BFT 75 A

BFT 75A/90A
BFT 75A
BFT 90A
BFT 75A
BFT 90A OB No.62ZY950US
14-01 NB OB No.62ZY950US
Printed in Japan 14-01 NB
BFT75-90AUS_Cover_140207.indd 1 14/02/07 10:56
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Introduction
Before reading this manual

This service manual provides information that is needed for inspection, service and repair of applicable
outboard motors. For our customers' safe and comfortable use of the products for long term, it is essential to
maintain the performance and quality of the outboard motors. To ensure this, the maintenance and service
have to be done properly by service technicians with fundamental knowledge and skills. This manual is
utilized so that our customers can always use their outboard motor with full satisfaction.
As this document contains information from the Honda Motor's Service Manual, the document contains
information about models that are not sold by our company. Additionally, the model names and part numbers
of the special tools mentioned in this document are the names and numbers used by Honda Motor Co., Ltd.
Please alter the model names and part numbers as follows.
Change model names with "BF" to "BFT".

Example: BF*** -> BFT***
Add "HCO-" at the beginning of part numbers of special tools.

Example: 07GD-0010100-OS -> HT07GD-0010100-OS

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How to use this manual

A few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage
this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use of special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not
recommended by Honda must determine the risks to their personal safety and the safe operation of this product.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer’s Safety
Proper service and maintenance are essential to the customer’s safety and the reliability of this product. Any error or oversight
while servicing this product can result in faulty operation, damage to the product, or injury to others.
Improper service or repairs can create an unsafe

condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and

precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around
pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure
that the hoist hook is securely attached to the product.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers, and clothing are out of the
way.
Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never store gasoline in an open container.
• Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.
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CONTENTS
SPECIFICATIONS 1
SERVICE INFORMATION 2
MAINTENANCE 3
TROUBLESHOOTING 4
FUEL SYSTEM 5
ENGINE COVER 6
CHARGING SYSTEM 7
IGNITION SYSTEM 8
STARTING SYSTEM 9
OTHER ELECTRICAL 10
COOLING SYSTEM 11
LUBRICATION SYSTEM 12
ENGINE REMOVAL/INSTALLATION 13
CYLINDER HEAD 14
CYLINDER BLOCK 15
GEAR CASE 16
MOUNT 17
TRIM/TILT 18
CONTROLS 19
TECHNICAL FEATURES 20
WIRING DIAGRAMS 21
INDEX

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INTRODUCTION
This manual covers the service and repair procedures for the Honda BF75DK3/BF80A/BF90DK4/BF100A outboard motors.
All information contained in this manual is based on the latest product information available at the time of printing. We reserve the
right to make changes at anytime without notice.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, by any means, electronic,
mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher. This includes text, figures, and
tables.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to this Honda product, other property, or the environment.
SAFETY MESSAGES
Your safety and the safety of others are very important. To help you make informed decisions, we have provided safety messages
and other safety information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards
associated with servicing these products. You must use your own good judgement.
You will find important safety information in a variety of forms, including:
• Safety Labels – on the product.
• Safety Messages – preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.

• Instructions – how to service these products correctly and safely.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS, AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda
Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT
INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF
MAINTENANCE ON Honda PRODUCTS.
© Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: January 2014
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SERVICE RULES
• Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design
specifications may damage the unit.
• Use the special tools designed for the product.
• Install new gaskets, O-rings, etc. when reassembling.
• When torquing bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the specified torque diagonally, unless
a particular sequence is specified.
• Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before assembly.
• After assembly, check all parts for proper installation and operation.
• Many screws used in this machine are self-tapping. Be aware that cross-threading or overtightening these screws will strip the
threads and ruin the hole.
Use only metric tools when servicing this unit. Metric bolts, nuts and screws are not interchangeable with non-metric fasteners. The
use of incorrect tools and fasteners will damage the unit.
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it will be explained specifically in the text without the use of the symbols.
Replace the part(s) with new one(s) before assembly.
Use the recommend engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).
Use marine grease (water resistant urea based grease).
Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
Apply sealant.
Use automatic transmission fluid.
( x )( ) Indicates the diameter, length, and quantity of metric bolts used.

page 1-1 Indicates the reference page.

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ABBREVIATIONS
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbreviated term Full term
AAT Ambient Air Temperature
ACG Alternator
API American Petroleum Institute
Assy. Assembly
ATDC After Top Dead Center
ATF Automatic Transmission Fluid
ATT Attachment
BAT Battery
BDC Bottom Dead Center
BTDC Before Top Dead Center
BARO Barometric Pressure
CKP Crankshaft Position
Comp. Complete
CMP Camshaft Position
CYL Cylinder
DLC Data Link Connector
EBT Engine Block Temperature
ECT Engine Coolant Temperature
ECM Engine Control Module
EMT Exhaust Manifold Temperature
EOP Engine Oil Pressure
EVAP Evaporative
EX Exhaust
F Front or Forward
GCU Generator Control Unit
GND Ground
HO2S Heated Oxygen Sensor
IAC Idle Air Control
IAT Intake Air Temperature
I.D. Inside Diameter
IG or IGN Ignition
IN Intake
INJ Injection
L. Left
MAP Manifold Absolute Pressure
MIL Malfunction Indicator Lamp
O.D. Outside Diameter
OP Optional Part
PGM-FI Programmed-Fuel Injection
P/N Part Number
Qty Quantity
R. Right
SAE Society of Automotive Engineers
SCS Service Check Signal
STD Standard
SW Switch
TDC Top Dead Center
Bl Black G Green Br Brown Lg Light green

Y Yellow R Red O Orange P Pink
Bu Blue W White Lb Light blue Gr Gray
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HOW TO READ A WIRING DIAGRAM & RELATED INFORMATION
The wiring diagram, connector general layout drawing, connector drawings, and the symbols used in troubleshooting are explained
in this section.
HOW TO READ CONNECTOR DRAWINGS
Connector drawings show the terminal arrangement, terminal No., number of pins, and the shape of terminal (male or female).
Both the male and female connectors are shown for the common connectors, while only the main wire harness side connectors are
shown for the dedicated connectors.
The double frame connectors represent the male connectors and the single frame connectors represent the female connectors.
Both the male and female connectors are shown by viewing them from the terminal side.
FEMALE CONNECTOR VIEWING DIRECTION
LOCK
VIEWING DIRECTION MALE CONNECTOR
TERMINAL ARRANGEMENT CONNECTOR No.

The connector drawing shows the terminal arrangement of
the connector with the lock of the connector UP.
FEMALE CONNECTOR DRAWING

(SINGLE FRAME)
Female connector viewed from the
terminal side.
CONNECTOR No.
LOCK
MALE CONNECTOR DRAWING
(DOUBLE FRAME)
Male connector viewed from the
terminal side.
TERMINAL No.
The system drawing shows the No.9 terminal of
the connector.

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HOW TO READ A WIRING DIAGRAM
SYMBOL OF TERMINAL
It shows the shape of each terminal to identify
whether it is a male or female terminal.
TERMINAL No.
3*0),0$,15(/$<
67$57(5
:%O
%O%X
%O:
:<
:
ղ)86( ն)86(
:
㸦$㸧㸦$㸧
%O:
%X
:
:
7
%O
:
7
&
67$57(5
%$77(5< 02725
:%O
%O:
7
*1'
23
:%O
%O:
%X
%O
%$7 :%O

%O
67 %O%X
%O
%O:

&20%,1$7,21
6:,7&+
*1'
%O:
:%O
1(875$/ -2,17&211(&725
6:,7&+
CONNECTOR/TERMINAL No.
Indicates the ground. Every connector and terminal has a number to help the users find the location and shape of
(Circled GND followed with No. in the connector and the terminal arrangement by referring to the “Connector general layout
white background) drawing” and/or the “Connector drawing.” All the connector/terminal numbers shown in this
Service Manual are either of those shown in this section.
: Connector that joins a harness to a harness (Circled No. in black background)

: Connector that connects to electrical equipment (Circled No. in white background)
: Connector (Circled C followed with No. in white background)
: Terminal (Circled T followed with No. in white background)
: Ground (Circled GND followed with No. in white background)
0-7
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1. SPECIFICATIONS
SERIAL NUMBER LOCATION ················· 1-2 DIMENSIONAL DRAWING ······················ 1-7
SPECIFICATIONS·································· 1-2

1-1
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SPECIFICATIONS
SERIAL NUMBER LOCATION
SPECIFICATIONS
The engine serial number is stamped on the right side of cylinder block and the product identification number is located on the right
stern bracket. Always specify these numbers when inquiring about the engine or when ordering parts in order to obtain the correct
parts for the outboard motor being serviced.
ENGINE SERIAL NUMBER PRODUCT IDENTIFICATION NUMBER
SPECIFICATIONS
DIMENSIONS AND WEIGHTS
Model BF75DK3
Description code BBAJ
Type LHGX LRTA LRTC LRTX
Overall length 904 mm (35.6 in) 746 mm (29.4 in)
Overall width 646 mm (25.4 in) 449 mm (17.7 in)
Overall height 1,566 mm (61.7 in)
Dry weight (*1) 167 kg (368 lbs) 165 kg (364 lbs)
Operating weight 172 kg (379 lbs) 170 kg (375 lbs)
(including oil)
*1: Including the propeller weight: 3.0 kg (6.6 lbs)
Model BF80A
Description code BBLJ
Type LHTD LRTL LRTD XRTL
Overall length 904 mm (35.6 in) 746 mm (29.4 in)
Overall width 646 mm (25.4 in) 449 mm (17.7 in)
Overall height 1,566 mm (61.7 in) 1,693 mm (66.7 in)
Dry weight (*1) 171 kg (377 lbs) 165 kg (364 lbs) 171 kg (377 lbs)
Operating weight 176 kg (388 lbs) 170 kg (375 lbs) 176 kg (388 lbs)
(including oil)
Model BF90DK4
Description code BBCJ
Type LHGX LRTA LRTC XRTA XRTC
Overall length 904 mm 746 mm
(35.6 in) (29.4 in)
Overall width 646 mm 449 mm
(25.4 in) (17.7 in)
Overall height 1,566 mm 1,693 mm
(61.7 in) (66.7 in)
Dry weight (*1) 168 kg 166 kg 172 kg
(370 lbs) (366 lbs) (379 lbs)
Operating weight 173 kg 171 kg 177 kg
(including oil) (381 lbs) (377 lbs) (390 lbs)
1-2
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SPECIFICATIONS
Model BF90DK4
Description code BBCJ
Type LHTD LRTL LRTD XRTL XRTD
(35.6 in) (29.4 in)
(25.4 in) (17.7 in)
(61.7 in) (66.7 in)
(379 lbs) (366 lbs) (379 lbs)
Model BF100A
Description code BBMJ
(35.6 in) (29.4 in)
(25.4 in) (17.7 in)
(61.7 in) (66.7 in)
(379 lbs) (366 lbs) (379 lbs)

1-3
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SPECIFICATIONS
FRAME
Model BF75DK3 BF80A
Type LHGX LRTA LRTC LRTX LHTD LRTL LRTD XRTL
Transom height (*1) 537 mm 664 mm
(21.1 in) (26.1 in)
Tilting angle (*1) 68°
Tilting stage Stageless
Trim angle (*1) – 4° to 16°
Swivel angle 30° right and left
Shaft length type L XL
Remote control box X ( ) X ( ) ( )
Long tiller handle X X X X X X
Power trim/tilt X
Gas assist tilt X X X X X X X
Tachometer ( ) ( ) ( ) ( ) ( )
Trim meter ( ) ( ) ( ) ( ) ( )
Fuel tank ( ) ( ) ( ) ( )
*1: Transom angle is at 12°
( ): Optional part
Model BF90DK4
Type LHGX LRTA LRTC XRTA XRTC
(21.1 in) (26.1 in)
Remote control box X ( ) ( )
Long tiller handle X X X X
Power trim/tilt X
Gas assist tilt X X X X
Tachometer ( ) ( ) ( )
Trim meter ( ) ( ) ( )
Fuel tank ( ) ( ) ( ) ( )
( ): Optional part
Model BF90DK4
(21.1 in) (26.1 in)
Power trim/tilt
Gas assist tilt X X X X X
Fuel tank ( ) ( )
( ): Optional part
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SPECIFICATIONS
Model BF100A
(21.1 in) (26.1 in)
Power trim/tilt
Gas assist tilt X X X X X
Fuel tank ( ) ( )
( ): Optional part
ENGINE
LRTA/XRTA/LRTC/XRTC type
Model BF75DK3 BF90DK4

Description code BEBAJ BEBCJ
Type 4-stroke, S.O.H.C., 4 cylinder
Displacement 1,497 cm3 (91.3 cu in)
Bore x stroke 73.0 x 89.4 mm (2.87 x 3.52 in)
Rated power 55.9 kW (75 HP) at 5,500 min-1 (rpm) 67.1 kW (90 HP) at 5,800 min-1 (rpm)
Maximum torque 118 N·m (12.0 kgf·m, 87 lbf·ft) 123 N·m (12.5 kgf·m, 91 lbf·ft)
Compression ratio 9.7: 1
Fuel consumption ratio 340 g/kW·h 350 g/kW·h
(at rated power)
Cooling system Forced water circulation by impeller pump with thermostat
Ignition system Fully transistorized, battery ignition
Ignition timing 2.4°at 750 min-1 (rpm) A.T.D.C
Spark plug Standard ZFR6K–9E (NGK)
Optional IZFR6K–11E (NGK)
Fuel supply system Programmed fuel injection
Fuel injection system Electronic control
Fuel injection nozzle Multi-point type
Fuel Unleaded gasoline
Fuel pump Electric and mechanical plunger type
Lubrication system Pressure lubrication by trochoid pump
Lubrication capacity 4.7 liter (5.0 US qt, 4.1 Imp qt)
[Without oil filter replacement: 4.2 liter (4.4 US qt, 3.7 Imp qt)]
[With oil filter replacement: 4.4 liter (4.6 US qt, 3.9 Imp qt)]
Starter system Electric starter
Exhaust system Water exhaust

1-5
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SPECIFICATIONS
LRTA/XRTA/LRTC/XRTC type
Model BF75DK3 BF80A BF90DK4 BF100A

Description code BEBAJ BEBLJ BEBCJ BEBMJ
Type 4-stroke, S.O.H.C., 4 cylinder
Displacement 1,496 cm3 (91.3 cu in)
Bore x stroke 73.0 x 89.4 mm (2.87 x 3.52 in)
Rated power 55.2 kW (75 PS) 58.8 kW (80 PS) 66.2 kW (90 PS) 73.6 kW (100 PS)
at 5,500 min-1 at 5,500 min-1 at 5,800 min-1 at 5,900 min-1
(rpm) (rpm) (rpm) (rpm)
Maximum torque 118 N·m 123 N·m 127 N·m
(12.0 kgf·m, 87 lbf·ft) (12.5 kgf·m, (13.0 kgf·m,
91 lbf·ft) 94 lbf·ft)
Compression ratio 9.7: 1
Fuel consumption ratio 340 g/kW·h 355 g/kW·h 350 g/kW·h 330 g/kW·h
(at rated power)
Cooling system Forced water circulation by impeller pump with thermostat
Ignition system Fully transistorized, battery ignition
Ignition timing 2.4°at 750 min-1 (rpm) A.T.D.C
Spark plug Standard ZFR6K–9E (NGK)
Optional IZFR6K–11E (NGK)
Fuel supply system Programmed fuel injection
Fuel injection system Electronic control
Fuel injection nozzle Multi-point type
Fuel Unleaded gasoline
Fuel pump Electric and mechanical plunger type
Lubrication system Pressure lubrication by trochoid pump
Lubrication capacity 4.7 liter (5.0 US qt, 4.1 Imp qt)
[Without oil filter replacement: 4.2 liter (4.4 US qt, 3.7 Imp qt)]
[With oil filter replacement: 4.4 liter (4.6 US qt, 3.9 Imp qt)]
Starter system Electric starter
Exhaust system Water exhaust
LOWER UNIT
Clutch Dog clutch (Forward – Neutral – Reverse)
Gear ratio Forward 2.33 (28/12)
Reverse 2.33 (28/12)
Reduction Spiral bevel gear
Gear case oil capacity 0.95 liter (1.00 US qt, 0.84 Imp qt)
Propeller rotating direction Clockwise (viewed from rear)
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SPECIFICATIONS
DIMENSIONAL DRAWING
REMOTE CONTROL TYPE
365 (14.4) Unit: mm (in)
30°
746 (29.4) 449 (17.7)
76.2 (3.0) 48.4 (1.91)

R8
07
(
596 (23.5)
31
.8)
44 (1.7)
X type: 1,693 (66.7)
L type: 1,566 (61.7)
X type: 664 (26.1)

L type: 537 (21.1)
.6)
(41 6.2)
6 (4
1,05 74
R , 1
e : R1
typ pe: 12°
L ty
X

1-7
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SPECIFICATIONS
LONG TILLER HANDLE TYPE
Unit: mm (in)
1,407 (55.4)
5.2)
348 (13.7)
5 (3
R 89
30°
648 (25.5)
30°
904 (35.6)
746 (29.4) 153 (6.0)
76.2 (3.0) 449 (17.7)

R8
596 (23.5)
07
728 (28.7)
(3
1.8
)
(1.7)
44
1,566 (61.7)
6)
41.
537 (21.1)
(
56
R 1,0
12°
1-8
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SPECIFICATIONS
Propeller shaft
ANSI INV.S.16/32 x 15T x 30°
(Ø1.2 -0.0016 )
-0.004 )
-0.002 )
-0.0008
+0.001
-0.020
-0.041
+0.03
-0.04
-0.1
M18 x 1.5
0
(Ø0.98
(Ø0.67
Ø24.9
Ø30
Ø16.9
30° +1°
0°
Ø4
(Ø0.2)
7 mm
(0.3 in)
28.5 mm 57.5 ± 0.5 mm 60 mm

(1.12 in) (2.26 ± 0.02 in) (2.36 in)
154.5 mm (6.1 in)

1-9
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MEMO

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2. SERVICE INFORMATION
MAINTENANCE STANDARDS ················· 2-2 TOOLS ·············································· 2-12
ENGINE & FRAME TORQUE VALUES ······ 2-4 CABLE/HARNESS ROUTING ················ 2-18
STANDARD TORQUE VALUES ··············· 2-7 TUBE ROUTING ·································· 2-43
LUBRICATION & SEAL POINT ················ 2-8

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SERVICE INFORMATION
MAINTENANCE STANDARDS
SERVICE INFORMATION
ENGINE
Unit: mm (in)
Part Item Standard Service limit
Engine Idle speed (in neutral) 750 ± 50 min-1 (rpm) –
Trolling speed 650 – 1,000 min-1 (rpm) –
Cylinder compression 1.45 – 1.65 MPa 0.93 MPa
(14.8 – 16.8 kgf/cm2, 211 – 239 psi) (9.5 kgf/cm2, 135 psi)
at 300 min-1 (rpm)
Compression gap between cylinders – 0.2 MPa
(2.0 kgf/cm2, 28 psi)
Spark plugs Gap Standard 0.80 – 0.90 (0.031 – 0.035) –
Optional 1.00 – 1.10 (0.039 – 0.043) 1.30 (0.051)
Valves Valve clearance IN 0.15 – 0.19 (0.006 – 0.007) –
EX 0.26 – 0.30 (0.010 – 0.012) –
Stem O.D. IN 5.480 – 5.490 (0.2157 – 0.2161) 5.450 (0.2146)
EX 5.450 – 5.460 (0.2146 – 0.2150) 5.420 (0.2134)
Overall length IN 118.55 – 119.15 (4.667 – 4.691) –
EX 117.25 – 117.85 (4.616 – 4.640) –
Valve O.D IN 27.85 – 28.15 (1.096 – 1.108) –
EX 22.85 – 23.15 (0.900 – 0.911) –
Stem-to-guide IN 0.020 – 0.050 (0.0008 – 0.0020) 0.080 (0.0032)
clearance EX 0.050 – 0.080 (0.0020 – 0.0032) 0.110 (0.0043)
Valve seats Seat width IN 0.85 – 1.15 (0.033 – 0.045) 1.60 (0.063)
EX 1.25 – 1.55 (0.049 – 0.061) 2.00 (0.079)
Seat installation height IN 46.0 – 46.6 (1.81 – 1.83) 46.9 (1.85)
EX 46.1 – 46.7 (1.81 – 1.84) 47.0 (1.85)
Valve guides Guide I.D. IN/EX 5.51 – 5.53 (0.217 – 0.218) 5.55 (0.219)
Guide installation height IN/EX 15.85 – 16.35 (0.624 – 0.644) –
Valve springs Free length IN 48.54 (1.911) –
EX 55.29 (2.177) –
Rocker arms Rocker arm I.D. IN/EX 20.012 – 20.030 (0.7879 – 0.7886) –
Rocker arm shaft O.D. 19.972 – 19.993 (0.7863 – 0.7871) –
Rocker arm-to-rocker IN/EX 0.019 – 0.058 (0.0007 – 0.0023) 0.080 (0.0032)
arm shaft clearance
Pistons Skirt O.D. 72.98 – 72.99 (2.873 – 2.874) 72.97 (2.873)
Piston-to-cylinder clearance 0.01– 0.04 (0.0004 – 0.0016) 0.05 (0.0020)
Pin bore I.D. 18.010– 18.014 (0.7091 – 0.7092) –
Ring groove width Top 1.050 – 1.060 (0.0413 – 0.0417) –
Second 1.220 – 1.230 (0.0480 – 0.0484) –
Oil 2.005 – 2.020 (0.0789 – 0.0795) –
Piston pins Pin O.D. 17.996 – 18.000 (0.7085 – 0.7087) –
Pin-to-pin bore clearance 0.010 – 0.018 (0.0004 – 0.0007) 0.020 (0.0008)
Piston rings Ring side clearance Top 0.065 – 0.090 (0.0026 – 0.0035) 0.150 (0.0059)
Second 0.030 – 0.055 (0.0012 – 0.0022) 0.130 (0.0051)
Ring end gap Top 0.15 – 0.30 (0.006 – 0.012) 0.60 (0.024)
Second 0.35 – 0.50 (0.014 – 0.020) 0.65 (0.026)
Oil 0.20 – 0.70 (0.008 – 0.028) 0.80 (0.031)
Ring thickness Top 0.970 – 0.985 (0.0382 – 0.0388) –
Second 1.175 – 1.190 (0.0463 – 0.0469) –
Cylinder head Warpage 0.08 (0.003) Max. 0.08 (0.003) Min.
Camshaft journal I.D. 41.995 – 42.019 (1.6533 – 1.6543) –
Head height 119.9 – 120.1 (4.72 – 4.73) –
Cylinder block Cylinder sleeve I.D. 73.00 – 73.02 (2.874 – 2.875) 73.07 (2.877)
Difference between top and bottom – 0.05 (0.002)
points of sleeve I.D.
Warpage 0.07 (0.003) Max 0.10 (0.004)
2-2
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SERVICE INFORMATION
Unit: mm (in)
Connecting Small end I.D. 17.964 – 17.977 (0.7072 – 0.7078) –
rods Small end-to-piston pin clearance 0.019 – 0.036 (0.0007 – 0.0014) –
Big end axial clearance 0.15 – 0.35 (0.006 – 0.014) 0.40 (0.016)
Connecting rod big end oil clearance 0.020 – 0.038 (0.0008 – 0.0015) 0.050 (0.0020)
Difference between upper and lower 0 – 0.05 (0 – 0.002) 0.05 (0.002)
parts of connecting rod bolt O.D.
Crankshaft Journal Main 49.976 – 50.000 (1.9676 – 1.9685) –
O.D. Pin 39.976 – 40.000 (1.5739 – 1.5748) –
Journal cylindicity (Main/Pin) 0.005 (0.0002) Max. 0.010 (0.0004)
Journal roundness (Main/Pin) 0.005 (0.0002) Max. 0.010 (0.0004)
Crankshaft runout 0.03 (0.001) Max. 0.04 (0.002)
Crankshaft main bearing oil clearance 0.018 – 0.036 (0.0007 – 0.0014) 0.050 (0.0020)
Thrust washer side clearance 0.10 – 0.35 (0.004 – 0.014) 0.45 (0.018)
Camshaft Camshaft axial clearance 0.05 – 0.25 (0.002 – 0.010) 0.50 (0.020)
Camshaft runout 0.03 (0.001) Max 0.04 (0.002)
Journal O.D. 41.935 – 41.950 (1.6510 – 1.6516) –
Cam BF75D/ IN 34.070 – 34.375 (1.3413 – 1.3533) 33.870 (1.3335)
height BF80A EX 35.223 – 35.508 (1.3867 – 1.3979) 35.023 (1.3789)
BF90D/ IN (PRI) 35.422 – 35.707 (1.3946 – 1.4058) 35.222 (1.3867)
BF100A IN (SEC) 34.710 – 34.995 (1.3665 – 1.3778) 34.510 (1.3587)
EX 35.223 – 35.508 (1.3867 – 1.3979) 35.023 (1.3789)
Camshaft oil clearance 0.045 – 0.084 (0.0018 – 0.0033) 0.100 (0.0039)
Fuel injector Resistance 9 – 11 Ω –
Oil pump Body I.D. 80.00 – 80.04 (3.150 – 3.151) –
Inner rotor-to-outer rotor clearance 0.02 – 0.16 (0.001 – 0.006) 0.20 (0.008)
Outer rotor-to-oil pump body clearance 0.10 – 0.19 (0.004 – 0.007) 0.23 (0.009)
Outer rotor height 17.98 – 18.00 (0.708 – 0.709) 17.96 (0.707)
Pump body depth 18.04 – 18.07 (0.710 – 0.711) –
Outer rotor - to-oil body side clearance 0.04 – 0.09 (0.002 – 0.004) 0.12 (0.005)
Vapor Float height 26 – 31 (1.0 – 1.2) –
separator
Fuel pump Discharge volume (with pump operated 20 cm3 –
for 2 sec. at 12 V) (0.7 US oz, 0.7 lmp oz) or more
Fuel pressure 325 – 375 kPa –
(3.3 – 3.8 kgf/cm2, 47 – 54 psi)
Alternator Stator resistance 0.09 – 0.14 Ω –
Starter motor Brush length 12.3 (0.48) 7.0 (0.28)
Insulator length (Micha depth) 0.40 – 0.50 (0.016 – 0.020) 0.20 (0.008)
Commutator O.D. 29.4 (1.16) 28.8 (1.13)
Commutator runout – 0.10 (0.004)
Thermostat Cylinder Begin to open 48 – 52 °C (118 °F – 126 °F) –
head side Full open 60 °C (140 °F) –
Valve lift more than 3.0 (0.12) –
Cylinder Begin to open 58 – 62 °C (136 °F – 144 °F) –
block side Full open 70 °C (158 °F) –
Valve lift more than 3.0 (0.12) –
EBT sensor/ Resistance 40°C /104 °F 1.0 – 1.3 kΩ –
ECT sensor 100°C/212 °F 0.1 – 0.2 kΩ –
IAT sensor Resistance 40°C /104 °F 1.0 – 1.3 kΩ –
VTEC solenoid Resistance 14 – 16 Ω –
valve
IAC valve Resistance 10 – 13 Ω –
HO2S heater Resistance 11.7 – 15.6 Ω –
PRI: Primary, SEC: Secondary

2-3
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SERVICE INFORMATION
FRAME
Unit: mm (in)
Propeller shaft Shaft O.D. At forward bevel gear 24.987 – 25.000 (0.9837 – 0.9843) 24.966 (0.9829)
bearing
At needle 30.007 – 30.020 (1.1814 – 1.1819) 29.986 (1.1805)
bearing
Runout 0.02 (0.001) or below –
Vertical shaft Shaft O.D. (at needle bearing) 28.566 – 28.575 (1.1246 – 1.1250) 28.545 (1.1238)
Runout 0.30 (0.012) or below –
Propeller/gear case Forward bevel gear backlash 0.10 – 0.28 (0.004 – 0.011) –
Power trim/tilt Lower chamber hydraulic pressure 8,826 – 11,768 kPa
assembly (90 – 120 kgf/cm2, 1,280 – 1,707 psi)
(Except LHGX type) Upper chamber hydraulic pressure 3,923 – 7,355 kPa (40 – 75 kgf/cm2, 569 – 1,067 psi)
Power tilt motor Brush length 9.8 (0.39) 4.8 (0.19)
assembly Mica depth – 0.5 (0.02)
(Except LHGX type)
Trim angle sensor Resistance Between 4.0 – 6.0 kΩ
(Except LHGX type) Light green – Black
–
Between 2.7 – 4.3 kΩ
Yellow/Blue – Black
ENGINE & FRAME TORQUE VALUES

Use standard torque values for fasteners that are not listed in this table.
ENGINE
Thread Dia. and pitch Torque values
Item Remarks
mm (in) N·m kgf·m lbf·ft
Crankcase bolt M10 x 1.25 – – – See page 15-13
Cylinder block sealing bolt M24 x 1.5 54 5.5 40
Cylinder head bolt M9 x 1.25 – – – See page 14-20
Cylinder head sealing bolt M14 x 1.5 29 3.0 21
Cylinder head sealing bolt M20 x 1.5 49 5.0 36
Cylinder head sealing screw PT 1/8 17 1.7 13
Spark plug M14 x 1.25 18 1.8 13
Connecting rod bolt M6 x 0.75 – – – See page 15-13
Tensioner pivot bolt M8 x 1.25 22 2.2 16
Cam chain driven sprocket bolt M10 x 1.5 61 6.2 45 Apply engine oil to the
threads and seating
surface.
Intake side valve adjusting lock nut M7 x 0.75 20 2.0 15 Apply engine oil to the
(BF90D/BF100A) threads and seating
surface.
Exhaust side valve adjusting lock M7 x 0.75 14 1.4 10 Apply engine oil to the
nut (BF90D/BF100A) threads and seating
surface.
Valve adjusting lock nut (BF75D/ M7 x 0.75 14 1.4 10 Apply engine oil to the
BF80A) threads and seating
surface.
Oil filter cartridge M20 x 1.5 12 1.2 9
Oil filter holder M22 x 1.5 49 5.0 36 Apply engine oil to the
threads and seating
surface.
Oil drain plug bolt M12 x 1.5 23 2.3 17
Rocker shaft bolt M8 x 1.25 29 3.0 21 Apply engine oil to the
threads and seating
surface.
Cam pulse plate bolt M14 x 1.5 34 3.5 25
Throttle body mounting bolt M8 x 1.25 22 2.2 16
IAC valve mounting bolt M8 x 1.25 22 2.2 16
Engine mounting bolt/nut M8 x 1.25 27 2.8 20
(Mount case side)
2-4
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SERVICE INFORMATION
Item Remarks
Flywheel bolt M12 x 1.0 103 10.5 76 Apply engine oil to the
threads and seating
surface.
Alternator rotor bolt M14 x 1.5 – – – See page 7-9
Starter motor bolt M10 x 1.25 44 4.5 32
EOP sensor M10 x 1.25 22 2.2 16
EBT sensor/ECT sensor M10 x 1.25 12 1.2 9 Apply sealant to the
threads and seating
surface.
HO2S M18 x 1.5 42 4.3 31
Knock sensor M12 x 1.25 31 3.2 23
(BF90D/BF100A only)
ECM mounting bolt M6 x 1.0 5 0.51 3.7
Air flow band bolt M5 x 0.8 – – – See page 5-68
Oil case bolt M8 x 1.25 21.5 2.2 16
Water tube joint PT 1/8 9 0.92 6.6 Apply sealant to the
threads and seating
surface.
Fuel pump service check bolt M6 x 1.0 11.8 1.2 9
Pressure regulator bolt M6 x 1.0 11.8 1.2 9
Fuel pump case bolt M6 x 1.0 11.8 1.2 9
Fuel pump cover screw M5 screw 3.4 0.35 2.5
Vapor separator cover M5 screw 3.4 0.35 2.5
screw/washer
Fuel pump strainer cover M5 screw 3.4 0.35 2.5
screw/washer
Fuel pump harness holder mounting M4 screw 2.1 0.21 1.5
screw
Vapor separator water jacket M4 screw 2.1 0.21 1.5
screw/washer
Vapor separator float screw M4 screw 2.1 0.21 1.5
Vapor separator drain screw M6 screw 1.5 0.15 1.1
Fuel injector clip bolt M6 x 1.0 9 0.92 6.6
Water separator body M5 screw 3.4 0.35 2.5
Oil pump sealing bolt M18 x 1.25 39.2 4.0 29
GEAR CASE
Item Remarks
Gear case bolt M10 x 1.25 34 3.5 25
(LRT/LHT/LHG type)
Gear case self-lock nut M10 x 1.25 34 3.5 25
(XRT type)
Pinion gear nut M16 x 1.0 103 10.5 76 Apply gear oil in to the
threads and seating
surface.
Oil check bolt M8 x 1.25 6.5 0.66 4.8
Oil drain plug bolt M8 x 1.25 6.5 0.66 4.8
Impeller housing bolt/washer M8 x 1.25 19.7 2.0 15
Water screen screw M5 x 0.8 1.0 0.10 0.7
Propeller castle nut M18 x 1.5 – – – See page 16-3
Gear case cover B bolt M6 x 1.0 12 1.2 9
64 mm lock nut M64 x 1.5 123 12.5 91 Apply gear oil in to the
threads and seating
surface.
EXTENSION/MOUNT CASE
Item Remarks
Lower rubber mount nut M12 x 1.25 83 8.5 61
Upper rubber mount nut M12 x 1.25 83 8.5 61

2-5
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SERVICE INFORMATION
STERN BRACKET
Item Remarks
Stern bracket self lock nut M25 x 2.0 34 3.5 25
Stern bracket self lock nut 7/18-14UNF 34 3.5 25
Grease fitting M6 x 1.0 3 0.31 2.2
POWER TRIM/TILT (Except LHGX type)

Item Remarks
Cylinder cap – 207.5 21.2 153 Apply marine grease
to the threads.
Rod guide – 139.5 14.2 103 Apply marine grease
to the threads.
Manual valve M14 x 1.5 3.4 0.35 2.5
Socket bolt A and B – 8.3 0.85 6.1
Power tilt motor mounting bolt/ 1/4 – 20 UNF 4.9 0.50 3.6
washer
Power tilt motor wire holder screw M4 screw 1.4 0.14 1.0
Oil tank mounting bolt/washer – 4.9 0.50 3.6
Oil tank cap – 2.5 0.25 1.8
STEERING ROD/REMOTE CONTROL BOX
Item Remarks
Steering rod nut 3/8-24 UNF 22 2.2 16
Remote control box cover C screw M5 tapping screw 2.5 0.26 1.8
Fast idle lever screw M5 screw 4.9 0.50 3.6
Power tilt cord clamp screw M5 tapping screw 0.7 0.07 0.5
Emergency stop switch nut M16 x 1.0 1.5 0.15 1.1
Combination switch nut M22 x 1.0 4.9 0.50 3.6
Spring set plate screw M5 tapping screw 2.5 0.26 1.8
Link joint bracket screw M6 x 1.0 5.9 0.60 4.4 Apply locking agent to
the seating surface.
Link joint bracket nut M5 x 0.8 4.9 0.50 3.6
Control wheel bolt M8 x 1.25 23.5 2.4 17
Neutral switch spacer screw M5 tapping screw 2.5 0.26 1.8
Neutral lock block screw M6 tapping screw 2.5 0.26 1.8
Lever setting plate screw M5 x 0.8 4.9 0.50 3.6
Remote control lever grip screw M5 tapping screw 2.5 0.26 1.8
TILLER HANDLE
Item Remarks
Steering bracket bolt M12 x 1.25 29 3.0 21
Under cover screw M5 screw 2.4 0.24 1.8
Cable/clamp bracket bolt M6 x 1.0 7 0.71 5.2 Apply locking agent to
Connector bracket bolt M6 x 1.0 7 0.71 5.2
Combination switch nut M22 x 1.0 3.9 0.40 2.9
Emergency stop switch nut M16 x 1.0 1.2 0.12 0.9
Grip pipe bolt M6 x 1.0 7 0.71 5.2
Throttle cable pivot nut M5 x 1.0 1.3 0.13 1.0
Switch holder bolt M5 x 1.0 4.5 0.46 3.3
Guide plate bolt M5 x 1.0 4.5 0.46 3.3
Shift frame bolt/washer M6 x 1.0 7 0.71 5.2
2-6
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SERVICE INFORMATION
OTHERS
Item Remarks
Neutral switch nut M20 x 1.0 2.5 0.26 1.8
Starter motor B terminal nut M8 x 1.25 11 1.1 8
PGM-FI/Main relay bolt M6 x 1.0 5 0.51 3.7
Connector bracket C bolt M6 x 1.0 5 0.51 3.7
Front separator cover bolt M6 x 1.0 (Special bolt) 10 1.0 7
Front separator cover bolt M6 x 1.0 (SH bolt) 5 0.51 3.7
Plug maintenance cover bolt M6 x 1.0 (SH bolt) 5 0.51 3.7
Engine under cover bolt M6 x 1.0 10 1.0 7
Under cover rear bracket bolt M6 x 1.0 (Special bolt) 5 0.51 3.7
Water joint cap nut M16 x 1.0 1.1 0.11 0.8 Apply locking agent to
MAP sensor screw M6 x 1.0 3.4 0.35 2.5
STANDARD TORQUE VALUES

Thread Dia. (mm) and Torque values
Item
pitch (length) N·m kgf·m lbf·ft
Screw 5 mm 4.2 0.43 3.1
6 mm 9 0.92 6.6
Bolt and nut 5 mm 5.2 0.53 3.8
6 mm 10 1.0 7
8 mm 21.5 2.2 16
10 mm 34 3.5 25
12 mm 54 5.5 40
Flange bolt and nut 6 mm (SH bolt) 10 1.0 7
6 mm (CT bolt) 12 1.2 9
6 mm 12 1.2 9
8 mm 26.5 2.7 20
10 mm 39 4.0 29
·SH bolt: Small head bolt
·CT bolt: Self-tapping bolt

2-7
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SERVICE INFORMATION
LUBRICATION & SEAL POINT
ENGINE
Material Location Remarks
Engine oil Crankcase mount bolt threads and seating surface
Oil filter holder threads (Cylinder block side)
Cylinder head bolt threads and seating surface
Alternator rotor bolt threads and seating surface
Connecting rod bolt threads and seating surface
Lost motion whole surface (BF90D/BF100A only)
Locker shaft bolt threads and seating surface
Valve stem seal inner surface
Valve adjusting screw threads
Valve adjusting lock nut threads and seating surface
Cam chain driven sprocket bolt threads and seating surface
Oil pump rotor chamber 5 cc (Suction side)
Flywheel mounting bolt threads and seating surface
Rocker arm piston outer surface
Piston stopper outer surface
Each O-ring outer circumference
Use molybdenum oil solution Cylinder sleeve inner surface
(mixture of the engine oil and Crankshaft main bearing, journal and thrust washer contact
molybdenum grease in a ratio surface
of 1:1) Piston outer surface and piston rings
Piston pin outer surface
Camshaft journal, cam profile and thrust area
Rocker shaft outer surface
Intake/exhaust valve stem (Valve guide sliding surface)
Connecting rod small end inner surface
Engine oil or silicone oil Fuel injector O-ring
(Shinetsu KF 9635 CS) Fuel hose O-ring
Liquid sealant Cylinder block mating surface See page 15-15
(Threebond® 1280B or Chain case mating surface See page 14-12
equivalent) (Cylinder block and cylinder head surface)
Liquid sealant Cylinder head cover packing height deference area See page 14-16
(Threebond® 1215 or Water tube joint threads
equivalent)
Liquid sealant EBT sensor threads and seating surface
(Threebond® 1201 or 1215 or ECT sensor 2, ECT sensor 3 threads and seating surface
equivalent)
Liquid sealant Oil case packing exhaust port sealing surface to oil case See page 12-6
(Threebond® 1211 or and mount case
equivalent) Cylinder head gasket exhaust port sealing surface to See page 14-20
cylinder head and cylinder block
Mount case gasket exhaust port sealing surface to cylinder See page 13-8
block and mount case
Soapy water or industrial parts Each oil seal and water seal outer circumference
cleaner solution (mixture of
the Threebond® 2720C and
water in a ratio of 1:9)
Use marine grease Each oil seal and water seal lip
(water resistant urea based Water tube grommet
grease)
2-8
dummyhead
SERVICE INFORMATION
FRAME
GEAR CASE
Use marine grease Vertical shaft engine side spline
(water resistant urea based Vertical shaft water seal (23 x 36 x 6 mm) lip and between
grease) seals
Vertical shaft bushing inner surface (XRT type)
Water pump liner inner surface
Water pump O-ring
Water pump housing O-ring
Water tube seal ring inner surface
Water tube insertion part
Propeller shaft spline and threads
Propeller shaft water seal (30 x 45 x 7 mm) lip and between
seals
Propeller shaft holder gear case installation part and O-ring
installation part
Propeller shaft holder O-ring
Shift rod water seal (12 x 21 x 6 mm) lip and between seals
Shift rod holder O-ring
Soapy water or industrial parts Vertical shaft water seal (23 x 36 x 6 mm) outer
cleaner solution (mixture of circumference
the Threebond® 2720C and Propeller shaft water seal (30 x 45 x 7 mm) outer
water in a ratio of 1:9) circumference
Shift rod water seal (12 x 21 x 6 mm) outer circumference
Hypoid gear oil SAE #90 Each bearing rotating area
Vertical shaft lock nut (64 mm) threads and seating surface
Pinion gear nut threads and seating surface
Needle bearing rotating area
Engine oil Mount case flange Bushing (14 x 16 x 22.5 mm) outer
circumference
STERN BRACKET MOUNT

Use marine grease Lower cylinder collar outer surface
(water resistant urea based Lower cylinder bushing inner and outer surface
grease) Mount frame shaft and spline
Thrust washer (34 mm)
Wave washer (40 mm)
Swivel case liner
Oil seal (39.5 x 52 x 6 mm) lip and outer surface
Swivel case shaft sliding part
Swivel case tilting shaft sliding part
Swivel case bushing inner and outer surface
Cylinder upper pin outer surface
Cylinder upper bushing inner and outer surface
Detent spring roller
Tilting bracket cam part
Tilting stopper bushing inner and outer surface
Tilting shaft bearing part and threads
Tilting shaft O-ring (15.54 x 2.62 mm)
Thrust receiver thrust sliding part
Swivel shaft circlip installation groove and circlip contact
area of mount frame
Tilting shaft threads (After nuts tighting)
Lower mount center housing spline part

2-9
dummyhead
SERVICE INFORMATION
LINKAGE
Use marine grease Shift rod A spline
(water resistant urea based Shift shaft A oil seal (14 x 26 x 6 mm) lip
grease) Shift shaft A oil seal contact surface and bearing part
Shift shaft B water seal contact surface and bearing part
O-ring (27 x 2 mm)
Seal holder O-ring groove and bearing part and water seal
installation area
Detent spring roller
Shift link bracket shift slide pivot insertion part, and throttle
arm insertion part, and bearing part
Throttle arm shift pivot insertion part, and bearing part, and
throttle link insertion part
Throttle rod throttle body insertion part
Throttle link throttle arm insertion part and throttle plate
insertion part
Throttle plate rotating part and insertion part
Linkage pivot throttle plate insertion part
Shift arm link pin insertion part and click part
Shift pivot bearing part
Link pin outer surface
Shift pivot plate bracket contact part
Shift slide pivot outer surface
Shift link pin outer surface
Soapy water or industrial parts Shift shaft oil seal (14 x 26 x 6 mm) outer
cleaner solution (mixture of circumference
the Threebond® 2720C and
water in a ratio of 1:9)
STEERING CABLE/REMOTE CONTROL BOX

Use marine grease Steering cable sliding area
(water resistant urea based Remote control box cable shift pivot contact area
grease) Fast idle spring sliding area
Fast idle detent roller sliding area
Fast idle detent spring sliding area
Fast idle wheel sliding area
Link joint arm sliding area
Link joint collar sliding area
Sliding plate sliding area
Sliding plate collar sliding area
Shift detent roller sliding area
Shift detent spring sliding area
Control wheel journal and hole area
Friction adjusting bolt sliding surface
Neutral switch spacer sliding area
Neutral lock block sliding area
Neutral release lever sliding area
Shift link arm washer sliding area
Shift link arm bearing part
Use molybdenum disulfide Control wheel and shift link arm sliding area
grease (containing more than
3% molybdenum disulfide,
NLGI #2 or equivalent).
Example:
• Molykote® BR-2 plus
manufactured by Dow
Corning U.S.A.
• Multi-purpose M-2
manufactured by
Mitsubishi Oil, Japan
2-10
dummyhead
SERVICE INFORMATION
TILLER HANDLE
Use marine grease Steering friction rod seating area
(water resistant urea based Tiller handle shift frame side and upper surface
grease) Throttle rod sliding surface
Tiller handle shift arm pin spring outer surface
Shift arm pin outer surface
Shift gear bushing outer surface
Shift gear teeth and roller contact area and steel ball
contact area
Throttle cable pivot sliding surface
Throttle arm fulcrum and pin outer surface
Shift lever O-ring whole surface
Shift lever bushing outer surface
Shift lever sliding surface
Shift lever stopper sliding surface
Tiller handle grip pipe installation part
Throttle friction pad circumference
Throttle cable pin whole surface
Grip pipe inner wall
Steering handle bushing inner surface
Steering bracket washer (12 mm large) whole surface
Steering bracket wave washer whole surface
Steering bracket and tiller handle pivot area
Liquid sealant Tiller handle housing See page 19-35
(Threebond® 1216E or
equivalent)
OTHERS
Use marine grease Extension case grommet water tube insertion part
(water resistant urea based Water mouth nut seat contact area
grease) Flash valve cover O-ring
Liquid sealant Extension case oil case side seal surface See page 16-12
(Threebond® 5222L or
equivalent)
Loctite® PRISM 403 Water joint cap nut seating surface
Loctite® 460 Engine cover seal See page 6-3

2-11
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SERVICE INFORMATION
TOOLS
COMMERCIALLY AVAILABLE TOOLS
ORDERING INFORMATION
These tools are distinguished by the words (Commercially available). They are not available through the American Honda Parts
Development. Most commercially available tools shown in this Shop Manual can be ordered through the Honda Marine Tool and
Equipment Program by calling (888) 424-6857. Refer to the catalog for a complete tool listing.
Tool name Tool number Application
Compression gauge EEPV303A Cylinder compression testing
Leak down tester KLIAT1006M Cylinder leak down
Gear case filler STV-S33
Gear case filling
Adapter, 8 x 1.25 mm STV-334Y
Pressure tester STV-V34
Gear case pressure check
Adapter, 8 x 1.25 mm STV-334Y
Clamps HCP6 Fuel strainer, water separator and fuel pump removal/
installation
Digital multimeter FLU-88 Idle speed/electrical testing
Engine oil pressure gauge SUNMT37A
Oil pressure testing/inspection
Engine oil pressure gauge adapter SUNAT77AH
Engine hanger VSB02C000021 Engine removal/Installation
HO2S wrench, 22 mm S6176 HO2S removal/installation
Valve seat cutter, #123 32° NWY-CU123
Valve seat reconditioning
Solid pilot bar, 5.5 mm NWY-140-5.5
T-wrench, #505 NWY-TW-505
Accessory package, #246 NWY-KACC246
Valve lapper LIL-21100 Valve lapping
Piston ring compressor RC40C Piston installation
Puller, 2 jaw see below
– Pins (2 required) CJ-105-11
– Pressure screw CJ-105-3
Propeller shaft holding during backlash inspection
– Jaws CJ105-6
– Tip CJ-66-15-3
– Yoke CJ-86-1
Heat gun ETB1600 Lower mount center housing removal/installation
Bearing puller OTC 1035 Lower mount center housing removal/installation
Torque angle gauge TA360 Bolt torquing
SPECIAL TOOLS
Attachment, 52 X 55 mm Gauge adapter, 100 mm Ring gear holder
07NAD-P200100 070PJ-ZY30100 070PB-ZY9A100
2-12
dummyhead
SERVICE INFORMATION
Threaded shaft SCS short connector Bearing driver attachment, 30 X 37 mm
07APF-ZY3A300 070PZ-ZY30100 070PD-ZY6A200
Float level gauge Fuel pressure gauge, 0 – 100 psi Driver, 40 mm I.D.
07401-0010000 07406-004000B 07746-0030100
Oil pressure gauge attachment Stem seal driver Remover weight

070MJ-0010101 07PAD-0010000 07936-371020A
Valve guide driver 5.5 mm Attachment, 32 X 35 mm Attachment, 37 X 40 mm

07742-0010100 07746-0010100 07746-0010200

2-13
dummyhead
SERVICE INFORMATION
Attachment, 42 X 47 mm Attachment, 52 X 55 mm Attachment, 22 X 24 mm
07746-0010300 07746-0010400 07746-0010800
Puller adapter Attachment, 24 X 26 mm Pilot, 10 mm

07APF-ZY3A200 07746-0010700 07746-0040100
Pilot, 14 mm Pilot, 17 mm Pilot, 25 mm

07746-0041200 07746-0040400 07746-0040600
Pilot, 28 mm Pilot, 30 mm Mandrel

07746-0041100 07746-0040700 07SPD-ZW0010Z
2-14
dummyhead
SERVICE INFORMATION
Driver Valve spring compressor Lock nut wrench, 30/64 mm
07749-0010000 07757-0010000 07916-MB00002
Bearing remover, 30 mm Remover handle MT.assembly holder

07936-8890300 07936-3710100 07KPF-VD60100
Bearing driver attachment, 37 mm Oil seal driver Driver handle, 15 x 280 mm

07ZMD-MBW0200 07947-SB04100 07949-3710001
Oil filter wrench, 65 mm Valve guide reamer, 5.5 mm Holder handle

07HAA-PJ70101 or 07AAA-PLCA100 07HAH-PJ7A100 07JAB-001020A
Pressure gauge, 0 – 5,000 psi Driver attachment, 50 mm Bearing race puller

07KPJ-VD6020B 07APF-ZY3A100 07LPC-ZV30101

2-15
dummyhead
SERVICE INFORMATION
Air pressure regulator Disassembly tool, B Pulley holder attachment, hex 50 mm
07AAJ-PNAA101 07964-MB00200 070PB-0010100 or 07NAB-001040A
Trim cap wrench, 4 mm Pin wrench, 6 mm Vertical shaft holder

070PA-001A100 07SPA-ZW1010A 07SPB-ZW10200
Gauge joint A (Upper chamber) Gauge joint B (Lower chamber) VTEC air stopper
07SPJ-ZW1010A 07SPJ-ZW1020A 07AAK-RMEA200
Test probe VTEC air adapter Backlash indicator attachment

07ZAJ-RDJA110 07AAK-RMEA100 07SPK-ZW10100
Oil seal driver Installer/remover 14.5 X 18.5 mm Piston pin tool set
07ZAD-PNAA100 07ZPF-ZW90300 07PAF-0010000
2-16
dummyhead
SERVICE INFORMATION
Piston pin pilot Insert adjuster Pilot collar 18
070AF-PWC0110 070AF-PWC0120 070AF-PWC0130
Backlash indicator tool

07SPJ-ZW0030B

2-17
dummyhead
SERVICE INFORMATION
CABLE/HARNESS ROUTING
AIR FLOW BAND

Tighten the air flow band bolt so
that the band inside dimension is
as shown. IAT SENSOR 2P
6 – 8 mm CONNECTOR
(0.24 – 0.31 in) IAT SENSOR
MAP SENSOR 3P
CONNECTOR
MAP SENSOR HARNESS

BAND CLIP
AIR FLOW BAND
IAC VALVE 2P
CONNECTOR
IAC
VALVE
HARNESS
BAND CLIP
TP SENSOR
MAIN HARNESS HARNESS BAND TP SENSOR 3P
CONNECTOR
2-18
dummyhead
SERVICE INFORMATION
WIRE CLAMP
• Install the pump harness into the
WIRE CLAMPER upper side of the clamp, and set the
REMOTE CONTROL CABLE
Set the pump harness clamp so that the opening is facing
or TILLER HANDLE 14P
above the power tilt the crankcase side.
INDICATOR LIGHT CONNECTOR
relay 3P connector • Install the pressure regulator return
6P CONNECTOR wire (Except LHGX hose into the lower side of the clamp,
type). and set the clamp so the opening is
facing the crankcase side.
FUEL PUMP (HIGH)

2P CONNECTOR
POWER TILT RELAY 3P
CONNECTOR WIRE
PRESSURE
REGULATOR
RETURN HOSE
PUMP CASE
PUMP
MAIN HARNESS
HARNESS POWER TILT RELAY
3P CONNECTOR
(Except LHGX type)

2-19
dummyhead
SERVICE INFORMATION
TP SENSOR 3P
CONNECTOR
TP SENSOR
MAIN HARNESS HARNESS BAND POWER TILT RELAY 3P

Set into the clamps of SILENCER CASE CONNECTOR
the silencer case (Except LHGX type)
properly.
HARNESS
BAND CLIP
WATER LEVEL
SENSOR 2P
CONNECTOR
HARNESS
BAND CLIP
CLAMPS
TRIM ANGLE
SENSOR 3P
HARNESS
CONNECTOR
BAND CLIP (Except LHGX
type)
TIE-WRAP BAND
(Except LHGX type)
POWER TILT RELAY SPIRAL TUBE

2P CONNECTOR (12 X 14.6 mm)
WIRE (Except LHGX type)
(Except LHGX type)
TRIM ANGLE
SENSOR WIRE
HARNESS (Except LHGX type)
BAND CLIP
POWER TILT RELAY POWER TILT

2P CONNECTOR CLIP C MOTOR WIRE
(Except LHGX type) (Except LHGX type)
POWER TILT MOTOR
2P CONNECTOR UNDER COVER
(Except LHGX type) GROMMET C
(Except LHGX type)
WATER LEVEL
SENSOR WIRE
2-20
dummyhead
SERVICE INFORMATION
HARNESS
BAND CLIP

or TILLER HANDLE 14P
CONNECTOR
MAIN HARNESS
INDICATOR LIGHT
6P CONNECTOR
HARNESS
BAND CLIP
HARNESS BAND CLIP

Clamp the remote control
cable harness or tiller
handle cable harness,
and indicator light
harness.
NEUTRAL SWITCH
FUSE CABLE 1P CLIP A HARNESS BAND CLIP

CONNECTOR WIRE (Except LHGX type)
(Except LHGX type)
NEUTRAL SWITCH 2P NEUTRAL SWITCH

CONNECTOR WIRE

2-21
dummyhead
SERVICE INFORMATION
LOCATING BAND LOCATING BAND

Set the water level sensor wire so the
locating band is above the harness clip Set the water level sensor wire so
as shown. RELAY the locating band is above clip C.
BRACKET
WATER LEVEL
SENSOR 2P
CONNECTOR
HARNESS CLIP
TRIM ANGLE SENSOR

3P CONNECTOR
CLIP C (Except LHGX type)
WATER LEVEL
SENSOR WIRE
TIE-WRAP BAND
POWER TILT MOTOR WIRE
Cut the band end.
Align the lower end of the
tape with the upper end of
grommet C
UNDER COVER TAPE

FRONT BRACKET
TRIM ANGLE
SENSOR WIRE
(Except LHGX type)
UNDER COVER
GROMMET C
(Except LHGX type)
2-22
dummyhead
SERVICE INFORMATION
FUEL PUMP (HIGH)

HARNESS 2P CONNECTOR
BAND CLIP
POWER TILT RELAY

3P CONNECTOR WIRE CLAMPER
(Except LHGX type) Set the pump harness
REMOTE CONTROL CABLE above the power tilt
or TILLER HANDLE 14P MAIN HARNESS relay 3P connector wire
CONNECTOR (Except LHGX type).
HARNESS
BAND CLIP
PUMP HARNESS
INDICATOR LIGHT
POWER TILT
6P CONNECTOR
RELAY 1P
CONNECTOR WIRE
(Except LHGX type)
POWER TILT RELAY 3P

CONNECTOR WIRE
HARNESS (Except LHGX type)
BAND CLIP
POWER TILT
RELAY GROUND
FUSE CABLE 1P
CABLE
CONNECTOR
(Except LHGX type)
HARNESS BAND CLIP

Clamp the remote control
cable harness or tiller
handle cable harness, and
indicator light harness.
POWER TILT HARNESS
RELAY BAND CLIP (Except LHGX type)
(Except LHGX type) Tighten the bolt while
pushing the ground
NEUTRAL SWITCH 2P terminal against the lug
CONNECTOR POWER TILT RELAY
on the crankcase.
2P CONNECTOR
(Except LHGX type) POWER TILT RELAY
1P CONNECTOR
HARNESS (Except LHGX type) LUG
BAND CLIP
POWER TILT MOTOR
FUSE CABLE 1P 2P CONNECTOR
CONNECTOR WIRE (Except LHGX type)
(Except LHGX type)

2-23
dummyhead
SERVICE INFORMATION
WIRE CLAMP
PUMP HARNESS
HARNESS
BAND
MAIN
HARNESS
WATER LEVEL
SENSOR 2P
CONNECTOR
REMOTE
CONTROL
CABLE
GROMMET
HARNESS
BAND CLIP
TRIM ANGLE
SENSOR 3P
CONNECTOR
(Except
LHGX type)
SPIRAL TUBE
(12 X 14.6 mm)
(Except LHGX type)
WATER LEVEL
SENSOR/WATER
SEPARATOR UNDER COVER
GROMMET C
(Except LHGX type)
CLIP (14 mm) (Except LHGX type)

Install the power tilt motor wire
LOCATING TAPE
by aligning the lower edges of
the locating tape and clip.
CLIP (14 mm)
POWER TILT
SPIRAL TUBE
MOTOR WIRE
(12 X 14.6 mm)
2-24
dummyhead
SERVICE INFORMATION
SHIFT CABLE THROTTLE CABLE
INDICATOR LIGHT
HARNESS
HARNESS or TILLER HANDLE
HARNESS
STARTER CABLE
REMOTE CONTROL CABLE FUEL TUBE A

GROMMET
<Front view with the grommet installed into the outboard motor>
FUEL TUBE A
STARTER CABLE
WHITE TAPE
Install the starter cable by
UNDER COVER aligning the white tape edge
FRONT BRACKET with the under cover front
bracket.
Remote control type:
INDICATOR LIGHT
HARNESS REMOTE CONTROL
CABLE GROMMET

HARNESS BAND
Install each band while pushing
it against the grommet.
Tiller handle type:
REMOTE CONTROL
CABLE GROMMET
TILLER HANDLE WHITE TAPE

HARNESS
Install the tiller handle harness
by aligning the white tape edge
with the grommet.

