace the needle valve assembly if bent or worn 6 33 Vapor separator disassembly Float height reference data 30 7 mm 1 21 in TIP e When adjusting the float height do not bend the lever e Bend both portions of equally when bending of the float 2 Check the float Replace if there is Assembling the vapor separator deterioration 1 Install the plates and and then tighten the float chamber plate screws 8 3 Check the filter Clean if there is dirt or to the specified torque residues Ad
126. assembly 1 Check the fuel cup assembly Clean with straight gasoline if there are foreign sub stances or replace if cracked NOTICE When cleaning the fuel cup assembly make sure not to remove the clip and float Check the water detection switch See Checking the water detection switch 5 20 6 10 ve py Fuel system Assemble the fuel filter assembly 1 Install the fuel element a new o ring 2 and the fuel cup assembly and then tighten the fuel cup assembly 8 to the specified torque Fuel cup assembly 8 5 Nm 0 5 kgf m 3 7 ft lb 2 Install the clamp a 115 125 mm 4 53 4 92 in 6 20 30 mm 0 79 1 18 in Installing the fuel filter assembly 1 Pass the fuel hose 1 through the bottom cowling 2 2 Install the hose D to the fuel joint with a clip 4 and then install the fuel joint L L 6 11 3 Install the fuel hose D to the clamps 6 and 4 Install the fuel filter assembly 8 ap LE E 5 Install the fuel hoses and with the clips AD 6 Install the clamp 4D and then connect the water detection switch coupler 8 Fuel filter assembly Fuel pump assembly Fuel pump assembly 3 N m 0 3 kgf m 2 2 ft lb Part name Remarks Fuel pump assembly Screw Washer Cover Diaphragm Fuel pump body 2 Diaphragm Pin Spring Fuel pump body 1 Nut Spring Plunger O ring Bolt M5 x 43 mm Not reusable
127. ator 6 90890 06706 11 Install the handle stopper 7 in the upper end 8 position of the tape 6 on the drive shaft and then tighten the nuts to the specified torque Handle stopper 7 EU0 23814 30 Nut shimming 2 N m 0 2 kgf m 1 5 ft lb 12 Install the special service tools 8 O and 40 and then put another special service tool D on the handle stopper 7 to apply a load EL Magnet base plate 8 90890 07003 Dial gauge set 9 90890 01252 Magnet base B 0 90890 06844 Pinion height gauge 90890 06668 13 Slowly turn the drive shaft clockwise and counterclockwise and then measure the backlash at the position where it stops in each direction TIP 22 Do not turn the drive shaft with excessive force Otherwise the forward gear will rotate leading to incorrect measurements Shimming 14 Turn the drive shaft 1802 clockwise and measure the backlash again TIP e Measure the backlash at 4 points and turning the drive shaft 180 clockwise after each measurement Note down the measurement data in the shim ming check sheet e When turning the drive shaft hold it with a little force A knocking sound may be heard when the drive shaft is rotated but this is the sound of the pinion contacting the reverse gear and does not affect the back lash measurement 15 Determine the backlash average value and then truncate the number by dropping
128. ce the fuel pump body 2 2 if deformed or worn 3 Remove the pin by pressing the plunger and the diaphragm ts 4 Remove the diaphragm the spring 8 the plunger and the spring O 6 14 vel py Fuel system Assembling the fuel pump assembly Before assembling the fuel pump assembly clean the parts and soak the valves and the diaphragm in gasoline to obtain prompt oper ation of the fuel pump assembly 1 Install the springs and the plunger 3 and the diaphragm 2 Align the hole in the plunger 8 with the hole in the diaphragm by pushing the plunger and the diaphragm 3 Install the pin 4 Turn the plunger 8 so that both the diaphragm tab and the groove face toward the same direction 6 15 5 Install the fuel pump body 2 a new diaphragm 7 and the cover 8 and then tighten the fuel pump screws to the specified torque Fuel pump screw 9 3 N m 0 3 kgf m 2 2 ft lb Installing the fuel pump assembly 1 Install the fuel pump assembly 2 Connect the fuel hose 2 with the clip Fuel pump assembly Checking the primer pump 1 Connect the special service tool D to the primer pump inlet hose 2 Cover the fuel outlet with a rubber plug 3 Apply the specified positive pressure to check that the pressure is maintained for at least 30 seconds Replace the primer pump if it does not maintain the pressure Le
129. ck the steering friction for proper adjustment See Installing the tiller han dle 3 11 step 16 and step 17 2 Check that the steering operates smoothly 3 Check that there is no interference with wires or hoses when steering the outboard motor Checking the throttle cable and shift cable 1 Set the shift lever to the N position and fully close the throttle grip tiller handle model Set the remote control lever to the N position and fully close the throttle lever remote control model 2 Check that the protrusion of the throttle control lever is aligned with the protrusion on the shift bracket 10 6 Maintenance 3 Check that the pin O is aligned with the alignment mark on the shift bracket a e gt EP VE Checking the hydro tilt system 1 Check that the outboard motor tilts up and down smoothly when the tilt lock lever 1 is in the release position 8 E Ud SS 2 Check that the outboard motor does not tilt up or down when the tilt lock lever 1 is in the lock position 3 Tilt the outboard motor to the fully up position and then support it with the tilt stop lever to check that the lock mechanism of the tilt stop lever works g i TIP Check that there is no interference with wires or hoses when the outboard motor is tilted Up Test run 1 Start the engine and then check that the gear shift operates smoothly 2 Check the engine idle sp
130. clockwise to align the protrusion of the flywheel mag net with the pulser coil protrusion 2 Measure the pulser coil air gap Adjust if out of specification es CS LS I E LA ELA ls D A ER GR A ANA Pulser coil air gap 8 0 35 1 35 mm 0 014 0 053 in Adjusting the pulser coil air gap 1 Loosen the pulser coil bolts D and adjust the pulser coil air gap ANG GET 2 Tighten the pulser coil bolts and then check the pulser coil air gap again Checking the valve clearance Measure the valve clearances when the engine is cold NOTICE Do not turn the flywheel magnet counter clockwise Otherwise the water pump impeller may be damaged 1 Remove the blowby hose the fuel hoses and the fuel filter assembly TP Use a rag to catch any spilled gasoline when removing the fuel components 2 Remove all the spark plug caps 4 from the spark plugs 3 Disconnect the ignition coil couplers a and then remove the ignition coils amp 4 Remove the clamps from the cylinder head cover 6 and then remove the cylinder head cover 6 Power unit check and adjustment Li 5 Turn the flywheel magnet clockwise and align the 1 mark on the driven sprocket 7 with the a mark on the cylinder head Power unit 6 Measure each valve clearance and following the step step 12 Ee TENPE n DE L O Fa Drs L m R N
131. code and checking step 4 6 e Engine monitor Each sensor status and the engine ECM data are displayed while the engine start switch is at ON This enables you to find the malfunctioning parts quickly In addition the data displayed using the Engine monitor function can be displayed in a graph Engine speed TPS voltage ntake temperature Intake pressure 1 Throttle valve opening Gg pe Atmospheric pressure ISC valve opening Shift position switch 73 Ignition timing Fuel injection duration Oil press switch Battery voltage Water temperature PA 1 Intake air pressure 3 Neutral switch 2 Engine shut off switch e Stationary test Operation tests can be performed vvith the engine off Ignite ignition coils 1 3 Operate injector 41 3 Operate ISC valve Operate electric fuel pump o yo e Active test The tests can be carried out while the engine is running and the shift is in the N position It is not possible to carry out the test while the boat is running Fully open ISC valve Angle of ISC valve opening e Data logger Displays 13 minutes of recorded data for 2 or more of the items stored in the engine ECM In addi tion the operating time as compared to the engine speed and the total operating time are dis played This allows you to check the operating status of the engine You can also save the engine ECM record data on a file so that you can view and display the graph later Engine speed TPS vol
132. ct the vapor shut off valve coupler 8 and then remove the vapor gas hoses and the holder 4 Checking the vapor shut off valve 1 Check the vapor shut off valve exterior 4 Disconnect the high pressure fuel pump Replace if cracked coupler b and then remove the high pressure fuel pump coupler c 2 Check the vapor shut off valve electrical SS performance See Checking the vapor lol Re tr shut off valve 5 23 Installing the vapor separator 1 Install the vapor separator assembly 1 5 Disconnect the quick connector See Disconnecting the quick connector 6 4 6 Disconnect the cooling water hoses 4 and 6 6 27 Vapor separator 2 Install the high pressure fuel pump sa CI coupler 2 and then connect the fuel o Q Or it pump coupler Ne SE S 7 A UG ET E V DS RS A ENG EN ES AV lt tre I lt gt 3 CHL gt T De wale i on PNAN IS qu Z A ml WEG Vo 2 le ds D gt Connect the quick connector 8 and NN L then install the holder aligning it with the white tape of the wiring harness O 3 Connect the fuel cooling water hoses 2 and 8 GD ES 5 Connect the vapor shut off valve coupler and then install the vapor gas hoses 6 and the holder e py Fuel system Vapor separator disassembly 5 N m 0 5 kgf m 3 7 ft lb 1 5 N m 0 15 kgf m 1 11 ft lb Remarks Quick connector C
133. ction control system Water detection switch Input voltage 4 5 5 25 Float height 1 19 4 0 74 Fuel injector Input voltage Resistance 1 at 20 C 68 F High pressure fuel pump Input voltage Resistance 1 at 20 C 68 F Vapor shut off valve Input voltage 12 0 Resistance at 20 C 68 F 30 0 34 0 1 The figures are for reference only Engine speed control system Item Throttle body Input voltage V 4 75 5 25 TPS Output voltage 1 with throttle valve fully closed with throttle valve fully open Throttle valve opening angle WI with throttle valve fully closed with throttle valve fully open 1 6 ee ue Specification Oil pressure switch Input voltage 12 0 kPa kgf 29 4 58 8 0 294 0 588 4 3 8 5 Working pressure cm2 psi 1 The figures are for reference only PTT system Trim sensor Free position resistance 1 Setting resistance 1 The figures are for reference only Charging system Lighting coil Output peak voltage at cranking unloaded 14 0 at 1500 r min unloaded 45 0 at 3500 r min unloaded 102 0 Resistance 1 at 20 C 68 F 0 561 0 759 Rectifier Regulator Output peak voltage at 1500 r min unloaded at 3500 r min unloaded 1 The figures are for reference only 1 7 Electrical technical data Starting system Starter motor Type Sliding gear Output 0 90 Cranking time limit 30 Commutator Standard dia
134. d exhaust Mai 5 do 9 33 Assembling the oil seal housing 8 17 Assembling the propeller shaft assembly 8 8 Assembling the propeller shaft housing B A a 8 8 Assembling the PTT cylinder 9 60 Assembling the PTT motor 9 50 Assembling the shift rod 9 17 Assembling the starter motor 5 38 Assembling the tiller handle 9 9 Assembling the upper ca8e 9 28 Assembling the vapor separator 6 34 Battery requirement 1 5 3 21 Bleeding the PTT unit see eee 9 61 Bracket Unit an 1 4 1 15 Bracket unit technical data 1 12 Breakin DEE 10 7 C Camshaft and valve 7 33 Changing the engine 0il 10 9 Changing the gear oil 10 11 Charging system 1 7 Charging unit and starting unit A 5 Charging units and components 5 24 Checking by use of YDIS 5 14 Checking by using the digital tester 5 15 Checking the air pressure sensor 5 28 Checking the air temperature sensor 5 28 Checking the alert buzzer 5 20 Checking the alert indicator tiller handle Model aaa ds 5 19 Checking the anode 10 8 Checking the battery 10 3 10 8 Checking the brush
135. d torque Throttle link rod E Z NO D D UM 3 FOIX L o N CO a ao Si X 5 1 Cc O Oa OE D Z OW X E J 6 24 ve py Fuel system Vapor separator Remarks Holder Holder Vapor shut off valve Nut Bolt Bracket Grommet Bracket Bolt Cover Fuse puller Holder Hose Bolt Grommet Collar M6 x 16 mm M6 x 20 mm M6 x 30 mm wW U UO k k do do k k k k MD 6 25 Draining the fuel 1 Drain the remaining gasoline in the vapor separator into a drain pan Loosen the drain screw 1 and then remove the cap 2 Push in the air valve with a screw driver 2 Tighten the drain screw to the specified torque and then install the cap Q Vapor separator drain screw 1 1 5 Nem 0 15 kgf m 1 11 ft lb Removing the fuel hose clamp 1 Reduce the fuel pressure See Reducing the fuel pressure 6 4 2 Remove the fuel hose clamp by cutting the crimped section of the clamp NOTICE If the fuel hose camp is removed without cutting the crimp first the fuel hose could be damaged Vapor separator 78 A gt SED E Installing the fuel hose clamp WARNING Do not reuse the fuel hose clamp Always replace it with a new one 1 Crimp the fuel hose clamp properly to securely fasten the fuel hose and the quick connector Removing the vapor separator 1 Remove the blowby hose 6 26 ve py Fuel system 2 Disconne
136. dations The maintenance cycle on these charts assume usage of 100 hours per year and regular flushing of the cooling water passages Maintenance frequency should be adjusted when operating the engine under adverse conditions such as extended trolling Disassembly or repairs may be necessary depending on the outcome of maintenance checks Expendable or consumable parts and lubricants will lose their effectiveness over time and through normal usage regardless of the warranty period When operating in salt water muddy turbid cloudy or acidic water the engine should be flushed with clean water after each use Maintenance interval chart Initial Every Ba Item Actions 20 hours 100 hours 300 hours 500hours to page 3 months 1 year 3 years 5 years Anode s external Check replace 9 43 Anode s cylinder head Check replace 7 42 Anode s E BA 49 exhaust cover exhaust 9 33 guide ge Battery Check charge replace electrolyte level terminal Cooling water leakage Check replace Cowing damp Engine starting condition Check noise Engneidespeedmose heck 1 q A oe E Engine start switch EA 4 engine shut off switch 10 1 Outline Initial Every L efer Item Actions 20 EL 100 A 300 hours 500 hours to page 3 months 1 year 3 years 5 years Fuel filter Check replace 6 10 can be disassembled Fuel hose high pressure Gheckreplace 0
137. ded 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 TP e The amount of memory and the amount of free space on the hard disk differs depending on the computer e Using this software while there is not enough free space on the hard disk could cause errors and result in insufficient memory e This software will not run properly on some computers e When starting up this program do not start other software applications e Do not use the screen saver function or the energy saving feature when using this program e If the engine ECM is changed restart the program e Windows XP and Windows Vista are multiuser operating system therefore make sure to end this program if the login user is changed 4 1 YDIS Function e Diagnosis Displays each part name and the engine ECM trouble codes and status when the engine start switch is turned to ON This allows you to quickly specify the malfunctioning parts The trouble codes displayed are the same as those described in this chapter See Trouble code and checking step 4 6 e Diagnosis record Displays each part name and the engine ECM trouble codes that have been registered This allows you to check the outboard motor s record of malfunctions The trouble codes displayed are the same as those described in this chapter See Trouble
138. deformation 2 Check the impeller the insert cartridge and the outer plate cartridge Replace if cracked or worn 3 Check the Woodruff key and the keyway on the drive shaft Replace if deformed or worn 8 5 Water pump Propeller shaft housing Propeller shaft housing 8 dr Q gr E A Part name Shift plunger Slider Spring Cross pin Dog clutch Spring Propeller shaft Washer Reverse gear Shim T2 Ball bearing O ring O ring Propeller shaft housing Bolt Needle bearing Oil seal Remarks ck sesch sesch td sch sch wech sesch sesch Not reusable Not reusable Not reusable M8 x 25 mm Not reusable Not reusable M M en 8 6 Lower unit Removing the propeller shaft housing assembly 1 Remove the bolts and then remove the propeller shaft housing assembly 2 TIP Insert flat head screwdrivers between the propeller shaft housing assembly 2 and the lower case to pry the assembly loose Disassembling the propeller shaft assembly 1 Remove the shift plunger 2 Remove the spring Q and then remove the cross pin 8 and the dog clutch 8 3 Remove the slider and the spring Disassembling the propeller shaft housing assembly 1 Remove the reverse gear and the shim s T2 8 Bearing separator 3 90890 06534 Stopper guide plate 4 90890 06501 Stopper guide stand 6 90890 06538 Bearing puller assembly
139. der block and then install the crankcase bolts 4 and 6 1 59 7 Tighten the M8 bolts 1 18 to the specified torque in 2 stages and then tighten the M6 bolts 9 16 to the specified torque in 2 stages Crankcase bolt 4 1 18 M8 1st 15 N m 1 5 kgf m 11 1 ft lb end 30 N m 3 0 kgf m 22 1 ft lb Crankcase bolt 9 16 M6 1st 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 N m 1 2 kgf m 8 9 ft lb TIP Do not turn the crankshaft until the crankshaft journal oil clearance measurement has been completed 8 Remove the crankcase and_ then measure the width of the compressed Plastigauge PG 1 on each crankshaft journal Replace the crankshaft journal bearing if out of specification NO Crankshaft journal oil clearance 0 012 0 036 mm 0 0005 0 0014 in TIP When loosening the crankcase bolts loosen them in the opposite order used for tighten ing Selecting the crankshaft journal bearing 1 When replacing the crankshaft journal bearing select the suitable bearing as follows 2 Check the crankshaft journal mark 8 3 Check the cylinder block mark Cylinder block 4 Select the bearing color for the crankshaft journal bearing from the table Crankshaft journal bearing selection table at 20 C 68 F Cylinder block mark b Bearing color Crankshaft jour nal mark a Green Assembling the cylinder block 1 Assemble the pist
140. dicate lower unit problem 4 Remove the check screw 4 and the gasket amp to allow the oil to drain completely NOTICE Check the used oil after it has been drained If the oil is milky water is getting into the lower case and this may cause gear damage 10 11 TIP Remove all metal particles before installing the magnetic drain screw 5 Put the outboard motor in an upright position 6 Install the gear oil pump into the drain hole and slowly fill with gear oil until oil flows out of the check hole and no air bubbles are visible 7 Install a new gasket 6 and the check screw 4 O Recommended gear oil Hypoid gear oil API GL 4 SAE 90 Oil quantity 0 430 L 0 455 US at 0 378 Imp qt General Periodic Maintenance 8 Remove the gear oil pump and then install a new gasket and the drain screw 2 9 Tighten the check screw 4 and the drain screw 2 to the specified torque Check screw 4 9 N m 0 9 kgf m 6 6 ft lb Drain screw 9 N m 0 9 kgf m 6 6 ft lb Checking the gear oil level D SE 1 Check the gear oil level See Checking TAO LO the gear oil level 10 5 ET us Lubricating the outboard motor TG ZEA 1 Apply water resistant grease to the spec CL ified areas lt 3 VU Ng ZC ANS 2 Apply low temperature resistant grease to the specified area P 3 Apply corrosion resistant grease to the specified area 10 12
