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Killer Whale150 EFI

1. Blowby hoses Fuel hose fuel tank to fuel filter 3 Fuel hoses fuel filter to fuel pumps Fuel hoses fuel pumps to fuel filter Fuel hose fuel filter to vapor separator High pressure fuel hose vapor separator to fuel rail Fuel hose pressure regulator to fuel cooler Fuel hose fuel cooler to vapor separator 63P3F 11 Special service tools Hose routing S63P4060 Fuel system Fuel filter fuel pump and intake silencer S63P4070 Remarks z Part Intake assembly Bolt Bolt Intake silencer Bolt Grommet Collar Bolt Fuel pump Bolt Fuel filter Bolt Grommet Collar Holder 2 lt M8 x 40 mm M8 x 20 mm M6 x 45 mm M6 x 20 mm M6 x 30 mm M6 x 30 mm N N N O N LS Q 4 3 63P3F11 Fuel filter fuel pump and intake silencer S63P4080 No Part name Q ty Remarks 1 Throttle lever 1 1 2 Throttle cam 1 3 Throttle lever 2 1 4 Throttle link rod 1 5 Bolt 1 M6 x 35 mm 6 Bolt 2 M6 x 25 mm 7 Collar 3 8 Wave washer 3 9 Washer 3 10 Spring
2. S63P5680 3 Remove the crankcase bolts in the sequence shown na r1 x Q e a E S63P5690 NOTE Do not remove the plugs D from the crank case 4 Remove the connecting rod bolts and the connecting rod caps and then remove the connecting rod and piston assem blies S63P5700 5 41 NOTE s Be sure to keep the bearings in the order as they were removed Mark each piston with an identification number 8 of the corresponding cylinder Do not mix the connecting rods and caps Keep them organized in their proper groups 5 Remove the main bearing cap bolts in the sequence shown S63P5710 6 Remove the crankshaft Checking the balancer assembly 1 Check the teeth of the balancer shaft gear for cracks or wear Replace the bal ancer assembly if necessary ULIS 11 i S63P5C20 Checking the piston diameter 1 Measure the piston outside diameter at the specified measuring point Replace if out of specification 63PSF11 S60C 5820 Piston diameter 93 928 93 934 mm 3 6979 3 6982 in Measuring point 5 0 mm 0 20 in up from the bottom of the piston skirt Checking the cylinder bo
3. S63P8100 6 11 Ignition and ignition control system 3 Measure the pulser coil output peak volt Ignition coil resistance age Replace the pulser coil if below Primary coil specification Red R Black white B W 1 53 2 07 Q at 20 C 68 F Secondary coil 12 50 16 91 at 20 C 68 F Checking the ECM 1 Disconnect a ignition coil coupler 2 Connect the test harness 2 pins to the ignition coil S63P8120 3 Measure the ECM output peak voltage If X Digital circuit tester 90890 03174 below specification measure the pulser d Peak voltage adapter B coil output peak voltage Replace the 90890 03172 ECM if the output peak voltage of the Test harness 3 pins 90890 06791 pulser coil is above specification Pulser coil output peak voltage White red W R Black B White black W B Black B Unloaded Loaded Cranking 1 500 3 500 3 5 3 6 23 9 49 7 S63P8110 Pulser coil resistance use as reference Digital circuit tester 90890 03174 _ Peak voltage adapter 90890 03172 Test harness 2 pins 90890 06792 459 561 Q ECM output peak voltage Black orange B O Ground Black white B W Ground Loaded Cranking 1 500 3 500 260 260 270 Checking the pulser coil 1 Remove the flywheel magnet cover and disconnect the pulser coil coupler 2 Connect the test harness 3 pi
4. 1 12 Crankshaft and cylinder 1 6 Cylinder block 5 38 Cylinder head 5 23 Cylinder head cover 1 8 D Diagnosing the electronic control i e ERES 9 19 Dimensions 2 9 Disassembling a fuel pump 4 7 Disassembling the cylinder block 5 41 Disassembling the drive shaft 6 17 6 46 Disassembling the forward 6 17 6 40 Disassembling the gear pump housing 7 34 Disassembling the lower case 6 17 6 46 Disassembling the pan 7 12 Disassembling the oil 5 49 Disassembling the power trim and tilt MOLON Pec DT TIRE 7 30 Disassembling the propeller shaft assembly 6 12 6 40 Disassembling the propeller shaft NOUSI cci oe reet t ttes 6 12 6 41 Disassembling the reverse gear 6 46 Disassembling the tilt cylinder and trim cylinder 7 37 Disassembly and assembly 1 4 Draining the engine oil 7 12 Drive shaft and lower case counter rotation model 6 44 Drive shaft and lower case regular rotation model
5. 7 28 Disassembling the power trim and tilt motor 7 30 Checking the power trim and tilt motor 7 31 Assembling the power trim and tilt motor 7 33 Removing the TeservOll 7 33 Disassembling the gear pump housing 7 34 Checking the gear pump 7 35 Assembling the gear pump housing 7 35 Disassembling the tilt cylinder and trim cylinder 7 37 Checking the tilt cylinder and trim cylinder 7 38 Assembling the tilt piston and trim pistons 7 39 Assembling the power trim and tilt unit 7 40 Bleeding the power trim and tilt unit 7 43 Installing the power trim and tilt unit 7 44 Bleeding the power trim and tilt unit built in 7 45 Power trim and tilt electrical system eene 7 46 Checking4lme TUSe odas oes us 7 47 Checking the power trim and tilt relay 7 47 Checking the power trim and tilt switch
6. 7 47 Checking the 7 48 Bracket unit Special service tools Up relief fitting 90890 06773 Down relief fitting 90890 06774 Hydraulic pressure gauge 90890 06776 Trim and tilt wrench New 90890 06587 Current 90890 06548 7 1 63P3F11 Bottom cowling 18 5 57 24 SC a w EC dum 22 o5 28 gt 18 N m 1 8 kgf m 13 3 ft Ib Part name Special service tools Bottom cowling Remarks S63P7080 Bracket Shift cut switch Bracket Neutral switch Screw Plate Bushing Grease nipple Bolt Bolt Screw Plate Bushing Washer Shift lever Bushing Shift rod 1 2 3 4 5 6 7 8 63PSF11 po AH AH M6 x 50 mm 94 x 16 mm 7 2 Bracket unit 18 5 57 24 SC a w EC 22 a 28 gt 18 N m 1 8 kgf m 13 3 ft S63P7080 Part name Remarks Spacer Bushing Bolt Bracket Ball Bolt Grease nipple Spacer Circlip Grommet Screw Adapter Hose joint Flushing hose Grommet Trim sensor coupler PTT motor lead M6 x 35 mm 6 x 20 mm j 7 3 63P3F11 Bottom cowling S63P7070 z Part j Remarks Bottom cowling Rubber sea Grommet Bolt Grommet Grommet Collar
7. 7 18 VIOW asana asa inier e e eed 8 5 After test run vrai 1 25 Applicable 1 5 Assembling a fuel pump 4 8 Assembling the drive shaft NOUSING u pu aus ua 6 19 6 48 Assembling the forward gear 6 19 Assembling the gear pump housing 7 35 Assembling the lower case 6 19 6 47 Assembling the oil pan 7 12 Assembling the oil pump 5 49 Assembling the pistons and cylinder 5 50 Assembling the power trim and tilt motor 7 33 Assembling the power trim and tilt unit 7 40 Assembling the propeller shaft assembly sees 6 14 Assembling the propeller shaft MOUSING 6 14 6 41 Assembling the reverse gear 6 48 Assembling the tilt piston and trim 7 39 Backlash counter rotation model 6 60 Backlash regular rotation model 6 29 iio niii em 1 7 Bleeding the power trim and tilt unit 7 43 Bleeding the power trim and tilt unit built in remet 7 45 Bottom cowling 7 2 Break iriz ui crei deer dee 1 25 C Changing the engine oil by draining it 3 5 Changing the engine oil using an oil changel
8. 63 8230 CD Stator coil B Black Rectifier Regulator G Green Fuse holder R Red Fuse 50 A 5 Accessory battery 6 Battery 63P3F11 8 24 ELEC EE Electrical systems Checking the stator coil 3 Measure the Rectifier Regulator output 1 Disconnect the stator coil coupler peak voltage If below specification mea sure the stator coil output peak voltage 2 Connect the test harness 3 pins to the Replace the Rectifier Regulator if the out stator coil put peak voltage of the stator coil is above specification 3 Measure the stator coil output peak volt age Replace the stator coil assembly if below specification S63P8170 Digital circuit tester 90890 03174 S63P8160 A Peak voltage adapter B 90890 03172 Peak voltage adapter B 90890 03172 Test harness 3 pins 90890 06847 Rectifier Regulator output peak voltage Red R Black B Unloaded 1 500 3 500 13 0 13 0 Stator coil output peak voltage Green G Green G Unloaded Cranking 1 500 12 50 Stator coil resistance use as reference Green G Green G 0 20 0 30 Q at 20 C 68 F Checking the Rectifier Regulator 1 Disconnect the Rectifier Regulator cou pler 2 Connect the test harness 3 pins to the Rectifier Regulator 8 25 63P3F11 TRBL 63PSF11 Troubleshooting Special service tools toii titus e
9. Fac e D 5 42 Checking the piston clearance a 5 42 Checking the piston rings quse dabei EUR ee 5 42 Checking the piston ring grooves a s 5 43 Checking the piston ring side 5 43 Checking the connecting rod big end side clearance 5 43 Checking the crankshaft dtu ctv Od qu EE 5 44 Checking the crankpin oil clearance aa 5 45 Selecting the connecting rod bearing 5 46 Checking the crankshaft main journal oil clearance 5 47 Selecting the crankshaft main bearing 5 48 Disassembling the oil pump eiit terre e d ne Renaud 5 49 CHECKING the oil DUIDD ii teer euet 5 49 Assembling the oil pump 5 49 Assembling the pistons and cylinder 5 50 Installing the power unit ep ego rx rere tex 5 55 63PSF11 Special service tools J LD s gt 5 lt Compression gauge Flywheel puller 90890 03160 90890 06521 Compression gauge extension Valve spring compressor 90890 0656
10. ome L JRS D Pulser coil 3 Intake air temperature sensor Fuse holder Main relay Fuse 20 A Fuse 50 A Battery Engine temperature sensor Idle speed control 8 15 Pi 58 ES R Y S63P8210 Throttle position sensor 2 Intake air pressure sensor 3 Fuel injector Electric fuel pump To remote control box switch panel 6 11 Fuel control system B Y 43 RIYO Oar GY JRS R Y B Black G Green L Blue O Orange P Pink R Red Y Yellow B Y Black yellow G B Green black G R Green red 63PSF11 G Y P G Pu B Pu G Pu R Pu Y W B W R Green yellow Pink green Purple black Purple green Purple red Purple yellow Red yellow White black White red Yellow green VY Pu B A aw 3 un L R R Y R Y TE Pu S63P8210 8 16 evec t 7 ELEC ES Electrical systems Checking the injectors 1 Measure the resistance of the fuel injec tors Repl
11. 6 16 i 2 EOM neus 1 17 Electrical eio aset tet 2 7 Electrical components 8 3 Electronic control system 1 17 Fail safe control 1 18 Features and benefits 1 6 Fire prevention 1 3 Fuel and blowby hoses 4 2 Fuel control 8 15 Fuel filter fuel pump and intake silencer 4 3 Fuel pump control 1 20 Fuel system 1 15 3 3 G aerelal aA NA 3 15 General specifications 2 1 General torques 2 13 Good working practices 1 4 H J i 3 Hose routing eiie ertet 4 2 How to use this manual 1 1 Identification 1 5 Ignition and ignition control system 8 9 Installing the clamp brackets 7 18 Installing the cylinder head 5 35 Installing the drive shaft 6 20 6 49 Installing the lower unit 6 23 6 52 Installing the power trim and tilt unit 7 44 Installing the power unit 5 55 Installing the pressure control valve 5 3
12. 8 22 Checking the brushes me 8 23 Checking the magnet switch tre ctetur de ina 8 23 Checking the starter motor operation 8 23 Charging system yau uuu tin ne cric cae E SET eai aS NO sa ERR EE 8 24 Checking the stator coil 8 25 Checking the Rectifier Regulator a 8 25 eLec 7 ELEC Electrical systems Special service tools Ignition tester 90890 06754 Test harness 3 pins 90890 06793 Digital circuit tester Test harness 3 pins 90890 03174 90890 06847 Peak voltage adapter B Test harness 3 pins 90890 03172 90890 06846 Test harness 2 pins 90890 06792 Test harness 3 pins 90890 06791 8 1 63P3F11 Special service tools Checking the electrical components Checking the electrical components Measuring the peak voltage NOTE Before troubleshooting the peak voltage check that all electrical connections are tight and free from corrosion and that the battery is fully charged to 12 V The condition of the ignition system can be determined by measuring the peak voltage Cranking speed is effected by many factors such as fouled or weak spark plugs or a weak battery one of these factors is p
13. 6 47 Checking the 5 6 47 Checking the drive Shaft cede oet nd puo seinen 6 47 Checking the lower case seeesssseeeeeeeenneneenene rennen 6 47 Assembling the lower CaS6 rura cte 6 47 Assembling the reverse gear eese 6 48 Assembling the drive shaft housing 6 48 Installing the drive SIalb s eeu on ete oet o DRE eU EAE ue tes 6 49 Installing the propeller shaft housing 6 49 Installing the water pump and shift 6 50 Installing the lower unit 6 52 Shimming counter rotation model 6 54 e C V 6 55 Selecting the pinion shims 6 55 Selecting the reverse gear shims ra 6 56 Selecting the forward gear 6 57 Selecting the propeller shaft 6 58 Backlash counter rotation model nem 6 60 Measuring the forward and reverse gear backlash 6 60 63PSF11 Lower unit Special service tools Ring nut wrench 4 90890 06512 s
14. 3 3 Checking the fuel filter rrt ette ederet ied 3 3 ouis Ee Sua uaa onda Didi 3 4 Checking the engine oil Renee 3 4 Changing the engine oil using an oil 3 4 Changing the engine oil by draining it 3 5 Replacing the Ze filter 3 5 Checking the timing e ete ener erbe prn 3 6 Replacing the timing belt Cetero o Dc det biet ER 3 6 Checking the valve clearance u 3 6 Checking the spark plugs tee pa Reet 3 6 Checking the thermostat 3 7 Checking the cooling water 3 8 Control system 3 8 Checking the engine idle speed 3 8 Adjusting the throttle link and throttle 3 8 Adjusting the throttle link and throttle cable operation using a thickness gauge tex 3 10 Checking the gear shift operation 3 11 Checking the ignition timing a r
15. 572 1 563 7110 Part name Remarks Gasket Notreusable Gasket Not reusable Exhaust guide 7 11 63P3F11 Upper case steering arm swivel bracket and clamp brackets Draining the engine oil 1 Place a drain pan under the drain hole and then remove the drain bolt 1 and let the oil drain completely S63P7140 2 Remove the upper and lower mounting nut and then remove the upper case S63P7160 3 Remove the muffler assembly from the upper case Checking the oil strainer i 1 Check the oil strainer for dirt and residue Disassembling the oil pan Clean if necessary 1 Remove the muffler D plate 2 and exhaust manifold 3 from the oil pan Assembling the oil pan 1 Install the new gasket onto the exhaust guide 563 7170 2 Install the oil strainer 3 and bolts and then tighten the bolts to the specified torque S63P7150 2 Remove the oil pan from the exhaust guide 3 Remove the oil strainer from the exhaust guide 5 563 7180 63P3F11 7 12 Bracket unit Oil strainer bolt 10 N m 1 0 7 4 ft lb 3 Install the oil pan 2 and then tighten the bolts finger tight 4 Install the exhaust manifold 5 and bolts and then tighten the bolts finger tight 5 Tighten the exhaust manifold bolts then the oil pan bolts 2 and then tighten them to the specified torques S63P7200
16. ro teca rat epar 6 36 Removing the water pump and shift 6 36 Checking the water pump and shift rod 6 37 Propeller shaft housing counter rotation model 6 38 Removing the propeller shaft housing assembly 6 40 Disassembling the propeller shaft assembly 6 40 Disassembling the forward 6 40 Disassembling the propeller shaft 6 41 Checking the propeller shaft housing 6 41 Checking the propeller shaft r naa anae 6 41 Assembling the propeller shaft housing 6 41 Drive shaft and lower case counter rotation model 6 44 Removing the drive shaft md D 6 46 Disassembling the drive shaft 6 46 Disassembling the reverse 6 46 Disassembling the lower case nenen 6 46 Checking the pinion and reverse
17. getters 1 25 Tightening torques 2 11 Top 1 10 3 3 TOP VIGW iere dente e 8 6 U Upper case steering arm swivel bracket and clamp brackets 7 6 Meritilatigri siue eee teet 1 3 Warning control 1 19 Wiring harness een 8 7 63PSF11 Y Diagnostic System Index Wiring diagram Killer Whale 150 Spark plug Ignition coil Thermoswitch Oil pressure sensor Diode Starter relay Starter motor Starting battery 9 Accessory battery Fuse holder 5 Fuse 30 A 2 Fuse 20 A Fuse 50 A Intake air temperature sensor 5 Power trim and tilt relay Power trim and tilt motor 0 Pulser coil Stator coil Engine temperature sensor Rectifier Regulator Power trim and tilt switch 3 Trim sensor Idle speed control 65 Throttle position sensor 69 Intake air pressure sensor 6 Fuel injector Electric fuel pump 69 Shift cut switch Neutral switch Main relay To trim meter To warning indicator mlolo fe gt special service tool 1 Isolator cable optional 2 Negative cable commercially available To personal computer for diagnosis To remote control box switch panel To diagnostic flash indicator Color code B Black Br Brown G Gree
18. 3 12 Power trim tilt unit l u u J 3 13 Checking the power trim and tilt operation 3 13 Checking the power trim and tilt fluid level 3 13 Lower UIDI noi ie cie ies diis eei as ru 3 13 Checking the gear oil level seseeseeeesseeenenen 3 13 Changing the gear oil ete rere eric ene enhn 3 14 Checking the lower unit for air leakage 3 15 Checking the propeller 3 15 3 15 Checking the anodes a 3 15 Checking the RR 3 16 Lubricating the outboard 10 3 16 ge ADJ Periodic checks and adjustments Special service tools Oil filter wrench 90890 06830 Digital tachometer 90890 06760 Timing light 90890 03141 Leakage tester 90890 06840 3 1 63P3F11 Special service tools Maintenance interval chart Maintenance interval chart Use the following chart as a guideline for general maintenance Adjust the maintenance intervals according to the operating conditions of the outboard motor Item Remarks Initial Every 10 hours 1 month 50 hours 3 months 6 months 100 hours 200 hours 1 year
19. After the engine start switch is turned on all of the fuel injectors are driven to prevent them from sticking before the electric fuel pump is driven 63P3F11 1 20 di General information Propeller selection The performance of a boat and outboard motor will be critically affected by the size and type of propeller you choose Propellers greatly affect boat speed acceleration engine life fuel economy and even boating and steering capabilities An incorrect choice could adversely affect performance and could also seriously damage the engine Use the following information as a guide for selecting a propeller that meets the operating conditions of the boat and the outboard motor Propeller size The size of the propeller is indicated on the propeller boss end 5691100 Propeller diameter in inches Propeller pitch in inches O Propeller type propeller mark Selection When the engine speed is at the full throttle operating range 5 000 6 000 r min the ideal propeller for the boat is one that pro vides maximum performance in relation to boat speed and fuel consumption 1 21 Regular rotation model Propeller size in Material 13 1 2 x 23 M 13 3 4 x 21 M 14x19 M 141 2x 17 M 15 1 4 x 15 M Aluminum 13 3 8 x 23 M 13 3 8 x 35 M 13 3 4 x 17 M2 13 3 4 x 19 M2 13 3 4 x 21 M 14 1 2x 15 M 1
20. C Check the battery lead connec tions and the starter motor posi tive terminal for damage and check that the ground lead bolt is not loose or that it has not come off Check for blown fuses Good condition No Repair or replace the defective parts Yes Check the starter relay for conti nuity Continued on next page 9 5 63PSF11 Power unit i Is there ml Replace the starter relay Yes J Check the wiring harness for continuity Is there continuity No Repair or replace the wiring har ness Yes J Disassemble and check the starter motor 63P3F11 9 6 TRBL e Troubleshooting Ignition system Check the condition of the spark plugs Good condition No Clean adjust or replace the spark plugs Yes Check the ignition spark using the spark gap tester WARNING Do nottouch any of the connections of the spark gap tester leads Do notlet sparks leak out of the removed spark plug caps Keep flammable gas and liquids away since this test can produce sparks Good spark p peak voltage or resistance Good condition No Replace the stator assembly Yes Yes Check the pulser coil output No di N Check the ignition coil resis Check the starting system or tance the fuel system N Z ON Good
21. M Measurement Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 6 61 8 Remove the special service tools from the propeller shaft 9 Install the propeller 8 the spacer 9 without the washer 9 then the washer as shown S63P6920 NOTE Tighten the propeller nut 2 while turning the propeller until the propeller can no longer be turned 10 Turn the shift rod to the reverse position O with the shift rod push arm 11 Turn the drive shaft clockwise until the dog clutch 3 is fully engaged S63P6930 12 Turn the shift rod to the neutral position with the shift rod push arm 13 Turn the drive shaft counterclockwise approximately 30 63PSF11 S63P6850 14 Turn the shift rod to the reverse position O with the shift rod push arm 15 Slowly turn the drive shaft clockwise and counterclockwise and measure the back lash when the drive shaft stops in each direction S63P6860 NOTE When measuring the reverse gear backlash turn the shift rod push arm towards the reverse position with force aN Reverse gear backlash 0 23 0 58 mm 0 0090 0 0228 in 16 Add or remove shim s if out of specifica tion Reverse gear backlash Less than Shim thickness To be decreased by 0 23 mm 0 0090 in 0 41 M x 0 67 More than To be increased by 0 58 mm 0 0228 in M 0 41 x 0 67 M Measurement
22. Specifications U m 0 Periodic checks and adjustments A gt c Fuel system dz Tl c m r ie gt Lower unit gt Bracket unit m Electrical systems CO ud m 9 3 U r Troubleshooting L O We Y General information How To use this aevi Ce vao amu da du 1 1 Manual format eet e e rebates m gite bet EE 1 1 ile i 1 2 Safety while eie erede er ito atto etek 1 3 Fire preventl lii S KAN KENAN 1 3 Vinilos Ac 1 3 Elf proteto n 1 3 Parts lubricants and sealants a a a 1 3 Good working practices 1 4 Disassembly and assembly 1 4 nane io d oh Fea rc ODORE qua dS dE EOD MR T FO CETUR 1 5 Applicable models tene tt orent cb e se Deb ede e ted at 1 5 Seral numbers ss Nee EE Do pA ee kukaa e e blat bite ene 1 5 Features benefits U J J J J J 1 6 Crankshaft and cylinder t o i ed sicut 1 6 Balancer etes be aE RAAE gener utri entere ue tma
23. ein ni ere 3 4 Changing the gear oil 3 14 Charging system 8 24 Checking the anodes 3 15 Checking the armature 8 22 Checking the balancer assembly 5 41 Checking the battery 1 22 3 16 Checking the bearings 6 18 6 47 Checking the brushes 8 23 Checking the 5 33 Checking the check valve 4 14 Checking the compression pressure 5 11 Checking the connecting rod big end side clearance 5 43 Checking the cooling water passage 3 8 Checking the cooling water pilot hole 1 25 Checking the crankpin oil clearance 5 45 Checking the 5 44 Checking the crankshaft main journal oil ania ette 5 47 Checking the cylinder bore 5 42 Checking the cylinder head 5 34 Checking the diaphragm and valves 4 8 Checking the drive shaft 6 18 6 47 Checking the 8 12 Checking the electric fuel pump 8 17 Checking the electrical components 8 2 Checking the engine idle speed 3 8 Checki
24. S69J6300 5 Install the washers D wave washer 8 spacer 9 and collar onto the drive shaft 4 O 56926305 63P3F11 6 22 Lower unit 7 Install the new O ring and pump hous ing assembly 9 into the lower case tighten the bolts 6 and then install the seal 7 and cover 8 S60V6330 Shift rod push arm 90890 06052 3 Install the two dowels into the lower unit 4 Install the lower unit into the upper case and then tighten the lower case mounting bolts to the specified torque 5 Install the trim tab 3 to its original posi tion and then tighten the trim tab bolt 4 to the specified torque When installing the pump housing apply grease to the inside of the housing and then turn the drive shaft clockwise while pushing down the pump housing Align the cover projection with the hole in the pump housing S63P6370 Installing the lower unit 1 Set the gear shift to the neutral position at the lower unit 2 Align the center of the set pin with the alignment mark on the bottom cowl ing S63P6380 Lower case mounting bolt 0 47 4 7 kgf m 34 7 ft lb Trim tab bolt 2 42 4 2 kgf m 31 0 ft lb S63P3270 6 23 63P3F11 Drive shaft and lower case regular rotation model 6 Install the propeller and propeller nut and then tighten the nut finger tight Place a block of wood between the an
25. 2 Valve guide remover installer 90890 06801 2 Install a new valve guide by striking the special service tool from the cam Valve guide inside diameter shaft side until the valve guide installer 5 504 5 522 mm 3 contacts the cylinder head 0 2167 0 2174 in 69J5800 NOTE Apply engine oil to the surface of the new valve guide 63P3F11 5 30 Checking the valve seat 1 Eliminate carbon deposits from the valve with a scraper 2 Apply a thin even layer of Mechanic s blueing dye Dykem onto the valve seat 3 Lap the valve slowly on the valve seat with a valve lapper commercially avail able as shown 56925820 4 Measure the valve seat contact width 8 where the blueing dye is adhered to the valve face Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification Replace the valve guide if the valve seat contact is uneven d 69 5830 5 31 69 5840 Valve seat contact width 8 Intake 1 1 1 4 mm 0 043 0 055 in Exhaust 1 4 1 7 mm 0 055 0 067 in Refacing the valve seat 1 Reface the valve seat with the valve seat cutter ESL 5695850 Valve seat cutter holder 90890 06316 Valve seat cutter 30 intake 90890 06327 30 exhaust 90890 06326 45 intake and exhaust 90890 06325 60 intake and exhaust 90890 06324 2 Cut the surface of the valve seat with
26. 7 34 Bracket unit 5 Remove the main valves S60X7450 WARNING Never look into the pump housing open ing while removing the main valves because the main valves and power trim and tilt fluid can be forcefully expelled out NOTE To remove the main valves cover the pump housing with a clean cloth and then blow compressed air through holes 8 and D while holding the cloth down 6 Remove the manual valve S60X7460 7 35 Checking the gear pump 1 Clean all the valves pistons and balls and then check them for damage or wear Check the filters for damage or clogs Replace if necessary 2 Check the drive gears for damage or wear Replace the gear pump assembly if necessary ee 29530 S63P7010 Assembling the gear pump housing CAUTION Install the components and parts in their original direction and positions 1 Install a new O ring D the up relief valve seat ball absorber valve pin 2 and spring into the gear pump hous ing S60X7480 63P3F 11 2 Install new O rings onto the main valves 7 and then install the main valves into the gear pump housing 560 7490 3 Install the drive gears into the gear pump housing 560 7500 4 Install the balls shuttle pistons 9 and balls into the gear pump cover 60 7510 TL Apply grease to the balls and shuttle piston
27. Rounded numeral Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Example lf T1 is 0 57 mm then the forward gear shim is 0 55 mm If T1 is 0 60 mm then the forward gear shim is 0 58 mm 63PSF11 Shimming regular rotation model Selecting the reverse gear shims 1 Install the ball bearing thrust washer and reverse gear onto the propeller shaft housing 2 Measure the gear height M2 from the thrust washer on the propeller shaft housing S63P6450 S68V6930 NOTE Nai Select the shim thickness T2 by using the specified measurement s and the calcula tion formula Measure the reverse gear at three points to find the height average K Shimming plate D 90890 06701 Digital caliper 90890 06704 6 28 Lower unit 3 Calculate the reverse gear shim thick ness T2 as shown in the examples below S69J6585 NOTE LL R is the deviation of the lower case dimen sion from standard The mark 8 is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the R mark is unreadable assume that R is zero and check the backlash when the unit is assembled Calculation formula Reverse gear shim thickness T2 2 29 90 100 Example If M2 is 30 70 mm and R is 3 then T2 30 70 29 90 3 100 mm 30 70 29 90 0 03 mm
28. nana anaa aana aana naen anana 4 7 Disassembling a fuel PUMP etude 4 7 Checking the diaphragm and valves 4 8 Assembling a fuel ase 4 8 Intake assembly and vapor Separator 4 9 Measuring the fuel pressure Ernte pa ur aene pe des seen dud 4 13 Checking the pressure regulator ra 4 13 Checking the check valve tese ertet eed 4 14 Reducing the fuel 4 15 Checking the vapor Se paralor 22 eter codeine nes 4 15 Synchronizing the throttle valves 4 16 Adjusting the throttle position sensor 4 17 Adjusting the throttle position sensor when disassembling or replacing the throttle body 4 18 e gh Fuel system Special service tools Vacuum pressure pump gauge set 90890 06756 Fuel pressure gauge 90890 06786 Digital circuit tester 90890 03174 Vacuum gauge 90890 03159 Digital tachometer 90890 06760 Test harness 3 pins 90890 06793 6 11 Hose routing Fuel and blowby hoses
29. Do not push the trim and tilt rams down while the power trim and tilt motor is removed from the power trim and tilt unit otherwise fluid can spurt out 2 Check the gear pump filter for dirt or resi due and for damage Clean or replace if necessary 7 30 7 Bracket unit 3 Remove the lead holder D and rubber spacers 5 from the stator and then slide them away from the stator 4 Remove the stator 3 60X7230 NOTE C C Place a clean cloth over the end of the arma ture shaft hold it with a pair of pliers and then carefully slide the stator off of the arma ture 5 Remove the armature from the PTT motor base CAUTION Do not allow grease or oil to contact the commutator 6 Disconnect the PTT motor lead sky blue S60X7240 NOTE eN Hold the brush with a screwdriver as shown and then disconnect the PTT motor lead sky blue 7 31 7 Remove the screw disconnect the PTT motor lead light green 5 and then remove the brushes 8 560 7250 CAUTION e Do not pull the PTT motor leads out from the stator Do not touch the bimetal otherwise the operation of the circuit breaker can be affected Checking the power trim and tilt motor 1 Measure the length of the brushes Replace if out of specification 560 7260 Brush length limit 4 8 mm 0 19 in 63P3F 11 2 Check the brush and circuit breaker for continuity Replace if there is n
30. gt Part name j Remarks Power trim and tilt unit PTT motor lead Shaft Plastic tie Circlip Notreusable M8 x 16 mm Bolt Washer Shaft Bushing Bolt Ground lead M6 x 10 mm a O wo GQ N 6 11 7 20 Bracket unit S 0 7 N m 0 07 kgf m 0 5 ft Ib Fx 5N m 0 5 kgf m 3 7 ft Ib S60X7180 No Part name Q ty Remarks 1 Power trim and tilt motor 1 2 Reservoir 1 3 Reservoir cap 1 4 O ring 1 5 O ring 1 6 Bolt 3 M6 x 14 mm 7 Bolt 4 M6 x 35 mm 8 O ring 1 9 Filter 1 10 Joint 1 7 21 63P3F11 Power trim and tilt unit 560 7190 2 o ON Part name 4 Remarks 84 x 15 mm Screw Stator Armature O ring Screw Brush holder Brush 2 Brush 1 Brush holder Brush spring PTT motor base Cil seal Bearing Screw Not reusable 84 x 12 mm Notreusable Notreusable g4 x 15 mm N po A 63P3F11 7 22 Bracket unit 8 N m 0 8 kgf m 5 9 ft 16 3 0 3 22ft ipj 10 S60X7200 z O OI Part name Remarks Bolt Gear pump assembly Ball Shuttle piston O ring Main valve Ball Bolt Bolt Circlip Manual valve O ring O ring Backup ring Spring Absorber valve pin Ball M5 x 16 mm Notreusable Notreusable Notreusable lt 7