2-25
dummyhead
SERVICE INFORMATION
EOP SENSOR
EOP SENSOR 3P CKP SENSOR 3P

CONNECTOR CONNECTOR
HARNESS
CKP SENSOR
BAND CLIPS
HARNESS CLIP
BRACKET A HARNESS CLIP
BRACKET C
IAC VALVE 2P
CONNECTOR MAIN
HARNESS
HO2S 4P
CONNECTOR
IAC VALVE
HARNESS
BAND CLIPS
2-26
dummyhead
SERVICE INFORMATION
CKP SENSOR 3P
IAT SENSOR 2P CONNECTOR
CONNECTOR HARNESS
BAND CLIPS
MAIN HARNESS
IAC VALVE 2P CKP SENSOR

CONNECTOR HARNESS
BAND CLIPS
IAC VALVE
HARNESS
BAND
CLIPS
HARNESS
BAND
CLIPS
KNOCK SENSOR
(BF90D/BF100A only)
KNOCK SENSOR 1P
CONNECTOR
(BF90D/BF100A only)

2-27
dummyhead
SERVICE INFORMATION
FUEL TUBE CLAMP A

• Set with fuel tube D positioned in front of the main harness.
• Set with the openings facing the fuel line side.
• Set by aligning the upper edge with the paint mark on fuel tube D.
FUEL TUBE C FUEL TUBE D MAIN HARNESS

PAINT MARK
PAINT MARK
No.1 FUEL
INJECTOR 2P
CONNECTOR
No.2 FUEL
INJECTOR 2P
CONNECTOR
No.3 FUEL
INJECTOR 2P
CONNECTOR
No.4 FUEL
TUBE CLAMP 7.5 - 11.5 INJECTOR 2P
CONNECTOR
• Set the small clamp onto the main harness with
FUEL TUBE CLAMP
the opening facing the cylinder block.
PAINT MARK BRACKET PAINT MARK
• Set the large clamp onto fuel tube C with the
opening facing the cylinder block.
• Set by aligning the upper edge with the paint
mark on fuel tube C. FUEL TUBE
CLAMP A
MAIN HARNESS
TUBE CLAMP
7.5 - 11.5
FUEL TUBE C FUEL

TUBE D
MAIN HARNESS
HARNESS
BAND CLIP HARNESS
BAND CLIP
2-28
dummyhead
SERVICE INFORMATION
HARNESS BAND CLIP KNOCK SENSOR

(BF90D/BF100A only)
KNOCK SENSOR 1P HARNESS BAND
CONNECTOR CLIP
EBT SENSOR
(BF90D/BF100A only)
No.2 FUEL
INJECTOR 2P
CONNECTOR
No.3 FUEL
INJECTOR 2P
CONNECTOR
HARNESS
BAND CLIP
No.4 FUEL
INJECTOR 2P
CONNECTOR
VTEC SOLENOID
(BF90D/BF100A only)
HARNESS BAND
EBT SENSOR 2P CLIP
CONNECTOR
HARNESS BAND CLIP
(BF90D/BF100A only)
VTEC SOLENOID 1P
HARNESS BAND CONNECTOR
CLIP (BF90D/BF100A only)
HARNESS BAND MAIN HARNESS

CLIP
HARNESS BAND
CLIP

2-29
dummyhead
SERVICE INFORMATION
MAIN HARNESS VTEC SOLENOID

HARNESS BAND CLIP (BF90D/BF100A only)
HARNESS BAND
(BF90D/BF100A only)
CLIP
HARNESS CLIP
VTEC SOLENOID 1P
CONNECTOR
(BF90D/BF100A only)
CMP SENSOR HARNESS MAIN HARNESS

CMP SENSOR 3P CONNECTOR STRAP (30 mm)
2-30
dummyhead
SERVICE INFORMATION
HARNESS BAND MAIN HARNESS ALTERNATOR

CLIP STATOR
HARNESS CLIP
BRACKET E
HARNESS CLIP
BRACKET C
STATOR
HARNESS
JOINT
CONNECTOR 1
HARNESS BAND
HO2S 4P
CLIP
CONNECTOR
JOINT
CONNECTOR 2

2-31
dummyhead
SERVICE INFORMATION
JOINT JOINT HO2S WIRE

CONNECTOR 1 CONNECTOR 2 The protector tube must
HARNESS BAND
contact the HO2S wire.
CLIP
No.1 IGNITION COIL

3P CONNECTOR
No.1 IGNITION COIL
No.2 IGNITION COIL HO2S

3P CONNECTOR
STATOR 3P
CONNECTOR
No.2 IGNITION COIL REGULATOR/
RECTIFIER
POWER TRIM/TILT
SWITCH 3P
ECT SENSOR 3 CONNECTOR
2P CONNECTOR (Except LHGX type)
70 A FUSE BOX
ECT SENSOR 3
No.3 IGNITION COIL FUSE CABLE
POWER TRIM/TILT
SWITCH
No.3 IGNITION COIL (Except LHGX type)
3P CONNECTOR
No.4 IGNITION COIL Tighten the bolt while pushing

the ground terminal against
No.4 IGNITION COIL the lug on the crankcase.
3P CONNECTOR
LUG
CMP 3P CONNECTOR REGULATOR/

RECTIFIER
HARNESS GROUND CABLE
STRAP (30 mm)
REGULATOR/
RECTIFIER 3P
CONNECTOR
2-32
dummyhead
SERVICE INFORMATION
ECM 36P
CONNECTOR B (Black)
ELECTRONIC
HARNESS HO2S 4P PARTS CASE ECM 36P
BAND CLIP CONNECTOR CONNECTOR A (Gray)
CLAMP STATOR HARNESS

HO2S WIRE ECM
The protector
tube must
contact the HARNESS
HO2S wire. BAND CLIP
HO2S
STATOR WIRE
Set into the clamp ENGINE SPEED CHECK
of the electronic 2P CONNECTOR (Blue)
parts case.
STATOR 3P
CONNECTOR DLC 4P (Red)
HARNESS
REGULATOR/ BAND CLIP
RECTIFIER
70 A FUSE
BOX
POWER TRIM/TILT
SWITCH 3P
CONNECTOR FUSE CABLE MAIN HARNESS
(Except LHGX type)
FUSE CABLE
FUSE BOX
STARTER SOLENOID STARTER MOTOR
STARTER CABLE (+)
PGM-FI/MAIN RELAY
WHITE WIRE

2-33
dummyhead
SERVICE INFORMATION
HARNESS
BAND CLIP
CLAMP
HARNESS STATOR HARNESS
MAIN HARNESS BAND CLIP
LUG
HARNESS
BAND CLIP
GROUND
PGM-FI/MAIN CABLE
RELAY
PGM-FI/MAIN RELAY
6P CONNECTOR
FUSE BOX 5P PGM-FI/MAIN RELAY

CONNECTOR WHITE WIRE
WIRE HARNESS
CLIP
HARNESS
BAND CLIP
CLAMP
PGM-FI/MAIN RELAY
5P CONNECTOR
PGM-FI/MAIN RELAY
WHITE WIRE ECT SENSOR 2
2P CONNECTOR
HARNESS
BAND CLIP NMEA 2000 6P
CONNECTOR
FUSE CABLE
FUSE CABLE
Set into the clamp of the electronic
parts case as shown.
HARNESS
PGM-FI/MAIN RELAY
BAND CLIP
WHITE WIRE
FUSE CABLE
2-34
dummyhead
SERVICE INFORMATION
HARNESS
GROUND
BAND CLIP
CABLE
PGM-FI/MAIN RELAY
6P CONNECTOR WIRE
WIRE HARNESS CLIP

PGM-FI/MAIN Clamp the PGM-FI/main
RELAY relay 5P connector wire.
CLAMP
Clamp the PGM-FI/main
relay white wire.
FUSE CABLE PGM-FI/MAIN RELAY

WHITE WIRE
PGM-FI/MAIN RELAY 5P
PGM-FI/MAIN RELAY CONNECTOR WIRE
5P CONNECTOR
TERMINAL COVER
FUSE CABLE
NUT (8 mm) (2)
WASHER (8 mm)
STARTER CABLE (+)
NUT (8 mm)
FUSE CABLE
Tighten so that the distance between the STARTER MOTOR
starter cable and starter motor is 10 – 20
mm (0.4 – 0.8 in). Also, set the fuse cable
parallel to the starter cable.
10 – 20 mm
(0.4 – 0.8 in)
STARTER CABLE (+)

2-35
dummyhead
SERVICE INFORMATION
LUG
GROUND CABLE
• Install with the Black and Blue terminal
onto the upper side, and the Black
terminals onto the lower side.
• Tighten the bolt while pushing the ground
terminal against the lug on the cylinder
block.
LUG
CLAMP STATOR HARNESS

Set into the clamp and above the
lug of the electronic parts case.
ELECTRONIC
PARTS CASE
LUG
STARTER CABLE (–)

Tighten the bolt while pushing the
cable terminal against the lug of
the cylinder block.
LUG
2-36
dummyhead
SERVICE INFORMATION
PGM-FI/MAIN RELAY
STARTER WHITE WIRE
CABLE (+) FUSE CABLE
MAIN HARNESS
POWER TRIM/ STARTER MOTOR Set into the clamps
TILT SWITCH 3P of the silencer case
CLAMPS
CONNECTOR properly.
(Except LHGX
type) NMEA 2000 6P
CONNECTOR
POWER TRIM/
TILT SWITCH
(Except LHGX
type)
REGULATOR/
RECTIFIER
GROUND CABLE
FUSE CABLE
(Except LHGX type)
STARTER
CABLE (–)
FUSE CABLE STARTER

(Except LHGX type) STARTER
CABLE (–)
CABLE (+)
STARTER
CABLE (+)
STARTER FUSE CABLE

CABLE (–) (Except LHGX type)

2-37
dummyhead
SERVICE INFORMATION
LEAD WIRE (137 mm)

Tighten the screw while pushing
the terminal against the lug of the
LUG
lower mount center housing.
LEAD WIRE
(137 mm)
UNDER COVER
GROMMET C LOWER MOUNT
(Except LHGX CENTER HOUSING
type)
CLIP (14 mm)

(Except LHGX type)
SPIRAL TUBE
(12 X 14.6 mm)
(Except LHGX type)
TRIM ANGLE SENSOR

(Except LHGX type)
TRIM ANGLE
SENSOR WIRE
(Except LHGX type)
WIRE
HARNESS CLIP
(Except LHGX type)
POWER TRIM
MOTOR WIRE
(Except LHGX type)
POWER TRIM MOTOR

(Except LHGX type)
MOTOR WIRE GROMMET CORRUGATE TUBE

UPPER (ENGINE SIDE) This should

TRIM ANGLE stand at
SENSOR WIRE right angle.
REARWARD
POWER TRIM
MOTOR WIRE (Viewed from the
inside of the
stern bracket)
2-38
dummyhead
SERVICE INFORMATION
POWER TRIM/TILT
LEAD WIRE
• Route between the lugs of the anode
metal.
• Install so that the angle is 90° as
shown at the power trim/tilt side.
90°
ANODE METAL
LUG
SPIRAL TUBE
(12 X 14.6 mm)
(Except LHGX type)
TRIM ANGLE
WIRE SENSOR WIRE
HARNESS CLIP (Except LHGX type)
(Except LHGX type)
POWER TILT
MOTOR WIRE
POWER TILT MOTOR (Except LHGX type) (Except LHGX type)
• Install by aligning the lower edge of the tape
with the motor wire bushing.
• Wrap the spiral tube by aligning the lower
edge with the upper edge of the tape on the
power tilt motor wire.
CORRUGATE TUBE
(Except LHGX type)
TAPE
MOTOR WIRE GROMMET

(Except LHGX type)

2-39
dummyhead
SERVICE INFORMATION
TILLER HANDLE TYPE:
REMOTE CONTROL
CABLE (SHIFT CABLE) POWER TRIM/
TILT SWITCH HARNESS
(Except LHGX BAND
type) (Except LHGX
type)
POWER TRIM/
TILT SWITCH
WARNING
WIRE
BUZZER (Except LHGX
type)
REMOTE CONTROL
CABLE (THROTTLE TUBE (40 mm)
CABLE) HARNESS BAND
(Except LHGX
type)
TUBE A
COMBINATION
SWITCH
INDICATOR
LIGHT
TUBE B
HARNESS
BAND B (2)
EMERGENCY
STOP SWITCH
TILLER HANDLE CABLE HARNESS BAND CLIP

GROMMET Cut the band end so its length is
Set the grommet between
harness bands B. Set the cable as shown. 15 – 20 mm (0.6 – 0.8 in).
<Grommet viewed from the

outboard motor side>
THROTTLE
CABLE HOLE
15 – 20 mm
HARNESS (0.6 – 0.8 in)
BAND B
SHIFT CABLE
TILLER HANDLE
HOLE
CABLE HARNESS
HOLE
2-40
dummyhead
SERVICE INFORMATION
<When the steering friction rod is installed on the right side>
STEERING
FRICTION SHAFT STEERING BRACKET
STEERING
FRICTION ROD
STEERING
FRICTION BLOCK
<When the steering friction rod is installed on the left side>
STEERING
STEERING BRACKET FRICTION SHAFT
STEERING
STEERING FRICTION ROD
FRICTION BLOCK

2-41
dummyhead
SERVICE INFORMATION
REMOTE CONTROL TYPE:

POWER TRIM/TILT SWITCH
INDICATOR LIGHT
POWER TRIM/TILT
SWITCH WIRE
WARNING BUZZER
WIRE HARNESS CLIP

TIE-WRAP BAND
COMBINATION SWITCH
EMERGENCY
STOP SWITCH
POWER TRIM/TILT
REMOTE CONTROL SWITCH WIRE
CABLE B
Lb Lb
REMOTE CONTROL POWER TRIM/TILT
CABLE B W/Bl W/Bl
SWITCH WIRE
Lg Lg
Bl BLACK Br BROWN
Y YELLOW O ORANGE
Bu BLUE Lb LIGHT BLUE
G GREEN Lg LIGHT GREEN
R RED P PINK
W WHITE Gr GRAY *1:
Power trim/tilt switch wire routing when the remote
control handle is installed as shown in Fig. A.
POWER TRIM/TILT *2:

SWITCH WIRE Power trim/tilt switch wire routing when the remote
control handle is installed as shown in Fig. B.
*1:
*2:
FIG. A. FIG. B.
POWER TRIM/TILT
SWITCH WIRE COMBINATION SWITCH
2-42
dummyhead
SERVICE INFORMATION
TUBE ROUTING
PRESSURE REGULATOR
CONTROL TUBE
VINYL TUBE PRESSURE REGULATOR
(5 X 9 X 240 mm) RETURN HOSE
TUBE CLIP B12
TUBE
CLAMP D TUBE CLIP
D10.7
FUEL TUBE A
FUEL TUBE B
GROMMET
FUEL HOSE
FUEL TUBE A
HOSE GROMMET
WATER LEVEL SENSOR/
WATER SEPARATOR HOSE CLIP FUEL TUBE
CLAMP B
VINYL TUBE FUEL TUBE B
(4 X 7 X 190 mm)
Insert into the hole in the
under case front bracket.

2-43
dummyhead
SERVICE INFORMATION
GROMMET
GUIDE
Install by aligning the groove with
the guide of the under cover front
bracket.
FUEL TUBE A
UNDER COVER
FRONT BRACKET
“→” MARK
FUEL TUBE A WATER LEVEL SENSOR/
WATER SEPARATOR
FUEL TUBE B
• Connect fuel tube A to the “→” mark joint
pipe of the water separator.
• Connect fuel tube B to the “←” mark joint
pipe, aligning the “←” mark and “I” mark.
“I” MARK “←” MARK
TUBE CLIP B12

Install with the clip ends
facing up.
WATER LEVEL SENSOR/

FUEL TUBE A WATER SEPARATOR
FUEL TUBE B
2-44
dummyhead
SERVICE INFORMATION
FUEL TUBE B FUEL TUBE B

PROTECTOR TUBE PROTECTOR TUBE
FUEL HOSE
HOSE CLIP
• Set onto fuel tube B between the protector tubes.
• Install with the opening facing the engine side.
• Set the fuel hose into the underside of the hose
clip.
FUEL TUBE CLAMP B

• Install at the protector tube end.
• Install with the opening facing the pump
case side.
FUEL TUBE B
PROTECTOR TUBE
FUEL TUBE B
PROTECTOR TUBE
FUEL HOSE
HOSE GROMMET

2-45
dummyhead
SERVICE INFORMATION
WIRE CLAMP
• Install the pump harness into the upper side of
the clamp, and set the clamp so that the
opening is facing the crankcase side.
• Install the pressure regulator return hose into
the lower side of the clamp, and set the clamp
so the opening is facing the crankcase side.
FUEL TUBE A TUBE CLIP D10.7

FUEL TUBE B
PUMP WIRE PRESSURE REGULATOR
HARNESS RETURN HOSE
TUBE CLIP
D10.7
PUMP CASE
PRESSURE REGULATOR
CONTROL TUBE
PRESSURE REGULATOR
WATER LEVEL SENSOR/
WATER SEPARATOR
2-46
dummyhead
SERVICE INFORMATION
HARNESS CLIP
BREATHER PIPE BRACKET A
TUBE CLIP B12
facing up. FUEL TUBE JOINT
BREATHER
FUEL TUBE C TUBE B
FUEL TUBE CLAMP B

Install with the clip
ends facing as shown.
BREATHER
TUBE A
HARNESS
CLIP
BRACKET B
TUBE FUEL PUMP

FUEL STRAINER (LOW)
(7.3 X 90 mm) FUEL TUBE D TUBE CLIP B12 (LOW)
facing out.

2-47
dummyhead
SERVICE INFORMATION
TUBE CLIP B12

Install with the clip ends TUBE CLIP B12
TUBE CLAMP facing up.
7.5 - 11.5 facing up.
TUBE (7.3 X 90 mm)

FUEL TUBE D FUEL
FUEL STRAINER
MAIN
TUBE C (LOW)
HARNESS
TUBE CLIP B12
facing out.
FUEL
TUBE B
FUEL PUMP (LOW)
FUEL TUBE
CLAMP A
FUEL
TUBE D
FUEL LINE
FUEL TUBE BRACKET
FUEL HOSE
FUEL TUBE
HOSE CLIP CLAMP B
HOSE FUEL
TUBE TUBE C
GROMMET FUEL TUBE
CLIP B12
CLAMP A FUEL
TUBE CLAMP
FUEL TUBE TUBE C
CLAMP B FUEL HOSE
FUEL TUBE
CLAMP B TUBE CLIP B12
(LRTA/XRTA/LRTC/
XRTC type only)
TUBE CLAMP D12

(Except LRTA/XRTA/
LRTC/XRTC type)
2-48
dummyhead
SERVICE INFORMATION
CHECK VALVE
Install with the CHECK VALVE
arrow facing down. TUBE A
CHECK VALVE
FUEL TUBE C TUBE B
T-JOINT
TUBE CLAMP
7.5 - 11.5
AIR VENT
TUBE B
CLAMP
FUEL
TUBE D
VAPOR
SEPARATOR
COVER
FUEL TUBE
CLAMP B
AIR VENT TUBE A AIR VENT
Set into the clamp of the TUBE C
vapor separator cover.
FUEL TUBE FUEL TUBE C

CLAMP A
TUBE CLAMP

2-49
dummyhead
SERVICE INFORMATION
TUBE CLAMP 7.5 - 11.5

Install fuel tube C into the large clamp, and check
valve tube B into the small clamp with the openings of
the clamp facing the cylinder block side. CHECK VALVE
FUEL STRAINER
TUBE B
(LOW)
FUEL
TUBE C
TUBE
PAINT MARK
(7.3 x 90 mm)
TUBE CLAMP 7.5 - 11.5
FUEL TUBE
CLAMP A
MAIN HARNESS
FUEL TUBE PAINT MARKS

CLAMP A
AIR VENT TUBE A
FUEL TUBE D
Install into the clamp FUEL TUBE
under the intake manifold. CLAMP B
FUEL TUBE CLAMP B (2)

Install with the opening
facing the fuel line side
and align the upper edge
with the paint mark.
FUEL TUBE B
AIR VENT TUBE C
FUEL TUBE CLAMP B HOSE CLIP

FUEL TUBE C
facing up and align the edge TUBE CLAMP
with the protector tube end
of fuel tube B. Install fuel tube C and
air vent tube C with the
openings of the clamp
facing up.
2-50
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SERVICE INFORMATION
FUEL TUBE CLAMP B

facing the fuel line side.
FUEL TUBE
AIR VENT
BRACKET
TUBE B
AIR VENT
STRAINER
FUEL TUBE
CLAMP B
AIR VENT
TUBE C
AIR VENT
TUBE A PAINT MARK
FUEL TUBE CLAMP B

PAINT MARKS
facing as shown and align
the upper edge with the
paint mark.
FUEL TUBE CLAMP A
Install with the openings

facing up and align the left FUEL TUBE C FUEL TUBE CLAMP B
edge with the right edge of
the paint marks.
facing the fuel tube C side.
FUEL TUBE D
HOSE CLIP
• Install fuel tube D into the inside clip with
the opening of the clip facing up.
• Install fuel tube C into the outside clip
with the opening of the clip facing the
fuel line side.

2-51
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SERVICE INFORMATION
FUEL TUBE CLAMP B

FUEL TUBE
Install with the opening CLAMP A
facing out.
FUEL TUBE D PAINT HOSE CLIP

MARK FUEL TUBE C
AIR VENT
TUBE C FUEL LINE
AIR VENT
TUBE A
FUEL HOSE
TUBE CLIP
B12
TUBE
CLIP B10 TUBE CLAMP
D29.0
TUBE CLIP 65
WATER TUBE A TUBE CLIP 65

PAINT MARK OIL TUBE
AIR VENT TUBE C
WATER TUBE B
FUEL TUBE CLAMP B
TUBE CLAMP
facing up and align the
left edge with the right
FUEL TUBE CLAMP B
edge of the paint mark
facing the cylinder block TUBE CLAMP
side.
• Clamp water tube B and the fuel hose so they
are horizontal.
• Align the left edge with the right edge of the
paint mark.
2-52
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SERVICE INFORMATION
WATER JACKET
COVER
LUG
LUG TUBE CLIP 65

facing down.
WATER TUBE A
Connect so the tube end
TUBE CLIP B10 is pushed against the lug
Install with the clip ends of the water jacket cover.
facing the cylinder
block side.
WATER TUBE B
Connect so the tube end
is pushed against the lug
of the water jacket cover.

2-53
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SERVICE INFORMATION
CYLINDER
HEAD COVER
AIR VENT TUBE C
TUBE CLAMP
FUEL HOSE
D29.0
FUEL TUBE CLAMP B
FUEL TUBE C
CLAMP
WATER TUBE A
TUBE CLIP 65
WATER TUBE B TUBE

OIL TUBE
CLIP B10
Set into the clamp of • Connect by aligning the lugs of the oil tube
the mount case. and cylinder head cover.
• Install tube clamp D29.0 with the clamp
ends facing down.
TUBE CLAMP
D29.0 CYLINDER
HEAD COVER
OIL TUBE
LUG
CLAMP ENDS
LUG
2-54
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SERVICE INFORMATION
WATER CHECK TUBE

Install into the clamp of the idle
exhaust port. TUBE CLIP B10
WATER TUBE B
TUBE CLIP B10

IDLE EXHAUST
PORT

2-55
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SERVICE INFORMATION
BREATHER PIPE BREATHER TUBE C

ALTERNATOR
Set into the alternator Set into the alternator
COVER
cover clamp. cover clamps.
FUEL TUBE CLAMP B
BREATHER FUEL TUBE BREATHER ALTERNATOR ALTERNATOR

TUBE A JOINT TUBE B COVER CLAMP COVER CLAMPS
BREATHER PIPE
ALTERNATOR BREATHER TUBE C
Set into the alternator COVER
cover clamps.
• Set into the alternator cover
clamps.
• Insert into the silencer case until
the paint mark is not visible.
PAINT MARK
ALTERNATOR ALTERNATOR
COVER CLAMPS SILENCER CASE
COVER CLAMP
2-56
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SERVICE INFORMATION
TUBE CLIP
B1 (13 mm)
TUBE CLIP D10.5
TUBE
(7 X 110 mm)
TUBE CLIP
D10.5
TUBE
(8 X 300 mm)

2-57
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MEMO

dummytext
3. MAINTENANCE
MAINTENANCE SCHEDULE ··················· 3-2 LUBRICATION ···································· 3-22
ENGINE OIL LEVEL CHECK/OIL WATER SEPARATOR CHECK··············· 3-25

CHANGE ·············································· 3-4
FUEL STRAINER (LOW PRESSURE SIDE)
ENGINE OIL FILTER CHANGE ················ 3-5 INSPECTION/CLEANING ······················ 3-25
GEAR CASE OIL CHANGE ····················· 3-6 FUEL FILTER (HIGH PRESSURE SIDE)
INSPECTION/REPLACEMENT··············· 3-28
THROTTLE CONTROL CABLE/THROTTLE
LINK CHECK/ADJUSTMENT ··················· 3-9 FUEL TANK/FILTER CLEANING ············ 3-29
VALVE CLEARANCE CHECK/ FUEL LINE CHECK/REPLACEMENT ······ 3-30

ADJUSTMENT ···································· 3-12
NUTS, BOLTS, FASTENERS ················· 3-31
SPARK PLUG CHECK/REPLACEMENT ·· 3-15
CRANKCASE BREATHER CHECK········· 3-31
PROPELLER AND SPLIT
PIN CHECK ········································ 3-17 WATER PUMP CHECK························· 3-31
ANODE METAL CHECK (OUTER SIDE) ·· 3-17 EMERGENCY STOP SWITCH CHECK ···· 3-31
ANODE METAL CHECK (INNER SIDE) ··· 3-19 POWER TRIM/TILT CHECK··················· 3-32
IDLE SPEED CHECK/ADJUSTMENT ······ 3-20 SHIFT CONTROL CABLE CHECK/

ADJUSTMENT ···································· 3-32

3-1
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MAINTENANCE
MAINTENANCE SCHEDULE
MAINTENANCE
Item REGULAR SERVICE PERIOD (2)

Perform at every indicated month or
operating hour interval, whichever comes first.
Refer
First Every 6 Every 2 Every 3
Every to page
Each After month months years years
year or
use use or 20 or 100 or 400 or 600
200 hrs.
hrs. hrs. hrs. hrs.
Engine oil Check
3-4
level
Change 3-5
Engine oil filter Replace 3-5
Gear case oil Change 3-6
Throttle linkage Check-
3-9
adjust
Valve clearance Check-
3-12
adjust
Spark Standard Check-
plug adjust
/Replace 3-15
Optional Check
Replace
Propeller and split pin Check 3-17
Anode metal Check
3-17
(Outer side)
Anode metal Check
(Inner side) (5) 3-19
Idling speed Check-

3-20
adjust
Lubrication Grease (1) (1) 3-22
Water separator Check 3-25
Fuel filter Check
3-25
(Low pressure side) Replace
Fuel filter Check
3-28
(High pressure side) Replace
Fuel tank and fuel filter Clean 3-29
Fuel line Check (7) 3-30
Replace Every 2 years (If necessary) (7) 5-73
Thermostat Check 11-12
Battery and cable Check
connection level- –
tightness
Bolts and Nuts Check-
3-31
tightness
Crankcase breather Check
3-31
tube
Cooling water Clean
(3) (3) –
passages
Coolant leak Check –
Water pump Check 3-31
Emergency stop Check
3-31
switch
Engine oil leak Check –
Each operation part Check –
Engine condition (4) Check –
Power trim/tilt Check
3-32
(Except LHGX type)
Shift control cable Check-
(6) 3-32
adjust
3-2
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MAINTENANCE
1. Lubricate more frequently when used in salt water.
2. For professional commercial use, log hours of operation to determine proper maintenance intervals.
3. When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.
4. Upon starting, check for unusual engine sounds and cooling water flowing freely from the check hole.
5. Replace the anodes when they have been reduced to about two-thirds of their original size, or if they are crumbling.
6. Except LRTA/XRTA/LRTC/XRTC type: The user who performs shift operation frequently will recommend you exchange of a
shift cable around three years.
7. Check the fuel line for leaks, cracks, or damage. Replace the fuel line if there are signs of leaks, cracks, or damage.
OPERATING HOUR NOTIFICATION SYSTEM

This ECM counts the number of operating hours since the last periodic maintenance. When the next periodic maintenance is due,
the engine notifies the NMEA 2000 network, and a maintenance indication is displayed on an NMEA 2000-compatible device. To
maintain the operating hours correctly, the operating hour counter must be reset every time after each periodic maintenance is
performed.
Periodic maintenance is required when either the operating hours or the time since last maintenance reaches the prescribed limit.
Therefore, periodic maintenance may be required based on the number of months since the last maintenance before the alert
based on engine operating hours displays.
• The operating hours are notified by the function of the notification system.
• The period (the number of months since the last maintenance) cannot be notified by the system.
Reset the hour counter whenever maintenance is performed, whether based on the time interval or the number of operating hours.
Operating hour notification timing:

Every 100 hours
20 hours 80 hours after 100 hours after

first reset second reset
Start of Notify Notify Notify

operation
OPERATING HOUR COUNTER RESET PROCEDURE
• Before performing the reset procedure, be sure to stop the engine.
1. Put the shift lever in "F" (Forward) or "R" (Reverse).
2. Turn the combination switch ON. The buzzer will sound once.
3. Press the emergency stop switch 5 times within 20 seconds. The buzzer will sound once when the hour counter is reset.
• When replacing the ECM, perform the reset procedure necessary the number of times according to the total operating hours at
the time of replacement, or adjust the operating hour notification timing.
• When installing the NMEA 2000 display later, perform the reset procedure the necessary number of times according to the total
operating hours at the time of installation, or adjust the operating hour notification timing.
OPERATING HOUR NOTIFICATION TIMING ADJUSTMENT
The operating hour notification timing can be adjusted from the maintenance notification setting of Dr. H. The following information
recorded in the ECM can be checked from the Data list.
• The total operating hours since the last reset
• The total operation hours when the next notification will be done
• The total number of times the reset is performed
Example:
When replacing the ECM within 20 hours of operation
• Set the remaining operating hours to the first periodic maintenance
When replacing the ECM after spending 20 hours or more
1. Reset the operating hours once.
2. Adjust the operating hours to the next periodic maintenance.

3-3
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MAINTENANCE
ENGINE OIL LEVEL CHECK/OIL
CHANGE
OIL LEVEL INSPECTION
Place the outboard motor in the vertical position (with
the engine level), and remove the engine cover.
Start the engine, let it warm up to the normal operating [1]
temperature, and stop the engine.
Remove the dipstick [1] and wipe it clean with a shop
towel.
Insert the dipstick into the oil level pipe securely, and
then remove it and check the oil level. Upper level
Check whether the oil is dirty or has a milky color.
Lower level
If the oil level is low, remove the oil filler cap [1], and
add the recommended oil to bring the oil level up to the
upper level mark on the dipstick.
[1]
RECOMMENDED ENGINE OIL:
SAE 10W-30
API Service classification SG/SH/SJ
SUGGESTED ENGINE OIL:
Honda SAE 10W-30 FC-WTM
If the oil has a milky color, check the seals and gaskets
and replace them with new ones if necessary:
– Mount case gasket (page 13-3)
– Cylinder head gasket (page 14-19)
– Oil case gasket (page 12-5)
Install the oil filler cap securely.
Remove the dipstick and wipe it clean again.
Insert the dipstick into the oil level pipe securely again,
and then remove it and check that the oil level is at the
upper level mark on the dipstick.
SAE VISCOSITY GRADE
TEMPERATURE
3-4
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MAINTENANCE
OIL CHANGE
[3] [2]
Used engine oil contains substances that have

been identified as carcinogenic.
If repeatedly left in contact with the skin for
prolonged periods, it may cause skin cancer.
Wash your hands thoroughly with soap and water
as soon as possible after contact with used engine
oil.
Drain the used oil while the engine is warm. Warm oil
drains quickly and completely.
Place the outboard motor on a level surface and
position the outboard motor vertically (with the engine
level), and remove the engine cover.
Remove the oil filler cap [1].
Place a suitable oil container next to the outboard [4]
motor.
Remove the oil drain plug bolt [2] and drain plug washer
[3]
[3], and drain the engine oil.
Please dispose of used motor oil in a manner that is
compatible with the environment.
We suggest you take used oil in a sealed container to Upper level
your local recycling center or service station for
reclamation.
Lower level
Do not throw it in the trash, pour it on the ground, or
pour it down a drain.
After draining, set a new drain plug washer on the oil
drain plug bolt.
Tighten the oil drain plug bolt to the specified torque. [1]
TORQUE: 23 N·m (2.3 kgf·m, 17 lbf·ft)

Refill with the recommended engine oil up to the upper
level mark on the dipstick [4].
ENGINE OIL CAPACITY:
4.2 liter (4.4 US qt, 3.7 lmp qt)
With oil filter replacement:
4.4 liter (4.6 US qt, 3.9 lmp qt)
Install the oil filler cap and dipstick.
Install the engine cover.
ENGINE OIL FILTER CHANGE

Remove the engine cover.
Drain the engine oil as described in the oil change
procedure (page 3-5). [1]
Place a shop towel under the oil filter [1] to absorb any
spilled oil, and then attach the special tool to the oil filter
and remove it.
TOOL:
Oil filter wrench, 65 mm [2] 07AAA-PLCA100 or
07HAA-PJ70101
[2]

3-5
dummyhead
MAINTENANCE
Apply clean engine oil to the O-ring [1] and threads [2]
of a new oil filter.
Clean the filter mounting base, and coat the stud with [2]
clean engine oil.
• Use only a Honda Genuine oil filter or a filter of
equivalent quality specified for your model. Using
the wrong Honda filter, or a non-Honda filter that is
not of equivalent quality, may cause engine
damage.
[1]
Screw on the filter [1] by hand first, and then screw it in

to the specified torque using the special tool used for [1]
removing the filter.
TOOL:
Oil filter wrench, 65 mm 07AAA-PLCA100 or
07HAA-PJ70101

Refill the engine with the specified amount of the
recommended oil as described in the oil change
procedure (page 3-5), and start the engine to warm it up
to the normal operating temperature.
Stop the engine and check for leaks from the oil filter.
Check the oil level (page 3-4).
GEAR CASE OIL CHANGE

INSPECTION
Remove the oil check bolt [1] and check whether gear
case oil flows out of the gear case.
Catch the oil in a suitable container.
If oil does not flow out, add oil (page 3-8). [1] [2]
Coat a new O-ring [2] with a clean gear oil and set it on
the oil check bolt.
Install the oil check bolt in the gear case and tighten the
bolt to the specified torque.
TORQUE: 6.5 N·m (0.66 kgf·m, 4.8 lbf·ft)
3-6
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MAINTENANCE
ADDING
level).
Remove the oil check bolt [1] and oil drain plug bolt [2],
and then check for metal particles on the magnet end
[3].
If there are metal particles on the magnet end of the
drain plug bolt, disassemble and inspect the gear case
(page 16-5).
[1]
Install a commercially available gear case filler (STV-
S33) [4] and filler adapter (STV-334Y) [5] in the oil drain
plug hole, and add gear oil until it flows out from the oil
check bolt hole.
GEAR OIL CAPACITY: [3]
0.95 liters (1.00 US qt, 0.84 Imp qt)
[2]
RECOMMENDED GEAR OIL:
MARINE SAE 90 Hypoid gear oil
API Service Classification (GL-4)
After adding gear oil, remove the gear oil pump. [6]
Apply gear oil to new O-rings [6] and install them on the
oil level check bolt and drain plug bolt.
Install and tighten the bolts to the specified torque.
[4]
[5]

3-7
dummyhead
MAINTENANCE
CHANGE
level).
Tilt the outboard motor up slightly until the drain hole is
at its lowest point.
Remove the oil check bolt [1], oil drain plug bolt [2], and
drain the old oil.
Check for metal particles on the magnet end [3] of drain
bolt.
[1]
If there are metal particles on the magnet end of the
drain plug bolt, disassemble and inspect the gear case
assembly (page 16-5).
If there is water in the oil, the water will flow out first
when the drain plug bolt is removed, or the oil will be a
milky color. If water in the gear oil is detected, perform a
gear case pressure check (page 16-42).
[2]
Tilt the outboard motor down until it is vertical.
Install a commercially available gear case filler (STV-
S33) [4] and filler adapter (STV-334Y) [5] in the oil drain
plug hole, and add gear oil until it flows out from the oil
check bolt hole.
GEAR OIL CAPACITY:
0.95 liters (1.00 US qt, 0.84 Imp qt) [2]
RECOMMENDED GEAR OIL:

MARINE SAE 90 Hypoid gear oil
API Service Classification (GL-4)
After adding gear oil, remove the gear oil pump.
Apply gear oil to new O-rings [6] and install them on the
oil level check bolt and drain plug bolt. [3]
Install and tighten the bolts to the specified torque.

[6]
[4]
[5]
3-8
dummyhead
MAINTENANCE
THROTTLE CONTROL CABLE/
THROTTLE LINK CHECK/
ADJUSTMENT
CHECK
Set the control lever [1] in the forward full open position.
"N" (Neutral)
• If it is hard to set the control lever in the "F"
(Forward) or "R" (Reverse) position, stop the engine Throttle full
and shift the gear by turning the propeller or close position
propeller shaft. "F" (Forward)
• Do not try to shift the gear with force. Damage to the [1]
gear shift system can occur.
Tiller handle type: Throttle full

Set the throttle grip [2] in the forward full open position. open position
• Align the " " mark [3] on the throttle grip with the
throttle mark’s full open position [4] and secure the
throttle grip using the throttle friction fixing dial [5].
Tiller handle type:
[5]
[2]
[4] [3]

3-9
dummyhead
MAINTENANCE
1. With the control lever or throttle grip in the full open
position, check that the throttle arm [1] is in contact [1] [3]
with the full open stopper [2] of the shift link bracket
[3].
2. Holding the control lever or throttle grip in the
position of step 1, check the clearance between the
throttle cam [4] and the stopper (full open side) [5] of
the throttle body. It must be 1.0 mm (0.04 in) or less.
3. Move the control lever or throttle grip to the full close
position. Check that the throttle cam [6] of the
throttle body is in contact with the stopper (full close
side) [7] securely.
Adjust if either step 1, 2 or 3 is not satisfied.
[2]
If step 1 is not satisfied, go to the procedure
THROTTLE ARM NOT IN FULL OPEN POSITION
[5]
(page 3-11).
If either step 2 or 3 is not satisfied, go to the
procedure THROTTLE CAM NOT IN FULL OPEN
POSITION (page 3-11).
Tiller handle type:
If the throttle arm is not in the full open position or
the throttle cam is not in the full open position, go to
OR THE THROTTLE CAM NOT IN FULL OPEN
POSITION (page 3-12). 1.0 mm (0.04 in) maximum
[4]
[7]
Must be in contact
securely.
[6]
3-10
dummyhead
MAINTENANCE
ADJUSTMENT
1. Loosen the shift pivot lock nut [1] of the remote
control cable (throttle side) [2] and remove the shift [4] [2]
pivot [3] from the throttle arm link pin [4].
2. Screw in the shift pivot until the throttle arm comes in
contact with the full open stopper and loosely install
the shift pivot on the throttle arm.
3. Remote control type:
Set the control lever in the full open position (page 3-
9).
Tiller handle type:
Align the " " mark on the throttle grip with the full
open position of the throttle mark (page 3-9). [3] [1]
4. Check that steps 1, 2 and 3 of the throttle control
cable check are satisfied (page 3-10).
If steps 1, 2 and 3 of the throttle control cable
adjustment are not satisfied, adjust the throttle
control cable again starting with step 1.
If the throttle arm is in contact with the full open [1]
stopper but steps 2 and 3 are not satisfied, go to the
procedure <Throttle cam not in full open position>.
5. Remote control type:
Move the control lever in the "N" (Neutral) position,
and tighten the shift pivot lock nut securely.
Tiller handle type:
Move the throttle grip to the full close position and [3]
the gear shift lever in the "N" (Neutral) position, and
tighten the shift pivot lock nut securely.
THROTTLE CAM NOT IN FULL OPEN POSITION

Adjust the throttle control cable with it connected to the
throttle arm.
[2] [3]
1. Remove the throttle rod linkage pivot [1] from the
throttle plate [2] and loosen the linkage pivot lock nut
[3].
2. While holding the throttle arm in contact with the full
open stopper, adjust the clearance between the
throttle cam and the stopper (full open side) to 1 mm
or less by turning the throttle rod linkage pivot.
3. Loosely install the linkage pivot on the throttle plate.
4. Check that steps 1, 2 and 3 of the throttle control
cable check are satisfied (page 3-10).
5. Tighten the linkage pivot lock nut. [1]
6. After tightening the lock nut, check that the throttle
cam side pivot of the throttle rod is not out of the
throttle cam.

3-11
dummyhead
MAINTENANCE
THROTTLE ARM NOT IN FULL OPEN POSITION OR
THE THROTTLE CAM NOT IN FULL OPEN
POSITION
1. Remove the following:
– Under cover (page 19-23)
– Grip rubber and grip pipe (page 19-27)
2. Loosen the lock nut [1] of the tiller handle side
throttle cable pivot [2] and turn the throttle cable
pivot so that the throttle arm is in the full open [2]
position or the throttle cam is in the full open
position.
3. After adjustment, tighten the lock nut to the specified
torque.
4. Install the following:
– Grip pipe and grip rubber (page 19-38) [1]
– Under cover (page 19-45)
VALVE CLEARANCE CHECK/

ADJUSTMENT
• Valve clearance inspection and adjustment must be
performed with the engine cold.
1. Remove the following:
– Engine cover
– L./R. engine under cover (page 6-5)
– Under cover rear bracket (page 6-15)
– Cylinder head cover (page 14-15)
– Alternator cover (page 7-5)
2. Move the remote control lever or shift lever to the "N"
position.
3. Attach the wrench [1] to the rotor bolt/washer [2] and
turn the alternator rotor [3] clockwise. [1]
With the "UP" mark [4] on the cam chain driven
sprocket facing up, align the "I" marks [5] with the
cylinder head upper surface. (The No.1 piston is at
top dead center of its compression stroke at this
time.)
• Do not turn the alternator rotor counterclockwise.
[2] [3]
[5]
[4]
3-12
dummyhead
MAINTENANCE
4. With the No.1 piston at top dead center of its
compression stroke as described in step 3, check [1]
the intake and exhaust valve clearance on the No.1
cylinder by inserting a feeler gauge [1] between the
intake/exhaust side rocker arm valve adjusting
screw [2] and the valve stem end [3].
Valve clearance:
IN: 0.15 – 0.19 mm (0.006 – 0.007 in)
EX: 0.26 – 0.30 mm (0.010 – 0.012 in)
[3]
[2]
Intake side: Exhaust side:
No.1 No.1
No.2 No.2
No.3 No.3
No.4 No.4
5. If adjustment is necessary, loosen the valve

adjusting lock nut [1] while holding the valve [2] [3]
adjusting screw [2] with a screwdriver or equivalent
tool [3].
6. Insert the feeler gauge [4] between the intake/
exhaust side rocker arm valve adjusting screw and
the valve stem end.
7. Adjust the intake and exhaust valve clearance by
turning the valve adjusting screw.
8. After adjustment, secure the valve adjusting screw,
and tighten the lock nut to the specified torque.
TORQUE:
BF90D/BF100A 20 N·m (2.0 kgf·m, 15 lbf·ft) [1]
Intake side:
BF90D/BF100A 14 N·m (1.4 kgf·m, 10 lbf·ft)
Exhaust side: [4]
BF75D/BF80A: 14 N·m (1.4 kgf·m, 10 lbf·ft)
9. Recheck the valve clearances again. If the
measurements are out of specification, readjust the
valve clearances.

3-13
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MAINTENANCE
10.After adjusting the intake and exhaust valve
No.3 Piston at top dead center of
clearances of the No.1 cylinder, turn the alternator
compression stroke:
rotor clockwise by increments of 180° and bring the
piston of each cylinder at the top dead center of its
compression stroke.
Repeat the procedure from step 4 through step 9.
• Do not turn the alternator rotor counterclockwise.
• Perform this check on each cylinder with its piston at
top dead center of its compression stroke.
11.Install the following:
– Engine cover No.4 Piston at top dead center of
compression stroke:
No.2 Piston at top dead center of

compression stroke:
3-14
dummyhead
MAINTENANCE
SPARK PLUG CHECK/REPLACEMENT
REMOVAL
Remove the bolt [1] and plug maintenance cover [2]. [1]
[2]
Disconnect the ignition coil 3P connector [1].

Remove the bolts [2] and ignition coils [3]. Take care [1]
not to an impact or drop the ignition coils. Replace the [3]
ignition coil if dropped.
[2]
Clean any dirt from around the spark plug bases.

Use a spark plug wrench [1] and remove the spark
plugs.
[1]

3-15
dummyhead
MAINTENANCE
CHECK
Visually inspect the spark plug. Replace the plug if it is
Standard:
heavily fouled or the insulator [1] is cracked or chipped.
Check the following and replace if necessary.
[4] [3] [1] [2] [1]
– Insulator and sealing washer [2] for damage
– Center electrode [3] and side electrode [4] for wear
– Burning condition, coloration
RECOMMENDED SPARK PLUG:
Standard: ZFR6K-9E (NGK)
Optional (Iridium): IZFR6K-11E (NGK)
Measure the plug gap with a wire-type feeler gauge.
PLUG GAP:
Standard: 0.80 – 0.90 mm (0.031 – 0.035 in) 0.80 – 0.90 mm (0.031 – 0.035 in)
Optional (Iridium): 1.00 – 1.10 mm (0.039 – 0.043 in)
SERVICE LIMIT: Optional (Iridium):

Optional (Iridium): 1.30 mm (0.051 in)
[3] [1]
Standard plug: If the measurement is out of the specification, adjust by [4] [1]
bending the side electrode.
Optional iridium If the gap is out of specification, replace the plug. Do
plug: not clean or adjust the plug gap.
1.00 – 1.10 mm
(0.039 – 0.043 in) [2]
INSTALLATION
A loose spark plug can become very hot and can

damage the engine. Overtightening the spark plugs can
damage the threads in the engine.
Install and hand tighten the spark plugs to the cylinder
head, and then tighten the spark plugs to the specified [2]
torque.
Install the ignition coil and tighten the bolt.
Install the plug maintenance cover [1] and tighten the
bolt [2] to the specified torque.
TORQUE: 5 N·m (0.51 kgf·m, 3.7 lbf·ft)
[1]
3-16
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MAINTENANCE
PROPELLER AND SPLIT PIN CHECK
Check the propeller [1] for bending or damage.
Make sure the split pin [2] ends are bent as shown to [3] [2]
lock the castle nut [3].
Replace the propeller or split pin, if necessary.
[1]
ANODE METAL CHECK (OUTER SIDE)

GEAR CASE
Check the anode metal [1] for excessive wear or
corrosion. [1]
Replace the anode with a new one if it is corroded
excessively (page 16-4).

3-17
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MAINTENANCE
Remove the trim tab (page 16-4).
[1]
Check the continuity between the anode [1] and gear
case trim tab installation area [2].
Remove any corrosion; it prevents continuity.
Perform continuity inspection between the anode metal
surface without corrosion and the bare aluminum
surface of the gear case trim tab installation area.
If there is no continuity, remove the anode metal (page
16-4).
Remove the corrosion from the bolt, nut, anode metal,
and anode metal installation surface.
Install the anode metal and recheck the continuity.
If there is no continuity, replace the anode metal with a
new one and recheck.
[2]
STERN BRACKET
Check the anode [1] for excessive wear or corrosion.
Replace the anode with a new one if it is corroded
excessively:
– Except LHGX type (page 18-14)
– LHGX type only (page 18-48)
[1]
Check the continuity between the anode [1] and stern

bracket or power trim/tilt.
Perform continuity inspection between the anode metal
surface without corrosion and the bare aluminum
surface of the stern bracket, or the power trim/tilt.
If there is no continuity, remove the anode metal:
– Except LHGX type (page 18-14)
– LHGX type only (page 18-48)
Remove the corrosion from the bolt, anode metal, and
anode metal installation surface. [1]
If there is no continuity, replace the anode metal with a
3-18
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MAINTENANCE
ANODE METAL CHECK (INNER SIDE)
CYLINDER SLEEVE WATER JACKET
Remove the cylinder head water jacket anode (page
11-4).
Check the anode [1] for excessive wear or corrosion.
If the anode is worn to less than 2/3 of its original [1]

length, replace the screw, anode metal, sealing bolt
with new ones as a set.
If the sealing bolt is rusty or damaged, replace the
screw, anode metal, and sealing bolt with new ones as
a set.
Check the continuity between the anode [1] and

cylinder head. [1]
Perform the continuity inspection between the anode
metal surface without corrosion and the bare aluminum
surface of the cylinder head.
If there is no continuity, remove the anode metal and

remove the corrosion of the following parts using a soft
resin brush or shop towel. [4] [2] [6]
– Anode metal (cylinder head attaching area) [1] [5]
– Cylinder head (anode metal attaching area) [2]
– Screw (Anode metal attaching area) [3]
– Screw (male screw area) [4]
– Anode metal (screw head attaching area) [5]
Clean the cylinder head (female nut area) [6] using a
M6 x 1.0 tap.
[3] [1]
If there is no continuity, replace the screw, anode metal,
and screw with new ones as a set.