141. du mm Tampere SE EE EE E T HHH E Cos SS m SS CE SS ES OS SS ES IE ES F SS EE AR ES Reverse gear shim thickness 12 measurement in 2 A mm eeng SE EE EE EE T f E es f FE ss SS E CES PE SS ES SS ES I ES ES SS EE DS 8 24 Lower unit Measuring the forward and reverse gear backlash before disassembly 1 Install the lower unit onto a repair stand 2 Remove the water pump assembly See Removing the water pump 8 5 3 Set the gear shift to the N position o RY EON gt kl oS Shift rod push arm D 90890 06052 4 Install the special service tools and and then tighten the center bolt 4 temporarily e l E E Le Gr UCA El Y A Bearing housing puller claw S 2 90890 06564 Stopper guide plate 3 90890 06501 Center bolt 4 90890 06504 5 Turn the lower unit so that the propeller shaft is pointing downward 6 Turn the drive shaft 10 times or more to seat the taper roller bearing 7 Tighten the center bolt to the specified torque while holding the drive shaft to prevent it from turning 8 25 Center bolt 4 shimming 5 N m 0 5 kgf m 3 7 ft lb 8 Turn the lower unit upright 9 Install the special service tool 6 onto the drive shaft at the lowest possible position the point where the shaft diameter is 16 0 mm 0 63 in 10 Wrap 5 layers of tape 6 around the drive shaft Backlash indic
142. e before disconnecting the quick connector 1 Reduce the fuel pressure Hose routing Fuel line 2 Release the lock by pulling 2 and disconnect the quick connector by pressing both sides of 3 Disconnect the quick connector from the fuel rail TIP e Cover the quick connector with a rag to catch any spilled fuel when disconnecting it e Cover the quick connector and the fuel rail with a plastic bag to prevent damage and protect them from dirt Measuring the fuel pressure 1 Reduce the fuel pressure 2 Disconnect the quick connector 3 Connect the special service tool D between the quick connector and the fuel rail Fuel pressure gauge adapter 1 90890 06842 6 4 ve Fuel system 4 Connect the special service tool 2 WARNING Gently screw in the gauge until it is firmly connected to prevent fuel from leaking out Also make sure that the drain screw 3 is tightened securely before measuring the fuel pressure Fuel pressure gauge 2 90890 06786 5 Turn the engine start switch to ON and then measure the fuel pressure within 3 seconds Fuel pressure reference data 280 0 kPa 2 80 kgf cm2 40 6 psi TIP The fuel pressure decreases 3 seconds after the engine start switch is turned to ON 6 Start the engine and warm it up until the idle speed gets stable at 750 850 r min Measure the fuel pressure Check the vapor separator if below specificati
143. e ECM simultaneously trans mits injection signals to all the cylinders regardless of crankshaft angle In the fuel injection cut off mode fuel injection Is cut off synchronizing with the engine speed control mode of the ignition timing control See Ignition timing control 2 6 and Engine speed control 2 CO Engine speed control When the engine speed is approaching the upper limit or overheat or lovv oil pressure is detected the engine speed control system vvill stop the fuel injection and ignition to prevent damage to the engine When over revving Engine speed control starts vvhen engine speed exceeds the specified level When overheat The control starts when the engine cooling water temperature exceeds the specified level The injection and ignition to the cylinder 3 are stopped first If the engine speed does not drop to the target speed injection and ignition to the cylinders 3 and 2 will be also stopped Once the cooling water temperature drops to below the specified level and fully closed throttle is detected the engine speed control ends and automatically shifts to the normal operating mode Overheat is detected and control starts at 79 174 or higher Control is cancelled at 70 C 158 PF or lower Cylinders to stop injection and ignition 3 or 3 2 Max engine speed around 3000 r min Technical features and description When oil pressure is too low Engine speed control starts when the oil
144. e loss of control or swamping Consult the boat manufacturer for the maximum engine weight allowable on the transom which is differ ent from the overall boat capacity Overloading the transom with a motor that is too heavy could also damage the hull the transom the deck or the helm area as well as the motor and other equipment A WARNING Consult the manufacturer of engine jack plates or brackets before mounting Excessive loads could damage the plates or brackets the boat s transom steering system or the engine This could cause loss of control 3 1 Outboard motor installation Dimensions Dimensions Exterior Aruana 40 E B S mm in ADS JL eh P D CL gt ls lw LO Na N N Ft LO CO EE S 816 32 1 342 13 5 L 923 36 3 235 9 3 S Si X O Q S y GS 3 e E N lt t SE FE D I gt n BE i Se o E OG ET NJ S 0 0 O __ gt El L 29 1 1 522 20 6 1 Transom height 3 2 Exterior Aruana 40 E ST PT mm in Srl 796 97 261 134 5 3 345 13 ol 888880 65 2 6 EN tg S LU O GL 90 G 8L LZp LU L 9 22 969 1 Transom height 3 5 Dimensions Clamp bracket mm in 0 01 YSZ c e G GG 20 S 81 Jai e G o LO 00 N O LO G mn o LO O N LO N O r 00 Y 3 6 wh Rigging information Crate top
145. e oil pressure switch eee e ee ee eee 7 50 Installing the thermo Sensor cesse ee eee eee eee ee eee eee ee ee 7 50 Installing the exhaust COVED esse eee eee eee 7 50 Cylinder block EE 7 52 Disassembling the cylinder block 7 53 Checking the piston diameter sse eee eee 7 54 Checking the cylinder bore esse eee eee 7 54 Checking the piston ring eserse a 7 54 Checking the piston ring end gap ccccseeeeeeeeeeeeeeceeeeeeeaaeees 7 55 Checking the piston ring groove sss eee ee eee eee 7 55 Checking the piston ring side clearance sse eee eee eee 7 55 Checking the piston pin boss inside diameter 7 55 Checking the piston pin ccooocccnccconcnnccconnncononccnnononnnnconanennnnns 7 55 Checking the connecting rod small end and big end inside A NE Sed 7 56 Checking the connecting rod big end side clearance 7 56 Checking the crankshaft AAA 7 56 Checking the crankpin oil clearance ese eee eee ee eee e 7 57 Selecting the crankpin bearing see eee ee ee ee ee e eee 7 58 Checking the crankshaft journal oil clearance 7 58 selecting the crankshaft journal bearing 7 60 Assembling the cylinder block 7 60 Power unit Power unit check and adjustment Checking the compression pressure 1 Start the engine and warm it up for 5 min utes 2 Remove the clip from the engine shut off switch 3 Remove all the spark plug caps from the spark plu
146. easurement point O Measurement point h Measurement point k 0 018 Truncated average M 12 Determine the pinion shim thickness T3 in the Pinion shim T3 selection tables according to the truncated average M and the deviation P stamped on the lower case Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 8 30 Lower unit Example M 0 19 P 3 T3 0 60 mm from the pinion shim T3 selection table Pinion height measurement M sampa 2 lower case P TP The P mark is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the P mark is unreadable replace the lovver case 13 Remove the special service tools and then install the determined shim s T3 8 31 Shimming Pinion shim T3 selection table mm 0 05 006 007 008 008 o10 0 41 042 048 014 015 016 13 0 32 0 32 0 35 0 38 0 40 0 40 042 0 42 042 0 42 0 45 045 045 0 48 0 48 0 48 0 50 0 50 045 045 0 52 0 45 0 48 0 48 0 48 0 50 0 50 0 52 0 52 0 55 052 055 055 0 55 058 058 0 58 0 60 055 055 055 0 58 058 058 0 60 055 055 058 0 58 058 060 060 0 62 055 055 058 0 58 058 0 60 0 60 0 62 062 055 058 058 0 58 0 60 0 60 0 62 0 62 065 0 55 058 058 058 0 60 0 60 062 062 0 65 0 65 055 055 0 68
147. ed thor ough electrical system testing is required Replace damaged components 3 19 System diagram Outboard motor application 1 Install the water proof cap to the open termi nal 1 Remote control box 2 Switch panel 3 Extension wiring harness 4 Engine ECM 6 Pigtail bus wire 6 Single hub 7 Main bus wire 8ft power wire 9 Fuse 10A Tachometer unit OD Speedometer unit 2 Receiver 3 Power lead In line resister a Power port b Bus port C Device port Color code B Black G Green R Red Y Yellow wh Rigging information Rigging recommendations Battery requirement Select the stud of battery which is best suited to the terminal size Solder the connection of terminals and cables to prevent them from corroding Ambient temperature above 0 C 32 F Capacity CCA EN 430 0 Amps 20HR IEC 70 0 Ah Propeller selection The performance of a boat and outboard motor will be critically affected by the size and type of the propeller you choose Propel lers 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 to select the propeller that meets the operating conditions of the boat and the outboard motor Propeller size The size of the propeller is indicated
148. eed after the engine has been warmed up 3 Operate at trolling speed 4 Run the outboard motor according to the break in procedure 5 Check that the outboard motor does not tilt up when shifting into reverse and that water does not flow in over the transom 6 Check that the PTT operates smoothly while the outboard motor is running TIP The test run is part of the break in operation Break in Run the engine under load in gear with a propeller installed for 10 hours as follows 1 Forthe ist hour of operation a Run the engine at varying speeds up to 2000 r min or approximately half throttle 2 Forthe 2nd hour of operation Increase engine speed as much as necessary to put the boat on plane but avoid full throttle operation then back off on the throttle while keeping the boat at a planing speed 3 Remaining 8 hours Run the engine at any speed However avoid operating at full throttle for more than 5 minutes at a time 4 After the 1st 10 hours Operate the engine normally Gi PERS 0 1 2 10 Hour After test run 1 Check for water in the gear oil 2 Check for fuel leakage in the cowling 3 Flush the cooling water passage with fresh water NOTICE Do not perform this procedure on land while the engine is running Otherwise the water pump may be damaged and severe engine damage from overheat may take place TIP When using the flushing device flushing hose joint adapter
149. eee 7 18 ENGINE ECM vu 7 19 VING B Ts 7 20 Removing the Wiring harness eee eee ee ee ee ee ee ee eee 7 22 Installing the wiring harness esse eee eee ee ee ee dada 7 24 Starner e e E 7 27 Removing the starter MOtor esse eee eee ee eee 7 29 Installing the starter Motor ese ee ee eee ee 7 29 CVIINGGr Head in eu 7 30 Removing the cylinder head sss eee eee eee 7 31 Installing the cylinder head sese eee eee eee 7 31 Camshaft nd valve mecenes 7 33 Disassembling the cylinder head sse sees eee 7 35 Checking the cylinder head sse 7 36 Checking the valve Spring esse eee ee eee eee 7 36 CGMECKING NE EE 7 37 Checking the valve guide sse see 7 37 Replacing the valve guide sss sees 7 38 Checking the valve Seat oonccccoccnccoconnnocononoconcnnononononononononenoss 7 38 Refacing the valve seat sees e eee ee eee 7 39 Checking the rocker arm and rocker arm shaft 7 41 CHECKING th er ue T 7 41 Checking the Spark DUO EE 7 42 Checking the cylinder head anode sss sese sees 7 42 Assembling the cylinder head esse esse eee eee eee 7 42 EXNAUST COVER passed 7 46 Removing the exhaust cover sse eee eee eee eee 7 48 Removing the thermo Sensor eee eee ee eee ee ee eee eee ee ee 7 48 Removing the oil pressure switch eee eee ee eee 7 48 Removing the oil filter sees eee eee eee eee 7 48 Checking the exhaust cover anode see eee eee 7 49 Checking the thermostat esse ee eee eee eee eee 7 49 Jaez Taieb NE OE d 7 49 Installing th
150. een G Blue L 6 Reverse the PTT motor lead connections between the battery terminals to fully extend the tilt ram PTT motor Battery lead terminal p Bet Green O TIP e Repeat the step 5 and step 6 to fully extend and retract the tilt ram 4 or 5 times e If the tilt ram does not move up and down easily push and pull on the ram to assist the operation 9 62 BRKT Bracket unit 7 Fully extend the tilt ram 8 Remove the reservoir cap and then check the fluid level in the reservoir WARNING Make sure that the tilt ram is fully extended when removing the reservoir cap Otherwise fluid can spurt out from the unit due to internal pressure TP If the fluid is below the correct level add fluid to the correct level and then repeat the step 4 step 8 until the fluid remains at the correct level 9 Install the reservoir cap and then tighten the reservoir cap to the specified torque Reservoir cap 7 N m 0 7 kgf m 5 2 ft lb 9 63 Maintenance S R T vr 10 1 Maintenance interval Chart sse eee eee 10 1 PredeliVer Ei el 10 3 Checking the battery 10 3 Checking the cooling water pilot hole 10 3 Checking the engine oil level eee eee eee 10 4 Checking the engine start switch and engine shut off switch 10 4 Checking the fuel system 10 5 Checking the gear oil level eee eee 10 5 Checking the gear shift and throttle operation
151. eew ysepyoeg v pos ss ov s0 for se or fso fue SCI CIS CIC CI CI CIE ww 001 1 F 00L G6 06 S8 08 SZ OL S9 09 GG OG Gp Ov SE OF Ge De GL OL 9 Le 1 1 I I LL la dd SS TL oro D DDR TT S A CAS E T TT TT NN TITT wu FT Ee FETT T oro TT FT T ogo FT dd FI tl bi bib be yey U01399 J9S ZL wys 1896 9519194 O mM 00 Shimming SSSUXYDIU WIYS JO Buisee198p Jo Bulseaou 4 219 juawealnseau ysepyoeg v a paa ww 001 1 VI 00 S6 06L c8L 08L GAL 021 S9 09L SSL OS Syl OpL GEL OEL Gal OcL GLL OLI SOL OO TITT EE EE Cha TITTTTTIT ITU TTT ONE AN nina a A CC TTT CECILE eee III a MTT re TT ae TT ed I sri i iT FT TITT TT TT TT RNA nina a OB ww 8 40 Bracket unit Sterno CUOR siria 9 1 Removing the friction plate esse eee eee 9 3 Disassembling the friction plate sese eee ee 9 3 Assembling the friction plate sese eee ee 9 3 Installing the friction plate assembly 9 4 Filer in A he aaea 9 5 Disassembling the tiller handle sse sees 9 8 Assembling the tiller handle css sees 9 9 Electrical components multifunction 00000nnn0000000200 9 13 Disassembling the electrical components multifunction 9 14 Assembling the electrical components multifunction 9 14 Shift rod and shift bracket rrrnvrrnnnvrnnnnvnnnnvrnnnnvrnnnnvnnnnnvnnnnn 9 16 Disassembling the shift rod css eee eee 9 17 ASS
152. el 703 remote control model Checking the fuel system 1 Check that the fuel hoses are securely connected To check the fuel hose con nections see Fuel hose 6 1 NOTICE This is a 4 stroke engine Never use premixed fuel or 2 stroke outboard motor oil Checking the gear oil level 1 Put the outboard motor in an upright position 10 5 2 Remove the check screw D and then check the gear oil level in the lower case TIP za If the oil is at the correct level a small amount of oil should overflow out of the check hole when the gear oil check screw is removed 3 Install a new gasket 2 and the check screw D and then tighten the check screw 1 to the specified torque Check screw 1 9 N m 0 9 kgf m 6 6 ft lb Checking the gear shift and throttle operation WARNING Do not overtighten the friction adjuster If there is too much resistance it could be difficult to move the remote control lever or the throttle grip which could result in an accident 1 Check that the gear shift operates smoothly when the shift lever is shifted from the N to the F or R position tiller handle model Check that the gear shift operates smoothly when the remote control lever is shifted from the N to the F or R position remote control model TIP The shift lever can be operated only when the throttle grip is in the fully closed position tiller handle model 2 Check that the throttle operates smoothly wh
153. emperature sensor The air temperature sensor Is a component of the throttle body which cannot be disas sembled 1 Measure the ambient temperature 2 Connect the YDIS to display Intake tem perature air temperature 3 Check that the difference between the ambient temperature and the displayed intake temperature is within 5 C 9 F TP e Check the air temperature sensor when the engine is cold e When checking the air temperature sensor remove the top cowling and do not start the engine Checking the air pressure sensor The air pressure sensor is a component of the throttle body which cannot be disassem bled 1 Connect the YDIS to display Intake pres sure 2 Start the engine and warm it up and then measure the intake air pressure 5 28 sel ELEC i Electrical system Checking the thermo sensor 1 Disconnect the thermo sensor coupler a 2 Turn the engine start switch to ON and then measure the input voltage at the thermo sensor coupler 9 Check the wiring harness for continuity Thermo sensor input voltage Black Yellow B Y Black B 4 75 5 25 V 3 Turn the engine start switch to OFF Wiring harness continuity 4 Remove the thermo sensor Terminal 1 Terminal 26 Terminal 2 Terminal 10 5 Place the thermo sensor in a container of water and heat the water slowly 10 Connect the engine ECM coupler 11 Connect the thermo sensor co
154. en the throttle grip is turned from the fully closed position to the fully open position tiller handle model Check that the throttle operates smoothly when the remote control lever is shifted from the F or R position to the fully open positions remote control model Checking the outboard motor mounting height 1 Check that the anti cavitation plate is aligned with the bottom of the boat Q If the mounting height is too high cavita tion will occur and propulsion will be reduced Besides 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 and performance TIP The optimum mounting height depends on 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 PTT system 1 Check that the outboard motor tilts up and down smoothly when operating the PTT unit 2 Check that there is no abnormal noise produced when the outboard motor is tilted up or down Predelivery check 3 Check that there is no interference with wires or hoses when steering the tilted up outboard motor 4 Check that the trim meter points down when the outboard motor is tilted all the way down remote control model Checking the steering system 1 Che
155. endix b T General information ASafety while working EE 0 1 RO SA An e oe A ERRIRE ER 0 1 eend lt la a a ius 0 1 o na 0 1 FO E 0 1 Handling of gasoline sese eee eee ee 0 1 Ve 0 1 TROR rs 0 2 WOKING it er 0 2 Handling of burner sss sese eee eee 0 2 Part lubricant and Sealant e 0 2 Handling of sealant sese eee 0 2 PENNEN H 0 3 FAEN TE re 0 3 Non reusable ef 0 3 Disassembly and assembly 0 3 How to use this manual ses 0 4 Manta TONTO resa EAEE EE 0 4 POOLE E el EE mn 0 5 Sealant and locking agent rnnnnrnnnnvnnnnvennnnvnnnnnennnnnennnnvennnnnen 0 6 SK 1911 010 a a mia 0 6 Special service too rrrnnnnvennnnnnvnnnnnnnvnnnnnnnvnnennnvenesnnnnenesnnnnese 0 7 mn f General information A Safety while working To prevent an accident or injury and to ensure quality service follow the safety pro cedures provided below Rotating part e Hands feet hair jewelry clothing Personal flotation device straps and so on can become entangled with internal rotating parts of the engine resulting in serious injury or death e Keep the top cowling in place whenever possible Do not remove or replace the cowling with the engine running e Only operate the engine with the cowling removed according to the specific instruc tions in the manual Keep hands feet hair jewelry clothing Personal flotation device straps and so on away from any exposed moving parts Hot part During and after operation
156. engine parts are hot enough to cause burns Avoid touching any parts under the top cowling until the engine has cooled Electric shock Do not touch any electrical parts while start ing or operating the engine They can cause shock or electrocution Propeller Do not hold the propeller with your hands when loosening or tightening it 0 1 Handling of gasoline e Gasoline is highly flammable Keep gaso line and all flammable products away from heat sparks and open flames e Gasoline is poisonous and can cause injury or death Handle gasoline with care Never siphon gasoline by mouth If you happen to swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor immediately If gasoline spills on your skin wash with soap and water If gasoline spills on your cloth ing change your clothes Ventilation e 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 e When test running an engine indoors example in a water tank make sure to do so where adequate ventilation can be main tained Self protection e Protect your eyes by wearing safety glasses or safety goggles during all opera tions involving drilling and grinding or when using an air compressor e Protect your hands and feet by wearing pro tective gloves and safety shoes when nec es