31. Example If M6 is 15 70 mm and M7 is 12 55 mm and A is 6 and B is 5 then 4 29 30 6 100 5 100 15 70 12 55 mm 29 30 0 06 0 05 15 70 12 55 mm 0 94 mm 6 59 4 Round the numerals for the propeller shaft shim s T4 as follows Calculated numeral at 1 100 place 1 2 3 4 5 6 7 8 9 10 Rounded numeral Example If T4 is 0 94 mm then the propeller shaft shim is 0 92 mm If T4 is 1 00 mm then the propeller shaft shim is 0 98 mm 5 Calculate and select the propeller shaft shim thickness 4 as shown in the examples below Calculation formula 2 Propeller shaft shim thickness T 4 T4 0 30 Example If T4 is 0 92 mm then T 4 0 92 0 30 mm 0 62 mm Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 6 If the A mark or B mark is unreadable measure the propeller shaft free play as shown 7 Install the shim s thrust bearing 4 propeller shaft 5 and taper roller bear ing C into the propeller shaft housing S63P6900 6 11 Shimming counter rotation model Backlash counter rotation model 8 Measure the propeller shaft free play Repeat steps 1 7 if out of specification S60X6370 S63P6910 NOTE Tighten the center bolt while turning the drive 2 Propeller shaft free play shaft until the drive shaft can no longer be 0 25 0 35 mm 0 0098 0
32. N AN a NAN Bd 6 S63P1070 Throttle body assembly Oil gas separator 3 Direct exhaust system Rectifier Regulator Offset 10 mm 0 39 in amp Balancer shafts 63P3F11 1 6 an General information Balancer A iwo piece balancer is used in the crankcase to reduce the secondary forces of inertia produced by reciprocating pistons The balancer shaft 1 is driven by the gear on the crankshaft The balancer shaft 2 is driven by the gear on the balancer shaft 1 The two counterrotating balancer shafts rotate at twice the speed of the crankshaft and reduce the forces of inertia of the connecting rods and each balancer shaft Therefore engine vibration is reduced S63P1080 CD Balancer shaft 1 Piston secondary force of inertia Balancer shaft 2 Balancer force of inertia Piston and piston ring A forged piston has been adopted for durability Hard chromium plating is applied to the piston rings The top and 2nd piston rings differ and are identified by a mark on each ring Install the piston rings on the piston with the identification marks facing up S63P1090 Top ring 2nd ring Upper oil ring rail Lower oil ring rail 1 7 63P3F11 Features and benefits Connecting rod A direction mark for installing the connecting rod to the crankshaft in the proper direction is on the connecting rod cap The direction mark should face the flywheel The connecting rod and connecting rod cap
33. Refer to page Anodes external Check replace O O 3 15 Battery Check charge 3 16 Cooling water passages Clean O O 3 8 Top cowling Check 3 3 Fuel filter can be disassembled Check replace 3 3 Fuel system Check 3 3 Gear oil Change 3 14 Lubrication points Lubricate 3 16 Engine idle speed EFI models Check adjust 3 8 PCV Pressure Control Valve Check 5 37 Power trim and tilt unit Check 3 13 Propeller and cotter pin Check replace 3 15 Shift link shift cable Check adjust 3 11 Thermostat Check 3 7 Throttle link throttle cable throttle pick up timing Check adjust 3 8 3 10 Water pump Check 6 9 6 37 Engine oil Check change 3 4 Oil filter Change 3 5 Spark plugs Clean adjust replace 3 6 Timing belt NOTE Check replace 3 6 5 16 When operating in salt water turbid or muddy water the engine should be flushed with clean water after each use Remarks Every 500 hours 2 5 years 1 000 hours 5 years 2 000 hours 10 years Refer to page Timing belt Replace 5 16 Valve clearance DOHC Check adjust 5 12 Anodes internal Check replace O Balancer NOTE Replace When using lead or high sulfur gasol
34. W SS NP d BE i CAUTION BEA JN The shift cable joint must be screwed in TES 12 S63P3280 minimum of 8 0 mm 0 31 in 7 Connect the cable joint install the clip ME OCRUN 4 Check that the TDC mark on the fly 8 Check the gear shift for smooth operation Wheel magnet is aligned with the mark on the pointer and if necessary repeat steps 3 7 Checking the ignition timing 2 TOC 1 Startthe engine and warm it up for 5 min a CS utes 2 Attach the special service tool to spark plug wire 1 D and then check the e lo engine idle speed 78 S63P3290 Ignition timing at engine idle speed TDC 63P3F11 3 12 ge ADJ Periodic checks and adjustments Power trim and tilt unit Checking the power trim and tilt operation 1 Fully tilt the outboard motor up and down a few times and check the entire trim and tilt range for smooth operation Check the power trim and tilt fluid level if necessary NOTE Be sure to listen to the winding sound of the power trim and tilt motor for smooth opera tion 2 Fully tilt the outboard motor up and then support it with the tilt stop lever to check the lock mechanism of the lever S60X3020 Checking the power trim and tilt fluid level 1 Fully tilt the outboard motor up and then support it with the tilt stop lever 1 S60X3020 3 13 WARNING After til
35. e Bj M e S63P5100 2 Remove the camshafts and cylinder head bolts in the sequence shown SIE L TEN 2 CE T Bru 9r 9 9 5 eel SO DO 18 si Ps MG 072 14 S63P5170 CAUTION Do not scratch or damage the mating sur faces of the cylinder head and cylinder block 3 Remove the valve shim from the valve lifter using compressed air S63P5510 NT Do not mix the valve train parts Keep them organized in their proper groups 63PSF11 Cylinder head 4 Remove the intake valve and exhaust valves S63P5520 NOTE Be sure to keep the valves springs and other parts in the order as they were removed Valve spring compressor 3 90890 04019 Valve spring compressor attachment 2 90890 06320 Checking the valve springs 1 Measure the valve spring free length Replace if out of specification S69J5720 Valve spring free length 44 20 mm 1 7402 in 2 Measure the valve spring tilt D Replace if out of specification Valve stem diameter Intake 5 477 5 492 mm 0 2156 0 2162 in Exhaust 5 464 5 479 mm 0 2151 0 2157 in 4 Measure the valve stem runout Replace if out of specification 69J5730 aN Valve spring tilt limit 1 5 mm 0 06 in Checking the valves 1 Check the valve f
36. 6 v DL N lt S63P5090 NOTE oK Hold the camshaft using a wrench and be careful not to damage the driven sprocket 12 Remove the camshaft caps in the order shown in the illustration 6 11 5 5 5 4 3 63 5100 13 Remove the camshafts 14 Remove the valve shim 7 from the valve lifter 8 using compressed air S63P5C60 NOTE nM Do not mix the valve train parts Keep them organized in their proper groups 15 Measure the valve shim thickness using a micrometer and then note the mea surement 16 Select the necessary valve shim by cal culating its thickness using the following formula Necessary valve shim thickness Removed valve shim thickness Measured valve clearance Specified valve clearance Example If the Removed valve shim thickness is 2 10 mm the Measured valve clearance is 0 30 mm and the Specified valve clearance is 0 20 mm then the Necessary valve shim thickness 2 10 0 30 0 20 2 20 mm 63PSF11 Power unit 17 Install the necessary valve shim into the valve lifter 18 Install the camshafts into the cylinder head with new oil seals B S63P5110 N S63P5C70 NOTE Install the camshafts so that the dowels are facing inward and that they are aligned with the mating surface of the cylinder head 5 14 19 Ins
37. 90890 07003 Dial gauge set 90890 01252 Magnet base B 7 90890 06844 6 Slowly turn the drive shaft clockwise and counterclockwise and measure the back lash when the drive shaft stops in each direction Forward gear backlash 0 14 0 46 mm 0 0055 0 0181 in 7 Add or remove shim s if out of specifica tion 63PSF11 Forward gear backlash Less than 0 14 mm 0 0055 in 0 30 M x 0 67 More than To be increased by 0 46 mm 0 0181 in M 0 30 x 0 67 Shim thickness To be decreased by M Measurement Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 8 Remove the special service tools from the propeller shaft 9 Apply a load to the reverse gear by installing the propeller 8 the spacer 9 without the washer 9 then the washer as shown S69J6660 NOTE aaa ak Tighten the propeller nut 2 while turning the drive shaft until the drive shaft can no longer be turned 6 30 Lower unit 10 Slowly turn the drive shaft clockwise and counterclockwise and measure the back lash when the drive shaft stops in each direction S6D06040 X Reverse gear backlash 0 32 0 67 mm 0 0126 0 0264 in 11 Add or remove shim s if out of specifica tion Reverse gear backlash Less than To be increased by 0 32 mm 0 0126 in 0 50 M x 0 67 More than To be decreased by 0 67 mm 0 0264 in M 0 50 x 0 67 Shim thickn
38. Item Maintenance specification Model Killer Whale 150 Oil ring Dimension B Dimension T End gap Side clearance 2 40 2 47 0 0945 0 0972 2 30 2 70 0 0906 0 1063 0 15 0 60 0 0059 0 0236 0 04 0 13 0 0016 0 0051 Camshafts Intake A Exhaust A Intake and exhaust B Camshaft journal diameter Camshaft journal oil clearance Camshaft runout limit 45 300 45 400 1 7835 1 7874 44 350 44 450 1 7461 1 7500 35 950 36 050 1 4154 1 4193 24 960 24 980 0 9827 0 9835 0 020 0 060 0 0008 0 0024 0 03 0 0012 Valves Valve clearance cold Intake Exhaust Head diameter A Intake Exhaust Face width B Intake Exhaust Seat contact width C Intake Exhaust Margin thickness D Intake Exhaust Stem diameter Intake Exhaust Guide inside diameter Intake and exhaust Stem to guide clearance Intake and exhaust Stem runout limit 0 20 0 03 0 008 0 001 0 34 0 03 0 013 0 001 34 85 35 15 1 37 1 38 29 85 30 15 1 18 1 19 2 11 0 0831 2 43 0 0957 1 10 1 40 0 0433 0 0551 1 40 1 70 0 0551 0 0669 0 70 0 0276 1 00 0 0394 5 477 5 492 0 2156 0 2162 5 464 5 479 0 2151 0 2157 5 504 5 522 0 2167 0 2174 0 025 0 058 0 0010 0 0023 0 01 0 0004 Valve springs Free length Minimum free length Tilt limit v omm 63PSF11 44 20 1 7402 42 60 1 6771 1 5 0 06 Killer Whale 150 SX SPEC
39. Make sure that the mark C of the connect ing rod faces towards the flywheel magnet side of the crankshaft Apply engine oil to the connecting rod bolts before installation Make a mark d on the connecting rod bolts and connecting rod caps and then tighten the bolts 90 from the mark Connecting rod bolt 1st 23 N m 2 3 kgf m 17 0 ft lb 2nd 43 N m 4 3 31 7 ftlb 90 5 52 10 Install half of the main bearings into the crankcase 11 Apply sealant to the mating surface of the crankcase ii J S63P5A30 NOTE Install the main bearings in their original positions Do not get any sealant on the main bear ings 12 Install the crankcase onto the cylinder block 13 Tighten the crankcase bolts to the speci fied torques in two stages and in the sequence shown 5 po HEROS 9 oH 5 belo oo 6 PICS 8 i S63P5990 5 53 NOTE IRR Crankcase bolts 1 4 can be reused three times Apply engine oil to the crankcase bolts before installation Tighten crankcase bolts 1 4 to the speci fied torques in two stages first and then tighten crankcase bolts 5 14 to the speci fied torques in two stages Make a mark on the crankcase and crankcase bolts and then tighten crank case bolts 1 4 90 from the mark 1 4 Crankcase bolt M10 1st 30 N m 3 0 kgf m 22 1 ft
40. NOTE Install the main bearings in their original posi tions 5 Setthe crankshaft 9 and oil seal 9 into the cylinder block as shown 5 51 S63P5960 NOTE Apply engine oil to the inner oil seal before installation 6 Install half of the main bearings into the main bearing cap 2 NOTE Install the main bearings in their original posi tions 7 Tighten the main bearing cap bolts to the specified torques in two stages and in the sequence shown 63PSF11 S63P5980 NOTE Main bearing cap bolts 1 6 can be reused three times Apply engine oil to the main bearing cap bolts before installation Make a mark on the main bearing caps and main bearing cap bolts and then tighten the main bearing cap bolts 90 from the mark Main bearing cap bolt 1st 30 N m 3 0 kgf m 22 1 ft lb 2nd 90 8 Install the piston with the UP mark on the piston crown facing towards the fly wheel magnet S63P5A10 63PSF11 Cylinder block NOTE TT Apply engine oil to the side of the pistons and piston rings before installation Q Piston ring compressor 90890 05158 9 Install the connecting rod caps to the connecting rods and then tighten the connecting rod bolts to the specified torques in three stages S63P5A20 CAUTION Do not reuse the connecting rod bolts always replace them with new ones NOTE
41. Rounded numeral Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 6 27 Example If is 0 53 mm then the pinion shim is 0 52 mm If T3 is 0 78 mm then the pinion shim is 0 75 mm Selecting the forward gear shims 1 Turn the taper roller bearing outer race two or three times to seat the rollers and then measure the bearing height M1 as shown S63P6430 S69J6615 NOTE Select the shim thickness T1 by using the specified measurement s and the calcula tion formula Measure the bearing outer race at three points to find the height average 2 Shimming plate 2 90890 06701 Digital caliper 3 90890 06704 2 Calculate the forward gear shim thick ness T1 as shown in the examples below 6 11 S69J6570 NOTE _ F is the deviation of the lower case dimen sion from standard The mark is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark is unreadable assume that F is zero and check the backlash when the unit is assembled Calculation formula Forward gear shim thickness T1 28 60 F 100 M1 Example If M1 is 28 08 mm and F is 5 then T1 28 60 5 100 28 08 mm 28 60 0 05 28 08 mm 0 57 mm 3 Select the forward gear shim s T1 as follows Calculated numeral at 1 100 place 1 2 3 4 5 6 7 8 9 10
42. Z C S63P1170 Exhaust manifold Water Muffler Exhaust gas Water 1 12 63P3F 11 General information Lubrication system The lubrication oil flow diagram is as follows Crankcase Oylinder head Oylinder sleeve Piston Balancer journal Camshaft Camshaft journal Crankshaft main journal E IN EX valve Oil pressure sensor S63P1260 There is a small hole in the relief valve to allow oil to drain from the oil filter bracket so that it does not remain in the oil filter This prevents oil from spilling out when replacing the oil filter S63P1180 D Relief valve Oil filter bracket Cil 1 13 63P3F11 Features and benefits A dual oil drain system is adopted An oil drain bolt is located on the bottom of the oil pan A long dipstick guide which reaches the bottom of the oil pan can also be used to pump out the oil completely with an oil extracting tool o S63P1190 Drain bolt Dipstick guide 63P3F11 1 14 General information Fuel system A fuel pressure regulator is incorporated onto the outlet of the electric fuel pump to obtain a compact design and simple fuel delivery Fuel discharged from the pressure regulator returns to the vapor separator after being cooled in the fuel cooler
43. 0 77 mm 4 Select the reverse gear shim s T2 as follows Calculated numeral at 1 100 place 1 2 3 4 5 6 7 8 9 10 Rounded numeral Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 6 29 Example If T2 is 0 77 mm then the reverse gear shim is 0 78 mm If T2 is 0 79 mm then the reverse gear shim is 0 80 mm Backlash regular rotation model Measuring the forward and reverse gear backlash 1 Remove the water pump assembly 2 Set the gear shift to the neutral position at the lower unit S60V6330 Shift rod push arm 90890 06052 3 Install the special service tools so that it pushes against the propeller shaft TaN Q 50 5 S60X6370 NOTE Tighten the center bolt while turning the drive shaft until the drive shaft can no longer be turned 63PSF11 Shimming regular rotation model Backlash regular rotation model Cz Bearing housing puller claw L D 90890 06502 Stopper guide plate 2 90890 06501 Center bolt 3 90890 06504 4 Install the backlash indicator onto the drive shaft 22 4 mm 0 88 in in diame ter then the dial gauge onto the lower unit 5 Setthe lower unit upside down S6D06050 NOTE Install the dial gauge so that the plunger contacts the mark on the backlash indica tor 2 Backlash indicator 90890 06706 A Magnet base plate
44. 4 New 90890 06587 Current 90890 06548 Tilt cylinder end screw 130 N m 13 0 kgf m 96 0 ft Ib 11 Install the joint and gear pump filter 3 into the gear pump housing 560 7760 63PSF11 Power trim and tilt unit 12 Fill the gear pump housing with the rec ommended fluid to the correct level as shown 560 7770 Recommended power trim tilt fluid ATF Dexron II 13 Remove all of the air bubble using a syringe or suitable tool NOTE Turn the joint with a screwdriver to bleed the gear pump 14 Install a new O ring 2 and the power trim and tilt motor 5 and then tighten the bolts 6 to the specified torque 560 7780 NOTE Align the armature shaft with the recess in the joint PTT motor mounting bolt 5 N m 0 5 3 7 ft lb 7 42 Bracket unit 15 Remove the reservoir cap and then check the fluid level in the reservoir NOTE If the fluid is at the correct level the fluid should overflow out of the filler hole when the reservoir cap is removed 16 If necessary add sufficient fluid of the recommended type until it overflows out of the filler hole Recommended power trim and tilt fluid ATF Dexron II 17 Install the reservoir cap and then tighten it to the specified torque Reservoir cap 0 7 N m 0 07 kgf m 0 5 ft lb 18 Bleed the power trim and tilt unit 19 C
45. CAUTION Add or remove shim s if necessary if replacing the forward gear taper roller bearing propeller shaft housing thrust washer or lower case 2 Tighten the ring nut to the specified torque S63P6710 NOTE ee To secure the ring nut bend one tab 8 of the claw washer into a slot in the ring nut Bend all other tabs toward the propeller shaft housing assembly Ring nut wrench 4 90890 06512 Ring nut wrench extension 2 90890 06513 Ring nut 142 N m 14 2 kgf m 104 7 ft Ib Installing the water pump and shift rod 1 Install the shift rod assembly 63PSF11 S63P6720 Install a new gasket the outer plate cartridge 3 and dowels 2 lt gt e 5 S63P6970 6 50 Lower unit 3 Install the Woodruff key into the drive shaft 4 Align the groove in the impeller with the Woodruff key and then install the impeller onto the drive shaft S69J6300 5 Install the washers wave washer 9 spacer 9 and collar onto the drive shaft 56926305 NOTE The collar and spacer should fit together firmly While pulling the drive shaft up install the collar with an appropriate tool 8 that fits over the drive shaft as shown 6 Install the new O ring and insert car tridge 45 into the pump housing 3 S63P6360 NOTE 2 Align the insert cartridge projections
46. Green Blue Blue Blue Blue Red Red Red 5 47 NOTE Example the connecting rod big end inside diameter 8 is 35 and the crankpin mark D is 81 then select the bearing col ors in If the connecting rod inside diameter can not be measured measure the crankpin oil clearance using Plastigauge PG 1 and select the suitable combination of upper and lower bearings from the table above so that the oil clearance is within specification Checking the crankshaft main journal oil clearance 1 Clean the bearings main journals and bearing portions of the crankcase and cylinder block 2 Place the cylinder block upside down on a bench 3 Install half of the bearings the crankshaft into the cylinder block 3 S63P5810 NOTE UU Install the main bearings in their original posi tions 4 Put a piece of Plastigauge PG 1 on each main journal parallel to the crank shaft 6 11 Cylinder block Selecting the crankshaft main bearing 1 When replacing the main bearing select the suitable bearing as follows 2 Check the crankshaft journal mark 8 on the crankshaft and the cylinder block mark on the cylinder block S63P5820 NOTE Do not put the Plastigauge PG 1 over the oil hole in the main journals of the crankshaft 5 Install the remaining half of the bearings into the main bearing cap and crankcase NOTE Install the main bearings in
47. Replace if necessary 5696045 6 11 Lower unit regular rotation model Propeller shaft housing regular rotation model Propeller shaft housing regular rotation model 142 m 14 2 kgf m 104 7 ft Ib S63P6060 z o OI Part name 4 Remarks Shift rod joini Ball Shift slider Ball Ball Spring Dog clutch Cross pin Spring Propeller shaft Reverse gear shim Washer Reverse gear Thrust washer Ball bearing O ring Propeller shaft housing NN NN Notreusable Notreusable a 63P3F11 6 10 Lower unit 142 m 14 2 kgf m 104 7 ft Ib S63P6060 Part name 4 Remarks Straight key Needle bearing Cil seal Claw washer Ring nut Cooling water inlet cover Nut Screw Not reusable NO 6 11 63P3F11 Removing the propeller shaft housing assembly 1 Straighten the claw washer tabs 8 and then remove the ring nut and claw washer S62Y6595 Cz Ring nut wrench 4 90890 06512 Ring nut wrench extension 2 90890 06513 2 Pull out the propeller shaft housing assembly 56856310 Bearing housing puller claw L 90890 06502 Stopper guide plate 2 90890 06501 Center bolt 5 90890 06504 Disassembling the propeller shaft assembly 1 Remove the spring D then the cross dog clutc
48. Screw KR S S OMY HA M6 x 35 mm Notreusable 6 x 30 mm 5 4 4N m 0 4 kgf m 3 0 ft Ib No j Remarks 1 2 3 4 5 6 7 8 Starter motor Bolt Terminal Nut Cap Bolt Starter motor lead Ignition coil Holder Holder Bracket Holder Bolt Oil filter M8 x 45 mm M6 x 10 mm M6 x 25 mm A PO HM 5 5 63P3F11 13 Power unit 63 5600 No Part name Q ty Remarks 1 Grommet 1 2 Fuse holder 1 3 Terminal plate 4 4 Terminal 8 5 Terminal 8 6 Fuse holder 1 7 Fuse 2 50A 8 Screw 4 85 x 10 9 2 20 10 Relay 1 11 Fuse 1 30A 12 Screw 6 g3 x 10 13 Screw 3 95 20 63P3F11 5 6 m 0 4 kgf m 3 0 ft Ib S63P5610 z Part name j Remarks Junction box ECM Bolt Wiring harness Bolt Washer Nut Cap Power trim and tilt relay Bolt Starter relay Holder Bolt Cap Screw Grommet Plastic tie M6 x 16 mm M6 x 20 mm M6 x 20 mm M6 x 10 mm g6 x 19 mm N NM NN AH Notreusable 5 7 63P3F11 Power unit m 0 4 kgf m 3 0 ft Ib S63P5610 Part name j Remarks Holder
49. The pressure check valve is incorporated onto the fuel rail for easier servicing of the fuel system Fuel tank Fuel filter fuel tank Fuel pump Vapor separator Electric fuel pump Fell rail 738 valve E E E E 4 Pressure regulator S63P1200 D Pressure regulator Vapor separator 3 Fuel cooler Fuel flow 1 15 63P3F11 Features and benefits Rectifier Regulator A water cooled Rectifier Regulator is incorporated onto the exhaust outer cover This allows for a compact engine design and produces a large electric current output for charging the battery under low engine speed 40 35 30 25 20 0 1 000 2 000 3 000 4 000 5 000 6 000 7 000 S63P1210 Charging current A Engine speed r min Isolator An isolator is incorporated into the Rectifier Regulator If a second battery is used connect an optional isolator lead Isolator lead P N 69J 81949 00 3 8 m 12 5 ft 68F 81949 00 2 7 m 9 ft 3 8 m 12 5 ft 2 7 m 9 ft S63P1220 Red tube 63PSF11 an General information Technical tips Electronic control system The electronic control system consists of the sensors and the ECM electronic control module Under various conditions the ECM provides the best suitable engine operation S63P1230 Intake a
50. The warning control mode deactivates when the engine speed is less than 1 600 r min or the throt tle opening angle is less than 7 degrees 63PSF11 Technical tips Shift cut control This outboard motor is equipped with a shift cut control system for easier shifting This device misfires and retards the ignition of some cylinders to fluctuate the engine speed instantly when the engine is running from 400 to 2 000 r min This allows smooth engagement and or disengagement of the dog clutch When shifting the ignition is shut off as shown in the table Engine speed r min less than 400 400 to 729 730 to 2 000 2 001 or more N A N A Misfires the 1 Retards ignition and 4 cylinders timing and then retards ignition timing N A No misfire control Over revolution control This outboard motor is equipped with an over revolution control system to protect the engine If the engine speed exceeds 6 200 r min the fuel injection is shut off as shown in the table below Engine speed r min Injected cylinder Note 6 199 or less 1 2 3 and 4 Normal operation 6 200 to 6 300 2 and 3 6 301 to 6 550 2 Over revolution control mode 6 551 or more None Fuel pump control The electric fuel pump operates for 3 seconds after the engine start switch is turned on and contin ues to operate while the engine is running The electric fuel pump stops 1 second after the engine is stopped NOTE
51. put voltage with the throttle valves fully closed If the output voltage is out of specification adjust the throttle position sensor 63P3F11 NOTE To measure the output voltage connect the positive tester probe to the pink wire of the test harness and the negative tester probe to the orange wire of the test harness Digital circuit tester 90890 03174 Throttle position sensor output voltage Pink P Black B 0 70 0 02 V 7 Install the intake silencer 8 Start the engine and check the engine idle speed Digital tachometer 90890 06760 Engine idle speed 700 50 r min Adjusting the throttle position sensor when disassembling or replacing the throttle body l Install the intake assembly 2 Connect the test harness 3 pins to the throttle position sensor 563 8130 3 Loosen the synchronizing screw 63P3F11 Intake assembly and vapor separator S63P4280 4 Loosen the throttle stop screw and fully close the throttle valves 1 and 72 Y H 4 g Se3P4240 5 Turn the engine start switch to ON 6 Loosen the throttle position sensor screw and adjust the throttle position sensor output voltage to specification Throttle position sensor output voltage Pink P Black B 0 66 V 7 Turn the throttle stop screw in until the throttle positio
52. B O B W B at cranking loaded at 1 500 r min loaded at 3 500 r min loaded Pulser coil output peak voltage W R W B B at cranking unloaded at cranking loaded at 1 500 r min loaded at 3 500 r min loaded Pulser coil resistance W R W B B Pulser coil air gap Throttle position sensor Input voltage O B Output voltage P B Intake air temperature sensor resistance at 20 C 68 F Engine temperature sensor resistance B Y B Y at 20 C 68 F at 100 C 212 F TDC at engine idle speed 1 0 1 1 0 039 0 043 1 53 2 07 12 50 16 91 3 5 3 6 23 9 49 7 459 561 0 3 0 7 0 0118 0 0276 5 0 70 0 02 at engine idle speed 2 20 2 70 54 2 69 0 3 12 3 48 Fuel control system Fuel injector resistance at 20 C 68 F 1 The figures are for reference only 2 7 14 0 15 0 6 11 Item Maintenance specification Model Killer Whale 150 Killer Whale 150 SX Starter motor Type Output Cranking time limit Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit kW Second mm in Sliding gear 1 40 30 15 5 0 61 9 5 0 37 29 0 1 14 28 0 1 10 0 5 0 8 0 02 0 03 0 2 0 01 Charging system Fuse Stator coil output peak voltage G G at cranking unloaded at 1 500 r min unloaded at 3 500 r min unloaded Stator coil resistance at 20
53. Bracket unit Iw 15N m 1 5 kgf m 11 1 ft Ib S63P7130 No Part name Q ty Remarks 18 Anode 1 19 Through tube 1 20 Bolt 1 M8 x 20 mm 21 Tilt stop lever 1 22 Bush 4 23 Collar 1 24 Distance collar 2 25 Spring pin 2 26 Pin 1 27 Spring 1 28 Spring hook 1 29 Bolt 1 M6 x 10 mm 30 Tilt stop lever 1 7 17 63P3F11 Removing the clamp brackets 1 Remove the power trim and tilt unit For removal procedures see Removing the power trim and tilt unit 2 Remove the anode 3 Remove the bolt and grease nipples and then disconnect the ground leads 4 Remove the self locking nut and bolt 5 Remove the through tube then disas semble the clamp brackets trim sensor cam and swivel bracket 6 Remove the trim sensor 7 Remove the tilt stop levers Installing the clamp brackets 1 Install the tilt stop levers onto the swivel bracket assembly 2 Install the trim sensor D and bushings onto the swivel bracket assembly S60X7140 3 Assemble the clamp brackets washers and swivel bracket and then install the through tube NOTE Make sure that the trim sensor cam is installed between the swivel bracket holes Adjust the trim sensor cam after assembly 4 Install the bolts on the through tube and then tighten the self locking nut to the specified torque 63PSF11 Clamp brackets Self locking nut 15 1 5 kgf m 11 1 ft l
54. Oil capacity Without oil filter replacement 5 2 L 5 5 US qt 4 6 Imp qt Checking the battery 1 Check the capacity electrolyte level and specified gravity of the battery Recommended battery capacity CCA EN 711 A 20HR IEC 100 Ah Electrolyte specified gravity 1 280 at 20 C 68 F 2 Check that the positive and negative bat tery leads are securely connected 1 22 an General information Checking the outboard motor mounting height 1 Check that the anti cavitation plate is aligned with the bottom of the boat If the mounting height is too high cavitation will occur and propulsion will be reduced Also the engine speed will increase abnormally and cause the engine to overheat If the mounting height is too low water resistance will increase and reduce engine efficiency A t S69J1160 The optimum mounting height is affected by the combination of the boat and the outboard motor To determine the optimum mounting height test run the outboard motor at differ ent heights 2 Check that the clamp brackets are secured with the clamp bolts Checking the remote control cables 1 Set the remote control lever to the neu tral position and fully close the throttle lever 2 Check that the stopper on the throttle lever 2 contacts the fully closed stopper on the cylinder block 1 23 563 1040 3 Check that the center of the set is aligned with the alig
55. Power unit mounting bolt M8 PTT motor lead bolt 20 N m 2 0 kgf m 14 8 ft lb Power unit mounting bolt M10 42 N m 4 2 31 0 ft lb 8 Connect the shift cable and throttle Apron bolt cable and then adjust their lengths 8 N m 0 8 5 9 ft lb For adjustment procedures see Chapter Apron screw 3 Adjusting the throttle link and throttle 4 0 4 kgf m 3 0 ft lb cable and Checking the gear shift oper ation 4 0 4 kgf m 3 0 ft lb 4 Connect the PTT switch coupler shift cut switch coupler neutral switch coupler 0 cooling water pilot hose and flushing emt hose B Pre 5 Install the dipstick guide 563 5080 63P3F11 5 56 9 Connect the battery leads 2 63 5 10 Positive battery cable nut 9 N m 0 9 kgf m 6 6 10 10 Install the stator coil assembly 11 Install the Woodruff key 563 5350 12 Install the flywheel magnet S63P5370 CAUTION Apply force in the direction of the arrows shown to preventthe flywheel holder from slipping off easily NOTE Apply engine oil to the flywheel magnet nut before installation 5 57 Flywheel holder 90890 06522 Sy Flywheel magnet nut 270 N m 27 0 kgf m 199 1 ft Ib 13 Install all parts removed during disas sembly 6 11 Cylinder block MEMO 63P3F11 5 58 Lower unit Special service tools eere nnne n