3-19
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MAINTENANCE
IDLE SPEED CHECK/ADJUSTMENT
INSPECTION
Check the following before starting the idle speed
inspection.
– Battery must be in good condition
– Boat equipment (electrical loads) must be removed
– Spark plug inspection (page 3-15)
– MIL must be OFF
Place the outboard motor vertically (with the engine
level to the ground), and set the remote control lever in
the "N" (Neutral) position.
Remove the propeller. Set the outboard motor gear
case in a test tank filled with water.
USING THE Dr.H
Remove the dummy connector [1] from the DLC and
connect the Dr.H [2]. [1]
Start the engine. [2]

Wait until the engine speed stabilizes under no load,
and check the idle speed.
SPECIFIED IDLE SPEED (AT NEUTRAL):
750 ± 50 min-1 (rpm)
• If the idle speed is outside the specification, perform
the ADJUSTMENT procedure on page 3-21.
USING THE DIGITAL TACHOMETER (KOWA: KEK-

8-MT600)
Remove the dummy connector [1] from the engine
[1] [2]
speed check 2P connector.
Connect the connector cable (KOWA: KEK-8-MT600- [3]
ATHM) [2] to the engine speed check 2P connector.
Connect the connector cable pin jack [3] to the digital
tachometer (KOWA: KEK-8-MT600).
Start the engine.
Wait until the engine speed stabilizes under no load,
and check the idle speed.
750 ± 50 min-1 (rpm)
• If the idle speed is outside the specification, perform
the ADJUSTMENT procedure on page 3-21.
3-20
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MAINTENANCE
ADJUSTMENT
Remove the propeller and set the outboard motor gear
case in a test tank filled with water. Start the engine. [1]
Disconnect the 2P connector [1] from the IAC valve.
The MIL [2] should come ON and the warning buzzer
should sound (intermittent sound: long beep).
[2]
Wait until the engine speed stabilizes, and then check

the idle speed. [1]
If the idle speed is outside the specification, adjust by
turning the idle adjusting screw [1] in or out.
BASE IDLE SPEED (AT NEUTRAL):
620 ± 30 min-1 (rpm) (with IAC valve connector
disconnected)
After adjustment, stop the engine and apply Nippon

Paint Uni-pack 200 or equivalent to the entire surface of
the idle adjusting screw [1] head.
[1]
Connect the IAC valve 2P connector.
Reset the ECM (page 5-5).
Start the engine. Wait until the engine speed stabilizes
under no load, and recheck the idle speed.
750 ± 50 min-1 (rpm)
If the idle speed is outside the specification, inspect and
troubleshoot the idle control system (page 4-6).

3-21
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MAINTENANCE
LUBRICATION
[1] Throttle arm pivot and sliding part [1] Detent spring roller
[2] Throttle plate pivot and sliding part
[3] Shift slide pivot sliding part
[4] Link pin [1]
[5] Shift link pin
[6] Throttle arm link pin
[1] [2] [1] Tiller handle
[6]
[3]
[5] [1] Tiller handle
[4]
[1] Vertical shaft

[2] Shift rod [1]
[1]
[2]
[1] Propeller shaft [1] Mount frame circlip installation part
[1] [1]
3-22
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MAINTENANCE
[1] Mount frame

[1] Throttle rod hole in the throttle body
Engine oil
[1] [1]
[1] Tilting shaft threads
[1] Detent spring roller

[2] Tilting shaft cam
[1]
[1]
[1] Grease fitting [2]

(Tilting shaft outer surface)
[1]
[1] Grease fitting

Gear oil (Tilting shaft outer surface)
[1] Gear case
[1]
[1]

3-23
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MAINTENANCE
[1] Tilting stopper bearing

[1] Upper cylinder bushing, pin
[1]
[1]
ATF
[1] Power trim/tilt (Except LHGX type)
[1]
[1] Lower cylinder bushing color [1] Thrust receiver (Except LHGX type)
[1]
[1]
3-24
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MAINTENANCE
WATER SEPARATOR CHECK
INSPECTION
Gasoline is highly flammable and explosive.

You can be burned or seriously injured when
handling fuel.
• Keep heat, sparks, and flame away.
• Wipe up spills immediately.
• Handle fuel only outdoors.

Check the water separator [1] for water accumulation or
sediment. If water or sediment is found, or the warning
buzzer sounds, disassemble and clean the water
separator (page 5-87).
If water or sediment is not found but the warning buzzer
sounds, check the water level sensor (page 5-106).
[1]
FUEL STRAINER (LOW PRESSURE

SIDE) INSPECTION/CLEANING
[1]
handling fuel.
INSPECTION
Visually check the fuel strainer [1] for water or blockage
with foreign material.
If there is water or blockage with foreign material,
disassemble and clean the fuel strainer.

3-25
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MAINTENANCE
REPLACEMENT
Place a shop towel under the fuel tubes.
Clamp fuel tube C [1] and fuel tube [2] securely with a [3]
commercially available tube clip [1].
[1]
[2]
Remove the fuel strainer [1] and strainer suspension [2]

from harness clip bracket B [3].
Disconnect fuel tube C [4] and fuel tube [5].
Remove the fuel strainer from the strainer suspension. [3]
[1]
[4] [5]
[2]
3-26
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MAINTENANCE
Set the strainer suspension [1] on a new fuel strainer [2]
with the projection [3] up. [3]
Install the strainer suspension by aligning the suction
[1]
side joint base [4] of the fuel strainer with the "I" mark
[5] on the strainer suspension.
[4]
[2]
[5]
Fuel strainer view from the front:
Install the fuel strainer [1] in harness band clip bracket

B [2].
Connect fuel tube C [3] to the suction side joint [4] of the [6] [3] [7] [5]
[4]
fuel strainer and connect the fuel tube [5] to the mark
side [6] of the fuel strainer joint as shown.
Install tube clip B12 [7] with the lugs up.
After connecting the fuel tubes, check for leaking
gasoline from the joints.
[2]
[1]

3-27
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MAINTENANCE
FUEL FILTER (HIGH PRESSURE SIDE)
INSPECTION/REPLACEMENT

handling fuel.
• Disconnect the battery cable from the battery

negative (–) terminal before relieving the fuel
pressure.
• Replace the sealing washer when the service check
bolt is loosened or removed.
• Catch the gasoline draining from the filter to avoid
contaminating the engine parts with gasoline.
Replace the fuel filter (high pressure side) at the
replacement interval shown or in the following case.
– Regular replacement period of every 2 years or 400
operating hours.
– When the fuel pressure does not reach 325 – 375
kPa (3.3 – 3.8 kgf/cm2, 47 – 54 psi) with the pressure
regulator vacuum tube disconnected, check the
following.
If the following items are normal, replace the fuel
strainer (high pressure side).
– Fuel pump (page 5-97)
– Pressure regulator (page 5-98)
[6] [4] [3]
Relieve the fuel pressure (page 5-66). [5] [1]
Place a rag or a shop towel over the strainer cover [1] [2]
and remove the three screw/washers [2], spring [3], and
the strainer cover.
Remove the fuel filter [4] and replace it if necessary.
Replace the O-ring [5] with a new one.
Install the fuel filter in the pump cover [6] securely as
shown.
Install the strainer cover, screw/washers, and tighten [6] [4]
them to the specified torque. [1]

Replace the sealing washer [7], and tighten the service
check bolt [8] to the specified torque.
TORQUE: 11.8 N·m (1.2 kgf·m, 9 lbf·ft)
Install the removed parts in the reverse order of
removal.
[5] [3]
[7]
[8]
3-28
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MAINTENANCE
FUEL TANK/FILTER CLEANING

handling fuel.
Remove the four screws [1] and fuel tank filter [2].
[1]
Clean the fuel tank with solvent, and allow the fuel tank
to dry thoroughly.
Clean the fuel filter [3] with solvent. and check to be
sure the fuel filter screen is undamaged.
Check the fuel filter and filter gasket [4] for
deterioration, clacks, or signs of leakage.
Replace if it necessary.
After cleaning, install the following:
– Filter gasket on to the fuel tank filter
– Fuel tank filter
– Four screws
Tighten the screws.
[2]
[4]
[3]

3-29
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MAINTENANCE
FUEL LINE CHECK/REPLACEMENT

handling fuel.
Check the fuel line, fuel hose, and the fuel tubes for
damage, fuel leakage, corrosion, and other
abnormalities. Check that the hoses and tubes are not
interfering with the neighboring parts.
Turn the combination switch ON to operate the fuel
pump (High pressure side) and check for fuel leakage.
Replace the hose or tube if there is damage, fuel
leakage, corrosion, etc.
Replace the following fuel tube (or hose) as necessary:
– Fuel strainer line (page 3-25)
– Water separator line (page 5-87)
– Fuel pump (Low pressure side) tube (page 5-67)
– Fuel pump (High pressure side)/Vapor separator
hose (page 5-76)
– Fuel injector (page 5-73)
FUEL TUBE C TUBE (7.3 X 90 mm)
PRESSURE REGULATOR
FUEL TUBE B FUEL HOSE RETURN HOSE FUEL TUBE D
FUEL HOSE
FUEL TUBE C
3-30
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MAINTENANCE
NUTS, BOLTS, FASTENERS
Check that all chassis nuts and bolts are tightened to
their correct torque values (page 2-4).
Check that all safety clips, hose clamps, and cable
stays are in place and properly secured.
CRANKCASE BREATHER CHECK

Check if the crankcase breather tube [1] is bent or
damaged. [1]
Replace the crankcase breather tube if necessary.
WATER PUMP CHECK

Place the outboard motor in a test tank or connect an
external water supply to the water inlet.
Start the engine and idle the engine in neutral.
Water should flow from the cooling system indicator
while the engine is running.
If water stops flowing while the engine is running,
inspect the water pump and water passage (page 11-
6).
[1]
EMERGENCY STOP SWITCH CHECK

Make sure that the clip [1] is set at the emergency stop
switch.
Start the engine and idle the engine in neutral.
The engine should stop when the clip is removed.
If there is a problem with the system, check the
emergency stop switch.
[1]

3-31
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MAINTENANCE
POWER TRIM/TILT CHECK
Set the swivel case to the uppermost position.
Make sure that the power trim/tilt has no ATF leaks.
If the ATF leaks, replace or repair the faulty part(s)
(page 18-41).
SHIFT CONTROL CABLE CHECK/

ADJUSTMENT
CABLE CHECK
Remove the following:
– Engine cover
– Front separator cover (page 6-4)
Check the shift control cable for damage or corrosion.
Replace if necessary (page 19-3).
Check the shift control cable connected parts for
damage or loose fitting.
Tighten loose fitting or replace if necessary (page 19-3).
Start the engine.
Check the shift control cable for smooth operation.
Check that the shift lever operates properly through
each position ("F" (Forward), "R" (Reverse), "N"
(Neutral)).
Stop the engine.
Replace if necessary (page 19-3).
CONTROL CHECK
Check the following before connecting the shift control
cable to the outboard motor. [4]
[3]
Shift control cable adjustment procedure is the same
when the long tiller handle type is used.
– Remote control box side (Tiller handle side) cable is
connected properly.
– Control lever is in the "N" (Neutral) position.
– Tip [1] of the neutral switch is set in the detent
assisted spring [2] securely and the detent spring
roller [3] is set in the groove [4] in the shift arm.
When the detent spring roller is set in the groove in
the shift arm but the tip of the neutral switch is not in
the detent assisted spring securely, check the detent
[2]
assisted spring. Replace the detent assisted spring
with a new one if it is deformed or damaged.
[1]
3-32
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MAINTENANCE
CONTROL ADJUSTMENT
1. Move the control lever to the "N" (Neutral) position.
[4]
2. Loosen the shift pivot lock nut [1] of the remote
control cable (shift side) [2] and remove the shift
pivot [3] from the shift link pin [4].
[3]
[1] [2]
3. Move the control lever [1] to the "F" (Forward)

position [2] and return it to the "N" (Neutral) position [4]
[3] slowly. [3]
4. While holding the shift control cable [4] and the [1] [2]
control lever in the position described in step 3, mark
(A) [5] at the end of the cable outer seal [6] on the
inner cable.
[5]
[6]
5. Move the control lever [1] to the "R" (Reverse)

position [2] and return it slowly to the "N" (Neutral)
position [3].
[3]
6. While holding the control lever in the position
described in step 5, mark (B) [4] at the end of the [2] [1]
cable outer seal on the inner cable.
[4]
7. Mark (C) [1] at the midpoint between the mark (A) [2]
and the mark (B) [3] on the inner cable.
[1]
[2] [3]

3-33
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MAINTENANCE
8. Align mark (C) [1] made in step 7 with the end of the
cable outer seal.
[1]
9. Check that the detent spring roller sits in the groove

in the shift arm.
10.Move the tip [1] of the shift link pin lightly to the right
and left. If there is free play in the shift link pin, set [2]
the shift link pin at the center [2] of the free play.
[1]
11.While holding the shift control cable [1] in the

position described in step 8 (i.e. mark (C) aligned
with the end of the cable outer seal), adjust the shift
control cable length by turning the shift pivot [2] right
or left until the shift pivot can be set on the shift link
pin [3] smoothly. Install the shift pivot on the shift link [4]
pin.
• Take care not to bring mark (C) out of alignment with
the end of the cable outer seal. Do not move the
shift link pin out of the center of the free play, either,
during installation of the shift pivot on the shift link
pin. [2]
Tighten the shift pivot lock nut [4] securely. [3]

12.After connecting the shift control cable, move the
control lever back and forth to check for gear shift.
• If it is hard to set the control lever in the "F"
(Forward) or "R" (Reverse) position, stop the engine
and shift the gear by turning the propeller or
propeller shaft.
• Do not try to shift the gear with force. Damage to the
gear shift system can occur.
[2]
[1]
3-34
dummyhead
MAINTENANCE
13.Move the control lever from the "F" (Forward) to the
“N” (Neutral) position. If the gear does not shift to
neutral, disconnect the shift control cable from the
shift link pin. Move the inner cable toward the mark Adjustment range
(A) [1] and repeat the procedure from step 9.
[1]
14.Move the control lever from the "R" (Reverse) to the

"N" (Neutral) position. If the gear does not shift to
neutral, disconnect the shift control cable from the
shift link pin. Move the inner cable toward mark (B) Adjustment range
[1] and repeat the procedure from step 9.
15.After adjustment, move the control lever to each
gear position. If the gear does not shift to neutral
properly, repeat step 11 or step 12.
16.After installation, tighten the shift pivot lock nut [2].
[2] [1]

3-35
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MEMO

dummytext
4. TROUBLESHOOTING
BEFORE TROUBLESHOOTING ··············· 4-2 ALERT SYSTEM/WARNING SYSTEM

TROUBLESHOOTING ·························· 4-16
ENGINE TROUBLESHOOTING ················ 4-2
FRAME TROUBLESHOOTING··············· 4-23
FUSE/ELECTRIC POWER LINE
TROUBLESHOOTING ·························· 4-12

4-1
dummyhead
TROUBLESHOOTING
BEFORE TROUBLESHOOTING
TROUBLESHOOTING
• Use a known-good battery for troubleshooting.

• Check that the connectors are connected securely.
• Check for sufficient fresh fuel in the fuel tank.
• Check that the emergency stop switch clip is set securely.
• Read the circuit tester's operation instructions carefully, and observe the instructions during inspection.
• When a commercially available circuit tester is used for inspection, use the special tool [Tester probe (Male)
07ZAJ-RDJA110], and take care not to apply excessive force to the connector terminal.
• Switch the tester lead polarities to check the circuit, including the diode. The circuit is normal if there is
continuity in one direction but not the other. If there is continuity in both directions or in neither direction, the
circuit is abnormal.
– Indicator light
– PGM-FI/main relay
– Regulator/rectifier
– Power tilt relay
ENGINE TROUBLESHOOTING
ENGINE DOES NOT START OR ENGINE STALLS
ENGINE DOES NOT START
1. Electrical power system inspection
Turn the combination switch ON.
Check that the MIL and warning buzzer sound.
Does the MIL come ON for 2 seconds and warning buzzer sound twice?
YES – GO TO STEP 2.
NO – Perform fuse/electrical power system troubleshooting (page 4-12).
2. Alert system inspection
Check the warning buzzer sound.
Does the warning buzzer sound twice and then stop?
NO – Perform alert system/warning system troubleshooting (page 4-16).
3. Starting system inspection
Check that the starter motor operates properly.
Does the starter motor turn?
NO – Perform starting system troubleshooting (page 9-3).
4. Vapor separator inspection
Loosen the vapor separator drain screw and check whether fuel flows out.
Does the fuel flow properly?
NO – • Clogged or damaged fuel tube
• Closed fuel tank vent knob
• Faulty primer bulb
• Clogged fuel strainer (Low pressure side)
• Clogged water separator
• Faulty fuel pump (Low pressure side)
• Clogged vapor separator air vent tube or filter
• Faulty vapor separator
4-2
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TROUBLESHOOTING
5. Fuel Pump (High pressure side) Inspection
You should hear the pump hum when the combination switch is turned "ON".
Is the hum heard?
NO – Perform fuel pump system (High pressure side) inspection (page 5-99).
6. Fuel Flow Inspection
Inspect the fuel flow (page 5-99)
Is the fuel flow within specification?
NO – • Clogged fuel feed hose
• Clogged fuel strainer (High pressure side)
• Pressure regulator malfunction (page 5-98)
• Faulty fuel pump (High pressure side)
7. Spark plug inspection
Remove and inspect the spark plugs.
Is the spark plug wet?
YES – • Incorrect spark plug heat range
• Incorrect spark plug gap
• Clogged between the silencer and cylinder head
• Improper vapor separator float height
NO – GO TO STEP 8.
8. Cylinder Compression
Check the cylinder compression (page 14-32).
Is the compression normal?
NO – • Improper valve clearance
• Valve stuck open
• Worn cylinder and piston rings
• Damaged cylinder head gasket
• Seized valve
• Improper cam chain adjustment
9. Fuel injector inspection
Inspect the fuel injector (page 5-103)
Is the fuel injector normal?
NO – • Repair the open or short circuit in the fuel injector wire
• Faulty fuel injector
10. Ignition system inspection
Check the ignition system (page 8-3).
Is the ignition system normal?
NO – Faulty ignition system.

4-3
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TROUBLESHOOTING
11. IAC valve inspection
Replace the IAC valve with a new one and start the engine.
Engine starts?
YES – Faulty original IAC valve.
NO – Replace the ECM with a new one and recheck.
ENGINE STARTS BUT STALLS SOON

2. Engine idle speed inspection
Adjust by turning the idle adjusting screw in or out.
Start the engine.
Does the engine stall?
NO – Adjust the idle adjusting screw (page 3-20).
4. Intake air leak inspection
Check for secondary air in the system.
Is there an air leak?
YES – • Loose IAC valve and/or throttle body mounting bolt
• Leaking or damaged throttle body and/or IAC valve gasket
• Loose intake manifold mounting bolt
• Leaking or damaged intake manifold seal ring
• Loose fuel line mounting bolts
• Leaking or damaged fuel injector seal ring
• Clogged or damaged fuel feed hose
4-4
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TROUBLESHOOTING
6. Pressure regulator inspection
Check the fuel pressure and record it (page 5-97)
Disconnect the pressure regulator vacuum tube.
Check the fuel pressure.
Is the fuel pressure higher with the vacuum tube disconnected?
NO – • Clogged pressure regulator vacuum tube
• Faulty pressure regulator
Inspect the fuel injector (page 5-103).
Engine stopped?
YES – Replace the ECM with a new one and recheck.
NO – Faulty original IAC valve.

4-5
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TROUBLESHOOTING
ENGINE DOES NOT RUN SMOOTHLY OR THE ENGINE STALLS DURING
DECELERATION
ENGINE SPEED IS NOT STABLE DURING IDLE AND TROLLING
Adjust by turning the idle adjusting screw in or out (page 3-20).
Is the idle speed normal?
YES – Improperly adjusted idle adjusting screw.
4-6
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TROUBLESHOOTING
7. Neutral switch inspection
Inspect the neutral switch (page 9-22)
Is the neutral switch normal?
NO – Faulty original neutral switch.
9. Throttle body inspection
Inspect and clean the throttle body (page 5-105).
Is the throttle body normal?
NO – Clean or replace the throttle body (page 5-105).
ENGINE SPEED IS HIGHER THAN THE SPECIFIED TROLLING SPEED AFTER WARMING UP

4-7
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TROUBLESHOOTING
ENGINE SPEED IS LOWER THAN THE SPECIFIED IDLE SPEED OR TROLLING SPEED AFTER
WARMING UP
Is the engine speed stable during idle and trolling?
ENGINE SPEED DOES NOT INCREASE

1. Throttle link and throttle cable inspection
Inspect the throttle link and throttle cable (page 3-9).
Is the throttle link and throttle cable adjustment correct?
NO – Improper throttle link and throttle cable adjustment (page 3-9)
2. Propeller inspection
Match the propeller.
Is the propeller correct?
NO – Propeller mismatched.
4-8
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TROUBLESHOOTING
5. Valve clearance inspection
Inspect the valve clearance (page 3-12)
Is the valve clearance correct?
NO – Improper valve clearance adjustment
6. Neutral switch inspection
Inspect the neutral switch (page 9-22)
Is the neutral switch normal?
NO – Replace the neutral switch with a new one and recheck.
YES – • BF75D/80A: Replace the ECM with a new one and recheck.
• BF90D/100A: GO TO STEP 8.
8. VTEC system inspection (BF90D/100A only)
Inspect the VTEC system
Is the VTEC system operating properly?
NO – Faulty VTEC system.

4-9
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TROUBLESHOOTING
ENGINE SPEED DOES NOT STABILIZE WHEN RUNNING AT HIGH SPEED AND ENGINE SPEED IS NOT
AS HIGH AS IT USED TO BE WHEN RUNNING WITH THE THROTTLE FULLY OPEN
Inspect the throttle cable (page 3-9).
NO – Improper throttle link and throttle cable adjustment (page 3-9)
ENGINE SPEED DOES NOT DECREASE

Inspect the throttle cable (page 3-9).
NO – Improper throttle link and throttle cable adjustment (page 3-9).
2. Throttle shaft inspection
Check the throttle shaft operates smoothly.
Throttle shaft moves smoothly?
NO – Clean or replace the throttle body (page 5-105).
Check the engine idle speed (page 3-20).
NO – Improperly adjusted idle adjusting screw.
Does the engine speed decrease?
4-10
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TROUBLESHOOTING
ENGINE SPEED INCREASES EXCESSIVELY
1. Propeller inspection
Check the propeller.
Is the propeller correct?
NO – • Propeller mismatched
• Faulty propeller
2. Outboard motor installation inspection
Inspect the outboard motor installation (Transom height/tilt angle).
Is the outboard motor installation correct?
NO – Faulty outboard motor installation.

4-11
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TROUBLESHOOTING
FUSE/ELECTRIC POWER LINE
TROUBLESHOOTING
FUSE BOX CONNECTION TABLE
Fuse No. Amps. Component (s) or Circuit (s) Protected
– 70 A Regulator/Rectifier
1 10 A Fuel pump (High pressure)
2 10 A Power tilt relay, Combination switch, PGM-FI/Main relay,
Oil indicator light, Overheat indicator light, MIL, Alternator indicator,
Warning buzzer, Tachometer, Trim meter,
Hour meter, Volt meter,
3 15 A Ignition coil
4 10 A HO2S heater, DLC
5 15 A ECM (IGP1, IGP2), Fuel injector, CKP sensor, CMP sensor
6 30 A PGM-FI/Main relay
FUSE BOX
70A FUSE
4-12
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TROUBLESHOOTING
FUSE LOAD CHART
W To REGULATOR/RECTIFIER
(OUTPUT TERMINAL)
POWER TRIM/TILT
FUSE SWITCH
(70 A) (OUTBOARD MOTOR Lg To POWER TILT RELAY
SIDE)
Lb To POWER TILT RELAY

POWER TRIM/TILT
SWITCH
Bl (REMOTE CONTROL BOX/
W W/Bl W/Bl
TILLER HANDLE SIDE)
Bl/R To ECM (EMS)
OFF
2 FUSE
(10 A)
Bl W W/Bl Bl/Y Bl/Y To BUZZER
ON
Bl/Y To INDICATOR LIGHT
START Bl/Y To TACHOMETER
BATTERY
COMBINATION Bl/Y Bl/Y To TRIM METER
SWITCH Y To VOLTMETER (OPTION)
Y To HOUR METER (OPTION)
W Bl/W
PGM-FI MAIN
RELAY
6 FUSE 3 FUSE
(30 A) (15 A)
W W W/Y W/Bl Y Y/Bl To IGNITION COILS
MAIN
W
Bl
1 FUSE
(10 A)
5 FUSE
W/Bu W/Bu
(15 A)
W/G Y Y/Bl To ECM (IGP1, IGP2)
Y/Bl To FUEL INJECTORS
Y/Bl To CKP SENSOR
STARTER FUEL 4 FUSE
(10 A) Y/Bl To CMP SENSOR
W/R Y Y/Bl To H02S HEATER
Y/Bl To DLC
Lg/R Lg To ECM (FLR 1,2)
Bu/R To FUEL PUMP
(HIGH PRESSURE SIDE)
W To STARTER SOLENOID
Bl/Bu Bu Bl Bl/Bu Bl
NEUTRAL
SWITCH
Bl BLACK Br BROWN
Y YELLOW O ORANGE
R RED P PINK
W WHITE Gr GRAY

4-13
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TROUBLESHOOTING
MIL AND WARNING BUZZER DOES
NOT OPERATE
1. Fuse inspection
Turn the combination switch OFF.
Check for blown No.2, No.6, and No.5 fuses.
Is the fuse blown?
YES – Replace the blown fuse and check for
short in the main wire harness or incorrect
load by referring to the "FUSE LOAD
CHART."(page 4-13)
2. ECM power line inspection
ECM CONNECTOR B IGP2
Disconnect ECM connector B . (Yellow/Black)
MAIN WIRE HARNESS SIDE
Measure the battery voltage between the respective
terminals of the main wire harness side No.8
(Yellow/Black) terminal and No.9 (Yellow/Black)
terminal of ECM connector B and the engine
ground.
Does battery voltage exist?
IGP1
(Yellow/Black)
3. ECM ground line inspection

PG3
Disconnect the ECM connector A . ECM CONNECTOR A
(Green)
Check for continuity between the ECM connector A
main wire harness side No.17 (Green)
terminal, No.35 (Green) terminal and engine
ground.
Check for continuity between the ECM connector B
main wire harness side No.5 (Blue) terminal,
No.17 (Green) terminal, No.23 (Blue) terminal,
No.35 (Green) terminal and engine ground. PG4
(Green)
Is there continuity?
YES – Replace the ECM with a new one and
recheck.
ECM CONNECTOR B
NO – Repair open in the wire harness between MAIN WIRE HARNESS SIDE
the ECM and engine ground.
PG1 LG1
(Green) (Blue)
PG2 LG2
(Green) (Blue)
4-14
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TROUBLESHOOTING
4. No.6 fuse line inspection
PGM-FI/MAIN RELAY 4P CONNECTOR
Disconnect PGM-FI/main relay 5P connector .
Measure the voltage between the PGM-FI/main
relay 5P connector main wire harness side
No.5 (White) terminal and engine ground.
NO – Repair open in the wire harness between +B
the battery and PGM-FI/main relay. (White)
5. No.2 fuse line inspection

Disconnect the PGM-FI/main relay 6P connector
. PGM-FI/MAIN RELAY 6P CONNECTOR
Measure the voltage between the PGM-FI/main
No.2 (Black/Yellow) terminal and No.4 (Black)
terminal.
YES – GO TO STEP 6. LOAD SIGNAL GND
(Black)
NO – • Repair open in the wire harness (Black/yellow)
between the battery and combination
switch
• Repair open in the wire harness
between the combination switch and
PGM-FI/main relay
• Faulty combination switch
6. Main relay inspection
Remove the PGM-FI/main relay (page 10-3).
Inspect the PGM-FI/main relay (page 10-13).
Is PGM-FI/main relay normal?
YES – • Repair open in the wire harness
between the ECM and PGM-FI/main
relay.
• Replace the ECM with a new one and
recheck.
NO – Replace the PGM-FI/main relay with a new
one and recheck.

4-15
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TROUBLESHOOTING
ALERT SYSTEM/WARNING SYSTEM TROUBLESHOOTING
• Perform the MIL initial check before starting the engine.
The warning buzzer can sound when the starter motor speed is extremely low, but the alert system/warning system is normal if
the buzzer stops sounding after starting the engine.
When the warning buzzer keeps sounding after MIL initial check, refer to the following symptom chart and perform the
necessary troubleshooting.
If the symptom is not shown in the following symptom chart, perform a function test according to the following procedure:
– FUNCTION TEST USING THE Dr.H (page 4-17)
– FUNCTION TEST WITHOUT USING THE Dr.H (page 4-18)
SYMPTOM CHART
Condition Indicator light
Oil Overheat MIL Alternator Warning
indicator indicator (Red) indicator buzzer
light light (Red) light (Red)
(Green)
Combination switch ON
Sounds twice
(MIL initial check) (for 2 sec.) (for 2 sec.) (for 2 sec.)
2 sec. after turning the combination Stop
switch ON
Normal operation Stop
Low oil pressure Continuous
sound
Overheat Continuous
sound
MIL faulty Intermittent
*1 *2 sound
(Long beep)
Abnormal charging Intermittent
sound
(Long beep)
Water contamination Intermittent
sound
(Short beep)
: ON : OFF
When two or more problems occur the same time, the warnings for both problems are indicated together.
The prolonged buzzer sound takes precedence over the short buzzer sound.
Example: When problems occur with overheat and abnormal charging at the same time, the oil indicator light, and the alternator
indicator light all come on and the buzzer sounds continuously.
*1: The oil indicator light blinks when a problem with the EOP sensor occurs at the same time as a MIL malfunction.
*2: The overheat indicator light blinks when a problem with the ECT sensor occurs at the same time as a MIL malfunction.
4-16
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TROUBLESHOOTING
FUNCTION TEST USING THE Dr.H
1. Buzzer inspection
Turn the combination switch OFF and connect the Dr.H.
Test the warning buzzer using the Dr.H.
Does the buzzer sound?
NO – • Inspect the warning buzzer
• Inspect the combination switch
• Repair the open or short circuit in the main wire harness
• Replace the ECM with a new one and recheck
2. Alternator indicator light inspection
Test the alternator indicator light using the Dr.H.
Does the alternator indicator light blink?
NO – • Inspect the indicator light
• Repair the open circuit in the main wire harness
3. MIL inspection
Test the MIL using the Dr.H.
Does the MIL blink?
4. Overheat indicator light inspection
Test the overheat indicator light using the Dr.H.
Does the overheat indicator light blink?
5. Oil indicator light inspection
Test the oil indicator light using the Dr.H.
Does the oil indicator light blink?
YES – Indicator light/warning buzzer is normal.

4-17
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TROUBLESHOOTING
FUNCTION TEST WITHOUT USING THE Dr.H
1. Indicator light/buzzer short circuit inspection
Turn the combination switch OFF and disconnect the ECM connector A and B .
Does the warning buzzer sound and/or indicator come ON?
YES – • Inspect the warning buzzer
• Inspect the indicator light
• Repair the short circuit in the main wire harness
Short the No.19 terminal (Yellow/Green) of the ECM ECM CONNECTOR A
connector A main wire harness side 36P
connector to engine ground using a jumper wire.
Does the warning buzzer sound?
NO – • Inspect the warning buzzer
• Inspect the combination switch
• Repair the open circuit in the main wire
harness BUZZ
• Replace the ECM with a new one and (Yellow/Green)
recheck
ECM CONNECTOR A
Short the No.2 terminal (White/Blue) of the ECM MAIN WIRE HARNESS SIDE
Does the alternator indicator light come ON?
NO – • Inspect the indicator light ACGLP
• Repair the open circuit in the main wire (White/Blue)
harness
recheck
4. MIL inspection
ECM CONNECTOR A
Short the No.3 terminal (Red/Blue) of the ECM MAIN WIRE HARNESS SIDE
Does the MIL come ON?
NO – • Inspect the indicator light WARNL
• Repair the open circuit in the main wire (Red/Blue)
harness
recheck
4-18
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TROUBLESHOOTING
5. Overheat indicator light inspection
Turn the combination switch OFF. ECM CONNECTOR A
Short the No.32 terminal (Red) of the ECM MAIN WIRE HARNESS SIDE
Does the overheat indicator light come ON?
NO – • Inspect the indicator light OHL
• Repair the open circuit in the main wire (Red)
harness
recheck
6. Oil indicator light inspection

ECM CONNECTOR A
Turn the combination switch OFF. MAIN WIRE HARNESS SIDE
Short the No.31 terminal (Yellow) of the ECM
Does the oil indicator light go off?
OPL
YES – Indicator light/warning buzzer is normal. (Yellow)
• Repair the open circuit in the main wire
harness
recheck

4-19
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TROUBLESHOOTING
WARNING BUZZER SOUNDS CONTINUOUSLY
• The warning buzzer can sound when the starter motor speed is extremely low, but the alert system/warning
system is normal if the buzzer stops sounding after starting the engine.
AND THE OVERHEAT INDICATOR LIGHT COMES ON OR BLINKS
1. MIL inspection
Check to see if the MIL stays on.
Does the MIL stay ON?
YES – Perform PGM-FI troubleshooting (page 5-16)
2. Outboard motor installation inspection
Inspect the outboard motor installation (transom height/tilt angle).
Is the outboard motor installation correct?
NO – Faulty outboard motor installation.
3. Water screen inspection
Stop the engine and check the water screen.
Is it blocked with foreign material?
YES – Remove the foreign material.
4. Cooling water inspection
Check the cooling water with the engine idling.
Is the water flowing through the check port steadily?
NO – • Faulty water pump
• Blocked or damaged water passage
5. Engine cool down procedure
Put the outboard motor into gear for a few minutes and let the engine cool down at idle speed.
Does the overheat indicator light go OFF and the buzzer stop sounding?
YES – Temporary failure (disappears)
6. Thermostat inspection
Check the thermostat (page 11-12).
Is the thermostat normal?
NO – Replace the thermostat with a new one and recheck.
ECM CONNECTOR A
Check for continuity between the ECM connector A MAIN WIRE HARNESS SIDE
main wire harness side No.19 (Yellow/Green)
terminal and engine ground.
YES – Short in the wire harness between the
ECM and Buzzer.
BUZZ
NO – Replace the ECM with a new one and (Yellow/Green)
recheck
4-20
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TROUBLESHOOTING
AND THE OVERHEAT INDICATOR LIGHT GOES OFF AND OIL INDICATOR LIGHT GOES OFF OR
BLINKS
1. MIL inspection
YES – Perform PGM-FI troubleshooting (page 5-16)
2. Oil level inspection
Stop the engine and check the oil level.
Is the oil level at the proper level?
NO – Adjust the oil level.
3. Oil indicator light inspection 1
Let the engine idle.
Check the oil indicator light and buzzer.
Does the oil indicator light come ON and warning buzzer stop sounding?
4. Oil indicator light inspection 2
Snap the engine (4,000 min-1 (rpm) or above under load) and check the oil indicator light and buzzer.
Does the oil indicator light come ON and warning buzzer stop sounding?
YES – Temporary failure (disappears)
ECM CONNECTOR A
Check for continuity between the ECM connector A MAIN WIRE HARNESS SIDE
main wire harness side No.19 (Yellow/Green)
YES – Short in the wire harness between the
ECM and Buzzer
BUZZ
NO – GO TO STEP 6. (Yellow/Green)
6. Oil Pressure inspection

Turn the combination switch OFF and connect the ECM connector A .
Reset the ECM following:
– Using the Dr.H (page 5-5)
– Without using the Dr.H (page 5-5)
Check the oil pressure (page 12-10).
Is the oil pressure within specification?
NO – • Oil filter cartridge is clogged
• Oil strainer is clogged
• Faulty oil pump
• Oil passage is clogged

4-21
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TROUBLESHOOTING
7. EOP sensor inspection
Replace the EOP sensor (page 5-84).
Check the oil indicator light and buzzer.
Does the oil indicator light come ON and the buzzer stop sounding?
YES – Faulty original EOP sensor.
AND THE OVERHEAT INDICATOR LIGHT GOES OFF AND OIL INDICATOR LIGHT COMES ON
1. Overheat indicator light and oil indicator light inspection
Check the overheat indicator light and oil indicator light as follows:
– Using the Dr.H (page 5-5)
– Without using the Dr.H (page 5-5)
Are they correct?
NO – Replace or repair the faulty part.
WARNING BUZZER SOUNDS INTERMITTENTLY (LONG BEEP)

1. MIL inspection
YES – Perform PGM-FI troubleshooting (page 5-16).
Check to see if the alternator indicator light stays on.
Does the alternator indicator light stay ON?
YES – Perform charging system troubleshooting (page 7-3).
NO – Check the indicator light:
• Perform "FUNCTION TEST USING THE Dr.H" (page 5-13)
• Perform "FUNCTION TEST WITHOUT USING THE Dr.H" (page 5-43)
• If indicator light is correct, replace the ECM with a new one and recheck
3. Battery charging voltage inspection
Start the engine and check the battery voltage.
Voltage of the battery is normal (16.5 v or less)?
NO – (16.5 v or less) Faulty regulator/rectifier.
NO – (Without voltage) Perform the charging system trouble shooting.
4. Battery inspection
Stop the engine and check the battery voltage.
Voltage of the battery is 10 v or less?
YES – Replace or charge the battery.
NO – Check the indicator light:
• FUNCTION TEST USING THE Dr.H (page 5-13)
• FUNCTION TEST WITHOUT USING THE Dr.H (page 5-43)
• If indicator light is correct, replace the ECM with a new one and recheck
4-22
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TROUBLESHOOTING
WARNING BUZZER SOUNDS INTERMITTENTLY (SHORT BEEP)
1. Water separator/fuel strainer (low pressure side) inspection
Check the water separator and the fuel strainer (low pressure side).
Is there water in the cup?
YES – Remove the water and clean the cup of the water separator and fuel strainer.
2. Water level sensor inspection
Disconnect the water level sensor 2P connector and recheck.
Does the warning buzzer sound the intermittent short term sound?
YES – Repair the shorted wire between ECM and water level sensor. If the wires are correct, replace the
ECM with a new one and recheck.
NO – Faulty water level sensor.
FRAME TROUBLESHOOTING
HARD TO SHIFT
1. Control cable inspection
Check the remote control cable (engine side) for corrosion.
Is the control cable normal?
NO – Replace the remote control cable.
2. Shift control cable adjustment
Adjust the shift control cable (page 3-32).
Check the remote control lever of the remote control box for proper operation.
Is the remote control box operation proper?
YES – Improper cable adjustment.
3. Shift link/link rod inspection
Check the following to see if they are bent or deformed.
– Shift link
– Shift link rod
Are they normal?
NO – Replace the faulty part (s).
4. Shift shaft/shift shaft gear inspection
Check shift shaft A and B to see if they are bent or deformed.
Check shift shaft A and B gear teeth for wear or damage.
Are they normal?
NO – Replace the faulty part (s).
5. Shift rod inspection
Check the shift rod to see if it is bent or damaged.
Is it normal?
YES – Gear case problem (clutch shifter and propeller shaft are corroded).
NO – Replace the shift rod with a new one and recheck.

4-23
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TROUBLESHOOTING
POWER TRIM/TILT DOES NOT MOVE
1. power tilt motor inspection
Operate the power trim/tilt switch and check the power tilt motor sound.
Do you hear the motor sound?
NO – Perform "POWER TILT MOTOR DOES NOT OPERATE" troubleshooting (page 4-25).
2. Manual valve inspection
Check the manual valve tightness.
Is the manual valve tight?
NO – Tighten the manual valve to the specified torque: 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft)
3. Oil leak inspection
Check for oil leakage from the power trim/tilt.
Is there oil leakage?
YES – Replace the O-ring and oil seal at the leaking point (when the manual valve O-ring or piston rod
(cylinder cap) oil seal is leaking, replace it as an assembly).
Check the oil level with each rod fully extended.
Is the oil level within the specification?
NO – Fill the oil to the specified level.
5. Air bleed inspection
Check for air in the system.
Air in the system?
YES – Bleed air from the system (page 18-36)
NO – Power trim/tilt faulty.
Repair the faulty part by referring to the "POWER TRIM/TILT QUICK
REFERENCE CHART (page 4-27).
4-24
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TROUBLESHOOTING
POWER TRIM/TILT DOES NOT HOLD POSITION
1. Manual valve inspection
Check the manual valve tightness.
Is the manual valve tight?
NO – Tighten the manual valve to the specified torque: 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft)
Check for oil leakage from the power trim/tilt.
Is there oil leakage?
YES – Replace the O-ring and oil seal at the leaking point (when the manual valve O-ring or piston rod
(cylinder cap) oil seal are leaking, replace it as an assembly).
3. Hydraulic pressure inspection
Check the hydraulic pressure (page 18-38).
Is the hydraulic pressure within the specification?
NO – Replace the pump and recheck.
Check the oil level with each rod fully extended.
Is the oil level within the specification?
NO – Fill the oil to the specified level.
5. Air bleed system inspection
Check for air in the system.
Air in the system?
YES – Bleed air from the system (page 18-36)
NO – Power trim/tilt faulty.
Repair the faulty part by referring to the "POWER TRIM/TILT QUICK
REFERENCE CHART (page 4-27).
POWER TILT MOTOR DOES NOT OPERATE

1. Power tilt motor inspection
Connect the battery to the power tilt motor and check whether the motor operates.
Does the motor turn?
2. Power tilt relay inspection
Check the power tilt relay (page 10-15)
Is the power tilt relay normal?
NO – Replace the power tilt relay with a new one and recheck.
3. power trim/tilt switch inspection
Check the power trim/tilt switch (page 10-16)
Is the power trim/tilt switch normal?
YES – Repair the main wire harness or replace it.
NO – Replace the power trim/tilt switch with a new one and recheck.

4-25
dummyhead
TROUBLESHOOTING
4. Overheat inspection
Check the motor for overheating.
Is the motor overheated?
YES – Cool down the motor.
5. Power tilt motor continuity inspection
Check for continuity at the motor (page 18-46).
NO – Repair or replace the motor.
6. Breaker inspection
Check the breaker inside the motor (page 18-46).
Is the breaker normal?
NO – Replace the front bracket.
Check for oil inside the motor.
Is oil inside?
YES – Replace the motor (page 18-23).
NO – Disassemble the motor and replace the faulty part (page 18-41).
GAS ASSISTED DAMPER TILT-UP LOAD IS HEAVY (LHGX TYPE ONLY)

1. Gas assisted damper stick inspection.
Check the damper stick.
Is it stuck from corrosion?
YES – Replace the damper stick.
NO – Replace the gas assisted damper (page 18-48).
GAS ASSISTED DAMPER DOES NOT HOLD IN POSITION (LHGX TYPE ONLY)
1. Tilt lever inspection.
Check the tilt lever position.
Position of the tilt lever is "LOCK”?
YES – Replace the gas assisted damper (page 18-48).
NO – Move the tilt lever to the "LOCK" position.
4-26
dummyhead
TROUBLESHOOTING
POWER TRIM/TILT QUICK REFERENCE CHART
Symptom Pressure check Check/repair method
Does not Does not Does not hold Lower chamber Upper chamber Check point
tilt up tilt down Lowers Extends hydraulic hydraulic
pressure lower pressure lower
than spec or than spec or
pressure drops. pressure drops.
[1] Motor Check according to the motor
check procedure.
[2] manual Check that the manual valve is
valve installed securely. Replace if it is
damaged. Check the O-ring for
damage and replace if
necessary. If there is no damage,
clean the O-ring and install it on
the manual valve properly.
[3] Backup ring Check the O-ring for damage and
O-ring replace if necessary. If there is no
[4] Backup ring damage, clean the O-ring and
O-ring reinstall it properly.
[5] Check valve Check the ball seat for damage or
foreign material. The check valve
cannot be replaced as an
individual part. Replace the free
piston assembly if the check
valve is defective.
[6] O-ring Check the O-ring for damage and
replace if necessary. If there is no
damage, clean the O-ring and
reinstall it properly.
[7] Shock relief Check the ball seat for damage or
valve foreign material. The shock valve
cannot be replaced as an
individual part. Replace the
piston rod assembly if the shock
valve is defective.
[8] Dust seal/O- Check the dust seal and O-ring
ring for damage. The dust seal and O-
ring cannot be replaced as
individual parts. Replace the
piston rod assembly if the dust
seal or O-ring are defective.
[9] Oil Check the oil level and add the oil
if necessary.
[10] Pump Do not disassemble the pump
[11] Down relief assembly. If any of the following
valve parts are defective, replace the
[12] Lower pump assembly.
chamber check
valve
[13] Lower
chamber spool
valve
[14] Upper
chamber check
valve
[15] Upper
chamber spool
valve

4-27
dummyhead
TROUBLESHOOTING
[1] MOTOR [15] UPPER CHAMBER SPOOL VALVE

[10] PUMP
[11] DOWN RELIEF VALVE
[13] LOWER CHAMBER

SPOOL VALVE
[12] LOWER CHAMBER

CHECK VALVE
[2] MANUAL VALVE
[14] UPPER CHAMBER CHECK VALVE
[8] DUST SEAL/O-RING PISTON ROD A ASSEMBLY
[1] MOTOR
[9] OIL
[10] PUMP ASSEMBLY
[7] SHOCK RELIEF VALVE
[6] O-RING
[4] BACKUP RING

/O-RING
[3] BACKUP RING

/O-RING [3] BACKUP RING
/O-RING
FREE PISTON [5] CHECK VALVE
4-28
dummytext
5. FUEL SYSTEM
SERVICE PRECAUTIONS ····························· 5-2 ECT SENSOR 2 REMOVAL/INSTALLATION ··· 5-85
PIPING CONNECTIONS································ 5-7 ECT SENSOR 3 REMOVAL/INSTALLATION ··· 5-85

5
CIRCUIT DIAGRAM······································ 5-8 AIR VENT STRAINER/CHECK VALVE
REMOVAL/INSTALLATION ·························· 5-86
SYSTEM LOCATION ···································5-10
WATER SEPARATOR REMOVAL/
INSTALLATION·········································· 5-87
ECM TERMINAL ARRANGEMENT ················5-11
WATER SEPARATOR DISASSEMBLY/
DTC TROUBLESHOOTING ··························5-13 ASSEMBLY ··············································· 5-89
MIL TROUBLESHOOTING ···························5-43 SILENCER CASE DISASSEMBLY/

ASSEMBLY ··············································· 5-90
FUEL PRESSURE RELIEVING······················5-66
FUEL PUMP (HIGH PRESSURE SIDE)/VAPOR
FUEL PUMP (LOW PRESSURE SIDE) SEPARATOR DISASSEMBLY/ASSEMBLY ····· 5-91
REMOVAL/INSTALLATION ··························5-67
FUEL TANK/FUEL TANK TUBE
SILENCER CASE REMOVAL/ DISASSEMBLY/ASSEMBLY························· 5-96
INSTALLATION ··········································5-67
FUEL PRESSURE MEASUREMENT ·············· 5-97
INTAKE MANIFOLD REMOVAL/
INSTALLATION ··········································5-69 FUEL PRESSURE REGULATOR
INSPECTION ············································· 5-98
FUEL INJECTORS REMOVAL/
INSTALLATION ··········································5-73 FUEL PUMP (LOW PRESSURE SIDE)
INSPECTION ············································· 5-99
FUEL PUMP (HIGH PRESSURE SIDE)/VAPOR
SEPARATOR REMOVAL/INSTALLATION ······5-76 FUEL PUMP (HIGH PRESSURE SIDE)
INSPECTION ············································· 5-99
MAP SENSOR REMOVAL/INSTALLATION ·····5-81
VAPOR SEPARATOR INSPECTION ············ 5-102
IAT SENSOR REMOVAL/INSTALLATION ·······5-81
FUEL INJECTOR INSPECTION··················· 5-103
IAC VALVE REMOVAL/INSTALLATION ·········5-82
THROTTLE BODY INSPECTION ················· 5-105
HO2S REMOVAL/INSTALLATION ·················5-82
EBT SENSOR/ECT SENSOR 2/3
VTEC SOLENOID VALVE REMOVAL/ INSPECTION ··········································· 5-106
INSTALLATION (BF90D/BF100A ONLY) ········5-82
WATER LEVEL SENSOR INSPECTION········ 5-106
CKP SENSOR REMOVAL/INSTALLATION ·····5-83
VTEC SOLENOID VALVE INSPECTION
CMP SENSOR REMOVAL/INSTALLATION ·····5-83 (BF90D/BF100A ONLY) ····························· 5-107
EOP SENSOR REMOVAL/INSTALLATION ·····5-84 IAC VALVE INSPECTION··························· 5-107
KNOCK SENSOR REMOVAL/INSTALLATION IAT SENSOR INSPECTION ························ 5-107

(BF90D/BF100A ONLY) ·······························5-84
HO2S INSPECTION ·································· 5-108
EBT SENSOR REMOVAL/INSTALLATION······5-84

5-1
dummyhead
FUEL SYSTEM
SERVICE PRECAUTIONS
FUEL SYSTEM
GENERAL TROUBLESHOOTING
Before troubleshooting
• First, check the MIL.
• Be sure to turn the combination switch OFF before
disconnecting and connecting the connectors.
• Clear the DTCs after inspection.
– DTC (with the Dr.H: page 5-5)
– MIL (without the Dr.H: page 5-5)
PERMANENT FAILURE
When there is a problem in the system, the MIL will
blink and go off when the engine is turned off.
When there is a permanent failure, the MIL will blink
again when the engine is started again, as the problem
still exists.
Most permanent failures will be indicated when the
combination switch is turned on and engine is started,
while others are indicated only under certain conditions.
MIL will blink constantly until the problem part is fixed or
replaced.
INTERMITTENT FAILURE
When there is an intermittent failure, the MIL will not
blink again when the engine is restarted.
The ECM stores the problem code in its memory.
An intermittent failure is often associated with a loose
connector or poor contact in the circuit.
Opens and Shorts
An open or a short are common electrical terms. An
open is a break in a wire or at a connection. A short is
an accidental connection of a wire to ground or to
another wire. This usually means something will not
work at all. With an ECM, an open or short may cause
something to work, just not the way it is supposed to.
FUEL LINE SERVICE

handling fuel.
Disconnect the battery cable from the battery negative

(–) terminal.
Before removing and installing the fuel line, relieve the
fuel pressure by loosening the service check bolt [1] as
described in "How to relieve fuel pressure" (page 5-66).
Replace the sealing washer during reassembly.
[1]
5-2
dummyhead
FUEL SYSTEM
Replace the O-ring (7.47 x 3.6 mm) [1] and O-ring (7.45
x 3.61 mm) [2] with new ones when the fuel line is
removed/installed or replaced.
[2]
• Install the O-rings in their proper locations.
• Apply engine oil to the O-rings before installation.
• Avoid using vegetable oil and alcohol based
lubricants.
[1]
CHECK AFTER OPERATION

Check the parts for secure installation and the bolts,
screws, and other fasteners for secure tightening.
Connect the battery cable to the battery negative (–)
terminal.
FUEL LEAK CHECK

Turn the combination switch ON (but do not turn the
starter) after connecting the fuel lines. The fuel pump
(high pressure side) should operate for approximately 2
seconds and the fuel pressure in the high pressure side
fuel line should rise. Repeat this operation 2 or 3 times
and check for fuel leakage.
WHEN THE BOAT IS EQUIPPED WITH

RADIO EQUIPMENT/D-GPS
The ECM and its wires are designed to be unaffected
by radio waves. However, the ECM can malfunction
when it senses an extremely powerful electric wave.
Note the following to avoid malfunction of the ECM.
• Install the antenna and the body of the radio
equipment at least 50 cm (20.0 in) away from the
ECM, remote control cable, remote control box,
NMEA 2000 interface cable, and network cable.
• Antenna wire must not be too long. Do not route the
antenna wire along the main wire harness and other
cables/wires.
• Do not mount high output power radio equipment on
the boat. (The maximum output power of the radio
equipment should be 10 W.)
• Install the D-GPS antenna and the body unit at least
3 m away from the engine.
• Connect the D-GPS antenna ground wire to ground.