157. er and then tighten it to the specified torque Oil filter wrench 8 90890 01426 Oil filter 18 N m 1 8 kgf m 13 3 ft lb Installing the oil pressure switch 1 Install the oil pressure switch to the specified torque 2 Install the oil pressure switch lead D and then tighten the oil pressure switch bolt S to the specified torque EG all Oil pressure switch 8 9 N m 0 9 kgf m 6 6 ft lb Oil pressure switch bolt 2 N m 0 2 kgf m 1 5 ft lb Installing the thermo sensor 1 Install a new gasket and the thermo sensor 2 and then tighten the thermo sensor 2 to the specified torque 2 Install the thermo sensor coupler 8 to the bracket 3 and the thermo sensor lead to the clamp 4 Exhaust cover SC pg 2 pr 2 Tighten the exhaust cover bolts 7 to the specified torque in the sequence in 2 stages numbers 1 2 8 O g Je O 1 N R O Exhaust cover bolt 7 1st 6 Nem 0 6 kgf m 4 4 ft lb 2nd 12 N m 1 2 kgf m 8 9 ft lb Thermo sensor 23 N m 2 3 kgf m 17 0 ft lb Installing the exhaust cover 1 Install a new gasket the exhaust cover 2 a new gasket the thermostat 4 a new gasket the thermostat cover 6 and the exhaust cover bolts 3 Install a new O ring amp and the exhaust cover anode to the exhaust cover anode plug and then tighten the exhaust cover anode screw OD to the
158. er union bo o 40 25 amer 1 18 155 Dee 5 08 66 OI pressure switch ba w 2 og 15 Thermo sensor a 23 vo CO PE w Exhaust cover anode screw w 2 og ms Exhaustooveranodepuig 18 18 155 Die a IPIE T EE Re e os 44 97 17 125 SPEC Specification Tightening torques RENE 2nd ER 11 1 Crankcase bolt Lower unit pe sd torques dite ae Les Tim WE gemenge or nana AA ME Propeller shat tous ba CSC ns Pop as 35 m Geisen a og 66 Drain sneg gt o 66 Tiller handle model Part to be tightened Screw size wen Be er Tilerhandent 37 37 273 Fiction plate nut 7 07 52 LI wees Frictionadjustingnt 4 04 30 Throttlegrpseew m 2 02 15 Grease mipple 8 08 22 Tiller handle bracketnut 2 32 236 Engine start switoh nut 5 05 87 Engine shut off switoh nut 25 025 184 Alert indicator screw 2 02 15 7 Bracket unit HE torques Part to be tightened Wm Wm SCH Shift rod detent bolt a sl C Pl Flushing hose adapter screw 5 08 37 Upper mounting nut a 24 7 Vi ES Reeg at ss Special tightening torque Part to be tightened Screw size AG orgues Engine oil drain bol TH Exhaust manifold bol Steering arm stud bolt 20 20 148 node pa m6 8 08 59 Stein 2 22 162 Grease nipple
159. es properly 2 Check the throttle body electrical performance See Checking the throttle body 5 17 Installing the throttle body 1 Install new gaskets and 2 onto the intake manifold Q Make sure that each tab on the gaskets Is properly and firmly fitted into the each groove on the intake manifold 6 19 Throttle body 4 Connect the pressure regulator hose 6 ms O and then install the drain hose to the DRO intake manifold LES EE D SH 9 Install a new O ring and the silencer 2 ESO GEN ANS BE 7 dd Er 07 awe VA 6 Connect the vapor gas hose III LA 10 Install the cover 3 and then connect the 10 pin coupler 9 Hr 7 Connect the throttle link rod of the throttle body side 8 Connect the throttle body coupler C and the blowby hose 0 ve py Fuel system Throttle link rod Part name Remarks Throttle link rod Bolt Collar Wave washer Throttle cam Bolt Cotter pin Throttle cam roller Throttle control lever Spring Collar M6 x 45 mm M6 x 35 mm Not reusable r 2 3 4 5 6 7 8 9 k sesch td td zech wech bh wesch O 6 21 Removing the throttle link 1 Remove the clip D and the throttle cable 2 Remove the link rod 3 Remove the throttle cam assembly 4 a GN VARO G NEE ORES Q NN NS 2 4 Remove the bolt 6 the collar 6 and the wave washer
160. first and tighten fasteners starting in the center and moving outward Non reusable part Always use new gaskets seals O rings cot ter pins and so on when installing or assem bling parts 0 3 Disassembly and assembly e Use compressed air to remove dust and dirt during disassembly e Apply engine oil to the contact surfaces of moving parts before assembly e Install bearings with the manufacture identi fication mark in the direction indicated in the installation procedure In addition be sure to lubricate the bearings liberally e Apply a thin coat of water resistant grease to the lip and periphery of an oil seal before installation e Check that moving parts operate normally after assembly A Safety while working How to use this manual How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under stand Use the information below as a guide for effective and quality service s Parts are shown and detailed in an exploded diagram and are listed in the component list see 1 in the figure below for an example page e The component list consists of part names and quantities as well as bolt and screw dimensions see 2 in the figure below e Symbols are used to indicate important aspects of a procedure such as the grade of lubricant and lubrication point see 8 in the figure below Tightening torque specifications are provided in
161. ft housing SEN s 8 7 Removing the PTT motor 9 49 Removing the PTT unit 9 45 Removing the starter motor 5 35 7 29 Removing the stator assembly 7 14 Removing the steering arm 9 36 Removing the thermo sensor 7 48 Removing the throttle body 6 18 Removing the throttle link 6 22 Removing the timing belt and sprocket 7 14 Removing the upper case 9 24 Removing the vapor separator 6 26 Removing the water pDump eee 8 5 Removing the wiring harness 7 22 Replacing the oil filter 10 10 Replacing the timing belt 10 14 Replacing the valve goude 7 38 Reverse gear shim T2 selection chart 8 39 Rigging grommet description 3 11 Rigging recommendations ooe 3 21 Rotating Dall SSS 0 1 Safety while working 0 1 sealant and locking agent 0 6 Selecting the crankpin bearing 7 58 Selecting the crankshaft journal bearing 7 60 selecting the pinion shim T3 8 29 A ance 3 21 Self protection 0 2 Se al UMD ur ns uen 1 2 SHIMANO ur 8 28 elle um le EE 8 22 8 28 Shimming check sheet 8 23 Shimming workflow
162. g when trouble codes are not available consists of the following 3 items Symptom 1 Specific trouble conditions Symptom 2 Trouble conditions of an area or individual part Cause The content considered as the trouble factors for symptom 2 Not applicable Symptom 1 Shift mechanism of forward gear and reverse gear does not operate properly Refer to Shift cable malfunction Adjust the shift cable Shift rod malfunction Check the shift rod for wear Check the detent mechanism Check the dog clutch 8 8 Check the forward gear reverse gear and the pinion for damage and wear 8 14 Adjust the shims Shift mechanism malfunction Check the shift rod cam for proper posi 8 11 in lower unit tion 4 13 Troubleshooting the power unit MEMO 4 14 Electrical system Electrical component and wiring harness routing 5 1 Sel GT 5 1 SENAT VIEW ee 5 3 ENN D 5 PTI A ns cle mettans 5 6 FEN Hp 5 7 Bottom cowling tiller handle model 5 8 Bottom cowling remote control model 5 9 Tiller handle tiller handle model esse 5 10 GIFCUI s Tt Tr T save 5 12 ECM coupler e E 5 13 Checking the electrical component rrrnnrrnnnvnnnnnvnnnnnvnnnnn 5 14 Checking by USE ST d BI 5 14 Measuring the peak voltage sse eee ee eee ee eee 5 14 Checking by using the digital tester e2 ee 5 15 Engine control
163. gear pump housing Lubricate the parts with ATF Dexron II during assembly NOTICE e Do not use a rag when assembling the PTT unit because dust and particles on the PTT unit can lead to poor perfor mance e DO not reuse the O rings replace them with new ones Always 1 Install a new O ring the valve seal the valve pin the spring 4 and the lock screw 6 to the relief valve 6 PTT gear pump TIP Saz Turn in the lock screw 6 the same number of turns as It was turned out when removed 2 Install a new O ring to the valve lock screw 8 3 Install the relief valve assembly 9 and 4 then tighten the valve lock screvv 8 to the specified torque 0 3 O o P Valve lock screw 8 6 N m 0 6 kgf m 4 4 ft lb Install new O rings 40 4D and 42 to the main valves 3 Install a new O ring to the shuttle piston 5 Install the shuttle piston 45 and then tighten the main valves D to the specified torque 9 56 BRKT Bracket unit Main valve 3 11 N m 1 1 kgf m 8 2 ft lb 7 Install new O rings and 4D to the manual valve 8 Install the manual valve seats 9 the adapter 0 the spring and the manual valve 8 and then install the circlip Manual valve 8 3 N m 0 3 kgf m 2 2 ft lb 9 Install new O rings amp the filters 4 the valve seal 5 the valve pin Op the spring OO and new O rings 8 10 Install the gear pump assembly
164. gs 4 Remove all the spark plugs and then install the special service tool 1 into a spark plug hole NOTICE Before removing the spark plugs blow compressed air into the spark plug well to clear out any dirt or dust that may fall into the cylinder i EE 7 CRIA a ES el N E T IGJEN ETG TZ DO SIS 5 Fully open the throttle 6 Crank the engine until the reading on the compression gauge stabilizes and then Check the compression pressure Minimum compression pressure reference data 840 0 kPa 8 40 kgf cm2 121 8 psi at 20 C 68 F Checking the oil pressure 1 Disconnect the oil pressure switch lead at the oil pressure switch end 2 Remove the oil pressure switch and then install an oil pressure gauge 1 to the oil pressure switch installation hole 7 1 3 Start the engine and warm it up until the idle speed gets stable at 750 850 r min 4 Check the oil pressure Oil pressure gauge 1 commercially available Oil pressure reference data at 60 C 140 F with SL 10W 30 engine oil and at 800 r min 230 0 kPa 2 30 kgf cm2 33 4 psi at 61 C 142 F with SL 10W 30 engine oil and at 3000 r min 480 0 kPa 4 80 kgf cm 69 6 psi TIP e Use a pressure gauge with an adapter that has a 1 8 pitch thread e The actual oil pressure may vary depending on the temperature and viscosity of the engine oil Checking the pulser coil air gap 1 Turn the flywheel magnet
165. he engine speed increases intake volume of fuel evaporation gas increases On the contrary the valve closes at engine start Tachometer output 6 pulses of digital and analog outputs per crankshaft revolution Alert buzzer output The buzzer comes on when overheat or low oil pressure is detected when the engine is cranked while the engine shut off switch is ON or when the gear is shifted to the N position with the engine start switch ON and the water detected in the fuel filter Alert indicator output The alert indicator will turn on when overheat is detected or oil pressure gets too low The check engine indicator will come on through the failure diagnosis control system when the 6Y8 Multifunction Meter is equipped Trouble diagnosis control The following information will be available by connecting to the YDIS current diagnosis code past diagnosis records current engine operation status past engine operation status actuator test and running hours Digital network control 6Y8 Multifunction Meter see Digital network system 2 11 Main relay control Turns the main relay on and off 2 3 Engine control system Sensor switch and actuator Pulser coil Detects the engine speed TT teste ansat angle ana the piston posters Neutral switch Detects the neutral position Engine shut off switch Activates the engine stop function compulsorily Fuel injector Gives the optimum amount of fuel at the optimum
166. he output voltage 00000600000000000 000000 060400000000 Wiring harness continuity Terminal 1 Terminal 7 Terminal 2 Terminal 26 Terminal 3 Terminal 25 8 Install the water pressure sensor and then connect the water pressure sensor coupler 8 See Installing the water pressure sensor 3 16 Pressure pump 0 commercially available 9 Connect the engine ECM coupler b Test harness 3 pins 2 90890 06869 Checking the speed sensor option 1 Disconnect the speed sensor coupler 8 5 41 8 6Y8 Multifunction Meter sensor PTT electrical system Speed sensor output voltage reference data Blue L Black B 2 5 V at 392 0 kPa 3 92 kgf cm 56 8 psi 4 5 V at 784 0 kPa 7 84 kgf cm 113 7 psi Turn the engine start switch to OFF and then disconnect the test harness 2 and the pressure pump Disconnect the engine ECM coupler 0000000 000000000 o0000000000000000 Wiring harness continuity Terminal 1 Terminal 7 Terminal 2 Terminal 26 Terminal 3 Terminal 8 Install the speed sensor and then con nect the speed sensor coupler a See Installing the speed sensor 3 17 Connect the engine ECM coupler PTT electrical system Checking the PTT relay 1 Measure the input voltage between the PTT relay terminal and the terminal as Le FL Loos SEN e E S sa T a H PTT relay input voltage Terminal
167. he reverse gear shim thickness T2 8 37 Reverse gear shim 12 selection chart ese ee ee ee eee 8 39 Lower unit Lower unit E o CO JO GQ E O M 8 1 Drain screw Gasket Bolt Check screw Dowel Hose nipple Plastic tie Hose Nipple Bolt Lower unit Anode Propeller nut Cotter pin Washer Washer Propeller Part name M dl dl FF nm ech k ND NN A P Mi Not reusable M10 x 40 mm Not reusable M8 x 35 mm Not reusable 35 N m 3 5 kgf m 25 8 ft lb 40 N m 4 0 kgf m 29 5 ft lb Remarks Lower unit 35 N m 3 5 kgf m 25 8 ft lb Part name i Remarks Spacer Trim tab Bolt M8 x 25 mm Bolt M8 x 60 mm 8 2 Lower unit Removing the lower unit A WARNING e Make sure to disconnect the battery cables from the battery and then remove the clip from the engine shut off switch e When removing the lower unit with the power unit installed make sure to sus pend the outboard motor If the outboard motor is not suspended it can fall sud denly and result in severe injuries e Do not hold the propeller with your hands when loosening or tightening it 1 Drain the gear oil 2 Remove the cotter pin 3 Set the gear shift to the N position and place a block of wood between the anti cavitation plate and the propeller to keep the propeller from turning and then remove the propeller nut and the propeller 4 Mark an alignment mark 8 o
168. he start up mode the engine ECM keeps injecting fuel simultaneously to all the cylinders at fixed timings until the engine starts D cion timing Simultaneous fuel injection at Cylinder 1 at BTDC 10 Until cylinder is identified EE NN Synchronous fuel injection at Each cylinder at BTDC 10 Until engine start is detected ER ET In the normal operating mode the injecting timing and volume are determined based on the signals from the pulser coil and the air pressure sensor This mode includes the synchronous fuel injection in which injectors are operated synchronously with the crank angles and the non synchronous fuel injection mode in which injection to all the cylinders is effected by detecting the signals from the sen SOS In the case of the synchronous fuel injection the optimum injecting timing and amount are selected from the map depending on the engine speed and intake pressure In the normal operating mode the system also makes several compensations based on the engine operating conditions 2 1 Engine control system Intake air temperature compensation Air temperature sensor First injection end timing is set and then injection start timing will be calculated according to the determined injection amount Injection end timing Each cylinder at BTDC 120 In the case of the non synchronous fuel injection upon detecting changes in signals that exceed a predetermined level from the TPS or the air pressure sensor the engin
169. he tilt piston 9 3 Install the cylinder end screw C and the tilt piston to the tilt ram 9 60 BRKT Bracket unit Recommended PTT fluid ATE Dexron TT 11 Tighten the cylinder end screw O to the specified torque 8 Install a new O ring amp to the free piston 6 and then install the free piston into the cylinder Cylinder end screw wrench 8 90890 06568 Cylinder end screw C bottom of the tilt ram 90 N m 9 0 kgfm 66 4 ft lb 9 Place the cylinder end screw C at the 10 Install the tilt ram assembly into the 12 Install the PTT motor See Installing the cylinder PTT motor 9 51 Bleeding the PTT unit Make sure that the tilt ram is fully extended 1 Place the PTT unit in an upright position 2 Turn the manual valve O counterclockwise to close it 3 Remove the reservoir cap 2 and then check the fluid level in the reservorr w Recommended PTT fluid ATF Dexron II TIP e If the fluid is at the correct level a small amount of fluid should overflow out of the filler hole e If fluid is below the correct level add the recommended PTT fluid 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 5 Connect the PTT motor leads to the battery terminals to fully retract the tilt ram PTT cylinder R Ram PTT mo Battery lead terminal tor Green G E Gr
170. hen remove the connecting rod and the piston assemblies 6 1 53 TIP e Make sure to keep the crankpin bearings in their original groups e Mark each piston with an identification number of the corresponding cylinder e Do not mix the connecting rode and caps Keep them organized in their proper groups 4 Remove the crankshaft the crankshaft journal bearings and the oil seals and 8 5 Remove the piston pin clips and the piston pin 00 and then remove the connecting rod Cylinder block a 10 0 mm 0 39 in b 48 0 mm 1 89 in 85 0 mm 3 35 in Cylinder bore Di De Checking the piston diameter 65 000 65 015 mm 1 Measure the piston outside diameter 8 at the specified measuring point Replace if out of specification Piston diameter 8 64 950 64 965 mm 2 5571 2 5577 in Measuring point 5 0 mm 0 20 in above the bottom of the piston skirt Oversize piston diameter Oversize 1st 65 200 65 215 mm 2 5669 2 5675 in Oversize 2nd 65 450 65 465 mm 2 5768 2 5774 in Checking the cylinder bore 1 Measure the cylinder bore Di De at measuring points and and in direction D1 Ds Ds parallel to the crankshaft and direction Dz Da De at a right angle to the crankshaft 2 5591 2 5596 in Checking the piston ring Measure the piston ring dimensions B and T Replace the piston ring set
171. him s T2 with a combined thick ness of 0 50 mm e DO not reuse a shim if deformed or scratched 2 Install the propeller shaft housing assembly into the lower case See Installing the propeller shaft housing assembly 8 18 3 Check that the drive shaft rotates smoothly 4 Measure the reverse gear backlash See Measuring the forward and reverse gear backlash before disassembly 8 25 step 18 step 21 Reverse gear backlash 0 75 1 23 mm 0 0295 0 0484 in Adjusting the reverse gear shim thickness T2 1 Remove the reverse gear and the shim s T2 See Disassembling the propeller shaft housing assembly 8 7 step 1 2 Measure the thickness of each original shim s T2 in 2 places 8 37 TIP Do not reuse a shim if deformed or scratched 3 Determine the reverse gear shim thickness 12 adjustment using the Reverse gear shim T2 selection chart according to the truncated average BL2 from Measuring the reverse gear backlash Example BL2 1 25 mm T2 adjustment 0 16mm from the Reverse gear shim T2 selection chart The current shim thickness must be increased by 0 16 mm 1 100 105 110 115 120 1 100 mm lt Backlash measurement BL2 Shim thickness adjustment Np 1 If the shim thickness adjustment value is positive the current shim thickness must be increased by that amount and if the value is negative the current shim th
172. hydro tilt anode sss sees eee eee 9 43 Installing the hydro tilt assembly 9 43 FUTUNA EE 9 44 Removing the PTT UNE 9 45 A svare 9 45 PO Le EE tere enne tn eet erect on reser 9 47 REMOVING tne Cap Wir lee WE 9 49 Disassembling the PTT motor esse eee eee 9 49 Checking the PITT nle eT 9 50 GneckiRg Me MUSA WE 9 50 Assembling the PTT motor RENE 9 50 Je liste but R E e e RE 9 51 EC A cern scecaincemenn cies eee 9 52 Disassembling the gear pump housing sese eee eee ee 9 55 Checking Ne gear PUMP vare 9 56 Checking the gear pump housing sss eee eee eee eee 9 56 Checking the valve Seal eee 9 56 Ghecking the E 9 56 Assembling the gear pump housing sss sees eee ee eee eee ee 9 56 PI R RA MING oniran 9 58 Disassembling the PTT Cylinder sees eee eee eee 9 59 Checking the PTT cylinder and piston sese eee 9 59 Assembling the PTT Cylinder ccccccecseceeceeeeeeeeeeeeeeeneeeeeas 9 60 Blend IE PTUN sd alabada 9 61 BRKT Bracket unit Steering friction gt NS 7 N m 0 7 kgf m 5 2 ft lb 37 N m 3 7 kgf m 27 3 ft lb 32 N m 3 2 kgf m 23 6 ft lb e 4 N m 0 4 kgf m 3 0 ft lb 8 N m 0 8 kgf m 5 9 ft lb Tiller handle assembly Self locking nut Washer Washer Bushing Tiller handle bracket Collar Wave washer Washer Bolt Self locking nut Bolt Steering lock shaft Bracket Collar Washer Steering lock lever CON OOF ODD M12 x 80 mm M5 x 20 mm 9 1 Steering friction 7 N m 0 7 kgf m 5