56. Ring nut wrench extension 90890 06513 SS Bearing housing puller claw L 90890 06502 Stopper guide plate 90890 06501 Center bolt 90890 06504 Bearing separator 90890 06534 Stopper guide stand 90890 06538 Bearing puller assembly 90890 06535 Needle bearing attachment 90890 06610 90890 06612 90890 06653 90890 06654 Driver rod L3 90890 06652 63PSF11 Driver rod SS 90890 06604 D Bearing depth plate 90890 06603 lt Bearing inner race attachment 90890 06640 90890 06660 Drive shaft holder 6 90890 06520 ZA nut holder New 90890 06715 Current 90890 06505 63PSF11 Special service tools Bearing outer race puller assembly 90890 06523 Ball bearing attachment 90890 06633 90890 06636 90890 06629 Bearing outer race attachment 90890 06619 j Driver rod LL 90890 06605 Y Driver rod LS 90890 06606 Lower unit Shift rod push arm 90890 06052 Pinion height gauge 90890 06710 Digital caliper 90890 06704 SFL Shimming plate 90890 06701 Backlash indicator 90890 06706 Magnet base plate 90890 07003 Dial gauge set 90890 01252 Magnet base B 90890 06844 Ring nut wrench 90890 06578 Outer race puller claw B 90890 06533 63P3F 11 Special service tools Lower unit regular rotation model Lower unit regular rotation model m 0 9 kgf m 6 6 ft Ib
57. counter rotation model Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Example If T2 is 0 33 mm then the forward gear shim is 0 35 mm If T2 is 0 79 mm then the forward gear shim is 0 80 mm Selecting the propeller shaft shims 1 Turn the taper roller bearing outer race two or three times to seat the rollers and then measure the bearing height M6 as shown T4 S63P6820 S69J6720 NOTE UU e Select the shim thickness T 4 by using the specified measurement s and the calcula tion formula Measure the taper roller bearing at three points to find the height average YO Shimming plate 2 90890 06701 Digital caliper 3 90890 06704 6 58 Lower unit 2 Install the thrust bearing 2 onto the pro peller shaft 5 and then measure the propeller shaft flange and thrust bearing thickness M7 as shown 56926696 3 Calculate the propeller shaft shim thick ness T4 as shown in the examples below 5696626 A and B are the deviation of the propeller shaft housing dimension from standard The A mark and B mark D are stamped on the propeller shaft housing in 0 01 mm units If the A mark or B mark is unreadable assume that A and B are zero and check the free play when the unit is assembled Calculation formula 1 Propeller shaft shim thickness T4 29 30 A 100 B 100 M6 M7
58. is 0 90 mm then the reverse gear shim is 0 88 mm If T1 is 1 15 mm then the reverse gear shim is 1 12 mm Selecting the forward gear shims 1 Install the thrust washer and taper roller bearing onto the forward gear S63P6770 2 Measure the gear height M2 from the thrust washer on the taper roller bearing S63P6790 4 563 6890 E lt NOTE _ Select the shim thickness T2 by using the specified measurement s and the calcula tion formula Measure the forward gear at three points to find the height average 6 11 CL Shimming plate 90890 06701 Digital caliper 4 90890 06704 3 Calculate the forward gear shim thick ness T2 as shown in the examples below S69J6585 NOTE _ 5 R is the deviation of the lower case dimen sion from standard The R mark is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the R mark is unreadable assume that R is zero and check the backlash when the unit is assembled Calculation formula Forward gear shim thickness T2 M2 29 50 R 100 Example If M2 is 29 84 mm and R is 1 then T2 29 84 29 50 1 100 mm 29 84 29 50 0 01 mm 0 33 mm 4 Select the forward gear shim s T2 as follows Calculated numeral at 1 100 place 1 2 Rounded numeral 3 4 5 6 7 8 9 10 63PSF11 Shimming
59. recommended type until it overflows out of the filler hole Recommended power trim and tilt fluid ATF Dexron II 12 Install the reservoir cap and then tighten it to the specified torque Reservoir cap 0 7 N m 0 07 kgf m 0 5 ft Ib 63PSF11 13 Connect the PTT motor leads to the bat tery terminals to fully retract the trim and tilt rams and then measure the hydraulic pressure If out of specification overhaul the power trim and tilt unit S63P7300 Battery terminal Light green Lg Sky blue Sb Hydraulic pressure down 6 9 MPa 60 90 kgf cm 14 Reverse the PTT motor leads between the battery terminals to fully extend the trim and tilt rams PTT motor lead 863 7310 Battery terminal Sky blue Sb Light green Lg PTT motor lead 15 Remove the special service tools and then install the manual valve and circlip Manual valve 3 N m 0 3 kgf m 2 2 ft lb 63PSF11 Power trim and tilt unit NOTE s Quickly install the manual valve before any fluid flows out of the hole Disassembling the power trim and tilt motor 1 Remove the power trim and tilt motor O ring gear pump filter and joint from the gear pump housing 60 7220 CAUTION Make sure that the trim and tilt rams are fully extended when removing the power trim and tilt motor otherwise fluid can spurt out from the unit due to internal pressure
60. 0138 turned Bearing housing puller claw LO 90890 06502 Magnet base B 90890 06844 Dial gauge set 9 90890 01252 Stopper guide plate 90890 06501 Backlash Center bolt 3 90890 06504 counter rotation model 4 Install the backlash indicator onto the Measuring the forward and reverse drive shaft 22 4 mm 0 88 in in diame gear backlash ter then the dial gauge onto the lower 1 Remove the water pump assembly unit 2 Set the gear shift to the neutral position at the lower unit S60V6330 Shift rod push arm 90890 06052 3 Install the special service tools so that it pushes against the propeller shaft 63P3F11 6 60 Lower unit 5 Setthe lower unit upside down S6D06050 NOTE Install the dial gauge so that the plunger contacts the mark on the backlash indica tor 1 Backlash indicator 2 90890 06706 Magnet base plate 5 90890 07003 Dial gauge set 6 90890 01252 Magnet base B 7 90890 06844 6 Slowly turn the drive shaft clockwise and counterclockwise and measure the back lash when the drive shaft stops in each direction X Forward gear backlash 0 14 0 42 mm 0 0055 0 0165 in 7 Add or remove shim s if out of specifica tion Forward gear backlash Less than To be increased by 0 14 mm 0 0055 in 0 28 M x 0 67 More than To be decreased by 0 42 mm 0 0165 in M 0 28 x 0 67 Shim thickness
61. 1 63P3F11 4 4 e Fuel system 8 N m 0 8 kgf m 5 9 ft Ib S63P4040 No Part name Q ty Remarks 1 Bolt 1 M6 x 14 mm 2 Bracket 1 3 Bolt 1 M6 x 16 mm 4 Washer 1 5 Holder 1 6 Cap 1 7 O ring 1 8 Fuel filter element 1 9 Float 1 10 Spring 1 11 O ring 1 12 Cup 1 13 Nut 1 4 5 63P3F11 Fuel filter fuel pump and intake silencer m 0 4 kgf m 3 0 ft 16 z Part name 2 lt S63P4050 Remarks Screw Cover Fuel pump body 2 Fuel pump body 1 Plunger Spring Nut Spring Pin Diaphragm Nut Spring Valve Screw Gasket O 63P3F11 N N N N G H H H G g6 x 35 mm Notreusable 4 6 s D Fuel system Checking the fuel pumps 1 Place a drain pan under the fuel hose connections and then disconnect the fuel hoses from the fuel pumps 2 Connect the special service tool to the fuel pump inlet 3 Cover the fuel pump outlet with a finger and then apply the specified positive pressure Check that there is no air leak age S63P4090 CL Vacuum pressure pump gauge set 90890 06756 2 Specified pressure 50 kPa 0 5 kgf cm 7 3 psi 4 Apply the specified negative pressure and check that there is no air leakage im S63P4100 Specified pressure 30 kPa 0 3 kgf cm 4 4
62. 10W 30 or 10W 40 Oil quantity Without oil filter replacement 5 2 L 5 5 US qt 4 6 Imp qt 3 4 ge ADJ Periodic checks and adjustments 6 Install the oil filler cap and dipstick and then start the engine and warm it up for 5 minutes 7 Turn the engine off and then check the oil level and correct it if necessary Changing the engine oil by draining it 1 Start the engine warm it up and then turn it off 2 Remove the engine oil dipstick and oil filler cap D S63P3060 3 Place a drain pan under the drain hole and then remove the drain bolt and let the oil drain completely S63P3080 NOTE Be sure to clean up any oil spills 4 Install the drain bolt and then tighten it to the specified torque Drain bolt 27 N m 2 7 kgf m 20 0 ft lb 5 Pour the specified amount of the recom mended engine oil into the oil filler hole 3 5 Recommended engine oil 4 stroke motor oil API SE SF SG SH or SJ SAE 10W 30 or 10W 40 Oil quantity Without oil filter replacement 5 2 L 5 5 US qt 4 6 Imp qt 6 Install the oil filler cap and dipstick and then start the engine and warm it up for 5 minutes 7 Turn the engine off and then check the oil level and correct it if necessary Replacing the oil filter 1 Extract the engine oil with an oil changer or drain it 2 Place a rag under the oil filter and then remove the oil filter using a 72 5 mm 2 9 in oil filer wren
63. 47 N m 4 7 kgf m 34 7 ft Ib 47 N m 4 7 kgf m 34 7 ft Ib S63P6010 No Part name Remarks 1 2 3 4 5 6 7 8 Lower unit Check screw Gasket Bolt Drain screw Grommet Bolt Bolt Spacer Propeller Washer Washer Cotter pin Propeller nut Trim tab Dowel Water pipe Notreusable M10 x 45 mm M10 x 44 mm M10 x 70 mm L transom model Notreusable X transom model X transom model NN Lg 63P3F11 6 4 Lower unit S63P6010 Part name j Remarks Extension X transom model Bolt M10 x 45 mm X transom model Bolt M10 x 200 mm X transom model 6 5 63P3F11 Lower unit regular rotation model S63P6020 2 o ON O OI Part name 4 Remarks Shift rod Oil seal Oil seal housing O ring Spring Circlip Bolt Hose nipple O ring Woodruff key Bolt Cover Seal Water pump housing O ring Insert cartridge O ring Not reusable Not reusable M6 x 20 mm Notreusable M8 x 45 mm Notreusable Notreusable 63P3F11 6 6 Lower unit S63P6020 Part name 4 Remarks Collar Spacer Washer Wave washer Impeller Outer plate cartridge Gasket Dowel Dowel Not reusable N N p 6 7 63P3F11 Lower unit regular rotation model Removing the lower
64. Bolt Intake air temperature sensor Grommet Screw Bracket Screw Holder Collar Grommet Bolt Wiring harness M6 x 12 mm g6 x 19 mm g6 x 19 mm M6 x 35 mm G GD UO 63P3F11 5 8 60 N m 6 0 kgf 44 3 ft Ib Pw 39 N m 3 9 kgf m 28 8 ft Ib MIC 8 N 0 8 kgf m 5 9 ft Ib ee La 8N m 0 8 kgf m 5 9 ft Ib NI ET X 7 m 0 7 kgf m 5 2 ft Ib S63P5590 z o O OI Part name 4 Remarks Timing belt Timing belt tensioner Bolt Drive sprocket Plate Woodruff key Bolt Driven sprocket Cil seal Dowel Camshaft Camshaft Camshaft cap Camshaft cap Bolt Bolt Gasket M5 x 40 mm M10 x 35 mm N N M7 x 48 mm M7 x 37 mm Not reusable aa 5 9 63 11 Power unit 60 N m 6 0 kgf 44 3 ft Ib Pw 39 N m 3 9 kgf m 28 8 ft Ib MIC 8 N 0 8 kgf m 5 9 ft Ib ee La 8N m 0 8 kgf m 5 9 ft Ib NI ET X 7 m 0 7 kgf m 5 2 ft Ib S63P5590 Part name Remarks Screw g4x 8mm Plate Grommet Cylinder head cover Bolt M6 x 30 mm Holder Bolt M6 x 10 mm Clamp Hose Dowel Dowel 63P3F11 5 10 Checking the compression pressure 1
65. C 68 F G G Rectifier Regulator output peak voltage R B at 1 500 r min unloaded at 3 500 r min unloaded 20 30 50 12 50 110 0 20 0 30 Power trim and tilt system Trim sensor Setting resistance Resistance Fluid type Brushes Standard length Wear limit Commutator Standard limit Wear limit Mica Standard undercut Wear limit P B P B 1 The figures are for reference only 63PSF11 9 11 9 378 8 ATF Dexron II 2 8 mm in S63P2010 63P3F11 0 92 099 A Sel 4 TL CN OO m LO N T N Lx o gi 2 N Y Y Y 1 A d o oO o ox 5 gt lt gt 9 e 0 1 589 LOL 962 Y gt la 81 Sr 620 sar 6 1 SSP o gt lt p lt FOS 692 esz vo x E02 919 7 8 012 0 98 916 40 L X 04 24 9v6 1 Dimensions Exterior 2 9 Clamp bracket 180 7 1 180 7 1 163 5 6 4 163 5 6 4 367 14 4 Maintenance specificat mm in 125 4 4 9 13 0 5 125 4 4 9 63PSF11 ion S63P2020 2 10 SPEC v TES Specifications Tightening torques Specified torques Tightening torque
66. Cowling lock lever Bushing Plate Bolt Wave washer Lever Washer Bolt Stay Bolt M8 x 35 mm M6 x 30 mm M6 x 20 mm N N N N N oN TF N 5 gt F N M6 x 20 mm 63P3F11 7 4 Bracket unit S63P7070 Part name j Remarks Grommet Holder Bolt Retaining plate Bolt Cable holder Bolt Cable holder Bolt Cable holder Bolt Bracket Bolt Power trim and tilt switch Water outlet Cover Rubber trim M6 x 20 mm M6 x 30 mm M6 x 20 mm M6 x 20 mm M6 x 20 mm M6 x 20 mm P PO 7 5 63P3F11 Bottom cowling Upper case steering arm swivel bracket and clamp brackets Upper case steering arm swivel bracket and clamp brackets 74 N m 7 4 kgf m 54 6 ft Ib 572 23 48 N m 4 8 kof m 35 4 ft Ib S63P7090 2 o Part Remarks Upper case assembly Cover Ground lead Bolt Bolt Adapter Plastic tie Hose Circlip Nut Nut Washer Steering yoke Washer Bushing O ring Bushing M6 x 10 mm M6 x 17 mm Not reusable Notreusable N N YO B N He AN A 63P3F11 7 6 Bracket unit 74 N m 7 4 kgf m 54 6 ft Ib 572 23 48 N m 4 8 kof m 35 4 ft Ib S63P7090 Part name 4 Remarks Steering arm Washer Washer Trim stopper Nut Bolt 7 7 6
67. Replace if necessary 69J6415 2 Check the dog clutch shift rod joint and shift slider for cracks or wear Replace if necessary 69J6420 Assembling the propeller shaft housing 1 Install the needle bearing into the propel ler shaft housing to the specified depth 6 11 S63P6100 NOTE __ Install the needle bearing with the manufac ture identification mark facing toward the oil seal propeller side When using the driver rod do not strike the special service tool in a manner that will force the stopper out of place Driver rod SS D 90890 06604 t lt A Needle bearing attachment 2 90890 06610 Bearing depth plate 3 90890 06603 Depth 24 75 25 25 mm 0 974 0 994 in Apply grease to new oil seals and then install them into the propeller shaft hous ing to the specified depth u dl 10 H m S60V6680 NOTE Install an oil seal halfway into the propeller shaft housing then the other oil seal Bearing inner race attachment 2 90890 06640 63PSF11 Propeller shaft housing counter rotation model 3 Install the original shim s and thrust bearing with the propeller shaft into the propeller shaft housing Depth 4 75 5 25 mm 0 187 0 207 in CAUTION Add or remove shim s if necessary if replacing the propeller shaft thrust bear ing or propeller shaft housing 4 Install a new taper roller be
68. a 45 cutter by turning the cutter clockwise until the valve seat face has become smooth 63P3F11 S63P5240 69J5870 Slag or rough surface CAUTION Do not over cut the valve seat Be sure to turn the cutter evenly downward ata pres sure of 40 50 4 5 kgf 8 8 11 Ibf to prevent chatter marks 3 Use a 30 cutter to adjust the contact width of the top edge of the valve seat gt 30 69J5880 p Previous contact width 4 Use a 60 cutter to adjust the contact width of the bottom edge of the valve seat 63PSF11 Cylinder head gt e S69J5890 D Previous contact width 5 Use a 45 cutter to adjust the contact Previous contact width O Specified contact width 6 If the valve seat contact area is too wide and situated in the center of the valve face use a 30 cutter to cut the top edge of the valve seat a 60 cutter to cut the bottom edge to center the area and set its width width of the valve seat to specification NS 45 S69J5900 S69J5910 D Previous contact width 5 32 7 If the valve seat contact area is too nar row and situated near the top edge of the valve face use a 30 cutter to cut the top edge of the valve seat If necessary use a 45 cutter to center the area and set its width 56975920 p Previous contact width 8 If the valve seat contact area is too nar row and situated near the bottom edge of th
69. engine start switch is turned to OFF OFF 1 START 60 1070 Check that the engine turns off when the engine stop lanyard is pulled from the engine stop lanyard switch 69J1220 1 24 an General information Checking the cooling water pilot hole 1 Check that cooling water is discharged from the cooling water pilot hole Test run 1 Start the engine and then check that the 3 gear shift operates smoothly 2 Check the engine idle speed after the engine has been warmed up 3 Operate at trolling speed 4 Run the outboard motor for 1 hour at 2 000 r min or at half throttle then for another hour at 3 000 r min or at 3 4 throttle 5 Check that the outboard motor does not tilt up when shifting into reverse and that water does not flow in over the transom NOTE The test run is part of the break in operation Break in During the test run perform the break in operation in the following three stages 1 One hour at 2 000 r min or at approxi mately half throttle 2 One hour at 3 000 r min or 3 4 throttle and 1 minute out of every 10 at full throt tle 3 Eight hours O at any speed however avoid running at full speed for more than 5 minutes 1 25 2 S69J1240 Hour Wi C After test run Po 63P3120 1 Check for water in the gear oil Check for fuel leakage in the cowling Flush the cooling water passage with fresh water usi
70. lb 2nd 90 5 14 Crankcase bolt 8 1st 14 N m 1 4 10 3 ft lb 2nd 26 N m 2 6 kgf m 19 2 ft lb 14 Align the keyway in the crankshaft with the cylinder block and crankcase mating surfaces S63P5A40 15 Align the marks 9 on the balancer shafts with the alignment marks S63P5A50 63P3F 11 16 Apply sealant to the mating surface of the balancer assembly S63P5A60 NOTE _ 1 1 1 1 Do not get any sealant inside the balancer assembly 17 Install the balancer assembly onto the crankcase and then tighten the balancer assembly bolts to the specified torques in two stages and in the sequence shown S63P5A70 1 10 Balancer bolt 8 1st 18 N m 1 8 13 3 ft lb 2nd 31 N m 3 1 kgf m 22 9 ft lb m 2 Balancer bolt 6 1st 7 Nam 0 7 kgf m 5 2 ft lb 2nd 13 1 3 9 6 ft lb 63P3F 11 Cylinder block 18 After installing the balancer assembly onto the crankcase apply sealant around the periphery of the seals 3 and then install them onto the balancer assembly S63P5A80 19 Align the oil pump gear with the crank shaft and then install the oil pump 2 S63P5B10 NOTE Before installing the oil pump be sure to fill it with a small amount of engine oil through the oil passage When installing the oil p
71. psi 5 Connect the special service tool to the fuel pump outlet 6 Apply the specified positive pressure and check that there is no air leakage Disas semble the fuel pump if necessary C e 563 4110 Specified pressure 50 kPa 0 5 kgf cm 7 3 psi NOTE ee Assemble the fuel pump valve to the fuel pump body and moisten the inside of the fuel pump with gasoline to ensure a good seal Disassembling a fuel pump 1 Disassemble the fuel pump as shown S60C4060 6 11 2 Push down on the plunger and the dia phragm turn fuel pump body 1 D approximately 90 to a position where the can be removed easily and then remove the pin 60C4070 S60C4080 3 Slowly let up on the plunger and dia phragm and then remove them Checking the diaphragm and valves 1 Check the diaphragm for tears the valves for cracks Replace if neces sary c S60C4090 63P3F11 Fuel filter fuel pump and intake silencer Assembling a fuel pump NOTE LE Clean the parts and soak the valves and the diaphragm in gasoline before assembly to obtain prompt operation of the fuel pumps when starting the engine 1 Align the plunger and diaphragm installa tion holes 8 and then install the plunger into the diaphragm 2 Push down on the plunger and the dia phragm and then install the pin 60C4100 3 Turn fuel pump body 1 approximately 9
72. puller 90890 06521 Removing the oil filter 1 Place a rag under the oil filter and then remove the filter using a 72 5 mm 2 9 in oil filter wrench S63P5920 63PSF11 Power unit NOTE Be sure to clean up any oil spills Oil filter wrench 90890 06830 Removing the timing belt and sprockets 1 Turn the drive sprocket clockwise and align the A mark 8 on the plate with the I mark D on the cylinder block and check that I marks and on the driven sprockets are aligned S63P5450 NOTE Do not turn the drive sprocket counterclock wise 5 20 2 Using a hexagon wrench turn the timing belt tensioner clockwise to push the timing belt increase strength gradually and then insert a 25 0 mm 0 2 in pin into the hole 9 3 Remove the timing belt 3 from the driven sprocket side 63 5460 4 Remove the timing belt tensioner NOTE Do not remove the pin from the timing belt tensioner 5 Remove the drive sprocket and plate 6 Remove the cylinder head cover and then remove the driven sprockets AN Z 65 A s CCL L N S63P5090 NOTE Hold the camshaft using a wrench and be careful not to damage the driven sprocket 5 21 Checking the timing belt and sprockets 1 Check the interior and exterior of the tim ing belt for cracks damage or wear Replace if necessary 69 5570 2 Ch
73. rci Ca gt u uu 9 1 Diagnostic System esee sae crus Dx NG NAN NOE EF CLR NE Qua CI A C Qui 9 2 erm 9 2 Power uqu cosi Ta susuwa Sasa aya a saka say 9 5 9 19 Diagnosing the electronic control system 9 19 TRBL e Troubleshooting Special service tools Diagnostic System 60V 85300 02 GYAMAHA OUTBOARDS YAMAHA 555 WATERCRAFT Diagnostic System 60V WS 853 02 Diagnostic flash indicator B 90890 06865 9 1 63P3F11 Special service tools Diagnostic System Diagnostic System Introduction Features The newly developed Diagnostic System provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods By connecting your computer to the ECM Electronic Control Module of an outboard motor using the communication cable this software can be used to display sensor data and data stored in the ECM on a computer s monitor If this software is run on Microsoft Windows 95 Windows 98 Windows Me Windows 2000 or Windows XP the information can be displayed in colorful graphics Also the software can be oper ated using either a mouse or a keyboard In addition the data for the main functions Diagnosis Diagnosis record Engine monitor and Data logger can be saved on a disk or printed out Fun
74. saver function or the energy saving feature when using this program If the is changed restart the program Window XP is a multiuser operating system therefore be sure to end this program if the login user is changed The USB adapter cannot be used with Windows 95 For operating instructions of the Diagnostic System refer to the Diagnostic Sys tem Instruction Manual 9 3 63P3F11 Diagnostic System Connecting the communication cable to the outboard motor Models F L 150A Bow view ana 3 pin communication coupler S63P9030 63P3F11 9 4 TRBL e Troubleshooting NOTE Before troubleshooting the outboard motor check the compression pressure the mounting and rigging of the outboard motor and the operation of the engine start switch Also make sure that specified fuel has been used and that the battery is fully charged To diagnose a mechanical malfunction use the troubleshooting charts for each trouble located in this chapter Also when checking and maintaining the outboard motor see Chapters 3 8 for safe maintenance procedures To diagnose a sensor or switch malfunction use the diagnostic flash indicator to determine the cause Power unit Symptom 1 Engine does not start or starting the engine is difficult Starting system Check the starter motor opera tion Good operating Yes Check the ignition system and condition fuel system
75. that your computer meets the following requirements before using this software Computer IBM compatible computer Operating system Microsoft Windows 95 Windows 98 Windows Me Windows 2000 or Windows XP English version CPU Windows 95 98 i486X 100 MHz or higher Pentium 100 MHz or higher recommended Windows Me 2000 Pentium 166 MHz or higher Pentium 233 MHz or higher recommended Windows XP Pentium 300 MHz or higher Pentium 500 MHz or higher recommended Memory Windows 95 98 16 MB or more 32 MB or more recommended Windows Me 32 MB or more 64 MB or more recommended Windows 2000 64 MB or more 128 MB or more recommended Windows XP 128 MB or more 256 MB or more recommended Hard disk free space 20 MB or more 40 MB or more recommended Drive CD ROM drive Display VGA 640 x 480 pixels SVGA 800 x 600 pixels or more recommended 256 or more colors Mouse Compatible with the operating systems mentioned above Communication port RS232C Dsub 9 pin port USB port Printer Compatible with the operating systems mentioned above NOTE The amount of memory and the amount of free space on the hard disk differs depending on the computer Using this software while there is not enough free space on the hard disk could cause errors and result in insufficient memory This software will not run properly on some computers When starting up this program do not start other software applications Do not use the screen
76. the cover oil seals and needle bearing le S69J6185 Needle bearing attachment 1 90890 06610 Driver rod L3 2 90890 06652 Disassembling the reverse gear 1 Remove the roller bearing inner race from the reverse gear using a press 63PSF11 Disassembling the lower case Remove the roller bearing and shim s S67H6270R 2 Remove the needle bearings from the reverse gear using a chisel 56856160 563 6610 Bearing outer race puller assembly D 90890 06523 Outer race puller claw B 90890 06533 6 46 Lower unit 2 Remove the needle bearing from the lower case S63P6980 24 Ball bearing attachment 90890 06636 Driver rod LL 2 90890 06605 Checking the pinion and reverse gear 1 Check the teeth of the pinion and the teeth and dogs of the reverse gear for cracks or wear Replace if necessary S69J6200 Checking the bearings 1 Check the bearings for pitting or rum bling Replace if necessary S63P6950 Checking the drive shaft 1 Check the drive shaft for bends or wear Replace if necessary 6 47 v A S69J6210 Checking the lower case 1 Check the skeg and torpedo for cracks or damage Replace the lower case if nec essary Ox Assembling the lower case 1 Install the original shim s and roller bearing into the lower case S60V6220 0 S63P6640 CAUTION Add or remove shim s if necessary i
77. the ring nut and claw washer S62Y6595 Z Ring nut wrench 4 90890 06512 Ring nut wrench extension 2 90890 06513 2 Pull out the propeller shaft housing assembly 56856310 Bearing housing puller claw L 90890 06502 Stopper guide plate 90890 06501 Center bolt 5 90890 06504 Disassembling the propeller shaft assembly 1 Remove the spring then the cross pin 2 dog clutch shift slider balls spring and shift rod joint 2 Remove the forward gear assembly 63PSF11 Propeller shaft housing counter rotation model S63P6500 Disassembling the forward gear 1 Remove the bearing outer race taper roller bearing and thrust washer from the forward gear S63P6510 6 40 Lower unit Disassembling the propeller shaft housing 1 Remove the oil seals and needle bear ing V S63P6520 Needle bearing attachment 90890 06653 Driver rod L3 2 90890 06652 Checking the propeller shaft housing 1 Clean the propeller shaft housing using a soft brush and cleaning solvent and then check it for cracks or damage Replace if necessary S62Y6650 2 Check the teeth and dogs of the forward gear for cracks or wear Replace the gear if necessary S62Y6640 6 41 3 Check the bearings for pitting or rum bling Replace if necessary 69J6410 Checking the propeller shaft 1 Check the propeller shaft for bends or wear
78. the starting system or the ignition system u 9 9 63P3F11 Power unit Symptom 2 Engine speed at wide open throttle is low engine speed decreases or engine stalls poor acceleration or poor deceleration Check the battery lead connec tions and check that the ground lead bolt is not loose or that it has not come off i Good condition i Repair or replace the defective parts Yes J Check the throttle position sen sor and check that the connec tor is securely connected i Good condition jme or replace the defective lt J Check the throttle valves for bends or for stuck throttle valve shafts Good condition NA e the throttle body Yes J Check the ignition system or the fuel system 63P3F11 9 10 TRBL e Troubleshooting Ignition system Check the condition of the spark plugs Good condition No Clean adjust or replace the spark plugs Yes Check the ignition spark using the spark gap tester amp WARNING Do nottouch any of the connections of the spark gap tester leads Do notlet sparks leak out of the removed spark plug caps Keep flammable gas and liquids away since this test can produce sparks Good spark Yes Check the pulser coil output peak voltage or resistance No J Good condition No Replace the stat
79. the water pump and shift fod ie lesa a ees 6 8 6 36 Replacing the oil filter 3 5 Replacing the timing belt 3 6 5 16 Replacing the valve guides 5 30 S Safety while working 1 3 Selecting the connecting rod bearing 5 46 Selecting the crankshaft main bearing 5 48 Selecting the forward gear shims 6 27 6 57 Selecting the pinion shims 6 26 6 55 Selecting the propeller shaft shims 6 58 Selecting the reverse gear shims 6 28 6 56 Selection 1 21 Self diagnosis 9 19 Self protection 1 3 Serial number 1 5 Shift cut control 1 20 Shimming 6 26 6 55 Shimming counter rotation model 6 54 Shimming regular rotation model 6 25 Special service tools 3 1 4 1 5 1 6 1 7 1 8 1 9 1 Specified torques 2 11 Starter motor sss 8 20 Starting system 8 18 Symbols atem ET 1 2 Synchronizing the throttle valves 4 16 T eth 1 17 TS TU tices gives
80. turn after they contact the fixing plate 5 Z Pinion height gauge 90890 06710 2 Install the pinion and pinion nut and then tighten the nut to the specified torque 6 55 Pinion nut 93 N m 9 3 68 6 ft Ib 3 Measure the distance M4 between the special service tool and the pinion as shown 4 Turn the thrust bearing two or three times to seat the drive shaft housing and then measure the housing height M3 as shown S60V6640 NOTE Measure the thrust bearing at three points to find the height average 5 Calculate the pinion shim thickness T3 as shown in the examples below 63PSF11 S69J6555 NOTE _ P is the deviation of the lower case dimen sion from standard The P mark 8 is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the P mark is unreadable assume that P is zero and check the backlash when the unit is assembled Calculation formula Pinion shim thickness T3 80 00 100 4 Example If M3 is 46 68 mm and M4 is 32 49 mm and P is 5 then 80 00 5 100 46 68 32 49 mm 80 00 0 05 46 68 32 49 mm 0 78 mm 6 Select the pinion shim s T3 as follows Calculated numeral at 1 100 place 1 2 3 4 5 6 7 8 9 10 Rounded numeral Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Example If
81. v T Specifications Item Model Killer Whale 150 Killer Whale 150 SX Valve lifters Valve lifter outside diameter Valve lifter to cylinder head clearance 32 982 32 997 1 2985 1 2990 0 020 0 055 0 0008 0 0022 Valve shims Valve shim thickness in 0 020 mm increments 2 3 2 9 0 09 0 12 Connecting rods Big end inside diameter Crankpin oil clearance Big end bearing thickness Green Blue Red 53 025 53 045 2 0876 2 0884 0 027 0 052 0 0011 0 0020 1 496 1 502 0 0589 0 0591 1 505 1 511 0 0593 0 0595 1 514 1 520 0 0596 0 0598 Crankshaft Crankshaft journal diameter Crankpin diameter Crankpin width Runout limit 51 980 52 000 2 0465 2 0472 49 980 50 000 1 9677 1 9685 22 00 22 10 0 8661 0 8701 0 03 0 0012 Crankcase Crankshaft main journal oil clearance Upper crankcase main journal bearing thickness Green Red Yellow Lower crankcase main journal bearing thickness Green Red Yellow Blue green Main journal bearing 3 thickness lower Green Red Yellow 2 5 0 021 0 050 0 0008 0 0020 2 506 2 509 0 0987 0 0988 2 512 2 515 0 0989 0 0990 2 518 2 521 0 0991 0 0993 2 506 2 509 0 0987 0 0988 2 512 2 515 0 0989 0 0990 2 518 2 521 0 0991 0 0993 2 524 2 527 0 0994 0 0995 2 504 2 509 0 0986 0 0988 2 510 2 515 0 0988 0 0990 2 516 2 521 0 0991 0 0993 63PSF11 Unit Killer Whale 150 Mai