5-3
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FUEL SYSTEM
SYSTEM DESCRIPTION
SELF-DIAGNOSIS SYSTEM
The ECM has a self-diagnosis function that memorizes
the failure code and turns the MIL ON when it detects
an abnormality with the input/output system.
FAIL-SAFE FUNCTION
The PGM-FI system is provided with a fail-safe function
to provide minimum running capability even when there
is trouble in the system. When any abnormality is
detected by the self-diagnosis function, running
capability is maintained by pre-programed value in the
simulated program map. When any abnormality is
detected in the MAP sensor or CKP sensor, the fail-safe
function stops the engine to protect it from damage.
DTC (Diagnostic Trouble Code)
• The DTC is composed of a main code and a sub
code and it is displayed as a hyphenated number
when retrieved from the ECM with the Dr.H.
The digits in front of the hyphen are the main code,
they indicate the component of function failure.
The digits behind the hyphen are the sub code, they
detail the specific symptom of the component or
function failure.
For example, in the case of the TP sensor:
– DTC 07 – 1 = (TP sensor voltage) – (lower than
the specified value)
– DTC 07 – 2 = (TP sensor voltage) – (higher than
the specified value).
• The MAP, EBT, TP, and IAT sensor diagnosis will be
made according to the voltage output of the affected
sensor.
If a failure occurs, the ECM determines the Function
Failure, compares the sensor voltage output to the
standard value, and then outputs the corresponding
DTC to the Dr.H.
For example:
– If the input voltage line (A) on the MAP sensor is
opened, the ECM detects the output voltage is
about 5 V, then the DTC 3-2 (MAP sensor circuit
high voltage) will be displayed.
– If the input voltage line (B) on the TP sensor is
opened, the ECM detects the output voltage is 0
V, then the DTC 7-1 (TP sensor circuit low
voltage) will be displayed.
5V
MAP SENSOR TP SENSOR
5V 5V
[B]
[A] OUTPUT OUTPUT
VOLTAGE VOLTAGE
5V IAT SENSOR 5V
EBT SENSOR
OUTPUT OUTPUT
VOLTAGE VOLTAGE
5-4
dummyhead
FUEL SYSTEM
DTC READOUT
Turn the combination switch ON; the MIL [1] will stay on
for a few seconds, then go off.
Start the engine and check the MIL.
• If the engine will not start, turn the starter motor for
more than 10 seconds and check the MIL.
If the MIL stays on or blinks, read the following:
• DTC (with the Dr.H: page 5-6)
• MIL (without the Dr.H: page 5-6)
[1]
CLEARING DTC
How to clear the DTC with Dr.H
Connect the Dr.H to the DLC (page 5-6).
Turn the combination switch ON, and clear the DTC
with the Dr.H.
• If there is any problem in the system, the ECM keeps
running the self-diagnosis function and the DTC
cannot be cleared.
How to clear the DTC with SCS service connector

1. Turn the combination switch to OFF.
2. Remove the engine cover.
3. Disconnect the dummy connector [1] from the DLC [1]
[2] and short the DLC terminals using the special
tool. [2]
TOOL:
SCS short connector [2] 070PZ-ZY30100
4. Turn the combination switch to ON.
• Perform steps 5 though 7 within 20 seconds.
5. Turn the emergency stop switch ON (push for 0.5
sec. or more) and OFF (release for 0.1 sec. or
more). [2]
Repeat the procedure five times.
6. Check that the buzzer sounds twice.
The MIL should stay ON.
Sound
7. Turn the combination switch OFF. (ECM reset
procedure completes.) 0.5 sec. or more
ON
OFF
0.1 sec. or more
20 sec. or less
BUZZER
COMBINATION COMBINATION
SWITCH ON SWITCH OFF

5-5
dummyhead
FUEL SYSTEM
READING DTC WITH THE Dr.H
• The Dr.H can readout the DTC and other engine
conditions.
• Refer to the Instruction Manual for the Dr. H how to
use.
Turn the combination switch to OFF.
Remove the dummy connector [1] from the DLC [2].
[3]
Connect the Dr.H [3] to the DLC. [1]
Turn the combination switch ON and check the DTC.

Read the DTC and follow the troubleshooting index
(page 5-13).
[2]
READING DTC WITHOUT THE Dr.H

• If the ECM has any DTC in its memory, it can be
read out by the number of blinks of the MIL.
Turn the combination switch to OFF.
Disconnect the dummy connector [1] from the DLC [2] [1]
and short DLC terminals using the special tool.
[3]
TOOL:
SCS short connector [3] 070PZ-ZY30100
Turn the combination switch ON, note the MIL blinks,
and refer to the "MIL INDEX". (page 5-43).
• The number of blinks of the MIL is the same as that
of the DTC main code. Note that the MIL does not
show any sub code.
• The MIL has two types of blinks, a long blink and [2]
short blink. One long blink is the equivalent of 10
short blinks. For example, when 1 long blink is Single problem:
followed by 4 short blinks, the MIL is 14 (1 long See DTC 3
blinks = 10 blinks, plus 4 short blinks).
• When multiple problems occur simultaneously, the See DTC 14
MIL repeatedly indicates them by blinking separate
codes, one after another. Multiple problems:
See DTC 3 and 4
See DTC 3 and 14
INSPECTION AT ECM CONNECTOR

• Always clean around and keep any foreign material
away from the ECM [1] connector before
disconnecting it.
• A faulty PGM-FI system is often related to poorly
connected or corroded terminals. Check those
connections before proceeding.
• In testing at the ECM connector (wire harness side)
terminal, always use the test probe. Insert the test
probe into the connector terminal, and then attach [1]
the digital multimeter probe to the test probe.
TOOL: [2]
Test probe [2] 07ZAJ-RDJA110
5-6
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FUEL SYSTEM
FINAL PROCEDURE (AFTER
TROUBLESHOOTING)
Clear the DTCs.
• DTC (with the Dr.H: page 5-5)
• MIL (without the Dr.H: page 5-5)
Disconnect the SCS service check connector or Dr.H
from the DLC and connect the dummy connector.
PIPING CONNECTIONS
[6]
[5]
[4]
[3]
[1] [2]
[15]
[14] [9]
[13] [12] [7]
[10]
[8]
[11]
[1] Vapor separator [9] TP sensor

[2] Fuel pump (High pressure side) [10] MAP sensor
[3] Fuel strainer (High pressure side) [11] IAC valve
[4] Pressure regulator [12] Injector
[5] Air vent strainer [13] Water separator
[6] Check valve [14] Fuel strainer (Low pressure side)
[7] Breather tube [15] Fuel pump (Low pressure side)
[8] Silencer case

5-7
dummyhead
FUEL SYSTEM
CIRCUIT DIAGRAM
REGULATOR/
ALTERNATOR
RECTIFIER
FUSE
(70 A) PGM-FI/MAIN RELAY
No.6 FUSE (30 A) 1RFUSE (10 A)

No.2 FUSE (10 A) 1RFUSE (15 A)
MAIN 1RFUSE (15 A)
N0.1 FUSE (10 A) COMBINATION SWITCH
BATTERY ST FFP
To STARTER MOTOR
FUEL PUMP
B8 B17
IGP1 PG1
B9 A17
IGP2 PG3
B5 B35
LG1 PG2
B23 A35
LG2 PG4
5V
A13
CMP A24 FLR1
SENSOR TDC
A14
5V FLR2
FUEL
CKP A20
CRK INJECTORS
SENSOR B16
5V INJ1
5V No.1
B6
VCC1 B15
INJ2
MAP A9 No.2
PB B14
SENSOR INJ3
B24 No.3
SG1 5V B13
B7 INJ4
VCC2 No.4
5V
B25 IGNITION COILS
SG2 A15
IGN1
TP A8 5V No.1
THL 5V
SENSOR
A12
EBT SENSOR IGN2
A7 5V No.2
TE
5V
A30
IGN3
IAT SENSOR 5V No.3
A23
TA
A33
5V IGN4
12 V VTEC No.4
ECT SENSOR 2 SOLENOID VALVE
A22 TOH1 B10
VTS
5V BF90D/
12 V BF100A only
ECT SENSOR 3 5V
A26 B18
TOH2
EACVP
EOP A10 POIL IACV
B36
SENSOR KNOCK SENSOR EACVM
B29
KS
BF90D/ 12 V
BF100A only
B28
FFD
WATER
LEVEL
SENSOR
5-8
dummyhead
FUEL SYSTEM
NEUTRAL
SWITCH
B27 H02S
NTSW A27
O2
B25
SG2
A18
O2HT
TRIM
ANGLE
SENSOR 5V
B22 WARNING
VCC3 BUZZER
A19
BUZZ
TRIM
METER
A6
TRMA
ALTERNATOR
A2
ACGLP
EMERGENCY 12 V PGM-FI
B30 12 V A3
STOP SWITCH EMS1 WARNL
B31
EMS2 OVERHEAT
A32
5V OHL
A31
OPL
5V
OIL
A11 K-LINE
B33
SCS
DLC
B11 UP
TLUP
TACHOMETER B12
TLDN
DOWN
A4
TACHO
TROLLING
CONTROL
SWITCH
(OP)
ENGINE SPEED
CHECK
CONNECTOR

5-9
dummyhead
FUEL SYSTEM
SYSTEM LOCATION
[3]
[4]
[5]
[2]
[6]
[1]
[12]
[7]
[11]
[8]
[14]
[15]
[13]
[16]
[10] [9]
[17]
[22]
[21]
[18]
[20] [19]
[1] IAC valve [12] MAP sensor

[2] IAT sensor [13] HO2S
[3] Alternator stator [14] ECT sensor 2
[4] CKP sensor [15] ECM
[5] EOP sensor [16] PGM-FI/main relay
[6] Injector [17] DLC
[7] Knock sensor (BF90D/BF100A only) [18] Fuse box
[8] VTEC solenoid valve (BF90D/BF100A only) [19] 70A fuse box
[9] EBT sensor [20] CMP sensor
[10] Fuel strainer pump (High pressure side) [21] Regulator/rectifier
[11] TP sensor [22] ECT sensor 3
5-10
dummyhead
FUEL SYSTEM
ECM TERMINAL ARRANGEMENT
ECM CONNECTOR A (GRAY)
ECM side connector (viewed from the terminal side)
Terminal No. Terminal mark Name Content/Signal

1 – – –
2 ACGLP Alternator indicator light Alternator indicator light output
3 WARNL MIL MIL output
4 TACHO Tachometer Tachometer pulse output
5 – – –
6 TRMA Trim angle sensor Trim angle sensor input
7 TE EBT sensor EBT sensor input
8 THL TP sensor TP sensor input
9 PB MAP sensor MAP sensor input
10 POIL EOP sensor EOP sensor input
11 K-LINE Communication signal Serial communication signal input/output
12 IGN2 No.2 ignition coil No.2 ignition coil signal output
13 FLR1 Fuel pump relay 1 Fuel pump relay 1 driver
14 FLR2 Fuel pump relay 2 Fuel pump relay 2 driver
16 – – –
17 PG3 Power ground 3 Power ground 3
18 O2HT HO2S heater HO2S heater driver
19 BUZZ Warning buzzer Warning buzzer driver
20 CRK CKP sensor (+) CKP sensor (+) input
21 – – –
22 TOH1 ECT sensor 2 ECT sensor 2 input
23 TA IAT sensor IAT sensor input
24 TDC CMP sensor CMP sensor input
25 – – –
26 TOH2 ECT sensor 3 ECT sensor 3 input
27 O2 HO2S HO2S input
28 – – –
29 – – –
31 OPL Oil indicator light Oil indicator light driver
32 OHL Overheat indicator light Overheat indicator light driver
34 FUP Fuel consumption meter Fuel consumption volume signal output
36 – – –

5-11
dummyhead
FUEL SYSTEM
ECM CONNECTOR B (BLACK)
ECM side connector (viewed from the terminal side)
Terminal No. Terminal mark Name Content/Signal

1 CAN 1H NMEA 2000 CAN HI NMEA 2000 CAN HI output
2 CAN 12V NMEA 2000 12V power source NMEA 2000 12V power input
3 CAN GND NMEA 2000 ground NMEA 2000 ground
4 – – –
5 LG1 Logic ground 1 Logic ground 1
6 VCC1 Sensor power 1 Sensor power 5 V output 1
8 IGP1 ECM power source 1 ECM main power 12 V input 1
9 IGP2 ECM power source 2 ECM main power 12 V input 2
10 VTS VTEC solenoid valve VTEC solenoid valve driver
(BF90D/BF100A only)
11 TLUP Trolling control switch Up Trolling control switch Up input
12 TLDN Trolling control switch Down Trolling control switch Down input
13 INJ4 No.4 injector No.4 injector driver
18 EACVP IAC valve (+) IAC valve (+) driver
19 CAN 1L NMEA 2000 CAN LO NMEA 2000 CAN LO output
20 SHILD NMEA 2000 shield NMEA 2000 shield
21 – – –
23 LG2 Logic ground 2 Logic ground 2
24 SG1 Sensor ground 1 Sensor ground 1
25 SG2 Sensor ground 2 Sensor ground 2
26 – – –
27 NTSW Neutral switch Neutral switch input
28 FFD Water level sensor Water level sensor input
29 KS Knock sensor Knock sensor input
(BF90D/BF100A only)
30 EMS1 Emergency stop switch 1 Emergency stop switch input 1
31 EMS2 Emergency stop switch 2 Emergency stop switch input 2
32 – – –
33 SCS Service check signal Service check signal input
34 – – –
36 EACVM EACV (–) EACV (–) driver
5-12
dummyhead
FUEL SYSTEM
DTC TROUBLESHOOTING
DTC INDEX
DTC MIL Detected component Probable cause Ref. page
MIL does not ECM • Loose or poor contact of the 4-17
come ON/ connector
blink • Faulty indicator light
0 or does not
• Open circuit in MIL wire
communicate
• Open circuit in ECM power/ground
cable
• Faulty ECM
0 or does not MIL stay ON ECM • SCS service check connector 5-16
communicate activated
• Short circuit in DLC wire
• Short circuit in MIL wire
• Short circuit in sensor power circuit
• Faulty ECM
0-2 ON ECM (internal failure) • Faulty ECM 5-19
0-5
0-8
1-4 ON HO2S (failure) • Loose or poor contact of the 5-19

connector
• Open or short circuit in HO2S wire
• Faulty fuel supply system
• Faulty HO2S
3-1 ON MAP sensor (voltage too low) • Loose or poor contact of the 5-20
connector
• Short circuit in MAP sensor wire (PB)
• Open circuit in MAP sensor wire
(VCC1)
• Faulty MAP sensor
3-2 ON MAP sensor (voltage too high) • Loose or poor contact of the 5-21
connector
• Open circuit in MAP sensor wire (PB)
(VCC1)
(SG1)
4-1 ON CKP sensor (no pulse) • Loose or poor contact of the 5-23
connector
• Open or short circuit in CKP sensor
wire (CRK)
• Open circuit in CKP sensor wire
(IGP2)
• Open circuit in CKP sensor wire (LG1)
• Faulty CKP sensor
4-2 ON CKP sensor (abnormal pulse) • Loose or poor contact of the 5-24
connector
• Faulty crank purser plate
6-1 ON EBT sensor • Loose or poor contact of the 5-25
(voltage too low) connector
• Short circuit in EBT sensor wire (TE)
• Faulty EBT sensor
6-2 ON EBT sensor • Loose or poor contact of the 5-26
(voltage too high) connector
• Open circuit in EBT sensor wire (TE)
• Open circuit in EBT sensor wire (SG2)
7-1 ON TP sensor (voltage too low) • Loose or poor contact of the 5-27
connector
• Open or short circuit in TP sensor wire
(THL)
• Open circuit in TP sensor wire (VCC2)
• Faulty TP sensor

5-13
dummyhead
FUEL SYSTEM
7-2 ON TP sensor (voltage too high) • Loose or poor contact of the 5-28
connector
• Open circuit in TP sensor wire (SG2)
8-1 ON CMP sensor (no pulse) • Loose or poor contact of the 5-29
connector
• Open or short circuit in CMP sensor
wire (TDC)
• Open circuit in CMP sensor wire
(IGP2)
• Open circuit in CMP sensor wire
(LG1)
• Faulty CMP sensor
8-2 ON CMP sensor (abnormal pulse) • Loose or poor contact of the 5-30
connector
• Faulty cam purser plate
10-1 ON IAT sensor (voltage too low) • Loose or poor contact of the 5-31
connector
• Short circuit in IAT sensor wire (TA)
• Faulty IAT sensor
10-2 ON IAT sensor (voltage too high) • Loose or poor contact of the 5-32
connector
• Open circuit in IAT sensor wire (TA)
• Open circuit in IAT sensor wire (SG2)
14-1 ON IAC valve (control failure) • Loose or poor contact of the 5-33
connector
• Open or short circuit in IAC valve wire
(EACVP)
• Open or short circuit in IAC valve wire
(EACVM)
• Faulty IAC valve
21-1 ON VTEC solenoid valve • Loose or poor contact of the 5-34
(BF90D/ (failure) connector
BF100A only) • Open or short circuit in VTEC solenoid
valve wire
• Faulty VTEC solenoid valve
22-1 ON EOP sensor (voltage too low) • Loose or poor contact of the 5-35
connector
• Short circuit in EOP sensor wire
(POIL)
• Open circuit in EOP sensor wire
(VCC2)
• Faulty EOP sensor
22-2 ON EOP sensor (voltage too high) • Loose or poor contact of the 5-36
connector
(POIL)
(VCC2)
(SG2)
23-1 ON Knock sensor (no pulse) • Loose or poor contact of the 5-37
(BF90D/ connector
BF100A only) • Open or short circuit in knock sensor
wire (KS)
• Faulty knock sensor
41-2 ON HO2S heater (failure) • Loose or poor contact of the 5-38
connector
• Open circuit in HO2S heater wire
• Faulty HO2S
5-14
dummyhead
FUEL SYSTEM
140-1 ON ECT sensor 2 (voltage too low) • Loose or poor contact of the 5-39
connector
• Short circuit in ECT sensor 2 wire
(TOH1)
• Faulty ECT sensor 2
140-2 ON ECT sensor 2 (voltage too high) • Loose or poor contact of the 5-40
connector
• Open circuit in ECT sensor 2 wire
(TOH1)
(SG2)
141-1 ON ECT sensor 3 (voltage too low) • Loose or poor contact of the 5-41
connector
• Short circuit in ECT sensor 3 wire
(TOH2)
141-2 ON ECT sensor 3 (voltage too high) • Loose or poor contact of the 5-42
connector
(TOH2)
(SG2)

5-15
dummyhead
FUEL SYSTEM
MIL IS ON BUT DTC IS 0 OR DOES NOT COMMUNICATE
TP SENSOR MAP SENSOR

յ No.2 No.4
FUSE FUSE FUSE
ECM (15 A) (10 A) (10 A)
1 2 3 1 2 3
Y
29
21 26
PG4 G
Bu R/Bl G Br/Y W/R G
35
WARNL R/Bu
3
12 V
THL R/Bl
8
PB W/R W/Bl Y 3
9
K-LINE Bu Bu
11
1
PG3 G Bl
17
2
TRMA Y/Bu Y/Bl DLC
3
Lg
REMOTE CONTROL type 5V
4
5V VCC1 Br/Y 12
COMBINATION
6
SWITCH VCC2 Bu G JOINT
CONNECTOR 2
15
C47
IGP1 Y/Bl G
Bl/Y Bl/Y LOAD
21
IGP2 Y/Bl
TRIM
ANGLE
9
C52
W/Bl W/Bl BAT 5V PG1 17 G 15 SENSOR
VCC3 Br/W Br/W Lg/Bl
22
3
5V
SG1 G Y/Bu
24
2
INDICATOR SG2 G Bl
LIGHT
25
1
C55 SCS Lg
33
Bl/Y Bl/Y BAT Bu

LG1 Bu
5
C58 Bl
R/Bu R/Bu WARNL PG2 G Bl Bl
35
LG2 Bu
23
28
Bl
39 4 Bl Bl Bl Y Y/Bl
R/Bu R/Bu GND5 GND4 GND7 GND6
3
6 3 2 16 14 13
42 5
W/Bl W/Bl
JOINT CONNECTOR 1
1
TILLER HANDLE type
COMBINATION
SWITCH
C50
Bl/Y Bl/Y LOAD
C56
W/Bl W/Bl BAT
INDICATOR
LIGHT
C58
Bl/Y Bl/Y BAT
C61
R/Bu R/Bu WARNL
4
Bl BLACK Br BROWN
R/Bu
Y YELLOW O ORANGE
6

5
W/Bl G GREEN Lg LIGHT GREEN

1
R RED P PINK
W WHITE Gr GRAY
1. DLC power/GND line open circuit inspection

Turn the combination switch OFF and disconnect
the Dr.H.
DLC
Measure the voltage at the DLC No.3
(Yellow/Black) terminal and No.2 (Black) terminal.
Does battery voltage exit?
YES – GO TO STEP 2. GND IGP3
(Black) (Yellow/Black)
NO – • Repair open in the Yellow/Black wire
between the No.4 fuse and DLC.
• If main wire harness is normal, inspect
the No.4 fuse circuit in the fuse box
(page 10-14).
5-16
dummyhead
FUEL SYSTEM
2. DLC signal line short circuit inspection
Measure the voltage between the DLC No.4
(Light green) terminal and engine ground. DLC
Is the measurement within 4.75 – 5.25 V?
NO – Repair short in the main wire harness
between the ECM and the DLC. SCS
(Light green)
3. MIL ON line short circuit inspection

Disconnect ECM connector A .
Turn the combination switch ON and check the MIL.
Does the MIL go OFF?
between the ECM and the MIL.
4. MAP sensor power line short circuit inspection 1
Connect ECM connector A .
Disconnect the MAP sensor 3P connector .
YES – Replace the MAP sensor.
Measure the voltage between the MAP sensor 3P
connector main wire harness side No.1
(Brown/Yellow) terminal and engine ground. MAP SENSOR 3P CONNECTOR
between the ECM and the MAP sensor. VCC1
(Brown/Yellow)
6. TP sensor power line short circuit inspection 1

Disconnect the TP sensor 3P connector .
YES – Replace the TP sensor.

5-17
dummyhead
FUEL SYSTEM
Measure the voltage between the TP sensor 3P
connector main wire harness side No.1 (Blue)
TP SENSOR 3P CONNECTOR
NO – Repair short in the main wire harness VCC2
between the ECM and the TP sensor. (Blue)
8. Trim angle sensor power line short circuit

inspection 1
Disconnect the trim angle sensor 3P connector
.
YES – Replace the trim angle sensor.
inspection 2
Measure the voltage between the trim angle sensor
3P connector main wire harness side No.3
(Brown/White) terminal and engine ground. TRIM ANGLE SENSOR 3P CONNECTOR
recheck.
NO – Repair short in the main wire harness VCC3
between the ECM and the trim angle (Brown/White)
sensor.
5-18
dummyhead
FUEL SYSTEM
DTC 0-2, 0-5, 0-8
(INTERNAL FAILURE OF ECM)
1. Reproduction test
Turn the combination switch ON and wait for more
than one second.
Clear the DTC (page 5-5).
• Continue the procedure if the DTC does not
clear.
Start the engine and recheck the DTC.
Does the DTC 0-2, 0-5, 0-8 appear?
recheck
NO – Temporary failure (code does not
reappear)
DTC 1-4 (HO2S FAILURE)
ECM 29
25
HO2S
O2 Bl/Y Bl/Y Bl
27
1
G Gr
2
SG2 G
25
28
12 Bl BLACK Br BROWN
21 17 Y YELLOW O ORANGE
JOINT Bu BLUE Lb LIGHT BLUE
CONNECTOR 2 R RED P PINK
W WHITE Gr GRAY
1. Symptom reproduction test

Disconnect the HO2S 4P connector , ECM
connector A , ECM connector B , joint
connector 2 and then reconnect them.
clear.
Start the engine and let it run at 3,000 min-1 (rpm) for
5 minutes or more under no load.
Let the engine idle for 1 minute or more.
Check the DTC using the Dr.H.
Does the DTC 1-4 appear?
reappear).

5-19
dummyhead
FUEL SYSTEM
2. HO2S inspection
the HO2S 4P connector .
Inspect the HO2S (page 5-108).
Is the HO2S correct?
NO – Replace the HO2S with a new one and
recheck.
3. Fuel supply system inspection
Measure the fuel pressure (page 5-97).
Is the fuel pressure normal?
YES – Repair open or short in the main wire
harness between the ECM and HO2S. If
the main wire harness is correct, replace
the ECM with a new one, and recheck.
NO – Repair fuel supply system and recheck
under normal fuel pressure.
DTC 3-1, 3-2 (MAP SENSOR VOLTAGE TOO LOW OR TOO HIGH)
Bl BLACK Br BROWN
Y YELLOW O ORANGE
ECM R RED P PINK
W WHITE Gr GRAY
5V
29
PB W/R
MAP
SENSOR
9
26
5V Br/Y
1
VCC1 Br/Y W/R

6
SG1 G G
24
28
DTC 3-1 (MAP SENSOR VOLTAGE IS TOO LOW)

Disconnect the MAP sensor 3P connector ,
ECM connector A , ECM connector B
and then reconnect them.
clear.
Measure the MAP sensor voltage using the Dr.H.
YES – Temporary failure (code does not
reappear).
5-20
dummyhead
FUEL SYSTEM
2. MAP sensor signal line short circuit inspection
the MAP sensor 3P connector . MAP SENSOR 3P CONNECTOR
Turn the combination switch ON. MAIN WIRE HARNESS SIDE
(White/Red) terminal and engine ground.
Is the measurement within 4.75 – 5.25 V? PB
(White/Red)
NO – Repair open in the White/Red wire. If the
main wire harness is normal, replace the
3. MAP sensor power line open circuit inspection

connector main wire harness side No.1 MAP SENSOR 3P CONNECTOR
(Brown/Yellow) terminal and engine ground. MAIN WIRE HARNESS SIDE
YES – Replace the MAP sensor with a new one
and recheck.
NO – Repair open in the Brown/Yellow wire. If
the main wire harness is normal, replace VCC1
the ECM with a new one and recheck. (Brown/Yellow)
DTC 3-2 (MAP SENSOR VOLTAGE IS TOO HIGH)

clear.
Measure the MAP sensor voltage using the Dr.H.
reappear).

5-21
dummyhead
FUEL SYSTEM
the MAP sensor 3P connector .
MAP SENSOR 3P CONNECTOR
(Brown/Yellow) terminal and engine ground.
Is the measurement within 4.75 – 5.25 V? VCC1
(Brown/Yellow)
the main wire harness is normal, replace
the ECM with a new one and recheck.
3. MAP sensor signal/GND line open circuit

inspection
(White/Red) terminal and No.3 (Green) terminal. MAIN WIRE HARNESS SIDE
and recheck.
NO – • Repair open or short in the White/Red
wire. SG1 (Green) PB
• Repair open in the Green wire. (White/Red)
• If the main wire harness is normal,
replace the ECM with a new one, and
recheck
5-22
dummyhead
FUEL SYSTEM
DTC 4-1, 4-2 (NO CKP SENSOR PULSE OR ABNORMAL CKP SENSOR
PULSE)
Bl BLACK Br BROWN
Y YELLOW O ORANGE
No.5
R RED P PINK
FUSE
W WHITE Gr GRAY (15 A)
Y
13
24 22
ECM 29 JOINT CONNCTOR 1 CKP SENSOR

5V
Y/Bl
3
CRK Bu Bu
20
1
G/Bl
2
Bu
23
GND5
DTC 4-1 (NO CKP SENSOR PULSE)

Disconnect the CKP sensor 3P connector ,
ECM connector A , and joint connector 1
, and then reconnect them.
clear.
Start the engine and check the DTC using the Dr.H.
reappear)

5-23
dummyhead
FUEL SYSTEM
2. CKP sensor power line open circuit inspection
the CKP sensor 3P connector .
Turn the combination switch ON. CKP SENSOR 3P CONNECTOR
Measure the voltage between the CKP sensor 3P
(Yellow/Black) terminal and engine ground.
IGP2
Does battery voltage exist? (Yellow/Black)
NO – Repair open in the Yellow/Black wire. If
main wire harness is normal, inspect the
No.5 fuse circuit in the fuse box.
3. CKP sensor signal line open or short circuit/

GND line open circuit inspection
terminal and No.2 (Green/Black) terminal. CKP SENSOR 3P CONNECTOR
YES – Replace the CKP sensor with a new one
and recheck.
NO – • Repair open or short in the Blue wire.
• Repair open in the Green/Black wire.
CRK
• If the main wire harness is normal, LG1 (Blue)
replace the ECM with a new one, and (Green/Black)
recheck.
DTC 4-2 (ABNORMAL CKP SENSOR PULSE)

clear.
NO – Temporary failure (disappears)
2. Crank pulser plate inspection
Check the crank pulser plate.
(page 7-13).
Is the crank pulser plate correct?
and recheck. If the CKP sensor is
replaced, but DTC 4-2 still appears,
replace the ECM with a new one and
recheck.
NO – Replace the alternator rotor and recheck.
5-24
dummyhead
FUEL SYSTEM
DTC 6-1, 6-2 (EBT SENSOR VOLTAGE IS TOO LOW OR TOO HIGH)
ECM
EBT
5V
SENSOR
29 20
TE R/W R/W
1
G
2
SG2 G
25
G G
28
12
21 24
Bl BLACK Br BROWN
Y YELLOW O ORANGE
G GREEN Lg LIGHT GREEN JOINT CONNCTOR 2
R RED P PINK
W WHITE Gr GRAY
DTC 6-1 (EBT SENSOR VOLTAGE IS TOO LOW)

Disconnect the EBT sensor 2P connector ,
ECM connector A , ECM connector B ,
and joint connector 2 , and then reconnect
them.
clear.
Measure the EBT sensor voltage using the Dr.H.
reappear)
2. EBT sensor signal line short circuit inspection
the EBT sensor 2P connector . EBT SENSOR 2P CONNECTOR
Measure the voltage between the EBT sensor 2P
connector main wire harness side No.1 (Red/
White) terminal and engine ground.
TE
YES – Replace the EBT sensor with a new one (Red/White)
and recheck.
NO – Repair short in the Red/White wire. If the
main wire is normal, replace the ECM with
a new one and recheck.

5-25
dummyhead
FUEL SYSTEM
DTC 6-2 (EBT SENSOR VOLTAGE IS TOO HIGH)
• When the DTC code 6-2, 7-2, 10-2, 22-2, 140-2, and
141-2 are indicated at the same time, the ground line
(SG2) is open.
them.
clear.
Measure the EBT sensor voltage using the Dr.H.
reappear)
2. EBT sensor signal/GND line open circuit
inspection
White) terminal and No.2 (Green) terminal. TE
SG2
Is the measurement within 4.75 – 5.25 V? (Green) (Red/White)
YES – Replace the EBT sensor with a new one
and recheck.
NO – Repair open in the Red/White wire or
Green wire. If the main wire harness is
normal, replace the ECM with a new one
and recheck.
5-26
dummyhead
FUEL SYSTEM
DTC 7-1, 7-2 (TP SENSOR VOLTAGE IS TOO LOW OR TOO HIGH)
ECM 29
THL R/Bl TP
SENSOR
8
21
5V Bu
1
VCC2 Bu R/Bl
2
SG2 G G
25
3
28
G G
12
21 15
Bl BLACK Br BROWN
Y YELLOW O ORANGE
JOINT
R RED P PINK CONNECTOR 2
W WHITE Gr GRAY
DTC 7-1 (TP SENSOR VOLTAGE IS TOO LOW)

• When the DTC code 7-1 and 22-1 or 22-2 are
indicated at the same time, the power line (VCC2) is
open.
Disconnect the TP sensor 3P connector ,
them.
clear.
Measure the TP sensor voltage using the Dr.H.
reappear)
2. TP sensor power/signal line open circuit
inspection
the TP sensor 3P connector . TP SENSOR 3P CONNECTOR
terminal and No.2 (Red/Black) terminal.
s the measurement within 4.75 – 5.25 V?
VCC2
YES – GO TO STEP 3. (Blue)
THL
NO – • Repair open in the Blue wire.
(Red/Black)
• Repair open in the Red/Black wire.
recheck.

5-27
dummyhead
FUEL SYSTEM
3. TP sensor signal line short circuit inspection
Disconnect ECM connector A .
Check for continuity between the TP sensor 3P
Black) terminal and engine ground.
YES – Repair short in the Red/Black wire.
NO – Replace the throttle body with a new one
and recheck.
DTC 7-2 (TP SENSOR VOLTAGE IS TOO HIGH)
(SG2) is open.
them.
clear.
Measure the TP sensor voltage using the Dr.H.
reappear)
2. TP sensor inspection
Turn the combination switch ON and measure the
TP sensor voltage using the Dr.H.
Is the measurement within 4.49 – 4.85 V when
the throttle is fully open and within 0.44 – 0.56 V
when the throttle is fully closed?
recheck.
NO – Repair the open circuit in the Green wire. If
the throttle body with a new one and
recheck.
5-28
dummyhead
FUEL SYSTEM
DTC 8-1, 8-2 (NO CMP SENSOR PULSE OR ABNORMAL CMP SENSOR
PULSE)
Bl BLACK Br BROWN
Y YELLOW O ORANGE
No.5 G GREEN Lg LIGHT GREEN
FUSE R RED P PINK
(15 A) W WHITE Gr GRAY
Y
13
24 23
CMP
ECM 29 JOINT CONNECTOR 1 SENSOR
5V
Y/B
3
TDC G G
24
1
G/Bl
2
Bu
24
GND5
DTC 8-1 (NO CMP SENSOR PULSE)

Disconnect the CMP sensor 3P connector ,
clear.
reappear)

5-29
dummyhead
FUEL SYSTEM
2. CMP sensor power line open circuit inspection
the CMP sensor 3P connector . CMP SENSOR 3P CONNECTOR
Measure the voltage between the CMP sensor 3P

Does battery voltage exist? IGP2
(Yellow/Black)
3. CMP sensor signal line open or short circuit/

connector main wire harness side No.1 CMP SENSOR 3P CONNECTOR
(Green) terminal and No.2 (Green/Black) terminal.
YES – Replace the CMP sensor with a new one
and recheck.
NO – • Repair open or short in the Green wire.
LG1
• Repair open in the Green/Black wire. (Green/Black) TDC
• If the main wire harness is normal, (Green)
recheck.
DTC 8-2 (ABNORMAL CMP SENSOR PULSE)

ECM connector A , joint connector 1
clear.
NO – Temporary failure (disappears)
2. Cam pulser plate inspection
Check the cam pulser plate (page 14-22).
Is the cam pulser plate correct?
YES – Replace the CMP sensor with a new one
and recheck. If the CMP sensor is
replaced, but DTC 8-2 still appears,
recheck.
NO – Replace the cam pulser plate, and
recheck.
5-30
dummyhead
FUEL SYSTEM
DTC 10-1, 10-2 (IAT SENSOR VOLTAGE IS TOO LOW OR TOO HIGH)
ECM 29 IAT
5V
19
SENSOR
TA R/Y R/Y
23
1
G
2
SG2 G
25
G G
28
12
21 13
Bl BLACK Br BROWN
Y YELLOW O ORANGE
R RED P PINK JOINT CONNECTOR 2
W WHITE Gr GRAY
DTC 10-1 (IAT SENSOR VOLTAGE IS TOO LOW)

Disconnect the IAT sensor 2P connector ,
them.
clear.
Measure the IAT sensor voltage using the Dr.H.
reappear)
2. IAT sensor signal line short circuit inspection
IAT SENSOR 2P CONNECTOR
the IAT sensor 2P connector .
Measure the voltage between the IAT sensor 2P
connector main wire harness side No.1 (Red/ TA
Yellow) terminal and engine ground. (Red/Yellow)
YES – Replace the IAT sensor with a new one
and recheck.
NO – Repair short in the Red/Yellow wire. If the

5-31
dummyhead
FUEL SYSTEM
DTC 10-2 (IAT SENSOR VOLTAGE IS TOO HIGH)
(SG2) is open.
them.
clear.
Measure the IAT sensor voltage using the Dr.H.
reappear)
2. IAT sensor signal line open circuit inspection
the IAT 2P connector . IAT SENSOR 2P CONNECTOR
Yellow) terminal and No.2 (Green) terminal.
SG2 TA
Is the measurement within 4.75 – 5.25 V? (Green) (Red/Yellow)
and recheck.
NO – Repair open in the Red/Yellow wire or
and recheck.
5-32
dummyhead
FUEL SYSTEM
DTC 14-1 (IAC VALVE CONTROL FAILURE)
ECM
IAC
12V 27
VALVE
EACVP G G
18
2
EACVM Bl Bl
36
1
28
Bl BLACK Br BROWN
Y YELLOW O ORANGE
R RED P PINK
W WHITE Gr GRAY

Disconnect the IAC valve 2P connector and
ECM connector B , and then reconnect them.
clear.
reappear)
Inspect the IAC valve (page 5-107).
Is the IAC valve normal?
YES – Repair open or short in the Green wire or
Black wire between the ECM and IAC
valve. If main wire harness is normal,
recheck.
NO – Replace the IAC valve with a new one and
recheck.

5-33
dummyhead
FUEL SYSTEM
DTC 21-1 (VTEC SOLENOID VALVE FAILURE)
ECM
VTEC
12 V SOLENOID
11 VALVE
VTS G/Y G/W

10
1
Bl BLACK Br BROWN
Y YELLOW O ORANGE
28 Bu BLUE Lb LIGHT BLUE
R RED P PINK
W WHITE Gr GRAY

Disconnect the VTEC solenoid valve 1P connector
, ECM connector B and then reconnect
them.
clear.
Disconnect the neutral switch 2P connector .
Raise the engine speed slowly and let it run at 5,200
min-1 (rpm) for a few seconds.
Recheck the DTC with the Dr.H.
reappear).
2. VTEC solenoid valve inspection
Inspect the VTEC solenoid valve
(page 5-107).
Is the VTEC solenoid valve correct?
harness between the ECM and VTEC
solenoid valve. If main wire harness is
correct, replace the ECM with a new one
and recheck.
NO – Replace the VTEC solenoid valve with a
5-34
dummyhead
FUEL SYSTEM
DTC 22-1, 22-2 (EOP SENSOR VOLTAGE TOO LOW OR TOO HIGH)
ECM
5V
29
POIL Y/R EOP

SENSOR
10
22
5V Bu
1
VCC2 Bu Y/R
7
2
SG2 G G
25
3
28
G G
12
21 23
Bl BLACK Br BROWN
Y YELLOW O ORANGE
R RED P PINK
W WHITE Gr GRAY
JOINT CONNECTOR 2
DTC 22-1 (EOP SENSOR VOLTAGE IS TOO LOW)
open.
Disconnect the EOP sensor 3P connector ,
them.
clear.
Measure the EOP sensor voltage using the Dr.H.
Is the measurement within 0.5– 4.5 V?
reappear)
2. EOP sensor signal line short circuit inspection
the EOP sensor 3P connector . EOP SENSOR 3P CONNECTOR
Measure the voltage between the EOP sensor 3P

(Yellow/Red) terminal and engine ground.
YES – GO TO STEP 3. POIL
(Yellow/Red)
NO – Repair short in the Yellow/Red wire. If the

5-35
dummyhead
FUEL SYSTEM
3. EOP sensor power line open circuit inspection
terminal and engine ground. EOP SENSOR 3P CONNECTOR
YES – Replace the EOP sensor with a new one
and recheck.
NO – Repair open in the Blue wire. If the main
wire harness is normal, replace the ECM VCC2
with a new one and recheck. (Blue)
DTC 22-2 (EOP SENSOR VOLTAGE IS TOO HIGH)

(SG2) is open.
open.
them.
clear.
Measure the EOP sensor voltage using the Dr.H.
reappear)
the EOP sensor 3P connector .
EOP SENSOR 3P CONNECTOR
VCC2 (Blue)
wire harness is normal, replace the ECM
with a new one and recheck.
5-36
dummyhead
FUEL SYSTEM
3. EOP sensor signal/GND line open circuit
inspection
connector main wire harness side No.2 EOP SENSOR 3P CONNECTOR
(Yellow/Red) terminal and No.3 (Green) terminal. MAIN WIRE HARNESS SIDE

and recheck.
NO – • Repair open or short in the Yellow/Red SG2 POIL
wire. (Green) (Yellow/Red)
• Repair open in the Green wire.
recheck.
DTC 23-1 (KNOCK SENSOR NO PULSE)

ECM
KNOCK
10
SENSOR
Bl BLACK Br BROWN
Y YELLOW O ORANGE
KS R/Bu R/Bu
29
1
R RED P PINK
W WHITE Gr GRAY
28

Disconnect the knock sensor 1P connector
and ECM connector B , and then reconnect
them.
clear.
7 minutes under no load.
Increase the engine speed gradually and run it at
3,000 min-1 (rpm) for 10 seconds.
Recheck the DTC with the Dr.H.
reappear)

5-37
dummyhead
FUEL SYSTEM
2. Knock sensor line open or short circuit
inspection
and ECM connector B .
Check for open and short circuit between the knock
sensor 1P connector main wire harness side
No.1 (Red/Blue) terminal and ECM connector B
No.29 (Red/Blue) terminal.
Is the knock sensor line normal?
NO – Repair open or short in the Red/Blue wire.
3. Knock sensor inspection
Replace the knock sensor with a new one (page 5-
84).
Perform the knock sensor symptom reproduction
test (page 5-37).
recheck.
NO – Faulty original knock sensor.
DTC 41-2 (HO2S HEATER FAILURE)
No.4
FUSE
(10 A)
Y
13
16 17
ECM 29
JOINT
CONNECTOR 1
HO2S
25
HEATER
O2HT W/Bl W/Bl W
18
Bl BLACK Br BROWN Y/Bl W

4
Y YELLOW O ORANGE
R RED P PINK
W WHITE Gr GRAY

Disconnect the HO2S 4P connector , and
,and then reconnect them.
clear.
Check the DTC using the Dr.H
5-38
dummyhead
FUEL SYSTEM
reappear)
2. HO2S heater inspection
Inspect the HO2S heater (page 5-108).
Is the HO2S heater normal?
YES – Repair open in the main wire harness
between the No.4 fuse and the HO2S or
between the HO2S and ECM. If the main
wire harness is correct, replace the ECM
recheck.
DTC 140-1, 140-2 (ECT SENSOR 2 VOLTAGE IS TOO LOW OR TOO HIGH)
ECM 29 ECT
5V
SENSOR 2
17
TOH1 R/Bl R/Bl

22
1
G
2
SG2 G
25
G G
28
12 21 19
Bl BLACK Br BROWN
Y YELLOW O ORANGE
G GREEN Lg LIGHT GREEN JOINT CONNECTOR 2
R RED P PINK
W WHITE Gr GRAY
DTC 140-1 (ECT SENSOR 2 VOLTAGE IS TOO LOW)

Disconnect the ECT sensor 2 (2P) connector ,
joint connector 2 and then reconnect them.
clear.
Measure the ECT sensor 2 voltage using the Dr.H.
reappear)

5-39
dummyhead
FUEL SYSTEM
2. ECT sensor 2 signal line short circuit inspection
the ECT sensor 2 (2P) connector . ECT SENSOR 2 (2P) CONNECTOR
Measure the voltage between the ECT sensor 2
(2P) connector main wire harness side No.1
(Red/Black) terminal and engine ground.
TOH1
Is the measurement within 4.75 – 5.25 V? (Red/Black)
YES – Replace the ECT sensor 2 with a new one
and recheck.
between the ECT sensor 2. If the main
wire is correct, replace the ECM with a
DTC 140-2 (ECT SENSOR 2 VOLTAGE IS TOO HIGH)
(SG2) is open.
them.
clear.
reappear)
2. ECT sensor 2 signal/GND line open circuit
inspection
(Red/Black) terminal and No.2 (Green) terminal.
SG2 TOH1
Is the measurement within 4.75 – 5.25 V? (Green) (Red/Black)
and recheck.
NO – Repair open in the Red/Black wire or
and recheck.
5-40
dummyhead
FUEL SYSTEM
DTC 141-1, 141-2 (ECT SENSOR 3 VOLTAGE IS TOO LOW OR TOO HIGH)
ECM 29
ECT
5V
18
SENSOR 3
TOH2 R R
26
1
G
2
SG2 G
25
G G
28
12 21 22
Bl BLACK Br BROWN
Y YELLOW O ORANGE
W WHITE Gr GRAY
DTC 141-1 (ECT SENSOR 3 VOLTAGE IS TOO LOW)

them.
clear.
reappear)
2. ECT sensor 3 signal line short circuit inspection
(Red) terminal and engine ground.
TOH2
Is the measurement within 4.75 – 5.25 V? (Red)
YES – Replace ECT sensor 3 with a new one and
recheck.
NO – Repair short in the Red wire. If the main

5-41
dummyhead
FUEL SYSTEM
DTC 141-2 (ECT SENSOR 3 VOLTAGE IS TOO HIGH)
(SG2) is open.
them.
clear.
reappear)
2. ECT sensor 3 signal/GND line open circuit
inspection
(Red) terminal and No.2 (Green) terminal.
Is the measurement within 4.75 – 5.25 V? SG2 TOH2
(Green) (Red)
YES – Replace ECT sensor 3 with a new one and
recheck.
NO – Repair open in the Red wire or Green wire.
If the main wire harness is normal, replace
5-42
dummyhead
FUEL SYSTEM
MIL TROUBLESHOOTING
MIL INDEX
MIL Detected component Probable cause Ref.
No. of blinks Condition page
MIL does not Detected ECM • Loose or poor contact of the 4-18
blink component connector
• Faulty indicator light
• Open circuit in MIL wire
• Open circuit in ECM power/ground
cable
• Faulty ECM
Stays ON ON ECM Normal with the SCS service connector 5-45
installed - If engine condition continues
without the MIL blinking, check the
following:
• Short circuit in DLC wire
• Short circuit in MIL wire
• Short circuit in sensor power circuit
• Faulty ECM
1 Blink HO2S • Loose or poor contact of the 5-48
connector
• Open or short circuit in HO2S wire
• Faulty fuel supply system
• Faulty HO2S
3 Blink MAP sensor • Loose or poor contact of the 5-49
(voltage too low or too high) connector
• Open or short circuit in MAP sensor
wire
4 Blink CKP sensor • Loose or poor contact of the 5-51
(no pulse or abnormal pulse) connector
• Open or short circuit in CKP sensor
wire
• Faulty crank purser plate
6 Blink EBT sensor • Loose or poor contact of the 5-53
• Open or short circuit in EBT sensor
wire
7 Blink TP sensor • Loose or poor contact of the 5-54
• Open and short circuit in TP sensor
wire
8 Blink CMP sensor • Loose or poor contact of the 5-56
(no pulse or abnormal pulse) connector
• Open or short circuit in CMP sensor
wire
• Faulty cam pulser plate
10 Blink IAT sensor • Loose or poor contact of the 5-58
• Open and short circuit in IAT sensor
wire
14 Blink IAC valve • Loose or poor contact of the 5-59
(control failure) connector
• Open and short circuit in IAC valve
wire
• Faulty IAC valve

5-43
dummyhead
FUEL SYSTEM
MIL Detected component Probable cause Ref.
No. of blinks Condition page
21 Blink VTEC solenoid valve • Loose or poor contact of the 5-60

(BF90D/ (failure) connector
100A only) • Open and short circuit in VTEC
solenoid valve wire
• Faulty VTEC solenoid valve
22 Blink EOP sensor • Loose or poor contact of the 5-61
• Open and short circuit in EOP sensor
wire
23 Blink Knock sensor • Loose or poor contact of the 5-62
(BF90D/ (no pulse) connector
100A only) • Open and short circuit in knock
sensor wire
• Faulty knock sensor
24 Blink ECT sensor 2 • Loose or poor contact of the 5-63
• Open and short circuit in ECT sensor
2 wire
25 Blink ECT sensor 3 • Loose or poor contact of the 5-64
• Open and short circuit in ECT sensor
3 wire
41 Blink HO2S sensor heater • Loose or poor contact of the 5-65
(failure) connector
• Open circuit in HO2S heater wire
• Faulty HO2S
5-44
dummyhead
FUEL SYSTEM
MIL TURNS ON BUT DOES NOT BLINK WITH SCS SERVICE CHECK
CONNECTOR CONNECTED
TP SENSOR MAP SENSOR

յ No.2 No.4
FUSE FUSE FUSE
ECM (15 A) (10 A) (10 A)
1 2 3 1 2 3
Y
29
21 26
PG4 G
Bu R/Bl G Br/Y W/R G
35
WARNL R/Bu
3
12 V
THL R/Bl
8
PB W/R W/Bl Y 3
9
K-LINE Bu Bu
11
1
PG3 G Bl
17
2
TRMA Y/Bu Y/Bl DLC
3
Lg
REMOTE CONTROL type 5V
4
5V VCC1 Br/Y 12
COMBINATION
6
SWITCH VCC2 Bu G JOINT
CONNECTOR 2
15
C47
IGP1 Y/Bl G
Bl/Y Bl/Y LOAD
21
IGP2 Y/Bl
TRIM
ANGLE
9
C52
W/Bl W/Bl BAT 5V PG1 G 15 SENSOR
17
VCC3 Br/W Br/W Lg/Bl
22
3
5V
SG1 24 G Y/Bu
2
INDICATOR SG2 G Bl
LIGHT
25
1
C55 SCS Lg
33
Bl/Y Bl/Y BAT Bu

LG1 Bu
5
C58 Bl
R/Bu R/Bu WARNL PG2 G Bl Bl
35
LG2 Bu
23
28
Bl
39 4 Bl Bl Bl Y Y/Bl
R/Bu R/Bu GND5 GND4 GND7 GND6
3
6 3 2 16 14 13
42 5
W/Bl W/Bl
JOINT CONNECTOR 1
1
TILLER HANDLE type
COMBINATION
SWITCH
C50
Bl/Y Bl/Y LOAD
C56
W/Bl W/Bl BAT
INDICATOR
LIGHT
C58
Bl/Y Bl/Y BAT
C61
R/Bu R/Bu WARNL
R/Bu Bl BLACK Br BROWN

6
Y YELLOW O ORANGE
5 Bu BLUE Lb LIGHT BLUE
W/Bl
1
R RED P PINK
W WHITE Gr GRAY

5-45
dummyhead
FUEL SYSTEM
1. DLC signal line short circuit inspection
Turn the combination switch OFF and remove the
SCS service check connector [1] from DLC .
Turn the combination switch ON. [1]
Measure the voltage between the DLC No.4
(Light green) terminal and engine ground.
NO – Repair short in the Light green wire.
DLC
SCS
(Light green)
2. MIL ON line short circuit inspection

Disconnect the ECM connector A .
between the ECM and the MIL.
Connect ECM connector A .
Disconnect the MAP sensor 3P connector .
YES – Replace the MAP sensor.
5-46
dummyhead
FUEL SYSTEM
(Brown/Yellow) terminal and engine ground. MAIN WIRE HARNESS SIDE
NO – Repair short in the Brown/Yellow wire. VCC1
(Brown/Yellow)

Disconnect the TP sensor 3P connector .
YES – Replace the TP sensor.
terminal and engine ground. TP SENSOR 3P CONNECTOR
NO – Repair short in the Blue wire.
VCC2
(Blue)

inspection 1
Disconnect the trim angle sensor 3P connector
.
YES – Replace the trim angle sensor.