173. ickness must be decreased by that amount The gray colored area on the selection chart indicates the range of the specified backlash Shimming is not required if the measured backlash is within the gray col ored area e The values for the shim thickness adjust ments specified in the selection chart are intended to achieve the median value within the range for the specified forward or reverse gear backlash e The table below the selection chart shows the shim thickness adjustments for the points marked on the chart 4 Calculate the new reverse gear shim thickness T2 in the same way as in the example Calculation formula New reverse gear shim thickness T2 Cur rent reverse gear shim thickness Shim thickness adjustment Example If the current reverse gear shim thickness is 0 62 mm and the shim thickness adjustment is 0 22 mm then 12 0 62 mm 0 22 mm 0 62 mm 0 22 mm 0 40 mm Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm TIP e Use the lowest number of shims to achieve the required shim thickness e If the calculated shim thickness cannot be obtained with a combination of the available shims increase or decrease the shim thick ness by 0 01 mm 5 Install the shim s 12 and propeller shaft housing assembly Shimming 8 38 LOWR t Lower unit abed 1xau anunuos EE CTT ozo SSOUYOIY WIYS JO BUISL8199P Jo Bulseaou fa 219 Juswesns
174. ide 7 14 Power unit PO AR Crankshaft holder 16 8 90890 06355 TIP Use the air tool to loosen the drive sprocket nut easily 3 Remove the drive sprocket nut the retaining plate the drive sprocket 6 and the Woodruff key 4 Loosen the driven sprocket bolt 7 and then remove the driven sprocket 8 NOTICE Do not turn the camshaft when loosening the driven sprocket bolt Flywheel holder 90890 06522 Checking the timing belt and sprocket 1 Check the interior and exterior of the tim ing belt Replace if cracked damaged or worn 2 Check the drive sprocket and the driven sprocket Replace if cracked damaged or worn Flywheel magnet and timing belt Installing the sprocket and timing belt NOTICE D Do not turn the crankshaft or the driven sprocket when the timing belt is not installed Otherwise the piston and valves could collide with each other and be damaged 1 Install the driven sprocket D and then i ES tighten the driven sprocket bolt 2 to the specified torque PA LZ 5 a gt ER Je 3 Tighten the drive sprocket nut to the SO AY specified torque Flywheel holder 3 90890 06522 Driven sprocket bolt 2 Crankshaft holder 16 8 90890 06355 38 N m 3 8 kgf m 28 0 ft lb Drive sprocket nut O 2 Install the Woodruff key 4 the drive 150 N m 15 0 kgf m 110 6 ft lb sprocket 6
175. ion is sent from the TPS the mode shifts to the normal operating mode However it will restart the engine speed control when closing the throttle Engine speed limit 1100 r min Cylinders to stop injection and ignition 3 or 3 2 2 9 Engine control system Failsafe When the sensors malfunction the trouble diagnosis control commands the engine ECM to enter failsafe mode The trouble diagnosis control system records the trouble codes depending on the engine trouble conditions Trou LAN ble Item gauge Trouble conditions to be detected code display Water temp sensor Short or open in the thermo sensor circuit At engine start Sets to 5 C 41 F 20 C 68 F or 40 C 104 F depending on the signals from the air temperature sensor 2 Thermo sensor OT After engine start maintained at 40 C 104 F 2 Short or open in the TPS circuit Determines the fully closed position of the throttle based on the signals from the air pressure sensor 2 Battery voltage Remains below 12 V for 2 minutes when engine speed is above 2000 r min Short or open in the air temperature sensor V 1 Intake temp sensor C E Air temperature sensor circuit Operates at 40 C 104 F 2 Water in fuel Neutral switch is at ON and water detection W F Ee erh switch is at ON Throttle position sensor TPS O0 19 23 27 Shift position switch Cranks with the neutral switch OFF 28
176. it _ Wey NE Q Y WN P sE K L 16 Install the PTT motor leads to the plastic ties 49 the clamp and the PTT relay PTT model 17 Tighten the PTT motor lead bolts to the specified torque PTT model 18 Install the caps PTT model 19 Install the battery cables 4 CO er L PTT motor lead bolt 4 N m 0 4 kgf m 3 0 ft lb 20 Install the cover 5 21 Connect the 10 pin coupler Cf and then fasten it to the cover 5 with a plastic tie 22 Install the extension wiring harness to the clamp 8 and then fasten the extension wiring harness to the bracket with a plastic tie 40 TIP Before fastening the extension wiring har ness to the clamp and the bracket 9 pull it to prevent loosening 23 Install the shift cable and the throttle cable See Installing the shift cable and throttle cable remote control model 3 14 Power unit assembly Flywheel magnet and timing belt Flywheel magnet and timing belt 38 N m 3 8 kgf m 28 0 ft lb Part name Remarks Width across flats 30 mm Washer Flywheel magnet Bolt Pulser coil Bolt Stator assembly Base assembly Dowel Timing belt Nut Retaining plate Drive sprocket Woodruff key Woodruff key Bolt Washer M5 x 16 mm M6 x 30 mm r 2 3 4 5 6 7 8 Width across flats 41 mm M10 x 35 mm 7 12 Power unit 38 N m 3 8 kgf m 28 0 ft lb o E co LO T
177. justing the float height 1 Adjust the float height to the specified height by bending a of the float Float chamber plate screw 8 2 N m 0 2 kgf m 1 5 ft lb N Install the needle valve the float and the float pin Float height 42 1 2 0 mm 1 66 0 08 in 2 Adjust the float height A to the specified height by bending of the float 6 34 ER Fuel system TIP e Do not reuse the float pin Always replace it with a new one e Install the float pin with its tapered end fac ing towards the mark 8 on the float cham ber cover 3 Measure the float heights amp and Adjust the float heights if out of specification Float height amp 42 1 2 0 mm 1 66 0 08 in Float height reference data 30 7 mm 1 21 in 6 35 TIP The float should be resting on the needle valve when measuring the float height Do not press the float 4 Install the filter 5 Connect the high pressure fuel pump connectors 9 and then install a new O ring 8 and the high pressure fuel pump 9 6 Install the filter holder a new gasket AD and the cover assembly 2 and then tighten the float chamber cover screws 3 to the specified torque Float chamber cover screw 3 3 N m 0 3 kgf m 2 2 ft lb 7 Connect the lead 4 8 Install the pressure regulator 3 the pressure regulator bolts 46 new O rings 47 and the nipples 3 and then tighten the pre
178. k the piston and piston ring for 7 52 damage Check the cylinder for scratch 7 54 Symptom 1 High engine idle speed Refer to Air leakage throttle RE e 6 17 inder head and the throttle body cable are not installed correctly cable 6 23 YDIS Symptom 1 Limited engine speed Refer to Buzzer comes on over Clogged cooling water inlet Check the pilot hole for cooling water dis 10 3 heat alert indicator charge comes on Water pump impeller malfunc ir 5 Water leakage from water Check the water pump housing pump housing Check the outer plate cartridge Clogged cooling water pas Check the cooling water passage sage Thermostat malfunction Check the thermostat Troubleshooting the power unit Refer to Buzzer comes on oil Insufficient engine oil pressure alert indicator comes or Engine oil pressure decrease Check the oil pressure switch Check the oil pump Check the oil strainer Check the oil passage power unit and 2 16 the oil pump Replace the oil filter 10 10 Symptom 1 Discharged battery Refer to gravity tion in charging circuit for proper connections nection and damage Lighting coil malfunction Check the lighting coil output peak volt 5 24 age Check the lighting coil resistance Rectifier Regulator malfunction Check the Rectifier Regulator output 5 25 peak voltage Troubleshooting the PTT unit Troubleshooting when trouble codes are not available consist
179. kgf m 5 2 ft lb Collar 6 and amp dimensions A 9 0 mm 0 35 in 8 3 7 mm 0 15 in 8 0 mm 0 31 in O 5 4 mm 0 21 in TIP e Make sure that the TOP mark h on the steering lock lever 6 is facing upwards e Make sure to install the collars and 8 in the correct positions as the collar dimen sions are different Installing the friction plate assembly 1 Install the friction plate assembly D and then tighten the friction plate bolts 2 to the specified torque Friction plate bolt 2 8 N m 0 8 kgf m 5 9 ft lb De Steering friction Install the tiller handle See Installing the tiller handle 3 11 Move the steering lock lever Q to the position 8 and then tighten the friction adjusting nut 4 to the specified torque Friction adjusting nut 4 4 N m 0 4 kgf m 3 0 ft lb 9 4 BRKT Bracket unit Tiller handle 3 N m 0 3 kgf m 2 2 ft lb Part name Remarks Shift lever Bolt Screw Bushing Nut Friction piece Bushing Retainer Spring Collar Washer Plate Cotter pin PTT switch Cap Screw Screw M8 x 40 mm 96 16 mm Not reusable PTT model PTT model M6 x 15 mm PTT model M6 x 15 mm Hydro tilt model 9 5 Part name Throttle grip Screw Bushing Cotter pin Throttle friction adjuster Plate Screw Grease nipple Holder Clamp Holder Bracket Bolt Screw Control link assembly Throttle rod Tiller handle 3
180. l 1 Disconnect the 10 pin coupler 2 Turn the engine start switch to START and then check the neutral switch for continuity at the shift lever positions F N and R 3 Remove the neutral switch 4 Check the neutral switch for continuity 5 Install the neutral switch See Assembling the tiller handle 9 9 6 Connect the 10 pin coupler Starting units and components 5 32 sel ELEC i Electrical system Starter motor 3 N m 0 3 kgf m 2 2 ft lb Part name Armature Brush holder assembly Bracket Bolt M5 x 105 mm Screw set M6 x 25 mm Cover screw M5 x 8 mm Bracket screw Bracket Bolt Starting motor gear assembly Pinion shaft Planetary gear Pinion stopper set Clutch assembly Outer gear Stator Cover assembly Lever assembly M5 x 25 mm k k ld k k L Ni 5 33 Starter motor 12 AE N N IE i l e XL E e E Z mM Remarks Part name Magnet switch 9 34 sel ELEC i Electrical system Removing the starter motor 1 Remove the starter motor from the power unit See Removing the starter motor 7 29 Checking the starter motor operation 1 Connect the positive battery cable to the magnet switch terminal and then connect the negative battery cable 2 to the starter motor body 2 Connect the starter motor Brown Br lead to the positive battery terminal and then check the starter motor operation WARNING Do
181. l PUMP sse ee eee ee eee ee 6 33 Checking the vapor separator see ee eee eee 6 33 Adjusting the float height sees eee eee 6 34 Assembling the vapor separator eee eee ee eee 6 34 SET Le suges 6 38 Removing the fuel injector esse eee eee 6 39 Checking NE TUSEN alll saa 6 39 Installing the fuel injector see eee eee eee ee iaia 6 39 el gy Fuel system Hose routing Fuel hose Z Y ns E Ve ep E p Gr S pa L Ce NN e KH EUA AN UCE 1 Fuel hose 2 Fuel hose 3 Fuel hose 4 Fuel hose 5 Fuel hose 6 Fuel hose 7 Fuel hose Fuel hose tor 9 Pressure regulator hose pressure regulator to intake manifold fuel joint to joint joint to fuel filter fuel filter to fuel pump fuel pump to strainer strainer to vapor separator pressure regulator to fuel cooler fuel cooler to vapor separator vapor separator to quick connec DR mS TN en 6 1 TF a U SES ES LA CACA gt R Y g s SA a Fuel joint Joint C Fuel filter d Fuel pump 8 Strainer P Vapor separator 9 Pressure regulator h Fuel cooler K Quick connector DT Fuel rail N Fuel injector Hose routing Vapor gas hose 1 Vapor gas hose 2 Vapor gas hose 8 Vapor gas hose 4 Vapor gas hose tle body 6 Blowby hose cylinder head cover to intake silencer vapor separator to joint vapor separator to joint joint to vapor shut
182. l new oil seals and 9 on the crankshaft 40 and then install the crankshaft onto the cylinder block TR IIIII2 Make sure to install the oil seals into the cyl inder block so that the oil seals are securely seated at the stepped area 9 Install the connecting rod caps to the connecting rods and then tighten the new connecting rod bolts 4D to the specified torque in 2 stages NOTICE Do not reuse the connecting rod bolts Always replace them with new ones Cylinder block Connecting rod bolt 4 1st 6 N m 0 6 kgf m 4 4 ft lb 2nd 17 N m 1 7 kgf m 12 5 ft lb TIP e Make sure that the protrusions on the connecting rod and connecting rod caps k face towards the flywheel magnet side of the crankshaft e After tightening the connecting rod cap bolts 4D check that the crankshaft rotates smoothly 10 Install the crankshaft journal bearings 42 into the crankcase 11 Apply sealant to the mating surface of the crankcase 8 oi AA H U a m T Es EN TIP e Install the crankshaft journal bearings 2 in their original positions e Do not get any sealant on the crankshaft journal bearings 2 7 62 Power unit 12 Install the crankcase onto the cylinder block and then install the crankcase bolts 43 and 49 13 Tighten the M8 bolts 1 8 to the specified torque in 2 stages and then tighten the M6 bolts 9 16 to the specified torque in 2 stages
183. lamp Hose Hose Clip Clamp Strainer Holder Hose Bolt Pressure regulator Hose Hose Plastic tie Hose Joint Cover CON OOF ODD M6 x 12 mm Not reusable L 2 2 O ND WD k k 6 29 Vapor separator disassembly 5 N m 0 5 kgf m 3 7 ft lb 1 5 N m 0 15 kgf m 1 11 ft lb Remarks 18 Cap Hose Holder Screw Nipple O ring Clamp Hose Holder Hose Screw Fuel cooler Hose Joint Hose Drain screw O ring M5 x 14 mm Not reusable M6 x 14 mm Not reusable 6 30 R Fuel system 5 N m 0 5 kgf m 3 7 ft lb 1 5 N m 0 15 kgf m 1 11 ft lb Remarks 35 Drain hose 1 36 Float chamber 1 37 Needle valve 1 38 Float 1 39 Pin 1 40 Plate 1 41 Plate 1 42 Screw 2 M4 x 7 mm 43 O ring 1 44 Gasket 1 45 High pressure fuel pump 1 46 Clip 1 47 Filter 1 48 Joint 1 49 Clip 1 50 Holder 1 1 51 Lead 6 31 Vapor separator disassembly Disassembling the vapor separator 1 Remove the cooling water hoses D and Q CES 5 aa lL LER G 2 Remove the fuel hose 8 and the drain hose 4 So 4 We A 6 Remove the fuel cooler 3 Remove the vapor gas hoses 7 Remove the lead 4 the pressure and the pressure regulator hose 8 regulator 45 the nipple and the O ring 7 4 Remove the fuel hose 9 and the cooling water hose 0 8 Remove the cover assembly 8 the g
184. lator If the fuel pressure is not reduced replace the pressure regulator Turn the engine start switch to OFF Disconnect the special service tool 2 and then connect the pressure regulator hose 1 Reduce the fuel pressure See Reducing the fuel pressure 6 4 Disconnect the special service tools See Measuring the fuel pressure 6 4 step 10 step 12 Fuel line 6 6 TD Fuel system Fuel filter assembly WED RS e Clip Hose Cover Hose Joint Clamp Plastic tie Bolt Bracket Nut Fuel filter element O ring Clip Float Fuel cup assembly Fuel filter assembly Hose Not reusable M8 x 20 mm 0 N MD GQ E M Not reusable A h do do nm nm nm Ny sch i sch KR 6 Fuel filter assembly CI 9 gt E 10 q LL DS ES WM es 9 18 Grommet 1 19 Fuel joint 1 20 Bolt 1 M6 x 25 mm 6 8 vel py Fuel system Removing the fuel filter assembly Use a rag to catch any spilled gasoline when removing the fuel Components 1 Disconnect the fuel hoses 1 and 2 Disconnect the water detection switch coupler 8 3 Remove the fuel filter assembly 8 AIF RED Su 4 Remove the fuel hose 1 from the clamps 4 6 and 6 O 5 Remove the fuel joint 6 9 Checking the fuel joint 1 Check the fuel joint Replace if cracked or damaged 2 Connect the special service tool 1 to the fuel joint outlet 8
185. lay C Fuse 20A starter relay To tiller handle remote contro A 3 Fuel unit and ignition unit Starter motor R R relay co R 01 10 ie Starter relay rere V CCC CO 4 or gt a Sam DS MIRI S L SE LL LL O KE qi sde VI UU 2 B Y H ae ME fo SER GN ER KA E AA Y LEl ANE O IAS EE EA ll i ev T E TFT H ES ev O pp sE eo Oo DU LL HH ov i EN r a ll TT T G HE WO RO DO DOE G R HEEN E A El KES KASSE RASE Eee AA E THH F A va a a GE mH Joint coupler 1 i aes El i Engine ECM BW To Ss L EE PS VETA ER VARG ET a A VASS VGS VRANG NENNE SEET rss R Y THT inne CTT i G B El ESE DUE EES D EE El DE ES ES EN El ESE EEES EES Pu B REE A PANA E GS H MN NE beren EE bi GENENE E En ran gt gt VM AE H A E Goa SOLA r pressure nectar Vapor Thermo Pulser coil svilleh 1 L Naa switch SEN High hrottle switch fuel pump y Charging unit and starting unit a Fuse 20A engine start switch PTT switch b Fuse 30A main relay C Fuse 20A starter relay d Diode connect to PTT relay To tiller handle remote control To diagnostic flash indicator To YDIS D To trolling switch To 6Y8 Multifunction Meter To alert indicator tiller handle digital tachometer Connect the couplers when displaying the 6Y8 Multifunction Meter A 5 Charging unit
186. ly 1 Remove the taper roller bearing NOTICE Do not press the drive shaft threads 8 directly El Ne A Bearing inner race attachment 2 90890 06641 Disassembling the forward gear 1 Remove the taper roller bearing ais W s ES C e aA Re as Pr Y w N WEN Driver rod L3 2 90890 06652 Needle bearing attachment 8 90890 06612 Bearing separator 4 90890 06534 Disassembling the lower case WARNING e Use heat resistant gloves Otherwise burns could result e To avoid the risk of fire remove any flammable substances such as gasoline and oil around the working area e Keep good ventilation while working 1 Remove the water inlet covers 2 Remove the needle bearing 1 Driver rod L3 2 90890 06652 Needle bearing attachment 8 90890 06614 3 Heat the installation area of the taper roller bearing outer race in the lower case with a gas torch and then remove the taper roller bearing outer race 4 and shim s Ti NOTICE When heating the lower case heat the entire installation area evenly Otherwise the paint on the lower case could be burned TIP e Before removing the taper roller bearing outer race 4 place some cushioning mate rial under the lower case to catch the outer race when it falls out e If the taper roller bearing outer race does not come out lightly tap the lower case tor pedo with a plastic hammer Drive shaft and lower
187. ment new O ring to the shift rod 90890 06639 Assembling the drive shaft NOTICE Do not reuse the bearing Always replace it with a new one 1 Install a new taper roller bearing Assembling the oil seal housing 1 Install new oil seals to the specified depth 8 4 Install the forward gear assembly 5 Install the drive shaft assembly the pinion O and the pinion nut 0 LL Driver rod LS 2 90890 06606 Ball bearing attachment 8 90890 06634 8 17 Drive shaft and lower case TIP When installing the pinion lift up the drive shaft 8 slightly and then align the pinion splines with the shaft splines 6 Tighten the pinion nut to the specified torque Drive shaft holder 3 4 90890 06517 Pinion nut holder 42 90890 06715 Pinion nut 74 N m 7 4 kgf m 54 6 ft lb 7 Check that the drive shaft rotates smoothly 8 Install the washer 3 the oil seal housing assembly 44 and the cover 1 Installing the propeller shaft housing assembly 1 Install the washer D and the propeller shaft assembly 2 into the propeller shaft housing 8 2 Install the shift plunger and the propeller shaft housing assembly MO 3 Tighten the propeller shaft housing bolts to the specified torque 8 18 Lower unit Propeller shaft housing bolt 6 6 Install a new O ring 40 and water pump 16 Nem 1 6 kgf m 11 8 ft lb housing assembly 4D to the l