82. voltage is 0 2 V or lower or 4 5 V or higher Controlled accord ing to the basic injection map Normal control Controlled by Intake air pressure and engine speed Fuel injection vol ume is controlled by the throttle position sensor Engine temperature sensor Output voltage is 0 18 V or lower or 4 93 V or higher Normal control Normal control Intake air tempera ture sensor Output voltage is 0 10 V or lower or 4 61 V or higher Normal control Normal control Neutral switch Switch is off when starting the outboard motor Normal control Normal control Thermoswitch Shift cut switch The switch is on when the engine temperature is 40 C 104 F or lower or the switch is off when the engine temperature is 130 C 266 F or higher Output voltage is 4 50 V or higher the switch is on when the outboard motor is started or both the shift cut switch and neutral switch are on for 5 seconds Normal control Normal control Normal control Normal control Oil pressure sensor Output voltage is 0 3 V or lower or 4 8 V or higher Normal control Normal control During fail safe control the engine idle speed increases to 900 r min except if the neutral switch is off when the outboard motor is started 63PSF11 aa General information Warning control This outboard motor is equipped with warning control functions to avoid serious engine damage The e
83. 0 and then push down on the plunger several times to make sure that the pin does not come out 60C4110 NOTE Make sure that the gasket and diaphragm are kept in place through the assembly process 4 8 D Fuel system Intake assembly and vapor separator 5 N m 0 5 kgf m 3 7 ft Ib S63P4010 z Part name Remarks 2 lt Boli Fuel cooler Vapor separator Fuel hose Fuel hose Hose Electric fuel pump coupler Intake assembly Bolt M6 x 25 mm 1 2 3 4 5 6 7 8 9 2 M6 x 35 mm 4 9 63P3F11 Intake assembly and vapor separator e 10 EN 11 S63P4030 No 1 2 3 4 5 6 7 8 Part name j Remarks Notreusable O ring Float chamber Drain screw Pressure regulator Screw O ring Cover Screw Electric fuel pump Filter Filter holder O ring Collar Needle valve Screw Float Pin M6 x 12 mm Notreusable 4 x 16 mm Notreusable N 63P3F11 4 10 e Fuel system x 13 N m 1 3 kgf 9 6 ft Ib Part name Ix 13 N m 1 3 kgf m 9 6 ft Ib S63P4020 Remarks Fuel rail Bolt O ring Rubber damper Fuel injector Rubber seal Electric fuel pump lead Gasket Intake manifold Screw Intake air pressure sensor O ring O ring Scr
84. 0 A R Red Fuse 50 A Br W Brown white Starter relay 6 Starter motor C Battery To remote control box switch panel 63P3F11 8 18 evec t 7 ELEC ES Electrical systems Checking the fuses 1 Check the fuses for continuity Replace if there is no continuity 69 8340 Checking the starter relay 1 Connect the digital circuit tester leads to the starter relay terminals 2 Connect the positive battery terminal to the brown Br lead 3 Connect the negative battery terminal to the black B lead 4 Check for continuity between the starter relay terminals Replace if there is no continuity 5 Check that there is no continuity between the starter relay terminals after discon necting a battery terminal from the brown or black lead Replace if there is continu ity S60V8265 8 19 63P3F11 Starter motor 1 5 PO mif U z Part name Starting system Starter motor S63P8050 Remarks Clip Pinion stopper Starter motor pinion Spring Bolt Housing Bearing Clutch assembly E clip Washer Bracket Pinion shaft Planetary gear Outer gear Plate Armature Stator O 63P3F11 GQ KS M6 x 35 mm Notreusable 8 20 ELEC EE Electrical systems oS eo 2 9 3
85. 1 5 f nmm mif UJ S63P8050 Part name j Remarks Brush assembly Brush spring Brush holder Plate Washer Bracket Screw Bolt Rubber seal Shift lever Spring Magnet switch assembly Washer Nut 94 x 15 mm M6 x 120 mm FPE 8 21 63P3F11 Removing the starter motor pinion 1 Slide the pinion stopper down as shown and then remove the clip 5 E 5 A P S69J8370 NOTE Remove the clip with a thin screwdriver Checking the starter motor pinion 1 Check the teeth of the pinion for cracks or wear Replace if necessary 5 69J8380 2 Check for smooth operation Replace if necessary NOTE A 22 2 Turn the pinion counterclockwise to check that it operates smoothly and turn it clockwise to check that it locks in place Checking the armature 1 Check the commutator for dirt Clean with 600 grit sandpaper and com pressed air if necessary 63PSF11 Starter motor S69J8390 2 Measure the commutator diameter Replace the armature if out of specifica tion S69J8400 Commutator diameter limit 28 0 mm 1 10 in 3 Measure the commutator undercut 3 Replace the armature if out of specifica tion 69J8410 Commutator undercut limit 3 0 2 mm 0 01 in 8 22 ELEC ES Electrical systems 4 Check the armature for continuity Replace if out o
86. 23 63P3F11 Power trim and tilt unit 8 N m 0 8 kgf m 5 9 ft 16 3 0 3 22ft ipj 10 S60X7200 Part name Remarks Up relief valve seat O ring Filter O ring Down relief valve Valve pin O ring Valve seat Pin Ball O ring Notreusable Notreusable Notreusable Ss PF S Notreusable 63P3F11 7 24 Bracket unit CO 1 13 16 15 13 14 S 130 N m 13 0 kgf m 96 0 ft Ib S63P7350 z O Part name Remarks Tilt ram Trim ram Cylinder body Free piston Backup ring O ring Dust seal Seal Trim cylinder end screw O ring Backup ring O ring Dust seal Tilt cylinder end screw O ring O ring Tilt piston Notreusable Notreusable Notreusable Notreusable Notreusable Notreusable Notreusable Notreusable NS NB ND ND HAH AH AH 7 25 63P3F11 Power trim and tilt unit S63P7350 Part name j Remarks O ring Not reusable O ring Not reusable Washer Nut Ball Valve Spring 63PSF11 7 26 Bracket unit Removing the power trim and tilt unit 1 Fully tilt the outboard motor up and then support it with the tilt stop lever S60X3020 S60X7090 After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could su
87. 3 90890 04019 WO Test harness 3 pins Valve spring compressor attachment New 90890 06869 90890 06320 Current 90890 06769 Valve guide remover installer Flywheel holder 90890 06801 90890 06522 Valve guide installer Oil filter wrench 90890 06810 90890 06830 5 1 63P3F11 di Valve guide reamer 90890 06804 ZN Valve seat cutter holder 90890 06316 Valve seat cutter 90890 06324 90890 06325 90890 06326 90890 06327 O 2 Needle bearing attachment 90890 06611 90890 06654 Driver rod L3 90890 06652 63PSF11 Special service tools Piston ring compressor 90890 05158 Power unit ES 20 N m 2 0 kgf m 14 8 ft Ib 214 N 0 4 kgf m 3 0 ft Ib S63P5560 No Part name Q ty Remarks 1 Dipstick 1 2 Bolt 1 M6 x 20 mm 3 Dipstick guide 1 4 O ring 1 5 Flywheel magnet cover 1 6 Power unit 1 7 Spark plug wire cover 1 8 Dowel 2 9 Gasket 1 10 Bolt 4 M10 x 35 mm 11 Bolt 8 M10 x 140 mm 12 Bolt 3 M8 x 35 mm 13 Bolt 4 M6 x 16 mm 14 Apron 1 15 Screw 2 06 40 16 Nut 2 5 3 63P3F11 Power unit lt o Part name 1270 N m 27 0 kgf m 199 1 ft Ib S63P5570 Remarks 0 63P3F11 Nut Washer Flywheel magnet Bolt Holder Bracket Collar Holder Stator coil bracket Hose Plastic tie Woodruff key Stator coil
88. 3P3F11 Upper case steering arm swivel bracket and clamp brackets 54 N m 5 4 kgf m 39 8 ft Ib MAN m 0 4 kgf m 3 0 ft 16 S63P7100 Remarks z O o lt Part name Upper case Dowel Grommet Damper Screw Baffle plate Drive shaft bushing Circlip Cap Bolt Washer Washer Washer Lower mount Washer Bolt Bolt M14 x 225 mm M10 x 45 mm M14 x 205 mm N Q N N N N N N N KH N N 63P3F11 7 8 Bracket unit N m 5 4 kgf m 39 8 ft Ib MAN m 0 4 kgf m 3 0 ft 16 S63P7100 No Part name Q ty Remarks 18 Washer 2 19 Washer 2 20 Upper mount 2 21 Washer 2 22 Collar 2 23 Bolt 2 M8 x 30 mm 24 Bolt 4 M10 x 45 mm 25 Muffler assembly 1 26 Gasket 1 27 Rubber seal 1 28 Washer 1 29 Drain bolt 1 M14 x 12 mm 30 Bracket 1 7 9 63P3F11 Upper case steering arm swivel bracket and clamp brackets 572 20 N m 2 0 kgf m 14 8 ft Ib 20 N m 2 0 kgf m 14 8 ft Ib 1 S63P7110 z O Part name Remarks Bolt Muffler Dowel Pipe Rubber seal Gasket Plate Gasket Bolt Exhaust manifold Gasket Bolt Oil pan Dowel Bolt Collar Cil strainer Notreusable Notreusable M8 x 60 mm lt Notreusable M8 x 35 mm k 63P3F11 7 10 Bracket unit
89. 4 1 2x 21 M 14 1 2x 23 M 14 1 2x 25 M 14 1 2x 27 M 14 7 8x 24 M 15x19 M 15 1 4 x 15 M 15 1 4 x 17 M 15 3 4 x 13 M Counter rotation model Propeller size in Stainless Material 14x 19 ML 14 1 2x 17 ML Aluminum 13 3 8 x 23 ML 13 3 4 x 17 ML1 13 3 4 x 19 13 3 4 x 21 ML 14 1 2x 23 ML 14 7 8 x 21 ML 15 1 4 x 15 ML 15 1 4 17 ML 15 1 4 x 19 ML Stainless 63P3F11 Predelivery checks To make the delivery process smooth and efficient the predelivery checks should be completed as explained below Checking the fuel system 1 Check that the fuel hoses are securely connected and that the fuel tank is full with fuel S63P1030 CAUTION This is a 4 stroke engine Never use pre mixed fuel Checking the gear oil level 1 Check the gear oil level S60V1290 63PSF11 Propeller selection Predelivery checks Checking the engine oil level 1 Check the engine oil level S63P3050 NOTE E If the engine oil is above the maximum level mark H extract sufficient oil with an oil changer or drain it until the level is between H and L If the engine oil is below the minimum level mark L add sufficient oil until the level is between H and L Recommended engine oil 4 stroke motor oil API SE SF SG SH or SJ SAE 10W 30 or 10W 40
90. 5 ft Ib 4 Fully extend the trim and tilt rams 5 Remove the circlip then the manual valve Q 6 Install the up relief fitting 3 and hydraulic pressure gauge 2 S60X7350 NOTE Quickly install the special service tools before any fluid flows out of the hole Z5 Up relief fitting 3 90890 06773 Hydraulic pressure gauge 2 90890 06776 7 28 Bracket unit 7 Connect the PTT motor leads to the bat tery terminals to fully retract the trim and tilt rams S63P7300 Battery terminal Light green Lg Sky blue Sb PTT motor lead 8 Reverse the PTT motor leads between the battery terminals to fully extend the trim and tilt rams and then measure the hydraulic pressure S63P7310 Battery terminal Sky blue Sb Light green Lg PTT motor lead Hydraulic pressure up 10 12 MPa 100 120 kgf cm 9 Replace the up relief fitting with the down relief fitting NOTE Quickly install the special service tools before any fluid flows out of the hole 7 29 560 7380 Cz Down relief fitting 5 90890 06774 Hydraulic pressure gauge 90890 06776 10 Remove the reservoir cap and then check the fluid level S60X7340 NOTE aunq If the fluid is at the correct level the fluid should overflow out of the filler hole when the reservoir cap is removed 11 If necessary add sufficient fluid of the
91. 5370 CAUTION Apply force in the direction of the arrows shown to preventthe flywheel holder from slipping off easily NOTE Apply engine oil to the flywheel magnet nut before installation Flywheel holder 90890 06522 Flywheel magnet nut 270 N m 27 0 kgf m 199 1 ft lb 14 Install the flywheel magnet cover Removing the power unit NOTE LM It is recommended to loosen the flywheel magnet nut before removing the power unit to improve working efficiency 1 Remove the flywheel magnet cover 5 18 2 Disconnect the battery leads S63P5380 3 Disconnect the throttle cable 2 and shift cable 3 Bw 4 Remove the junction box cover and then disconnect the PTT motor leads 4 63 5400 S63P5410 6 Remove the dipstick guide 5 19 S63P5420 Disconnect the PTT switch coupler shift cut switch coupler neutral switch cou pler cooling water pilot hose and flush ing hose Remove the apron S63P5430 9 Remove the power unit by removing the bolts 8 S63P5440 10 Remove the flywheel magnet 6 11 S63P5280 S63P5290 CAUTION To prevent damage to the engine or tools screw in the puller set bolts evenly and completely so that the puller plate is par allel to the flywheel magnet NOTE Apply force to the crankshaft end until the fly wheel magnet comes off the tapered portion of the crankshaft Flywheel
92. 6 1 Lower unit regular rotation model eene 6 4 Removing the lower unit 6 8 Removing the water pump and shift 6 8 Checking the water pump and shift rod 6 9 Propeller shaft housing regular rotation model 6 10 Removing the propeller shaft housing assembly 6 12 Disassembling the propeller shaft assembly 6 12 Disassembling the propeller shaft housing 6 12 Checking the propeller shaft housing 6 13 Checking the propeller shaft oe ber etit ete trus 6 13 Assembling the propeller shaft 6 14 Assembling the propeller shaft 6 14 Drive shaft and lower case regular rotation model 6 16 Removing the drive Shall ER qu gem ERE 6 17 Disassembling the drive shaft 6 17 Disassembling the forward gear 6 17 Disassembling the lower case 6 17 Chec
93. 63P3F 11 Backlash counter rotation model Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 17 Remove the special service tools and then install the water pump assembly 6 62 Lower unit MEMO 6 63 63P3F11 63PSF11 Bracket unit Special service tools uuu Dci ic conari a Teo Ue s ce UA ava ca EU CRIT GR 7 1 Bottom coWIlIngu u I kawanan eei dun CEA Ce cu kae dus CR EDO CUIR 7 2 Upper case steering arm swivel bracket and clamp brackets 7 6 Draining the engine oil o D nd eue e ppc pela dies 7 12 Disassembling the oil 7 12 Checking the oil strainer eio ute eene 7 12 Assembling the oil ceto xS erre Pee omnc e 7 12 Removing the Steering ar aoo ten oec cea uerunt eet a ce ua ee 7 14 Installing the steering arm cesses 7 14 Installing the upper rb xe Ru MEER RE 7 15 Clamp Brackets 7 16 Removing the clamp brackets 7 18 Installing the clamp brackets eeernn ee 7 18 Adjusting the trim sensor cam 7 18 Power trim and tilt Unit iiit boats U u REUS Rae RE US 7 20 Removing the power trim and tilt unit 7 27 Checking the hydraulic pressure
94. 7 Installing the propeller shaft eer 6 21 6 49 Installing the sprockets and timing belt 5 21 Installing the steering arm 7 14 Installing the upper case 7 15 Installing the 5 34 Installing the water pump and ShIfUTOQ 1 centes 6 21 6 50 Intake assembly and vapor separator 4 9 Intake system uu u 1 9 Introduction eese rece 9 2 Isolator saa ied 1 16 Junction box assembly 8 4 Lower unit 2 6 3 13 Lower unit counter rotation model 6 32 Lower unit regular rotation model 6 4 Lubricating the outboard motor 3 16 Lubrication system 1 13 M LI Maintenance interval chart 3 2 Maintenance specification 2 3 Manual format 1 1 Measuring the forward and reverse gear backlash 6 29 6 60 Measuring the fuel pressure 4 13 Measuring the lower resistance 8 2 Measuring the peak voltage 8 2 O Over revolution control 1 20 P Parts lubricants and sealants 1 3 Piston and piston ring 1 7 POF
95. 8 3 63P3F11 Electrical components Junction box assembly S63P8020 ECM Power trim and tilt relay Starter relay Diode Fuse 30 A amp Main relay Fuse 20 A Fuse 50 A Intake air temperature sensor 63P3F11 8 4 evec t 7 ELEC EE Electrical systems Aft view 563 8030 Intake air pressure sensor Throttle position sensor Fuel injector Shift cut switch Neutral switch Ignition coil Thermoswitch Spark plug 8 5 63P3F11 Top view Fuel injector Ignition coil Starter motor Stator coil Engine temperature sensor Throttle position sensor Idle speed control Intake air pressure sensor Shift cut switch Neutral switch 63P3F 11 Electrical components Power trim and tilt switch 563 8040 8 6 0 000 N H H G20 60 091900 t9 00000 0 99000 O09 9X0 24342 06969 69 62
96. Checking the water pump and shift rod 1 Check the water pump housing for defor mation Replace if necessary 5696030 2 Check the impeller and insert car tridge 2 for cracks or wear Replace if necessary 63 6050 3 Check the Woodruff key 3 and the key way 8 in the drive shaft for wear Replace if necessary 5696040 4 Check the shift rod for cracks or wear Replace if necessary 6 37 S69J6360 63P3F11 Lower unit counter rotation model Propeller shaft housing counter rotation model Propeller shaft housing counter rotation model 4N m 0 4 kgf m 3 0 ft Ib S63P6490 2 o O 0 GQ Part name 4 Remarks Shift rod joini Ball Shift slider Ball Ball Spring Dog clutch Cross pin Spring Forward gear shim Forward gear Thrust washer Taper roller bearing assembly Propeller shaft Thrust bearing Propeller shaft shim O ring Not reusable YO NN Notreusable a a ua 63P3F11 6 38 Lower unit 4N m 0 4 kgf m 3 0 ft Ib S63P6490 Part name 1 Remarks Propeller shaft housing Straight key Needle bearing Cil seal Claw washer Ring nut Cooling water inlet cover Nut Screw Notreusable po po 6 39 63P3F11 Removing the propeller shaft housing assembly 1 Straighten the claw washer tabs 8 and then remove
97. Dernier 1 7 Piston and PISTON u uuu e ipee ot te co PEDE edd ehe 1 7 Connecting Tod eena oe M etta bansa s up tM ctm akana 1 8 Cylinder head COVER 1 8 1 9 TOP san AN GA 1 10 64E type power trim and tilt unit 1 11 Eoi ao OE pcm 1 12 Lubrication 2 eres nates seen 1 13 PUG Ey rcu cL 1 15 Rectifier Regulator pe beatus itn 1 16 D 1 16 Technical UPS U n 1 17 Electronic control system eaten echoes etae EO Pagi dia tos 1 17 M tes e e s 1 17 Fail safe ooniro s saa u KA a PET 1 18 Warning eet un t e uS ace eet ees tee 1 19 Shift eut control E 1 20 Over revolution control idee tate da eto td eta 1 20 Fuel pump Controls eot o euer este Re Ne EPUM UE ud he 1 20 Propeller selection MM 1 21 aiisc l igri T 1 21 i em M ES 1 21 63PSF11 Predelivery checKs u A L kdo C a 1 22 Checking the fuel system me te dtt boe i eto e battus 1 22 Checking the gear oil 1 22 Checking the engine oil level 1 22 Checking the batlery Roter Ue i Ht Punk
98. J7525 Checking the power trim and tilt relay 1 Check the power trim and tilt relay for continuity Replace if out of specification 2 563 7370 M Be sure to set the measurement range 8 shown in the illustration when checking for continuity Power trim and tilt relay continuity Sky blue Sb Black B Light green Lg Black B Terminal Terminal Terminal Terminal Terminal Terminal 3 Terminal 2 Terminal 3 Continuity Continuity No continuity 2 Connect the digital circuit tester between power trim and tilt relay terminals 2 and 7 47 3 Connect the light green Lg lead to the positive battery terminal and the black B lead to the negative battery terminal as shown 4 Check for continuity between terminals and 3 Replace if there is no continu ity stone V Kare yy 563 7380 5 Connect the digital circuit tester between power trim and tilt relay terminals and 6 Connect the sky blue Sb lead to the positive battery terminal and the black B lead to the negative battery terminal as shown 7 Check for continuity between terminals and Replace if there is no continu ily S63P7390 Checking the power trim and tilt switch 1 Check the power trim and tilt switch for continu
99. Killer Whale150 EFI SERVICE MANUAL Marine NOTICE This manual has been prepared by Selva primarily for use by Selva dealers and their trained mechanics when performing maintenance procedures and repairs to Selva equipment It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use Because Selva has a policy of continuously improving its products models may differ in detail from the descriptions and illustrations given in this publication Use only the latest edition of this manual Authorized Selva dealers are notified periodically of modifications and significant changes in specifications and procedures and these are incorporated in successive editions of this manual Important information Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the outboard motor CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the out board motor NOTE Contents k General information z
100. LVIOW aer pete eee tients 8 3 Power trim and tilt electrical system 7 46 Power trim and tilt unit 3 13 7 20 Power 2 3 3 4 5 3 9 5 Predelivery checks 1 22 Propeller selection 1 21 Propeller shaft housing counter rotation model 6 38 Propeller shaft housing regular rotation model 6 10 Propeller size eese 1 21 R Rectifier Regulator 1 16 Reducing the fuel pressure 4 15 Refacing the valve seat 5 31 Removing the clamp brackets 7 18 Removing the cylinder head 5 28 Removing the drive shaft 6 17 6 46 Removing the exhaust cover 5 37 Removing the lower 6 8 6 36 Removing the oil filter 5 20 Removing the power trim and tilt unit 7 27 Removing the power 5 18 Removing the propeller shaft housing assembly 6 12 6 40 Removing the reservoir 7 33 Removing the starter motor pinion 8 22 63P3F11 Removing the steering arm 7 14 Removing the timing belt and sprockets 5 20 Removing
101. Muffler bolt 20 N m 2 0 14 8 ft lb Install the muffler assembly by insert ing the tip of the cooling water pipe 2 into the joint hole 8 of the upper case 10 Install muffler assembly bolts and 2 and then tighten them to the specified torques S63P7190 Exhaust manifold bolt 6 20 N m 2 0 14 8 ft lb Oil pan bolt 2 20 N m 2 0 kgf m 14 8 ft lb 6 Install the plate 8 7 Install the cooling water pipe 9 into the muffler 49 8 Install the muffler and bolts into the oil pan and then tighten the bolts to the specified torque l S63P7210 7 13 63P3F11 Upper case steering arm swivel bracket and clamp brackets Muffler assembly bolt 3 20 2 0 kgf m 14 8 ft lb Muffler assembly bolt 4 42 N m 4 2 kgf m 31 0 ft lb 11 Install the upper mounts 9 and bolts into the upper case 12 Install the bracket 49 and bolts and then tighten the bolts to the specified torque 563 7220 Upper mount bracket bolt 54 N m 5 4 39 8 ft lb Removing the steering arm 1 Remove the circlip 2 Remove the steering yoke 2 by striking it with a plastic hammer S69J7075 63P3F11 3 Remove the steering arm from the swivel bracket by pulling the arm off the bracket Installing the steering arm 1 Install the washer and bushing 2 onto the steering arm 3 2 Place the swivel bracket in an upright
102. O69 62 63 62 G 60 09 0 6206 6303 Pe Connect to Fuse holder Fuse holder 3 Diagnostic flash indicator Starter relay Ground Power trim and tilt relay ECM Intake air temperature sensor 9 Personal computer for diagnosis Power trim and tilt switch Warning indicator Remote control Engine temperature sensor 8 7 0722774 Mee G Y G R Y c S63P8190 Throttle position sensor 9 Neutral switch Shift cut switch Fuel injector Electric fuel pump Intake air pressure sensor Idle speed control Pulser coil Oil pressure sensor 63 Thermoswitch Ignition coil 63P3F 11 Black Br Brown G Green Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue White Y Yellow B O Black orange B W Black white 63P3F11 R Y QR in is eH c 9 w 7 I 7 LJ cu PHI 7 Pu B Pu G Pu R Pu Y s Px B B B puta t H 11 1777774 st da G B PE E E GY G Black yellow Green black Green red Green yellow Blue green Blue white Blue yellow Pink black Pink green Pink white Purple black Purple green Purple red Purple yellow R Y W B
103. PSF11 B Power trim and tilt unit Lower unit Check the oil for metal and discoloration and its viscosity Check the internal parts of the lower case if necessary Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible S60V3340 S60V3350 Recommended gear oil Hypoid gear oil SAE 90 Oil quantity Regular rotation model 980 cm 33 1 US oz 34 6 Imp oz Counter rotation model 870 cm 29 4 US oz 30 7 Imp oz Install the check screw and quickly install the drain screw 3 14 ge ADJ Periodic checks and adjustments Checking the lower unit for air leakage 1 Remove the check screw D and then install the special service tool S60V3370 2 Apply the specified pressure to check that the pressure is maintained in the lower unit for at least 10 seconds CAUTION Do not over pressurize the lower unit oth erwise the oil seals can be damaged NOTE 1 Cover the check hole with a rag when remov ing the tester from the lower unit aN Lower unit holding pressure 70 kPa 0 7 kgf cm 10 psi 3 If pressure drops below specification check the drive shaft and propeller shaft oil seals for damage Checking the propeller 1 Check the propeller blades and splines for cracks damage or wear Replace if necessary 3 15 69J3580 General Che
104. Start the engine warm it up for 5 min utes and then turn it off 2 Remove the engine stop lanyard from the engine stop lanyard switch on the remote control box 3 Remove the spark plug wire cover and all spark plugs and then install the special service tools into a spark plug hole S63P5010 CAUTION Before removing the spark plugs blow compressed air in the spark plug well to clear out any dirt or dust that may fall into the cylinder Compression gauge D _ 90890 03160 Compression gauge extension 90890 06563 4 Fully open the throttle crank the engine until the reading on the compression gauge stabilizes and then check the compression pressure Minimum compression pressure reference data 880 kPa 8 8 kgf cm 128 psi 5 If the compression pressure is below specification and the compression pres sure for each cylinder is unbalanced add a small amount of engine oil to the cylin der and then check the pressure again NOTE e f the compression pressure increases check the pistons and piston rings for wear Replace if necessary e lf the compression pressure does not increase check the valve clearance valve valve seat cylinder sleeve cylinder head gasket and cylinder head Adjust or replace if necessary Checking the oil pressure 1 Place a rag under the oil pressure sen sor 2 Remove the oil pressure sensor and then install an oil pressure gaug
105. Turn throttle lever 1 and the throttle cam 8 counterclockwise so that they are in the positions shown in the illustration S63P3160 5 Check that the throttle valves are fully closed and then adjust the throttle link rod joint to align its hole with the ball joint 9 on throttle lever 1 22 TN 6 Connect the throttle link rod joint 5 and then tighten the locknut 2 S63P3170 7 Connect the link rod joint 8 Contact the stopper on the throttle lever 2 to the fully closed stopper on the cylinder block and check for clear ance between the throttle cam roller and the throttle cam 3 9 S63P3180 NOTE If there is no clearance loosen the locknut and the throttle link rod joint one turn and then repeat steps 6 and 8 9 Operate throttle lever 2 to check that the throttle valves fully close and fully open TB N Z JE S63P3190 NOTE The throttle valves are fully open when the throttle cam roller 2 is within the range shown in the illustration 6 11 10 Contact the stopper on the throttle lever 2 to the fully closed stopper on the cylinder block and check that throttle cam roller is aligned with the align ment mark 63 3200 11 Adjust the position of the throttle cable joint until its hole
106. W R Y G Electrical components S63P8190 Red yellow White black White red Yellow green 8 8 ELEC EE Electrical systems Ignition and ignition control system HER BIW OS KN mal BQBQOOQODOO OOOD OYO OGR QR GB Spark plug Ignition coil Thermoswitch Oil pressure sensor Pulser coil 8 Stator coil ECM Intake air temperature sensor 9 Fuse holder Main relay 8 9 tte amp 563 8200 To remote control box switch panel Fuse 20 A Fuse 50 A 3 Battery Rectifier Regulator 5 Engine temperature sensor Idle speed control Throttle position sensor Intake air pressure sensor Shift cut switch Neutral switch 63P3F 11 Ignition and ignition control system BQBQOOQODOO OOOD OYO 89 lt amp S63P8200 B Black G R Green red G Green G Y Green yellow Orange Blue green P Pink L Y Blue yellow R Red P G Pink green Y Yellow P W Pink white Black orange R Y Red yellow B W Black
107. ace for pitting or wear Replace if necessary 2 Measure the valve margin thickness S69J5760 Valve stem runout 0 01 mm 0 0004 in a Checking the valve guides CIL NOTE c7 c cc Before checking the valve guide make sure that the valve stem diameter is within specifi cation 69J5740 Replace if out of specification 1 Measure the valve guide inside diameter Valve margin thickness 8 Intake 0 70 mm 0 0276 in Exhaust 1 00 mm 0 0394 in 3 Measure the valve stem diameter Replace if out of specification 69J5770 Valve guide inside diameter 5 504 5 522 mm 0 2167 0 2174 in S69J5750 5 29 63P3F11 Cylinder head 2 Calculate the valve stem to valve guide clearance as follows Replace the valve 2 Valve guide remover installer guide if out of specification E 90890 06801 Valve guide installer 90890 06810 Valve stem to valve guide clearance valve guide inside diameter valve 3 Insert the special service tool into the stem diameter valve guide and then ream the valve Intake and exhaust guide 0 025 0 058 mm 0 0010 0 0023 in Replacing the valve guides 1 Remove the valve guide by striking the special service tool from the combus tion chamber side 69 5810 Turn the valve guide reamer clockwise to ream the valve guide Do not turn the reamer counterclockwise when removing the reamer 8695790
108. ace if out of specification 69 4150 S60V8450 Checking the electric fuel pump 1 Turn the engine start switch to ON Fuel injector resistance 2 use as reference 14 0 15 0 Q at 20 C 68 F Listen for the operating sound of the electric fuel pump D Check the fuel sys tem if there is no sound NOTE Check the operation of the fuel injectors using the Stationary test of the Diagnostic System Checking the main relay 1 Remove the fuse holder cover and then remove the fuse holder S63P8150 2 Connect the digital circuit tester leads to NOTE TT the main relay terminals and After the engine start switch is turned to ON the electric fuel pump will operate for 3 sec 3 Connect the positive battery terminal to onds the main relay terminal 4 Connect the negative battery terminal to the main relay terminal 3 5 Check for continuity between the main relay terminals Replace if there is no continuity 6 Checkthat there is no continuity between the relay terminals after disconnecting a battery terminal from the main relay ter minals and 3 Replace if there is con tinuity 8 17 63P3F11 Fuel control system Starting system Starting system 63 8220 Fuse holder B Black Q Fuse 30 A Br Brown 3 Fuse 2
109. and in the sequence shown S63P5120 NOTE Install the camshaft caps in the proper posi tion as shown and with the stamped num bers facing upside down Apply engine oil to the camshaft cap bolts before installation Camshaft cap bolt 1st 8 0 8 5 9 ft lb 2nd 17 N m 1 7 12 5 ft lb 5 36 Removing the exhaust cover 1 Remove the cover 1 and thermostat 2 S63P3110 2 Remove the exhaust cover bolts in the sequence shown Bl e E u S63P5660 Checking the pressure control valve 1 Remove the pressure control valve 2 Check the pressure control valve for wear or damage Replace if necessary 3 Check the grommet for deformation Replace if necessary 4 Check the spring for fatigue or defor mation Replace if necessary A po o gt 5 37 S60V5610 Installing the pressure control valve 1 Install a new gasket and the pressure control valve and then tighten the bolts y ps lal aa e gj A re 2 W B 563 5670 6 11 Cylinder head Cylinder block Cylinder block 12 m 1 2 kgf m 8 9 ft Ib WAN m 0 4 kgf m 3 0 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 13 m 1 3 kgf m 9 6 ft Ib S63P5640 2 o Part name j Remarks Engi