5-47
dummyhead
FUEL SYSTEM
inspection 2
Measure the voltage between the trim angle sensor
3P connector main wire harness side No.3 TRIM ANGLE SENSOR 3P CONNECTOR
(Brown/White) terminal and engine ground. MAIN WIRE HARNESS SIDE
recheck.
VCC3
NO – Repair short in the Brown/White wire. (Brown/White)
MIL BLINKS ONCE (HO2S)

ECM 29
25
HO2S
O2 Bl/Y Bl/Y Bl
27
1
G Gr
2
SG2 G
25
28
Bl BLACK Br BROWN
12 Y YELLOW O ORANGE
21 17
JOINT G GREEN Lg LIGHT GREEN
R RED P PINK
CONNECTOR 2 W WHITE Gr GRAY

Disconnect the HO2S 4P connector , ECM
connector A , ECM connector B , joint
connector 2 and then reconnect them.
Let the engine idle for 1 minute or more.
Turn the combination switch OFF and connect the
SCS service connector.
Turn the combination switch ON and check the
number of blinks of the MIL.
Does the MIL blink once?
reappear).
5-48
dummyhead
FUEL SYSTEM
2. HO2S inspection
Inspect the HO2S (page 5-108).
Is the HO2S correct?
recheck.
3. Fuel supply system inspection
Measure the fuel pressure (page 5-97).
Is the fuel pressure normal?
harness between the ECM and HO2S. If
the main wire harness is correct, replace
the ECM with a new one, and recheck.
NO – Repair fuel supply system and recheck
under normal fuel pressure.
MIL BLINKS 3 TIMES (MAP SENSOR)
Bl BLACK Br BROWN
Y YELLOW O ORANGE
ECM G GREEN Lg LIGHT GREEN
R RED P PINK
W WHITE Gr GRAY
5V
29
PB W/R
MAP
SENSOR
9
26
5V Br/Y
1
VCC1 Br/Y W/R
6
SG1 G G 2
24
28

Start the engine.
SCS service check connector.
Does the MIL blink 3 times?
reappear)

5-49
dummyhead
FUEL SYSTEM
the MAP sensor 3P connector . MAP SENSOR 3P CONNECTOR
(Brown/Yellow) terminal and engine ground.
VCC1
(Brown/Yellow)
3. MAP sensor signal open or short circuit/GND

line open circuit inspection
(White/Red) terminal and No.3 (Green) terminal. MAIN WIRE HARNESS SIDE
and recheck.
SG1
NO – • Repair open or short in the White/Red (Green)
wire.
• Repair open in the Green wire. PB
• If the main wire harness is normal, (White/Red)
recheck.
5-50
dummyhead
FUEL SYSTEM
MIL BLINKS 4 (CKP SENSOR)
Bl BLACK Br BROWN
Y YELLOW O ORANGE
Bu BLUE Lb LIGHT BLUE No.5
G GREEN Lg LIGHT GREEN FUSE
R RED P PINK
W WHITE Gr GRAY
(15 A)
Y
13
24 22
ECM 29 JOINT CONNCTOR 1 CKP SENSOR

5V
Y/Bl
3
CRK Bu Bu
20
1
G/Bl
2
Bu
23
GND5

Start the engine.
Does the MIL blink 4?
reappear)
2. CKP sensor power line open circuit inspection
the CKP sensor 3P connector .
CKP SENSOR 3P CONNECTOR
Does battery voltage exist? IGP2
YES – GO TO STEP 3. (Yellow/Black)

No.5 fuse circuit in the fuse box

5-51
dummyhead
FUEL SYSTEM
3. CKP sensor signal line open or short circuit/
connector main wire harness side No.1 (Blue) CKP SENSOR 3P CONNECTOR
terminal and No.2 (Green/Black) terminal. MAIN WIRE HARNESS SIDE
NO – • Repair open or short in the Blue wire
• Repair open in the Green/Black wire
LG1 CRK
• If the main wire harness is normal, (Green /Black)
replace the ECM with a new one, and (Blue)
recheck.
4. Crank pulser plate inspection

Check the crank pulser plate (page 7-13).
Is the crank pulser plate correct?
and recheck. If the CKP sensor is
replaced, but MIL blinks 4, replace the
NO – Replace the alternator rotor and recheck.
5-52
dummyhead
FUEL SYSTEM
MIL BLINKS 6 (EBT SENSOR)
ECM
EBT
5V
SENSOR
29 20
TE R/W R/W
1
G
2
SG2 G
25
G G
28
12
21 24
Bl BLACK Br BROWN
Y YELLOW O ORANGE
R RED P PINK
W WHITE Gr GRAY JOINT CONNCTOR 2
• When the MIL blinks 6, 7, 10, 22, 24, and 25 at the

same time, the ground line (SG2) is open.
them.
reappear)
2. EBT sensor signal line open or short circuit/
White) terminal and No.2 (Green) terminal.
SG2 TE
Is the measurement within 4.75 – 5.25 V? (Green) (Red/White)
YES – Replace the EBT sensor with a new one
and recheck.
NO – • Repair open or short in the Red/White
wire
• Repair open in the Green wire
recheck.

5-53
dummyhead
FUEL SYSTEM
MIL BLINKS 7 (TP SENSOR)
ECM 29
THL R/Bl TP
SENSOR
8
21
5V Bu
1
VCC2 Bu R/Bl
2
SG2 25 G G
3
28
G G
12
21 15
Bl BLACK Br BROWN
Y YELLOW O ORANGE
R RED P PINK JOINT
W WHITE Gr GRAY
CONNECTOR 2

• When the MIL blinks 7 and 22 at the same time, the
power line (VCC2) is open.
them.
Start the engine.
reappear)
2. TP sensor power/GND line open circuit
inspection
the TP sensor 3P connector . TP SENSOR 3P CONNECTOR
terminal and No.3 (Green) terminal.
SG2 VCC2
(Green) (Blue)
NO – Repair open in the Blue wire or Green
wire. If the main wire harness is normal,
recheck.
5-54
dummyhead
FUEL SYSTEM
3. TP sensor signal line open or short circuit
inspection
Disconnect the ECM connector A .
Check for open circuit between the TP sensor 3P
Black) terminal and ECM connector A main
wire harness side No.8 (Red/Black) terminal.
Check for short circuit between the TP sensor 3P
Black) terminal and engine ground.
Is the signal line is correct?
YES – Replace the throttle body with a new one
and recheck.
NO – Repair open or short in the Red/Black wire.

5-55
dummyhead
FUEL SYSTEM
MIL BLINKS 8 (CMP SENSOR)
Bl BLACK Br BROWN
Y YELLOW O ORANGE
No.5 Bu BLUE Lb LIGHT BLUE
FUSE G GREEN Lg LIGHT GREEN
(15 A) R RED P PINK
W WHITE Gr GRAY
Y
13
24 23
CMP
ECM 29 JOINT CONNECTOR 1 SENSOR
5V
Y/G
3
TDC Bu G
24
1
G/Bl
2
Bu
24
GND2

Start the engine.
reappear)
2. CMP sensor power line open circuit inspection
the CMP sensor 3P connector . CMP SENSOR 3P CONNECTOR
IGP2
YES – GO TO STEP 3. (Yellow/Black)
5-56
dummyhead
FUEL SYSTEM
3. CMP sensor signal line open or short circuit/
connector main wire harness side No.1 CMP SENSOR 3P CONNECTOR
(Green) terminal and No.2 (Green/Black) terminal. MAIN WIRE HARNESS SIDE
NO – • Repair open or short in the Green wire
• Repair open in the Green/Black wire TDC
• If the main wire harness is normal, LG1
(Green/Black) (Green)
recheck.
4. Cam pulser plate inspection

Check the cam pulser plate (page 14-22).
Is the cam pulser plate correct?
YES – Replace the cam sensor with a new one
and recheck. If the CMP sensor is
NO – Replace the cam pulser plate, and
recheck.

5-57
dummyhead
FUEL SYSTEM
MIL BLINKS 10 (ONE LONG BLINK AND NO SHORT BLINK) IAT SENSOR
ECM 29 IAT
5V
19
SENSOR
TA 23 R/Y R/Y
1
G
2
SG2 G
25
G G
28
12
21 13
Bl BLACK Br BROWN
Y YELLOW O ORANGE
R RED P PINK
W WHITE Gr GRAY JOINT CONNECTOR 2

them.
Does the MIL blink 10 (one long blink)?
reappear)
2. IAT sensor signal open or short circuit/GND line
open circuit inspection
the IAT sensor 2P connector . IAT SENSOR 2P CONNECTOR
Yellow) terminal and No.2 (Green) terminal.
SG2 TA
Is the measurement within 4.75 – 5.25 V? (Green) (Red/Yellow)
and recheck.
NO – • Repair open or short in the Red/Yellow
wire
• Repair open in the Green wire
recheck.
5-58
dummyhead
FUEL SYSTEM
MIL BLINKS 14 (ONE LONG BLINK AND 4 SHORT BLINKS) IAC VALVE
Bl BLACK Br BROWN
Y YELLOW O ORANGE
ECM G
R
GREEN
RED
Lg
P
LIGHT GREEN
PINK
W WHITE Gr GRAY
IAC
12V 27
VALVE
EACVP G G
18
2
EACVM Bl Bl
36
1
28

Disconnect the IAC valve 2P connector , ECM
connector B and then reconnect them.
Start the engine.
reappear)
Inspect the IAC valve (page 5-107).
Is the IAC valve normal?
YES – Repair open or short in the Green wire or
Black wire between the ECM and IAC
valve. If the main wire harness is normal,
recheck.
NO – Replace the IAC valve with a new one and
recheck.

5-59
dummyhead
FUEL SYSTEM
MIL BLINKS 21 TIMES (2 LONG BLINKS AND ONE SHORT BLINK) VTEC
SOLENOID VALVE
Bl BLACK Br BROWN
Y YELLOW O ORANGE
ECM G GREEN Lg LIGHT GREEN
R RED P PINK
W WHITE Gr GRAY
VTEC
12 V SOLENOID
11 VALVE
VTS G/Y G/W

10
1
28

Disconnect the VTEC solenoid valve 1P connector
, ECM connector B and then reconnect
them.
Raise the engine speed slowly and let it run at 5,200
min-1 (rpm) for a few seconds.
SCS service connector.
reappear).
2. VTEC solenoid valve inspection
Inspect the VTEC solenoid valve
(page 5-107).
Is the VTEC solenoid valve correct?
harness between the ECM and VTEC
solenoid valve. If main wire harness is
correct, replace the ECM with a new one
and recheck.
NO – Replace the VTEC solenoid valve with a
5-60
dummyhead
FUEL SYSTEM
MIL BLINKS 22 (2 LONG BLINKS AND 2 SHORT BLINKS) EOP SENSOR
ECM
5V
29
POIL Y/R EOP

SENSOR
10
22
5V Bu
1
VCC2 Br/W Y/R
2
SG2 25 G G
3
28
G G
12
21 23
Bl BLACK Br BROWN
Y YELLOW O ORANGE
R RED P PINK
• When the MIL blinks 7 and 22 at the same time, the
power line (VCC2) is open.
them.
reappear)
the EOP sensor 3P connector . EOP SENSOR 3P CONNECTOR
YES – GO TO STEP 3. VCC2
(Blue)

5-61
dummyhead
FUEL SYSTEM
3. EOP sensor signal line open or short circuit/
connector main wire harness side No.2 EOP SENSOR 3P CONNECTOR
(Yellow/Red) terminal and No.3 (Green) terminal. MAIN WIRE HARNESS SIDE
and recheck.
NO – • Repair open or short in the Yellow/Red
wire SG2 POIL
• Repair open in the Green wire. (Green) (Yellow/Red)
recheck.
MIL BLINKS 23 (2 LONG BLINKS AND 3 SHORT BLINKS)

KNOCK SENSOR
ECM
KNOCK
10
SENSOR
KS R/Bu R/Bu
Bl BLACK Br BROWN
29
Y YELLOW O ORANGE
R RED P PINK 28
W WHITE Gr GRAY

and ECM connector B , and then reconnect
them.
Increase the engine speed gradually and run it at
3,000 min-1 (rpm) for 10 seconds.
reappear)
5-62
dummyhead
FUEL SYSTEM
2. Knock sensor line open or short circuit
inspection
and ECM connector B .
Check for open and short circuit between the knock
sensor 1P connector main wire harness side
No.1 (Red/Blue) terminal and ECM connector B
No.29 (Red/Blue) terminal.
Is the knock sensor line open or short?
YES – Repair open or short in the Red/Blue wire.
NO – Replace the knock sensor with a new one
and recheck. If the knock sensor is

ECT SENSOR 2
ECM 29 ECT
5V
SENSOR 2
17
TOH1 R/Bl R/Bl

22
1
G
2
SG2 G
25
G G
28
12 21 19
Bl BLACK Br BROWN
Y YELLOW O ORANGE
R RED P PINK

them.
reappear)

5-63
dummyhead
FUEL SYSTEM
2. ECT sensor 2 signal line open or short circuit/
(Red/Black) terminal and No.2 (Green) terminal.
SG2 TOH1
Is the measurement within 4.75 – 5.25 V? (Green) (Red/Black)
and recheck.
NO – Repair open or short in the Red/Black wire
or open in the Green wire. If the main wire
harness is normal, replace the ECM with a

ECT SENSOR 3
ECM 29
ECT
5V
18
SENSOR 3
TOH2 R G
26
1
G
2
SG2 G
25
G G
28
12 21 22
Bl BLACK Br BROWN
Y YELLOW O ORANGE
G
R
GREEN
RED
Lg
P
LIGHT GREEN
PINK
JOINT CONNECTOR 2
W WHITE Gr GRAY

them.
reappear)
5-64
dummyhead
FUEL SYSTEM
2. ECT sensor 3 signal line open or short circuit/
(Red) terminal and No.2 (Green) terminal.
SG2 TOH2
(Green) (Red)
and recheck.
NO – Repair open or short in the Red wire or
open in the Green wire. If the main wire
harness is normal, replace the ECM with a
MIL BLINKS 41 (4 LONG BLINKS AND ONE SHORT BLINK)

HO2S HEATER
No.4
FUSE
(10 A)
Y
13
16 17
ECM 29
JOINT
CONNECTOR 1
HO2S
25
HEATER
O2HT W/Bl W/Bl W
18
Y/Bl W
4
Bl BLACK Br BROWN
Y YELLOW O ORANGE
R RED P PINK
W WHITE Gr GRAY

Disconnect the HO2S 4P connector , ECM A
connector , and joint connector 1 , and
then reconnect them.
reappear)

5-65
dummyhead
FUEL SYSTEM
2. HO2S sensor heater inspection
Inspect the HO2S heater (page 5-108).
Is the HO2S heater normal?
YES – Repair open in the main wire harness
between the ECM and HO2S. If main wire
harness is correct, replace the ECM with a
recheck.
FUEL PRESSURE RELIEVING

handling fuel.
• Disconnect the battery cable from the battery

negative (–) terminal before relieving the fuel
pressure.
• Replace the sealing washer when the service check
bolt is loosened or removed.
[2]
Set a wrench on the service check bolt [1] on the vapor
separator and place a shop towel or equivalent material
[2] over the service check bolt.
Loosen the service check bolt approximately one turn
slowly to relieve the fuel pressure.
[1]
After relieving the fuel pressure, remove the service

check bolt [1] and replace the sealing washer [2] with a
[2]
new one.
Install and tighten the service check bolt to the specified
torque.
[1]
5-66
dummyhead
FUEL SYSTEM
FUEL PUMP (LOW PRESSURE SIDE)
REMOVAL/INSTALLATION

handling fuel.

[1]
• Clamp the fuel tubes before disconnecting them [2] [5]
from the fuel pump, using commercially available
tube clips
Disconnect fuel tube E [1] and D [2] from the fuel pump
(low pressure side) [3].
Remove the two bolts [4] from the fuel pump (low
pressure side) and remove the fuel pump (low pressure
side).
Remove the O-ring [5] from the fuel pump (low pressure
side) and replace with a new one.
Installation is in the reverse order of removal. [3] [4]
• Apply engine oil to a new O-ring.
SILENCER CASE REMOVAL/

INSTALLATION
REMOVAL
Remove the following: [5]
– Engine cover [1]
Disconnect the IAT sensor 2P connector [1] and [3]
release the harness band clip [2] from the silencer case
[3].
Open the wire harness band [4], and remove breather
tube C [5], main wire harness [6] and the wire harness
band from the silencer case.
Release the vinyl tube [7] from the under cover front
[2]
bracket and fuel tube clamp D.
[6] [7]
[4]
Loosen the air flow clamp screw [1].
[1]

5-67
dummyhead
FUEL SYSTEM
Remove the two bolt/washers [1] and remove the
silencer case [2]. [2]
[1]
INSTALLATION
Set the air flow band [1] on the silencer grommet [2],
and connect the silencer grommet into the throttle body [2]
until it stops. Tighten the two bolt/washers [3] securely.
[3]
[1]
Tighten the air flow band to the dimension shown or

tighten it to the specified torque. [1]
6 - 8 mm
(0.24 - 0.31 in)
Set the main wire harness [1] on the silencer case, and
[3]
fasten the wire harness band [2]. [4] [6]
Connect breather tube C [3] to the silencer case
securely until the painted part of the breather tube [4] is
hidden in the silencer case.
Connect the vinyl tube [5] to the under cover front
bracket, and set the fuel tube clamp D.
Connect the IAT sensor 2P connector [6], and set the
harness band clip [7] on the silencer case.
Install the following:
[7]
– Engine cover
[1] [5]
[2]
5-68
dummyhead
FUEL SYSTEM
INTAKE MANIFOLD REMOVAL/
INSTALLATION
REMOVAL
[1]
– Engine cover
– Silencer case (page 5-67)
Disconnect the MAP sensor 3P connector [1] and
remove the harness band clip [2].
[2]
Disconnect the TP sensor 3P connector [1].
[1]
Remove the throttle rod [1].

• Do not loosen the pivot lock nut. [3]
[2]
Remove the four bolts [2] and remove the throttle body
[3].
Remove the gasket [4].
[1] [4]
Disconnect the pressure regulator control tube [1] and

the vinyl tube [2] from the intake manifold. [1] [2]

5-69
dummyhead
FUEL SYSTEM
Disconnect the IAC valve 2P connector [1], and EOP
sensor 3P connector [2]. [1] [3] [2]
Remove the two harness band clips [3].
Remove the three harness band clips [1] from the

intake manifold.
[1]
Release tube D [1] from the clamp of the intake

manifold. Remove the three bolts [2], two bolt/washers
[3], and the two nuts [4], and remove the intake
manifold [5].
[1]
[3]
[2]
[4]
[5]
5-70
dummyhead
FUEL SYSTEM
INSTALLATION
Install the new intake manifold gasket [1] on the intake
manifold. [1]
• Align the projection [2] of the gasket with the groove [2]
[3] in the intake manifold.
[3]
Set the intake manifold [1] on the engine.

Install the three bolts [2], two bolt/washers [3], and the [1]
two nuts [4], and tighten them in the numbered 2.
sequence shown in two or three steps.
6.
[3] 4.
1.
[4]
3.
5.
7.
[2]
Install the new gasket [1] on the intake manifold.

Install the throttle body [2]. Tighten the four bolts [3] to
the specified torque in the numbered sequence shown [2]
[3]
in two or three steps.
1. 4.
Install the throttle rod [4].
• Do not loosen the throttle rod. 2.
3.
[4] [1]
Connect the IAC valve 2P connector [1], and EOP

sensor 3P connector [2]. [1] [3] [2]
Install the two harness band clips [3] in the position
shown.

5-71
dummyhead
FUEL SYSTEM
Install the three harness band clips [1] in the positions
shown.
[1]
Set the pressure regulator control tube [1] and the vinyl
tube [2] to the intake manifold. [1] [2]
Connect the TP sensor 3P connector [1].
[1]
Connect the MAP sensor 3P connector [1], and install

the harness band clip [2] on the set plate. [1]
– Engine cover
[2]
5-72
dummyhead
FUEL SYSTEM
FUEL INJECTORS REMOVAL/
INSTALLATION

handling fuel.
REMOVAL
(–) terminal.
Relieve the fuel pressure (page 5-66).
– Engine cover
– L. engine under cover (page 6-5)
Remove the three harness band clips [1]. [1]
Disconnect the 2P connector [2] from the each injector.
[2]
Remove the bolt [1] and disconnect the fuel hose [2].
[4] [2]
Remove the fuel pipe joint [3] and the two O-rings [4].
[1]
[3]

5-73
dummyhead
FUEL SYSTEM
Remove the two nuts [1], and remove the fuel line [2]
and two collars [3]. [3] [2]
[1]
Remove the following parts from the fuel line [1]:

– Two injector clips [2]
– Four bolts [3]
– Four fuel injectors [4]
– Four O-rings (7.47 x 3.6 mm) [5]
– Four O-rings (7.45 x 3.61 mm) [6]
[6]
[4]
[5]
[3]
[1]
[2]
5-74
dummyhead
FUEL SYSTEM
INSTALLATION
• Install the fuel injector as a set of 2.
Apply thin coat of engine oil to a new O-ring (7.47 x 3.6
mm) [1], and install one on each injector [2]. [3]
Set a new O-ring (7.45 x 3.61 mm) [3] to the each fuel
injector. [2]
Set the injector into the fuel line [4], aligning the
projection of the injector with the groove in the fuel line. [1]
Install the injector clips [5] on the injector, and tighten
the bolt [6] to the specified torque.
[6]
[5]
[4]
Set the two collars [1], apply engine oil to the new O-
rings [2] and install the fuel line [3]. [2]
[1] [3]
Tighten the two nuts [4] securely.
[4]
Apply engine oil to a two O-rings [1] and install them on

the fuel pipe joint [2]. [1] [3]
Set the fuel pipe joint into the fuel line [3] until stops.
[4]
• Be sure to insert the fuel pipe joint straight.
Set the fuel hose, and tighten bolt [4] securely.
• Check that the fuel hose is connected securely, and
it is not tightened at an angle.
[2]

5-75
dummyhead
FUEL SYSTEM
Connect the 2P connectors [1] to the corresponding
injectors.
Install the three harness band clips [2].
– Engine cover
[2]
[1]
FUEL PUMP (HIGH PRESSURE SIDE)/

VAPOR SEPARATOR REMOVAL/
INSTALLATION

handling fuel.
REMOVAL
(–) terminal. [1]
– Engine cover
the vinyl tube [2] from the intake manifold.
Remove fuel tube clamp D [3] from the pressure
regulator control tube.
[3] [2]
5-76
dummyhead
FUEL SYSTEM
Release the water level sensor 2P connector [1] and
the trim angle sensor 3P connector [2] from the relay [3] [1]
bracket and remove the harness band clip [3] from the
relay bracket.
Remove the hose clip [4] from the fuel hose and fuel
tube B.
[4] [2]
Disconnect air vent tube A [1] and fuel tube D [2] from
[1]
the vapor separator. [2]
Open the fuel hose grommet [1] and release the fuel
hose [2].
[4] [5]
Release fuel tube B [3] from the two fuel tube clamp Bs [3]
[4].
Release fuel tube C from the tube clamp [5].
[1] [2]
Release water tube A [1] and B [2] from the Water

jacket cover.
[2]
[1]

5-77
dummyhead
FUEL SYSTEM
Release the fuel hose [1] from three fuel tube clamps
[2].
[1]
[2]
Remove the bolt [1], and disconnect the fuel hose [2]
from the fuel line. [4] [2]
Remove the fuel pipe joint [3], and remove the two O-
rings [4]. [1]
[3]
Remove the bolt/washers [1], and pull the vapor

[2]
separator [2] toward you.
[1]
Release the pump harness [1] from the cord clamper

[3] [2]
[2]. Release the fuel pump (high pressure side) 2P
connector [3] from the relay bracket, and disconnect the [1]
fuel pump (high pressure side) 2P connector.
5-78
dummyhead
FUEL SYSTEM
INSTALLATION
Connect the fuel pump (high pressure side) 2P
[1] [2]
connector [1].
Connect the fuel pump (high pressure side) 2P
connector to the relay bracket, and secure the pump
harness to the cord clamp [2].
Install the vapor separator, and tighten the three bolt/

washers [1] securely.
[1]
Apply engine oil to two new O-rings [1], and install them
on the fuel pipe joint [2]. [1] [3]
Set the fuel pipe joint into the fuel line until it stops.
[4]
• Do not insert the fuel pipe joint at an angle.
Set the fuel hose [3], and tighten the bolt [4] securely.
• Check that the fuel hose is connected securely and
it is not tightened at an angle.
[2]
Secure fuel tube [1] to the three fuel tube clamps [2].
[1]
[2]

5-79
dummyhead
FUEL SYSTEM
Connect water tube A [1] and B [2] into the water jacket
cover until they stop, and install the tube clip and tube
clip B 10.
[2]
[1]
Set fuel tube B [1] to the two fuel tube clamp Bs [2] by
attaching the ends of the protector tubes to the fuel tube
clamp Bs. [2] [5]
[1]
Set the fuel hose [3] to the fuel hose grommet [4].
Set fuel hose C to the tube clamp [5].
[4] [3]
Connect air vent tube A [1] and fuel tube D [2] to the
[1]
vapor separator. [2]
Set the water level sensor 2P connector [1] and the trim
angle sensor 3P connector [2] on the relay bracket. [3] [1]
Set the harness band clip [3] on the relay bracket.
• Install the hose clip [4] between the protective tubes
on fuel tube B.
[4] [2]
5-80
dummyhead
FUEL SYSTEM
Connect the pressure regulator control tube [1] and the
vinyl tube [2] to the intake manifold. [1]
Set the pressure regulator control tube to the fuel tube
clamp D [3].
– Engine cover
[3] [2]
MAP SENSOR REMOVAL/

INSTALLATION
Remove engine cover.
Disconnect the MAP sensor 3P connector [1] from the [1] [3]
MAP sensor [2]. [4]
Remove the bolt [3] and remove the MAP sensor.
Apply engine oil to a new O-ring [4] and install the MAP
sensor.
Install the MAP sensor, and tighten the bolt to the
specified torque.
TORQUE: 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft) [2]
Connect the MAP sensor 3P connector.
IAT SENSOR REMOVAL/

INSTALLATION
Disconnect the IAT sensor 2P connector [1] from the [1]
IAT sensor [2]. [2]
Remove the IAT sensor.
Install the IAT sensor to the sensor grommet.
Connect the IAT sensor 2P connector.

5-81
dummyhead
FUEL SYSTEM
IAC VALVE REMOVAL/INSTALLATION
Loosen the three bolts, two nuts, two bolt/washers, and
[1]
air flow band of the intake manifold (page 5-69). [4]
[3]
Disconnect the IAC valve 2P connector [1] from the IAC
valve [2].
Remove the two bolts [3] and remove the IAC valve by
slightly shifting the intake manifold.
Install a new IAC valve gasket on the intake manifold.
Install the IAC valve and tighten the two bolts to the
specified torque.
[2]
Connect the IAC valve 2P connector.
Tighten the three bolts, two nuts, two bolt/washers, and
air flow band of the intake manifold (page 5-71).
HO2S REMOVAL/INSTALLATION
[4]
[2]
Release the harness band clip [1] from harness clip
bracket C and release the HO2S 4P connector [2]. [1]
Disconnect the HO2S 4P connector.
Remove the HO2S [3] from the water jacket cover,
using a commercially available HO2S wrench (S6176)
[4].
Tighten the HO2S to the specified torque using the
HO2S wrench.
[3]
Connect the HO2S 4P connector and set the harness
band clip to harness clip bracket C.
Set the HO2S 4P connector to harness clip bracket C.
VTEC SOLENOID VALVE REMOVAL/

INSTALLATION (BF90D/BF100A ONLY)
[1]
– Engine cover
Open the harness clip [1], and release the harness
band clip [2] from harness clip bracket D.
Release the VTEC solenoid valve 1P connector [3] from
harness clip bracket D, and disconnect the VTEC
solenoid valve 1P connector.
[3] [2]
5-82
dummyhead
FUEL SYSTEM
Remove the three bolts [1] and remove harness clip
bracket D [2], VTEC solenoid valve [3], gasket [4], and [4] [5]
the filter [5].
• Check the filter. If it is restricted, replace the engine [1]
oil and oil filter.
Install a new gasket and filter on the VTEC solenoid
valve.
Install the VTEC solenoid valve, and harness clip
bracket D and tighten three bolts.
Connect the VTEC solenoid valve 1P connector, and
install it on the connector bracket.
Set the harness band clip on harness band clip bracket [2] [3]
D and close the harness clip.
– Engine cover
CKP SENSOR REMOVAL/

INSTALLATION
(–) terminal. [4]
[1]
– Engine cover
Disconnect the CKP sensor 3P connector [1] from the
CKP sensor [2].
Remove the bolt [3] and remove the CKP sensor.
Apply engine oil to a new O-ring [4] and install on the
CKP sensor.
Install the CKP sensor, and tighten the bolt.
[3] [2]
Connect the CKP sensor 3P connector.
– Engine cover
CMP SENSOR REMOVAL/

INSTALLATION
[2]
– R. engine under cover (page 6-5)
Disconnect the CMP sensor 3P connector [1] from the
CMP sensor [2].
Remove the bolt [3] and remove the CMP sensor.
CMP sensor.
Install the CMP sensor, and tighten the bolt.
Connect the CMP sensor 3P connector. [1]
Install the following: [4]
– Engine cover

5-83
dummyhead
FUEL SYSTEM
EOP SENSOR REMOVAL/
INSTALLATION
Remove the intake manifold (page 5-69).
[3]
Disconnect the EOP sensor 3P connector [1] from the [1]
EOP sensor [2].
Apply engine oil to a new O-ring [3] and install on the [2]
cylinder block.
Install the EOP sensor and tighten to the specified
torque.
• Be sure to use a torque wrench to tighten the switch.

Overtightening will damage the cylinder block.
Connect the EOP sensor 3P connector.
Install the intake manifold (page 5-71).
KNOCK SENSOR REMOVAL/

INSTALLATION (BF90D/BF100A ONLY)
Disconnect the knock sensor 1P connector [1] from the
knock sensor [2].
Install the knock sensor and tighten to the specified
torque.
Connect the knock sensor 1P connector.
Install the intake manifold (page 5-71).
[2]
[1]
EBT SENSOR REMOVAL/

INSTALLATION
– Engine cover
– L. engine under cover (page 6-5) [3]
[1]
Disconnect the EBT sensor 2P connector [1] from the
EBT sensor [2].
Remove the EBT sensor.
EBT sensor.
Apply liquid sealant (Threebond® 1201, 1215 or
equivalent) to the threads and seating surface of the
EBT sensor.
[2]
Install the EBT sensor and tighten to the specified
torque.
Connect the EBT sensor 2P connector.
– Engine cover
5-84
dummyhead
FUEL SYSTEM
ECT SENSOR 2 REMOVAL/
INSTALLATION
Disconnect the ECT sensor 2 (2P) connector [1] from
ECT sensor 2 [2]. [3]
Remove ECT sensor 2.
Apply engine oil to a new O-ring [3] and install on ECT
sensor 2.
equivalent) to the threads and seating surface of ECT
sensor 2.
[2]
Install ECT sensor 2 and tighten to the specified torque.
[1]
Connect the ECT sensor 2 (2P) connector.
ECT SENSOR 3 REMOVAL/

INSTALLATION
Disconnect the ECT sensor 3 (2P) connector [1] from [1]
ECT sensor 3 [2]. [3]
Remove ECT sensor 3.
Apply engine oil to a new O-ring [3] and install on ECT
sensor 3.
equivalent) to the threads and seating surface of ECT
sensor 3.
Install ECT sensor 3 and tighten to the specified torque. [2]
Connect the ECT sensor 3 (2P) connector.

5-85
dummyhead
FUEL SYSTEM
AIR VENT STRAINER/CHECK VALVE REMOVAL/INSTALLATION
• Check each tube for deterioration or cracks and replace the tubes if necessary.
• After assembly, check that the tube clamps are set securely (page 2-43).
O-RING
HARNESS CLIP BOLT
BRACKET B (6 x 14 mm) (2)
FUEL TUBE E
FUEL STRAINER
(LOW PRESSURE TUBE CLIP (B12)
SIDE) (5) FUEL PUMP
T-JOINT (LOW PRESSURE
STRAINER SIDE)
SUSPENSION
BOLT
(6 x 22 mm) (2)
FUEL TUBE D
AIR VENT
TUBE B
CHECK VALVE
TUBE B
TUBE CLAMP
(7.5 - 11.5) (2)
CHECK VALVE
AIR VENT
ASSEMBLY: TUBE C
Install with the
arrow mark
toward check
valve tube A.
FUEL TUBE
CLAMP
BRACKET
BOLT
(6 x 14 mm) (2)
HOSE CLIP
CHECK VALVE AIR VENT

TUBE A TUBE A FUEL TUBE
FUEL HOSE
TUBE CLAMP JOINT C
AIR VENT FUEL TUBE CLAMP A (2)
STRAINER TUBE CLIP (B12) (2)
(LRTA/XRTA/LRTC/
FUEL TUBE CLAMP B (7) XRTC type only)
FUEL
TUBE C
TUBE CLAMP (D12) (2)
(Except LRTA/XRTA/
LRTC/XRTC type)
5-86
dummyhead
FUEL SYSTEM
WATER SEPARATOR REMOVAL/
INSTALLATION
REMOVAL
• Before removing the water separator, place a shop
towel under each tube and water separator, clamp [3]
the two fuel tubes with commercially available tube
clamps, and then disconnect the fuel tubes.
Clamp fuel tube A [1] and fuel tube B [2] securely with
the two commercially available tube clamps [3]. [4]
Disconnect fuel tube A and fuel tube B from the water
separator [4].
[1]
[2]
Remove the water separator [1] and the strainer [3]

suspension [2] as a set from the relay bracket [3]. [1]
Remove the suspension from the water separator cup.
[2]
Open the harness clip [1] and release the water level
sensor wire [2].
Release the water level sensor wire from clip C [3]. [3]
Disconnect the water level sensor 2P connector [4]. [4]
[1]
[2]

5-87
dummyhead
FUEL SYSTEM
INSTALLATION
• Check each tube for deterioration or cracks, and
replace if necessary. [3] [1]
Set the suspension [1] on the water separator cup [2]
with the projection [3] up.
Install the suspension so that the flat part on the
backside [4] of the suspension is in line with the
mark (suction side) [5] of the joint.
Or, install the suspension so that the "I" mark on the
suspension is in the line with the mark (discharge
side) [6] of the joint.
[5] [6]
[1]
[4]
[2]
Connect the water level sensor 2P connector [1].

Set the water level sensor wire in the harness clip and [1]
in clip C [2] so that the two positioning bands [3] are in
the positions shown.
Close the harness clip [4]. [3]
[4] [2]
5-88
dummyhead
FUEL SYSTEM
Connect fuel tube A [1] to the mark (suction side)
[1] [2]
[2] of the joint of the water separator.
Connect fuel tube B [3] to the mark (discharge side)
[4] of the joint of the water separator, aligning the "I"
mark [5] on fuel tube B with the mark on the water
separator.
Install tube clip B12 [6] with the lugs up.
After connecting the fuel tubes, check for gasoline
leaking from the joints.
Install the water separator on the relay bracket [7]
Install the engine cover. [5]
[4]
[3]
[6]
[7]
WATER SEPARATOR DISASSEMBLY/ASSEMBLY

Remove the water separator (page 5-87).
SCREW (5 X 12 mm) (3)

3.4 N·m (0.35 kgf·m, 2.5 lbf·ft)
PLATE
WATER SEPARATOR
CUP/WATER LEVEL
SENSOR
O-RING
BAFFLE PLATE
WATER SEPARATOR BODY

5-89
dummyhead
FUEL SYSTEM
SILENCER CASE DISASSEMBLY/ASSEMBLY
SENSOR GROMMET
ASSEMBLY:
Install the sensor grommet in
the direction shown.
COLLAR (2)
SILENCER CASE
GROMMET (2)
IAT SENSOR
AIR FLOW BAND
SILENCER GROMMET
ASSEMBLY:
Install the silencer grommet so the
projection on the silencer grommet sits
VINYL TUBE (4 x 7 x 190 mm) between the two projections on the
silencer case.
PROJECTION
PROJECTION
5-90
dummyhead
FUEL SYSTEM
FUEL PUMP (HIGH PRESSURE SIDE)/VAPOR SEPARATOR
DISASSEMBLY/ASSEMBLY
COMPONENTS LOCATION
Remove the fuel pump (high pressure side) and vapor separator (page 5-76).
PRESSURE
REGULATOR PRESSURE REGULATOR
CONTROL TUBE
O-RING
BOLT (6 x 14 mm) (2)
11.8 N·m (1.2 kgf·m, 9 lbf·ft) SCREW-WASHER (5 mm) (3)
CORD CLAMP 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft)
SCREW
PRESSURE REGULATOR 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
CONTROL TUBE
PUMP HARNESS
FUEL PIPE JOINT PUMP COVER
O-RING
O-RING (2)
FUEL STRAINER
BOLT (6 x 25 mm) (HIGH PRESSURE SIDE)
SPRING
SERVICE CHECK BOLT STRAINER

COVER
11.8 N·m (1.2 kgf·m, 9 lbf·ft) SEALING WASHER
O-RING
HOLDER SCREW-WASHER (3)

FUEL PUMP
(HIGH PRESSURE SIDE) 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft)
INSULATOR
INSULATOR
COLLAR (2)
O-RING
RING
DRAIN SCREW
1.5 N·m (0.15 kgf·m, 1.1 lbf·ft)
VAPOR SEPARATOR BODY
O-RING O-RING
FUEL TUBE CLAMP B
GROMMET
BRACKET
VINYL TUBE
BOLT (6 x 25 mm) (3)
11.8 N·m (1.2 kgf·m, 9 lbf·ft)
PUMP CASE
GROMMET (2)

5-91
dummyhead
FUEL SYSTEM
SCREW-WASHER (5 mm) (6)

3.4 N·m (0.35 kgf·m, 2.5 lbf·ft)
VAPOR SEPARATOR COVER
FLOAT VALVE
O-RING
FLOAT PIN
FLOAT
SCREW (2)
2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
GASKET
FUEL TUBE CLAMP B
VAPOR SEPARATOR BODY
WATER JACKET COVER
SCREW-WASHER (4 mm) (5)

2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
5-92
dummyhead
FUEL SYSTEM
FUEL PUMP ASSEMBLY
Install new O-rings [1] on the vapor separator body.
Install the pump case [2] with care not to allow the O-
rings to come out of position. [1]
Set the bracket [3] on the bolt [4].
[2]
Install tube clamp B [5] and grommet [6] on the bracket.
[9]
Connect the vinyl [7] tube to the pump case.
Apply engine oil to new O-ring [8], and install it on the [8] [5]
drain screw [9].
Tighten the drain screw to the specified torque.
[6]
[7]
[4] [3]
Install the ring [1] to the fuel pump (high pressure side)
[2]. [2]
Install the fuel pump (high pressure side) on the

insulator [3].
• Install by aligning the projection [4] on the pump with [1]
the hole [5] in the insulator.
[4]
[3]
[5]
Apply engine oil to a new O-ring [1], and install it on the
fuel pump/insulator [2].
Install the fuel pump/insulator on the pump case [3]. Be
sure to install it the direction shown. [2]
[1]
[3]
[3]

5-93
dummyhead
FUEL SYSTEM
Install the pump harness [1] on the pump cover [2], and
install the screw [3] and washer [4]. [3]
[4]
Tighten the screw to the specified torque. [1]

[2]
Set each wire in the respective recess [1] in the holder,

and set the Blue/Yellow terminal [2] and Black terminal [3]
[3] in the positions shown.
Set the holder in the pump cover.
Set the wires between the projections [4] on the holder.
[2]
[1]
[4]
Install the insulator [1] in the pump cover.

[1]
5-94
dummyhead
FUEL SYSTEM
Install a new O-ring [1] on the pump case.
Connect the Blue/Yellow wire [2] and Black wire [3] [2]
from the pump harness to the fuel pump.
[3]
• Connect the Blue/Yellow wire terminal to the positive
(+) terminal [4] of the pump, and the Black wire
terminal to the negative (-) terminal [5] of the pump
securely. [5]
[4]
[1]
Tighten the three screw-washers to the specified

torque. [1]

5-95
dummyhead
FUEL SYSTEM
FUEL TANK/FUEL TANK TUBE

handling fuel.
DISASSEMBLY
TUBE CLIP
BANDS (12.5 mm)
FUEL TUBE JOINT TUBE CLIP

BANDS (20 mm)
FUEL TUBE (SHORT)
OUTLET VALVE
TUBE CLIP BAND TUBE CLIP BAND

(12.5 mm) (12.5 mm)
INLET VALVE
FUEL TANK FILTER

PRIMER BULB
FUEL TUBE (LONG)

SCREW (5 mm) (4)
TUBE CLIP BAND FUEL TANK CAP

(12.5 mm)
TANK CAP PACKING

FUEL CONNECTOR
PRESSURE RELIEF
RETAINER
FUEL JOINT
FILTER GASKET FUEL STRAINER FUEL TANK
ASSEMBLY
Install the inlet valve [1] [has the pin [2]] at the side not
marked with " " mark [3] on the primer bulb [4].
Install the outlet valve [5] at the side marked with the [2]
" " mark.
• Do not confuse the inlet valve and the outlet valve
• Install the priming bulb with the " " mark toward the
motor side
Assembly of the other parts is in the reverse order of [4] [5]
disassembly.
[1] [2]
Fuel tank side [3] Motor side
5-96
dummyhead
FUEL SYSTEM
FUEL PRESSURE MEASUREMENT

handling fuel.

[1]
Remove the service check bolt and set the special tool
in the threaded bolt hole.
TOOL:
Fuel pressure gauge, 0 – 100 psi [1] 07406-004000B
Disconnect the pressure regulator control tube [1] from

the pressure regulator and clamp the tube.
Remove the propeller (page 16-3).
Set the outboard motor gear case in a test tank filled
[1]
with water. Start the engine and measure the fuel
pressure at idle.
Standard fuel pressure
[At idle speed of 750 ± 50 min-1 (rpm)]:
325 – 375 kpa (3.3 – 3.8 kgf/cm2, 47 – 54 psi)
When the fuel pressure is out of the specified standard
pressure, check the following:
• When fuel pressure is higher than standard
pressure:
– Check fuel return hose and fuel line for clogging.
– Check the high pressure side fuel pump for proper
operation (page 5-99).
• When fuel pressure is lower than standard pressure:
– Check the pressure regulator for proper operation
(page 5-98)
– Check the high pressure side fuel pump for proper
operation (page 5-99).
– Check the high pressure side fuel strainer for an
obstruction.
– Check the fuel hose and fuel line for leaking (page
5-3).
After measuring fuel pressure, install the service check
bolt (page 5-66).

5-97
dummyhead
FUEL SYSTEM
FUEL PRESSURE REGULATOR
INSPECTION

handling fuel.
Check that the pressure regulator control tube [1] is not

bent, disconnected, or damaged. [1]
Relieve the fuel pressure (page 5-66). [2]
Remove the service check bolt and set the special tool
in the threaded bolt hole.
TOOL:
Fuel pressure gauge, 0 – 100 psi [1] 07406-004000B
Set the outboard motor gear case in a test tank filled
with water. Start the engine and measure the fuel
pressure at idle.
With the engine idling, disconnect the control tube from

the pressure regulator [1] and clamp the control tube.
Check the fuel pressure. It should be higher than the
pressure measured with the control tube connected.
[1]
Standard fuel pressure
[At idle speed of 750 ± 50 min-1 (rpm)]:
325 – 375 kpa (3.3 – 3.8 kgf/cm2, 47 – 54 psi)
If the fuel pressure does not rise, connect the control

tube [1] to the pressure regulator. [1]
Pinch the pressure regulator return hose that goes from
the pressure regulator to the vapor separator 2 or 3
times lightly, and measure the fuel pressure again.
• Protect the pressure regulator return hose by
winding a shop towel or equivalent around the hose,
and lightly pinch the hose with the pliers.
If the measurement is out of the specified standard
pressure, replace the pressure regulator.
5-98
dummyhead
FUEL SYSTEM
FUEL PUMP (LOW PRESSURE SIDE)
INSPECTION
Remove the fuel pump (low pressure side) (page 5-67).
Push the fuel pump plunger [1] and make sure the [1]
plunger moves smoothly.
If the plunger is stiff, replace the fuel pump (low
pressure side).
FUEL PUMP (HIGH PRESSURE SIDE)

INSPECTION

handling fuel.
DISCHARGE VOLUME INSPECTION

• Use a known-good battery for the inspection.
Disconnect the pressure regulator return hose [1].
[1]
Place a measuring cylinder [2] under the hose.
Operate the fuel pump for approximately 2 seconds and
measure the fuel discharge volume of gasoline using a
measuring cylinder.
Discharge volume
20 cm3 (0.7 US oz, 0.7 Imp oz) or more
If the discharge volume is less than the specified value,
or no fuel is discharged, check the following.
– Fuel pump (high pressure side) circuit (page 5-100)
– Clogged fuel filter (high pressure side), and fuel [2]
hose/line.
– Pressure regulator operation (page 5-98)
If no abnormality is detected, replace the fuel pump
(high pressure side) (page 5-76).

5-99
dummyhead
FUEL SYSTEM
CIRCUIT INSPECTION
PGM-FI/MAIN RELAY
FUEL
FUEL PUMP
MAIN
W/Bu
W/Bl
W
ECM
Bu/Y
Bl
W/Bu
Bu/R
Lg/R
W/Y
Bl/Y
Bl
ղFUSE նFUSE ձFUSE
(10 A) (30 A) (10 A) 1 2
4 5 1 2 4 1 3 3 5
W/Bu
W/Bu
Bu/R
Bu/R
Bl/Y
Lg
W
Bl
Bl
FLR1
14 13
FLR2
Bl
29
W/Bl
Bl/Y
T3 T4
T1 5
1 2
C52
1 6 W/Bl
BAT
42 41
BATTERY
LOAD Bl/Y
Bl
Bl
C47
13 12
COMBINATION SWITCH
7 6 2 1
GND6 GND4
T2 Bl/Y
W/Bl
5
GND2 TILLER HANDLE TYPE: JOINT CONNECTOR 1 JOINT CONNECTOR 2
1 2
C56
W/Bl
BAT
Bl BLACK Br BROWN
LOAD Bl/Y
Y YELLOW O ORANGE
C50
COMBINATION SWITCH
R RED P PINK
Bl/Y
W WHITE Gr GRAY
W/Bl
1. Fuse inspection
Check for blown No.1 fuse.
Is the fuse normal?
NO – Replace the blown fuse and check for a
short in the main wire harness or incorrect
load by referring to the fuse load chart
(page 4-13).
2. Fuel pump power/ground line open circuit
inspection
the fuel pump (High pressure side) 2P connector FUEL PUMP (HIGH PRESSURE SIDE)
. 2P CONNECTOR
Measure the battery voltage between the fuel pump
(High pressure side) 2P connector main wire
harness side No.1 (Blue/Red) terminal and No.2 FUEL PUMP GND1
(Black) terminal. (Blue/Red) (Black)
Is there battery voltage for a few seconds?

YES – Replace the fuel pump (High pressure
side) with a new one and recheck.
5-100
dummyhead
FUEL SYSTEM
3. Pump harness inspection
the PGM-FI/main relay 6P connector .
Check for continuity between the PGM-FI/main
No.3 (Blue/Red) terminal and fuel pump (high
pressure side) 2P connector main wire
FUEL PUMP 1
harness side No.1 (Blue/Red) terminal.
(Blue/Red)
Check for continuity between the fuel pump (high
pressure side) 2P connector main wire
harness side No.2 (Black) terminal and engine
ground.
GND1
(Black)
NO – • Repair open in the Blue/Red wire.
• Repair open in the Black wire.
4. PGM-FI/main relay inspection

Remove the PGM-FI/main relay.
Check the MAIN circuit and FUEL circuit in the
PGM-FI/main relay (page 10-13).
Is the PGM-FI/main relay normal?
YES – • Repair the open in the wire harness
between the No.1 fuse and PGM-FI/
main relay.
• Repair the open in the wire harness
between the PGM-FI/main relay and
ECM.
• If wire harness is normal, replace the
NO – Replace the PGM-FI/main relay with a new
one and recheck.