188. meter i 29 4 1 16 Wear limit i 28 8 1 13 Standard undercut 0 5 0 02 Wear limit 0 2 0 01 Brushes Standard length i 12 3 0 48 Wear limit 5 5 0 22 Gauge sensor Water pressure sensor Input voltage 4 5 5 25 Output voltage 1 at 392 0 kPa 3 92 kgf cm2 56 8 psi at 784 0 kPa 7 84 kgf cm 113 7 psi Speed sensor Input voltage 4 5 5 25 Output voltage 1 at 392 0 kPa 3 92 kgf cm2 56 8 psi at 784 0 kPa 7 84 kgf cm 113 7 psi 2 5 4 5 2 5 4 5 1 The figures are for reference only 1 8 SPEC O ncn Specification Fuel system technical data Fuel system Fuel pressure Within 3 G after engine start switch turned to ON at engine idle speed Fuel joint Holding pressure Positive pressure Fuel filter assembly Holding pressure Positive pressure Negative pressure Fuel pump Holding pressure Inlet positive pressure Inlet negative pressure Outlet positive pressure Primer pump Holding pressure Positive pressure Vapor separator tank Float height open Float height closed 1 Fuel strainer Holding pressure 1 The figures are for reference only 1 9 Unit kPa kgf cm2 psi kPa kgf cm2 psi kPa kgf cm2 psi kPa kgf cm psi kPa kgf cme psi kPa kgf cm psi kPa kgf cm psi kPa kgf cm psi kPa kgf cm2 psi kPa kgf cm2 psi Model em IEF 280 0 2 80 40 6
189. n Crankshaft runout 0 03 mm 0 0012 in Checking the crankpin oil clearance 1 Clean the crankpin bearings the con necting rod the connecting rod cap and the crankpin 2 Install the crankpin bearings into the connecting rod and the connecting rod cap mK DL TIP e Install the crankpin bearings in their original positions e Install the protrusions of the crankpin bearing into the grooves d on the connect ing rod a and connecting rod cap 3 Put a piece of Plastigauge PG 1 onto the crankpin parallel to the crankshaft 1 57 ANKE WA Do not put the Plastigauge PG 1 over the oil hole in the crankpin of the crankshaft 4 Install the connecting rod and the connecting rod cap to the crankpin 5 Tighten the connecting rod bolts to the specified torque in 2 stages Connecting rod bolt 2 1st 6 N m 0 6 kgf m 4 4 ft lb 2nd 17 N m 1 7 kgf m 12 5 ft lb TIP e Make sure that the protrusions f on the connecting rod 2 and connecting rod cap b face towards the flywheel magnet side of the crankshatt e Reuse the removed connecting rod bolts when checking the oil clearance e Do not turn the connecting rod 8 until the crankpin oil clearance measurement has been completed D Remove the connecting rod cap and then measure the width of the compressed Plastigauge PG 1 on each crankpin Replace the crankpin bearing if out of specifica
190. n the trim tab and the lower case and then remove the trim tab 5 Remove the lower case mounting bolts 2 and 8 and then remove the lower unit 6 Remove the speedometer hose 4 7 Remove the anode 8 3 TP When disassembling the lower unit measure the backlash before disassembly See Mea suring the forward and reverse gear backlash before disassembly 8 25 Checking the propeller 1 Check the propeller blades and splines Replace the propeller if cracked dam aged or worn Checking the lower unit anode 1 Check the anode and the trim tab Clean the anode or the trim tab if there is grease oil or scales NOTICE Do not grease oil or paint the anode or the trim tab Water pump CO N MD GQ E M Part name Cover Seal Water pump housing Insert cartridge Impeller O ring Outer plate cartridge Gasket Dowel Plate Rubber seal Woodruff key lt k gt NY sch sch ech Jr Not reusable Not reusable Lower unit Water pump Remarks 8 4 Lower unit Removing the water pump 1 Remove the water pump housing the insert cartridge 2 the impeller the O ring 4 and the Woodruff key 2 Remove the outer plate cartridge and the gasket 3 Remove the rubber seal 8 and the plate Checking the water pump 1 Check the water pump housing Replace if deformed TIP If the engine overheated check the water pump housing for
191. nce data 0 561 0 59 Q at 20 C 68 F 4 Disconnect the test harness D and then connect the Rectifier Regulator coupler Checking the Rectifier Regulator NOTICE If the battery cables are connected in reverse the Rectifier Regulator can be damaged 1 Disconnect the Rectifier Regulator cou pler 2 and then connect the test har ness 2 pins MV 2 Measure the Rectifier Regulator output peak voltage L Test harness 2 pins D 90890 06887 TIP Do not use peak voltage adapter B when measuring the Rectifier Regulator output peak voltage Rectifier Regulator output peak voltage Red R Ground Unloaded r min 1500 3500 D 25 3 Disconnect the test harness D and the Rectifier Regulator coupler 4 Check the Rectifier Regulator for continu ity Replace if out of specification OS Charging units and components Ignition units and components Rectifier Regulator continuity testing diode mode Tester probe Display value reference data OL Indicates overload Az Make sure to set the tester measurement range to the diode mode 5 Connect the Rectifier Regulator couplers a and Ignition units and components Checking the ignition spark 1 Disconnect the spark plug caps from the Spark plugs 2 Connect a spark plug cap to the special service tool 3 Check the ignition spark using the YDIS Stationary test
192. ndling 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 example welding equip ment lighted cigarettes e DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF THE REACH OF CHILDREN 1 Check the battery electrolyte level If the level is at or below the minimum level mark 8 add distilled water until the level is between the maximum and minimum level marks 10 3 2 Check the specific gravity of the electrolyte Fully charge the battery if below specification Representative examples Recommended battery capacity CCA EN 430 0 A 20HR 1EC 70 0 Ah Electrolyte specific gravity 1 280 at 20 C 68 F TP e Batteries vary depending on the manufac turer The procedures mentioned in this manual may not always apply Therefore consult the instruction manual of the bat tery e Disconnect the negative battery cable first and then the positive battery cable Checking the cooling water pilot hole 1 Start the engine
193. ne is straight The distances and b are of equal length And so are and di 2 Adjust the outboard motor so that the height of the anti cavitation plate is equal to or slightly above the bottom of the boat transom TIP This mounting height information is for refer ence only It is impossible to provide com plete instructions for every possible boat and outboard motor combination 3 Adjust the scale to the transom height H and set it on the special service tool 1 Secure the service tool 1 to the boat transom by means of a screw or a vise TIP See Dimensions 3 2 for the distance H Uncrate procedure Mounting the outboard motor When the outboard motor mount position has been determined mark the best suited 4 symmetrical mounting holes for the boat transom Drill the mounting holes vertically on the boat transom using a 13 0 mm 0 5 in drill C L Centerline of transom Drilling plate 90890 06783 5 Apply sealant to the mounting holes and secure the outboard motor with the supplied mounting bolts small washers 8 large washers 4 and nuts 6 NOTICE Make sure that there is no clearance on the surfaces between the transom and the clamp bracket Boat transom thickness D Mounting bolt M12 x 105 mm 4 13 in 65 75 mm 2 56 2 95 in TIP The second hole from the clamp bracket top is recommended for the upper mounting bolt 6 Secu
194. neutral switch sees eee ee 5 29 Checking the engine shut off SWITCH see eee eee ee 5 30 Starting units and components rrrnvrennnvnnnvrennnvennnnnnnnvrnnnen 5 30 Checking the starter relay esse eee 5 30 Checking the engine start switch eee eee eee 9 31 Checking the neutral switch tiller handle model 5 32 Starter Motor 2222 hi Li uen 5 33 Removing the starter motor VU 5 35 Checking the starter motor operation sse eee eee 5 35 Checking the Magnet switch ooccccccocccnccnoncnnccnnnnnnononcnnnnnans 5 35 Checking the starter motor PINION sse ee eee e eee 5 35 Disassembling the starter motor eee eee eee 5 36 Checking the starter motor see eee eee 5 37 EEE DIUS de 5 38 Assembling the starter motor 5 38 Installing the starter motor see eee ee eee eee eee 5 40 6Y8 Multifunction Meter sensor rrrnrnnvvrrnnnnvnennnnnvnvrnnnennnn 5 40 Checking the water pressure sensor option 5 40 Checking the speed sensor option see eee eee eee 5 41 PTT electrical system 5 42 Checking the PTT relay oocccccoccncccccncocccnnonaconocononononcnonnncnnoss 5 42 Checking the PTT switch on bottom Cowling 5 43 Checking the PTT switch tiller handle model 5 44 Checking the trim sensor VV 5 45 sel ELEC Electrical system Electrical component and wiring harness routing Port view 1 Engine ECM 2 Fuse
195. ng compressor 7 90890 04019 Valve spring compressor attachment 8 90890 06320 TIP Face the fine pitch side of the valve spring toward the spring seat 3 Compress the valve spring and then install the valve cotters 9 4 Lightly tap the valve spring retainer with a plastic hammer to set the valve cotters O securely 7 43 5 DOO 6 Driver rod LS OD 90890 06606 Bearing outer race attachment 2 90890 06626 Install the camshaft 43 in the direction of the arrow and then install a new gasket and tighten the retaining bolt 45 7 Align the dowel hole in the camshaft with the a mark on the cylinder head La Sle G S TO 8 Install the rocker arms 6 47 and washers 8 into the rocker arm shaft 9 and then install the tensioners 0 the stoppers OD the washers 2 and the rocker arm shaft bolts Camshaft and valve TIP Make sure that the arrow marks on the tensioners are facing towards the driven sprocket 9 Gradually tighten the rocker arm shaft bolts 83 to the specified torque and in the sequence numbers 1 2 Rocker arm shaft bolt 3 18 N m 1 8 kgf m 13 3 ft lb 10 Install new O rings and the cylinder head anodes amp to the cylinder head anode plugs and then tighten the cylinder head anode screws to the specified torque 11 Tighten the cylinder head anode plugs to the specified torque 12 I
196. ng the gear oil 10 11 step S step 9 8 21 Drive shaft and lower case Shimming Shimming Shimming workflow Remove the water pump assembly Measure the backlash before disassembly Wee US Shimming is not required NO Disassemble the lower unit Select the pinion shims T3 Assemble the lower unit Measure the backlash Adjust the forward gear shim thickness 11 and reverse gear shim thickness T2 Within specification YES Install the water pump assembly TIP e Shimming is not required if the backlash is within specification e Shimming is required when assembling the original inner parts and a new lower case e Shimming is required when replacing the pinion forward gear reverse gear bearings shaft or the housing 8 22 Lower unit Shimming check sheet Lower case deviation Serial number Pinion height mm Measurement point 1 Measurement point 2 Measurements Measurement point 4 Truncated average M Forward gear backlash mm Measurement paint Il Measurement paint 1 Measurement paint 1 pp Measurement point pp eme LL ll Truncated average ar Reverse gear backlash mm Measurement paint ll Measurement point 1 D Measurement point 3 as Measurement point Measurement para eas 1 pf f Truncated average BL2 Shimming Forward gear shim thickness T1 measurement in 2
197. nnect the engine ECM coupler VE 7T EI tt Cd TSE SE LU 0 OO T Fite E 6 OD IDE i T AK Mar TLC wie 5 Check the wiring harness for continuity 00000000 0 90000068090 0000066060 O O O 0 6363 0 Engine control units and components Tiller handle model Wiring harness continuity Remote control model ATerminal 1 Terminal 9 Terminal 2 O Terminal 26 TPS output voltage and throttle Terminal 3 O Terminal 23 valve opening angle reference data Terminal 4 OTerminal 15 Fully closed Fully open a Terminal 5 b Terminal 16 Output Terminal 7 O Terminal 6 voltage a Terminal 9 b Terminal 32 angle l Terminal 10 b Terminal 33 S Checking the ISC 6 Connect the engine ECM coupler and The ISC is a component of the throttle body the throttle body coupler 8 which cannot be disassembled 1 Check the operation of the ISC using the Checking the TPS YDIS Stationary test and check the The TPS is a component of the throttle body operating sound which cannot be disassembled 1 Connect the YDIS to display TPS volt 2 Start the engine and then check the age engine speed increases using the YDIS Active test 2 Start the engine and warm it up and then turn it off Checking the oil pressure switch 1 Remove the oil pressure switch lead 8 3 Turn the engine start switch to ON and then measure the output voltages of the
198. nnnnnnnnennn 2 11 Digital network System css eee eee eee 2 11 Variable trolling speed control esse eee eee eee 2 12 PM UE 2 15 JUNE NN 2 15 Lubrication System rrrnnvrnnnnvvnnnnnvnnnnnvennnnnnennnnnnnennnnenennnnnnnnnnnn 2 16 OUS en OAC LM EEE EE 2 16 Cooling system E 2 17 OUS CMA diar sea E eren 2 17 Intake and exhaust system se sss esse esse esse eee 2 18 DST EN E 2 18 PUR EE E 2 19 JUNE 2 19 iS 2 20 I e el in CDC CON NEE 2 21 Operation in case of malfunctions eee eee eee eee 2 22 When the outboard motor hits something in the water 2 22 Technical features and description Engine control system Outline The employs an electronically controlled fuel injection system The engine ECM determines the optimum ignition timing the fuel injecting timing and volume and the idle speed based on the signals transmitted from each sensor Besides the engine ECM has a self diagnosis function to per form failure diagnosis by using the YDIS 2 1 Digital network system Speed sensor option Water pressure sensor option wer tC ECM Air temperature sensor Air pressure sensor Thermo sensor Pulser coll Trim sensor L APE A 3 pressure switch e body SC valve 1 Vapor shut off valve SRE E H E EEE 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 HH 9 x ES Strainer me Fuel pump High pressure fuel pump E Vapor separator Water detection switch Engine control sys
199. nsert the special service tool into the valve guide 8 and then ream the valve guide Q fi N Valve guide reamer 4 90890 06804 Camshaft and valve TIP e Turn the valve guide reamer clockwise to ream the valve guide e Do not turn the reamer counterclockwise when removing it e Make sure to clean the valve guide after reaming it 4 Measure the valve guide inside diameter Valve guide inside diameter 5 500 5 512 mm 0 2165 0 2170 in Checking the valve seat 1 Eliminate any carbon deposits from the valves 2 Apply a thin even layer of Mechanic s blueing dye Dykem onto the valve seats 3 Lap the valve slowly on the valve seat with the special service tool 1 Valve lapper 1 90890 04101 4 Measure the valve seat contact width a where the blueing dye is adhered to the valve face Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification Replace the valve guide if the valve seat contact width is uneven 1 38 Power unit X S X aa Valve seat contact width a 1 30 1 50 mm 0 051 0 059 in Refacing the valve seat NOTICE After every lapping procedure make sure to clean off any remaining lapping com pound from the cylinder head and the valves 1 Reface the valve seats with the valve seat cutters son SN GN Valve seat cutter holder 90890 06316 Intake Valve seat cutter 30 9089
200. nstall the spark plugs and then tighten them to the specified torque Power unit 13 Install the engine hanger 9 Cylinder head anode screw 20 2 N m 0 2 kgf m 1 5 ft lb Cylinder head anode plugs 68 18 N m 1 8 kgf m 13 3 ft lb Spark plug 18 N m 1 8 kgf m 13 3 ft lb 7 49 Camshaft and valve Exhaust cover Exhaust cover CO N m 0 6 kgf m 4 4 ft lb 12 N m 1 2 kgf m 8 9 ft lb S SV a Y S P ID Ss o AS Si NG D CO S D TZ NO O CH Se ae Je YO Part name IN VO e N ACT T 2 an E o 1 Thermo sensor 2 Gasket 3 Clamp 4 Plate 5 Bolt M6 x 16 mm 6 Clamp 7 Bracket 8 Clamp 9 Gasket 10 Exhaust cover 11 Bolt M6 x 35 mm 12 Thermostat 13 Gasket 14 Gasket 15 Thermostat cover 16 Plug M18 x 17 mm 17 Gasket 7 46 Power unit N m 0 6 kgf m 4 4 ft lb 2 N m 1 2 kgf m 8 9 ft lb UG gt 2 Co Part name Not reusable M14 x 12 mm M5 x 24 mm 23 N m 2 3 kgf m 17 0 ft lb Gasket Plug Screw Anode O ring Anode plug Oil filter Union bolt Oil pressure switch Oil pressure switch lead Dowel Not reusable NN eck MA PO 7 47 Removing the exhaust cover 1 Remove the bracket 1 r H MI Viss U nw gt d x D a Oy 2 2 Remove the exhaust cover plugs 8
201. ody for air leakage Symptom 1 Unstable engine idle speed poor acceleration poor performance or limited engine speed Refer to Throttle valve does not Throttle valve malfunction Check the throttle valve for proper move 6 19 move properly ment Throttle link and the throttle Adjust the throttle link and the throttle 3 14 cable are not installed correctly cable 6 23 Spark plug does not Spark plug malfunction Check the ignition spark spark some cylinders Check the spark plugs Short open or loose connec Check the spark plug cap resistance tion in ignition coil circuit Check for wiring continuity between the 5 26 ignition coil and the engine ECM Ignition coil malfunction Check the ignition coil resistance Engine ECM malfunction Check the engine ECM output peak volt age Fuel pressure is low High pressure fuel line mal function Check the fuel titer or clog and dri 69 4 10 TRBL d SHTG e Troubleshooting Refer to Fuel not supplied some Fuel injector malfunction Check the fuel injector operation using the YDIS cylinders Check the fuel injector resistance Short open or loose connec Check the fuel injector input voltage tion in fuel injector circuit fuel injector and the main relay A 3 fuel injector and the engine ECM A 3 Replace the engine ECM Compression pressure low Compression leakage 74 Check the camshaft for damage Check the valve and valve seat for wear Chec
202. off valve vapor shut off valve to throt Fm Sm A mi a Vapor separator b Vapor shut off valve C Throttle body Intake silencer 6 2 e py Fuel system Cooling water hose 1 Cooling water hose exhaust cover to joint 2 Cooling water hose joint to joint 8 Cooling water pilot hose joint to fuel cooler 4 Cooling water hose fuel cooler to fuel cooler 6 Cooling water hose fuel cooler to joint 6 Cooling water hose joint to exhaust guide 7 Cooling water hose joint to cooling water out let Flushing hose flushing hose adapter to joint 6 3 a Fuel cooler b Cooling water outlet on the bottom cowling C Flushing hose adapter Fuel line Reducing the fuel pressure A WARNING Always reduce the fuel pressure in the high pressure fuel line before servicing the line or the vapor separator If the fuel pressure is not released pressurized fuel may spray out 1 Start the engine 2 Remove the fuse holder cover D and then remove the main fuse 30 A TIP 22 After removing the fuse wait until the engine stalls 3 After the engine stalls crank the engine 2 or 3 times 4 Turn the engine start switch to OFF 5 Install the main fuse 30 A and then install the fuse holder cover Disconnecting the quick connector A WARNING If the quick connector is disconnected suddenly pressurized fuel could spray out Make sure to reduce the fuel pressur
203. ombinations of the fol lowing SAE and API oil classifications SE SF SG SH SJ or SL 5W 30 10W 30 or 10W 40 1 5 1 59 1 32 1 7 1 80 1 50 Hypoid gear oil GL 4 90 0 430 0 455 0 378 1 If the recommended engine oil grades are not available use engine oil with an API classification of SH SJ or SL and an SAE classification of 15W 40 20W 40 or 20W 50 2 Meeting both API and SAE requirements 1 4 eo ue Specification Battery requirement Minimum cold cranking amps CCA EN Minimum rated capacity 20HR IEC PTT requirement Model Item Unit EE es EE AR Electrical technical data Ignition timing control system Model Engine ECM Output peak voltage at cranking unloaded Spark plug cap Resistance 1 at 20 C 68 F Ignition coil Primary coil resistance 1 at 20 C 68 F 0 1 89 0 2415 Secondary coll resistance at 20 C 68 F 3 256 4 884 Pulser coll Output peak voltage at cranking unloaded 5 0 at cranking loaded 2 7 at 1500 r min loaded 6 5 at 3500 r min loaded 9 8 Resistance at 20 C 68 F 152 0 228 0 Thermo sensor Input voltage 4 5 5 25 Resistance 1 at 20 C 68 F 26 460 at 75 C 167 F 0 370 at 90 C 194 F 240 3 Neutral switch Input voltage 1 1 5 Model data Electrical technical data Model Item Wm E mm Spark plug Gap mm in 0 8 0 9 0 032 0 035 1 The figures are for reference only Fuel inje