110. are manufactured as a single piece Then they are split using impact force Only use the connecting rods and connecting rod caps in their original combina tions do not interchange them S63P1100 Direction mark Cylinder head cover The oil gas separator is used to obtain low emissions and is built into the cylinder head cover to obtain a compact design The gas and oil flow is shown below S63P1110 Intake silencer Cylinder head cover with gas oil separator Blowby gas B Oil 63P3F11 1 8 an General information Intake system Multi point group fuel injection with four separate throttle valves is adopted for the intake system Intake air volume is calculated according to engine speed Intake air pressure and throttle position and then the fuel injection volume is determined by the intake air volume to obtain a precise air and fuel ratio under all operating conditions The cylinders are grouped 1 4 and 2 3 Fuel is injected twice during each full cycle of each cyl inder once during the exhaust stroke and once during the compression stroke Fuel is injected dur ing the compression stroke of the 1 cylinder and the exhaust stroke of the 4 cylinder and during the exhaust stroke of the 1 cylinder and the compression stroke of the 4 cylinder The same occurs during the compression and exhaust strokes of the 2 and 3 cylinde
111. aring 7 and the bearing outer race 8 into the propel ler shaft housing using a press S63P6550 6 42 Lower unit 5 Install the thrust washer 9 forward gear and dog clutch using a press S63P6960 NOTE Install the dog clutch with the F mark facing toward the forward gear Ring nut wrench 9 90890 06578 6 Install the spring 49 balls and shift slider into the propeller shaft and then install the cross pin 9 and spring L S63P6570 6 43 63P3F11 Propeller shaft housing counter rotation model Drive shaft and lower case counter rotation model Drive shaft and lower case counter rotation model S63P6580 Part name 4 Remarks Drive shaft Sleeve Cover Oil seal Bolt M8 x 25 mm Drive shaft housing Needle bearing O ring Pinion shim Thrust bearing Lower case Needle bearing Pinion Nut Reverse gear shim Roller bearing Thrust bearing 63P3F11 6 44 Lower unit S63P6580 No Part name Q ty Remarks 18 Needle bearing 2 19 Reverse gear 1 6 45 63P3F11 Drive shaft and lower case counter rotation model Removing the drive shaft 1 Remove the drive shaft assembly and pinion and then pull out the reverse gear and thrust bearing S68S6360J CL Drive shaft holder 6 0 90890 06520 Pinion nut holder New 90890 06715 Current 90890 06505 Disassembling the drive shaft housing 1 Remove
112. ater 0 0 56978240 2 Measure the engine temperature sensor resistance Replace if out of specifica tion Engine temperature sensor resistance Black yellow B Y Black yellow B Y at 20 C 68 F 54 2 69 0 at 100 C 212 F 3 12 3 48 63PSF11 Checking the thermoswitch 1 Place the thermoswitches in a container of water and slowly heat the water 06000000000 S69J8250 2 Check the switch for continuity at the specified temperatures Replace if out of specification j Z Y S69J8260 Temperature Time No continuity Continuity Thermoswitch continuity temperature Pink P Black B 84 90 C 183 194 F 68 82 154 180 F Checking the shift cut switch 1 Check the shift cut switch for continuity Replace if there is no continuity S69J8270 63P3F11 Ignition and ignition control system Lead color Switch position Blue yellow LY Black B Free Push O REL oO Checking the neutral switch 1 Check the neutral switch for continuity Replace if there is no continuity 56978270 Lead color Blue green L G Switch position Black B Free 8 Push Oo 1 oO 8 14 Fuel control system BY BY PET ol 52 Nav oan Sa RIYO
113. b 5 Install the power trim and tilt unit then the anode NOTE Se Install the ground lead between the power trim and tilt unit and the anode 6 Install the ground lead between the clamp brackets and the swivel bracket 7 Apply water resistant grease through the grease nipples S63P7320 NOTE Apply the grease until it comes out of the bushing Adjusting the trim sensor cam 1 Fully retract the power trim and tilt unit 2 Loosen the trim sensor cam screw 1 3 Adjust the trim sensor cam where the specified trim sensor setting resistance is obtained 7 18 Bracket unit Trim sensor resistance Pink P Black B 238 8 378 8 Q at 20 C 68 F 560 7160 Trim sensor setting resistance Pink P Black B 9 11 Q at 20 C 68 F Trim sensor cam screw 1 2 N m 0 2 kgf m 1 5 ft lb 4 Fully tilt the outboard motor up and then support it with the tilt stop lever 3 560 7170 After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure 5 Check the trim sensor resistance If the resistance is out of specification adjust the trim sensor cam position and check the trim sensor 7 19 63P3F11 Clamp brackets Power trim and tilt unit Power trim and tilt unit S60X7010 z
114. b with the holes O in the pump housing 7 Install the new O ring 2 and pump hous ing assembly into the lower case tighten the bolts 9 and then install the seal 47 and cover 8 S63P6370 NOTE When installing the pump housing apply grease to the inside of the housing and then turn the drive shaft clockwise while pushing down the pump housing Align the cover projection with the hole in the pump housing 6 11 Drive shaft and lower case counter rotation model Installing the lower unit 1 Set the gear shift to the neutral position at the lower unit 2 Align the center of the set pin 8 with the mark on the bottom cowling 25 S63P3270 60 6330 Shift rod push arm 90890 06052 3 Install the two dowels into the lower unit 4 Install the lower unit into the upper case and then tighten the lower case mounting bolts 2 to the specified torque 5 Install the trim tab 3 to its original posi tion and then tighten the bolt to the specified torque 63PSF11 S63P6730 Lower case mounting bolt 47 4 7 kgf m 34 7 ft lb Trim tab bolt 2 42 4 2 kgf m 31 0 ft lb 6 52 Lower unit 6 Install the propeller and propeller nut and then tighten the nut finger tight Place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then tighten the nut to the sp
115. ch S63P3090 NOTE eS Wait more than 5 minutes after turning the engine off to replace the oil filter Be sure to clean up any oil spills Oil filter wrench 90890 06830 3 Apply a thin coat of engine oil to the O ring of the new oil filter 4 Install the oil filter and then tighten it to the specified torque using a 72 5 mm 2 9 in oil filter wrench 63P3F 11 5 S63P3100 Oil filter 18 N m 1 8 kgf m 13 3 ft lb Pour the specified amount of the recom mended engine oil into the oil filler hole Recommended engine oil 4 stroke motor oil API SE SF SG SH or SJ SAE 10W 30 or 10W 40 Oil quantity With oil filter replacement 5 4 L 5 7 US qt 4 8 Imp qt Install the oil filler cap and dipstick and then start the engine and warm it up for 5 minutes Turn the engine off and then check the oil level and correct it if necessary Checking the timing belt 1 2 Remove the flywheel magnet cover While turning the flywheel magnet clock wise check the interior and the exte rior of the timing belt for cracks damage or wear Replace if necessary Turn the crankshaft clockwise two turns to take up slack in the timing belt 63PSF11 Power unit Replacing the timing belt NOTE For replacement procedures see Chapter 5 Replacing the timing belt Checking the valve clearance NOTE For checking procedures see Chapter 5 Checking the valve c
116. cking the anodes 1 Check the anodes and trim tab for scales grease or oil Clean if necessary S63P3300 S60X3080 S69J3610 63P3F11 CAUTION Do not oil grease or paint the anodes or the trim tab otherwise they will be ineffec tive 2 Replace the anodes or trim tab if exces sively eroded Checking the battery 1 Check the battery electrolyte level If the level is at or below the minimum level mark add distilled water until the level is between the maximum and minimum level marks 69J3620 2 Check the specific gravity of the electro lyte Fully charge the battery if out of specification WARNING Battery electrolyte is dangerous it con tains sulfuric acid which is poisonous and highly caustic Always follow these preventive measures Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury Wear protective eye gear when handling or working near batteries Antidote EXTERNAL SKIN Wash with water lt EYES Flush with water for 15 minutes and get immediate medical attention Antidote INTERNAL Drink large quantities of water or milk followed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention 63PSF11 Lower unit General Batteries generate explosive hydrogen gas Always follow these preventive mea sures lt Charge batteries in a wel
117. condition No Repair or replace the defective parts M P Yes Check the spark plug wire tance and the spark plug caps for salt buildup Continued on next page 9 7 63P3F11 Power unit i Good condition o Repair or replace the spark plug wires Yes Check the main relay for conti nuity Is there continuity s Replace the main relay F Yes Check the ECM output peak voltage Nn Fuel system Check the electric fuel pump operation Can the opera No Check the fuse holder fuse tion sound be and wiring harness for continu heard ity Yes No Repair or replace 2 shee defective parts Yes Check the fuel filters for clogs Replace the electrical fuel and the hoses for leaks pump Continued on next page 63P3F11 9 8 TRBL e Troubleshooting i Clogs or leaks Yes Repair or replace the defective parts No Check the fuel pump diaphragm Cracks or damage Replace the diaphragm Lk Check the vapor separator needle valve Is the needle valve Yes bent or worn Check the injector resistance and check the injectors for clogs i Good condition Replace the needle valve F B Replace the injectors Yes Check
118. ctions 1 Diagnosis With the engine main switch ON each sensor s status and each ECM diagnosis code or item is displayed This enables you to find malfunctioning parts and controls quickly 2 Diagnosis record Sensors that had been activated and ECM diagnostic codes that have been recorded are displayed This allows you to check the outboard motor s record of malfunctions 3 Engine monitor Each sensor status and the ECM data are displayed while the engine is run ning This enables you to find malfunctioning parts quickly 4 Stationary test With the engine off the ignition fuel injection electric fuel pump and ISC valve are checked These tests can be performed quickly 5 Active test With the engine running the ISC valve is checked 6 Data logger Displays 13 minutes of recorded data for two or more of the items stored in the ECM In addition the operating time as compared to the engine speed and the total operating time are displayed This allows you to check the operating status of the engine 7 Some files Lets you select and run other applications while continuing to run the diagnostic program Contents 1 Software 1 EJ YAMAHA 2 Adapter 1 DIAGNOSTIC SYSTEM 3 Communication cable 1 4 Instruction Manual 1 5 Installation Manual 1 o amp 63P3F11 9 2 TRBL e Troubleshooting Hardware requirements Make sure
119. d denly lower if the power trim and tilt unit should lose fluid pressure If the power trim and tilt does not operate loosen the manual valve 2 and tilt the out board motor up manually If the manual valve is loosened be sure to tighten it to the specified torque after tilting the outboard motor up Manual valve 3 N m 0 3 kgf m 2 2 16 7 27 2 Remove the bolt and disconnect the ground lead at the bottom of the power trim and tilt unit 3 Remove the plastic ties and then pull out the PTT motor leads 60X7100 4 Remove the bolts then the lower mount ing shaft 560 7110 5 Remove the circlip then the upper mounting shaft 6 11 NOTE Hold the power trim and tilt unit with one hand and pull the upper mount shaft out at a downward angle with the other 6 Remove the collars Checking the hydraulic pressure 1 Remove the reservoir cap and then check the fluid level in the reservoir 560 7340 NOTE ee E If the fluid is at the correct level the fluid should overflow out of the filler hole when the reservoir cap is removed 2 f necessary add sufficient fluid of the recommended type until it overflows out of the filler hole 63P3F 11 Power trim and tilt unit Recommended power trim and tilt fluid ATF Dexron II 3 Install the reservoir cap and then tighten it to the specified torque Reservoir cap 0 7 N m 0 07 kgf m 0
120. d 700 50 r min 4 Check the vacuum pressure of all cylin ders 4 16 s gi Fuel system 5 Turn the synchronizing screw so that the vacuum pressure of cylinder 3 or 4 is within 2 kPa 15 mmHg based on the vacuum pressure of cylinder 1 or 2 MILS Vacuum pressure is increase Vacuum pressure is decrease Direction Direction Example Check results Cylinder kPa mmHg Adjust the difference of the vacuum pressure between cylinders 1 and 4 within 2 kPa 15 mmHg Check results Cylinder kPa mmHg Adjust the difference of the vacuum pressure between cylinders 2 and 4 within 2 kPa 15 mmHg Adjusting the throttle position sensor NOTE Be sure to adjust the throttle valve s open ing before measuring the throttle position sensor output voltage When measuring the throttle position sen sor output voltage set the digital tester to the manual range 4 17 1 Remove the intake silencer 2 Disconnect the throttle joint link rod from the throttle lever 1 F x S63P4260 3 Check that the throttle valves are in the fully closed position 563 4270 4 Connect the test harness 3 pins to the throttle position sensor 5 63 8130 5 engine start switch to ON 6 Measure the throttle position sensor out
121. e ERR 1 22 Checking the outboard motor mounting height 1 23 Checking the remote control cables a 1 23 Checking the steering system seessseeneeeeen 1 24 Checking the gear shift and throttle operation 1 24 Checking the power trim and tilt system 1 24 Checking the engine start switch and engine stop lanyard switch 1 24 Checking the cooling water pilot hole 1 25 1 25 zii e sua 1 25 After test TUN sasa gas apa codo eene nagka NG bak aaa agan 1 25 63PSF11 General information How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under stand Use the information below as a guide for effective and quality service Parts are shown and detailed in an exploded diagram and are listed in the components list 2 Tightening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions Symbols are used to indicate important aspects of a procedure such as the grade of lubricant and lubrication point The components list consists of part names and part quantities as well as bolt and screw dimen sions 5 Serv
122. e D to the oil pressure sensor installation hole S63P5020 NOTE Use a general pressure gauge 3 Start the engine and warm it up for 5 min utes 4 Check the oil pressure Check the oil pump oil leakage and oil strainer if out of specification Oil pressure reference data 450 kPa 4 5 kgf cm 65 3 psi at engine idle speed 6 11 Power unit Checking the oil pressure sensor Checking the valve clearance 1 Connect the test harness 3 pins to the 1 Remove the flywheel magnet cover and oil pressure sensor spark plug wire cover 2 Startthe engine and warm it up for 5 min 2 Disconnect the fuel hoses from the fuel utes pumps 3 Measure the oil pressure sensor input 3 Disconnect the spark plug wires D and voltage Check the wiring harness con remove the blowby hoses 9 spark nection or replace the ECM if out of spec plugs and cylinder head cover 3 ification 4 Measure the oil pressure sensor output voltage Replace if out of specification S63P5050 4 Turn the flywheel magnet clockwise and align the TDC mark 8 on the flywheel S63P5030 magnet with the pointer and check that I marks and on the driven sprockets are aligned 2 8 1 2 i I I I i 450 kpa 4 5 kgf cm 65 3 psi 63 5040 Output voltage Oil pressure gt Test harness 3 pins New 90890 06869 Current 90890 06769 Oil pressure se
123. e hydraulic system components Small pieces of fibers remaining on them can cause the system to malfunction NOTE Place container under the power trim and tilt unit to catch the fluid 2 Remove the reservoir and O rings S60X7400 CAUTION Make sure that the trim and tilt rams are fully extended when removing the reser voir otherwise fluid can spurt out from the unit due to internal pressure Do not push the tilt and trim rams down while the power trim and tilt motor is removed from the power trim and tilt unit otherwise fluid can spurt out 63PSF11 3 Drain the fluid from the reservoir and check it for damage Replace if neces sary 4 Check the reservoir cap and O ring for damage Replace if necessary Disassembling the gear pump housing 1 Remove the gear pump housing S60X7410 NOTE A Make sure that the O rings valve pin and valve seat assembly are removed 2 Remove the filters down relief valve and O ring from the gear pump housing 2 S60X7420 NOTE _ _ Remove the back filter using compressed air being careful not to blow the filter out abruptly 3 Remove the gear pump cover and drive gears 63PSF11 Power trim and tilt unit S60X7430 NOTE Make sure that the shuttle pistons and balls are removed since they tend to stick to the gear pump cover 4 Remove the up relief valve assembly 0 C 0o gt qu 60 7440
124. e camshaft oil clearance as follows Replace the camshaft and cylinder head as a set if out of specifica tion Camshaft oil clearance Camshaft cap inside diameter Camshaft journal diameter 0 020 0 060 mm 0 0008 0 0024 in 6 11 1 Eliminate carbon deposits from the com bustion chambers and check for deterio ration Check the cylinder head warpage using a straightedge 1 and thickness gauge in seven directions as shown Replace if out of specification S63P5190 S63P5200 Cylinder head warpage limit 0 10 mm 0 0039 in Installing the valves Install a new valve seal 1 into the valve guide 569 5 20 5 34 2 Install the valve valve spring and valve spring retainer in the sequence shown and then attach the special ser vice tool 69J5A30 NOTE _ 0 The valve spring can be installed in any direction 2 Valve spring compressor 90890 04019 Valve spring compressor attachment 90890 06320 3 Compress the valve spring and then install the valve cotter using a thin screwdriver with a small amount of grease applied to it S69J5A40 4 Lightly tap the valve spring retainer with a plastic hammer to set the valve cotter securely 5 35 an a Wi CO lt gt Oi CUI S63P5210 NOTE Apply engine oil to the valve shims and valve lifters bef
125. e data 310 kPa 3 1 kgf cm 45 0 psi Start the engine warm it up for 5 min utes and then measure the fuel pres sure below specification check the high pressure fuel line and the vapor separator X Fuel pressure reference data 260 kPa 2 6 kgf cm 37 7 psi WARNING e Before measuring the fuel pressure make sure that the drain screw is tight ened securely Do not loosen the drain screw while measuring the fuel pressure Loosening the drain screw can cause fuel to spray out creating a fire hazard After measuring the fuel pressure cover the end of the hose with a clean dry rag point the hose downward and then loosen the drain screw to drain the remaining fuel from the hose and gauge When storing the fuel pressure gauge make sure that the drain screw is tight ened securely Checking the pressure regulator 1 Remove the cap 2 Connect the fuel pressure gauge to the pressure check valve 3 Disconnect the pressure regulator hose and then connect the special service tools to the pressure regulator S63P4140 Fuel pressure gauge 90890 06786 A Vacuum pressure pump gauge set 90890 06756 63P3F 11 WARNING e When connecting the fuel pressure gauge first cover the connection between the gauge and the pressure check valve with a clean dry rag to pre vent fuel from leaking out lt Gently screw in the gauge until it is firmly connected 4 Startthe engine a
126. e servicing the line or the vapor separator If the fuel pressure is not released pressurized fuel may spray out S63P4160 3 Place a container under the vapor sepa rator drain hose and then loosen the drain screw 2 4 Remove the cap 5 Drain the fuel from the vapor separator drain hose by pressing the valve using a thin screwdriver S63P4170 4 15 Checking the vapor separator 1 Check the needle valve for bends or wear Replace if necessary S69J4080 2 Check the float for deterioration Replace if necessary O S63P4180 3 Check the filter for dirt or residue Clean if necessary N S63P4190 6 11 Synchronizing the throttle valves CAUTION Do not adjust the throttle valve when it is operating properly Excess adjustment may cause poor engine performance 1 Remove the caps D and then attach the special service tool to the intake manifold as shown Q gt gt i 563 4210 563 4220 6 11 Intake assembly vapor separator NOTE For best results use vacuum gauge mercially available like 2 or 3 shown in the illustration that has four adapters 2 Start the engine and warm it up for 5 min utes 3 Attach the special service tool to spark plug wire 1 and then check the engine idle speed S63P4250 Engine idle spee
127. e the bearing always replace it with a new one Bearing separator 1 90890 06534 2 Remove the needle bearings from the forward gear using a chisel INS 56856160 CAUTION Do not reuse the bearing always replace it with a new one Disassembling the lower case 1 Remove the taper roller bearing outer race and shim s S63P6165 6 11 Drive shaft and lower case regular rotation model NOTE Install the claws as shown CL Bearing outer race puller assembly D 90890 06523 2 Remove the needle bearing S63P6170 22 Ball bearing attachment 90890 06636 Driver LL 90890 06605 Checking the pinion and forward gear 1 Check the teeth of the pinion and the teeth and dogs of the forward gear for cracks or wear Replace if necessary S69J6200 Checking the bearings 1 Check the bearings for pitting or rum bling Replace if necessary 63P3F11 S69J6205 Checking the drive shaft 1 Check the drive shaft for bends or wear Replace if necessary 69J6210 Checking the lower case 1 Check the skeg and torpedo for cracks or damage Replace the lower case if nec essary S60V6220 6 18 Lower unit Assembling the lower case 1 Install the original shim s and taper roller bearing outer race 0 0 S63P6190 CAUTION Add or remove shim s if necessary if replacing the forward gear or lower case CZ B
128. e throttle valves open Yes Synchronize the throttle valves excessively or replace the defective parts Check the throttle valve opening No Adjust the throttle cable Symptom 5 Engine speed rises even when the throttle position is fixed Check the throttle cable operation Good condition Adjust the throttle cable Yes Synchronize the throttle valves 6 11 Power unit 9 18 TRBL e Troubleshooting Self diagnosis Diagnosing the electronic control system 1 Connect the special service tool to the outboard motor as shown S63P9010 NOTE _ 1 1 1 When performing this diagnosis all of the electrical wires must be properly connected 2 Diagnostic flash indicator B 90890 06865 2 Start the engine and let it idle 3 Check the flash pattern of the diagnostic flash indicator to determine if there are any malfunctions Normal condition no defective part or irregular process ing is found Single flash is given every 4 95 sec onds 8 Light on 0 33 second Light off 4 95 seconds 9 19 69 9020 Trouble code indication Example The illustration indicates code number 23 Light on 0 33 second Light off 4 95 seconds Light off 0 33 second d Light off 1 65 seconds 69 9030 4 flash pattern listed the diagnostic code chart is displayed check the mal fu
129. e valve face use a 60 cutter to cut the bottom edge of the valve seat If neces sary use a 45 cutter to center the area and set its width NE 5695930 p Previous contact width 9 Apply a thin even layer of lapping com pound onto the valve seat and then lap the valve using a valve lapper commer cially available 56925820 5 33 CAUTION Do not get the lapping compound on the valve stem and valve guide 10 After every lapping procedure be sure to clean off any remaining lapping com pound from the cylinder head and the valve 11 Check the valve seat contact area of the valve again Checking the camshaft 1 Measure the cam lobe Replace if out of specification S69J5950 Cam lobe 8 Intake 45 300 45 400 mm 1 7835 1 7874 in Exhaust 44 350 44 450 mm 1 7461 1 7500 in Cam lobe Intake and exhaust 35 950 36 050 mm 1 4154 1 4193 in 2 Measure the camshaft runout Replace if out of specification 63PSF11 Cylinder head Checking the cylinder head S63P5180 X Camshaft runout limit 0 03 mm 0 0012 in 3 Measure the camshaft journal diameter and cylinder head journal inside diam eter d Replace the camshaft and cylin der head if out of specification S69J5970 Camshaft journal diameter 24 960 24 980 mm 1 0 9827 0 9835 in Camshaft cap inside diameter d 25 000 25 021 mm 0 9843 0 9851 in 4 Calculate th
130. earing outer race attachment 1 90890 06619 Driver rod LL 90890 06605 2 Install the needle bearing outer case into the lower case S63P6210 NOTE TEN Apply gear oil to the needle bearing outer case before installation Z Ball bearing attachment 4 90890 06633 Bearing outer race puller assembly 2 90890 06523 3 Install the needle bearing into the needle bearing outer case 6 19 NOTE Apply gear oil or grease to the needle bear ing before installation Assembling the forward gear 1 Install new needle bearings into the for ward gear to the specified depth Needle bearing attachment Q 90890 06612 Driver rod SS 2 90890 06604 Bearing depth plate 3 90890 06603 20 95 21 45 mm 0 825 0 844 in Depth 4 45 4 95 mm 0 175 0 195 in 2 Install a new taper roller bearing into the forward gear using a press S63P6250 GS Needle bearing attachment 4 90890 06654 Assembling the drive shaft housing 1 Install the needle bearing into the drive shaft housing to the specified depth 63PSF11 Drive shaft and lower case regular rotation model S63P6270 Needle bearing attachment _ 90890 06610 Driver rod SS 2 90890 06604 Bearing depth plate 3 90890 06603 aN Depth 5 75 6 25 mm 0 226 0 246 in 2 Apply grease to a new oil seals and then install them into the drive shaft housin
131. ecified torque S60V6660 S69J6540 WARNING e Do not hold the propeller with your hands when loosening or tightening it Be sure to disconnect the battery leads from the battery and the engine stop lan yard from the engine stop lanyard switch Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning NOTE gt If the grooves in the propeller nut do not align with the cotter pin hole tighten the nut until they are aligned 6 53 Propeller nut 52 N m 5 2 kgf m 38 4 ft Ib 63PSF11 Drive shaft and lower case counter rotation model Shimming counter rotation model Shimming counter rotation model S63P6740 63P3F11 6 54 Lower unit Shimming NOTE Shimming is not required when assembling the original lower case and inner parts Shimming is required when assembling the original inner parts and a new lower case e Shimming is required when replacing the inner part s Selecting the pinion shims 1 Install the special service tools onto the drive shaft D 69J6600 NOTE Select the shim thickness by using the specified measurement s and the calcula tion formula Install the special service tool onto the drive shaft so that the shaft is at the center of the hole Tighten the wing nuts another 1 4 of a
132. eck the drive sprocket 1 and driven sprockets for cracks damage or wear Replace if necessary 569J5580 Installing the sprockets and timing belt 1 Install the driven sprockets D and then tighten the bolts to the specified torque 2 Check that I marks 8 and D on the driven sprockets are aligned 3 Install a new gasket and the cylinder head cover 2 and then tighten the bolts to the specified torques in two stages 6 11 Power unit Drive sprocket bolt 7 Nem 0 7 5 2 ft lb Timing belt tensioner bolt 39 N m 3 9 28 8 ft lb 6 Install the timing belt from the drive sprocket side with its part number in the upright position turn the belt a half turn counterclockwise to align it and then remove the pin S63P5470 Driven sprocket bolt 60 N m 6 0 kgf m 44 3 ft lb Cylinder head cover bolt 1st 8 N m 0 8 kgf m 5 9 ft lb 7 Turn the drive sprocket clockwise two 2nd 8 N m 0 8 kgf m 5 9 ft lb turns and then check that the alignment marks are aligned S63P5150 4 Install the drive sprocket and timing belt tensioner 2 and then tighten the bolts to the specified torques 5 Check that the a mark on the plate is aligned with the I mark on the cyl inder block Align if necessary gt S63P5500 NOTE Do not turn the drive sprocket countercloc
133. er head cover bolts and then tighten them to the specified torques in two stages Spark plug 25 N m 2 5 kgf m 18 4 ft lb Cylinder head cover bolt 1st 8 N m 0 8 kgf m 5 9 ft lb 2nd 8 N m 0 8 kgf m 5 9 ft lb 27 Install the blowby hoses and connect the spark plug caps 28 Install the spark plug wire cover and fly wheel magnet cover Replacing the timing belt 1 Remove the flywheel magnet cover 2 Turn the flywheel magnet clockwise and align the TDC mark on the flywheel magnet with the pointer and check that I marks and on the driven sprockets are aligned 63P3F 11 Power unit S63P5060 NOTE Do turn the flywheel magnet counter clockwise 3 Loosen the flywheel magnet nut S63P5260 CAUTION Apply force in the direction of the arrows shown to preventthe flywheel holder from slipping off easily Flywheel holder 90890 06522 5 16 4 Remove the flywheel magnet S63P5280 S63P5290 CAUTION To prevent damage to the engine or tools screw in the puller set bolts evenly and completely so that the puller plate is par allel to the flywheel magnet NOTE Apply force to the crankshaft end until the fly wheel magnet comes off the tapered portion of the crankshaft Flywheel puller 90890 06521 5 Disconnect the stator coil coupler and pulser coil coupler and remove the blowby hose 3 and stator asse
134. er unit 2 Apply grease to new oil seals and then install them into the drive shaft housing to the specified depth S63P6290 NOTE E Install an oil seal halfway into the drive shaft housing then the other oil seal 2 Ball bearing attachment 90890 06633 Driver rod LS 90890 06606 Depth 0 25 0 75 mm 0 01 0 03 in Installing the drive shaft 1 Install the reverse gear into the lower case 2 Install the drive shaft housing D thrust bearing 2 and original shim s 3 onto the drive shaft S69J6265 CAUTION Add or remove shim s if necessary if replacing the drive shaft housing or drive shaft 6 49 3 Install the sleeve drive shaft and drive shaft housing into the lower case then the pinion and pinion nut and then tighten the nut to the specified torque S63P6310 NOTE sDMh Install the drive shaft by lifting it up slightly then aligning it with the pinion and the spline of the drive shaft 02 Drive shaft holder 6 5 90890 06520 ___ Pinion nut holder New 90890 06715 Current 90890 06505 Pinion nut 93 9 3 kgf m 68 6 ft lb Installing the propeller shaft housing 1 Install the original shim s and propel ler shaft housing assembly into the lower case and then install the straight key claw washer 2 and ring nut S63P6690 63P3F11 Drive shaft and lower case counter rotation model