5-101
dummyhead
FUEL SYSTEM
VAPOR SEPARATOR INSPECTION
FLOAT VALVE
Disassemble the vapor separator (page 5-91).
If gasoline overflows from the vapor separator, perform [1]
the following check.
Remove the float valve [1] from the float.
Check the float valve tip and valve seat [2] for wear and
damage.
Replace the float valve or the vapor separator cover if
necessary.
OK ??
[2]
FLOAT HEIGHT
If gasoline overflows from the vapor separator, perform
the following check. [1]
The float valve and float must be installed on the vapor
separator cover properly.
Place the cover as shown and measure the distance
between the float and cover (i.e. float height) at the tip
of the float.
TOOL:
Float level gauge [1] 07401-0010000
Float height: 26 – 31 mm (1.0 – 1.2 in)

If the float height is out of the specification, adjust the
float height by bending the brass float tab [2] slowly with
care not to damage the float.
Check float operation.
[2]
5-102
dummyhead
FUEL SYSTEM
FUEL INJECTOR INSPECTION
OPERATION INSPECTION
• If engine does not start, refer to "ENGINE DOES
NOT START" (page 4-2). [1]
Start the engine and let it idle.
Confirm the fuel injector operates with a sounding rod
or stethoscope [1].
If the fuel injector does not operate, check the following:
– Fuel injector inspection (page 5-103)
– Circuit inspection (page 5-104)
If circuit inspection and fuel injector inspection are
normal, replace the ECM with a new one and recheck.
FUEL INJECTOR INSPECTION

Remove the engine cover. [2]
Disconnect the fuel injector 2P connector [2]. [1]
Measure the resistance between the fuel injector [2]

terminals.
Resistance: 9 – 11 Ω (at 20 °C/68 °F)

5-103
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FUEL SYSTEM
CIRCUIT INSPECTION
ECM FUEL FUEL FUEL FUEL

INJECTOR 4 INJECTOR 3 INJECTOR 2 INJECTOR 1
No.5
FUSE
37 36 35 34 (15 A)
1 2 1 2 1 2 1 2
INJ4 Y
INJ3 13
14 Bu
INJ2 R
15
INJ1 Br
16
28
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y
13 21 20 19 18 24
Bl BLACK Br BROWN
Y YELLOW O ORANGE
W WHITE Gr GRAY
1. Fuel injector power line open circuit inspection

the fuel injector 2P connectors , , ,
and . FUEL INJECTOR 2P CONNECTOR
Measure the battery voltage between each fuel
injector 2P connector main wire harness side No.1
(Yellow/Black) terminal and ground.
Is battery voltage present? IGP 2
(Yellow/Black)
NO – • Repair the open in the wire harness
between the No.5 fuse and fuel injector.
• Faulty joint connector 1
2. Fuel injector signal line open or short circuit

Inspection
Disconnect the ECM connector B .
Check for open or short circuit between each fuel
injector 2P connector main wire harness side No.2
terminal and ECM connector B main wire
harness side terminal.
Is circuit normal?
YES – Circuit is normal.
NO – Repair the open or short circuit wire
between the fuel injector and ECM.
5-104
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FUEL SYSTEM
THROTTLE BODY INSPECTION
INSPECTION
Check that the throttle valve turns smoothly when the
throttle cam is turned.
Check that there is no looseness on the throttle valve
shaft when turning the throttle lever.
Make sure there is no clearance between the throttle [2]
stop screw [1] and the throttle valve lever stopper [2].
• Do not adjust the throttle stop screw as it is factory
preset.
CLEANING
Remove the throttle body (page 5-69).
Check the throttle valve and bore for dirt or stains.
If the throttle body is dirty, clean the throttle body.
• Wipe away any carbon or other dirt or stain with soft
dry shop towels sprayed with carburetor cleaner,
and clean the throttle valve and bore.
• The inside of the throttle body is coated with
molybdenum. Do not wipe the molybdenum coated
area [1] of the throttle valve.
• Throttle body (page 5-71)
• Silencer case (page 5-68)
After installing the throttle body, reset the ECM
(page 5-5). [1]

5-105
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FUEL SYSTEM
EBT SENSOR/ECT SENSOR 2/3
INSPECTION
– EBT sensor (page 5-84) [2]
– ECT sensor 2 (page 5-85)
Heat the coolant with an electric heating element.
Suspend the sensor [1] in heated coolant and check the
continuity through the sensor as the coolant heats up.
• Soak the sensor in coolant up to its threads with at
least 40 mm (1.57 in) from the bottom of the pan to
the bottom of the switch.
• Keep temperature constant for 3 minutes before
testing. A sudden change of temperature will result
in incorrect readings. Do not let the thermometer [2]
or sensor touch the pan. [1]
Temperature 40 °C (104 °F) 100 °C (212 °F)
Resistance 1.0 – 1.3 kΩ 0.1 – 0.2 kΩ
Replace the sensor if it is out of specifications.
– EBT sensor (page 5-84)
WATER LEVEL SENSOR INSPECTION

Disassemble the water separator (page 5-89).
Check that the float [1] inside the water separator cup [2]
[2] moves smoothly.
If it does not, replace the water separator cup.
With the water separator cup removed, place the water
separator cup right side up (condition when it is
installed) and check there is no continuity between the
2P connector terminals [3].
With the water separator cup removed, place the water
separator cup up side down (condition when the cup is
inverted) and check there is continuity between the 2P
connector terminals.
If there is any abnormality, replace the water separator [3]
cup. [1]
[2]
Normal Inverted
(Water separator (Water separator
cup being installed) cup up side down)
5-106
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FUEL SYSTEM
VTEC SOLENOID VALVE INSPECTION
(BF90D/BF100A ONLY)
– Engine cover
– L. engine under cover (page 6-5).
Disconnect the VTEC solenoid valve 1P connector [1].
Measure the resistance between the VTEC solenoid
valve 1P connector terminal and body ground.
Resistance: 14 - 16 Ω
If the resistance is not as specified, replace the VTEC
solenoid valve.
[1]
IAC VALVE INSPECTION

Turn the combination switch OFF and disconnect the
IAC valve 2P connector.
[1]
Measure the resistance between the IAC valve side
No.1 terminal and No.2 terminal of the IAC valve 2P
connector [1].
Resistance: 10 - 13 Ω
If the resistance is not as specified, replace the IAC
valve.
IAT SENSOR INSPECTION

IAT sensor 2P connector.
Measure the resistance between the IAT sensor side
No.1 terminal and No.2 terminal of the IAT sensor 2P
connector [1].
Resistance: 1.0 - 1.3 kΩ (40 °C/104 °F)
If the resistance is not as specified, replace the IAT
sensor.
[1]

5-107
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FUEL SYSTEM
HO2S INSPECTION
SYSTEM INSPECTION
1. HO2S operation test 1
the HO2S 4P connector.
HO2S 4P CONNECTOR SENSOR SIDE
Connect the battery positive (+) cable to the sensor
side No.4 (White) terminal and the battery negative
cable (–) to the sensor side No.3 (White) terminal of
the HO2S 4P connector respectively.
Start the engine and let it run at 3,000 min-1 (rpm) for O2 SG
3 minutes or more under no load. (Black) (Gray)
Snap the engine throttle with the engine speed in
the range between idle speed and 4,000 ± 500 min-1
(rpm).
Let the engine idle for 1 minute or more. O2HT (White)
(White)
Make sure that the voltage is above 0.6 V at the
No.1 (Black) terminal and No.2 (Gray) terminal of
the HO2S sensor side 4P connector.
If the voltage is temporarily below 0.6 V, recheck the
above inspection after the engine idles for 1 minute 12V BATTERY
or more.
• The normal voltage at idle speed is above 0.6 V.
Depending on the condition of the warm-up, the
voltage may become temporarily less than 0.6 V.
Is the voltage above 0.6 V?
NO – Faulty HO2S.
2. HO2S operation test 2
Snap the engine throttle with the engine speed in
the range between idle speed and 4,000 ± 500 min-1
(rpm).
Or let it run at 4,000 ± 500 min-1 (rpm) under no load,
and then quickly close the throttle valve.
Is the measurement above 0.6 V when the
throttle is fully open and below 0.6 V when the
throttle is fully closed?
YES – HO2S is normal.
NO – Faulty HO2S.
HEATER INSPECTION
HO2S 4P connector.
HO2S 4P CONNECTOR
Measure the resistance between the No.3 (White) and SENSOR SIDE
No.4 (White) terminals of the HO2S sensor.
Resistance:11.7 - 15.6 Ω
If the resistance is not as specified, replace the HO2S.
O2HT IGP3
(White) (White)
5-108
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6. ENGINE COVER
COMPONENT LOCATION ······················· 6-2 UNDER COVER FRONT BRACKET

REMOVAL/INSTALLATION ··················· 6-12
ENGINE COVER REMOVAL/
INSTALLATION ····································· 6-3 UNDER COVER REAR BRACKET REMOVAL/
INSTALLATION··································· 6-15
FRONT SEPARATE COVER REMOVAL/
INSTALLATION ····································· 6-4 UNDER COVER FRONT BRACKET
DISASSEMBLY/ASSEMBLY·················· 6-17
L./R. ENGINE UNDER COVER REMOVAL/
INSTALLATION ····································· 6-5 R. ENGINE UNDER COVER DISASSEMBLY/
ASSEMBLY ········································ 6-18
ENGINE SIDE STOPPER REMOVAL/
INSTALLATION ··································· 6-11 UNDER COVER REAR BRACKET
DISASSEMBLY/ASSEMBLY·················· 6-18

6-1
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ENGINE COVER
COMPONENT LOCATION
ENGINE COVER
10 N·m (1.0 kgf·m, 7 lbf·ft)
5 N·m (0.51 kgf·m, 3.7 lbf·ft)

5 N·m (0.51 kgf·m, 3.7 lbf·ft)
10 N·m (1.0 kgf·m, 7 lbf·ft)
10 N·m (1.0 kgf·m, 7 lbf·ft)
10 N·m (1.0 kgf·m, 7 lbf·ft)
10 N·m (1.0 kgf·m, 7 lbf·ft)
5 N·m (0.51 kgf·m, 3.7 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft)
6-2
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ENGINE COVER
ENGINE COVER REMOVAL/
INSTALLATION
REMOVAL
Unlock the locks on the front and rear sides of the engine cover and remove the engine cover.
ENGINE COVER
ENGINE COVER SEAL
INSTALLATION
Apply glue (LOCTITE® 460 or equivalent) to the engine
cover seal [1] at the points shown.
Glue (LOCTITE® 460 or equivalent)
• Note that the application points for the glue agent on Application points (Outer side: At 8 points)
the inner side and outer side of the engine cover
seal are different.
Install the engine cover seal on the engine cover.
Set the engine cover on the outboard motor, and lock
the engine cover on the front and rear sides.
Glue (LOCTITE® 460 or equivalent)

Application points (Inner side: Circumference)
[1]
Inner side: Outer side:

6-3
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ENGINE COVER
FRONT SEPARATE COVER REMOVAL/INSTALLATION
REMOVAL
Remove the bolt [1], special bolt (6 x 17 mm) [2], special bolt (6 x 37 mm) [3] and, front separate cover [4].
[1]
[2]
[4]
[3]
INSTALLATION
Install the front separate cover [1] on the outboard
motor and loosely tighten the bolt [2], special bolt (6 x [1]
[3] [2]
17 mm) [3], and special bolt (6 x 37 mm) [4].
• Make sure that the shoulder on each special bolt
goes into hole on the front separate cover.
Tighten each bolt to the specified torque in the 3.
2.
numbered order shown.
TORQUE:
Special bolt: 10 N·m (1.0 kgf·m, 7 lbf·ft)
bolt: 5 N·m (0.51 kgf·m, 3.7 lbf·ft)
1.
[4]
6-4
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ENGINE COVER
L./R. ENGINE UNDER COVER REMOVAL/INSTALLATION
REMOVAL
– Front separate cover (page 6-4)
Remove the flush plug cap [1] from the water joint cap
[2] of the R. engine under cover.
[1]
Disconnect the power trim/tilt switch 3P connector [1].
[1]
Remove the rivet screw [1].
[1]

6-5
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ENGINE COVER
Remove the six bolt/washers [1], five special bolts [2], and rear bracket bolt [3] from the L./R. engine under
covers.
[2] [3] [2]
[1]
[1]
Remove the L. engine under cover [1] and R. engine

under cover [2] from the engine side stoppers [3]. [3]
[1]
[3]
[2]
6-6
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ENGINE COVER
Remove the L. engine under cover [1] and R. engine under cover [2] from the outboard motor.
[1]
[2]
INSTALLATION
Align the L. engine under cover installation groove [1]
with the under cover seal A [2] of the mount case as [2]
shown, and install the L. engine under cover [3] on the
outboard motor from the top of the outboard motor.
[1]
[3]

6-7
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ENGINE COVER
Install the L. engine under cover [1] on the engine side
stoppers [2].
[2]
[1]
Pull out the power trim/tilt switch wire through the top of
the R. engine under cover. [2]
Align the R. engine under cover installation groove [1]
with the under cover seal A [2] of the mount case as
shown, and install the R. engine under cover [3] on the
outboard motor from the top of the outboard motor.
Be sure that the tube (8 x 300 mm) with the water
mount nut is on the outside of the R. engine under
cover.
[1]
[3]
Install the R. engine under cover [1] on the engine side

stopper [2]. [2]
[1]
6-8
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ENGINE COVER
Install the L./R. engine under covers, aligning the
projection [1] on the front side (swivel case side) of the
L. engine under cover with the recess [2] in the R. [2]
engine under cover as shown.
• Do not allow the R. engine under cover to interfere
with the tube (8 x 300 mm) of the mount case or with
the oil drain part of the oil case during installation.
[1]
Install the L./R. engine under covers, aligning the

projection [1] on the rear side of the L. engine under
cover with the recess [2] in the R. engine under cover
as shown.
Securely install the L./R. engine under covers in the
groove [3] of the under cover rear bracket.
[2]
[1]
[3]

6-9
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ENGINE COVER
Loosely tighten the six bolt/washers [1] and five special bolts [2] to the L./R. engine under covers.
Loosely tighten the rear bracket bolt [3] to the under cover rear bracket.
• Be sure that the shoulders on the special bolts go into the holes on the L./R. engine under covers.
Tighten the bolts to the specified torque in the numbered order as shown.
TORQUE:
Rear bracket bolt: 5 N·m (0.51 kgf·m, 3.7 lbf·ft)
Bolt/washer: 10 N·m (1.0 kgf·m, 7 lbf·ft)
Special bolt: 10 N·m (1.0 kgf·m, 7 lbf·ft)
[2] [3] [2]
1.
2. 7.
8.
3.
4. 9.
12.
5. 6. 11. 10.
[1]
[1]
Check that the end of the clip [1] aligns with the end of
the taped part [2] of the power tilt motor wire as shown.
Set the clip on the L. engine under cover [3] with care
not to bring it out of alignment with the end of taped part [2]
of the power tilt motor wire.
Tighten the rivet screw [4].
[1]
[1]
[4] [3]
6-10
dummyhead
ENGINE COVER
Connect the power trim/tilt switch 3P connector [1].
[1]
Tighten the flush plug cap [1] against the water joint cap
[2] of the R. engine under cover. [2]
– Engine cover
[1]
ENGINE SIDE STOPPER REMOVAL/INSTALLATION

REMOVAL
Remove the L./R. engine under cover (page 6-5).
[1] [4]
Release air vent tube C from fuel tube clamp B [1].
Release the fuel hose from the fuel tube clamp B [2].
[5]
Remove the bolt/washer [3] and engine side stopper
[4].
Remove the seat side rubber [5], grommet [6], and
collar [7] from the engine side stopper.
[3]
[6]
[7]
[2]
[4]
[7] [6] [5] [3]

6-11
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ENGINE COVER
INSTALLATION
– Grommet [1] [7] [4]
– Collar [2]
– Seat side rubber [3] [3]
Install the engine side stopper [4] and loosely tighten
the bolt/washer [5].
Set the fuel hose from fuel tube clamp B [6].
Set air vent tube C to fuel tube clamp B [7].
Set the engine side stopper at right angles to the engine
installation surface as shown. [5]
Tighten the bolt/washer.
[1]
Install the L./R. engine under cover (page 6-7). [2]
[6]
[4]
[2] [1] [3]

[5]
[4]
UNDER COVER FRONT BRACKET REMOVAL/INSTALLATION

REMOVAL
[1]
– Remote control cable grommet (page 19-3)
Remove the vinyl tube [1] from the under cover front
bracket [2].
6-12
dummyhead
ENGINE COVER
Remove the bolt/washers [1] and pull the under cover
front bracket [2] toward you.
[2]
[1]
Disconnect the trim angle sensor 3P connector [1] and

the power tilt motor 2P connector [2]. [1]
[2]
Remove under case grommet C [1] from the under

cover front bracket [2].
Pull out the wires [3] from the hole in the under cover [3]
front bracket. [2]
[1]
Remove the under cover front bracket [1] from the

outboard motor.
[1]

6-13
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ENGINE COVER
INSTALLATION
Set the under cover front bracket [1] on the outboard
motor.
[1]
Pass the wires [1] through the hole [2] in the under
cover front bracket.
[1]
[2]
Check that the end of the taped parts [1] of the power
tilt motor wire align with the end of under case grommet
C [2], and install under case grommet C [3] on the [3] [2]
under cover front bracket [4]. [5] [1]
Be sure that the under cover front bracket sits securely
in the groove [5] of under case grommet C. [4]
Connect the trim angle sensor 3P connector [1] and

power tilt motor 2P connector [2]. [1]
[2]
6-14
dummyhead
ENGINE COVER
Install the bolt/washer (6 x 95 mm) [1], bolt/washers (6 x
27 mm) [2], and tighten them.
[1]
[2]
Install the vinyl tube [1] into the under cover front
[2]
bracket [2].
Install the following: [1]
– Remote control cable grommet (page 19-5)

– Engine cover
UNDER COVER REAR BRACKET REMOVAL/INSTALLATION

REMOVAL
[1]
– Engine cover
Disconnect the idle exhaust port [1] from the mount
case [2].
[2]
Disconnect the water check tube [1] from the under

cover rear bracket [2].
[2]
[1]

6-15
dummyhead
ENGINE COVER
Remove the two bolts [1], two washers [2], and two distance collars [3].
Remove the under cover rear bracket [4] from the outboard motor.
[4] [3]
[2]
[1]
INSTALLATION
Install the under cover rear bracket [1] and two distance collars [2] on the outboard motor.
Install the two bolts [3] and two washers [4] and tighten the bolts.
[1] [2]
[4]
[3]
Connect the water check tube [1] to the under cover

rear bracket [2].
Install the water check tube into the clamp [3] of the idle
exhaust port (page 2-43).
[2]
[1]
[3]
6-16
dummyhead
ENGINE COVER
Insert the idle exhaust port [1] into the mount case [2]
until the upper and lower lips [3] of the idle exhaust port [1]
sit on the mount case securely and the upper lip [4] is
level to the mount case as shown. [3]
– Engine cover
[2]
[4]
[2]
[3]
UNDER COVER FRONT BRACKET DISASSEMBLY/ASSEMBLY

Remove the under cover front bracket (page 6-12)
BRACKET CAP
UNDER CASE GROMMET (3)
FRONT BRACKET COLLAR
COLLAR (2) UNDER COVER FRONT

BRACKET

6-17
dummyhead
ENGINE COVER
R. ENGINE UNDER COVER DISASSEMBLY/ASSEMBLY
Remove the L./R. engine under cover (page 6-5).
Remove the nut [1] and water joint cap [2].
Remove the switch stay [3] and power trim/tilt switch [4].
Install the water joint cap on the R. engine under cover [5].
Apply locking agent to the seating surface of the nut and tighten it to the specified torque.
Install the power trim/tilt switch on the R. engine under cover with the "UP" mark toward up.
Check that the retaining tab [6] of the power trim/tilt switch hooks against the power trim/tilt switch stay
securely.
[3]
[1]
(Seating surface)
[2]
[5]
[6]
[4]
UNDER COVER REAR BRACKET DISASSEMBLY/ASSEMBLY

Remove the under cover rear bracket (page 6-15).
UNDER COVER
REAR BRACKET
UNDER CASE GROMMET (2)
CASE COLLAR (2)
WATER CHECK
GROMMET
IDLE EXHAUST PORT
CLIP NUT
6-18
dummytext
7. CHARGING SYSTEM
SYSTEM LOCATION ······························ 7-2 ALTERNATOR COVER··························· 7-5 7
SYSTEM DIAGRAM ······························· 7-2 ALTERNATOR REMOVAL/

INSTALLATION····································· 7-6
CHARGING SYSTEM
TROUBLESHOOTING ···························· 7-3 ALTERNATOR INSPECTION ················· 7-13
COMPONENT LOCATION ······················· 7-4 REGULATOR/RECTIFIER INSPECTION ·· 7-13

7-1
dummyhead
CHARGING SYSTEM
SYSTEM LOCATION
CHARGING SYSTEM
ECM
ALTERNATOR
REGULATOR/RECTIFIER
SYSTEM DIAGRAM
ECM
ALTERNATOR
ALTERNATOR FUSE 70 A
W/Bl
W
T5 T6
2 FUSE ACGLP
2
(10 A)
29
W/Bu
W
W/Bl
W
W
W
1 2 5 4
1 2 3 1 2 T4
Bl
Bl
T3
1 5
REGULATOR/ INDICATOR LIGHT COMBINATION
RECTIFIER T1 (ALTERNATOR WARNING LIGHT) SWITCH
42 39
BATTERY 1 2 ACGLP BAT LOAD BAT

Bl/Y
T2
C59 C55 C47
W/Bu W/Bu Bl/Y Bl/Y
C52
W/Bl W/Bl
GND1 GND2
5 4
TILLER HANDLE TYPE:
1 5
INDICATOR LIGHT COMBINATION
(ALTERNATOR WARNING LIGHT) SWITCH
Bl BLACK Br BROWN ACGLP BAT LOAD BAT

Y YELLOW O ORANGE
Bl/Y
G GREEN Lg LIGHT GREEN C62 C58 C50

R RED P PINK W/Bu
W WHITE Gr GRAY C56
W/Bl W/Bl
7-2
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CHARGING SYSTEM
CHARGING SYSTEM TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
1. Battery test
Remove the battery.
Check the battery condition using a commercially available battery tester.
Is the battery in good condition?
NO – Faulty battery.
2. Fuse inspection
Check for blown fuse (70 A).
Is it normal?
NO – Battery connected incorrectly or reverse polarity.
• Check for short in the main wire harness
• Incorrect load by referring to the fuse load chart (page 4-12)
• Replace the blown fuse
3. Load inspection
Check whether an excessive load is connected.
Is the load normal?
NO – Remove the load and recheck.
4. Alternator stator inspection
Check the alternator stator (page 7-13).
Is it normal?
NO – Faulty alternator stator.
5. Regulator/rectifier inspection
Check the regulator/rectifier (page 7-13).
Is it normal?
YES – Repair or replace the main wire harness.
NO – Faulty regulator/rectifier.

7-3
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CHARGING SYSTEM
COMPONENT LOCATION
Tighten the bolt in 3 steps:

1. Torque to 187 N·m (19.1 kgf·m,
138 lbf·ft) to seat the alternator rotor,
and then loosen the bolt.
27 lbf·ft).
3. Tighten an additional 90°.
7-4
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CHARGING SYSTEM
ALTERNATOR COVER
ALTERNATOR COVER
INSTALLATION:
After installing the alternator cover, BOLT (6 X 25 mm)
set the breather tube on the hooks of
the alternator cover.
WASHER (6 mm)
HOOKS
ALTERNATOR
COVER GROMMET
CASE COLLAR
HOOKS
BREATHER TUBE C
PAINTED PART
INSTALLATION:
Insert the breather tube C up to the painted
part securely into the silencer case.

7-5
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CHARGING SYSTEM
ALTERNATOR REMOVAL/
INSTALLATION
REMOVAL
[1] [2] [4] [3]
– Engine cover
Disconnect the CKP sensor 3P connector.
Remove the bolt [1] and CKP sensor [2] from the chain
case [3].
Remove the O-ring [4] from the CKP sensor.
Loosen the bolt/washer using the pulley holder

attachment and the holder handle (special tools) as
[1] [2]
shown.
TOOLS:
Pulley holder attachment, 070PB-0010100 or
hex 50 mm [1] 07NAB-001040A
Holder handle [2] 07JAB-001020A
Remove the bolt/washer [1], and remove the alternator [1]

rotor [2]. [2]
• Note that the alternator rotor has very strong
magnetic force. Hold the alternator rotor [3] by the
pulley during installation and removal and do not
hold it by the rotor pulser plate [4] so you don’t pinch
your fingers with the rotor.
[3]
[4]
Remove the two bolts [1] and harness clip bracket C [2].
[1] [2]
7-6
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CHARGING SYSTEM
Remove the two bolts [1] and ECM.
[1]
Remove the harness band clip [1] from the electronic

parts case. [1]

parts case. [2] [1]
Release the stator harness [2] from the electronic parts
case clamp and disconnect the stator 3P connector [3].
[3]
Release the stator harness [1] from the projection [2] of

the electronic parts case. [2] [1]

7-7
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CHARGING SYSTEM
Release the stator harness [1] through the gap between
the electronic parts case [2] case and main wire [2] [3] [1]
harness [3].
Remove the bolt [1] and harness clip bracket E [2].

Release the stator harness [3] from the electric parts [4]
and chain case [5]. [4] [2] [1]
[3]
[5]
Remove the three bolts [1] and alternator stator [2].

[1]
[2]
7-8
dummyhead
CHARGING SYSTEM
EXPLODED VIEW
ALTERNATOR ROTOR BOLT/WASHER (14 X 36 mm)
BOLT (6 X 14 mm) Tighten the bolt in 3 steps:

HARNESS
138 lbf·ft) to seat the alternator rotor,
BAND CLIP E
and then loosen the bolt.
O-RING 27 lbf·ft).
3. Tighten an additional 90°.
CKP SENSOR
BOLT (6 X 32 mm) (3)
ALTERNATOR
STATOR
BOLT (6 X 16 mm)
INSTALLATION
Install the alternator stator [1] on the chain case by
aligning part A [2] of the alternator stator with the recess [2] [1]
[3] in the chain case as shown.
[3]
Install the three bolts [1] and tighten them.

[1]

7-9
dummyhead
CHARGING SYSTEM
Set the stator harness [1] on the chain case [2] and
electronic parts case [3] as shown. [3] [4] [5]
Install harness clip bracket E [4] and tighten the bolt [5].
[1]
[2]
Route the stator harness [1] through the gap between

the electronic parts case [2] and main wire harness [3] [2] [3] [1]
as shown.
Set the stator harness [1] on the projection [2] of the

electronic parts case as shown. [2] [1]
Connect the stator 3P connector [1] and set the stator

harness [2] on the electronic parts case [3]. [2] [4]
Set the harness band clip [4] on the electronic parts

case.
[3]
[1]
7-10
dummyhead
CHARGING SYSTEM
Set the main wire harness band clip [1] on the
electronic parts case. [1]
Install the ECM [1] and two bolts [2].

Tighten the bolts to the specified torque.
[2] [1]
Install harness clip bracket C [1] and two bolts [2] to the
chain case [3]. [2]
[3] [1]
Tighten the bolts.
Clean the bolt/washer [1], the threaded part of the

alternator rotor [2], and the threaded part of the : Clean thoroughly
crankshaft [3] with the clean shop towel or equivalent. : Apply engine oil
Apply engine oil to the threads and seat of the bolt/ [1]
washer.
[2]
[3]

7-11
dummyhead
CHARGING SYSTEM
Install the alternator rotor [1] on the crankshaft, and
loosely tighten the bolt/washer [2]. [2]
[1]
• Note that the alternator rotor has very strong
magnetic force. Hold the alternator rotor [3] by the
pulley during installation and removal and do not
hold it by the rotor pulser plate [4] so you don’t pinch
your fingers with the rotor.
[3]
[4]
Torque the bolt/washer to the specified torque to seat

the alternator rotor, and then loosen the bolt. [1]
[2]
TOOLS:
Pulley holder attachment, 070PB-0010100 or
hex 50 mm [1] 07NAB-001040A
Holder handle [2] 07JAB-001020A

Torque the bolt/washer to specified torque.
Tighten the bolt/washer an additional 90°.
TORQUE: 37 N·m (3.8 kgf·m, 27 lbf·ft) + 90°

CKP sensor [2].
Install the CKP sensor on the chain case [3], and [4] [2] [1]
tighten the bolt [4].
Connect the CKP sensor 3P connector. [3]

– Engine cover
7-12
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CHARGING SYSTEM
ALTERNATOR INSPECTION
ALTERNATOR ROTOR
Check the pulser plate for deformation and damage.
Replace the pulser plate with a new one if necessary.
[1]
ALTERNATOR STATOR
Measure the resistance between the following
terminals.
Between No.1 and No.2 terminals

Between No.1 and No.3 terminals 0.09 – 0.14 Ω
Between No.2 and No.3 terminals
No.3 No.2 No.1
REGULATOR/RECTIFIER INSPECTION
Check for continuity between the terminals listed below.
Resistance (Ω)
REGULATOR/
Tester plobe (+) side RECTIFIER CONNECTOR
(+) AC1 AC2 AC3 (-) (Gray)
110k-
(+) 6k-3M 6k-3M
Tester plobe (-) side
6k-3M
4.5k- 4.5k- 150k- AC3 AC2 AC1
AC1 250-3.5M 180M 180M
4.5- 4.5k- 150k-
AC2 250-3.5M 180M 180M
4.5k- 4.5k- 150k-
AC3 250-3.5M 180M 180M
(-) 450-2M 250-4M 250-4M 250-4M
If the measurements are outside the specification,

replace the regulator/rectifier.
CONNECTOR (-)
(+)
(Black)

7-13
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MEMO

dummytext
8. IGNITION SYSTEM
SYSTEM LOCATION ······························ 8-2 IGNITION SYSTEM

TROUBLESHOOTING ···························· 8-3
8
SYSTEM DIAGRAM ······························· 8-2

8-1
dummyhead
IGNITION SYSTEM
SYSTEM LOCATION
IGNITION SYSTEM
PGM-FI MAIN RELAY CKP SENSOR
IGNITION COIL ECM
SYSTEM DIAGRAM
6 FUSE (30 A) 3 FUSE (15 A) IGNITION COIL NO.1 IGNITION COIL NO.3
Bl W W Y W/Bl
T1 2 FUSE 5 FUSE
(10 A) (15 A)
W/Bl Y W/G 3 2 1 3 2 1
30 32
BATTERY
W/G
SPARK SPARK
Y/Bl
Y/Bl
W
Bu
Bl
Bl
T2 PLUG PLUG
T4 T3 PGM-FI/
GND2 4 MAIN RELAY IGNITION COIL NO.2 IGNITION COIL NO.4
W/Bl
EMERGENCY
4
C35 STOP SWITCH W/G

2
Bl W/Y
5
C41 3 2 1 3 2 1
31 33
Bl/Y
Bl/Y
Bl/R Bl/R
Bl
4
COMBINATION
W/Bu
SPARK Bu/R
Bl/Y SPARK
Y/Bl
Y/Bl
SWITCH
2
Bl
Bl
C47
Bl/Y LOAD PLUG PLUG
3
C48
Bl Bl
C49
Bl Bl GND
C50
Bl/R Bl/R IG
Bl/R
C52
29 ECM
W/Bl W/Bl BAT
C53 W/Bu IGN2
Bl Bl
12
C54 Bu IGN1
15
Bl Bu CRK
C55
20
Bl/Y
Bl/Y Bu/R IGN4
33
41 5 W/G IGN3
30
Bl/Y Bl/Y Bl/Y

6
Bl Bl Bl IGP1
Y/Bl
4
W/Bl W/Bl W/Bl Y/Bl IGP2

1
Bl/R Bl/R Bl/R Bl/R EMS1

3
30
Bl CONNECTOR Bl/R EMS2

42
31
TILLER HANDLE TYPE: 28

EMERGENCY
C38 C44 STOP SWITCH
Bl
C45
Bl/Y
Bl/Y
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Bl/R Bl/R
Bl
Bl
Y
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
G/Bl
Y/Bl
Bu
Bu
13 12
Bl
Bl
C50
COMBINATION 4 6 7 24 22 8 10 9 12 11 1 4 5 6 3
Bl/Y Bl/Y
SWITCH 23
C51
Bl/Y LOAD GND4 GND5 3 2 1
C52
CKP
Bl Bl SENSOR
C53 JOINT CONNECTOR 1 JOINT CONNECTOR 2 GND6
Bl Bl GND
C57
Bl
C54
Bl/R Bl/R
Bl/R IG
C56 Bl BLACK Br BROWN
W/Bl W/Bl BAT
C58
Y YELLOW O ORANGE
Bl/Y
Bl/Y 5 Bu BLUE Lb LIGHT BLUE
Bl G GREEN Lg LIGHT GREEN
3
Bl/Y R RED P PINK

2
W/Bl W WHITE Gr GRAY

1
Bl/R
9
Bl CONNECTOR
8-2
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IGNITION SYSTEM
IGNITION SYSTEM TROUBLESHOOTING
1. MIL inspection 1
Does the MIL stay on for a few seconds, and then go off?
2. MIL inspection 2
Check the MIL stay on or does not MIL come on.
Does the MIL stay ON or not come on?
Stays on – PGM-FI troubleshooting (page 5-16).
Does not come on – FUSE/ELECTRIC POWER LINE TROUBLESHOOTING (page 4-12).
3. Fuse inspection
Check for a blown No.3 (15 A) fuse and No.5 (15 A) fuse.
Is the fuse blown?
YES – Replace the blown fuse and check for a short in the main wire harness or incorrect load by
referring to the fuse load chart (page 4-13).
4. Emergency stop switch clip inspection
Check the emergency stop switch clip.
Is the emergency stop switch clip connected?
NO – Set the clip securely.
Remove and inspect the spark plug gaps.
Are the spark plug gaps within specification?
NO – Replace the iridium spark plug (s) or adjust the standard spark plug gap(s).
6. Spark plug replacement
Replace the spark plugs if necessary.
Restart the engine.
Does the engine start properly?
YES – Dirty or faulty original spark plug.
7. Emergency stop switch signal line short circuit inspection
Make sure that the emergency stop switch clip is connected.
Disconnect ECM connector A and ECM connector B .
Check for continuity between engine ground and ECM connector B main wire harness side No.30
(Black/Red) terminal, and No.31 (Black/Red) terminal.
YES – • Repair short in the main wire harness between the ECM and remote control box or tiller handle.
• Replace the emergency stop switch.

8-3
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IGNITION SYSTEM
8. Ignition coil power/ground line open circuit inspection
Disconnect the ignition coil 3P connector. IGNITION COIL 3P CONNECTOR
Measure the voltage between the ignition coil 3P
connector main wire harness side No.3 (Yellow/
IGP 1/2/3/4
Black) terminal and No.2 (Black) terminal.
(Yellow/Black)
GND1
YES – GO TO STEP 9. (Black)
NO – • Repair open in the main wire harness
between the No.3 fuse and ignition coil.
• Repair open in the main wire harness
between the ignition coil and ground.
9. Ignition coil signal line open or short circuit inspection
Check for continuity between the ECM connector A main wire harness side and ignition coil 3P
connector main wire harness side No.1 terminal.
There should be continuity.
Check for continuity between the ignition coil 3P connector main wire harness side No.1 terminal and
engine ground.
There should be no continuity.
Are they normal?
NO – Repair open or short in the main wire harness between the ECM and ignition coil.
10. Ignition coil replacement
Replace the ignition coil(s) and restart the engine.
Does the engine start properly?
YES – Faulty original ignition coil(s).
8-4
dummytext
9. STARTING SYSTEM
SYSTEM LOCATION ······························ 9-2 FLYWHEEL REMOVAL/INSTALLATION···· 9-8
SYSTEM DIAGRAM ······························· 9-2 STARTER MOTOR DISASSEMBLY/

ASSEMBLY ········································ 9-10 9
STARTING SYSTEM
TROUBLESHOOTING ···························· 9-3 STARTER MOTOR INSPECTION ··········· 9-19
STARTER MOTOR REMOVAL/ FLYWHEEL INSPECTION ····················· 9-22

INSTALLATION ····································· 9-5
NEUTRAL SWITCH INSPECTION··········· 9-22

9-1
dummyhead
STARTING SYSTEM
SYSTEM LOCATION
STARTING SYSTEM
PGM-FI/MAIN RELAY
STARTER MOTOR
NEUTRAL SWITCH
SYSTEM DIAGRAM
Bl BLACK Br BROWN
Y YELLOW O ORANGE PGM-FI/MAIN RELAY
STARTER
R RED P PINK
W WHITE Gr GRAY
W/Bl
Bl/Bu
Bl/W
W/Y
2 FUSE 6 FUSE
W
(10 A) (30 A) 4 5 3 6 5
Bl/W
Bu
W
T3 T4
Bl
W
T1
C1
STARTER
BATTERY MOTOR
W/Bl
Bl/W
T2
GND2
5 5
TILLER HANDLE TYPE: REMOTE CONTROL TYPE:
1 8 1 8
W/Bl
Bl/W
W/Bl
Bl/W
Bu
Bl
C56 C52
42 41
BAT W/Bl BAT W/Bl
14 1 2
1 3
Bl
C55 C51
Bl/Bu
Bl
ST Bl/W ST Bl/W
13 5 6
COMBINATION COMBINATION
SWITCH SWITCH
GND6
Bl/W
W/Bl
NEUTRAL JOINT CONNECTOR 1
SWITCH
9-2
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STARTING SYSTEM
STARTING SYSTEM TROUBLESHOOTING
STARTER MOTOR DOES NOT TURN
1. Standard inspection
Check the following:
– Battery condition
– Blown No. 2 (10 A) fuse
– Blown No. 6 (30 A) fuse
Are the above items in good condition?
NO – Replace or repair the malfunctioning part(s).
2. Starter relay operation inspection
Turn the combination switch to the START position.
Check the operation of the starter relay.
Does the starter relay click?
3. Starter solenoid inspection
Remove the starter motor (page 9-5).
Check for continuity between the S terminal and
front bracket.
Check for continuity between the S terminal and M
terminal.
NO – Faulty starter solenoid.
4. Starter motor inspection

Apply battery voltage to the starter motor directly
and check the operation (A large amount of current
flows, so do not use a thin wire).
Does the starter motor turn?
YES – • Poorly connected starter motor cable
• Repair the open circuit in the starter
cable (+) or fuse cable.
• Faulty PGM-FI/Main relay
NO – Inspect the starter motor (page 9-19).

9-3
dummyhead
STARTING SYSTEM
5. Shift control cable inspection
Control lever is in the "N" (Neutral) position.
Tip [1] of the neutral switch is set in the detent [4]
[3]
assisted spring [2] securely and the detent spring
roller [3] is set in the groove [4] in the shift arm.
Shift cable adjustment correct?
NO – Adjust the shift control cable.
[2]
[1]
6. Starter relay coil line open circuit inspection

Turn the combination switch to the START position. NEUTRAL SWITCH 2P CONNECTOR
Measure the voltage at the neutral switch 2P MAIN WIRE HARNESS SIDE
terminal and No.2 (Black) terminal.
YES – Faulty neutral switch. NTSW GND
(Blue) (Black)
7. Combination switch open circuit inspection

Disconnect the 14P connector .
Turn the combination switch to the START position.
Check for continuity at the 14P connector combination switch side No.1 (White/Black) terminal and
No.8 (Black/White) terminal.
NO – • Repair the open circuit in the combination switch wire
• Replace the combination switch with a new one and recheck
8. PGM-FI/main relay Inspection
Inspect the PGM-FI/main relay (page 10-13).
Is the PGM-FI/main relay normal?
YES – • Repair the open circuit in the main wire harness.
• Poorly connected connector.
NO – Replace the PGM-FI/main relay with a one and recheck.
9-4
dummyhead
STARTING SYSTEM
STARTER MOTOR TURNS SLOWLY
• Low battery voltage
• Poorly connected battery terminal cable
• Poorly connected starter motor cable
• Faulty starter motor
• Poorly connected battery ground cable
• Incorrect engine oil viscosity
STARTER MOTOR TURNS, BUT ENGINE DOES NOT TURN

• Starter motor is running backwards
– Case assembled improperly
– Terminals connected improperly
• Faulty starter overrunning clutch
• Damaged or faulty starter planetary gear
STARTER RELAY SWITCH "CLICKS", BUT ENGINE DOES NOT TURN OVER
• Crankshaft does not turn due to engine problems
STARTER MOTOR REMOVAL/

INSTALLATION
REMOVAL
[4]
– Battery (-) terminal
– Engine cover
– Regulator/rectifier/70A fuse box (page 10-4)
– Fuse box bracket (page 10-4)
Remove the bolt [1] and oil level gauge pipe [2].
Remove the O-ring [3] from the oil level gauge pipe.
Disconnect the starter solenoid terminal [4]. [2]
[1]
[3]
Move the terminal cover [1] aside, and remove the nut
[2].
Disconnect the fuse cable [3] from the B terminal [4] of
the starter motor. [1] [4] [3]
Remove the washer [5] and nut [6], and disconnect the
starter cable (+) [7] from the B terminal of the starter [2]
motor.
[5]
[6]
[7]

9-5
dummyhead
STARTING SYSTEM
Remove the bolts [1] and starter motor [2].
[2]
[1]
Remove the O-ring [1] from the starter motor [2].

[1]
[2]
INSTALLATION
Install a new O-ring [1] to the starter motor [2].
[2]
[1]
Install the bolts [1] and tighten them to the specified

torque.
[1]
9-6
dummyhead
STARTING SYSTEM
Set the PGM-FI/Main relay white wire [1] and the fuse
cable [2] in the recess [3] in the electronic parts case. [3]
[2]
[1]
Set the starter cable (+) [1] on the B terminal [2] of the
[8] [2] [6]
starter motor [3].
Install and tighten the nut [4] to the specified torque [7]
while adjusting the clearance between the starter cable
(+) and the starter motor to 10 – 20 mm (0.4 – 0.8 in) as
shown.
TORQUE: 11 N·m (1.1 kgf·m, 8 lbf·ft) [5]
Install the washer [5] on the starter motor B terminal.

Install the fuse cable [6] on the B terminal. [4]
Hold the fuse cable parallel to the starter cable (+).
Install and tighten the nut [7] to the specified torque. [1]
[6] [3]
Install the terminal cover [8] over the B terminal.
10 – 20 mm
(0.4 – 0.8 in)
[1]
Apply engine oil to a new O-ring [1] and install it to the
oil level gauge pipe [2].
[2]
[1]
Install the oil level gauge pipe [1] and bolt [2].
Tighten the bolt. [3]
Connect the starter solenoid terminal [3].
– Regulator/rectifier/70 A fuse box (page 10-4)
– Engine cover
– Battery (-) cable [1]
[2]

9-7
dummyhead
STARTING SYSTEM
FLYWHEEL REMOVAL/INSTALLATION
REMOVAL
Remove the engine (page 13-3).
Remove the starter motor (page 9-5). [1]
[2]
Set the special tool on the mounting flange of the starter
motor.
TOOL
Ring gear holder [1] 070PB-ZY9A100
Insert the starter motor mounting bolt (10 x 75 mm) [2]
that has been tightening the starter motor into the bolt
hole, and secure the special tool by tightening the [3]
starter mounting bolt (10 x 35 mm) [3].
• Avoid scores, scratches, and other damage to the
cylinder block’s mating surface with the mount case
gasket.
• Check that the special tool is set on the ring gear
securely.
Remove the six bolts [1] and flywheel [2].
[2]
[1]
EXPLODED VIEW
FLYWHEEL
BOLT (12 mm) (6)

103 N·m (10.5 kgf·m, 76 lbf·ft)
9-8
dummyhead
STARTING SYSTEM
INSTALLATION
Clean the crankshaft and flywheel mating surfaces
Apply engine oil to the threads and seating surface of [2] [3]
the bolts.
Install the flywheel [2] on the crankshaft [3] and loosely
tighten the six bolts. [1]
Set the special tool on the mounting flange of the starter

motor. [1]
[2]
TOOL
Ring gear holder [1] 070PB-ZY9A100
Insert the starter motor mounting bolt (10 x 75 mm) [2]
that has been tightening the starter motor into the bolt
hole, and secure the special tool by tightening the
starter mounting bolt (10 x 35 mm) [3].
• Avoid scores, scratches, and other damage to the [3]
cylinder block’s mating surface with the mount case
gasket.
• Check that the special tool is set on the ring gear
securely.
Tighten the bolts to the specified torque in the
numbered sequence shown in two or three steps. [1]
TORQUE: 103 N·m (10.5 kgf·m, 76 lbf·ft) 1.
Remove the special tool and install the starter motor
(page 9-6). 6.
4.
Install the engine on the outboard motor (page 13-8).
2. 3.
5.

9-9
dummyhead
STARTING SYSTEM
STARTER MOTOR DISASSEMBLY/
ASSEMBLY
DISASSEMBLY
Remove the nut [1] by pulling off the terminal cover [2]
[2] [1]
and disconnect the motor wire [3] from the M terminal
[4].
[3] [4]
Remove the two screws [1].
[2]
Remove the starter solenoid [2], spring [3], and plunger
[4].
[3]
[4]
[1]
Remove the two bolts [1] and yoke/rear bracket [2] from
[1]
the front bracket [3].
Remove the packing [4] and plate [5].
[2]
[4]
[3] [5]
9-10
dummyhead
STARTING SYSTEM
Remove the yoke [1] from the armature/rear bracket
[2]
assembly [2].
[1]
Remove the two screws [1] and rear bracket [2] from
[1] [2]
the armature [3].
[3]
Remove the brush holder [1] from the armature [2].

[1]
[2]
Remove the steel ball [1] and three planetary gears [2]
[2] [1]
from the front bracket [3].
[3]

9-11
dummyhead
STARTING SYSTEM
Remove the packing [1] from the front bracket [2].
[1]
[2]
Remove the overrunning clutch [1] and clutch fork [2]

from the front bracket [3]. [1]
[3]
[2]
Secure the gear shaft [1] by placing a wood block [2]

under the gear shaft assembly, taking care not to touch
the internal gear [3]. [4]
Prepare a pipe [4] of the following dimensions. [5]
• I.D.: approximately 11 mm (0.4 in) [1]
O.D.: approximately 15 mm (0.6 in)
LENGTH: approximately 20 mm (0.8 in)
Set the pipe on the gear shaft stopper [5] and drop the
gear shaft stopper into the overrunning clutch by
tapping on the pipe.
Remove the snap ring [6] using a screwdriver or
equivalent tool. [3]
[6]
[5]
[2]
9-12
dummyhead
STARTING SYSTEM
Remove the gear shaft stopper [1], internal gear [2], [1]
and overrunning clutch [3] from the gear shaft [4].
[2]
[3]
[4]
Remove the clip [1] and plate [2] from the brush holder
[3]. [2]
Remove the brush sets [4] and four brush springs [5].
[5]
[1]
[4]
[3]

9-13
dummyhead
STARTING SYSTEM
EXPLODED VIEW
After assembling the starter motor, apply a sufficient
amount of water resisting sealant (Sumitomo 3M
Padding Sealer #8533 or equivalent) to the mating
sections of each part (page 9-18).
CLIP
BRUSH SET
PLATE
REAR BRACKET
BRUSH HOLDER
BRUSH SPRING (4) SCREW (5 x 8 mm) (2)
PACKING
BOLT (2)
YOKE
ARMATURE
SCREW (6 x 22 mm) (2)
SNAP RING
GEAR SHAFT STOPPER
OVERRUNNING CLUTCH
INTERNAL GEAR
FRONT BRACKET PLATE STEEL BALL
PACKING PLANETARY
CLUTCH FORK GEAR (3)
PLUNGER NUT (8 mm)
SPRING
GEAR SHAFT
STARTER SOLENOID
9-14
dummyhead
STARTING SYSTEM
ASSEMBLY
Set the four brush springs [1] and brush sets [2] into the
brush holder [3]. [4]
Install the plate [4] on the brush holder and secure it

with the clip [5].
[1]
[5]
[2]
[3]
[5]
Apply grease to the internal gear [1], inner wall of the

overrunning clutch [2], gear shaft [3] outer surface, and [4]
whole surface of the gear shaft stopper [4]. [2]
Assemble the overrunning clutch, gear shaft, and the [1]

gear shaft stopper with the internal gear.
Install a new snap ring [5].
Holding the overrunning clutch, push the gear shaft into
the overrunning clutch. Push the gear shaft stopper up
to set the snap ring in the groove of the gear shaft
stopper securely.
[3]
[5]
[4]

9-15
dummyhead
STARTING SYSTEM
Apply grease to the sliding surface of the clutch fork [1].
Set the clutch fork in the indicated position of the
overrunning clutch groove [2] as shown.
[1]
[2]
Install the overrunning clutch [1] assembly on the front
bracket [2]. [1] [3]
• Install the overrunning clutch by aligning the bolt

[4]
holes [3] on the outer surface of the ring gear with
the bolt holes [4] in the front bracket.
[2]
Install the packing [1].

[2]
• Install the packing by aligning the bolt holes [2] on [1]
the packing with the bolt holes [3] in the front bracket
[4].
[4]
[3]
Apply grease to the planetary gears [1], steel ball [2], [2]
and internal gear [3].
Install the planetary gears, steel ball, and internal gear.
[1] [3]
9-16
dummyhead
STARTING SYSTEM
Install the brush holder [1] onto the armature [2].
[4]
Apply grease to the armature shaft.
Install the rear bracket [3].
Apply water resisting sealant (Sumitomo 3M Padding
Sealer #8533 or equivalent) to the seating surface of
each screw [4].
Install and tighten the two screws.
[3]
[2] [1]
Check the inner wall of the yoke [1] for foreign material.
[3] [2]
Install the armature/rear bracket assembly [2] by
aligning the grommet [3] with the cutout [4] in the yoke.
[4] [1]
Install the plate [1] and packing [2] on the front bracket
[3]. [7]
Install the yoke/rear bracket assembly [4] by aligning [4]

the projection [5] on the yoke with the cutout [6] in the
front bracket.
Apply water resisting sealant (Sumitomo 3M Padding [7]
Sealer #8533 or equivalent) to the seating surface of
each bolt [7].
Install and tighten the two bolts.
[2]
[5]
[1]
[3] [6]

9-17
dummyhead
STARTING SYSTEM
Install the spring [1] and plunger [2] to the starter
solenoid [3], then assemble the plunger and clutch fork
[4] as shown.
[3]
Install and tighten the two screws [5].
Connect the motor wire [6] to the M terminal [7] and
tighten the nut [8].
[1]
[2]
[4]
[5]
[2]
[8]
[7] [6]
WATER RESISTING SEALANT

APPLICATION POINTS
After the assembling the starter motor, apply a sufficient
amount of water-resisting sealant (Sumitomo 3M [1] [7]
Padding Sealer #8533 or equivalent) to the mating
surfaces as shown.
– Packing/front bracket mating section [1] [4]
– Starter solenoid/front bracket mating section [2]
– Starter solenoid mounting screw [3]
– Screw/ bolt and rear bracket mating sections [4]
– Wire grommet and rear bracket [5]
– Engagement sections with yoke [6]
– Starter solenoid case caulking section [7]
[5]
(7)
[6]
[2]
[1]
[3]
9-18
dummyhead
STARTING SYSTEM
STARTER MOTOR INSPECTION
BRUSH LENGTH
Measure the brush length [1]. If brush length is less
than the service limit, replace the brushes as a set.
STANDARD: 12.3 mm (0.48 in)

SERVICE LIMIT: 7.0 mm (0.28 in)
[1]
MICA DEPTH
Measure the mica depth [1].
STANDARD: 0.40 – 0.50 mm (0.016 – 0.020 in)

If the grooves are clogged or mica depth is less than the
service limit, recut the grooves using a hacksaw blade [1]
or a small file.
ARMATURE
Check the armature and shaft gear for wear and
damage.
Check the commutator [1] for damage, dust, dirt, and

metal particles. [1]
If there is stain, irregularity, and/or evidence of burning,

clean with emery paper [2] #500 or #600.
[2]

9-19
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STARTING SYSTEM
Measure the commutator [1] O.D.

If the measurement is less than the service limit,
replace the armature with a new one.
[1]
Measure commutator [1] runout using a dial gauge [2].

[2]
If the measurement is more than the service limit,
replace the armature with a new one.
[1]
Check for continuity between each segment.

If an open circuit exists between any two segments,
replace the armature.
Check for continuity between the armature and

armature shaft.
If there is no continuity, replace the armature.
9-20
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STARTING SYSTEM
Check for continuity between the commutator and
armature coil core.
If continuity exists, replace the armature.

armature shaft.
If there is continuity, replace the armature.
Place the armature in an armature tester (commercially

available).
Hold a hacksaw blade close to the armature core. If the
blade is attracted to the core or vibrates when the core
is turned, the armature is shorted. Replace the
armature.
OVERRUNNING CLUTCH
Turn the gear shaft assembly [1] by holding the
overrunning clutch [2]. The gear shaft assembly should
turn only clockwise.
If the clutch turns freely in both directions or if it does [1]
not turn at all, replace the overrunning clutch. [2]
Check the pinion gear teeth for wear and damage and
replace if necessary.
If the pinion gear is worn or damaged, the flywheel ring
gear must be inspected.
Check the overrunning clutch for smooth axial
movement.
[2]
Clean and apply grease to the spline, if necessary.
If the overrunning clutch does not move smoothly after
cleaning or coated with grease, replace the overrunning
clutch.

9-21
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STARTING SYSTEM
STARTER SOLENOID
Check for continuity between the S terminal and front
bracket.
If there is no continuity, replace the starter solenoid.
Check for continuity between the S terminal and M
terminal.
If there is no continuity, replace the starter solenoid.
FLYWHEEL INSPECTION
Check the ring gear [1] for wear and damage.
If it is worn or damaged, check the pinion gear of the
starter motor.
Replace the flywheel or starter motor pinion gear, if
necessary.
[1]
NEUTRAL SWITCH INSPECTION

Release the neutral switch 2P connector [1] from the [5]
connector holder and disconnect the connector.
Attach the tester leads to the two connector terminals at [2]
the neutral switch. [3]
[4]
Continuity should exist between the each position as
follows:
SWITCH PUSHED
Continuity
(Shift lever in "N")
SWITCH RELEASED
No continuity
(Shift lever in "F" or "R")
[1]
If the continuity is abnormal, check the following and
replace if necessary:
• Control lever is in the "N" (Neutral) position. [5]
Tip [2] of the neutral switch is set in the detent
assisted spring [3] securely.
• The detent spring roller [4] is set in the groove [5] in
the shift arm. [4]
[2]
[3]
9-22
dummytext
10. OTHER ELECTRICAL
SYSTEM LOCATION ···························· 10-2 PGM-FI/MAIN RELAY INSPECTION······· 10-13
ECM, PGM-FI/MAIN RELAY REMOVAL/ FUSE BOX INSPECTION ····················· 10-14

INSTALLATION ··································· 10-3
70 A FUSE BOX/FUSE INSPECTION ····· 10-14
REGULATOR/RECTIFIER/FUSE BOX/70 A 10
FUSE BOX REMOVAL/INSTALLATION··· 10-4 POWER TILT RELAY INSPECTION ······· 10-15
STARTER CABLE/FUSE CABLE POWER TRIM/TILT SWITCH INSPECTION

REMOVAL/INSTALLATION ··················· 10-6 (OUTBOARD MOTOR SIDE)················· 10-16
POWER TILT RELAY/RELAY BRACKET TRIM ANGLE SENSOR INSPECTION ···· 10-16
REMOVAL/INSTALLATION ··················10-11

10-1
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OTHER ELECTRICAL
SYSTEM LOCATION
OTHER ELECTRICAL
PGM-FI/MAIN RELAY
ECM
70 A FUSE BOX
FUSE BOX
POWER TILT RELAY
10-2
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OTHER ELECTRICAL
ECM, PGM-FI/MAIN RELAY REMOVAL/INSTALLATION
– Battery (-) cable
– Engine cover
COLLAR (4) ELECTRONIC PARTS

CASE GROMMET (4)
ELECTRONIC
PARTS CASE
BOLT/WASHER
(6 X 27 mm) (4)
STATOR HARNESS
ECT
SENSOR 2
HARNESS CLIP
BRACKET C
BOLT
(6 X 10 mm)
5 N·m (0.51 kgf·m,
3.7 lbf·ft)
ECM BRACKET
PGM-FI/
MAIN RELAY
BOLT
(6 X 14 mm) (2)
5 N·m (0.51 kgf·m, BOLT (6 X 20 mm) (2)
3.7 lbf·ft)
(BF75D/BF90D LRTA, XRTA,
NMEA 2000 6P
LRTC, XRTC only and
CONNECTOR
MAIN HARNESS BF80A/BF100A)
BOLT 5 N·m (0.51 kgf·m, 3.7 lbf·ft)
ECM
(6 X 12 mm) (2)
When replacing the ECM, perform
GROUND TERMINALS the reset procedure the necessary
TORX BOLT (6 X 20 mm) (2)
number of times according to the
total operating hour at the time of (Except BF75D/BF90D LRTA,
replacement, or adjust the operating XRTA, LRTC, XRTC type and
hour notification timing. BF80A/BF100A)
5 N·m (0.51 kgf·m, 3.7 lbf·ft)

10-3
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OTHER ELECTRICAL
Set the ground terminals with the Blue and black
terminals [1] on the upper side, and the Black terminals [2] [4]
[2] on the lower side as shown.
Tighten the two bolts [3] while pushing the ground
terminals against the projections [4] on the cylinder
block as shown.
Route the wire harness properly (page 2-18).
[2]
[3]
REGULATOR/RECTIFIER/FUSE BOX/70 A FUSE BOX REMOVAL/

INSTALLATION
– Battery (-) cable
– Engine cover
FUSE BOX
BRACKET BOLT (6 x 14 mm) (2)
FUSE BOX
CONNECTOR
HOLDER CLIP B
FUSE
FUSE BOX
COVER
70 A FUSE
BOX
REGULATOR 70 A FUSE
GASKET
BOLT/WASHER
REGULATOR/ (6 x 27 mm) (2)
RECTIFIER
BOLT (6 x 20 mm) (4)
COLLAR (2)
GROMMET (2)
SCREW
(5 x 10 mm) (2)
70 A FUSE BOX
COVER
BOLT /WASHER
BOLT (5 x 9 mm) (2) SCREW
(6 x 12 mm)
(3 x 7 mm) (2)
70 A FUSE
10-4
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OTHER ELECTRICAL
Insert a screwdriver or equivalent tool [1] into the
locking lug [2] on the fuse box [3] and unlock. [1]
With the lock unlocked, pull the fuse box toward you. [3]
Remove the fuse box from the fuse box bracket [4].
[2]
[4]
[1]
[4]
[3]
[2]
Remove the power trim/tilt switch 3P connector [1] and
the two harness band clips [2] from the fuse box bracket
[3]. [2]
Remove the two bolts [4] and fuse box bracket. [3] [1]
Installation is in the reverse order of removal.
Route the wire harness properly (page 2-18).
[4]

10-5
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OTHER ELECTRICAL
STARTER CABLE/FUSE CABLE
REMOVAL
– Battery (+) cable and (-) cable [2] [4]
– Engine cover
– R./L. engine under cover (page 6-5)
– Under cover front bracket (page 6-12)
Remove the harness band clip [1] from the neutral
switch bracket [2].
Release the fuse cable 1P connector [3] from the relay
bracket [4].
Disconnect the fuse cable 1P connector.
[1]
[3]
Move the terminal cover [1] aside, and remove the nut
[2]. [1] [4] [3]
Disconnect the fuse cable [3] from the B terminal [4] of
the starter motor. [2]
Remove the washer [5] and nut [6], and disconnect the
starter cable (+) [7] from the B terminal of the starter
motor.
[5]
[6]
[7]
Remove the bolt [1] and starter cable (-) [2] from the
cylinder block.
[1]
[2]
10-6
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OTHER ELECTRICAL
Release the starter cable (+) [1], starter cable (-) [2], and fuse cable [3] from the starter cable holder [4].
[4]
[1]
[2]
[3]

parts case [2] and release the fuse cable [3]. [1]
[3]
[2]
Remove the 70 A fuse box cover [1].