204. on Fuel pressure reference data 230 0 kPa 2 30 kgf cm 33 4 psi at engine idle speed 8 Turn the engine start switch to OFF 9 Reduce the fuel pressure See Reducing the fuel pressure 6 4 6 5 10 11 12 Disconnect the special service tools D and WARNING Before disconnecting the special service tools and cover the end of the hose with a clean and dry rag Connect the quick connector to the fuel rail After measuring the fuel pressure cover the end of the hose with a clean and dry rag with the hose end pointing down And then loosen the drain screw 8 to drain the remaining fuel from the hose and the gauge WARNING When storing the fuel pressure gauge make sure that the drain screw Gi is tightened securely Checking the pressure regulator 1 Reduce the fuel pressure See Reducing the fuel pressure 6 4 Disconnect the quick connector See Disconnecting the quick connector 6 4 Connect the special service tools See Measuring the fuel pressure 6 4 step 3 and step 4 Disconnect the pressure regulator hose 1 and then connect the special service tool 2 to the pressure regulator 8 Vacuum pressure pump gauge set 2 90890 06756 10 11 Cover the pressure regulator hose end during the measurement Start the engine and let it idle Check that the fuel pressure is reduced when vacuum pressure IS applied to the pressure regu
205. on Q the connecting rod a the piston pin and the piston pin clips NOTICE Do not reuse the piston pin clips Always replace them with new ones 7 60 Power unit 5 Install the crankpin bearings 4 into the connecting rod 8 and the connecting rod cap 9 TIP Face the protrusions on the connecting rod a in the same direction as the UP mark on the piston Do not align the piston pin clip end with the groove of the piston 2 Install the oil rings the 2nd ring and the top ring onto each piston TIP TIP e Install th kpin beari in their original After installing the piston rings check that ai crankpin bearings in their origina they move smoothly y y e Install the protrusions of the crankpin bearing into the grooves on the connect dm and the top ring O are Sei ing rod and connecting rod cap 2nd ring and the top ring are facing upward 6 Apply engine oil to the side of the piston 4 Offset the piston ring end gaps the piston rings and the cylinder wall and NOTICE Do not scratch the pistons then install the piston with the UP mark or break the piston rings on the piston crown facing towards the flywheel magnet 7 61 Piston slider 6 90890 06529 7 Install the crankshaft journal bearings 6 into the cylinder block TIP Install the crankshaft journal bearings in their original positions 8 Instal
206. on the propeller boss end and on the side of the pro peller boss 3 21 a Propeller diameter in inches b Propeller pitch in inches C Propeller type propeller mark Selection When the engine speed is at full throttle oper ating range the ideal propeller for the boat is the one that provides maximum performance in relation to the boat speed and fuel con sumption 5000 6000 r min 10 3 4 x 16 G 10 5 8 x 12 G 11 1 2x 13 G Stainless 10 1 4x 16 G Aluminum TRBL SHTO Troubleshooting M a a a no 4 1 FE CE eege 4 1 Hardware requirement ese eee ee ee ee ee ee ee eee 4 1 FIN 4 2 DIS aaa PT 4 3 Connecting the communication cable to the outboard motor 4 3 Troubleshooting the power unit snrrnnnnnvvrnnnnnvrnnnnnnvnennnnvnen 4 4 Troubleshooting procedure s sese eee eee eee eee 4 4 Troubleshooting the power unit using the YDIS 4 4 Trouble code and checking Step sse eee eee 4 6 Troubleshooting the power unit using the diagnostic flash NACION EE EN nan 4 8 Troubleshooting the power unit trouble code not detected 4 9 Troubleshooting the PTT unit occccnccncnccnccncnccncnnnnnnnnonannnnncnnos 4 12 Troubleshooting the lower unit eee eee eee eee eee eee 4 13 TRBL d SHTG e Troubleshooting YDIS This manual contains model specific information See YDIS Instruction Manual for detailed infor mation Feature The newly developed YDIS provides q
207. op the engine and leave it OFF for Remove the dipstick 2 and wipe it clean 5 10 minutes 10 9 with a rag General Periodic Maintenance 8 Insert the dipstick and remove it again Make sure to completely insert the dipstick into the dipstick hole Otherwise the oil level measurement may be Oil filter wrench D 90890 01426 TIP e Wait for more than 5 minutes after turning incorrect HSS off the engine to replace the oil filter 9 Recheck the oil level using the dipstick to e Make sure to clean up any oil spills make sure that the level falls between the upper level 8 and the lower level 3 Install the oil filter and then tighten it to RQ the specified torque YR VE N i 4 10 Start the engine and make sure that the oil pressure alert indicator remains off Oil filter Also make sure that there is no oil 18 N m 1 8 kgf m 13 3 ft lb leakage NOTICE If the oil pressure alert indicator comes on or if there is 4 Pour the specified amount of the oil leakage stop the engine and find recommended engine oil into the oil filler the cause Continued operation with a hole problem could cause severe engine Recommended engine oil 4 stroke motor oil with combinations of Checking the engine oil level the following SAE and API oil classifica 1 Check the engine oil level See Check tions ing the engine oil level 10 4 API SE SF SG SH SJ or SL damage SAE
208. option b Electrical e Variable trolling speed control tiller handle model or 6Y8 Multifunction Meter equipped model e Alert systems including low oil pressure overheat and water detection e New YDIS 1 32 version e Start in gear protection C Bracket unit e Long span mounts e Small and compact PTT PTT model e High pressure gas assisted hydro tilt nydro tilt model e Multifunction tiller handle d Upper case e Labyrinth idle exhaust system Lower unit e Lower unit equivalent to that of a one class higher model 1 1 Model features Model designation F40FER DL D 0 P Model description F 4 stroke regular rotation 20 40 Product generation F and up o E Electric starter L H Tiller handle Functions D Hydro tilt T PTT Transom height S S 15 in L L 20 in Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket ALT JR NP du s 1 1 Model name 2 Approved model code 3 Transom height 4 Serial number E Specification Model data BE ee I Dimension and Weight Overall length 1362 0 53 6 717 0 28 2 Overall width 384 0 15 1 Overall height 1228 0 e BBO vous L 1350 0 53 1 Boat transom height 414 0 S 16 3 414 0 16 3 L 536 0 21 1 Weight without propeller 97 1 92 1 93 6 tag ea ga 102 7 104 6 97 7 99 6 226 4 23
209. or cam in direction 0 e To increase the resistance turn the trim sensor cam in direction 4 Tighten the trim sensor cam screw to the specified torque Trim sensor cam screw 1 2 N m 0 2 kgf m 1 5 ft lb Clamp bracket and swivel bracket Hydro tilt Hydro tilt Part name Remarks E clip Shaft Bushing Bushing Bolt Washer Shaft Bushing Tilt lock lever Bolt Cap Hydro tilt assembly Anode Screw Collar Collar M8 x 15 mm M6 x 10 mm M6 x 25 mm 9 42 BRKT Bracket unit Removing the hydro tilt assembly Checking the hydro tilt anode 1 Check the anode Clean if there is A WARNING gt grease oil or scales NOTICE Do not When removing the hydro tilt assembly grease oil or paint the anode with the power unit installed make sure to suspend the outboard motor Installing the hydro tilt assembly 1 Tilt the swivel bracket to the fully up posi 1 Install the anode Q the bushings Q tion and then support it with the tilt stop and 8 lever 2 Install the hydro tilt assembly the upper mount shaft and the E clips 3 Install the collars 8 and the lower mount shaft 40 and then tighten the hydro tilt bolts 4 2 Remove the hydro tilt bolt the lower mount shaft the collars 4 and the bushings 3 Remove the E clips the upper mount shaft 8 the hydro tilt assembly the bushings 0 4D and the anode 2 Checking the hydro tilt 1
210. orce the fluid out of the cylinder and to return it to the reservoir and avoid damaging the cylinder The protection valve opens at 25 0 MPa 250 0 kgf cm 3625 0 psi Relief circuit When the outboard motor hits something in the water When the outboard motor is tilted up after colliding with an object while operating an upwardly directed force is applied to the tilt ram This force increases the fluid pressure in the tilt cylinder upper chamber allovving the 5 piston absorbers 8 to start functioning to avoid damaging the PTT unit For returning one piston absorber 9 functions to return the piston to the position of free piston 0 The piston absorber opens at 11 3 MPa 113 0 kgf cm 1638 5 psi Fluid flow when the outboard returns to the original position Fluid flow when the outboard collides with an object 2 22 E Rigging information Outboard motor installation rrnnornnnnornnnnvnnnnvrnnnnvrnnnnennnnnnn 3 1 DIMENSIONS serranos 3 2 SG die 3 2 DST EEE 3 5 A 3 6 Crate top cover pictograph description 0nnn000n00nn0n0nnn 3 7 Uncrate procedure rrannnnvnnnnnnnennnnnnvnnnnnnnnnnnnnnnnnnnnnnnenennnnnenennnnen 3 8 Mounting the outboard motor vrrrnnnnvvnnnnnvennnnnnvennnnnnvenennnnnn 3 9 Mounting the rigging grommet vvrrrsnnnnnnnvnnnnnnnnnnnvnnnnnnnnnne 3 11 Rigging grommet description e sese eee eee 3 11 Installing the tiller handle sss eee eee eee 3 11 Installing the shift cable
211. oting Troubleshooting the power unit trouble code not detected Troubleshooting when trouble codes are not available consists of the following 3 items Symptom 1 Specific trouble conditions Symptom 2 Trouble conditions of an area or individual part Cause The content considered as the trouble factors for symptom 2 Not applicable Symptom 1 Engine does not crank Refer to Gear shift not in the N position Set the gear shift to the N position Blown fuse Check the fuse sei Starter relay malfunction Check the starter relay Engine start switch malfunction Check the engine start switch Neutral switch malfunction Check the neutral switch Short open or loose connec Check the starter relay input voltage 5 30 tion in the starter motor circuit A 5 Check the wiring harness for continuity Starter motor malfunction Disassemble and check the starter motor Starter motor operates Starter motor malfunction Check the starter motor pinion but the engine does not Check the magnet switch crank Stuck piston or crankshaft Disassemble and check the power unit 7 52 Stuck drive shaft Check the drive shaft bushing Disassemble and check the lower unit Symptom 1 Engine will not start engine cranks Refer to Engine ECM does not Check the fuse operate Main relay malfunction Check the main relay Short open or loose connec Check for wiring continuity between the 5 16 tion in engine ECM circuit main relay
212. ower unit NOTICE Do not turn the drive shaft Installing the water pump counterclockwise Otherwise the 1 Install the plate and the rubber seal water pump impeller may be damaged 2 Install the dowels a new gasket 7 Install the seal 42 and the cover 3 and the outer plate cartridge TIP 3 Install the Woodruff key When installing the water pump housing apply grease to the inside of the insert car 4 Align the key way on the impeller tridge and then turn the drive shaft clockwise with the Woodruff key and then install while pushing down on the water pump hous the impeller ing Checking the lower unit for air leakage 1 Remove the gear oil check screw 1 and then install the special service tool 5 Install the insert cartridge 8 aligning the protrusion on the insert cartridge with the groove of the water pump housing 8 19 Drive shaft and lower case Leakage tester 2 90890 06840 2 Apply the specified pressure to check that the pressure is maintained in the lower unit for at least 10 seconds NOTICE Do not over pressurize the lower unit Otherwise the oil seals may be damaged Holding pressure 68 6 kPa 0 686 kgf cm 9 9 psi Shift rod push arm 90890 06052 3 If the specified pressure cannot be maintained check the drive shaft the propeller shaft and the shift rod oil seals for bends or damage 3 Install the dowels 8 and the hose
213. pressure drops to below the specified value and the oil pressure switch remains on for more than the specified period of time The injection and ignition to the cylinder 3 is stopped first If the engine speed does not drop to the target speed injection and ignition to the cylinders 3 and 2 will be also stopped Once the oil pressure switch is turned on and fully closed throttle is detected the engine speed control ends and automatically shifts to the normal operating mode Oil pressure switch ON 29 4 58 8 kPa 0 294 0 588 kgf cm 4 3 8 5 psi Low oil pressure is detected and control starts Cooling water temperature is at 40 C 104 or higher Control starts Once engine speed exceeds 1100 r min Low oil pressure duration Cylinders to stop injection and ignition 3 or 3 2 Max engine speed around 3000 r min When intake malfunctions The engine ECM will start the engine speed control upon detecting problems with the air pressure sensor when all the following conditions are satisfied the shift is at the F or R positions a fully closed signal is sent from the TPS engine speed exceeds the specified limit and the ISC valve is in the fully closed position The injection and ignition to the cylinder 3 is stopped first If the engine speed does not drop to the target speed injection and ignition to the cylinders 3 and 2 will be also stopped Once the throttle is opened and a signal different from that of the fully closed posit
214. re the bolts and firmly tighten the nuts only until the clamp bracket does not bite into the boat transom Firmly tighten the locknuts se BN ORK 3 3 10 wh Rigging information Mounting the rigging grommet Rigging grommet description a Alert indicator harness 6 Trolling switch harness C Extension wiring harness d Speedometer hose e Battery cable P 6Y8 Multifunction Meter harness Immobilizer wiring harness for European market Installing the tiller handle 1 Remove the nut and the nuts and then remove the steering retainer 2 Install the tiller handle assembly to the steering arm and then tighten the tiller handle nuts to the specified torque Tiller handle nut 37 N m 3 7 kgf m 27 3 ft lb Remove the plastic tie and then remove the main wiring harness coupler a Remove the cover 8 SB pe RQ Q 4 EN LT S PR Ze a Insert the extension wiring harness into the bottom cowling and then insert the battery cables into the bottom cowling Install the battery cables 0 KE Q a FDJ Q LAN GG 7 AR O Des S 6 NN dd BEG TU FEN QS amp 7 sp OSS ES 7 Install the cover 8 8 Connect the 10 pin coupler amp and then fasten it to the cover 8 with a plastic tie D 9 Install the extension wiring harness 9 to the clamp 4D and then fasten the extension wiring harness to the bracket
215. rt switch coupler 00000000690006000000 H Starting units and components Wiring harness continuity Checking the starter relay 1 Disconnect the starter relay connector a 2 Turn the engine start switch to START and then measure the starter relay input voltage Terminal 1 Terminal 30 Terminal 2 Terminal 26 8 Connect the engine ECM coupler P 5 30 sel ELEC ii Electrical system Starter relay input voltage Brown Br Ground 12 0 V battery voltage 3 Turn the engine start switch to OFF 4 Disconnect the starter relay leads and then remove the starter relay NOTICE Always disconnect the negative battery terminal before disconnecting the starter relay terminals 5 Connect the positive battery lead to the relay connector 8 and the negative battery lead to the relay lead and then check for continuity between terminals C and 0 Replace the starter relay if out of specification 5 31 6 Install the starter relay and then connect the starter relay leads Checking the engine start switch 1 Disconnect the 10 pin or engine start switch coupler 2 Check the engine start switch for continuity OFF EN START Tiller handle model and 703 remote control model 704 remote control model Switch position om oo gt 10400 L SG 3 Connect the 10 pin or the engine start switch coupler Checking the neutral switch tiller handle mode
216. s P Upper case and mounts Remove the lovver mount cover bolts 8 the covers 0 the lower mounts OD the washers 2 43 the rubber washers 4 the washers 5 the lower mounting bolts 6 and the caps AD av Installing the upper case 1 N Install the plate and the upper mount ing bolts 2 to the upper mount 8 and then install the upper mount assembly Tighten the upper mount bolts 4 temporarily 9 24 BRKT Bracket unit 3 Install the washers the rubber washers 7 the washers 8 and the lower mounting bolts to the lower mounts and then install the caps AD and the lower mount assemblies Install the lower mount covers 2 and then tighten the lower mount cover bolts 3 temporarily teg 5 D 572 Install the upper and lower mounting bolts into the bracket assembly simultaneously Install the upper mounting nuts 3 the washers 6 and the lower mounting nuts 4D and then tighten the upper mounting nuts 5 to the specified torque Upper mounting nut 45 24 N m 2 4 kgf m 17 7 ft lb Tighten the upper mount bolts and the lower mount cover bolts PORT and STBD 3 Install the ground lead Upper case DI 21 Num 2 1 kgf m 15 5 ft lb 21 N m 2 1 kgf m 15 5 ft lb CO CO NN OC Qn BE M Part name Bolt Dowel Rubber seal Guide Screw Baffle plate Upper case Grommet Gasket Plug Circlip Collar
217. s of the following 3 items Symptom 1 Specific trouble conditions Symptom 2 Trouble conditions of an area or individual part Cause The content considered as the trouble factors for symptom 2 Not applicable Symptom 1 PTT unit does not operate E Refer to 5 1 PTT relay does not oper Blown fuse Check the fuse MEN ate PTT switch malfunction Check the PTT switch 5 44 PTT relay malfunction Check the PTT relay Short open or loose connec Check the PTT switch input voltage 5 43 tion of the wiring harness 5 44 Check the PTT relay input voltage Check for wiring continuity between the PTT switch and the PTT relay 4 12 TRBL e SHTG 0 Troubleshooting Symptom 2 Cause Checking ste Ge ymp SE GEES PTT motor does not Check the PTT motor 9 50 tion of the PTT motor lead PTT motor and the PTT relay terminal PTT fluid pressure does not increase PTT fluid leakage Check the PTT unit for leakage 10 13 Clogged fluid passage Disassemble and check the PTT unit 9 58 Symptom 1 PTT unit does not hold the outboard motor up Refer to PTT fluid pressure does Manual valve opened Check the manual valve not increase Insufficient PTT fluid Add sufficient fluid 10 13 PTT fluid leakage Check the PTT unit for leakage 10 13 Clogged fluid passage Disassemble and check the PTT unit 9 58 Check the valves for damage Check the fluid passage for clog Troubleshooting the lower unit Troubleshootin
218. sary Working with crane e Outboard motors weighing 18 0 kg 39 7 Ib and over must be carried by a crane e Use a wire rope of adequate strength and lift up the outboard motor with the three point suspension e If the outboard motor does not have three or more points to be suspended support it with additional ropes or the like so that the outboard motor can be lifted and carried in a stable manner A Safety while working Handling of burner Incorrect handling of burner may result in burns Refer to the operation manual issued by the manufacturer to assure the correct handling e When using a burner keep it away from the gasoline and oil to prevent a fire e Components become hot enough to cause burns Do not touch them directly p Part lubricant and sealant Use only genuine parts lubricants and sealants or those recommended by when servicing or repairing the out board motor Handling of sealant e Wear protective gloves to protect your skin when using the sealants e Refer to the material data sheet issued by the manufacturer Some of the sealants may be harmful for human health a General information Special service tool Use the recommended special service tools to work safety and to protect parts from dam age Tightening torque Follow the tightening torque specifications provided throughout the manual When tight ening nuts bolts and screws tighten the large sizes