135. ess M Measurement Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 12 Remove the special service tools and then install the water pump assembly 6 31 63P3F11 Backlash regular rotation model Lower unit counter rotation model Lower unit counter rotation model 9 N m 0 9 kgf m 6 6 ft Ib 47 N m 4 7 kgf m 34 7 ft Ib 47 N m 4 7 kgf m 34 7 ft Ib S63P6460 2 o O Part name 4 Remarks Lower unit Check screw Gasket Bolt Drain screw Grommet Bolt Bolt Spacer Propeller Washer Washer Cotter pin Propeller nut Trim tab Dowel Water pipe Notreusable M10 x 45 mm M10 x 44 mm M10 x 70 mm L transom model for Europe Not reusable X transom model X transom model NN Lg 63P3F11 6 32 Lower unit S63P6460 Part name j Remarks Extension X transom model Bolt M10 x 45 mm X transom model Bolt M10 x 200 mm X transom model 6 33 63P3F11 Lower unit counter rotation model S63P6470 2 o ON O OI Part name 4 Remarks Shift rod Oil seal Oil seal housing O ring Spring Circlip Bolt Hose nipple O ring Woodruff key Bolt Cover Seal Water pump housing O ring Insert cartridge O ring Not reusable Not reusable M6 x 20 mm Notreusable M8 x 45 mm Notreusable Not
136. eta o iom pecias eae dla 8 11 Checking the EG Misono cand on he EDEN 8 12 Checking the pulser nd ened lepus 8 12 Checking the throttle position sensor 8 13 Checking the intake air temperature 8 13 Checking the engine temperature 8 13 Checking the thermoswitch a 8 14 Checking the shift cut switch d oet e ent net 8 14 Checking the neutral switch 8 14 Fuel control system rne tii cie dnce nia EPIO u REVUE Y 8 15 Checking the injectors od E EU e RR ER E Den 8 17 Checking the main relay t oet be rel eed Enea 8 17 Checking the electric fuel pump ara 8 17 Starting SySteri isuu inan daga sanga naga nip Ge pu auci ua ui utasa a in kaa wasa Naya awa 8 18 Checking the t rd rte npa ru I Feu Eu exu 8 19 Checking the starter relay 8 19 Starter motor U u u u E IR 4 8 20 Removing the starter motor PINION 8 22 Checking the starter motor ass 8 22 Checking the armatlure tr
137. ew Idle speed control O ring Gasket O O WN N B 5 N M8 x 25 Notreusable Notreusable Notreusable Notreusable g5 x 15 mm Notreusable Notreusable 94 x 15 mm Notreusable Notreusable 63P3F11 x 13 N m 1 3 kgf 9 6 ft Ib Intake assembly and vapor separator Ix 13 N m 1 3 kgf 9 6 ft Ib S63P4020 No Part name Q ty Remarks 18 Collar 6 19 Grommet 3 20 Bracket 1 21 Screw 4 96 16 mm 22 Screw 2 94 x 12 mm 23 Throttle position sensor 1 24 O ring 1 25 Throttle body 1 1 26 Bolt 6 M8 x 70 mm 27 Bracket 2 28 Screw 4 96 x 16 mm 29 Throttle joint link rod 1 30 Spring 1 31 Throttle body 2 1 32 Bracket 1 33 Screw 4 g6 x 16 mm 63P3F11 4 12 e D Fuel system Measuring the fuel pressure 1 Remove the cap D 2 Connect the fuel pressure gauge to the pressure check valve S63P4130 A WARNING e When connecting the fuel pressure gauge first cover the connection between the gauge and the pressure check valve with a clean dry rag to pre vent fuel from leaking out lt Gently screw in the gauge until it is firmly connected 3 Turn the engine start switch to ON and then measure the fuel pressure within 3 seconds NOTE The fuel pressure decreases 3 seconds after the engine start switch is turned to ON Fuel pressure referenc
138. f replacing the reverse gear roller bearing orlower case 22 Ball bearing attachment 90890 06629 Driver rod LL 90890 06605 63P3F11 Drive shaft and lower case counter rotation model 2 Install the needle bearing outer case into the lower case S63P6210 NOTE Apply gear oil to the needle bearing outer case before installation Z Ball bearing attachment 90890 06633 Bearing outer race puller assembly 2 90890 06523 3 Install the needle bearing into the needle bearing outer case NOTE Apply gear oil or grease to the needle bear ing before installation Assembling the reverse gear 1 Instal new needle bearings into the reverse gear to the specified depth t Needle bearing attachment 90890 06612 S63P6660 Driver rod SS 90890 06604 Bearing depth plate 90890 06603 63P3F11 Depth 20 95 21 45 mm 0 825 0 844 in Depth 4 45 4 95 mm 0 175 0 195 in 2 Install the roller bearing inner race into the reverse gear using a press S63P6680 K Bearing inner race attachment 90890 06660 Assembling the drive shaft housing 1 Install the needle bearing into the drive shaft housing to the specified depth e S63P6270 Cz Needle bearing attachment Q 4 90890 06610 Driver rod SS 90890 06604 Bearing depth plate 90890 06603 Depth 8 5 75 6 25 mm 0 226 0 246 6 48 Low
139. f specifications S69J8420 Commutator segments b Continuity Segment Armature core C No continuity Segment Armature shaft No continuity Checking the brushes 1 Measure the brush length Replace the brush assembly if out of specification 56978430 amp Brush length limit 3 9 5 mm 0 37 in 2 Check the brush holder assembly for continuity Replace if out of specifica tions 5698440 8 23 Brush continuity Brush D Brush 2 No continuity Checking the magnet switch 1 Connect the tester leads between the magnet switch terminals as shown 2 Connect the positive battery lead to the brown and white Br W lead 3 Connect the negative battery lead to the starter motor body S69J8450 CAUTION Do not connect the battery for more than one second otherwise the magnet switch can be damaged 4 Check that there is continuity between the magnet switch terminals Replace if there is no continuity 5 Check that there is no continuity after the negative battery terminal is removed Replace if there is continuity NOTE The starter motor pinion should be pushed out while the magnet switch is on Checking the starter motor operation 1 Check the operation of the starter motor after installing it onto the power unit 6 11 Starter motor Charging system Charging system
140. fied torques in two stages Thermostat cover bolt 1st 6 0 6 4 4 ft lb 2nd 12 N m 1 2 8 9 ft lb 6 11 Checking the cooling water passage 1 Check the cooling water inlet cover 1 and cooling water inlet for clogs Clean if necessary 60V3130 2 Place the lower unit in water and then start the engine 3 Check for water flow at the cooling water pilot hole If there is no water flow check the cooling water passage inside the out board motor VR 4 yY S63P3120 Control system Checking the engine idle speed 1 Start the engine and warm it up for 5 min utes 2 Attach the special service tool to spark plug wire 1 D and then check the engine idle speed 63PSF11 Power unit Control system USS ee 365 N S63P3140 Engine idle speed 700 50 r min Adjusting the throttle link and throttle cable NOTE Be sure to synchronize the throttle valves before adjusting the throttle cable For synchronizing procedures see Chapter 4 Synchronizing the throttle valves 1 Remove the intake silencer 2 Loosen the locknut D remove the clip and then disconnect the throttle cable joint 3 Loosen the locknut 2 and then discon nect the throttle link rod joint and the link rod joint S63P3150 3 8 ge ADJ Periodic checks and adjustments 4
141. g to the specified depth S63P6290 NOTE Install an oil seal halfway into the drive shaft housing then the other oil seal 2 Ball bearing attachment 2 90890 06633 Driver rod LS 5 90890 06606 2 Depth B 0 25 0 75 mm 0 010 0 030 in Installing the drive shaft 1 Install the forward gear into the lower case 63PSF11 2 Install the drive shaft housing CD thrust bearing 2 and original shim s 3 onto the drive shaft 2 S69J6265 CAUTION Add or remove shim s if necessary if replacing the drive shaft housing or drive shaft 3 Install the sleeve drive shaft and drive shaft housing into the lower case then the pinion and pinion nut and then tighten the nut to the specified torque S63P6310 NOTE Install the drive shaft by lifting it up slightly then aligning it with the pinion and the spline of the drive shaft US Drive shaft holder 6 G 90890 06520 __ Pinion nut holder New 90890 06715 Current 90890 06505 Pinion nut 93 9 3 kgf m 68 6 ft lb 4 Tighten the drive shaft housing bolts 6 20 Lower unit Installing the propeller shaft housing 1 Install the washer and propeller shaft assembly into the propeller shaft housing assembly 3 2 Apply grease to a new O ring and then install it onto the propeller shaft housing S63P6315 3 Install the original shim s and propel ler shaft housing assembly 5 into the lowe
142. g end side clearance 8 0 14 0 31 mm 0 006 0 012 in Checking the crankshaft 0 8661 0 8701 in 1 Check the teeth of the crankshaft gear for cracks or wear Replace the crank 3 Measure the crankshaft runout Replace shaft if necessary the crankshaft if out of specification S63P5C30 2 Measure the crankshaft journal diameter crankpin diameter and crankpin width Replace the crankshaft if out of S63P5550 specification Crankshaft runout limit 0 03 mm 0 0012 in S63P5750 63P3F11 5 44 Checking the crankpin oil clearance 1 Clean the bearings and the connecting rod 2 Install the upper bearing into the con necting rod 1 and the lower bearing into the connecting rod cap 5 S63P5770 NOTE ee Install the connecting rod bearings in their original positions 3 Put a piece of Plastigauge PG 1 onto the crankpin parallel to the crankshaft 69 5000 Be sure not to put the Plastigauge PG 1 over the oil hole in the crankpin of the crank shaft 4 Install the connecting rod to the crankpin 5 45 S63P5780 NOTE LL Make sure that the mark 8 of the connecting rod faces towards the flywheel magnet side of the crankshaft 5 Tighten the connecting rod bolts to the specified torques in three stages S63P5790 NOTE Reuse the removed connecting rod bolts when checking the oil c
143. ghten the bolts Light green Lg 6 Install the plastic ties route the NOTE J motor leads through the hole and then Repeat this procedure so that the rams go install the plastic ties up and down four or five times be sure to wait a few seconds before switching the 7 Connect the ground lead to the bottom of leads the power trim and tilt unit and then If the rams do not move up and down eas tighten the bolt ily push and pull on the rams to assist operation 8 Check the fluid level when the tilt ram is fully extended Add sufficient fluid if nec essary Installing the power trim and tilt unit 1 Fully tilt the outboard motor up and then support it with the tilt stop lever 1 242 S60X7130 560 7820 63P3F11 7 44 Bracket unit Bleeding the power trim and tilt unit built in 1 Fully turn the manual valve counterclock wise S60X7860 2 Fully tilt the outboard motor up and then release it to let it lower by its own weight four to five times 3 Tighten the manual valve by turning it clockwise 4 Let the fluid settle for 5 minutes 5 Push and hold the power trim and tilt switch in the up position to check that the outboard motor is fully tilted up 6 Support the outboard motor with the tilt stop lever S60X3020 7 45 After tilting up the outboard motor be sure to support it with the tilt stop le
144. h balls 2 spring shift slider and shift rod joint 63PSF11 Propeller shaft housing regular rotation model S63P6070 Disassembling the propeller shaft housing 1 Remove the reverse gear and thrust washer ben d b NS NN gt 7 A S68S6330 Ko Bearing separator 1 90890 06534 4 Stopper guide plate 2 90890 06501 Stopper guide stand 3 90890 06538 Bearing puller assembly 2 90890 06535 6 12 Lower unit 2 Remove the ball bearing 0 C NANG Sambi J 2 5 w 56856340 n 2 Stopper guide plate 90890 06501 Z Stopper guide stand 90890 06538 Bearing puller assembly 7 90890 06535 3 Remove the oil seals and needle bear ing 56856350 Needle bearing attachment 8 90890 06653 Driver rod L3 90890 06652 Checking the propeller shaft housing 1 Clean the propeller shaft housing using a soft brush and cleaning solvent and then check it for cracks Replace if necessary S62Y6650 6 13 2 Check the teeth and dogs of the reverse gear for cracks or wear Replace the gear if necessary S62Y6640 3 Check the bearings for pitting or rum bling Replace if necessary 6946115 Checking the propeller shaft 1 Check the propeller shaft for bends or wear Replace if necessary 69J6120 2 Check the dog clutch shift rod joint and shift slide
145. he injectors for clogs i Good condition B Replace the injectors Yes Check the starting system or the ignition system u 9 13 63P3F11 Power unit Lubrication system Check the engine oil level At specified level No Add engine oil to the correct level Yes Check the oil pressure Within specification No Check the oil pump for debris or oil leaks Yes Debris or leaks NL LN Check the oil passage Yes Check the oil pressure sensor J Clean or m menace parts i x Good condition m the oil pressure sensor Yes Check the ae system or the fuel system 63P3F11 9 14 TRBL e Troubleshooting Symptom 3 Engine speed not stable at low speeds Check the throttle position sen sor and check that the connec tor is securely connected i Good condition o Repair or replace the defective part F Yes Check the neutral switch for continuity Is there continuity Repair or replace the defective parts F Yes Check the throttle valve opening of each cylinder i Are the throttle valve openings incorrect or are the throttle valve links worn Yes Replace the throttle body Check the ignition system or the fuel system YY 9 15 63P3F11 Po
146. heck the hydraulic pressure of the power trim and tilt unit Bleeding the power trim and tilt unit 1 Tighten the manual valve by turning it clockwise 2 Place the power trim and tilt unit in an upright position 3 Remove the reservoir cap and then check the fluid level in the reservoir 7 43 NOTE L E If the fluid is at the correct level the fluid should overflow out of the filler hole when the reservoir cap is removed 4 f necessary add sufficient fluid of the recommended type until it overflows out of the filler hole Recommended power trim and tilt fluid ATF Dexron II 5 Install the reservoir cap and then tighten it to the specified torque Reservoir cap 0 7 N m 0 07 kgf m 0 5 ft Ib 6 Connect the PTT motor leads to the bat tery terminals to fully retract the trim and tilt rams 563 7330 Battery terminal Light green Lg e Sky blue Sb PTT motor lead 7 Reverse the PTT motor leads between the battery terminals to fully extend the trim and tilt rams 63PSF11 Power trim and tilt unit CAUTION After tilting the outboard motor up be sure to support it with the tilt stop lever 2 Install the collars 3 Lift the power trim and tilt unit up and 63P7340 then install the upper mounting shaft PTT motor lead Battery 4 Install the circlip terminal 5 Install the lower mounting shaft and then Sky blue Sb AA ti
147. ice points regarding removal checking and installation are shown in individual illustrations to explain the relevant procedure NOTE For troubleshooting procedures see Chapter 9 Troubleshooting LOWR t Lower unit Lower unit 35 m 3 5 kgf 25 ft Ib LOWR i Removing the drive shaft 1 Remove the drive shaft assembly and pinion and then pull out the forward Lower unit 7 N m 0 7 kgf m 5 1 ft Ib S62Y8740K 2 40 N m 4 0 kgf m 29 ft Ib CAUTION Do not reuse the bearing always replace 2 7 N m Q7 kgf 5 1 ft Ib S62Y6850K it with a new one 562Y6480K Drive shaft holder 4 1 90890 06518 Part name Remarks Pinion nut holder 2 90890 06505 Z Lower unit Socket adapter 2 90890 06507 dig tie Disassembling the drive shaft 2 Remove the needle bearing from the for ose 1 Install the pinion nut D tighten it finger ward gear tight and then remove the drive shaft Gasket bearing using a press P d mo Bearing separator 1 90890 06534 Check screw Dowel pin ren Bolt M10 40mm o Drain screw hus J Grommet t Bolt D Bolt E Thrust washer wi Propeller WE CAUTION Washer Do not reuse the bearing always replace Washer CAUTION it
148. ine checking valve clearance may be required more frequently than every 500 hours 63P3F11 3 2 CHK ADJ Top cowling Checking the top cowling 1 2 3 Check the fitting by pushing the cowling with both hands Adjust if necessary S63P3010 Loosen the bolts 7 Move the hook up or down slightly to adjust its position S63P3020 NOTE To loosen the fitting move the hook in direction To tighten the fitting move the hook in direction 4 Tighten the bolts 5 Check the fitting again and if necessary repeat steps 2 4 6 Check the top cowling hose for cracks or 3 3 damage Replace if necessary Periodic checks and adjustments S63P3030 Fuel system Checking the fuel joint and fuel hoses fuel joint to fuel injector 1 2 Remove the spark plug wire cover Check the low pressure fuel hose con nections and fuel joints for leaks Replace if necessary Also check the fuel filter D fuel pumps and fuel filter 3 for leaks or deterioration Replace if necessary Check the high pressure fuel hose con nections for leaks Replace if necessary Also check the vapor separator 2 fuel rail 5 fuel injectors 6 pressure regula tor D and fuel cooler for leaks or deterioration Replace if necessary S63P3360 Checking the fuel filter 1 Check the fuel filter element for dirt and residue and check the fuel filter cup for foreig
149. ir pressure sensor 5 Thermoswitch Engine temperature sensor Intake air temperature sensor Throttle position sensor ECM Pulser coil Oil pressure sensor ECM This engine is controlled by the ECM to obtain precise combustion under various operating condi tions for high power output low fuel consumption and low emissions The ECM controls the ignition timing the fuel injection timing and the fuel injection volume and ensures that optimum ignition timing and an optimum air and fuel ratio can be achieved under all operating conditions such as starting the engine normal operation and quick acceleration The self diagnostic function is incorporated into the ECM and can quickly detect a malfunction when a personal computer is used with the optional software installed Refer to the Diag nostic System Instruction Manual B EUR USA CAN OCE 63P 20 JPN S63P1240 ECM identification B Destination 1 17 63P3F11 Technical tips Fail safe control If the electrical components malfunction the ECM controls the ignition and fuel injection as shown in the table Malfunctioning item Details Ignition control Fuel control Pulser coil No signal received during four consecutive crankshaft rotations Fixed to BTDC 10 Fixed to BTDC 10 Throttle position sensor Intake air pressure sensor Output voltage is 0 3 V or lower or 4 7 V or higher Output
150. is 0 53 mm then the pinion shim is 0 52 mm If T3 is 0 78 mm then the pinion shim is 0 75 mm 63PSF11 Shimming counter rotation model Selecting the reverse gear shims 1 Turn the thrust bearing D two or three times to seat the roller bearing and then measure the bearing height M1 as shown S63P6760 S63P6880 NOTE UU Select the shim thickness T1 by using the specified measurement s and the calcula tion formula Measure the roller bearing at three points to find the height average Digital caliper 3 90890 06704 6 56 Lower unit 2 Calculate the reverse gear shim thick ness T1 as shown in the examples below 5696570 NOTE _ F is the deviation of the lower case dimen sion from standard The F mark is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark is unreadable assume that F is zero and check the backlash when the unit is assembled Calculation formula Reverse gear shim thickness T1 29 10 F 100 M1 Example If M1 is 28 25 mm F is 5 then T1 29 10 5 100 28 25 mm 29 10 0 05 28 25 mm 0 90 mm 3 Select the reverse gear shim s T1 as follows Calculated numeral at 1 100 place 1 2 3 4 5 6 7 8 9 10 Rounded numeral Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 6 57 Example If T1
151. is aligned with the set pin on throttle lever 2 S63P3210 CAUTION The throttle cable joint must be screwed in a minimum of 8 0 mm 0 31 in 12 Connect the cable joint install the clip and then tighten the locknut 13 Check the throttle cable for smooth oper ation and if necessary repeat steps 1 12 63P3F11 Control system Adjusting the throttle link and throttle cable operation using a thickness gauge 1 Remove the intake silencer 2 Loosen the locknut D remove the clip and then disconnect the throttle cable joint 3 Contact the stopper on the throttle lever 2 to the fully closed stopper on the cylinder block and adjust the throttle link rod joint so that the specified clearance 8 between the throttle cam roller and the throttle cam is obtained S63P3220 Clearance 8 0 5 mm 0 02 in 4 Connect the throttle link rod joint and then tighten the locknut 2 S63P3230 3 10 ge ADJ Periodic checks and adjustments 5 Operate throttle lever 2 to check that the throttle valves fully close and fully open J giae V Holl MS YI I a g S63P3240 NOTE The throttle valves are fully open when the throttle cam roller 8 is within the range shown in the illustration 6 Contact the stopper on the throttle lever 2 to the full
152. ith a piston crown 3 Check the piston ring end gap at the specified measuring point Replace if out of specification Q sesPsB70 Piston ring end gap Top ring 0 15 0 30 mm 0 0059 0 0118 in Second ring 0 30 0 45 mm 0 0118 0 0177 in Oil ring 0 15 0 60 mm 0 0059 0 0236 in Measuring point 8 20 mm 0 8 in Checking the piston ring grooves 1 Measure the piston ring grooves Replace the piston if out of specification S63P5720 5 43 Piston ring groove Top ring 1 23 1 25 mm 0 048 0 049 in Second ring 1 22 1 24 mm 0 048 0 049 in Oil ring 2 51 2 53 mm 0 099 0 100 in Checking the piston ring side clearance 1 Measure the piston ring side clearance Replace the piston and piston rings as a set if out of specification S63P5730 Piston ring side clearance Top ring 0 04 0 08 mm 0 0016 0 0031 in Second ring 0 03 0 07 mm 0 0012 0 0028 in Oil ring 0 04 0 13 mm 0 0016 0 0051 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 6 11 Cylinder block C S63P5760 Crankshaft journal diameter 8 51 980 52 000 mm S63P5740 2 0465 2 0472 in Crankpin diameter 49 980 50 000 mm 1 9677 1 9685 in Crankpin width O 22 00 22 10 mm Connecting rod bi
153. ity Replace if out of specification 63P3F11 60 7730 Lead color Switch Sky blue position Sb Lightgreen Red R L Up SG Free Down O Checking the trim sensor 1 Measure the trim sensor resistance Replace if out of specification S63P7280 NOTE Turn the lever D and measure the resistance as it gradually changes Trim sensor resistance Pink P Black B 238 8 378 8 Q at 20 C 68 F 9 11 Q at 20 C 68 F 63PSF11 Power trim and tilt electrical system 7 48 Bracket unit MEMO 7 49 63P3F11 63PSF11 Electrical systems Special service tools wei 8 1 Checking the electrical components U U 8 2 Measuring the peak voltage 8 2 Measuring the lower 8 2 Electrical c mponi rits tiri U UU U U uu 8 3 Port i e M 8 3 Junction box assembly Isto OD Pep eem pts 8 4 E 8 5 8 6 Wiring rc sus 8 7 Ignition and ignition control system eene 8 9 Checking the ignition spark gap a a 8 11 Checking the spark plug wires sseee 8 11 Checking the ignition coils Puer a
154. k wise S63P5480 63P3F11 5 22 Cylinder head 25 m 2 5 kgf m 18 4 ft Ib 19 m 1 9 kgf m 14 0 ft Ib 37 m 3 7 kgf m 27 3 ft Ib 90 No Part name S63P5620 Remarks Bolt Valve shim Valve lifter Valve cotter Valve spring retainer Valve spring Valve seal Valve guide Bolt Spark plug Bolt Bolt Cover Grommet Anode Cylinder head Exhaust valve 1 2 3 4 5 6 7 8 _ kj kj kj kD Q N N 5 23 Not reusable Not reusable M10 x 120 mm M8 x 40 mm M6 x 20 mm 63P3F11 Cylinder head 25 m 2 5 kgf m 18 4 ft Ib 14 N m 1 4 kgf m 10 3 ft Ib 28 N m 2 8 kgf m 20 7 ft Ib 19 m 1 9 kgf m 14 0 ft Ib 37 m 3 7 kgf m 27 3 ft Ib S63P5620 190 Remarks Part name Intake valve Gasket Notreusable Collar Anode Screw Anode g6 x 16 mm 63P3F11 23 N m 2 3 kgf m 17 0 ft Ib Ix 15N m 1 5 kgf m 1 18 N m 1 8 kgf m 13 3 ft Ib S63P5630 z O O WN Part name Remarks Engine temperature sensor Washer Bolt Plug Washer Engine hanger Bolt Bolt Bracket O ring Oil pre
155. king the pinion and forward 6 18 Checking the bearings ice deed 6 18 Checking the drive sShaft acce reed iet db e bet utere 6 18 Checking the lower case a nenen 6 18 Assembling the lower CaS6 oec cce tese eerte desi ic 6 19 Assembling the forward 6 19 Assembling the drive shaft housing 6 19 Installing the drive shaft Ir Meo Rage mte rcr dendi 6 20 Installing the propeller shaft housing 6 21 Installing the water pump and Shift 6 21 Installing the lower unit etre n reet nantes 6 23 Shimming regular rotation model eene 6 25 SNINMING ta Cu ER 6 26 Selecting the Pinion shims anana eaaa 6 26 Selecting the forward gear shims a 6 27 Selecting the reverse gear shims r r 6 28 Backlash regular rotation 6 29 Measuring the forward and reverse gear backlash 6 29 63PSF11 Lower unit counter rotation model eere nn 6 32 Removing the lower unit
156. l ventilated area Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN NOTE Batteries vary per manufacturer The cedures mentioned in this manual may not always apply therefore consult the instruc tion manual of the battery Disconnect the negative battery lead first then the positive battery lead Electrolyte specific gravity 1 280 at 20 C 68 F Lubricating the outboard motor 1 Apply water resistant grease to the areas shown S69J3630 SES Thess BL TN 3 16 CHK Q ADJ Periodic checks and adjustments S63P3320 S60X3090 S60X3100 a S63P3330 65 S60X3120 3 17 NOTE Apply grease to the grease nipple until it flows from the bushings 2 Apply low temperature resistant grease to the areas shown 3 Apply corrosion resistant grease to the areas shown 69J3720 63P3F11 63PSF11 Fuel system Special service t0015 Duci io contin a Te Ue a cere dec TU EU DTE EUG 4 1 Hose routing cu kV CRM Ta TER 4 2 Fuel and blowby hoses 4 2 Fuel filter fuel pump and intake silencer 4 3 Checking the fuel pumps
157. lancer bolt 18 1 8 31 3 1 Oil pump screw 4 0 4 Crankcase bolt 14 1 4 26 2 6 30 3 0 90 Main bearing cap bolt 30 3 0 90 Connecting rod cap 23 2 3 43 4 3 90 Lower unit regular rotation model Gear oil drain screw 0 9 Gear oil check screw 0 9 Lower case mounting bolt 4 7 Trim tab bolt 4 2 Propeller nut 5 2 Ring nut Cooling water inlet cover screw 0 4 Pinion nut 9 3 Lower unit counter rotation model Gear oil drain screw 0 9 Gear oil check screw 0 9 Lower case mounting bolt 4 7 Trim tab bolt 4 2 Propeller nut 5 2 Ring nut Cooling water inlet cover screw 0 4 Pinion nut 9 3 Bracket unit Shift rod detent bolt 1 8 Flushing hose adapter screw 0 3 Upper mount bracket bolt 63P3F11 5 4 2 12 wee Specifications Tighteni Part to be tightened Thread size Igntonng tordues N m kgf m M8 20 2 0 M10 42 4 2 Engine oil drain bolt M14 27 2 7 Baffle plate screw 95 4 0 4 Muffler bolt M8 20 2 0 Exhaust manifold bolt M8 20 2 0 Oil pan bolt M8 20 2 0 Oil strainer bolt M6 10 1 0 Upper mounting nut 74 7 4 Lower mounting nut 74 7 4 Trim stopper nut 48 4 8 Self locking nut 15 1 5 Trim sensor cam screw 0 2 Grease nipple 0 3 Power trim and til
158. lean cloth D and then blow com pressed air through the hole 8 to remove the free piston 5 560 7560 A WARNING Never look into the tilt cylinder opening while removing the free piston because the free piston and power trim and tilt fluid can be forcefully expelled out 7 Loosen the trim cylinder end screws and then remove the trim piston assemblies 63P3F 11 Power trim and tilt unit Checking the tilt cylinder and trim 4 Check the tilt ram for bends or excessive cylinder corrosion Polish with 400 to 600 grit sandpaper if there is light rust or replace 1 Disassemble the tilt piston assembly if necessary ae 560 7600 5 Check the trim pistons for scratches Replace if necessary 6 Check the trim rams for bends or exces sive corrosion Polish with 400 to 600 grit sandpaper if there is light rust or replace if necessary 8 e e O 2 Check the tilt piston and free piston for scratches Replace if necessary S60X7570 S60X7610 7 Check the inner walls of the trim and tilt cylinders for scratches Replace if neces sary 560 7580 3 Blow the tilt piston absorber valve with compressed air to remove any foreign material Check the valve for wear and the spring for deterioration Replace if necessary 560 7620 63P3F11 7 38 Bracket unit Assembling the tilt piston and trim pistons 1 Install the new dust seal D and new O rings a
159. learance Checking the spark plugs 1 Disconnect the spark plug wires and then remove the spark plugs Clean the electrodes with a spark plug cleaner or wire brush Replace the spark plug if necessary S69J3190 Check the electrodes for erosion and excessive carbon or other deposits and the gasket for damage Replace the spark plug if necessary 3 6 ge ADJ Periodic checks and adjustments 4 Check the spark plug gap Adjust if out of specification nm f I S69J3200 Specified spark plug LFR5A 11 NGK Spark plug gap 1 0 1 1 mm 0 039 0 043 in 5 Install the spark plugs tighten them fin ger tight then to the specified torque using a spark plug wrench 69J3210 Spark plug 25 N m 2 5 kgf m 18 4 ft lb Checking the thermostat 1 Remove the flywheel magnet cover 2 Remove the cover and thermostat S63P3110 3 7 3 Suspend the thermostat in a container of water 4 Place a thermometer in the water and slowly heat the water S69J5E40 5 Check the thermostat valve opening at the specified water temperatures Replace if out of specification S69J5E50 Water temperature Yale 9 0 05 mm 0 0020 in valve begins to lift above more than 70 C 158 F 4 3 mm 0 17 in 58 62 G 136 144 F 6 Install the thermostat and cover and then tighten the cover bolts to the speci
160. learance Do not turn the connecting rod until the crankpin oil clearance measurement has been completed Make a mark on the connecting rod bolts connecting rod caps and then tighten the bolts 90 from the mark 63PSF11 Cylinder block Example Connecting rod bolt 151 23 N m 2 3 17 0 ft Ib Connecting rod big Numerical value 2nd 43 N m 4 3 kgfm 31 7 ft lb end inside diameter in table 3rd 90 53 035 mm 35 6 Remove the connecting rod cap and 3 Check the crankpin mark D on the measure the width of the compressed crankshaft Plastigauge PG 1 on each crankpin Replace the connecting rod bearing if out of specification 69 5030 P1P2 P3P4 S63P5530 Crankpin oil clearance 0 027 0 052 mm 0 0011 0 0020 in Selecting the connecting rod bearing 1 When replacing the connecting rod bear ing select the suitable bearing as fol lows 2 Measure the connecting rod big end inside diameter 8 S60C5980 NOTE Reuse the connecting rod bolts 63P3F11 5 46 4 Select the suitable color C for the con necting rod bearing from the table S63P5800 Connecting rod big end inside diameter 8 32 33 34 35 36 37 38 Crankpin mark Upper bearing Lower bearing color color Green Green
161. lt and sprockets 5 21 Installing the sprockets and timing 5 21 Cylinder head me 5 23 Removing the cylinder 5 28 Checking the valve springs lr date ep ebat renis 5 28 Checking the 5 29 Checking the valve guides oio 5 29 Replacing the valve Quides sedente 5 30 Checking the valve Doe 5 31 Refacing the valve 58 5 31 Checking the 5 33 Checking the cylinder head naa anae 5 34 Installing the valves e ree etl e e ERE ee 5 34 Installing the cylinder i ER edes 5 35 Removing the exhaust ener nnn 5 37 Checking the pressure control valve 5 37 Installing the pressure control valve 5 37 63PSF11 Cylinder block am LY VR u u SEVA S NUR OK UE RR RE 5 38 Disassembling the cylinder block 5 41 Checking the balancer assembly a 5 41 Checking the piston diarmeter iii ome Genie tee deni 5 41 Checking the cylinder bore