Remove the bolt [2] and fuse cable [3]. [1]
[3]
[2]

10-7
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OTHER ELECTRICAL
Remove the ECM (page 10-3)
[2] [4] [3]
Release the fuse box 5P connector [1] from the ECM
bracket [2] and disconnect the 5P connector.
Open the wire harness clip [3], and remove the fuse
cable [4].
[1]
EXPLODED VIEW
TERMINAL COVER FUSE CABLE NEUTRAL SWITCH

BRACKET
NUT (8 mm) (2)
11 N·m (1.1 kgf·m, 8 lbf·ft)
WASHER (8 mm)
STARTER
CABLE (+)
BOLT
(8 x 18 mm)
STARTER
CABLE (-) STARTER CABLE
FUSE CABLE 1P
HOLDER HARNESS CLIP
CONNECTOR
INSTALLATION
Connect the fuse box 5P connector [1].
[2] [3] [4]
Set the fuse box 5P connector to the ECM bracket [2].
Route the fuse cable [3] and close the harness clip [4].
Install the ECM (page 10-3).
[1]
10-8
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OTHER ELECTRICAL
Set the fuse cable [1] and install the bolt [2].
Tighten the bolt. [3]
Install the 70 A fuse box cover [3].
[1]
[2]
Install the harness band clip [1] to the electronic parts

case [2]. [1]
Set the fuse cable [3] to the groove [4] of the electronic
parts case.
[3]
[2] [4]
Set the fuse cable [1], starter cable (+) [2], and starter cable (-) [3] on the starter cable holder [4] as shown.
[2] [1]
[4]
Engine side:
[3]
[2]
[4]
[3] [2]
[1]
Engine side:
[3]
[1]
[4]

10-9
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OTHER ELECTRICAL
Set the starter cable (+) [1] on the B terminal [2] of the
[8] [2] [6]
starter motor [3].
Install and tighten the nut [4] to the specified torque [7]
while adjusting the clearance between the starter cable
(+) and the starter motor to 10 – 20 mm (0.4 – 0.8 in) as
shown.
Install the washer [5] on the starter motor B terminal.

Install the fuse cable [6] on the B terminal. [4]
Hold the fuse cable parallel to the starter cable (+).
Install and tighten the nut [7] to the specified torque. [1]
[6] [3]
Install the terminal cover [8] over the B terminal.
10 – 20 mm
(0.4 – 0.8 in)
[1]
Tighten the bolts [1] while pushing the starter cable (-)
[2] terminal against the projection [3] on the cylinder [1]
block as shown. [2]
[3]
Connect the fuse cable 1P connector [1] and set the 1P

connector on the relay bracket [2]. [4]
[2]
Set the wire harness clip [3] to the neutral switch
bracket [4].
– Engine cover
– Battery (+) cable and (-) cable
[3] [1]
10-10
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OTHER ELECTRICAL
POWER TILT RELAY/RELAY BRACKET
– Battery cable (-)
– Engine cover
– R./L. Engine under cover (page 6-5)
– Water separator (page 5-87)
CODE CLAMPER
FUEL PUMP 2P
MAIN WIRE HARNESS
RELAY BRACKET (HIGH PRESSURE)
CONNECTOR
POWER TILT RELAY

3P CONNECTOR
NEUTRAL SWITCH
BRACKET
NEUTRAL SWITCH
2P CONNECTOR

10-11
dummyhead
OTHER ELECTRICAL
HARNESS
BRACKET CLIP
COLLAR (4) GROMMET (4)
RELAY BRACKET CLIP C
BOLT/WASHER
(6 x 28 mm) (4)
NUT (20 mm)

2.5 N·m (0.26 kgf·m,
1.8 lbf·ft)
NEUTRAL SWITCH
BRACKET
POWER TILT BOLT (6 x 12 mm)
BOLT (6 x 14 mm) RELAY COLLAR (2)
NEUTRAL
BOLT (6 x 14 mm) (2) POWER TILT RELAY
SWITCH
CLIP A
Tighten the bolt while pushing the ground cable [2]

against the projection [3] on the cylinder block as [2]
shown.
[3]
Route the wire harness properly (page 2-18)
[1]
10-12
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OTHER ELECTRICAL
PGM-FI/MAIN RELAY INSPECTION
• Check the battery condition before starting the
inspection.
• Do not connect the battery for more than 30
seconds. Wait for one minute or more before
connecting the battery again.
MAIN RELAY CIRCUIT INSPECTION
Connect the 6P connector PGM-FI/main relay side No.2
(Black/yellow) terminal to the battery (+) terminal using
a jumper wire. WIRE
CONNECTOR
(Black) terminal to the battery (-) terminal using a
(White)
jumper wire.
There should be continuity between the following
terminals of the 5P connector PGM-FI/main relay side:
• No.5 (White/yellow) – No.2 (White/green)
• No.5 (White/yellow) – No.3 (White/red)
• No.5 (White/yellow) – No.4 (White/black)
Viewed from the

FUEL RELAY CIRCUIT INSPECTION terminal side:
6P CONNECTOR
Connect the 5P connector PGM-FI/main relay side No.4 W/G
(White/black) terminal to the battery (+) terminal using a 5P CONNECTOR
W/Bu W/R
jumper wire.
(Light green/black) terminal to the battery (-) terminal
using a jumper wire. Wire
There should be continuity between the following W/Bl W/Y connector
terminals: (W)
5P connector – 6P connector Bl/Y Bu/R

No.1 (White/blue) No.3 (Blue/red)
Lg/R
STARTER RELAY CIRCUIT INSPECTION

Bl Bl/Bu
Connect the 6P connector PGM-FI/main relay side No.5 Bl/W
(Black/white) terminal to the battery (+) terminal using a
jumper wire.
(Black/blue) terminal to the battery (-) terminal using a
jumper wire.
There should be continuity between the following
terminals:
5P connector – Wire connector (White) W/G
No.5 (White/yellow) W/R
W/Bl
If above inspection are abnormal, replace the PGM-FI/
main relay. W/Y
W/Bu
Bu/R
Bl/Bu
Bl/W
Lg/R
Bl/Y
Bl
TERMINAL

10-13
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OTHER ELECTRICAL
FUSE BOX INSPECTION
• Disconnect the battery cable at the negative (-)
cable before the inspection. FUSE BOX
Remove the fuses and check for blown fuses.

If the fuses are normal, install them in the fuse box and
check for continuity between the terminals shown
below.
FUSE No. CHECK POINT

1 Between the terminal and fuse box
5P connector No.1 terminal.
2 Between the terminal and 14P
connector No.1 terminal.
3 Between the fuse box 5P connector
No.4 terminal and joint connector 2
No.8 terminal.
No.16 terminal.
No.24 terminal.
6 Between the and fuse box 5P
connector No.5 terminal.
If there is no continuity between the terminals listed

above, replace the fuse box.
70 A FUSE BOX/FUSE INSPECTION

• Disconnect the battery cable at the negative (-)
cable before the inspecting and replacing the 70 A
fuse box.
Remove the 70 A fuse and check it for continuity.
• If there is no continuity, replace the 70 A fuse with a
new one.
• If there is continuity, install the 70 A fuse in the fuse
box. Check for continuity between the regulator/
rectifier 3P connector No.1 (White) terminal [1] and
fuse cable White terminal [2].
When a spare fuse is installed on the backside of the
cover, install so that the stamp "70 A" can be seen from
your side.
[1]
[2]
10-14
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OTHER ELECTRICAL
POWER TILT RELAY INSPECTION
• Remove the power tilt relay before inspection.
Check for continuity between the following terminals.
Between Green and Black Continuity
Between Blue and Black Continuity
POWER TILT RELAY
Between Green and White No continuity
Between Blue and White No continuity
Bu
Bl
G Lg Lb
W
Connect a battery as shown. There must be continuity/

no continuity between the terminals shown.
• Use a known-good battery for the test.
Positive (+) battery terminal connected to Light
green terminal:
Between Green and Black No continuity
Between Blue and Black Continuity
Between Green and White Continuity
Between Blue and White No continuity
Positive (+) battery terminal connected to Light blue

terminal: G
Lb
Between Green and Black Continuity
Between Blue and Black No continuity Lg
Between Green and White No continuity
Between Blue and White Continuity
If above inspection is abnormal, replace the power tilt

relay.
Bu W Bl

10-15
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OTHER ELECTRICAL
INSPECTION (OUTBOARD MOTOR
SIDE)
Disconnect the power trim/tilt switch 3P connector [1].
Attach the tester lead to each terminal and check for
continuity.
When the switch is pushed "UP" or "DN", there should
be continuity between the terminals marked with a
circle in the table below.
Color
Lb W/Bl Lg
Switch position
UP [1]
Neutral
DN (Down)
TRIM ANGLE SENSOR INSPECTION

Disconnect the trim angle sensor 3P connector [1].
Measure the resistance between the trim angle sensor
3P connector sensor side terminals.
Between Light green/Black and Black 4.0 – 6.0 kΩ
Between Yellow/Blue and Black 2.7 – 4.3 kΩ
[1]
10-16
dummytext
11. COOLING SYSTEM
COMPONENT LOCATION ····················· 11-2 RELIEF VALVE REMOVAL/

INSTALLATION·································· 11-11
WATER LINE DESCRIPTION················· 11-3
FLUSH VALVE DISASSEMBLY/
THERMOSTAT/WATER JACKET COVER ASSEMBLY ······································· 11-12
THERMOSTAT INSPECTION················ 11-12
11
WATER PUMP REMOVAL/
INSTALLATION ··································· 11-6

11-1
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COOLING SYSTEM
COMPONENT LOCATION
COOLING SYSTEM
19.7 N·m (2.0 kgf·m, 15 lbf·ft)
11-2
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COOLING SYSTEM
WATER LINE DESCRIPTION
THERMOSTAT (50 °C) THERMOSTAT (60 °C)
CYLINDER BLOCK
WATER JACKET
ANODE
VAPOR SEPARATOR
REGULATOR/
RECTIFIER
RELIEF VALVE
CYLINDER HEAD
WATER JACKET
WATER CHECK
HOLE
FLUSH VALVE
MOUNT CASE/GEAR CASE

WATER TUBE
WATER PUMP
WATER SCREEN

11-3
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COOLING SYSTEM
THERMOSTAT/WATER JACKET COVER REMOVAL/INSTALLATION
REMOVAL
Remove the following parts.
– Engine cover
– R. engine under (page 6-5)
– Fuse box (70 A)/regulator/rectifier (page 10-4) [4]
Release the harness band clip from harness clip
bracket C and release the HO2S 4P connector (page 5- [1]
82).
Disconnect the ignition coil 3P connectors [1], ECT
sensor 3 (2P) connector [2], and the CMP sensor 3P
connector [3]. [5]
Release the harness band clip [4] and the three
harness straps [5] from the water jacket cover.
[1]
[5]
[2]
[1]
[5]
[3]
Remove the two bolts [1] from the cylinder block, and remove the thermostat cover [2], thermostat cover O-ring
[3], and the thermostat (60 °C) [4].
Remove the two bolts [5] from the water jacket cover [6], and remove the thermostat cover [7], thermostat cover
O-ring [8], and the thermostat (50 °C) [9].
Remove the twelve bolts [10] and remove the water jacket cover and water jacket cover gasket [11] from the
cylinder head.
Remove the two screws [12], and remove the two anode metals [13] from the cylinder head.
[13]
INSPECTION:
Check the anode metal for [11] [4]
corrosion and replace if
necessary. [3]
[12]
[2]
[1]
[9]
[5]
[7]
[8]
[10]
[6]
11-4
dummyhead
COOLING SYSTEM
INSTALLATION
• There are two types of the thermostats; one for the cylinder head and the other for the cylinder block. Do not
confuse them on assembly.
Install the two anode metals [1] on the cylinder head, and tighten the two screws [2] securely.
Install the new water jacket cover gasket [3] and the water jacket cover [4] on the cylinder head, and loosely
tighten the twelve bolts [5].
Install the thermostat (50 °C) [6], new thermostat cover O-ring [7], and the thermostat cover [8] on the water
jacket, and loosely tighten the two bolts (6 X 35 mm) [9].
Install the thermostat (60 °C) [10], new thermostat cover O-ring [11], and the thermostat cover [12] on the
cylinder block, and tighten the two bolts (6 X 22 mm) [13] securely/
THERMOSTAT FOR
[10] CYLINDER HEAD:
[3]
[11]
[1] [2] PAINT
[12]
[13]
[6]
[9]
[8]
THERMOSTAT FOR
CYLINDER BLOCK:
[7]
NO PAINT
[5]
[4]
Tighten the cover bolts [1] in the numbered sequence

shown in two or three steps. [1]
14.
13.
10.
4. 5.
6.
1.
2.
3.
8. 7.
9.
12. 11.

11-5
dummyhead
COOLING SYSTEM
Set the three harness straps [1] and the harness band
clips [2] on the water jacket cover.
Connector the ignition coil 3P connectors [3], ECT
sensor 3 (2P) connector [4], and CMP sensor 3P [2]
connector [5].
Connect the HO2S 4P connector and set the harness
[3]
band clip to harness clip bracket C (page 5-82).
– Fuse box (70 A)/regulator/rectifier (page 10-4)
[1]
– R. engine under (page 6-7)
– Engine cover
[3]
[1]
[4]
[3]
[1]
[5]
WATER PUMP REMOVAL/

INSTALLATION
REMOVAL
[1] [3]
– Propeller (page 16-3)
– Gear case (page 16-5) [2]
Remove the water tube seal ring [1] from the impeller
housing [2]. [4]
Remove the four bolts [3], four washers [4], four
distance collars [5], and impeller housing.
[5]
Remove the special key [6] from the vertical shaft.
• Check the special key and key groove of the vertical [6]
shaft for wear; replace them if necessary.
Remove the water pump O-ring [1] from the impeller

housing [2]. [2]
Remove the pump impeller [3] and pump liner [4] from
the impeller housing.
Check the impeller housing for deformation; replace it if
necessary. [1]
Check the impeller for cracks, wear, or damage from
overheating; replace them if necessary.
Check the pump liner for cracks or wear; replace it if
necessary
[3]
[4]
11-6
dummyhead
COOLING SYSTEM
Remove the impeller cover [1] and the impeller gasket
[2]. [1]
[2]
Remove the water pump housing [1] and water pump

gasket [2].
Remove the water pump housing O-ring [3] and two [4]
[1]
dowel pins [4].
Remove the gear case grommet [5] and rubber setting
plate [6] from the gear case.
[2]
[3]
[5]
[6]
Remove the two water seals [1] using a commercially

available oil seal remover.
[1]

11-7
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COOLING SYSTEM
EXPLODED VIEW
WATER TUBE SEAL RING
IMPELLER HOUSING BOLT (8 x 55 mm) (4)

DOWEL PIN 19.7 N·m (2.0 kgf·m, 15 lbf·ft)
(6 x 10 mm) (2)
WASHER (8 mm) (4)
WATER PUMP
DISTANCE COLLAR (4)
HOUSING
WATER PUMP O-RING

WATER PUMP
HOUSING GASKET
PUMP LINER
WATER PUMP
HOUSING O-RING PUMP IMPELLER
SPECIAL KEY
WATER SEAL
(23 x 36 x 6 mm) (2) IMPELLER COVER
IMPELLER GASKET
GEAR CASE GROMMET
RUBBER SETTING PLATE
11-8
dummyhead
COOLING SYSTEM
INSTALLATION
Apply soapy water to the outer circumference of the
new water seals (23 x 36 x 6 mm) [1]. WATER SEAL
INSTALLATION
Drive the water seals (23 x 36 x 6 mm) one by one into
DIRECTION:
the water pump housing using the special tools.
Note the installation direction of the water seals. GEAR CASE SIDE
Be sure to apply marine grease to the water seal mating
surfaces before installation.
TOOLS: [1]
Driver [2] 07749-0010000
Attachment, 32 x 35 mm [3] 07746-0010100
Apply marine grease to the water seal lips.
[2]
[3]
Install the rubber setting plate [1] and gear case

grommet [2] in the gear case.
Apply marine grease to the circumference of new water [6]
[4]
pump housing O-ring [3] and install it on the water
pump housing [4].
Install the new water pump gasket [5] and water pump
housing on the gear case. [5]
Install the two dowel pins [6] in the water pump housing.
[3]
[2]
[1]

11-9
dummyhead
COOLING SYSTEM
Install a new impeller gasket [1] and impeller cover [2].
[2]
[1]
Apply marine grease to the pump liner [1] inner surface.

Install the pump liner in the impeller housing [2] by [7]
aligning the two projections [3] on the pump liner with [4]
the two grooves [4] in the impeller housing. [3]
Be sure that part "A" [5] of the pump liner is in alignment
with part "B" [6] of the impeller housing.
Apply marine grease to a new water pump O-ring [7]
and install it into the impeller housing.
[5] [2] [6]

[1]
Set the special key [1] to the groove [2] in the vertical
shaft. [3] [4]
Install the pump impeller [3], aligning the key groove [4]
in the pump impeller with the special key.
[1]
Set the impeller housing [5] on the vertical shaft.
Install the impeller housing while turning the vertical
shaft clockwise.
• Be sure to turn the vertical shaft clockwise. [2]
[5]
11-10
dummyhead
COOLING SYSTEM
Install the four distance collars [1] on the impeller
housing and tighten the four impeller housing bolts [2]
and washers [3] to the specified torque.

[5] [2]
Apply marine grease to the inner wall of the water tube [4]
seal ring [4]. [3]
Install the water tube seal ring by aligning the projection
[5] with the hole [6] in the housing.
[1]
Perform the gear case pressure check after assembly
(page 16-42).
[6]
– Gear case (page 16-7)
RELIEF VALVE REMOVAL/INSTALLATION

Remove the cylinder head (page 14-19).
TUBE CLIP (B 10) (2) WATER TUBE JOINT

INSTALLATION:
WATER CHECK TUBE Apply liquid gasket (Threebond® #1215
INSTALLATION: or equivalent) to the threads.
Check the water check tube for TORQUE:
deterioration and cracks. 9 N·m (0.92 kgf·m, 6.6 lbf·ft)
Replace if necessary.
WATER TUBE B
INSTALLATION:
Check the water tube B for
deterioration and cracks.
RELIEF VALVE COVER
COVER O-RING
RELIEF VALVE
INSTALLATION:
Note the installation direction.
BOLT (6 x 22 mm) (2)
MOUNT CASE SIDE

11-11
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COOLING SYSTEM
FLUSH VALVE DISASSEMBLY/ASSEMBLY
Remove the engine under cover (page 6-5).
TUBE (7 X 110 mm) TUBE CLAMP (D 10.5) (2)

INSTALLATION:
Check the tube (7 X 110
mm) for deterioration and
cracks.
FLUSH VALVE
SPRING
(Apply grease to the part
where the water mouth FLUSH VALVE
nut contacts with the
water mouth seat.) INSPECTION:
Check the flush valve
gasket for deterioration and
cracks.
O-RING INSTALLATION:
Note the installation
direction.
WATER HOSE
FLUSH VALVE FLUSH
TUBE (8 X 300 mm) JOINT A
COVER VALVE
INSTALLATION: WATER MOUTH GASKET
Check the tube (8 X 300 SEAT FLUSH VALVE
mm) for deterioration and COVER SIDE
cracks. WATER MOUTH
Replace if necessary. NUT
BOLT (6 x 20 mm)
TUBE CLIP (13 mm)
THERMOSTAT INSPECTION
Remove the thermostat [1] (page 11-4).
Immerse the thermostat in water. [2]
Heat the water and observe the operation of the
thermostat as the water temperature increases.
Measure the water temperature when the thermostat
starts opening.
Cylinder head side:
START OPENING: 48 – 52 °C (118 – 126 °F)
FULLY OPEN: 60 °C (140 °F)
Cylinder block side:
START OPENING: 58 – 62 °C (136 – 144 °F) [1]
FULLY OPEN: 70 °C (158 °F)
Measure the lift height when the thermostat is fully
open.
LIFT HEIGHT: More than 3.0 mm (0.12 in)
11-12
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12. LUBRICATION SYSTEM
COMPONENT LOCATION ····················· 12-2 OIL PUMP REMOVAL/INSTALLATION···· 12-7
LUBRICATION SYSTEM DIAGRAM········ 12-3 OIL PUMP DISASSEMBLY/ASSEMBLY ·· 12-8
STARTING PROCEDURE AFTER OIL PRESSURE CHECK ······················ 12-10

INSTALLING MAJOR ASSEMBLIES······· 12-4
OIL PUMP INSPECTION ······················ 12-10
OIL CASE REMOVAL/INSTALLATION ···· 12-5
12

12-1
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LUBRICATION SYSTEM
COMPONENT LOCATION
LUBRICATION SYSTEM
23 N·m (2.3 kgf·m, 17 lbf·ft)
21.5 N·m (2.2 kgf·m, 16 lbf·ft)
12-2
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LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
CAM CHAIN JET 1

CAM CHAIN JET 2
CAMSHAFT
PISTON
ROCKER SHAFT
EOP SENSOR CRANKSHAFT
EXHAUST
ROCKER ARM
INTAKE
ROCKER ARM
OIL FILTER
OIL PUMP
RELIEF VALVE
VTEC SOLENOID VALVE

OIL STRAINER OIL CASE

12-3
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LUBRICATION SYSTEM
STARTING PROCEDURE AFTER
INSTALLING MAJOR ASSEMBLIES
Perform the starting procedure after installing the
following major assemblies.
– Engine removal/installation
– Cylinder head removal/installation
– Oil case removal/installation
Inspect the following and adjust if necessary:
– Shift control cable (page 3-32).
– Throttle control cable/throttle link (page 3-9).
Connect a commercially available digital multimeter or
Dr.H (page 3-20).
Start the engine, raise the engine speed to 2,500 ± 300
min–1 (rpm), and run it until the oil indicator light (green)
[1] comes on.
SPECIFIED ENGINE SPEED:
2,500 ± 300 min–1 (rpm)
After the oil indicator light (green) comes on, lower the
engine speed to the idle speed.
IDLE SPEED (AT NEUTRAL): [1]
750 ± 50 min–1 (rpm)
If the oil indicator light (green) does not come on within
10 seconds after starting the engine, the oil alert system
is activated and the warning buzzer operates.
If that happens, stop the engine and repeat the above
procedure.
If the oil indicator light (green) still does not come on,
perform the alert system troubleshooting (page 4-16)
and repeat the above procedure.
12-4
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LUBRICATION SYSTEM
OIL CASE REMOVAL/INSTALLATION
REMOVAL
Remove the extension case/lower rubber mount (page 16-9).
BOLT (6 x 12 mm)
OIL LEVEL PIPE
O-RING
OIL LEVEL GAUGE
OIL CASE GASKET
DOWEL PIN (6 x 10 mm) (2)
O-RING
BOLT (6 x 16 mm) (3)
OIL STRAINER
OIL CASE
OIL DRAIN PLUG BOLT
23 N·m (2.3 kgf·m, 17 lbf·ft)
DRAIN PLUG WASHER
BOLT (8 x 35 mm) (11)

21.5 N·m (2.2 kgf·m, 16 lbf·ft)
BOLT (8 x 100 mm) (5)

21.5 N·m (2.2 kgf·m, 16 lbf·ft)

12-5
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LUBRICATION SYSTEM
INSTALLATION
Apply engine oil to a new O-ring [1], and install it to the
oil strainer [2].
Install the oil strainer on the mount case, and tighten [1]
the three bolts [3] securely.
[2] [3]
Clean the oil case/mount case mating surfaces and

both sides of a new oil case gasket [1] thoroughly using [1]
a shop towel and degreasing cleaning solvent.
Apply a bead (1.0 - 6.0 mm (0.04 - 0.24 in) thick) of
liquid gasket (ThreeBond® #1211 or equivalent) to the
indicated area of the oil case gasket.
• Assemble within 90 minutes after application of the
liquid gasket. If the parts have been left
unassembled for 90 minutes or longer, remove the
old gasket and apply a liquid gasket again.
• Do not fill the oil case with engine oil and do not start
the engine for 15 minutes after assembly.
Install the two dowel pins [1], oil case gasket [2], and
the oil case [3] on the mount case, and loosely tighten [8]
the five bolts (8 x 100 mm) [4] and eleven bolts (8 x 35 [9]
mm) [5].
oil level pipe [7].
[7]
Install the oil level pipe on the mount case, and tighten [1]
the bolt [8] securely.
Install the oil level gauge/dipstick [9].
[6]
[2]
[1]
[3]
[4] [5]
12-6
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LUBRICATION SYSTEM
Tighten five bolts (8 x 100 mm) and eleven bolts (8 x 35
mm) to the specified torque in the numbered sequence 7.
shown in two or three steps. 16.
TORQUE: 21.5 N·m (2.2 kgf·m, 16 lbf·ft) 15.

8.
Tightening point Part name Qty
1-5 bolt (8 x 100 mm) 5
6 - 16 bolt (8 x 35 mm) 11 14. 3. 9.
5.
Install the new sealing washer on the bolt, tighten the 1.
bolt, and add engine oil in the oil case (page 3-4).
13.
Install the following parts. 10.
2. 4.
– Extension case/lower rubber mount (page 16-11)
– Gear case/extension separator (XRT type only) 12.
(page 16-5) 11.
– Engine under cover (page 6-7) 6.
– Engine cover
OIL PUMP REMOVAL/INSTALLATION

REMOVAL
Remove the cylinder head (page 14-19).
[3]
Remove the two bolts (8 x 60 mm) [1] and two bolts (8 x
40 mm) [2]. Remove the oil pump [3].
Remove the O-ring [4] from the oil pump. [1]
[4]
[2]
INSTALLATION
Pour one teaspoon (5 cc) of engine oil into the rotor
chamber (suction side) [1] of the oil pump.
(5 cc)
[1]

12-7
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LUBRICATION SYSTEM
Install a new O-ring [1] on the oil pump [2].
Install the oil pump on the cylinder head by aligning the [4]
oil pump shaft [3] with the socket of the cam pulser
plate bolt [4]. [3]
[2] [1]
Tighten the two bolts (8 x 60 mm) [1] and two bolts (8 x

40 mm) [2] securely. [1]
Install the cylinder head on the out board motor (page
14-20).
[2]
OIL PUMP DISASSEMBLY/ASSEMBLY

DISASSEMBLY
Remove the oil pump (page 12-7).
THRUST WASHER
OIL PUMP BODY
ROLLER (5 x 17.8 mm)
OIL PUMP SHAFT

RELIEF VALVE
RELIEF VALVE
SPRING SEALING
WASHER
O-RING
BOLT (6 x 18 mm) (3)
SEALING BOLT (18 mm)

39.2 N·m (4.0 kgf·m, 29 lbf·ft)
OUTER ROTOR
INNER ROTOR
OIL PUMP COVER
12-8
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LUBRICATION SYSTEM
ASSEMBLY
Check the relief valve [1] surface for scores, scratches
and other damage.
[7]
Apply engine oil to the relief valve and the relief valve
spring [2]. [6]
Install the following parts to the oil pump [3]. [8]
[3]
– Relief valve
– Relief valve spring
– New sealing washer [4]
– Sealing bolt [5]
Tighten the sealing bolt to the specified torque.
Install the roller [6] into the oil pump shaft [7], and install
the thrust washer [8] and oil pump shaft on the oil pump
body.
[1]
[2]
[4]
[5]
Clean the inner rotor [1] and the outer rotor [2]
thoroughly.
Apply engine oil to the inner rotor and outer rotor, and [5]
install them on the oil pump body.
Install the rotors in the same direction as noted on
disassembly. [4]
Install the new O-ring [3] on the oil pump body.
Install the oil pump cover [4] on the oil pump body, and
tighten the three bolts [5] securely.
After installation, check that the rotors move smoothly
by turning the oil pump shaft.
[1]
[2]
[3]

12-9
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LUBRICATION SYSTEM
OIL PRESSURE CHECK
Remove the oil filter (page 3-5).
[5]
Check the condition of the O-ring [1] of the special tool [1]
and install it to the oil filter flange [2].
Tighten the special tool to the specified torque. [3]
TOOL:
Oil pressure gauge 070MJ-0010101
attachment [3]

Install and tighten the adapter to the specified torque.
TOOL:
OIL PRESSURE GAUGE Commercially
ADAPTER, SUNAT 77AH [4] available
[2]
Install the pressure gauge [5] to the oil pressure gauge
adapter. [4]
TOOL:
OIL PRESSURE GAUGE Commercially
SUNMT37A available
Install the oil filter (page 3-5).
Check the engine oil level (page 3-4).
Run the outboard in a test tank.
Allow the engine to warm up to normal operating
temperature, and then measure the oil pressure.
OIL PRESSURE (Pressure check at 750 ± 50 min-1
(rpm) in neutral:)
117 kPa (1.2 kgf/cm2, 17 psi) or higher
If the oil pressure is lower than the specified value,
inspect the oil pump rotor and body for wear (page 12-
10).
Remove the special tools.
Install the oil filter (page 3-5).
OIL PUMP INSPECTION

OIL PUMP BODY I.D.
Measure the oil pump body I.D.
STANDARD:
80.00 – 80.04 mm (3.150 – 3.151 in)
If the measurement exceeds the standard limit, replace
the oil pump body.
12-10
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LUBRICATION SYSTEM
OIL PUMP BODY DEPTH
Measure the oil pump body depth.
STANDARD:
18.04 – 18.07 mm (0.710 – 0.711 in)
If the measurement exceeds the standard limit, replace
the oil pump body.
OUTER ROTOR HEIGHT

Measure the outer rotor height.
STANDARD:
17.98 – 18.00 mm (0.708 – 0.709 in)
SERVICE LIMIT:
17.96 mm (0.707 in)
replace the outer rotor with a new one.
INNER ROTOR-TO-OUTER ROTOR

CLEARANCE
Measure the inner rotor-to-outer rotor clearance.
STANDARD:
0.02 – 0.16 mm (0.001 – 0.006 in)
SERVICE LIMIT:
0.20 mm (0.008 in)
If the measurement exceeds the service limit, replace
the inner rotor and the outer rotor with the new ones as
a set.
OUTER ROTOR-TO-PUMP BODY

CLEARANCE
Measure the outer rotor-to-pump body clearance.
STANDARD:
0.10 – 0.19 mm (0.004 – 0.007 in)
SERVICE LIMIT:
0.23 mm (0.009 in)
the outer rotor and the oil pump body with the new ones
as a set.

12-11
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LUBRICATION SYSTEM
OUTER ROTOR-TO-OIL PUMP BODY
SIDE CLEARANCE
Measure the outer rotor-to-oil pump body side
clearance.
STANDARD:
0.04 – 0.09 mm (0.002 – 0.004 in)
SERVICE LIMIT:
0.12 mm (0.005 in)
the outer rotor and the oil pump body with the new ones
as a set.
12-12
dummytext
13. ENGINE REMOVAL/INSTALLATION
COMPONENT LOCATION ····················· 13-2 ENGINE INSTALLATION ······················ 13-8
ENGINE REMOVAL ····························· 13-3
13

13-1
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ENGINE REMOVAL/INSTALLATION
COMPONENT LOCATION
27 N·m (2.8 kgf·m, 20 lbf·ft)

27 N·m (2.8 kgf·m, 20 lbf·ft)
27 N·m (2.8 kgf·m, 20 lbf·ft)
27 N·m (2.8 kgf·m, 20 lbf·ft) 27 N·m (2.8 kgf·m, 20 lbf·ft)
27 N·m (2.8 kgf·m, 20 lbf·ft)
13-2
dummyhead
ENGINE REMOVAL

handling fuel.

– Battery negative (-) cable [1]
– Engine cover
– Gear case/extension separator (XRT type only)
(page 16-5)
– Starter cable/fuse cable(page 10-6)
– Shift link bracket/neutral switch (page 19-8)
– Seal holder (page 19-12)
Hook the engine hanger (commercially available:
VSB02C000021) hooks [1] on the two engine hangers
and secure the engine so it does not fall.
– Extension case/lower rubber mount (page 16-9)
– Oil case (page 12-5)
Relieve the fuel pressure according to the fuel pressure
relief procedure (page 5-66) [7]
[8] [5]
Remove the bolt [1], and disconnect the fuel hose [2]
and fuel pipe joint [3] from the vapor separator.
Remove the O-rings [4] from the fuel pipe joint.
[3]
vinyl tube [6] from the intake manifold [7].
Release the pressure regulator control tube from tube [2]
clamp D [8].
[1]
[4] [6]
Release the water level sensor 2P connector [1] and

[4] [1]
trim angle sensor 3P connector [2] from the relay
bracket [3].
Release the harness band clip [4] from the relay
bracket.
[2]
[3]

13-3
dummyhead
Open the hose grommet [1] and release the fuel hose
[2].
[5]
Release fuel tube B [3] from the two fuel tube clamp Bs [4]
[3]
[4].
Release fuel tube C from the tube clamp [5].
[1] [2]
Disconnect air vent tube A [1] and fuel tube D [2] from
the vapor separator. [1] [2]
Disconnect air vent tube C [1] from the mount case.

Disconnect water tube A [2] and water tube B [3].
[1]
[3]
[2]
Remove the three bolt/washers [1] and pull the vapor

[1]
separator [2].
[1] [2]
13-4
dummyhead
Release the fuel pump cord [1] from the cord clamper
[2] and disconnect the fuel pump 2P connector [3]. [3]
Remove the vapor separator.
[2]
[1]
Remove the regulator/rectifier and fuse box bracket

(page 10-4). [2]
Remove the bolt [1] from the starter motor [2].
[1]
Disconnect the oil tube [1] from the mount case [2].
[1]
[2]

13-5
dummyhead
Remove the six bolts (8 X 45 mm) [1], bolt (8 X 35 mm),
and two cap nuts [3] from the outboard motor. [2] [3] [1]
[1] [3]
13-6
dummyhead
Remove the seven bolts (8 X 100 mm) [1] and three
bolts (8 X 120 mm) [2] from the underside of the mount
case [3].
Pull the engine [4] up slowly, and remove it from the
mount case.
• Be sure that the engine hanger (commercially
available: VSB02C000021) hooks [5] are set on the
two engine hangers securely.
• Hold the engine level while pulling it up.
Remove the two dowel pins [6] and mount case gasket
[7] from the mount case.
[5]
[4]
[6]
[7]
[3]
[2] [1]

13-7
dummyhead
ENGINE INSTALLATION
Clean the engine /mount case mating surfaces and
both sides of a new mount case gasket [1] thoroughly Φ1.0 – 6.0 mm
(0.04 – 0.24 in) [1]
using a shop towel and degreasing cleaning solvent.
Apply a bead [Φ1.0 – 6.0 mm (0.04 – 0.24 in) thick] of
liquid gasket (Threebond® #1211 or equivalent) to the
indicated area of the mount case gasket.
• Assemble within 90 minutes after applying the liquid [1]
gasket. If the parts have been left unassembled for
90 minutes or longer, remove the old gasket and
apply a new gasket again.
• Do not fill the oil case within engine oil or start the
engine for 15 minutes after assembly.
(Apply on both sides)
Install the two dowel pins [1] and mount case gasket [2]
to the mount case [3].
While aligning the two stud bolts [4] and the shift shaft
[5] of the mount case with the installation holes [6] in the
engine, lower the engine slowly and install it on the
mount case.
• Check that the side washer [7] is set on the shift
shaft before lowing the engine.
• Lower the engine slowly while holding it level.
Do not ruin the spline part of the shift shaft and the
threads of the stud bolt.
[1]
Loosely tighten the seven bolts (8 X 100 mm) [8] and
the three bolts (8 X 120 mm) [9] from the underside of
the mount case.
[2]
[4]
[3]
[9]
[8]
[6] [5] [6]
[7] [4]
13-8
dummyhead
Tighten each bolt and nut to the specified torque in the
numbered order in two or three steps.
• Do not confuse the bolts on installation.
Tightening 14. 12.
Part name Qty
point
1–3 8 X 100 mm bolt (white) 3
4–7 8 X 100 mm bolt (black) 4
13. 11.
8 – 10 8 X 120 mm bolt 3
11 – 14 8 X 45 mm bolt 4 1. 5. 4.
15, 19 8 X 45 mm bolt 2
16, 18 8 mm cap nut 2
9.
17 8 X 35 mm bolt 1 8. 6. 10.
3. 2. 7.
17.
16. 15.
19. 18.
Connect the oil tube [1] to the mount case [2].

[1]
[2]

13-9
dummyhead
Loosen the bolt (10 X 35 mm) [1] and install the bolt (10
X 75 mm) [2].
Tighten the bolt (10 X 35 mm) and the bolt (10 X 75
mm) to the specified torque.
[3]
Install the regulator/rectifier and fuse box bracket (page

10-4).
[2]
Set the vapor separator on the outboard motor, and

connect the fuel pump 2P connector [1]. [1]
[3]
Set the fuel pump cord [2] in the cord clamper [3].
[2]
Install the three bolts [1] to the vapor separator [2] and
tighten them. [1]
[1] [2]
13-10
dummyhead
Connect air vent tube C [1] to the mount case joint.
Connect water tube A [2] and water tube B [3] to the
vapor separator.
[1]
[3]
[2]
Set fuel tube B [1] to the fuel tube clamp Bs [2] by

attaching the ends of the protector tubes to the fuel tube
[5]
clamp Bs. [2]
[1]
Set the fuel hose [3] to the hose grommet [4].
Set fuel hose C to the tube clamp [5].
[4] [3]
Connect air vent tube A [1] and fuel tube D [2] to the
vapor separator [3]. [4] [1] [2]
Set air vent tube A on the clamp [4] of the vapor
separator.
[3]
Set the harness band clip on the relay bracket [2].

[1] [2]
Set the water level sensor 2P connector [2] and trim
angle sensor 3P connector [3] to the relay bracket [4].
[4]
[3]

13-11
dummyhead
Connect the pressure regulator control tube [1] to the
intake manifold [2] and set the tube in tube clamp D [3].
Connect the vinyl tube [4] to the intake manifold.
Apply engine oil to new O-rings [5] and install them on
the fuel pipe joint [6].
Insert the fuel pipe joint on the vapor separator by
pushing it until it stops. [1] [2]
[3]
Connect the fuel hose [7] to the vapor separator.
• Connect the fuel hose securely until the connecting
surface of the fuel hose comes in contact with the
connecting surface of the vapor separator.
[6]
Install and tighten the bolt [8].
Install the following [7]
– Gear case/extension separator (XRT type only)

(page 16-7)
– Seal holder (page 19-12)
– Shift link bracket/neutral switch (page 19-11)
– Starter cable/fuse cable (page 10-8)
– Under cover rear bracket (page 6-16) [8]
– Under cover front bracket (page 6-14) [4]
– L./R. engine under cover (page 6-7) [5]
– Engine cover
– Battery negative (-) cable
To start the engine after installation, follow the starting
procedure after assembly (page 12-4).
13-12
dummytext
14. CYLINDER HEAD
COMPONENT LOCATION ····················· 14-2 ROCKER ARMS/SHAFT DISASSEMBLY/

ASSEMBLY ······································· 14-30
CHAIN CASE/CAM CHAIN REMOVAL/
INSTALLATION ··································· 14-4 CYLINDER COMPRESSION TEST········· 14-32
CYLINDER HEAD COVER REMOVAL/ CYLINDER HEAD INSPECTION ············ 14-32

INSTALLATION ··································14-15
VALVE GUIDE REPLACEMENT············ 14-40
CYLINDER HEAD REMOVAL/
INSTALLATION ··································14-19 VALVE SEAT RECONDITIONING·········· 14-41
CYLINDER HEAD ASSEMBLY/

DISASSEMBLY ··································14-22 14

14-1
dummyhead
CYLINDER HEAD
COMPONENT LOCATION
CYLINDER HEAD
22 N·m (2.2 kgf·m, 16 lbf·ft)
61 N·m (6.2 kgf·m, 45 lbf·ft)
14-2
dummyhead
CYLINDER HEAD
18 N·m (1.8 kgf·m, 13 lbf·ft)
29 N·m (3.0 kgf·m, 21 lbf·ft) + 130°

14-3
dummyhead
CYLINDER HEAD
CHAIN CASE/CAM CHAIN REMOVAL/
INSTALLATION
• Keep the magnetic parts away from the cam chain.
REMOVAL
Disconnect the battery negative (–) cable.
Make sure the remote control lever is in "N" (neutral) [4]
position.
[3]
– Engine cover
– Engine under cover (page 6-5) [1] [2]
Put the No.1 piston at the top dead center of its
compression stroke by turning the alternator rotor
clockwise (page 3-12).
Remove the alternator (page 7-6).
Remove the fuel strainer (low pressure side) [1] from
harness clip bracket B [2], and release the tube joint [3]
from fuel tube clamp B.
Remove the two bolts [4] and remove the harness clip
bracket B.
Remove the bolt [1] and remove harness clip A [2].

Remove the two bolts [3], and remove harness clip [1] [4]
[3]
bracket C [4].
[2]
Remove the bolt [1], and remove connector bracket A

[2] from the chain case.
[1] [2]
14-4
dummyhead
CYLINDER HEAD
Remove the bolt/washer [1] from the electronic parts
case.
[1]
Remove the bolt/washer [1] from the silencer case.

[1]
Remove the ten bolts (6 x 28 mm) [1], three bolts (6 x

22 mm) [2], bolt (6 x 40 mm) [3], and two special bolts
[4]
(6 x 31 mm) [4] from the chain case. Remove the chain
case [5] from the outboard motor. [2]
[3]
Remove the two alternator cover grommets [6] from the
chain case. [1]
[6]
[5]

14-5
dummyhead
CYLINDER HEAD
Remove the oil seal [1] from chain case.
[1]
Insert a screwdriver into the cam chain tensioner slider

[1] as shown, and remove the bolt [2] while holding the
cam chain tensioner slider. [2]
[1]
Remove the bolt [1], and remove the cam chain

tensioner slider [2]. [1]
[2]
Remove the tensioner pivot bolt [1], and remove the

cam chain tensioner [2]. [3]
[1]
Remove the two bolts [3], and remove the cam chain [2]
guide [4]. [4]
14-6
dummyhead
CYLINDER HEAD
Remove the bolt [1], oil pipe [2], and O-ring [3].
[1] [2]
Remove the cam chain [4]. [3]
[4]
Loosen the bolt/washer [1] while holding the camshaft

with a 30 mm open end wrench as shown.
[1]
Remove the bolt/washer [1], and remove the cam chain

driven sprocket [2] from the camshaft. [1]
[2]
Remove the cam chain drive sprocket [1] and the

special key [2] from the crankshaft. [1]
[2]

14-7
dummyhead
CYLINDER HEAD
EXPLODED VIEW
HARNESS CLIP
BRACKET C
BREATHER PIPE
TUBE JOINT
BREATHER TUBE B BREATHER TUBE C
BOLT
(6 x 14 mm) (2)
BOLT
(6 x 40 mm)
BOLT
(6 x 28 mm) (10) BOLT
(6 x 22 mm) (3)
BOLT
(6 x 14 mm) SPECIAL BOLT
(6 x 31 mm) (2)
HARNESS CLIP
BRACKET A
OIL SEAL
(40 x 55 x 7 mm)
JOINT
CONNECTOR
BOLT
(6 x 14 mm) CHAIN CASE
ALTERNATOR
CONNECTOR COVER
BRACKET A GROMMET (2)
TENSIONER PIVOT BOLT

BOLT
(6 x 14 mm) (2) 22 N·m (2.2 kgf·m, 16 lbf·ft)
CAM CHAIN TENSIONER

CAM CHAIN GUIDE
BOLT
(6 x 28 mm) (2)
CAM CHAIN
DRIVE SPROCKET
CAM CHAIN
BOLT/
WASHER SPECIAL KEY
(10 x 30 mm)
61 N·m (6.2 kgf·m, 45 lbf·ft)
BOLT/WASHER
(6 x 27 mm) (2)
CAM CHAIN DRIVEN
BOLT CAM CHAIN TENSIONER
SPROCKET
(6 x 14 mm) SLIDER
O-RING
OIL PIPE
14-8
dummyhead
CYLINDER HEAD
INSTALLATION
Clean the cam drive sprocket [1] seat and the
crankshaft [2] in the part where it contacts the sprocket [1]
seat thoroughly with the degreasing clean agent. [3]
Install the special key [3] in the key groove [4] in the [4] [2]
crankshaft. Install the cam chain drive sprocket on the
crankshaft. Align the punch mark [5] on the cam chain
drive sprocket with the “ ” mark [6] on the crankcase.
[1]
[6]
[5]
Align the recess [1] in the cam chain driven sprocket

with the dowel pin [2] on the camshaft, and install the [5]
cam chain driven sprocket on the camshaft.
Align the “-” marks [3] with the end of the cylinder head
with the “UP” mark [4] on the cam chain driven sprocket [1]
toward the end of the cylinder head as shown.
Apply engine oil to the threads and seat of the bolt/
washer [5], and loosely tighten it on the camshaft.
[2]
[4]
[3]

14-9
dummyhead
CYLINDER HEAD
Tighten the bolt/washer [1] to the specified torque while
holding the camshaft with a 30 mm open end wrench as
shown.
[1]
Align the cooler plate (1 place) [1] of the cam chain [2]
with the punch mark [3] on the cam chain drive sprocket [2]
as shown, and install the cam chain on the drive
sprocket.
Align the collar plates (3 places) [4] of the cam chain
with the “-” mark (2 places) [5] on the cam chain driven
sprocket, and install the cam chain on the driven
sprocket.
After installation, check that the cam chain drive
sprocket and the cam chain driven sprocket are at top
dead center of the compression stroke of the No.1
piston.
[1]
[3]
[5]
[4]
14-10
dummyhead
CYLINDER HEAD
oil pipe [2]. [3] [2]
Install the oil pipe and tighten the bolt [3] securely. [1]
Install the cam chain guide [1], and tighten the two bolts
[2] securely. [2] [4]
[3]
Install the cam chain tensioner [3], and tighten the
[1]
tensioner pivot bolt [4] to the specified torque.
Install the cam chain tensioner slider [1], and loosely [2]
tighten the bolt [2]. [1]
Apply engine oil to the sliding surface of the cam chain

tensioner slider [1].
[2]
Insert a screwdriver into the cam chain tensioner slider
as shown.
Align the bolt holes by turning the cam chain tensioner
slider in the direction of the arrow, and insert the bolt [2]
into the hole. Tighten the two bolts securely.
Check again that the cam chain drive sprocket and the
cam chain driven sprocket are at top dead center of the
compression stroke of the No.1 piston.
[1]

14-11
dummyhead
CYLINDER HEAD
Apply soapy water to the outer surface of a new oil seal
[1].
Install the oil seal in the chain case using the special
tool. Install the oil seal in the position shown. [2]
TOOL:
Driver [2] 07749-0010000
Attachment, 52 x 55 mm [3] 07746-0010400
After installation, apply grease to the oil seal lip. [3]
• Note the oil seal installation direction.
[1]
28.5 - 29.2 mm
(1.12 - 1.15 in)
Clean the mating surfaces of the crankcase/cylinder

block and the cylinder head/chain case thoroughly with
a degreasing cleaning agent.
liquid gasket (Threebond® #1280B or equivalent) to the
chain case in the areas shown.
Apply an additional bead of liquid gasket (2.5 mm (0.10
in) thick) to part A [1] (crankcase/cylinder block mating
surface) and to part B [2] (cylinder block/cylinder head
mating surface) as shown.
• Assemble the crankcase/cylinder block and the
cylinder head/chain case within 5 minutes after [1]
applying the liquid gasket. If it has been left for 5
minutes or longer, remove the old gasket and apply
the liquid gasket again.
• After assembly, wait at least 30 minutes before filling
the engine with oil.
[2]
14-12
dummyhead
CYLINDER HEAD
Install the two alternator cover grommets [1] on the
chain case.
[2]
First, loosely tighten the two special bolts [2] on the [4]
chain case to correctly position it. [5]
Then, loosely tighten the ten bolts (6 x 28 mm) [3], three
bolts (6 x 22 mm) [4], and the bolt (6 x 40 mm) [5] on the [3]
chain case.
[1]
Tighten the bolts securely in the numbered sequence

shown in two or three steps.
Tightening Part name Qty 7.

point 4. 5.
1,2 Special bolt 2
(6 x 31 mm) 2.
1.
3,6 Bolt (6 x 28 mm) 10
8 - 12
14 - 16
4,5,7 Bolt (6 x 22 mm) 3 6. 3.
13 Bolt (6 x 40 mm) 1
9.
8.
11.
10.
14.
13. 12.
16.
15.

14-13
dummyhead
CYLINDER HEAD
Tighten the bolt/washer [1] on the electronic parts case
securely.
[1]
Tighten the bolt/washer [1] on the silencer case

securely. [1]
Set connector bracket A [1] on the chain case, and

tighten the bolt [2] securely.
[2] [1]
Set harness clip bracket A [1] on the chain case, and

tighten the bolt [2] securely. [2] [3]
[4]
Set harness clip bracket C [3] on the chain case, and
tighten the two bolts [4] securely.
[1]
14-14
dummyhead
CYLINDER HEAD
Set harness clip bracket B [1] on the chain case, and
tighten the two bolts [2] securely.
[2]
Install the tube joint [3] on fuel tube clamp B, and install
the fuel strainer (low pressure side) [4] on harness clip [3]
bracket B.
Install the following parts: [4] [1]
– Alternator (page 7-9)
– Engine under cover (page 6-7)
– Engine cover
CYLINDER HEAD COVER REMOVAL/

INSTALLATION
REMOVAL
Disconnect the oil tube [1] from the mount case [2].
• Oil leaks out when the oil tube is removed. Catch the
leaking oil with a shop towel and a suitable
container, and wipe up any spilled oil.
[2]

14-15
dummyhead
CYLINDER HEAD
Disconnect breather tube [1] from the cylinder head
cover [2].
Remove the nine bolts [3], and remove the cylinder
head cover.
• Oil leaks out when the cylinder head cover is
removed. Catch the leaking oil with a shop towel and
a suitable container, and wipe up any spilled oil.
Disconnect the oil tube and remove the head cover
gasket from the cylinder head cover.
• Check the head cover gasket for damage and deterioration, and replace if necessary.
[1]
[2]
[3]
INSTALLATION
Clean the groove of the cylinder head cover [1], and
clean the head cover gasket [2].
[2]
Install the head cover gasket on the cylinder head
cover.
[1]
14-16
dummyhead
CYLINDER HEAD
Connect the oil tube to the cylinder head cover by
aligning the projection [1] on the oil tube with the
projection [2] on the cylinder head cover.
Set the tube clamp D29.0 with the lug [3] in the position [1]
shown.
[2]
[3]
Thoroughly clean the cylinder head/cylinder head cover

mating surfaces using a degreasing cleaning agent.
liquid gasket (Threebond® #1215 or equivalent) to the
cylinder head in the position shown (cylinder head/
chain case mating surfaces).
• Assemble the cylinder head cover within 5 minutes
after application of the liquid gasket. If it has been
left for 5 minutes or longer, remove the old liquid
gasket and apply the liquid gasket again.
• After assembly, wait at least 30 minutes before filling
the engine with oil. Do not start the engine for at
least 3 hours after assembly.
Install the cylinder head cover [1] on the cylinder head.

[1] [3]
After installation, move the cylinder head cover lightly
from side to side, making sure the gasket seats
properly.
[2]
Loosely tighten the nine bolts [2] on the cylinder head
cover.
Connect the breather tube [3] into the cylinder head
cover securely.

14-17
dummyhead
CYLINDER HEAD
Tighten the nine bolts securely in the numbered
6. 7.
3.
2.
1.
4. 5.
8.
9.
Connect the oil tube [1] to the mount case [2] securely. [1]
Install the following parts:
– Engine cover
[2]
14-18
dummyhead
CYLINDER HEAD
CYLINDER HEAD REMOVAL/
INSTALLATION
REMOVAL
• Remove the cylinder head assembly while the

engine is cold to prevent warpage.
• Take care not to damage the cylinder head and
cylinder block mating surfaces.
[2]
– Engine cover
– Cylinder head cover (page 14-15) 4. 1.
– Chain case/cam chain (page 14-4)
– Intake manifold (page 5-69)
– Ignition coil (page 3-15) 6.
– Fuse box/regulator/rectifier (page 10-4) 7.
Disconnect the following:

– ECT sensor 3 (2P) connector (page 5-85)
– CMP sensor 3P connector (page 5-83) 9.
10.
– HO2S 4P connector (page 5-82)
Loosen the two bolts [1].
Loosen the ten bolt/washers [2] in the numbered
sequence in two or three steps.
8. 5. [1]
2. 3.
Remove the ten bolt/washers [1] from the cylinder

head. Remove the two bolt [2]. [2]
[1]

14-19
dummyhead
CYLINDER HEAD
Remove the cylinder head [1] from the cylinder block.
[2]
Remove the cylinder head gasket [2] and two dowel
pins [3] from the cylinder block.
[1]
[3]
INSTALLATION
• Make sure there are no foreign objects between the
gasket and cylinder head and cylinder block.
• Take care not to damage the cylinder head and
cylinder head gasket mating surfaces. [2]
• Do not bend; the gasket is made of metal
• Check the washers for wear or damage
Check that the punch mark [1] on the cam chain drive
sprocket [2] aligns with the “ ” mark [3] on the
crankcase.
[3]
[1]
Apply liquid gasket (Threebond® #1211 or equivalent) to

the cylinder head gasket in the areas shown. [1]
Clean the exhaust passage sealing surface.
• To prevent leaks, do not install the parts if 90
minutes or more have elapsed since applying the
liquid gasket. Instead, reapply liquid gasket after
removing the old residue.
• Do not fill the engine oil and do not start the engine
for 15 minutes after assembly.
14-20
dummyhead
CYLINDER HEAD
Clean the cylinder head [1] and the cylinder block
mounting surfaces. [3]
Install the two dowel pins [2] on the cylinder block.