219. se with a gas torch and then install the drive shaft sleeve O original shim s T3 and a new taper roller bearing outer race OD NOTICE When heating the lower case heat the entire installation area evenly Otherwise the paint on the lower case could be burned Drive shaft and lower case TIP O2O222 e Install the drive shaft sleeve with the protru sion 9 facing forward e Do not reuse a shim if deformed or scratched 6 While holding the special service tool 8 strike the tool to check that the taper roller bearing outer race is installed properly If a high pitched metallic sound is produced when the special service tool is struck the outer race is installed properly Driver rod LL 8 90890 06605 Bearing outer race attachment 2 90890 06627 7 Install the water inlet covers 3 4 the nut 45 and the water inlet cover screw 6 and then tighten the water inlet cover screw 6 to the specified torque Sr SL Cas Q LS Re lt O 4 Water inlet cover screw 6 1 N m 0 1 kgf m 0 7 ft lb Assembling the forward gear 1 Install a new taper roller bearing 8 16 Lower unit y Installation depth 8 0 0 5 mm 0 0 02 in 2 Install a new O ring A Installing the shift rod drive shaft D and oil seal housing O art 1 Install a new O ring and a new oil seal UT T to the plate 9 2 Install the E clip the plate and a Bearing inner race attach
220. sealant to the parts e When assembling the lower unit after shimming is completed make sure to apply gear oil grease or sealant to the specified areas Shim location A H 8 28 Lower unit Selecting the pinion shim T3 e Spray anti rust lubricant on the bearing before installation Do not apply gear oil to the parts Otherwise correct measure ments cannot be obtained e Keep the parts free from foreign materials such as dirt or lint NOTICE Do not damage the measurement plane surface of the pinion height gauge Other wise accurate measurements cannot be obtained 1 Install the taper roller bearing and the drive shaft between and of the spe cial service tool D and then tighten the pinion height gauge bolts temporarily Pinion height gauge set 1 90890 06668 TIP Do not install the shim s T3 2 Install the pinion Q and the pinion nut Q and then tighten the pinion nut 8 temporarily 8 29 3 Check the gap between the pinion and the special service tool NOTICE When tightening the pinion nut check that the drive shaft rotates smoothly Also make sure that there is a gap between the pinion and the special service tool If there is no gap and the drive shaft does not rotate the special service tool could be damaged DD TIP If there is no gap the shim s T3 may not have been removed 4 Install the special service tool
221. sors the plastic air intake silencer 2 and intake manifold 8 the proven exhaust emission system and the optimally positioned covers are all incorporated to ensure Smooth and quiet operations The unit incorporates multipoint injectors 4 with high atomization performance and a computer controlled vapor reduction system to guarantee sure and reliable engine starts regardless of the ambient conditions 2 15 Power unit Lubrication system Lubrication system System diagram Oil pressure switch Oil pump Sleeve gt mme l iake and exhaust valves t t t Crankshaft journal Jam mme Carat journal t Main gallery Oil filter Relief valve J Am Oil pump Oil strainer lt A Engine oil flow 2 16 Technical features and description Cooling system System diagram Fuel cooler Thermostat Cooling water outlet Fuel cooler Exhaust guide em Exhaust cover Jam Thermostat S Cylinder block a Water pump t Propeller boss Trim tab water inlet Cooling water inlet y t t Water dm Cooling water flow Cooling system Intake and exhaust system Intake and exhaust system System diagram El Intake silencer N A V SS a Throttle body R EE T PTT fK Le Gi 2 By e P HET EL y 2 AN Intake manifold Exhaust guide ES Exhaust manifold Muffler YN YN O o 2 Q G O
222. ss inside diam eter Replace if out of specification Piston pin boss inside diameter 8 15 974 15 985 mm 0 6289 0 6293 in Checking the piston pin 1 Measure the piston pin outside diameter Replace if out of specification Piston pin outside diameter 8 15 965 15 970 mm 0 6285 0 6287 in Checking the connecting rod small end and big end inside diameter 1 Measure the connecting rod small end inside diameter and big end inside diameter b Replace the connecting rod assembly if out of specification Connecting rod small end inside diameter 15 985 15 998 mm 0 6293 0 6298 in Connecting rod big end inside diameter 36 000 36 024 mm 1 4173 1 4183 in Checking the connecting rod big end side clearance 1 Measure the connecting rod big end side clearance 8 Replace the connecting rod or crankshaft or both if out of specifi cation Cylinder block Connecting rod big end side clearance 8 0 05 0 22 mm 0 0020 0 0087 in Checking the crankshaft 1 Measure the crankshaft journal diameter a the crankpin diameter and the crankpin width Replace if out of spec ification Crankshaft journal diameter 42 984 43 000 mm 1 69231 6929 in Crankpin diameter b 32 984 33 000 mm 1 2986 1 2992 in Crankpin width 21 00 21 07 mm 0 8268 0 8295 in 7 56 Power unit 2 Measure the crankshaft runout Replace if above specificatio
223. ssure regulator bolts 4 and the nipple 48 to the specified torque 9 Install the fuel cooler 9 and then tighten the fuel cooler screws 20 to the specified torque Vapor separator disassembly Pressure regulator bolts 46 5 N m 0 5 kgf m 3 7 ft lb Nipple 8 4 N m 0 4 kgf m 3 0 ft lb Fuel cooler screw 20 3 5 N m 0 35 kgf m 2 58 ft lb 10 Install the fuel hose OD with the clamp and the fuel hose with the clamp 4 11 Install the cooling water hose and the fuel hose 6 12 Install the vapor gas hoses 88 and the pressure regulator hose 0 6 36 R Fuel system 13 Install the fuel hose GD and the drain hose 2 14 Install the cooling water hoses 8 and 4 JE QUO UNE si Be Vapor separator disassembly Fuel injector Fuel injector Remarks Fuel injector O ring set Fuel rail Holder Bolt M6 x 40 mm 6 38 ver py Fuel system Removing the fuel injector Checking the fuel rail Use a rag to catch any spilled gasoline when 1 Check the fuel rail Replace if cracked or removing the fuel Components deformed 1 Disconnect the fuel injector coupler 8 2 Check the fuel injectors See Checking 2 Remove the wiring harness from the the fuel injector 5 21 holder Installing the fuel injector 1 Install new O rings and to the fuel injector 1 2 Install the fuel injectors D onto the fuel rail and then in
224. stall the holders 4 Remove the holders 2 and the fuel injectors 8 6 39 3 Install the fuel rail assembly onto the cylinder head 4 Tighten the bolts 5 equally and gradually G 7 gt di a UN AS O es A Y l 5 Install the wiring harness to the holders and then connect the fuel injector couplers Fuel injector 6 40 Power unit Power unit check and adjustment rrnnnnnnnnvrnnnnvnnnnnvnnnnnn 7 1 Checking the compression pressure eee ee e eee eee 7 1 Checking the oil PreSSUre ccccooncnccccnonocononococonoconcnononnncnncnnonono 7 1 Checking the pulser coil air gap esse eee 7 1 Adjusting the pulser coil air gap ese eee 7 2 Checking the valve clearance esse eee ee eee 7 2 Adjusting the valve clearance eee eee e eee ee ee 7 4 Power unit assembly 7 5 Removing the power unit see eee ee ee ee ee ee eee 7 7 Installing the power unit 7 9 Flywheel magnet and timing belt ooccconcccncnccnoonnoo 7 12 Removing the flywheel magnet sse eee ee eee ee ee eee 7 14 Removing the stator assembly eee ee ee ee ee ee eee 7 14 Removing the timing belt and Sprocket 7 14 Checking the timing belt and sprocket sese eee 7 15 Installing the sprocket and timing belt esse eee eee eee eee ee 7 16 Installing the Stator assembly 7 17 Installing the flywheel magnet esse eee ee ee eee
225. sting the throttle link rod and throttle cable 10 14 Checking the top cowling esse sees eee eee 10 14 Checking the valve clearance esse eee ee eee 10 14 Checking the water pump esse e eee eee ee eee 10 14 Maintenance Outline e To ensure long product life Selva strongly recommends the specified periodic check and main tenance to be performed according to the maintenance interval chart If replacement parts are necessary use only genuine Selva parts of equivalent design and qual ity Any parts of inferior quality may cause malfunction and the resulting loss of control could endanger the operator and passengers Selva genuine parts and accessories are available from Selva dealers The service intervals provided in the Maintenance Chart are based upon typical operating condi tions that include speed variations sufficient time for engine warm up and cool down medium to light load and an average cruising speed in 3000 to 4000 r min range lf your normal operating conditions are more intensive more frequent servicing will be required especially the engine oil and gear oil changes Examples of the intensive operation will be wide open throttle trolling or idling operations for extended period of time carrying heavy loads or frequent starting and stop ping or shifting In most cases the frequent maintenance pays off in increased engine life and greater owner satisfaction Consult Selva dealer for additional recommen
226. stop lever works properly SS OG a 3 Check the PTT unit for fluid leakage Adjusting the shift cable 1 Remove the shift cable and then adjust it See Installing the shift cable and throt tle cable remote control model 3 14 Checking the spark plug 1 Check the spark plugs See Checking the spark plug 7 42 Checking the timing belt 1 Check the timing belt See Checking the timing belt and sprocket 7 15 Replacing the timing belt 1 Replace the timing belt See Flywheel magnet and timing belt 7 12 Checking the thermostat 1 Check the thermostat See Checking the thermostat 7 49 Adjusting the throttle link rod and throttle cable 1 Adjust the throttle link rod See Adjusting the throttle link rod 6 23 2 Install the throttle cable See Installing the shift cable and throttle cable remote control model 3 14 Checking the top cowling 1 Check the fitting by pushing the top cowl ing with both hands Adjust if there is free play 2 Loosen the nuts 1 3 Move the hook 2 up or down slightly to adjust its position General Periodic Maintenance 6 ode o y TIP e To loosen the fitting move the hook in direction a e To tighten the fitting move the hook in direction 4 Tighten the nuts 5 Check the fitting again Replace the cowling seal if the free play cannot be adjusted Checking the valve clearance 1 Check
227. t 1 4 Fuel control units and components 5 20 Fuel filter assembly 6 7 Fuel NOS ica 6 1 Fuel injection Control 2 7 Fuel injection control system 1 6 Fuel Mec TT 6 38 FU ME ii 6 4 Fuel pump assembly 6 12 Fuel System eee eee 1 8 1 13 Fuel system technical data 1 8 Fuel unit and ignition unt A 3 FUNCION treet mente tet rere 4 2 G GAUPE SEN 1 8 Ea THT EE 1 1 General Periodic Maintenance 10 8 General tightening torque 1 16 H Handling of burner 0 2 Handling of gasoline 0 1 Handling of sealamt 0 2 Hardware requirement 4 1 FOSC TOUUNG ennemis 6 1 FIOL DA da drid 0 1 How to use this manual eee ee eee 0 4 Ignition timing Control 2 6 Ignition timing control system 1 5 Ignition units and components 5 26 Installing the 6Y8 Multifunction Meter harness remote control model 3 16 Installing the battery eee eee eee 3 19 Installing the clamp bracket 9 40 Installing the cylinder head 7 31 Installing the exhaust cover 7 50 Installing the flushing hose 9 21 Installing the flywheel magnet 7 18 Installing the friction plate assembly
228. t of specification RE Brush standard length 12 3 mm 0 48 in Wear limit O 5 5 mm 0 22 in Assembling the starter motor NOTICE Do not allow grease or oil to contact the armature commutator Checking the brush 1 Push the brushes 8 into the holders 1 Check the brush holder assembly for and then install the armature to the continuity Replace the brush holder brush holder assembly assembly if out of specification DE ANONY e YN Y GS 00 9 38 sel ELEC i Electrical system 2 Install the armature assembly 2 to the bracket 3 and then install the stator 6 Install the pinion shaft assembly 8 the lever the planetary gears 0 and the 3 Install the outer gear the clutch rubber seal assembly and the stopper onto the pinion shaft 4 Install the clip into the pinion shaft groove 5 Install the clip into the groove on the stopper by tapping the pinion shaft 8 Install the bracket 4 5 39 Starter motor 6Y8 Multifunction Meter sensor 6Y8 Multifunction Meter sensor Checking the water pressure sensor option 1 Disconnect the water pressure sensor coupler 8 2 Turn the engine start switch to ON and then measure the input voltage at the water pressure sensor coupler 9 Install the magnet switch 2 cap and the starter motor lead 03 10 Tighten the starter motor lead screw to the specified torq
229. t reusable TIP Install a new needle bearing with the identi fication mark facing toward the water pump side When using the driver rod do not strike the special service tool in a manner that will force the stopper O out of place Heat the installation area of the taper roller bearing outer race in the lower case with a gas torch and then install the drive shaft sleeve original shim s T3 0 and a new taper roller bearing outer race NOTICE When heating the lower case heat the entire installation area evenly Otherwise the paint on the lower case could be burned Driver rod LL 8 90890 06605 Bearing outer race attachment 2 90890 06627 Install the water inlet covers 3 the nut and the water inlet cover screw b and then tighten the water inlet cover screw 6 to the specified torque er A Water inlet cover screw 8 1 N m 0 1 kgf m 0 7 ft lb Assembling the forward gear 1 Install a new taper roller bearing 0 4 a General information Abbreviation The following abbreviations are used in this service manual Ip omia gt R free gt au Society of Automotive Engineers TPS OO O O O Throttle Position Sensor WF Waern Fuel 7 ON AE DC PS F S T T VV 0 5 How to use this manual Sealant and locking agent Sealant and locking agent Symbol Symbols in an exploded diagram or illustration indicate the grade of
230. tage Intake pressure Battery voltage Water temperature Oil press switch e Record of engine oil exchange This function can record the history of engine oil exchanges TRBL d SHTG e Troubleshooting YDIS kit ltem Q ty wp m KON CD ROM software instruction manual ans Communication cable YDIS CD ROM Ver 1 32 D 60V WS853 05 YDIS KIT O 9 60V 85300 05 Connecting the communication cable to the outboard motor a YDIS coupler gray YDIS connecting harness 1 90890 06882 Y DIS Troubleshooting the power unit Troubleshooting the power unit Troubleshooting procedure 1 Before troubleshooting the outboard motor make sure that fresh fuel of the specified type has been used 2 Make sure that all electrical connections are secure and free from corrosion and that the battery is fully charged 3 Check the trouble code using the YDIS first and then check the electronic control system following the trouble code chart 4 When a trouble code is detected check the data logger of the engine ECM record data graph as well 5 If a trouble code is not detected check as well the power unit according to Troubleshooting the power unit trouble code not detected 4 9 6 Before using the YDIS to check the power unit check the engine ECM circuit See Checking the engine ECM circuit 5 16 TP AA e When deleting the diagnosis record on the YDIS make sure to check the time that the
231. tage cannot be mea sured properly Digital circuit tester 90890 03174 TIP Before measuring the peak voltage check all the wiring for proper connection and cor rosion and check that the battery is fully charged Use the peak voltage adapter B with the recommended digital circuit tester Connect the positive pin of the peak voltage adapter B to the positive terminal of the dig ital tester and the negative pin to the nega tive terminal When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode 5 14 sel ELEC i Electrical system Checking by using the digital tester The electrical technical data apply to the measurements taken by the Selva recom mendation tester The resistance shown is the value taken before engine start lt may change depending on the environmental conditions and the ambient temperature Input voltage changes depending on the bat tery voltage If the tester probe cannot be inserted into the coupler prepare a test lead suitable for the measurement TY Digital circuit tester 90890 03174 Test lead Terminal male commercially avail able Terminal female 2 commercially avail able TIP Use a terminal of appropriate size for the coupler terminal to be measured lf a terminal of appropriate size is not available adjust the width of the terminal 1 with a grinder Engine control units and components Checking the main
232. ted average BL1 from Measuring the forward gear backlash Example BL1 0 10 mm T1 adjustment 0 15 mm from the Forward gear shim T1 selection chart The current shim thickness must be decreased by 0 15 mm Backlash measurement BL1 Shim thickness adjustment 8 34 Lower unit TIP If the shim thickness adjustment value is positive the current shim thickness must be increased by that amount and if the value is negative the current shim thickness must be decreased by that amount The gray colored area on the selection chart indicates the range of the specified backlash Shimming is not required if the measured backlash is within the gray col ored area The values for the shim thickness adjust ments specified in the selection chart are intended to achieve the median value within the range for the specified forward or reverse gear backlash The table below the selection chart shows the shim thickness adjustments for the points marked on the chart 4 Calculate the new forward gear shim thickness T1 in the same way as in the example Calculation formula New forward gear shim thickness T1 Cur rent forward gear shim thickness Shim thickness adjustment Example If the current forward gear shim thickness is 0 50 and the shim thickness adjustment is 0 20 mm then T1 0 50 mm 0 20 mm 0 50 mm 0 20 mm 0 30 mm Available shim thicknesses 0 10 0
233. tem 1 Pulser coil 9 Neutral switch 2 Thermo sensor High pressure fuel pump 8 Ignition coil OD Fuel injector 4 Oil pressure switch 2 Fuel filter built in water detection switch 6 Engine ECM 6 Main relay 7 Vapor shut off valve Throttle body built in TPS air pressure sen sor air temperature sensor ISC valve 2 2 Technical features and description Engine ECM control systems Ignition timing control Adjusts the ignition timing according to the engine operating conditions See Ignition timing control 2 6 Fuel injection control Adjusts the injecting timing and volume according to the engine operating conditions See Fuel injection control 2 7 Idle speed control During idle the engine ECM controls the ISC valve opening by adjusting the stepping motor positions in order to achieve the target idle speed When reducing speed the control system closes the ISC valve and also initializes the valve position by returning it to the fully closed position when the engine start switch is turned to OFF Fuel pump control Keeps the high pressure fuel pump in operation for 3 seconds after the engine start switch is turned to ON and during engine operation Vapor shut off valve control Performs duty controls of the vapor shut off valve between the fully open and the fully closed positions to decide the engine intake volume of fuel evaporation gas depending on the engine operating conditions As t
234. the exploded diagrams see 4 in the figure below for an example and in the related detailed instructions Some torque specifications are listed in stages as torque figures or angles in degrees e Separate procedures and illustrations are used to explain the details of removal checking and installation where necessary see 6 in the figure below for an example page TIP For troubleshooting procedures see Chapter 4 Troubleshooting Drive shaft and lower case TIP Install the drive shaft sleeve with the protru sion facing forward Do not reuse a shim if deformed or scratched 6 While holding the special service tool 8 strike the tool to check that the taper roller bearing outer race is installed properly H a high pitched metallic sound Driver rod SL 6 90890 06602 is produced when the special service tool Needle bearing attachment is struck the outer race is installed 90890 06614 properly Bearing depth plate 8 90890 06603 Installation depth amp 40 N m 4 0 kgf m 29 5 ft lb 182 5 183 0 mm 7 19 7 20 in 9 N m 0 9 kgfm 6 6 ft lb 19 N m 0 9 kgf m 6 6 ft lb Zz o Part name Drain screw Gasket Bolt Check screw Dowel Hose nipple Plastic tie Hose Nipple Bolt Lower unit Anode Propeller nut Cotter pin Washer Washer Propeller 0 JO O1 E GM de Ee jr E es lt Not reusable M10 x 40 mm Not reusable M8 x 35 mm No