162. mbly 2 S63P5300 5 17 6 Using a hexagon wrench turn the timing belt tensioner 5 clockwise to push the timing belt increase strength gradually and then insert a 25 0 mm 0 2 in pin into the hole 9 NOTE Leave the pin inserted into the timing belt tensioner until the timing belt has been installed 7 Remove the timing belt from the driven sprocket side 563 5310 8 Check that I marks and on the driven sprockets are aligned and that the A mark on the plate is aligned with the I mark 9 on the cylinder block Align if necessary S63P5320 6 11 Power unit 9 Install a new timing belt 7 from the drive sprocket side with its part number in the upright position turn the belt a half turn counterclockwise to align it and then remove the pin S63P5330 D os S63P5340 CAUTION Do nottwist turn inside out or bend the timing belt beyond the maximum limit of 25 mm 1 0 in otherwise it can be damaged Do not get oil or grease on the timing belt 10 Turn the drive sprocket clockwise two turns and then check that all alignment marks are aligned NOTE Do not turn the drive sprocket counterclock wise 11 Install the stator assembly and blowby hose and connect the pulser coil coupler and stator coil coupler 12 Install the Woodruff key 63PSF11 563 5350 13 Install the flywheel magnet S63P
163. n Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Yellow B O Black orange B W Black white B Y Black yellow Br W Brown white G B Green black G R Green red G Y Green yellow Blue green L W Blue white L Y Blue yellow Pink black P G Pink green Pink white Pu B Purple black Pu G Purple green Pu R Purple red Pu Y Purple yellow R Y Red yellow W B White black W R White red Y G Yellow green Killer Whale 150 2696 190800902002 00 9X OO 0990 62432 O69 6968 6 6562 6362 6 69 0969 6769 6203 wusing ono Na anaa anan an aa anakan anakan anakan akan anana G R G BER Y L G Pu GgPu Y PuBE L P GN G LY gR Y RAN Qn ax GR EN Y 000000 s S63PWD02
164. n sensor output voltage is within specification Throttle position sensor output voltage Pink P Black B 0 70 0 02 V 4 18 gi Fuel system 8 Install the throttle joint link rod 3 so that the throttle cam roller is aligned with the alignment mark as shown o S63P4290 9 Synchronize the throttle valves Refer to Synchronizing the throttle valves 10 Check the engine idle speed If out of specification repeat steps 3 10 Engine idle speed 700 50 r min 4 19 63P3F11 Intake assembly and vapor separator MEMO 63P3F11 4 20 Power unit Special service tools octobre U U e u ag Ve uM E cU 5 1 Power UAE ciii a nuqa coque id a Ne kaanan 5 3 Checking the compression pressure 5 11 Checking the oil pressure ed ep nada duda 5 11 Checking the oil pressure sensor 5 12 Checking the valve clearance r rr 5 12 Replacing the timing belt e Dt o eau 5 16 Removing the power url credite tenere EE ete enr peer dee Rusa Ed 5 18 Removing the oil filter s doti ti cetero o frio tte d trad etam guts 5 20 Removing the timing belt and 5 20 Checking the timing be
165. n substances and cracks Clean the cup with straight gasoline and replace the element if necessary 6 11 56923070 NOTE Be sure not to spill any fuel when removing the fuel filter cup Power unit Checking the engine oil 1 Place the outboard motor in an upright position 2 Remove the engine oil dipstick wipe it clean and then insert it back into the oil filler hole 3 Remove the dipstick again to check the oillevel and to check the oil for discolora tion and its viscosity S63P3050 NOTE _ 1 1 5 Change the oil if it appears milky or dirty If the engine oil is above the maximum level mark H extract sufficient oil using an oil changer or drain it until the level is between H and L If the engine oil is below the minimum level mark L add sufficient oil until the level is between H and L 63PSF11 Top cowling Fuel system Power unit Changing the engine oil using an oil changer 1 Start the engine warm it up and then turn it off 2 Remove the engine oil dipstick and oil filler cap CD S63P3060 3 Insert the tube of the oil changer into the dipstick guide 3 S63P3070 4 Operate the oil changer to extract the NOTE Be sure to clean up any oil spills 5 Pour the specified amount of the recom mended engine oil into the oil filler hole Recommended engine oil 4 stroke motor oil API SE SF SG SH or SJ SAE
166. nctioning part according to the flash pattern NOTE Es When more than one problem is detected the light of the diagnostic flash indicator flashes in the pattern of the lowest numbered problem After that problem is corrected the light flashes in the pattern of the next lowest numbered problem This continues until all of the problems are detected and corrected 6 11 Symptom Normal Incorrect pulser coil signal Incorrect engine temperature sensor signal Incorrect throttle position sensor signal Incorrect battery voltage Incorrect intake air temperature sensor signal Incorrect neutral switch signal Incorrect intake air pressure sensor signal Incorrect idle speed control signal Incorrect oil pressure sensor signal Incorrect engine stop lanyard switch signal Incorrect shift cut switch signal 63PSF11 Incorrect thermoswitch signal Self diagnosis 9 20 Index Numerics 64E type power trim and tilt 1 11 A Adjusting the throttle link and throttle cable 3 8 Adjusting the throttle link and throttle cable operation using a thickness gauge 3 10 Adjusting the throttle position sensor 4 17 Adjusting the throttle position sensor when disassembling or replacing the throttle body sasana sanak akan saban a ana aa PA aas 4 18 Adjusting the trim sensor
167. nd 3 onto the tilt cylinder end screw 560 7650 Tilt piston nut 96 N m 9 6 kgf m 70 8 ft lb 0 6 Install new backup ring and new O ring 6 onto the free piston 4 560 7630 2 Install the tilt cylinder end screw onto the tilt ram AN S60X7660 Install a new oil seal 2 a new dust seal 8 and a new O ring onto each trim cylinder end screw I 8 Install the backup ring and a new O ring onto each trim piston 560 7640 3 Install new O rings onto the tilt piston 8 4 Install the ball valve 9 and spring 5 in this order 5 Install the tilt piston assembly and washer 2 onto the tilt ram 5 and then tighten the tilt piston nut 3 to the speci fied torque S63P7360 7 39 63P3F11 Assembling the power trim and tilt unit 1 Fil the tilt cylinder with the specified amount of the recommended fluid through the hole 8 S60X7680 Recommended power trim and tilt fluid ATF Dexron II Fluid quantity 30 cm 1 0 US oz 1 1 Imp oz 2 Push the free piston into the tilt cylin der until it bottoms out 560 7690 63PSF11 Power trim and tilt unit 3 Fil the trim cylinders with the recom mended fluid to the correct level through holes and and as shown S60X7700 Recommended power trim and tilt fluid ATF Dexron II 7 40 Bracket unit 4 Install the trim piston assemblies into the trim c
168. nd let it idle 5 Check that the fuel pressure reduces when vacuum pressure is applied to the pressure regulator the fuel pressure does not reduce replace the pressure regulator WARNING lt Before measuring the fuel pressure make sure that the drain screw is tight ened securely Do not loosen the drain screw while measuring the fuel pressure Loosening the drain screw can cause fuel to spray out creating a fire hazard After measuring the fuel pressure cover the end of the hose with a clean dry rag point the hose downward and then loosen the drain screw to drain the remaining fuel from the hose and gauge When storing the fuel pressure gauge make sure that the drain screw is tight ened securely Checking the check valve 1 Connect the special service tool to the check valve 2 Apply pressure to each check valve port Replace if necessary 63PSF11 Intake assembly and vapor separator S60V4200 ez Vacuum pressure pump gauge set 90890 06756 NOTE Check that air comes out of the opposite end of the check valve 4 14 e D Fuel system Reducing the fuel pressure 1 Remove the cap D 2 Cover the pressure check valve 8 of the fuel rail with a rag and then press in the pressure check valve 8 using a thin screwdriver to release the fuel pressure S WARNING Always reduce the fuel pressure in the high pressure fuel line befor
169. ne hanger Bolt Cil filler cap O ring Cil filler neck Gasket Bolt Seal Balancer assembly Bolt Bolt O ring Plug Oil pump assembly Cil seal O ring Gasket M6 x 20 mm M6 x 45 mm Not reusable N N WO on M8 x 55 mm M6 x 40 mm Not reusable Not reusable Not reusable Not reusable N 63P3F11 5 38 12 N m 1 2 kgf m 8 9 ft Ib WAN m 0 4 kgf m 3 0 ft Ib 7 N m 0 7 kgf m 5 2 ft Ib 13 m 1 3 kgf m 9 6 ft Ib S63P5640 Part name Remarks Oil seal Notreusable Oil seal Notreusable Bolt M6 x 40 mm 5 39 63P3F11 Cylinder block 30 N m 3 0 kgf m 22 1 ft Ib 90 30 N 3 0 kof 22 1 ft Ib 23N m 43N m 90 2 3 kgf m 17 0 ft Ib 4 3 kgf m 31 7 ft Ib S63P5650 No 1 2 3 4 5 6 7 8 Part name Remarks Bolt M10 x 85 mm Bolt M8 x 55 mm Crankcase Main bearing cap Collar Oylinder block Oil seal Crankshaft Main bearing Cil seal Connecting rod bearing Piston connecting rod assembly Connecting rod cap Bolt Oil ring 2nd piston ring Top ring Notreusable Notreusable RA gt ROA 63P3F11 5 40 Disassembling the cylinder block 1 Remove the oil pump 2 Remove the balancer bolts in the sequence shown 9 Jio
170. neces sary Assembling the oil pump 1 Install a new oil seal into the oil pump housing S63P5870 2 Needle bearing attachment 1 90890 06654 Driver rod L3 2 90890 06652 2 Apply grease to new oil seals and then install them into the oil pump housing 6 11 S63P5890 Needle bearing attachment 90890 0661 1 Driver rod L3 2 90890 06652 3 Install a new oil seal into the oil pump housing S63P5900 General pipe 45 mm 1 77 in 4 Install a new oil seal and the gasket and then tighten the screws 8 to the specified torque 563 5910 6 11 Cylinder block Screw 8 4 Nm 0 4 kgf m 3 0 ft lb Assembling the pistons and cylinder block 1 Install the oil ring D second ring and top ring 3 onto the pistons with the RN mark 8 of the second ring and the R mark 8 of the top ring facing upward 2 Offset the piston ring end gaps as shown 63 5930 CAUTION Do not scratch the pistons or break the piston rings NOTE After installing the piston rings check that they move smoothly 5 50 3 Install the upper bearing into the con necting rod 2 and the lower bearing into the connecting rod cap S63P5940 NOTE Install the connecting rod bearings in their original positions 4 Install half of the main bearings and the thrust bearing into the cylinder block S63P5950
171. ng the engine oil 3 4 Checking the engine oil level 1 22 Checking the engine start switch and engine stop lanyard switch 1 24 Checking the engine temperature CI 8 13 Checking the fuel filter 3 3 Checking the fuel joint and fuel hoses fuel joint to fuel injector 3 3 Checking the fuel pumps 4 7 Checking the fuel system 1 22 Checking the fuse 7 47 Checking the fuses 8 19 Checking the gear oil level 1 22 3 13 Checking the gear pump 7 35 Checking the gear shift and throttle 1 24 Checking the gear shift operation 3 11 Checking the hydraulic pressure 7 28 Checking the ignition coils 8 11 Checking the ignition spark gap 8 11 Checking the ignition timing 3 12 63PSF11 Checking the injectors 8 17 Checking the intake air temperature i re 8 13 Checking the lower 6 18 6 47 Checking the lower unit for air leakage 3 15 Checking the magnet switch 8 23 Checking the main relay 8 17 Checking the neutral s
172. ng the flushing kit and with the engine running at idle 63P3F11 63PSF11 Specifications General specifications l ieee laine 2 1 Maintenance specification u u 2 3 Da Ia T Wa 2 3 Lower UN e c 2 6 eere E eM I 2 7 DIMENSIONS EE 2 9 Tightening Bre E om 2 11 SDp6GIfIed TORQUES ssi ME 2 11 General torques EE 2 13 wee Specifications General specifications Item Model Killer Whale 150 Killer Whale 150 SX Dimension Overall length Overall width Overall height X Boat transom height L X 822 32 4 511 20 1 1 714 67 5 1 842 72 5 508 20 0 635 25 0 Weight with aluminium propeller L X with stainless propeller 214 0 472 218 0 481 216 0 476 220 0 485 Performance Maximum output Full throttle operating range Maximum fuel consumption Engine idle speed kW hp r min L US gal Imp gal hr r min 110 3 150 at 5 500 r min 5 000 6 000 55 8 14 7 12 3 at 6 000 r min 700 50 Power unit Type Cylinder quantity Total displacement Bore x stroke Compression ratio Control system Starting system Fuel system Ignition system Maximum generator output Spark plug Cooling system Exhaust system Lubrication sy
173. ngine speed is limited to approximately 2 000 r min if the engine overheats if the oil pressure is low or if a dual engine system DES is operated When a switch turns on the engine speed is controlled as shown in the table Engine speed Less than 2 000 r min Engine Thermo temperature switch Oil pressure sensor sensor 2 000 r min or more 130 higher lower 266 F or 0 63 V or Below specified oil pressure due to engine speed Fuel injection begins again in the cylinder order 3 4 and 1 Fuel injection is shut off in the cylinder order 1 4 and 3 The warning indicators light for 3 sec onds after the engine start switch is turned on The buzzer sounds if the lanyard is removed from the engine stop lanyard switch while starting the outboard motor Oil pressure warning indicator lights and buzzer sounds Overheat warning indicator lights and buzzer sounds Buzzer sounds Fuel injection is shut off in the cylinder order 1 4 and 3 at 2 5 second intervals when the engine is running at 2 000 r min or more Fuel injection to the 2 cylinder is not shut off When the throttle opening angle is 30 degrees or less fuel injection to the 3 cylinder will begin again When the engine speed decreases to less than 2 000 r min fuel injection will begin again in the cyl inder order 3 4 and 1 at 0 2 second intervals
174. nment mark b on the bottom cowling e S63P3270 S69J3370 CAUTION The shift throttle cable joint must be screwed in a minimum of 8 0 mm 0 31 in 63P3F11 Checking the steering system 1 Check the steering friction for proper adjustment Check that the smoothly steering operates 1 S63P1060 3 Check that there is no interference with wires or hoses when the outboard motor is steered Checking the gear shift and throttle operation 1 Check that the gear shift operates smoothly when the remote control lever is shifted from neutral to forward or reverse Check that the throttle operates smoothly when the remote control lever is shifted from forward or reverse to the fully open position 8 5691210 6 11 Predelivery checks Checking the power trim and tilt system 1 Check that the outboard motor tilts up and down smoothly when operating the power trim and tilt unit Check that there is no abnormal noise produced when the outboard motor is tilted up or down Check that there is no interference with wires or hoses when the tilted up out board motor is steered Check that the trim meter points down when the outboard motor is tilted all the way down Checking the engine start switch and engine stop lanyard switch 1 Check that the engine starts when the engine start switch is turned to START Check that the engine turns off when the
175. ns to the pulser coil 63P3F11 8 12 evec t 7 ELEC Eg Electrical systems Checking the throttle position sensor 1 Remove the flywheel magnet cover 2 Connect the test harness 3 pins to the throttle position sensor 3 Turn the engine start switch to ON 4 Measure the throttle position sensor input voltage Check the wiring harness connection or replace the ECM if out of specification 5 Measure the throttle position sensor out put voltage Adjust the throttle position sensor if out of specification S63P8130 NOTE To measure the output voltage connect the positive tester probe to the pink wire of the test harness and the negative tester probe to the orange wire of the test harness 2 Digital circuit tester 90890 03174 Test harness 3 pins 90890 06793 Throttle position sensor input voltage Orange O Black B 5V Throttle position sensor output voltage Pink P Black B 0 70 0 02 V 8 13 Checking the intake air temperature sensor 1 Place the intake air temperature sensor in a container of water and slowly heat the water 0 0 ud Os S69J8230 2 Measure the intake air temperature sen sor resistance Replace if out of specifi cation Intake air temperature sensor resistance at 20 C 68 F 2 20 2 70 Checking the engine temperature sensor 1 Place the engine temperature sensor in a container of water and slowly heat the w
176. nsor input voltage Orange O Black B 5 V S63P5060 Oil pressure sensor output voltage NOTE reference data Pink white PAN Black B Do not turn the flywheel magnet counter clockwise 2 8 V at engine idle speed 63P3F11 5 12 5 Check the intake valve clearance for cyl inders 1 and 2 and exhaust valve clearance for cylinders 1 and 3 Adjust if out of specification 6 Turn the flywheel magnet 360 clock wise 7 Check the intake valve clearance for cyl inders 3 and 4 and exhaust valve clearance for cylinders 2 and 4 Adjust if out of specification S63P5070 NOTE Check the valve clearance when the engine is cold Note the measurement Valve clearance Intake 0 20 0 03 mm 0 008 0 001 in Exhaust f 0 34 0 03 mm 0 013 0 001 in 8 Turn the flywheel magnet 360 clockwise and align the TDC mark on the flywheel magnet with the pointer and check that the I marks on the driven sprockets are aligned 5 13 9 Using a hexagon wrench turn the timing belt tensioner clockwise to push the timing belt increase strength gradually and then insert a 25 0 mm 0 2 in pin into the hole NOTE Leave the pin inserted into the timing belt tensioner until the timing belt has been installed 10 Remove the timing belt from the driven sprockets
177. ntenance specification Model Killer Whale 150 SX Oil pump Discharge at 97 103 C 207 217 F with 10W 30 engine oil Pressure Relief valve opening pressure L US gal Imp gal min kPa kgf cm psi kPa kgf cm psi 8 0 2 113 1 760 at 700 r min 132 0 162 0 1 32 1 62 19 1 23 5 392 490 3 92 4 90 56 84 71 05 Thermostats Opening temperature Fully open temperature Valve open lower limit Lower unit Item C F C F mm in 58 62 136 144 70 158 4 3 0 17 Model Killer Whale 150 Killer Whale 150 SX Gear backlash Pinion to forward gear Pinion to reverse gear Pinion shims Forward gear shims Reverse gear shims Propeller shaft shims 0 14 0 46 0 0055 0 0181 0 32 0 67 0 0126 0 0264 0 14 0 42 0 0055 0 0165 0 23 0 58 0 0090 0 0228 0 10 0 12 0 15 0 18 0 30 0 40 0 50 0 10 0 12 0 15 0 18 0 30 0 40 0 50 0 10 0 12 0 15 0 18 0 30 0 40 0 50 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Propeller shaft End play 63PSF11 0 25 0 35 0 0098 0 0138 2 6 SPEC F TR Specifications Electrical Item Model Killer Whale 150 Killer Whale 150 SX Ignition and ignition control system Ignition timing cylinder 1 Spark plug gap Ignition coil resistance Primary coil R B W at 20 C 68 F Secondary coil at 20 C 68 F output peak voltage
178. ntification mark in the direction indi cated in the installation procedure In addition be sure to lubricate the bearings liberally Apply a thin coat of water resistant grease to the lip and periphery of an oil seal before installation Check that moving parts operate nor mally after assembly 1 4 aa General information Identification Applicable models This manual covers the following models Applicable models Killer Whale 150 Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket 60X1010 Model name Approved model code Transom height Serial number Approved Starting model code serial No L 1000017 X 1000044 j L 1000013 Killer Whale 150 64P SX X 1000009 Model name Killer Whale 150 63P 1 5 63P3F11 Identification Features and benefits Features and benefits Crankshaft and cylinder The center of the crankshaft is offset 10 mm 0 39 in from the center of the cylinder to make more space to incorporate the throttle body assembly This design produces good engine balance and allows a compact design Exhaust gas from each cylinder flows directly into the exhaust manifold to obtain a compact design for the exhaust system Y ENR w 56 RD WA A WW 1 QV gt WW VAN
179. o continu ity 60X7270 CAUTION Do not touch the bimetal otherwise the operation of the circuit breaker can be affected 3 Measure the commutator diameter Replace if out of specification 560 7280 Commutator diameter limit C 21 0 mm 0 83 in 4 Check the armature for continuity Replace if out of specifications 63PSF11 Power trim and tilt unit Seoxz290 Commutator segments d Continuity Segment Armature core 8 No continuity Segment Armature shaft No continuity 5 Check the base for cracks or damage Replace if necessary 6 Check the bearing and oil seal for dam age or wear Replace if necessary NOTE S60X7300 If the bearing and oil seal are removed always replace them with new ones 7 32 Bracket unit Assembling the power trim and tilt motor 1 Connect the PTT motor leads D and then tighten the screws S60X7310 2 Push the brushes into the brush holder and then install the armature 2 60X7320 3 Install the stator onto the base 60X7330 NOTE Place a clean cloth over the end of the arma ture shaft hold it with a pair of pliers and then carefully slide the stator over the arma ture 7 33 Removing the reservoir 1 Hold the power trim and tilt unit in a vise using aluminum plates on both sides 560 7390 CAUTION Do not use rags or paper to clean th
180. or assembly Yes i DX Check the ignition coil resis Check the fuel system tance A i M A Good condition No Repair or replace the defective M J Yes Check the spark plug wire resis tance and check the spark plug caps for salt buildup Continued on next page 9 11 63P3F11 Power unit i Good condition No Repair or replace the spark plug wires Yes J Check the ECM output peak voltage Fuel system Check the electric fuel pump operation Can opera Check the fuse holder fuse tion sound be and wiring harness for continu heard ity Is there continuity No Repair or replace the defective parts Yes i Check the fuel filters for clogs J I saka Replace the electric fuel pump i E Good condition Repair or replace the defective pads of Yes Check the fuel pump dia phragm Continued on next page 63P3F11 9 12 TRBL SHTG Troubleshooting Cracks or damage Replace the diaphragm No Check the vapor separator nee dle valve Is the needle valve Yes bent or worn No Replace the needle valve F Check the vapor separator pressure regulator 1 Good condition Replace the pressure regulator Y Yes Check the injector resistance and check t
181. ore installation Installing the cylinder head 1 Install a new gasket and the cylinder head and then tighten the bolts to the specified torques in the sequence shown PORE 9 5 p E el Ce He 559 Y 9 9 Coe WwW e 0 Do 0600 60560560 A Ol eg 20 119 18 90 S63P5220 CAUTION Do not reuse the cylinder head gasket always replace it with a new one 6 11 NOTE O Apply engine oil to the cylinder head bolts before installation Tighten the M10 bolts to the specified torques in two stages first and then make a mark 8 on the M10 bolts and the cylinder head and then tighten the bolts 90 from the mark Tighten the 8 bolts to the specified torques in two stages Cylinder head bolt M10 1st 19 N m 1 9 kgf m 14 0 10 2nd 37 N m 3 7 27 3 ft lb 3rd 90 Cylinder head bolt 8 1st 14 N m 1 4 kgf m 10 3 ft lb 2nd 28 N m 2 8 kgf m 20 7 ft lb 2 Install the camshafts into the cylinder head with new oil seals S63P5110 63 5 70 Install the camshafts so that the dowels are facing inward and that they are aligned with the mating surface of the cylinder head 63PSF11 Cylinder head 3 Install the camshaft caps and then tighten the bolts to the specified torques in two stages
182. pli cation point Apply Gasket Maker Apply LOCTITE 242 blue Apply Yamabond No 4 Apply LOCTITE 572 Apply LOCTITE 271 red Apply silicon sealant 63P3F11 1 2 aa General information Safety while working To prevent an accident or injury and to ensure quality service follow the safety pro cedures provided below Fire prevention Gasoline is highly flammable Keep gasoline and all flammable products away from heat sparks and open flames 56921010 Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous If inhaled in large quantities they may cause loss of consciousness and death within a short time When test running an engine indoors e g in a water tank be sure to do so where ade quate ventilation can be maintained 69J1020 Self protection Protect your eyes by wearing safety glasses or safety goggles during all operations involv ing drilling and grinding or when using an air compressor Protect your hands and feet by wearing pro tective gloves and safety shoes when neces sary 1 3 56901030 Parts lubricants and sealants Use only genuine Selva parts lubricants and sealants or those recommended by Selva when servicing or repairing the out board motor 69J1040 Under normal conditions the lubricants men tioned in this manual should not harm or be hazardous to your skin However you should follow these precautions to minimize an
183. position and then install the steering arm onto the swivel bracket 56927080 3 Install the bushing new O ring bushing D and washer onto the swivel bracket 69J7085 7 14 Bracket unit 4 Install the steering yoke to the steer Installing the upper case ing arm by aligning the center of 1 Install the upper and lower mounting the yoke with the center of the steer bolts into the swivel bracket 1 simulta ing arm neously 5 Install the circlip 09 2 Install the upper mounting nut and lower mounting nut 3 and then tighten them to the specified torques 3 Install the covers 2 69J7090 6 Inject grease into the grease nipple until grease comes out from both the upper and lower bushings C S63P7240 Upper mounting nut 74 N m 7 4 54 6 ft lb Lower mounting nut 74 N m 7 4 kgf m 54 6 ft lb 69J7095 7 15 63P3F11 Upper case steering arm swivel bracket and clamp brackets Clamp brackets Clamp brackets Iw 15N m 1 5 kgf m 11 1 ft Ib S63P7130 Part name Remarks 2 o O Swivel bracket Clamp bracket Clamp bracket Self locking nut Grease nipple Ground lead Washer Bolt Washer Bushing Trim sensor Screw Trim sensor cam Screw Clamp Bolt Bracket M6 x 11 mm 96 x 15 g6 x 25 mm M6 x 30 mm N NON A W O 63P3F11 7 16
184. r case and then install the straight key claw washer 2 and ring nut S63P6320 CAUTION Add or remove shim s if necessary if replacing the reverse gear ball bearing propeller shaft housing thrust washer or lower case 4 Tighten the ring nut to the specified torque 6 21 S63P6340 NOTE To secure the ring nut bend one tab 8 of the claw washer into a slot in the ring nut Bend all other tabs toward the propeller shaft housing assembly Cz Ring nut wrench 4 90890 06512 Ring nut wrench extension 9 90890 06513 Ring nut 8 142 N m 14 2 104 7 ft lb Installing the water pump and shift rod 1 Install the shift rod assembly 563 6350 2 Install a new gasket 0 the outer plate cartridge 3 and dowels 2 63PSF11 Drive shaft and lower case regular rotation model NOTE The collar and spacer should fit together firmly NV While pulling the drive shaft up install the o collar with an appropriate tool that fits over the drive shaft as shown 6 Install the new O ring and insert car tridge 2 into the pump housing 3 S63P6970 3 Install the Woodruff key into the drive S63P6360 shaft NOTE 4 Align the groove in the impeller 5 with Align the insert cartridge projections with the Woodruff key and then install the the holes in the pump housing impeller onto the drive shaft
185. r for cracks or wear Replace if necessary 6 11 2 2 69 6125 Assembling the propeller shaft assembly 1 Install the dog clutch as shown S63P6080 NOTE sz Install the dog clutch with the F mark 8 facing toward the shift slider Assembling the propeller shaft housing 1 Install the needle bearing into the propel ler shaft housing to the specified depth S63P6100 63PSF11 Propeller shaft housing regular rotation model NOTE Install the needle bearing with the manufac ture identification mark 8 facing toward the oil seal propeller 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 22 Driver rod SS 90890 06604 A Needle bearing attachment 90890 06610 Bearing depth plate 3 90890 06603 Depth 24 75 25 25 mm 0 974 0 994 in Apply grease to new oil seals and then install them into the propeller shaft hous ing to the specified depth m S60V6680 NOTE Install an oil seal halfway into the propeller shaft housing then the other oil seal Bearing inner race attachment 90890 06640 Depth 4 75 5 25 mm 0 187 0 207 in 6 14 Lower unit 3 Install the thrust washer and new ball bearing onto the reverse gear using a press S63P6130 NOTE Install the ball bearing with the manufactu
186. re identification mark facing outward propel ler side Z Needle bearing attachment A 90890 06654 4 Install the reverse gear assembly into the propeller shaft housing using a press S63P6150 Z4 Needle bearing attachment 90890 06654 6 15 63PSF11 Propeller shaft housing regular rotation model Drive shaft and lower case regular rotation model Drive shaft and lower case regular rotation model 93 N m 9 3 kgf m 68 6 ft Ib S63P6160 Part name 4 Remarks Drive shaft Sleeve Cover Oil seal Bolt M8 x 25 mm Drive shaft housing Needle bearing O ring Notreusable Pinion shim Thrust bearing Lower case Needle bearing assembly Pinion Forward gear shim Taper roller bearing assembly Needle bearing Forward gear 63P3F11 6 16 Lower unit Removing the drive shaft 1 Remove the drive shaft drive shaft hous ing and pinion and then pull out the for ward gear S68S6360J CL Drive shaft holder 6 D 90890 06520 Pinion nut holder New 90890 06715 Current 90890 06505 Disassembling the drive shaft housing 1 Remove the cover oil seals and needle bearing t S69J6185 Needle bearing attachment 1 90890 06610 Driver rod L3 2 90890 06652 Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear using a press 6 17 5696186 CAUTION Do not reus
187. re 1 Measure the cylinder bore Dj Dg at measuring points 8 and and in direction D4 D3 05 which is parallel to the crankshaft and direction Do D Dg which is at a right angle to the crankshaft S69J5B70 8 20 mm 0 8 in D 60 mm 2 4 in O 100 mm 3 9 in Cylinder bore 0 05 94 000 94 017 mm 3 7008 3 7014 in 2 Calculate the taper limit Replace the cyl inder block if out of specification Taper limit D Ds direction Dz Dg direction 0 08 mm 0 0032 in 63P3F11 Cylinder block 3 Calculate the out of round limit Replace the cylinder block if out of specification Out of round limit D D measuring point Ds measuring point 0 05 mm 0 0020 in Checking the piston clearance 1 Replace the piston and piston rings as a set or the cylinder block or all parts if out of specification Piston clearance 0 075 0 080 mm 0 0030 0 0031 in Checking the piston rings 1 Check the piston ring dimensions of B and T Replace if out of specification MM Ege UJ S69J5B80 Piston ring dimensions Top ring B 1 17 1 19 mm 0 0461 0 0469 in T 2 80 3 00 mm 0 1102 0 1181 in Second ring B 1 17 1 19 mm 0 0461 0 0469 in T 3 70 3 90 mm 0 1457 0 1535 in Oil ring B 2 40 2 47 mm 0 0945 0 0972 in T 2 30 2 70 mm 0 0906 0 1063 in 5 42 2 Level the piston ring in the cylinder w