235. the figures after the 1 100 place without rounding Example mm Measurement point Measurement point Measurement point Measurement point Truncated average 16 Check that the forward gear backlash average is within specification 8 26 Lower unit Forward gear backlash 0 18 0 66 mm 0 0071 0 0260 in TIP Adjust the shim thicknesses if the forward gear backlash is out of specification 17 Remove the special service tools 18 Apply a load to the reverse gear by installing the propeller 42 without the spacer 3 the washers 4 5 and the propeller nut 6 19 Tighten the propeller nut to the specified torque Propeller nut 46 shimming 10 N m 1 0 kgf m 7 4 ft 1b 20 To measure the reverse gear backlash proceed to the step 8 step 15 21 Check that the reverse gear backlash average is within specification Reverse gear backlash 0 75 1 23 mm 0 0295 0 0484 in 8 27 TIP Adjust the shim thicknesses if the reverse gear backlash is out of specification 22 Remove the special service tools and then install the water pump assembly See Installing the water pump 8 19 Shimming Shimming e Before selecting the forward gear shim s T1 and reverse gear shim s T2 make sure to select the pinion shim s 13 e When assembling the lower unit to measure the backlash after selecting the pinion shim s 13 do not apply gear oil grease or
236. tie D and then disconnect the 10 pin coupler 8 4 Remove the extension wiring harness b from the clamp 8 and the plastic tie O 5 Remove the cover 0 6 Remove the battery cables 1 1 1 7 Remove the caps 2 and then remove the PTT motor leads 43 from the PTT relay 44 the clamp 5 and the plastic ties PTT model S S CA N Ni gt y 8 Disconnect the neutral switch coupler C and the 6Y8 Multifunction Meter harness coupler 9 Disconnect the trolling switch coupler and the alert indicator coupler tiller handle model 10 Remove the each harness from the clamps 7 11 Remove the water pressure sensor harness from the clamp 8 Ai DL Leary H De ent S Gr Power unit assembly 12 Remove the cooling water hose 9 EGET IN LY gt 4 Ce URL 13 Remove the fuel hose 00 i BE A Nr lee TN dE SN Le ay LSS 19 Install the shackles to the engine hangers and then install the lifting harnesses to the shackles 8 20 Suspend the power unit 2 Remove the power unit mounting bolts 30 and then remove the power unit 16 Remove the clip 9 and then remove the shift rod lever from the shift rod bracket 2 17 Remove the bracket 68 7 8 Power unit Installing the power unit 1 Clean the power unit mating surface and then install a new gasket 2 Install the power unit with the power
237. timing based on the engine ECM command signals Ignition coll Activates the ignition at the optimum timing based on the signals from the engine ECM High pressure fuel pump Pressurizes the fuel in the vapor separator and delivers the fuel to the fuel rail ISC valve Adjusts the amount of intake air entering the engine at idle Throttle body The TPS the intake pressure sensor the air temperature sensor and the ISC valve are incorpo rated into the throttle body assembly Idle speed cannot be adjusted manually because it is con trolled by the engine ECM Adjusting the TPS will not be necessary TPS ISC valve i ES Air pressure sensor E EN D E gt SS Be Jai Air temperature sensor L EE Bypass air Vapor gas 2 4 Technical features and description Pulser coil A single pulser coil determines the engine revolutions the crankshaft angle and the direction of the crankshaft rotation The pulser coil also detects the changes in pulse using the convexo concave shape in the outer edge of the flywheel magnet The engine ECM figures out the crankshaft angle based on the pulse signal changes Pulser coil Convexo concave shape Signals from the pulser coil and the ignition and injecting timing are as follows Injection and ignition orders are 1 3 2 but combustion order is 1 2 3 The engine ECM determines that the crankshaft angle is 43 TDC because there is no pulse signal
238. tion te r gt Crankpin oil clearance 0 016 0 040 mm 0 0006 0 0016 in A Selecting the crankpin bearing 1 When replacing the crankpin bearing select the suitable bearing as follows N Check the connecting rod mark a or painted color b 3 Check the crankpin mark Cylinder block bi P P3 4 Select the bearing color for the crankpin bearing from the table Crankpin bearing selection table at 20 C 68 F Connecting rod Crankpin Bearing mark color amp mark color Rec am B E Pink A KE Yellow 8 Green Checking the crankshaft journal oil clearance 1 Clean the crankshaft journal bearings the crankshaft journals and the bearing portions of the crankcase and the cylin der block 2 Place the cylinder block upside down 7 98 Power unit 3 Install the crankshaft journal bearings D and the crankshaft 2 into the cylinder block A A A TIP Install the crankshaft journal bearings in their original positions 4 Put a piece of Plastigauge PG 1 onto the crankshaft journals parallel to the crankshaft L GI dk S A AS S A A A TIP Do not put the Plastigauge PG 1 over the oil hole in the crankshaft journal 5 Install the crankshaft journal bearings into the crankcase TIP Install the crankshaft journal bearings in their original positions 6 Install the crankcase onto the cylin
239. top edge and then use a 45 cutter to cen ter the area and set its width 30 lt b Previous contact width e If the valve seat contact area is too narrow and situated near the bottom edge of the valve face use a 60 cutter to cut the valve seat bottom edge and then use a 45 cut ter to center the area and set its width b Previous contact width 7 40 Power unit 7 After refacing the valve seat to the Checking the camshaft specified contact width apply a thin 1 Measure the cam lobe height amp and even layer of lapping compound onto the width 6 Replace if out of specification valve seat and then lap the valve using the special service tool M NOTICE Do not get the lapping compound on the valve stem and valve guide Cam lobe height 8 Intake 30 3 30 83 mm 1 2101 1 2141 in Valve lapper 1 90890 04101 Exhaust 8 Check the valve seat contact area again 30 933 31 033 mm See Checking the valve seat 7 38 D dei ir 8 in 25 950 26 050 mm 1 0217 1 0256 in Checking the rocker arm and rocker arm shaft 1 Check the rocker arms the rocker arm 2 Measure the camshaft runout Replace if shaft and the contact surface a of each above specification rocker arm Replace if worn Measure the rocker arm inside diameter 6 and the rocker arm shaft outside diameter Replace if out of specification N Camshaft runout 0 007 mm 0 0003 in
240. torque PTT model 9 10 BRKT Bracket unit re lA va NA Hydro tilt model PTT model Throttle grip screw 0 2 N m 0 2 kgf m 1 5 ft lb PTT switch screw 4 2 N m 0 2 kgf m 1 5 ft lb 9 Install the holders PTT model 10 Check that the throttle grip operates smoothly and then check that the marks and are aligned and that the cut aways and 9 are also aligned 9 11 11 Check that the shift link lever operates smoothly when the shift lever is shifted from the N to the F or R position 12 Check that the neutral switch D operates properly en Paro A VIN GE S SZ VIs fs Wax Lei Ke BS OT NE RE Br 2 STE N Sus Cl N So JA A 13 Connect the connectors of the PTT switch Red R lead the Sky blue Sb lead and the Light green Lg lead PTT model 14 Connect the connectors of the neutral switch Brown Br leads and then install the holders 8 27 and the bracket 28 NA W a Rel ne 15 Install the shift cable 9 the throttle cable 30 the clips GD and the cable clamps 2 16 Connect the alert indicator couplers and h and then install the cover 83 17 Install the grease nipple and then tighten it to the specified torque 18 Install the bushings 5 the washers Gb and then install the bracket 67 19 Tighten the tiller handle bracket bolt 88 to the specified torque 20 Tighten the tiller
241. trouble codes were detected e When checking the input voltage of a part the coupler or connector must be disconnected As a result the engine ECM determines that the part is disconnected and a trouble code is detected Therefore make sure to delete the diagnosis record after checking the input voltage Troubleshooting the power unit using the YDIS 1 Use the trouble codes displayed by the YDIS to check each part according to the Trouble code and checking step table 2 Delete the trouble codes after checking repairing or replacing a part and check that the trouble codes are not detected again lf the same trouble codes are detected the engine ECM may be faulty 3 Check the items listed in the table If all the items are in good condition delete the trouble code and then check the trouble codes again If the same trouble codes are detected again the engine ECM is faulty Trouble code table O Indicate Not applicable Trouble ien Diagnostic YDIS diagnosis YDIS diagno code flash indicator sis record No trouble Functioning properly Water temp sensor malfunction Thermo sensor malfunction Throttle position sensor malfunction Intake temp sensor malfunction Air temperature sensor malfunction 27 Water in fuel 2 Shift position switch malfunction Neutral switch OF F Bd en Battery voltage malfunction Charging system malfunction 3 15 18 19 23 8 4 4 TRBL P SHTG e Troubleshooting
242. ue Water pressure sensor input voltage Orange O Black B 4 7 5 5 25 V 3 Remove the water pressure sensor and then connect the pressure pump D and the test harness 3 pins 2 4 Apply positive pressure to the water pres sure sensor slowly and then measure the output voltage Starter motor lead screw 4 3 N m 0 3 kgf m 2 2 ft lb TIP Check the starter motor operation before installing it to the power unit See Checking the starter motor operation 5 35 Installing the starter motor 1 Install the starter motor to the power unit See Installing the starter motor 7 29 Pressure pump 1 commercially available Test harness 3 pins 2 90890 06869 9 40 sel ELEC i Electrical system 2 Turn the engine start switch to ON and then measure the input voltage at the speed sensor coupler Water pressure sensor output voltage reference data Blue Black L B Black B 2 5 V at 392 0 kPa 3 92 kgf cm 56 8 psi 4 5 V at 784 0 kPa 7 84 kgf cm 113 7 psi 5 Turn the engine start switch to OFF and then disconnect the test harness 2 and the pressure pump 6 Disconnect the engine ECM coupler Speed sensor input voltage Orange O Black B 4 75 5 25 V 3 Remove the speed sensor and then con nect the pressure pump 1 and the test harness 3 pins 4 Apply positive pressure to the speed sen sor slowly and then measure t
243. uicker detection and analysis of engine malfunctions By connecting your computer to the engine ECM of an outboard motor using the communication cable this software can be used to display sensor data and data stored in the engine ECM on the computer s monitor If this software is run on Microsoft Windows 2000 Windows XP or Windows Vista the information can be displayed in colorful graphics Moreover the software can be operated using either a mouse or a keyboard In addition the data for the main functions Diagnosis Diagnosis record Engine monitor Data log ger and Record of engine oil exchange can be saved on a disk or printed out Hardware requirement Make sure that your computer meets the following requirements before using this software Computer IBM PC AT compatible computer Operating system Microsoft Windows 2000 Windows XP or Windows Vista CPU Windows 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 Windows Vista Core family 1 6 GHz or higher Core family 2 0 GHz or higher recommended Memory Windows 2000 64 MB or more 128 MB or more recommended Windows XP 128 MB or more 256 MB or more recommended Windows Vista Hard disk free space 1 GB or more 20 MB or more 40 MB or more recommended Drive CD ROM drive Display VGA 640 x 480 pixels 256 or more colors SVGA 800 x 600 pixels or more recommen
244. unit mounting bolts 3 Tighten the power unit mounting bolts and the upper case bolts to the specified torque in the sequence numbers LJ 2 in both stages 4 Tighten the upper case bolts to the specified torque 7 9 Power unit mounting bolt 1st 21 N m 2 1 kgf m 15 5 ft lb 2nd 21 N m 2 1 kgf m 15 5 ft lb Upper case bolt 1st 21 N m 2 1 kgf m 15 5 ft lb 2nd 21 N m 2 1 kgf m 15 5 ft lb Upper case bolt 4 21 N m 2 1 kgf m 15 5 ft lb 5 Install the apron and the apron bolts 6 and then tighten the apron screws 7 to the specified torque LT A o o L 2 A el Apron screw 3 N m 0 3 kgf m 2 2 ft lb 6 Install the bracket 8 7 Install the shift rod lever Q to the shift rod bracket 40 and then install the clip 4 8 9 Install the cooling water hoses 3 Power unit assembly 10 Install the fuel hose AO LET SS SJ RS a SSS 11 Install the cooling water hose 45 TNA a NN NG NES AG W Y TAQ Ak 12 Install the water pressure sensor harness a to the clamp 6 O Sy NA te E ent 4 13 Connect the trolling switch coupler and the alert indicator coupler tiller handle model 14 Connect the neutral switch coupler and the 6Y8 Multifunction Meter harness coupler 15 Install the each harness to the clamps 7 7 10 Power un
245. units and components rsnvrrnrnnvrrnvnnvrnnnnn 5 15 Checking the main relay srren 5 15 Checking the engine ECM circuit esse ee eee 5 16 Checking the throttle body esse sees 5 17 Checking ThE TPS save 5 18 Checking the IOG sser E 5 18 Checking the oil pressure switch eee eee ee eee 5 18 Checking the alert indicator tiller handle model 5 19 Checking the alert DuZZer esse eee 5 20 Checking the trolling SWITCH esse eee eee eee 5 20 Fuel control units and components es esse sss esse 5 20 Checking the water detection switch sse eee eee 5 20 Checking the fuel INE save 5 21 Checking the high pressure fuel pump esse eee eee ee eee 5 22 Checking the vapor shut off valve see eee eee e 5 23 Charging units and components svrrennnvnnnnnvennnnnvrnnnnnvnennn 5 24 Checking the lighting coil Stator assembly 5 24 Checking the Rectifier Regulator esse eee 5 25 Ignition units and components rrrnrnnvnnrnnnvnnnnnnnvrernrnnveennnn 5 26 Checking the ignition Spark 5 26 Checking the engine ECM occccoccncccccncccccncoconcncconcncnnncnnnnanonoss 5 26 Checking the spark plug cap ccccceeeeeseeeeeeseeeeeeeeeeeeaeeeeeas 5 27 Checking the ignition coll 5 27 CNECKING RE PUSET COI EE 5 27 Checking the air temperature sensor eee eee ee ee e ee 5 28 Checking the air pressure Sensor eee eee e e e eee eee 5 28 Checking the thermo Sensor eee eee ee eee eee eee e 5 29 Checking the
246. upler 8 Checking the neutral switch 1 Disconnect the neutral switch coupler 8 2 Turn the engine start switch to ON and then measure the input voltage 0 0 dD 0 000 009 6 Measure the thermo sensor resistance Thermo sensor resistance reference data at 20 C 68 F 26 460 RO at 75 C 167 F 0 370 kQ at 90 C 194 F 240 3 Q Neutral switch input voltage reference data Blue Green L G Black B 8 Disconnect the engine ECM coupler 11 1 V 7 Install the thermo sensor See Installing the thermo sensor 7 50 3 Turn the engine start switch to OFF 5 29 Ignition units and components Starting units and components 4 Remove the neutral switch 9 Install the neutral switch and then con nect the neutral switch coupler 8 5 Check the neutral switch continuity Checking the engine shut off switch 1 Disconnect the 10 pin or the engine start switch coupler 2 Turn the engine start switch to ON and then check the engine shut off switch for continuity 1 Neutral switch continuity Tiller handle model and 703 remote control model 704 remote control model Terminal Switch position Clip removed 7 Check the wiring harness for continuity Clip installed Button pushed in a S 1 ES 1 Tiller handle model only 3 Turn the engine start switch to OFF O OOO OOOO OOO O SO O OOO 4 Connect the 10 pin or the engine sta
247. ve any flammable substances such as gasoline and oil around the working area e Keep good ventilation while working 1 Install the original shim s 11 TP e If the original shim s T1 are missing install new shims with a combined thick ness of 0 50 mm e DO not reuse a shim if deformed or scratched 2 Install the taper roller bearing outer race See Assembling the lower case 8 15 step 2 and step 3 3 Install the forward gear assembly the drive shaft the pinion and the pinion nut See Installing the shift rod drive shaft and oil seal housing 8 17 step 4 step 7 4 Check that the drive shaft rotates smoothly 5 Install the propeller shaft housing assembly See Installing the propeller shaft housing assembly 8 18 6 Check that the drive shaft rotates smoothly Shimming 7 Measure the forward gear backlash See Measuring the forward and reverse gear backlash before disassembly 8 25 step 3 step 16 Forward gear backlash 0 18 0 66 mm 0 0071 0 0260 in Adjusting the forward gear shim thickness T1 1 Remove the taper roller bearing outer race See Disassembling the lower case 8 13 step 3 2 Measure the thickness of each original shim s T1 in 2 places TIP Do not reuse a shim if deformed or scratched 3 Determine the forward gear shim thickness T1 adjustment using the Forward gear shim T1 selection chart according to the trunca
248. y screw in the shift cable joint to be screwed in a minimum of 8 0 mm the shift cable 0 31 in 3 Set the remote control lever to the N Dimension h 8 0 mm 0 31 in or more position 8 Install the clip and then tighten the 4 Align the pin b with the mark on the shift cable locknut to the specified shift bracket 6 torque 3 14 wh Rigging information Shift cable locknut 7 5 Nm 0 5 kgf m 3 7 ft lb 9 Fully screw in the throttle cable joint 8 to the throttle cable 9 10 Check that the throttle control lever k contacts the stopper M Beat SE 11 Align the protrusion on the throttle lever 9 with the protrusion on the shift bracket 6 12 Adjust the throttle cable joint 8 and then install the throttle cable joint 8 to the pin of the throttle lever WARNING The throttle cable joint must be screwed in a minimum of 8 0 mm 0 31 in 3 15 Dimension 8 8 0 mm 0 31 in or more TIP A Pull the inner cable to avoid free play back lash 13 Install the clip and then tighten the throttle cable locknut OD to the specified torque y Throttle cable locknut 4 5 N m 0 5 kgf m 3 7 ft lb 14 Check the shift cable and the throttle cable for proper operation 15 Install the grommet 42 y SOL ET enn PS d L Mounting the rigging grommet Optional equipment Installing the wiring harness remote control model 1
249. ystem Switch poston os Wiring harness continuity a Terminal 1 8 Terminal 1 a Terminal 28 Terminal 2 a Terminal 3 Terminal 7 Connect the PTT relay coupler and 4 Disconnect the PTT relay coupler the PTT switch coupler 8 EN 1e 8 Install the fuse OD Checking the PTT switch tiller handle model 1 Disconnect the PTT switch connectors uke TONG E SS VC HN Oy AN X J Rh y O LA lR SK d EX ri FIN VE PTT switch connector and the ground a 2 Measure the input voltage between the 5 Remove the fuse al ah Bo 7 Vv eL a dE PTT switch input voltage Red R Ground 12 0 V battery voltage 3 Check the PTT switch for continuity Replace if out of specification 6 Check the wiring harness for continuity 5 44 sel ELEC i Electrical system LA Sb b L 1 SF E IE Y 3 ANA qd N sn NA A O Lg IL amp A GC Co FET Nr Switch Terminal position UP oo gt 4 Disconnect the 10 pin coupler and the PTT relay coupler Cf AN APS 7 SIG y gt DON ZY Terminal 1 Terminal Wiring harness continuity ei Terminal 5 Terminal 2 ER e Terminal 7 7 Terminal 1 GI s Ju Co Ler 7 Connect the PTT relay coupler the L AT 10 pi ler and the PTT switch E La pIN COUP er an e SWITC Te R Ap

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