188. resent the peak voltage will be lower than specification In addition if the peak voltage is lower than specification the engine will not operate properly S69J8020 WARNING When checking the peak voltage do not touch any of the connections of the digital tester leads NOTE Use the peak voltage adapter with the digi tal circuit tester When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode Connect the positive on the peak volt age adapter to the positive terminal of the digital circuit tester 63PSF11 Measuring the lower resistance When measuring a resistance of 10 Q or less with the digital circuit tester the correct mea surement cannot be obtained due to the internal resistance of the tester To obtain the correct value subtract the internal resistance from the displayed measurement NOTE To obtain the internal resistance of the digital circuit tester connect both of its probes and check the display Correct value displayed measurement internal resistance 8 2 evec t 7 ELEC EE Electrical systems Electrical components Port view S63P8010 D Starter motor Rectifier Regulator Thermoswitch Ignition coil 8 Cil pressure sensor Junction box Fuse holder
189. reusable 63P3F11 6 34 Lower unit S63P6470 Part name 4 Remarks Collar Spacer Washer Wave washer Impeller Outer plate cartridge Gasket Dowel Dowel Not reusable N N p 6 35 63P3F11 Lower unit counter rotation model Removing the lower unit 1 Drain the gear oil For draining proce dures see Chapter 3 Changing the gear oil 2 Set the gear shift to the neutral position and place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then remove the propeller nut and propeller S63P6480 X transom model NOTE WARNING Check that there is no oil on the spline and e Do not hold the propeller with your check it for wear hands when loosening or tightening it Be sure to disconnect the battery leads from the battery and the engine stop lan yard from the engine stop lanyard switch Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning S69J6545 Removing the water pump and shift rod 1 Remove the water pump assembly and shift rod assembly 3 Mark the trim tab at the area shown and then remove it 4 Loosen the bolts and then remove the ET lower unit from the upper case 8 L S63P6040 63P3F11 6 36 Lower unit
190. rotechnical Commission 63P3F11 2 2 punes Specifications Maintenance specification Power unit Model Killer Whale 150 Killer Whale 150 SX Item Unit Power unit Minimum compression kPa 880 8 8 128 pressure kgf cm psi Lubrication oil pressure kPa 450 4 5 65 3 at engine idle speed kgf cm psi Cylinder head Warpage limit i 0 10 0 0039 lines indicate straightedge position Camshaft cap inside diameter 25 000 25 021 0 9843 0 9851 Cylinders Bore size i 94 000 94 017 3 7008 3 7014 Taper limit i 0 08 0 0032 Out of round limit i 0 05 0 0020 Pistons Piston diameter D uh i 93 928 93 934 3 6979 3 6982 25 Measuring point 5 0 0 20 Piston to cylinder clearance 0 075 0 080 0 0030 0 0031 Piston pin boss bore 21 004 21 015 0 8269 0 8274 Piston rings Top ring Dimension B B i 1 17 1 19 0 0461 0 0469 Dimension T i 2 80 3 00 0 1102 0 1181 End gap i 0 15 0 30 0 0059 0 0118 Side clearance i 0 04 0 08 0 0016 0 0031 2nd piston ring Dimension B fe i 1 17 1 19 0 0461 0 0469 Dimension T i 3 70 3 90 0 1457 0 1535 End gap i 0 30 0 45 0 0118 0 0177 Side clearance i 0 03 0 07 0 0012 0 0028 1 Measure conditions Ambient temperature 20 C 68 F wide open throttle with spark plugs removed from all cylinders The figures are for reference only 2 The figures are for reference only 2 3 63P3F11
191. rs This allows a simpler fuel injection control system ORR SOM lt De SS SRM SA NS NS SM SENS SRY KS Nd Initial injection timing BTDC10 Y Y 1 cylinder Compression Aut Combustion gt Intake 3 cylinder Intake Combustion 4 cylinder 2 cyinder ums S63P1120 Four separate throttle valve 1 9 63P3F11 Features and benefits The shape of the fuel injectors is the same for the F115 F150 F200 and F225 Therefore each fuel injector is identified by color because the specifications of each fuel injector are different S63P1130 A Model D Orange B Injector color E Yellow C First three digits F Ivory Top cowling Water is separated from the intake air and flows down through the drain hoses before draining out through the bottom cowling The structure of the top cowling helps to prevent water from accumulating in the top cowling and entering the power unit 4 S63P1140 Water separator Air including water Drain hoses Water 1 10 63PSF11 an General information 64E type power trim and tilt unit 64E type clamp bracket and power trim and tilt unit used for current V4 and V6 outboard motors have been adopted This allows easier interchanging of Selva outboards wi
192. s Part to be tightened Thread size Nm kgf m 16 Fuel system Fuel filter holder bolt M6 Fuel filter bracket bolt M6 Fuel pump mounting bolt M6 Fuel pump screw 06 Fuel cooler bolt M6 Vapor separator mounting bolt M6 Fuel rail mounting bolt M8 Throttle body mounting bolt M8 Power unit 0 8 5 9 0 8 5 9 1 0 7 4 0 4 3 0 0 5 3 7 0 5 3 7 1 3 9 6 1 3 9 6 CO eA WI M8 2 0 14 8 4 2 31 0 Apron bolt M6 0 8 5 9 Apron screw 96 0 4 3 0 Flywheel magnet nut i ate gt 199 1 Starter motor bolt 21 4 Power unit mounting bolt Positive battery cable nut Timing belt tensioner bolt Drive sprocket bolt Driven sprocket bolt Camshaft cap bolt Cylinder head cover plate screw Cylinder head cover bolt Cylinder head bolt Spark plug Engine temperature sensor Cylinder block plug Engine hanger bolt Oil pressure sensor 2 11 63P3F11 Part to be tightened Thread size Tightening torques Tightening torques N m kgf m ft lb Exhaust cover bolt M6 6 0 6 4 4 12 1 2 8 9 Thermostat cover bolt M6 6 0 6 44 12 1 2 8 9 Exhaust cover plug 23 2 3 17 0 55 5 5 40 6 Oil filter union bolt 34 3 4 25 1 7 0 7 5 2 13 1 3 9 6 Ba
193. s to prevent them from falling out of the gear pump cover 63P3F11 Power trim and tilt unit 5 Install the gear pump cover 2 into the gear pump housing and then tighten the bolts S60X7520 6 Check that the gear pump turns smoothly and then tighten the gear pump cover bolts to the specified torque Gear pump cover bolt 6 N m 0 6 4 4 ft lb 7 Install a new O ring onto the down relief valve 8 Install the filter down relief valve and fil ter into the gear pump housing 20 560 7530 9 Install a new O ring onto the manual valve 10 Install the manual valve and circlip into the gear pump housing Manual valve 3 0 3 kgf m 2 2 ft lb 7 36 Bracket unit Disassembling the tilt cylinder and trim cylinder 1 Loosen the tilt cylinder end screw and then remove the tilt piston assembly 563 7020 CAUTION Make sure that the trim and tilt rams are fully extended before removing the tilt cyl inder end screw Z Trim and tilt wrench d New 90890 06587 Current 90890 06548 2 Drain the fluid 3 Loosen the trim cylinder end screws and then remove the trim piston assemblies 563 7030 lt Trim and tilt wrench New 90890 06587 Current 90890 06548 4 Drain the fluid 5 Install the trim piston assemblies and then tighten the trim cylinder end screws finger tight 7 37 6 Cover the tilt cylinder opening with a c
194. shaft is at the center of the hole Tighten the wing nuts another 1 4 of a turn after they contact the fixing plate 5 Z Pinion height gauge 90890 06710 2 Install the pinion and pinion nut and then tighten the nut to the specified torque 63P3F 11 Shimming regular rotation model Pinion nut 93 N m 9 3 68 6 ft Ib 3 Measure the distance M4 between the special service tool and the pinion as shown 4 Turn the thrust bearing two or three times to seat the drive shaft housing and then measure the housing height M3 as shown S60V6640 NOTE Measure the thrust bearing at three points to find the height average 6 26 Lower unit 5 Calculate the pinion shim thickness T3 as shown in the examples below S69J6555 NOTE _ __ gt P is the deviation of the lower case dimen sion from standard The P mark 8 is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the P mark is unreadable assume that P is zero and check the backlash when the unit is assembled Calculation formula Pinion shim thickness T3 80 00 P 100 M3 M4 Example If M3 is 46 68 mm and M4 is 32 49 mm and P is 5 then 80 00 5 100 46 68 32 49 mm 80 00 0 05 46 68 32 49 mm 0 78 mm 6 Select the pinion shim s T3 as follows Calculated numeral at 1 100 place 1 2 3 4 5 6 7 8 9 10
195. spark plug wires 8 11 Checking the spark plugs 3 6 Checking the starter motor operation 8 23 Checking the starter motor pinion 8 22 Checking the starter relay 8 19 Checking the stator coil 8 25 Checking the steering system 1 24 Checking the thermostat 3 7 Checking the thermoswitch 8 14 Checking the throttle position sensor 8 13 Checking the tilt cylinder and trim cylinder seen 7 38 Checking the timing belt 3 6 Checking the timing belt and sprockets 5 21 63PSF11 Checking the top 3 3 Checking the trim sensor 7 48 Checking the valve clearance 3 6 5 12 Checking the valve guides 5 29 Checking the valve 5 31 Checking the valve springs 5 28 Checking the valves 5 29 Checking the vapor separator 4 15 Checking the water pump and shift rod unus 6 9 6 37 Clamp brackets 7 16 Connecting rod 1 8 Control system 3 8 Cooling system
196. ssure sensor O ring Oil filter bracket Bolt Gasket Exhaust cover Bolt M14 x 12 mm M6 x 20 mm M6 x 16 mm Notreusable Notreusable M6 x 40 mm Notreusable M6 x 30 mm P po H k 5 25 63P3F11 23 2 3 kgf m 17 0 ft Ib 15 N 1 5 kgf m 1 18 m 1 8 kgf m 13 3 ft Ib Part name Cylinder head S63P5630 Remarks Gasket Thermostat Cover Thermoswitch Holder Bolt Gasket Rectifier Regulator Bolt Anode Grommet Cover Bolt Bolt Washer Plug Grommet 63PSF11 Q o Notreusable M6 x 30 mm Notreusable M6 x 30 mm M8 x 40 mm M6 x 20 mm M14 x 12 mm 5 26 23 N m 2 3 kgf m 17 0 ft Ib 6 N m 0 6 kgf 4 4 ft 10 12 N m 1 2 kgf m 8 9 ft Ib Ix 15N m 1 5 kgf m 1 18 N 1 8 kgf m 13 3 ft Ib S63P5630 No Part name Q ty Remarks 35 Pressure control valve 1 36 Spring 1 37 Gasket 1 38 Cover 1 39 Bolt 3 M6 x 20 mm 40 Washer 1 41 Plug 1 M18 x 17 mm 42 Holder 1 43 Bolt 1 M6 x 12 mm 44 Anode 1 45 Screw 1 46 Anode 7 47 Screw 7 g5 x 27 mm 5 27 63P3F11 Removing the cylinder head 1 Remove the camshaft caps in the sequence shown
197. stem 2 1 cm cu in mm in 4 stroke L 4 2 670 162 9 94 0 x 96 2 3 70 x 3 79 9 0 Remote control Electric Fuel injection TCI 12 35 LFR5A 11 NGK Water Propeller boss Wet sump 63PSF11 General specifications Model Killer Whale 150 Killer Whale 150 SX Fuel and oil Fuel type Fuel minimum rating Engine oil Engine oil grade Engine oil quantity without oil filter replacement with oil filter replacement Gear oil type Gear oil grade Gear oil quantity RON PON API SAE L US qt Imp qt L US qt Imp qt SAE cm US oz Imp oz Regular unleaded gasoline 91 86 4 stroke motor oil SE SF SG SH or SJ 10W 30 or 10W 40 5 2 5 5 4 6 5 4 5 7 4 8 Hypoid gear oil 90 980 33 1 34 6 870 29 4 30 7 Bracket unit Trim angle at 12 boat transom Tilt up angle Steering angle Degree Degree Degree 4 0 to 16 0 70 0 35 0 4 35 0 Drive unit Gear shift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction rear view Propeller mark F N R 2 00 28 14 Spiral bevel gear Dog clutch Spline Clockwise Counterclockwise M ML Electrical Battery minimum capacity CCA EN 20HR IEC 1 RON Research Octane Number PON Pump Octane Number RON Motor Octane Number 2 2 CCA Cold Cranking Ampere EN European Norm European standard IEC International Elect
198. t unit Reservoir cap 0 07 Reservoir mounting bolt 0 5 PTT motor mounting bolt 0 5 Gear pump cover bolt 0 6 Gear pump housing mounting bolt 0 8 Manual valve 0 3 Trim cylinder end screw 7 8 Tilt cylinder end screw Tilt piston nut 9 6 Muffler assembly bolt General torques This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch Tightening torque specifications for special components or assemblies are General torque specifications kgfm ft lb 5 0 5 3 6 provided in applicable sections of this man 0 8 5 8 ual To avoid warpage tighten multi fastener 18 1 8 13 assemblies in a crisscross fashion and pro 36 3 6 25 gressive stages until the specified torque is 43 4 3 31 reached Unless otherwise specified torque specifications require clean dry threads Components should be at room temperature 69J2150 2 13 63P3F11 CHK ADJ 63PSF11 Periodic checks and adjustments Special service tools i 3 1 Maintenance interval charrl u u 3 2 TOP COW G epu ze ea UY Ve I FREE EE T GENE e Fu UE MEE 3 3 Checking the top cowling tele e pedo 3 3 ECC MTS 3 3 Checking the fuel joint and fuel hoses fuel joint to fuel injector
199. tall the camshaft caps and then 21 Check that I marks and on the tighten them to the specified torques in driven sprockets are aligned Adjust if two stages and in the sequence shown in necessary the illustration 1 el 1 Z KO o 4 e 4 S63P5140 8 J 5 2 REJO pen 22 Install the timing belt turn the belt 6 Gear 7 3 P from the drive sprocket side a half turn 015 n AES counterclockwise to align it and then S63P5120 remove the pin NOTE Install the camshaft caps in the proper posi tion as shown and with the stamped num bers facing upside down Apply engine oil to the camshaft cap bolts before installation Camshaft cap bolt S63P5C90 1st 8 0 8 kgf m 5 9 ft lb 2nd 17 N m 1 7 kgf m 12 5 ft lb 23 Turn the flywheel magnet clockwise two turns and then check that all alignment 20 Install the driven sprockets and then marks are aligned tighten the bolts to the specified torque S63P5130 NOTE Apply engine oil to the driven sprocket bolts before installation Driven sprocket bolt 60 6 0 kgf m 44 3 ft lb S63P5160 5 15 63P3F11 NOTE Do not turn the flywheel magnet counter clockwise 24 Check the valve clearances Adjust if necessary 25 Install the spark plugs and then tighten them to the specified torque 26 Install the cylind
200. th the same classification because the mounting dimensions are the same For the power trim and tilt unit only the impact absorber valve opening pressure of the tilt piston fluid circuit has been changed The pressure is distinguished from those of other models by an iden tification mark stamped on the power trim and tilt unit S63P1150 Identification mark Applicable models YA Carbureted V4 and V6 2 6 YB N A Electronic fuel injected V6 2 6 HPDI 2 6 VX200 200H VX225 2250 and VX250 2500 YD F115 F115A LF115 FL115A and F100B YE VZ225 Z225H and VZ250 Z250F YF F150 F150A and LF150 FL150A 1 11 63P3F11 Features and benefits Cooling system The cooling water flow diagram is as follows To cool the propeller damper the cooling system is designed so that fresh cooling water is taken in from the front of the trim tab and supplied to the exhaust passage of the lower case to cool the exhaust gas Cooling water also accumulates around the exhaust muffler to cool the upper case and reduce exhaust noise Sea River Lake Pressure control valve Upper case Lower case Fuel cooler Propeller boss Cooling water pilot hole x Z M
201. their original posi tions S63P5540 6 Install the main bearing cap and crank case onto the cylinder block and apply engine oil to the threads of the bolts 7 Remove the main bearing cap and crank case and then measure the width of the compressed Plastigauge PG 1 on each main journal Replace the main bearing if out of specification S63P5840 S63P5830 Crankshaft main journal oil clearance 0 021 0 050 mm 0 0008 0 0020 in 63P3F11 5 48 3 Select the suitable color for the main bearing from the table S63P5850 Cylinder block mark 6 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Crankshaft journal mark 8 Upper bearing Lower bearing color color Green Green Green Red Red Red Red Yellow Yellow Yellow Yellow Blue green NOTE Example If the crankshaft journal mark 8 is 89 and the cylinder block mark is 28 then select the bearing colors in Main bearing 3 is a thrust bearing Disassembling the oil pump 1 Remove the screws 1 and disassemble the oil pump 5 49 S63P5860 Checking the oil pump 1 Check the gear teeth for cracks or wear and the oil pump case for scratches Replace the oil pump assembly if
202. ti cavitation plate and propeller to keep the propeller from turning and then tighten the nut to the specified torque S60V6650 69 6340 WARNING e Do not hold the propeller with your hands when loosening or tightening it Be sure to disconnect the battery leads from the battery and the engine stop lan yard from the engine stop lanyard switch Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning NOTE If the grooves in the propeller nut do not align with the cotter pin hole tighten the nut until they are aligned 63PSF11 Propeller nut 52 N m 5 2 kgf m 38 4 ft Ib 6 24 Lower unit Shimming regular rotation model A3 B3 L 1 Hee ie a D T1 4 SS B1 37 0 16 3 S63P6390 6 25 63P3F11 Shimming NOTE Shimming is not required when assembling the original lower case and inner parts Shimming is required when assembling the original inner parts and a new lower case e Shimming is required when replacing the inner part s Selecting the pinion shims 1 Install the special service tools onto the drive shaft D 69J6600 NOTE Select the shim thickness by using the specified measurement s and the calcula tion formula Install the special service tool onto the drive shaft so that the
203. ting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure 2 Remove the reservoir cap and then check the fluid level in the reservoir NOTE TT If the fluid is at the correct level the fluid should overflow out of the filler hole when the reservoir cap is removed 3 If necessary add sufficient fluid of the recommended type until it overflows out of the filler hole Recommended power trim and tilt fluid ATF Dexron II 4 Install the reservoir cap and then tighten it to the specified torque Reservoir cap 0 7 N m 0 07 0 5 ft lb Lower unit Checking the gear oil level 1 Fully tilt the outboard motor down 2 Remove the check screw D and then check the gear oil level in the lower case 6 11 S60V3320 NOTE 0 If the oil is at the correct level the oil should overflow out of the check hole when the check screw is removed 3 If necessary add sufficient gear oil of the recommended type until it overflows out of the check hole Recommended gear oil Hypoid gear oil SAE 90 4 Install the check screw Changing the gear oil 1 Tilt the outboard motor up slightly 2 Place a drain pan under the drain screw D remove the drain screw then the check screw 2 and let the oil drain com pletely S60V3330 63
204. ump install it so that the oil seal does not get damaged 5 54 20 Before installing the oil filter be sure to fill it with engine oil through the oil pas sage Q of the oil filter bracket S63P5B20 21 Install the oil filter and then tighten it to the specified torque using a 72 5 mm 2 9 in oil filter wrench S63P5B30 NOTE Apply thin coat of engine oil the O ring of the new oil filter before installation Oil filter wrench 90890 06830 Oil filter 18 N m 1 8 kgf m 13 3 ft lb 22 Install a new gasket and the exhaust cover and then tighten the bolts to the specified torques in two stages and in the sequence shown 5 55 S63P5C40 Exhaust cover bolt 1st 6 0 6 4 4 ft lb 2nd 12 N m 1 2 8 9 10 23 Install the thermostat and cover 49 S63P5C50 Thermostat cover bolt 1st 6 0 6 kgf m 4 4 ft lb 2nd 12 N m 1 2 8 9 10 Installing the power unit 1 Clean the power unit mating surface and install the dowels and a new gasket Q 2 Install the power unit 3 by installing the bolts and bolts 5 then tightening them to the specified torque 3 Install the apron 6 then tighten them to the specified torque 6 11 Cylinder block Connect the fuel hose D S63P5B80 7 Connect the PTT motor leads and S63P5B40 then install the junction box cover S63P5B50 S63P5B90
205. unit 1 Drain the gear oil For draining proce dures see Chapter 3 Changing the gear oil 2 Set the gear shift to the neutral position and place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then remove the propeller nut and propeller 63 6030 X transom model NOTE WARNING Check that there is no oil on the spline and e Do not hold the propeller with your check it for wear hands when loosening or tightening it Be sure to disconnect the battery leads Removing the water pump and shift from the battery and the engine stop lan rod yard rom henenging stop lanyard 1 Remove the water pump assembly and 5696015 switch Put a block of wood between the anti assembly a cavitation plate and propeller to keep the propeller from turning 3 Mark the trim tab at the area shown and then remove it 4 Loosen the bolts and then remove the ET lower unit from the upper case 8 L S63P6040 63P3F11 6 8 Lower unit Checking the water pump and shift rod 1 Check the water pump housing for defor mation Replace if necessary 5696030 2 Check the impeller and insert car tridge 2 for cracks or wear Replace if necessary 63 6050 3 Check the Woodruff key 3 and the key way 8 in the drive shaft for wear Replace if necessary 5696040 4 Check the shift rod for cracks or wear
206. ver Otherwise the outboard motor could sud denly lower if the power trim and tilt unit should lose fluid pressure 7 Remove the reservoir cap and then check the fluid level in the reservoir NOTE If the fluid is at the correct level the fluid should overflow out of the filler hole when the reservoir cap is removed 8 If necessary add sufficient fluid of the recommended type to the correct level Recommended power trim and tilt fluid ATF Dexron II 9 Install the reservoir cap and then tighten it to the specified torque Reservoir cap 0 7 N m 0 07 kgf m 0 5 ft Ib NOTE Repeat this procedure until the fluid remains at the correct level 6 11 Power trim and tilt unit Power trim and tilt electrical system Power trim and tilt electrical system Fuse holder Fuse 20 A Fuse 50 A Battery Power trim and tilt relay Power trim and tilt motor Diode Trim sensor Power trim and tilt switch 63P3F 11 A To remote control box switch panel B To trim meter 563 7270 Black Gray Light green Pink Red Sky blue 7 46 Bracket unit Checking the fuse 1 Check the fuse for continuity Replace if there is no continuity S69
207. wer unit Ignition system Check the condition of the spark plugs Good condition No Clean adjust or replace the spark plugs Yes Check the ignition spark using the spark gap tester WARNING Do nottouch any of the connections of the spark gap tester leads Do notlet sparks leak out of the removed spark plug caps Keep flammable gas and liquids away since this test can produce sparks Good spark Check the fuel system No Check the ignition coil resis tance Good condition Repair or replace the defective parts F Yes Check the spark plug wire resis tance and check the spark plug caps for salt buildup i Good condition N Repair or replace the spark plug wires I Yes Check the ECM output peak voltage C G 63P3F11 9 16 TRBL e Troubleshooting Fuel system Check the fuel pump dia phragm Yes Cracks or damage Replace the diaphragm Check the vapor separator nee dle valve Is the needle valve 165 Replace the needle valve bent or worn No Check the injector resistance and check the injectors for clogs T No ns Good condition Replace the injectors Yes Check the ignition system 9 17 63P3F11 Symptom 4 Hunting occurs of each cylinder i Are th
208. white W B White black B Y Black yellow W R White red G B Green black Y G Yellow green 63P3F11 8 10 evec t 7 ELEC ES Electrical systems Checking the ignition spark gap 1 Remove the spark plug wire cover 2 Disconnect the spark plug caps from the spark plugs 3 Connect a spark plug cap to the special service tool S63P8070 4 Crank the engine and observe the spark through the discharge window of the spark gap tester Check the ignition sys tem if the spark is weak S63P8090 WARNING Do not touch any of the connections of the spark gap tester leads e Do not let sparks leak out of the removed spark plug caps Keep flammable gas or liquids away since this test can produce sparks NOTE The ignition spark gap can also be checked using the Stationary test of the Diagnostic System 8 11 Checking the spark plug wires 1 Remove the spark plug wires from the spark plugs 2 Remove the spark plug wires from the ignition coil 3 Measure the spark plug wire resistance Replace if out of specification 56068100 Spark plug wire resistance 1 4 6 10 9 2 3 3 8 0 3 3 8 9 3 4 4 2 10 0 Checking the ignition coils 1 Remove the spark plug wires from the ignition coil 2 Disconnect the ignition coil coupler 3 Measure the ignition coil resistance Replace if out of specification
209. witch 8 14 Checking the oil pressure 5 11 Checking the oil pressure sensor 5 12 Checking the oil pump 5 49 Checking the oil strainer 7 12 Checking the outboard motor mounting height cede et dep 1 23 Checking the piston clearance 5 42 Checking the piston diameter 5 41 Checking the piston ring grooves 5 43 Checking the piston ring side clearance 5 43 Checking the piston rings 5 42 Checking the power trim and tilt fluid level 2 LA 3 13 Checking the power trim and tilt motor 7 31 Checking the power trim and tilt Operation oce eee eee re neta 3 13 Checking the power trim and tilt relay 7 47 Checking the power trim and tilt switch 7 47 Checking the power trim and tilt system 1 24 Checking the pressure control valve 5 37 Checking the pressure regulator 4 13 Checking the propeller 3 15 Checking the propeller shaft 6 13 6 41 Checking the propeller shaft HOUSING ecce tete rece Ete rend 6 13 6 41 Checking the pulser coil 8 12 Checking the Rectifier Regulator 8 25 Checking the remote control cables 1 23 Checking the shift cut switch 8 14 Checking the
210. with a new one Cotter pin Not reusable Do not press the drive shaft threads Propeller nut directly Stopper guide plate 90890 06501 Do not reuse the bearing always Stopper guide stand Trim tab I S62Y67s0K replace it with a new one 90890 06538 Bearing puller 90890 06535 1 Bearing puller claw 1 Bearing inner race attachment 3 G2Y5A11 Z 90890 06536 Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear using a press 62Y5A11 1 1 63P3F11 How to use this manual Symbols The symbols below are designed to indicate the content of a chapter General information Fuel system Bracket unit di Y FUEL BRKT Specifications Power unit Electrical systems g POWR ELEC Troubleshooting Special tool 5 Specified measurement Specified oil or fluid Specified electrical value 3 Specified engine speed resistance voltage electric current Specified tightening torque Symbols to in an exploded diagram indicate the grade of lubricant and the lubrication point Apply Selva 4 stroke motor oil Apply corrosion resistant grease Apply gear oil 9 Apply water resistant grease Apply low temperature resistant grease Apply molybdenum disulfide grease 3 Apply injector grease Symbols to in an exploded diagram indicate the type of sealant or locking agent and the ap
211. y closed stopper on the cylinder block and check that throttle cam roller is aligned with the align ment mark 63 3250 7 Adjust the position of the throttle cable joint until its hole is aligned with the set pin on throttle lever 2 TI cumak S63P3210 CAUTION The throttle cable joint must be screwed in a minimum of 8 0 mm 0 31 in 8 Connect the cable joint install the clip and then tighten the locknut 9 Check the throttle cable for smooth oper ation and if necessary repeat steps 1 8 Checking the gear shift operation 1 Check that the gear shift operates smoothly when shifting it from neutral to forward or reverse Adjust the shift cable length if necessary Set the gear shift to the neutral position Loosen the locknut D remove the clip and then disconnect the shift cable joint 4 Adgjust the position of the shift lever until the pin on the lever is aligned with the line on the shift position switch plate 4 Align the center of the set pin 8 with the alignment mark on the bottom cowl ing 63PSF11 Control system 2 ee 2 N S63P3140 a S63P3270 6 Adjust the position of the shift cable joint until its hole is aligned with the set pin 3 Attach the special service tool to spark plug wire 1 Bo dI 5693370 S
212. y risk when working with lubricants 1 Maintain good standards of personal and industrial hygiene 2 Change and wash clothing as soon as possible if soiled with lubricants 3 Avoid contact with skin Do not for example place a soiled rag in your pocket 4 Wash hands and any other part of the body thoroughly with soap and hot water after contact with a lubricant or lubricant soiled clothing has been made 5 To protect your skin apply a protective cream to your hands before working on the outboard motor 63PSF11 6 Keep a supply of clean lint free cloths for wiping up spills etc Good working practices Special service tools Use the recommended special service tools to protect parts from damage Use the right tool in the right manner do not improvise 5691050 Tightening torques Follow the tightening torque specifications provided throughout the manual When tight ening nuts bolts and screws tighten the large sizes first and tighten fasteners starting in the center and moving outward Non reusable parts Always use new gaskets seals O rings cot ter pins circlips etc when installing or assembling parts 56901060 6 11 Safety while working Disassembly and assembly 1 Use compressed air to remove dust dirt during disassembly Apply engine oil to the contact surfaces of moving parts before assembly 56971070 Install bearings with the manufacture ide
213. ylinders and then tighten the trim cylinder end screws to the specified torque 563 7040 CAUTION lt Make sure that the trim rams are fully extended when installing them Once installed never push the trim rams down otherwise fluid can spurt out Z Trim and tilt wrench New 90890 06587 Current 90890 06548 Trim cylinder end screw 78 N m 7 8 kgf m 57 5 ft lb 5 Install new O rings the valve pin and valve seat assembly onto the tilt cylinder 60 7720 NOTE Refer to the illustration for valve pin and valve seat assembly installation 6 Install the gear pump housing 7 41 S60X7730 Gear pump housing mounting bolt 8 N m 0 8 5 9 ft Ib 7 Install the O ring into the reservoir cap 8 Install the reservoir and O ring onto the gear pump housing S60X7400 Reservoir mounting bolt 5 N m 0 5 3 7 ft lb 9 Fill the tilt cylinder with the recommended fluid to the correct level through the hole as shown 560 7740 Recommended power trim tilt fluid ATF Dexron II 63PSF11 10 Install the tilt piston assembly into the tilt cylinder and then tighten the tilt cylinder end screw to the specified torque 60X7750 563 7060 CAUTION lt Make sure that the tilt ram is fully extended when installing it Once installed never push the tilt ram down otherwise fluid can spurt out Trim and tilt wrench

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