Install a new cylinder head gasket [3] on the cylinder
block by setting the projection of the cylinder head [1]
gasket in the position shown.
Align the dowel pins on the cylinder block with the
dowel pin installation positions of the cylinder head on
the cylinder block.
[2]

[2]
washers (9 x 155 mm) [1]. Loosely tighten the ten bolt/
washers (9 x 155 mm), bolt (8 x 110 mm) [2], and bolt (8
x 95 mm) [3] on the cylinder head. [3]
[1]
Tighten the ten bolt/washers (9 x 155 mm) [1] to the

[1]
specified torque in the numbered sequence shown in
two or three steps. 7. 10.
After tightening to the specified torque, tighten the bolt/
washers an additional 130° in the numbered sequence
shown.
5. 4.
Tighten the two bolts [2].
– Fuse box/regulator/rectifier (page 10-4)
– Ignition coil (page 3-15) 1. 2.
– Intake manifold (page 5-71)
– Chain case/cam chain (page 14-9)
– Cylinder head cover (page 14-16) 3. 6. [2]
– Engine cover
Connect the following:
– ECT sensor 3 (2P) connector (page 5-85) 9. 8.
– CMP sensor 3P connector (page 5-83)
– HO2S 4P connector (page 5-82)

14-21
dummyhead
CYLINDER HEAD
CYLINDER HEAD ASSEMBLY/DISASSEMBLY
DISASSEMBLY
• Mark the removed parts (e.g. valves, springs, and
other related parts) and store them securely, [1]
grouping them by intake side and exhaust side for
each cylinder. Install each part in the original
position on the assembly.
– Cylinder head (page 14-19)
– Water jacket (page 11-4)
– Oil pump (page 12-7)
– VTEC solenoid valve (page 5-82)
– CMP sensor (page 5-83)
– HO2S (page 5-82)
[2]
Loosen the rocker arm lock nut [1], and loosen the
adjusting screw [2] fully.
Loosen the five rocker shaft bolts [1] in the numbered
sequence shown in two or three steps. [1]
1.
3.
5.
4.
2.
Remove the five rocker shaft bolts [1]. Remove the

rocker shaft assembly [2] and dowel pin [3]. [1]
• Bundle the rocker arm assembly of each cylinder
with a strap [4] during removal of the rocker shaft [2]
assembly.
Remove the four lost motion springs [5] from the
cylinder head assembly. [3]
[4]
[5]
14-22
dummyhead
CYLINDER HEAD
Check whether the fuel pump lifter [1] is in contact with
the camshaft [2]. If it is, push the fuel pump lifter in [2] [1]
toward the cylinder head side.
[1]
Remove the cam pulser plate bolt [1] from the camshaft
[2], and remove the cam pulser plate [3].
[2]
Remove the camshaft from the oil pump side of the
cylinder head assembly.
[3]
[1]
Remove the fuel pump lifter [1] from the cylinder head
assembly.
[1]

14-23
dummyhead
CYLINDER HEAD
Use a socket [1] that matches the diameter of the valve
spring retainer. Attach the socket to the retainer, and
lightly tap on the socket to separate the valve keepers
from the retainer.
• Tap straight down on each valve stem head. Take
care not to bend the valve.
• Support the cylinder head with a suitable material to
prevent damage to the valve.
[1]
Compress the valve springs using the special tool as

shown.
TOOL:
Valve spring compressor [1] 07757-0010000 [1]
Remove the two valve keepers [2] from the groove in
the valve stem.
[2]
Remove the valve spring retainer [1], valve spring [2], [1]
valve [3], valve stem seal [4], and the valve spring seat
[5] from the cylinder head.
[2]
Check the valve for chipping and excessive carbon
deposits. Clean the valves if necessary
Check the cylinder head parts (page 14-32). [4]
[5]
[3]
14-24
dummyhead
CYLINDER HEAD
EXPLODED VIEW
ROCKER SHAFT BOLT (5)

29 N·m (3.0 kgf·m, 21 lbf·ft)
CAMSHAFT LOST MOTION

SPRING (4)
CAM PULSER PLATE
ROCKER SHAFT
ASSEMBLY
CAM PULSER PLATE

BOLT
34 N·m (3.5 kgf·m, 25 lbf·ft) DOWEL PIN (7 x 12 mm)
FUEL PUMP LIFTER
INTAKE VALVE
SPRING (8)
VALVE
KEEPER (32)
VALVE STEM SEAL A (8)
VALVE SPRING
RETAINER (16)
EXHAUST VALVE
SPRING (8)
VALVE STEM
SEAL B (8)
VALVE SPRING
INTAKE VALVE (8) SEAT (16)
EXHAUST VALVE (8)

14-25
dummyhead
CYLINDER HEAD
ASSEMBLY
Apply molybdenum disulfide oil to the valve stem sliding
surface, and insert the valve [1] into the valve guide.
Check that the valve moves up and down smoothly. [2]
• Do not confuse the intake valve and the exhaust
valve on assembly.
Install the valve spring seat [2].
[1]
Apply engine oil to the inner wall of a new valve stem

seal [1].
[3] [5]
• Note that valve stem seal A (intake side) [2] has the
white spring [3] and valve stem seal B (exhaust side)
[4] has the black spring [5].
Do not confuse them on assembly.
Set the valve stem seal in the special tool, and push it
straight into the valve guide by hand.
TOOL: [2] [4]
Stem seal driver [6] 07PAD-0010000
• Use the 5.5 mm side of special tool. [6]
[1] [6]
14-26
dummyhead
CYLINDER HEAD
Install the valve spring [1] and valve spring retainer [2].
• Do not confuse the intake valve spring and the PAINT
exhaust valve spring.
IDENTIFICATION:
The intake side can be identified by the blue paint on
the spring. [1]
The exhaust side can be identified by the white paint.
INSTALLATION DIRECTION:
Install the valve spring with the painted side toward the
valve spring retainer, and with the narrow pitch side [3] [2]
of the coil toward the valve spring seat [4].
[3]
[1]
[4]
Using the special tool, compress the valve spring and

set the two valve keepers [1] in the groove in the valve
stems securely.
• To facilitate installation of the valve keepers, apply a
small amount of grease to the valve keepers and [2]
push them in the groove in the valve stem.
TOOL:
Valve spring compressor [2] 07757-0010000
[1]

14-27
dummyhead
CYLINDER HEAD
Tap on the valve stem head [1] lightly with a plastic
hammer [2] two or three times, and set the valve stem [2]
and valve keepers in the proper position securely.
• Tap straight down on each valve stem head. Take
care not to bend the valve.
• Support the cylinder head with a suitable material to
prevent damage to the valve.
[1]
Install the fuel pump lifter [1] in the cylinder head

assembly.
[1]
Install the cam pulser plate [1] on the camshaft [2],

aligning the projection [3] on the cam pulser plate with [2]
the recess [4] in the camshaft.
Apply molybdenum disulfide oil to the camshaft journal, [1]
cam face and the thrust area.
Install the camshaft from the oil pump side of the [5]
cylinder head assembly.
Tighten the cam pulser plate bolt [5] to the specified
torque against the camshaft.
[3] [4]
[1]
14-28
dummyhead
CYLINDER HEAD
Apply engine oil to the four lost motion springs [1] and
install them in the cylinder head assembly. [5]
Set the dowel pin [2] in the cylinder head assembly and
install the rocker shaft assembly [3] on the cylinder [3]
head assembly.
[2]
• Before tightening the rocker shaft bolts, make sure
the thrust washers on the outside of each rocker arm
are installed properly. Failure to install the thrust
washers properly will result in engine damage. [4]
• After installing the rocker shaft assembly, remove

the straps [4] from the rocker arm assembly. [1]
Apply engine oil to the threads and seat of the five

rocker shaft bolts [5], and loosely tighten them on the
rocker shaft.
Tighten the five rocker shaft bolts [1] to the specified

torque in the numbered sequence shown in two or three [1]
steps.
5.
– HO2S (page 5-82) 3.
– CMP sensor (page 5-83)
– VTEC solenoid valve (page 5-82)
– Oil pump (page 12-7)
– Water jacket (page 11-5) 1.
Adjust the valve clearance (page 3-12).
2.
4.

14-29
dummyhead
CYLINDER HEAD
ROCKER ARMS/SHAFT DISASSEMBLY/ASSEMBLY
BF75D/80A
• Remove or install the rocker arm assembly from the cam chain side to disassemble or assemble the rocker
shaft assembly.
• Note the location of each part before disassembly. Do not confuse the parts. Install the parts in their original
positions.
• Check the camshaft contact surface of each rocker arm for wear or damage.
• Insert the rocker shaft bolt into the rocker shaft before removing or installing the rocker shaft with the
cylinder head assembly mounted on the outboard motor.
Apply molybdenum disulfide oil to the outer surface of the rocker shaft, thrust washers, and the intake wave
washers on assembly.
THRUST WASHER (12)
EXHAUST ROCKER ARM B (4)
INTAKE WAVE WASHER (4)
INTAKE ROCKER ARM (4)
EXHAUST ROCKER ARM A (4)
ROCKER SHAFT
14-30
dummyhead
CYLINDER HEAD
BF90D/100A
• Remove or install the rocker arm assembly from the cam chain side to disassemble or assemble the rocker
shaft assembly.
• Note the location of each part before disassembly. Do not confuse the parts. Install the parts in their original
positions.
• Check the camshaft contact surface of each rocker arm for wear or damage.
• Insert the rocker shaft bolt into the rocker shaft before removing or installing the rocker shaft with the
cylinder head assembly mounted on the outboard motor.
Apply molybdenum disulfide oil to the outer surface of the rocker shaft, thrust washers, and the intake wave
washers on assembly.
THRUST WASHER (16)
EXHAUST ROCKER ARM B (4)
INTAKE ROCKER ARM

ASSEMBLY (4)
EXHAUST ROCKER ARM A (4)
ROCKER SHAFT

14-31
dummyhead
CYLINDER HEAD
CYLINDER COMPRESSION TEST
Set the remote control lever in the "N" (neutral) position.
[1]
Remove the emergency stop switch clip.
Disconnect all the injector 2P connectors.
Disconnect the ignition coil 3P connector of each
cylinder, and remove the spark plugs (page 3-15).
Disconnect the remote control cable from the throttle
arm (page 19-8).
Install the compression gauge (commercially available:
EEPV303A) [1] in the No.1 plug hole.
Set the throttle arm in the full open position by pushing
the throttle arm [2] against the full throttle stopper by
hand as shown.
Turn the combination switch to the "START" position
and operate the starter motor to measure the cylinder [2]
compression.
CYLINDER COMPRESSION (Pressure check at 300
min-1 (rpm) with "N" (neutral) position):
1.45 – 1.65 MPa (14.8 – 16.8 kgf/cm2, 211 – 239 psi)
Check the compression on all cylinders.
CYLINDER HEAD INSPECTION

VALVE SPRING FREE LENGTH
Measure the free length of the valve springs.
STANDARD:
IN: 48.54 mm (1.911 in)
EX: 55.29 mm (2.177 in)
VALVE FACE/STEM O.D.

Inspect each valve face [1] for pitting or wear
irregularities.
Check each valve face for even seat.
Replace the valve if necessary.
Check each valve for bends, seizure, or damage.
Measure the valve stem O.D. at the sliding surface of
the valve guide.
STANDARD:
IN: 5.480 – 5.490 mm (0.2157 – 0.2161 in)
EX: 5.450 – 5.460 mm (0.2146 – 0.2150 in)
SERVICE LIMIT:
IN: 5.450 mm (0.2146 in) [1]
EX: 5.420 mm (0.2134 in)
replace the valve with a new one.
14-32
dummyhead
CYLINDER HEAD
VALVE LENGTH/VALVE O.D.
Measure the overall length and the O.D. of the valve.
Overall length
STANDARD:
IN: 118.55 – 119.15 mm (4.667 – 4.691 in)
EX: 117.25 – 117.85 mm (4.616 – 4.640 in)
Valve O.D.
STANDARD:
IN: 27.85 – 28.15 mm (1.096 – 1.108 in)
EX: 22.85 – 23.15 mm (0.900 – 0.911 in)
If the measurement is less than the standard, replace
the valve with a new one.
VALVE GUIDE I.D.
Using the valve guide reamer (special tool), ream the
valve guides to remove any carbon deposits before [1]
measuring.
• Turn the special tool clockwise, never turn it

counterclockwise. Continue to turn it clockwise as
you lift it from the valve guide.
TOOL:
Valve guide reamer, 5.5 mm [1] 07HAH-PJ7A100
Measure and record each valve guide I.D.
STANDARD:
IN/EX: 5.51 – 5.53 mm (0.217 – 0.218 in)
SERVICE LIMIT:
IN/EX: 5.55 mm (0.219 in)
the valve guide with a new one.
• Check the valve stem-to-valve guide clearance after
replacing the valve guide.
VALVE STEM-TO-VALVE GUIDE

CLEARANCE
Calculate the gap between the valve stem O.D. and the
valve guide I.D.
STANDARD:
IN: 0.020 – 0.050 mm (0.0008 – 0.0020 in)
EX: 0.050 – 0.080 mm (0.0020 – 0.0032 in)
SERVICE LIMIT:
IN: 0.080 mm (0.0032 in)
EX: 0.110 mm (0.0043 in)
If the stem-to-guide clearance exceeds the service limit,
replace the valve guide with a new one (page 14-40).
If the stem-to-guide clearance exceeds the service limit
with new guides, replace the valves as well.
• Recondition the valve seats whenever the valve
guides are replaced (page 14-41).

14-33
dummyhead
CYLINDER HEAD
VALVE SEAT WIDTH
Thoroughly clean the combustion chambers and valve
seats to remove carbon deposits. Apply a light coat of
Prussian Blue compound or erasable felt-tipped marker
ink to the valve faces.
Insert the valves, and then lift them and snap them
closed against their seats several times. Be sure the
valve does not rotate on the seat. The transferred
marking compound will show any area of the seat that
is not concentric.
Measure the valve seat width.
STANDARD:
IN: 0.85 – 1.15 mm (0.033 – 0.045 in)
EX: 1.25 – 1.55 mm (0.049 – 0.061 in)
SERVICE LIMIT:
IN: 1.60 mm (0.063 in)
EX: 2.00 mm (0.079 in)
If the valve seat width is too wide or narrow, or if the VALVE SEAT
valve seat is too high or low, recondition the valve seat TOO LOW
(page 14-41).
VALVE SEAT
TOO HIGH
VALVE SEAT INSTALLATION HEIGHT

Measure the valve seat installation height [1].
[1]
STANDARD:
IN: 46.0 – 46.6 mm (1.81 – 1.83 in)
EX: 46.1 – 46.7 mm (1.81 – 1.84 in)
SERVICE LIMIT:
IN: 46.9 mm (1.85 in)
EX: 47.0 mm (1.85 in)
the cylinder head with a new one (page 14-22).
ROCKER ARM SHAFT O.D.

Measure and record the rocker arm shaft O.D. at the
sliding part of each rocker arm.
STANDARD:
19.972 – 19.993 mm (0.7863 – 0.7871 in)
Replace the rocker arm shaft if its O.D. is smaller than
the standard (page 14-30).
14-34
dummyhead
CYLINDER HEAD
ROCKER ARM I.D.
Measure and record each rocker arm I.D.
STANDARD:
IN/EX: 20.012 – 20.030 mm (0.7879 – 0.7886 in)
Replace the rocker arm shaft if its O.D. is smaller than
the standard (page 14-30).
ROCKER ARM SHAFT-TO-ROCKER

ARM CLEARANCE
Subtract each rocker arm shaft O.D. from the
corresponding rocker arm I.D.
STANDARD:
0.019 – 0.058 mm (0.0007 – 0.0023 in)
SERVICE LIMIT:
0.080 mm (0.0032 in)
If the rocker arm shaft-to-rocker arm clearance exceeds
the service limit, replace the rocker arm and recheck.
If the rocker arm shaft-to-rocker arm clearance still
exceeds the service limit, replace the rocker arm shaft
(page 14-30).
VTEC ROCKER ARM TEST

(BF90D/BF100A only)
Disconnect the battery negative (–) cable.
Remove the cylinder head covers (page 14-15). [2]
Put the No.1 piston at top dead center of the
compression stroke (page 3-12).
Move the secondary rocker arm [1] of the No.1 cylinder
up and down with your finger. Check that the secondary
rocker arm moves independently from the primary
rocker arm [2].
• If it does not, remove and disassemble the rocker
arm assembly to check (page 14-30).
Put the piston of each cylinder at top dead center of its
compression stroke. Check that the secondary rocker
arm moves independently from the primary rocker arm.
[1]

14-35
dummyhead
CYLINDER HEAD
• Use the special tool under the following conditions:
– At cylinder head assembly
– If the engine power drops at high speed but the
cause cannot be determined.
Install the cylinder head cover (page 14-16).
Start the engine and let it warm up five minutes. [2]
Remove the cylinder head cover (page 14-15).

Remove the No.5 rocker shaft bolt, and install the air
stopper (special tool) as shown.
Remove the No.3 rocker shaft bolt, and install the
special tool as shown.
TOOLS:
Air pressure regulator [1] 07AAJ-PNAA101
VTEC air adapter [2] 07AAK-RMEA100
VTEC air stopper [3] 07AAK-RMEA200
• Check that the following conditions are met before
using the air supply (special tool). The following
conditions are essential for use of the air supply, as
the specified air pressure of 340 kPa (3.5 kgf/cm2,50
psi) must be maintained at the gauge of the tool.
Stop using the air tool if the specified pressure [1] [3]
cannot be maintained.
– Check whether the air compressor tank is under
the specified air pressure and the tank gauge
shows the value of the set pressure.
– Connect the air supply to the air intake port
located close to the compressor.
– Check as quickly as possible (within 6 seconds),
or the air pressure may drop, making it hard to
switch the valve timing to the high lift side.
• Check on each cylinder with the piston at top dead
center of its compression stroke.
• Oil can spurt out when air pressure is applied. Adjust
the air pressure with the regulator valve (special
tool) and increase the air pressure gradually.
Apply the specified air pressure to the special tool.
Air pressure: 340 kPa (3.5 kgf/cm2, 50 psi)
Check that the two intake rocker arms are
interconnected when applying the specified amount of [2]
air pressure. Move the secondary rocker arm [1] up and
down with finger, and check that the primary rocker arm
[2] moves up and down to.
If there is an abnormality in the rocker arm movement,
disassemble and check the rocker arms. Replace the
rocker arms as an assembly.
Remove the special tools, and tighten the rocker shaft
bolts to the specified torque.
After set the cylinder head cover, check that the MIL
does not come on.
[1]
14-36
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CYLINDER HEAD
VTEC ROCKER ARM INSPECTION
(BF90D/BF100A only)
Disassemble the rocker arm assembly parts:
[1]
– Primary rocker arm [1] [2]
– Rocker arm piston [2] [3]
– Piston stopper [3] [4]
[5]
– Return spring [4]
– Retainer [5]
– Secondary rocker arm [6]
• Remove the pistons from the primary rocker arm by
applying low air pressure to the rocker arm. Take
care not to apply excessive air pressure as the
pistons can jump out of the rocker arm.
Check that the rocker arm pistons move smoothly.
If the pistons do not move smoothly, replace the rocker [6]
arms as an assembly.
Apply the engine oil to the rocker arm piston and piston
stopper on assembly.
CAM HEIGHT
Clean the camshaft and check the cam surface for wear
and damage. IN
BF75D/BF80A:
Clean the cylinder head bearing surfaces and check the
bearing surfaces for wear and damage. CAM CHAIN
Measure the cam height. SIDE
BF75D/BF80A
STANDARD: EX
IN: 34.070 – 34.375 mm (1.3413 – 1.3533 in) IN: (PRIMARY) IN: (SECONDARY)
EX: 35.223 – 35.508 mm (1.3867 – 1.3979 in)
SERVICE LIMIT: BF90D/100A:
IN: 33.870 mm (1.3335 in) CAM CHAIN
EX: 35.023 mm (1.3789 in) SIDE
BF90D/BF100A
STANDARD: EX
IN/PRI: 35.422 – 35.707 mm (1.3946 – 1.4058 in)
IN/SEC: 34.710 – 34.995 mm (1.3665 – 1.3778 in)
EX: 35.223 – 35.508 mm (1.3867 – 1.3979 in)
SERVICE LIMIT:
IN/PRI: 35.222 mm (1.3867 in)
IN/SEC: 34.510 mm (1.3587 in)
EX: 35.023 mm (1.3789 in)
replace the camshaft with a new one.
CAMSHAFT JOURNAL O.D.
Clean the camshaft and check the journals for wear or
damage.
Measure the O.D. of each camshaft journal.
STANDARD:
41.935 – 41.950 mm (1.6510 – 1.6516 in)

14-37
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CYLINDER HEAD
CAMSHAFT JOURNAL I.D.
Measure the I.D. of each camshaft journal.
STANDARD:
41.995 – 42.019 mm (1.6533 – 1.6543 in)
CAMSHAFT OIL CLEARANCE

Calculate the difference between the camshaft journal
O.D. and the cylinder head journal I.D.
STANDARD:
0.045 – 0.084 mm (0.0018 – 0.0033 in)
SERVICE LIMIT:
0.100 mm (0.0039 in)
the camshaft with a new one and recheck.
If the measurement still exceeds the service limit after
replacing the camshaft, replace the cylinder head with a
new one (page 14-22).
CAMSHAFT AXIAL CLEARANCE

Check the camshaft axial clearance with the oil pump
mounted on the outboard motor.
Install the rocker shaft on the cylinder head and tighten
the rocker shaft bolts to the specified torque (page 14-
26).
Put the camshaft at the top dead center of the
compression stroke of the No.1 piston (with the dowel
pin on your side).
Install the dial indicator.
Check the camshaft axial play by moving the camshaft
up and down with a screwdriver.
STANDARD: [1]
0.05 – 0.25 mm (0.002 – 0.010 in)
SERVICE LIMIT:
0.50 mm (0.020 in)
the oil pump body with a new one and recheck.
replacing the oil pump body, replace the camshaft with
a new one.
14-38
dummyhead
CYLINDER HEAD
CAMSHAFT RUNOUT
Place V blocks or equivalent under the journal at both
ends of the camshaft.
Install the dial indicator on the camshaft, and measure
the camshaft runout by turning the camshaft.
STANDARD: 0.03 mm (0.001 in) max.
the camshaft with a new one.
CYLINDER HEAD WARPAGE

Remove the carbon deposits from the combustion
chamber.
Clean off any gasket material from the cylinder head
surface.
Check the spark plug holes and valve areas for cracks.
Check the cylinder head for warpage using a straight
edge [1] and a feeler gauge [2].
If the measurement exceeds the service limit,
recondition the cylinder head.
CYLINDER HEAD RECONDITIONING PROCEDURE:
Apply Prussian Blue compound to the level block to
identify the warpage, and using a fine oil stone, grind [1]
the cylinder head in a figure "8", with the warped part
being the center of the ground part.
Or use the lapping machine to recondition the cylinder
head.
[2]
CYLINDER HEAD HEIGHT

Measure the cylinder head height.
STANDARD:
119.9 – 120.1 mm (4.72 – 4.73 in)

14-39
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CYLINDER HEAD
VALVE GUIDE REPLACEMENT
Chill the replacement new valve guides in a freezer for
about an hour.
Use a hot plate or oven to heat the cylinder evenly to
150°C (302°F). Check the temperature with a
temperature indicating stick (available at a welding
supply store) or equivalent.
• Do not use a torch to heat the cylinder head;

warpage of the cylinder head may result.
• Do not get the head hotter than 150 °C (302 °F);
excessive heat may loosen the valve seats.
Remove the heated cylinder head from the hot plate,
and support it with wooden blocks. Wear heavy gloves
to protect your hands.
Drive the valve guide out from the combustion chamber
side using a special tool.
• Be careful not to damage the cylinder head mating
surface. [1]
TOOL:
Valve guide driver, 5.5 mm [1] 07742-0010100
Allow the cylinder head to cool to room temperature.
Clean and inspect the valve guide bores in the cylinder
head.
Use a hot plate or oven to heat the cylinder head evenly
to 150 °C (302 °F). Check the temperature with a
temperature indicating stick or equivalent.
Install new valve guides [1] from the valve spring side of
the cylinder head. [1]
Drive each valve guide to the specified height,
measured from the top of the valve guide to the cylinder
casting as shown. [3]
TOOL:
[2]
Valve guide driver, 5.5 mm [2] 07742-0010100
Valve guide installation height [3]:

IN/EX: 15.85 – 16.35 mm (0.624 – 0.644 in)
For best results, be sure the cylinder head is at room

temperature before reaming valve guides.
Coat the reamer and valve guide with cutting oil.
Rotate the reamer clockwise through the valve guide for [1]
the full length of the reamer.
Continue to rotate the reamer clockwise while removing
it from the valve guide.
• Turn the special tool (valve guide reamer, 5.5 mm)

clockwise, never turn it counterclockwise. Continue
to turn it clockwise as you lift it from the valve guide.
TOOL:
Valve guide reamer, 5.5 mm [1] 07HAH-PJ7A100
14-40
dummyhead
CYLINDER HEAD
Thoroughly clean the cylinder head to remove any
cutting residue.
Check the valve guide bore; it should be straight, round
and centered in the valve guide. insert the valve and
check operation. If the valve does not operate
smoothly, the guide may have been bent during
installation.
Replace the valve guide if it is bent or damaged.
Check the Valve Stem-to-Valve Guide Clearance (page
14-33).
CORRECT INCORRECT
VALVE SEAT RECONDITIONING

Thoroughly clean the combustion chambers and valve
seats to remove carbon deposits.
Apply a light coat of Prussian Blue compound or
erasable felt-tipped marker ink to the valve faces [1].
Insert the valves, and then lift them and snap them
closed against their seats several times.
Be sure the valve does not rotate on the seat.
The transferred marking compound will show any area
of the seat that is not concentric.
[1]
Using the 45° cutter, remove enough material to

produce a smooth and concentric seat. Follow the valve
seat cutter manufacturer’s instructions.
Turn the cutter clockwise, never counterclockwise.
Continue to turn the cutter as you lift it from the valve
seat.
TOOLS (commercially available)
Valve seat cutter, # 111 60° NWY-CU270
T-wrench, #505 NWY-TW-505
Accessory package, #246 NWY-KACC246

14-41
dummyhead
CYLINDER HEAD
Use the 30° – 32° and 60° cutters to narrow and adjust
the valve seat so that it contacts the middle of the valve OLD SEAT
CONTACT TOO HIGH
face. WIDTH
The 30° – 32° cutter removes material from the top

edge.
The 60° cutter removes material from the bottom edge. 32°
CONTACT TOO LOW
OLD SEAT
WIDTH
60°
Be sure that the width of the finished valve seat is within

specification.
STANDARD:
IN: 0.85 – 1.15 mm (0.033 – 0.045 in)
EX: 1.25 – 1.55 mm (0.049 – 0.061 in)
Make a light pass with the 45° cutter to remove any
possible burrs at the edges of the seat.
IN: 0.85 – 1.15 mm
After resurfacing the seats, inspect for even valve
(0.033 – 0.045 in)
seating.
Apply Prussian Blue compound or erasable felt-tipped EX: 1.25 – 1.55 mm
marker ink to the valve faces. Insert the valves, and (0.049 – 0.061 in)
then lift them and snap them closed against their seats
several times. Be sure the valve does not rotate on the
seat. The seating surface, as shown by the transferred
marking compound, should have good contact all the
way around.
Lap the valves into their seats, using a hand valve
lapper (LIL-21100; commercially available) [1] and
lapping compound.
• To avoid severe engine damage, be sure to remove

all lapping compound from the cylinder head before
assembly. [1]
Recheck the seat contact after lapping (page 14-34).

Check the valve installation height (page 14-34).
14-42
dummytext
15. CYLINDER BLOCK
COMPONENT LOCATION ····················· 15-2 CRANKSHAFT/PISTON/CYLINDER

BLOCK INSPECTION ·························· 15-18
CRANKCASE/CRANKSHAFT/CYLINDER
BLOCK/PISTON DISASSEMBLY/ BEARING SELECTION ························ 15-25
ASSEMBLY ········································ 15-3
15

15-1
dummyhead
CYLINDER BLOCK
COMPONENT LOCATION
CYLINDER BLOCK
10 N·m (1.0 kgf·m, 7 lbf·ft) + 90°
24 N·m (2.4 kgf·m, 18 lbf·ft) + 40°
49 N·m (5.0 kgf·m, 36 lbf·ft)
15-2
dummyhead
CYLINDER BLOCK
CRANKCASE/CRANKSHAFT/
CYLINDER BLOCK/PISTON
CYLINDER BLOCK DISASSEMBLY
Store the removed parts (e.g. bearings, connecting
rods, rod caps, bolts) securely, grouping them for each
cylinder.
Move the shift to the "N" (Neutral) position.
Remove the engine from the outboard motor (page 13-
3)
Remove the following parts.
– Oil filter cartridge (page 3-5)
– Fuel strainer (low pressure side) (page 3-25)
– Intake manifold/throttle body (page 5-69)
– Air vent strainer/air vent tube (page 5-86)
– Starter motor (page 9-5)
– Electronic parts case (page 10-3)
– Knock sensor (page 5-84)
– EOP sensor (page 5-84)
– ECT sensor 2(page 5-85)
– Flywheel (page 9-8)
Turn the alternator rotor clockwise until it sets the No.1
piston at top dead center of its compression stroke
(page 3-12).
Remove the two bolts [1] from the crankcase and
remove the oil filter extension [2] and O-ring [3]. [2]
[3]
[1]
Remove the two bolts [1] from the flywheel side of the
crankcase [1]

15-3
dummyhead
CYLINDER BLOCK
Remove the ten bolts [1] from the crankcase.
[1]
Loosen the ten bolt/washers [1] in the numbered order

shown in two or three steps. [1]
Remove the ten bolt/washers from the crankcase.
Insert a screwdriver into the recesses in the crankcase

and separate the crankcase a little at a time.
• Take care not to damage the crankcase and cylinder
block mating surfaces.
15-4
dummyhead
CYLINDER BLOCK
Remove the crankcase [1] and oil seal [2] from the
cylinder block [3].
[1]
[2]
[3]
Check the lower main bearings [1] for damage (scores,

scratches, etc.) before removing them. Replace the [1]
lower main bearings if necessary.
Remove the five lower main bearings from the
crankcase.
• Store the removed lower main bearings separately
for each main journal.
Check that the piston is at bottom dead center of its [1]

stroke. If not, move the piston to bottom dead center by
turning the crankshaft. [2]
Remove the connecting rod bolts [1] and the connecting
rod cap assembly [2].
[3]
Check the connecting rod bearing [3] for damage
(scores, scratches, etc.) before removing it. Replace
the connecting rod bearings if necessary.
Remove the connecting rod bearing from the
connecting rod cap.
• Store the connecting rod cap and connecting rod
bearing separately for each cylinder.

15-5
dummyhead
CYLINDER BLOCK
Remove the crankshaft [1] from the cylinder block, [1]
bearing careful not to damage the journals.
Remove the two thrust washers [2] from the cylinder
block. Check the thrust washers for damage (scores,
scratches, etc.), and replace if necessary.
[3]
Check the upper main bearings [3] for damage (scores,
scratches, etc.) before removing them. Replace the
upper main bearings if necessary.
Remove the five upper main bearings from the cylinder [2]
block.
• Store the removed upper main bearings separately
for each main journal.
Remove the piston assembly [1] from the cylinder by

pushing the piston assembly with the handle of a [2]
hammer [2] as shown. [1]
• Store the removed piston assembly components
separately for each cylinder.
• Before removing the piston assembly, remove the

carbon deposits from the cylinder. Be careful not to
damage the piston.
• Do not damage the cylinder with the connecting rod.
Remove the ten dowel pins [1] from the cylinder block.
[1]
• Check the dowel pins for damage or deformity and
replace if necessary.
15-6
dummyhead
CYLINDER BLOCK
PISTON DISASSEMBLY
Before removing the connecting rod bearing, check it
for damage (scores, scratches, etc.) and replace if [1] [2]
necessary.
Remove the connecting rod bearing and the piston
rings from the piston assembly.
Check the piston rings for damage and replace if
necessary.
• Store the removed connecting rod bearings and the
piston rings separately for each piston.
• Do not expand the piston ring excessively as it can
break easily.
• Do not damage the piston with the piston ring.
Replace the piston pin pilot [1], insert adjuster [2], and
the pilot collar 18 [3] of the piston pin tool set (special [4]
tool) [4] with the corresponding tools listed below. [2]
TOOLS:
Piston pin tool set 07PAF-0010000
Piston pin pilot 070AF-PWC0110
Insert adjuster 070AF-PWC0120
Pilot collar 18 070AF-PWC0130
[1]
[3]
Set the spring [1] and the piston pin pilot (special tool)
[2] on the piston base [3] as shown. [1] [7]
Install the piston base head attachment [4] on the piston
[4]
base head [5] and loosely tighten the screws [6].
Install the piston base head on the piston base and
tighten the screws [7].
TOOLS:
Piston pin pilot 070AF-PWC0110
[5]
[6]
[3] [2]

15-7
dummyhead
CYLINDER BLOCK
Install the insert adjuster (special tool) [1] on the insert
pin [2].
Adjust dimension A to 45 mm (1.8 in) by turning the
insert adjuster. DIMENSION A
45 mm (1.8 in)
TOOLS:
[1]
[2]
Set the pilot collar 18 (special tool) [1] on the piston

base assembly [2]. [1] [3]
While maintaining the clearance between the pilot collar
18 and the piston base head attachment [3] at 1 mm,
tighten the screws [4] to secure the piston base head
attachment.
After tightening the screws, remove the pilot collar 18
from the piston pin tool set.
TOOLS:
1 mm 1 mm
[4] [4]
[2]
Set the piston assembly [1] on the piston base

assembly [2] with the model marks [3] facing up as
INSERT PIN
shown.
• Check that the piston base head attachment (special
tool) is set securely on the outer side from the piston
pin hole. [4] [1]
Apply engine oil to the outer surface of pilot collar 18
(special tool) [4].
Set pilot collar 18 on the insert adjuster (special tool) [5]
[2]
and drive the piston pin [6] out of the connecting rod
using a hydraulic press.
TOOLS:
[3] INSERT PIN
Pilot collar 18 070AF-PWC0130 [1]
[5]
[6]
[2] [4]
15-8
dummyhead
CYLINDER BLOCK
EXPLODED VIEW
TOP RING
PISTON RING
SECOND RING
SIDE RAIL (TOP SIDE)
OIL RING
PISTON
SIDE RAIL
PISTON PIN
(SKIRT SIDE)
CONNECTING
ROD
CONNECTING ROD BEARING (2)
CONNECTING
ROD CAP
CONNECTING ROD BOLT (2)

10 N·m (1.0 kgf·m, 7 lbf·ft) + 90°

15-9
dummyhead
CYLINDER BLOCK
PISTON ASSEMBLY
• Use the same special tools as those used during
disassembly (page 15-7). DIMENSION A
45 mm (1.8 in)
Install the insert adjuster (special tool) [1] on the insert
pin [2].
Adjust dimension A of the insert adjuster to 45 mm (1.8
in) by turning the insert adjuster.
TOOLS:
Insert adjuster 070AF-PWC0120 [1]
[2]
Set the pilot collar 18 (special tool) [1] on the piston

base assembly [2] as shown.
[1]
TOOLS:
[2]
Set the piston [1] and the connecting rod [2] on the
special tool with the model marks [3] facing up. INSERT PIN
• Check that concave [4] in the connecting rod and

"IN" mark [5] on the piston head are in the same
direction. [6]
[1]
Apply molybdenum disulfide oil to the outer surface of
the piston pin [6].
Insert the piston pin into the pin hole in the piston and
set the special tool. [5]
• Check that the piston base head attachment is set

on the outer side from the piston pin hole securely [2]
Drive the piston pin into the connecting rod using a
hydraulic press. [3]
[5]
• Drive in the piston pin pilot (special tool) until it
comes in contact with the piston base [7] (oil pres-
sure of the hydraulic press rises slightly). [4]
TOOLS:
Insert adjuster [8] 070AF-PWC0120
Pilot collar 18 [9] 070AF-PWC0130
[1] INSERT PIN
[2] [8]
[9]
[6]
[7]
15-10
dummyhead
CYLINDER BLOCK
Install the top ring [1] and the second ring [2] in the ring
grooves in the piston with the maker marks facing up. [1]
Install the oil ring [3] in the ring groove, aligning the
retaining tab [4] of the side rail (top side) [5] with the
positioning groove [6] in the ring groove. [2]
• Clean the ring grooves thoroughly before installing
the piston rings. [5]
• Install the piston rings with care not to break them.
Take care not to score or scratch the piston.
• Do not confuse the top ring and the second ring. The
top ring is glossy while the second ring has a dark [3]
color.
• Check that the retaining tab of the side rail (top side)
is in the positioning groove of the ring groove
securely.
SIDE RAIL
SPACER (SKIRT SIDE)
To install the oil rings, install the spacer first, and then
install the side rails.
[6] [4]
[5]
After installing the piston rings, turn each ring by hand

TOP RING
to check for smooth movement (except the side rail (top
side)).
SECOND RING
Stagger the piston ring end gaps as shown.
• Do not align with the piston pin, and avoid the SIDE RAIL
direction that makes a right angle with the piston pin. (TOP SIDE)
SPACER
SIDE RAIL
(SKIRT SIDE)
APPROX. 10°
APPROX. 15°
SPACER RING
END GAP
SIDE RAIL APPROX. 15°
END GAP
(TOP SIDE)
[FIXED SIDE RAIL
POSITION] END GAP
(SKIRT SIDE)
APPROX. 120°
APPROX. 120°
PISTON PIN
SECOND RING END GAP

TOP RING END GAP

15-11
dummyhead
CYLINDER BLOCK
CRANK CASE/CRANK SHAFT EXPLODED VIEW
CONNECTING ROD BOLT (8)

BOLT/WASHER (10 x 105 mm) (10) BOLT
10 N·m (1.0 kgf·m, 7 lbf·ft) + 90°
(6 x 32 mm) (12)
24 N·m (2.4 kgf·m, 18 lbf·ft) + 40°
CONNECTING ROD CAP (4)
CONNECTING ROD
BEARING (8)
BOLT LOWER MAIN BEARING (5)

(6 x 25 mm) (2)
O-RING
CRANK CASE
CRANKSHAFT
THRUST WASHER (2)

O-RING
UPPER MAIN BEARING (5)
DOWEL PIN (10)
BOLT (8 x 20 mm) (4)
OIL SEAL
(80 x 98 x 10 mm)
CYLINDER BLOCK
OIL FILTER HOLDER ENGINE HANGER (2)

49 N·m (5.0 kgf·m, 36 lbf·ft)
PISTON (4)
15-12
dummyhead
CYLINDER BLOCK
CYLINDER BLOCK ASSEMBLY
Set the dowel pin [1] in the cylinder block by lightly
tapping on the dowel pin with a plastic hammer as
shown.
• Tap lightly at right angles to the cylinder block. Take [1]
care not to deform the dowel pin.
Drive the dowel pin [1] into the cylinder block using the
special tools and the hydraulic press as shown.
• Support the cylinder block with a suitable material to [2]
prevent damage to the gasket matting surface of the
cylinder block.
TOOLS:
Driver [2] 07749-0010000 [3]
Pilot, 10 mm [3] 07746-0040100
[1]
Apply molybdenum disulfide oil to the outer side of the

piston and to the inner wall of the cylinder sleeve. [3]
[1]
Push the piston into the cylinder block gently using the
handle of a hammer.
Install with the "IN" mark [1] on the piston head toward
the intake valve and the " " mark [2] toward the cam
chain.
Install the connecting rod bearing on the connecting
rod, aligning the projection [3] on connecting rod
bearing with the concave [4] in the connecting rod.
[4]
[2]

15-13
dummyhead
CYLINDER BLOCK
Install the upper main bearings [1] on the cylinder block, [2]
aligning the projection [2] on each upper main bearing [1]
with the concave [3] in the cylinder block.
Apply molybdenum disulfide oil to the crankshaft main
journal, crank pin and the thrust washer mating surface.
Put the No.2 and No.3 pistons at bottom dead center of
their stroke.
Install the crankshaft on the cylinder block while
aligning it with the No.2 and No.3 connecting rods.
[3]
[1]
Install the connecting rod bearing [1] and the

connecting rod cap [2], aligning the projection [3] on the [3]
connecting rod bearing with the recess [4] in the
connecting rod cap.
[1]
[4]
[2]
Apply engine oil to the threads and seat of the

connecting rod bolts [1]. [2]
Install the connecting rod cap assembly [2] on the
connecting rod [3], and tighten the two connecting rod [1]
bolts to the specified torque.
After tightening to the specified torque, tighten the bolts
an additional 90°.
• Install the connecting rod cap assembly, aligning the
code number [4] with the number on the connecting
rod. [4]
• Check that the piston is at the bottom dead center of
its stroke before tightening the bolts. If not, turn the
crankshaft to bring the piston at the bottom dead
center.
[3]
15-14
dummyhead
CYLINDER BLOCK
Install the thrust washers [1] on the cylinder block No.4
journal. [1]
• Install the thrust washers with the grooved side [2]
toward the crankshaft.
[2]
Install the lower main bearing [1] on the crank case,

[2]
aligning the projection [2] on the lower main bearing
with the concave [3] in the crankcase.
[1]
[3]
Clean the cylinder block/crankcase mating surfaces

using the degreasing cleaning solvent.
Apply a bead (2.0 – 3.0 mm (0.8 – 0.12 in) thick) of
liquid gasket (ThreeBond® #1280B or equivalent) to the
indicated area of the crankcase.
• Assemble the cylinder block/crankcase within 5
minutes after applying the liquid gasket.
If it has been left for 5 minutes or longer, remove the
old gasket and apply the liquid gasket again.
• Do not pour engine oil into the crankcase for at least
30 minutes after assembly.
Install the crankcase [1] on the cylinder block [2].

[1]
[2]

15-15
dummyhead
CYLINDER BLOCK
washers [1]. [1]
Loosely tighten the ten bolt/washers on the crankcase,

and tighten them to the specified torque in two or three 9. 10.
steps in the numbered sequence shown.
After tightening to the specified torque, tighten the bolt/
washers additionally by 40° in the numbered sequence
shown. 5. 6.

1. 2.
4. 3.
8. 7.
Loosely tighten the twelve bolts [1] on the crankcase,

and tighten them securely in the numbered order [1]
9. 10.
5.
6.
1.
2.
4.
3.
8.
7.
11. 12.
Install a new O-ring [1] and the oil filler extension [2] on
the crankcase, and tighten the two bolts [3] securely. [2]
[1]
[3]
15-16
dummyhead
CYLINDER BLOCK
Apply soapy water to the outer surface of a oil seal [1].
Using the special tools as shown, install the oil seal on
the cylinder block assembly as shown.
Drive in the oil seal so its upper side is 1.0 to 2.0 mm
(0.04 to 0.08 in) deep from the surface.
TOOLS:
Driver [2] 07749-0010000 [2]
Oil seal drier [3] 07ZAD-PNAA100
Apply grease to the lip of the oil seal.
• Install the oil seal with the lip in the direction shown.
Install the following parts.
– Flywheel (page 9-9)
– ECT sensor 2(page 5-85)
– EOP sensor (page 5-84) [3]
– Knock sensor (page 5-84)
– Electronic parts case (page 10-3)
– Starter motor (page 9-6) [1]
– Air vent strainer/air vent tube (page 5-86)
– Intake manifold/throttle body (page 5-71)
– Fuel strainer (low pressure side) (page 3-25)
– Oil filter cartridge (page 3-5) 1.0 - 2.0 mm
(0.04 - 0.08 in)
Install the engine on the outboard motor (page 13-8).

15-17
dummyhead
CYLINDER BLOCK
CRANKSHAFT/PISTON/CYLINDER
BLOCK INSPECTION
PISTON SKIRT O.D.
Check the piston outer surface for damage (scores,
scratches, etc.). [1]
Check the piston for warpage and cracks.
Measure and record the piston O.D. [1] at 13 mm (0.5
in) [2] from the bottom and perpendicular to the piston [2]
pin bore.
STANDARD:
72.98 – 72.99 mm (2.873 – 2.874 in)
SERVICE LIMIT:
72.97 mm (2.873 in)
If the measurement is less than the service limit, 90°
replace the piston with a new one.
CYLINDER SLEEVE I.D.

Check the inner wall of the cylinder for damage (scores,
scratches, etc.).
Measure and record the cylinder I.D. at three levels in
both X and Y axes.
Take the maximum reading to determine the cylinder
I.D.
STANDARD:
73.00 – 73.02 mm (2.874 – 2.875 in)
SERVICE LIMIT:
73.07 mm (2.877 in)
the cylinder block with a new one.
DIFFERENCE BETWEEN TOP AND

BOTTOM POINTS OF SLEEVE I.D. TOP
Determine the difference of the cylinder sleeve I.D.
between the top and the bottom measurements. X
SERVICE LIMIT:
0.05 mm (0.002 in) Y

PISTON-TO-CYLINDER CLEARANCE
Determine the difference between the piston skirt O.D.
and the cylinder sleeve I.D. MIDDLE
STANDARD:
0.01 – 0.04 mm (0.0004 – 0.0016 in) BOTTOM
SERVICE LIMIT:
0.05 mm (0.002 in)
15-18
dummyhead
CYLINDER BLOCK
PISTON RING THICKNESS
Check the piston ring for damage (scores, scratches,
etc.).
Measure the piston ring thickness.
STANDARD:
TOP 0.970 – 0.985 mm
(0.0382 – 0.0388 in)
SECOND 1.175 – 1.190 mm
(0.0463 – 0.0469 in)
The oil rings are the combination rings.
Replace the side rails and the spacer as a set when
either the top or second ring needs replacement.
PISTON RING GROOVE WIDTH

Check the piston ring grooves for uneven wear,
damage or restricted oil hole.
Measure the piston ring groove width.
[1]
STANDARD:
TOP [1] 1.050 – 1.060 mm
(0.0413 – 0.0417 in) [2]
SECOND [2] 1.220 – 1.230 mm
(0.0480 – 0.0484 in)
OIL [3] 2.005 – 2.020 mm
(0.0789 – 0.0795 in) [3]
PISTON RING SIDE CLEARANCE

Set the piston ring on the piston properly so it is almost
flush with the piston outer surface.
Measure the piston ring side clearance.
STANDARD:
TOP 0.065 – 0.090 mm
(0.0026 – 0.0035 in)
SECOND 0.030 – 0.055 mm
(0.0012 – 0.0022 in)
SERVICE LIMIT:
TOP 0.150 mm (0.0059 in)
SECOND 0.130 mm (0.0051 in)
the piston ring with a new one and recheck.
replacing the piston ring, replace the piston with a new
one.

15-19
dummyhead
CYLINDER BLOCK
PISTON RING END GAP
Use the piston to push the piston ring [1] into the
cylinder sleeve and position it horizontally at 15 to 20
mm (0.6 to 0.8 in) from the bottom of the cylinder.
Measure the piston end gap [2]. [1]
STANDARD:
TOP 0.15 – 0.30 mm
(0.006 – 0.012 in)
SECOND 0.35 – 0.50 mm
(0.014 – 0.020 in)
OIL 0.20 – 0.70 mm
(0.008 – 0.028 in) 15 - 20 mm
SERVICE LIMIT: (0.6 - 0.8 in)
TOP 0.60 mm (0.024 in)
SECOND 0.65 mm (0.026 in) [2]
OIL 0.80 mm (0.031 in)
If the end gap is larger than the service limit, check the
cylinder sleeve I.D. (page 15-18).
If the cylinder sleeve I.D. is smaller than the service
limit, replace the piston ring with a new one.
PISTON PIN-TO-PIN BORE
CLEARANCE
Check the outer surface of the piston pin for damage
(scores, scratches, etc.).
Measure the piston pin O.D. at three levels.
Take the minimum reading to determine the piston pin TOP
O.D.
MIDDLE
STANDARD:
17.996 – 18.000 mm (0.7085 – 0.7087 in) BOTTOM
Measure the I.D. of each of the two piston pin bores.

Take the maximum measurement to determine the
piston pin bore I.D.
STANDARD:
18.010 – 18.014 mm (0.7091 – 0.7092 in)
Calculate the gap between the piston pin O.D. and the
piston pin bore I.D.
STANDARD:
0.010 – 0.018 mm (0.0004 – 0.0007 in)
SERVICE LIMIT:
0.020 mm (0.0008 in)
the piston pin with a new one and recheck.
replacing the piston pin, replace the piston with a new
one.
15-20
dummyhead
CYLINDER BLOCK
CONNECTING ROD SMALL END-TO-
PISTON PIN CLEARANCE
Measure the connecting rod small end I.D.
STANDARD:
17.964 – 17.977 mm (0.7072 – 0.7078 in)
Calculate the gap between the piston pin O.D. and the
connecting rod small end I.D.
STANDARD:
0.019 – 0.036 mm (0.0007 – 0.0014 in)
CONNECTING ROD BIG END AXIAL

CLEARANCE
Measure the axial clearance at each connecting rod big
end.
STANDARD:
0.15 – 0.35 mm (0.006 – 0.014 in)
SERVICE LIMIT:
0.40 mm (0.016 in)
the connecting rod and the connecting rod cap with the
new ones as a set, and recheck.
replacing the connecting rod and the connecting rod
cap, replace the crankshaft with a new one.
THRUST WASHER SIDE CLEARANCE

Measure the clearance between the No.4 main journal
thrust washer and the crankshaft.
STANDARD:
0.10 – 0.35 mm (0.004 – 0.014 in)
SERVICE LIMIT:
0.45 mm (0.018 in)
If the measurement exceeds the service limit, check the
thrust washer and the cylinder block thrust surface.
Replace the thrust washer with a new one if necessary
and recheck.
replacing the thrust washer, replace the crankshaft with
a new one.
CRANKSHAFT MAIN JOURNAL O.D.
Measure the crankshaft main journal [1] O.D.
STANDARD: [1]
49.976 – 50.000 mm (1.9676 – 1.9685 in)

15-21
dummyhead
CYLINDER BLOCK
CRANK PIN JOURNAL O.D.
Measure the crank pin journal [1] O.D.
[1]
STANDARD:
39.976 – 40.000 mm (1.5739 – 1.5748 in)
CRANKSHAFT JOURNAL (MAIN, PIN)

ROUNDNESS
Measure the crankshaft main journal O.D. and the
crank pin O.D. in the A and B directions. Measure the roundness at the
Calculate the difference between the measurements to center of the journal.
determine the roundness.
STANDARD:
0.005 mm (0.0002 in) max.
SERVICE LIMIT:
0.010 mm (0.0004 in)
the crankshaft with a new one.
CRANKSHAFT JOURNAL (MAIN, PIN) Measure the cylindricity at both ends
CYLINDRICITY of the journal.
Measure the crankshaft main journal O.D. and the

crank pin O.D. at the C and D locations.
Calculate the difference between the measurements to B
determine the cylindricity.
STANDARD: ROUNDNESS: A
0.005 mm (0.0002 in) max.
SERVICE LIMIT:
0.010 mm (0.0004 in) C D

CYLINDRICITY:
CONNECTING ROD BOLT O.D.

Measure the O.D. of each connecting rod bolt at two
points as shown. 30 mm (1.2 in)
Calculate the difference between the two
measurements.
STANDARD:
0 – 0.05 mm (0 – 0.002 in)
SERVICE LIMIT: 15 mm (0.6 in)
0.05 mm (0.002 in)
the connecting rod bolt with a new one.
• Measure the O.D. on each connecting rod bolt.
15-22
dummyhead
CYLINDER BLOCK
CRANKSHAFT RUNOUT
Install the No.1 upper main bearing [1] and the No.5
[4]
upper main bearing [2] on the cylinder block [3].
Install the crankshaft [4] on the cylinder block.
Set the dial indicator [5] on the crankshaft as shown.
Measure the crankshaft runout by turning the
crankshaft. [2] [1]
STANDARD:
0.03 mm (0.001 in) max.
SERVICE LIMIT:
0.04 mm (0.002 in)
[3]
[5]
CRANKSHAFT MAIN BEARING OIL

CLEARANCE
Clean the crankshaft main journals and main bearings,
and check the journals and the bearings for wear or [1]
damage.
Install the five upper main bearings and crankshaft on
the cylinder block, and install the five lower main
bearings on the crankcase.
Install the crankcase on the cylinder block, and tighten
the bolts to the specified torque (page 15-13).
Remove the crankcase, and set the plastigauge [1] on
each main journal of the crankshaft as shown.
• Set the plastigauge in the axial direction
• Avoid the oil passage in the bearing journal to set
the plastigauge.
Reinstall the crankcase on the cylinder block and
tighten the bolts to the specified torque (page 15-13).
• Do not turn the crankshaft during this check.

15-23
dummyhead
CYLINDER BLOCK
Remove the crankcase.
Measure the compressed width of the plastigauge [1]
using the scale [2] printed on the bag of the [1]
plastigauge.
• Take the widest width on the plastigauge.
STANDARD:
0.018 – 0.036 mm (0.0007 – 0.0014 in)
SERVICE LIMIT:
0.050 mm (0.0020 in)
the main bearing with an undersize bearing by referring
to the crankshaft main bearing selection table (page 15-
[2]
25). Recheck the oil clearance.
replacing the main bearing, replace the crankshaft with
a new one.
CONNECTING ROD BEARING OIL

CLEARANCE
Clean the crank pin and the bearing of the connecting
rod cap assembly.
Check the crank pin and the bearing for wear and [1]
damage.
Install the crankshaft on the cylinder block.
Install the connecting rod cap assembly on the
connecting rod, and tighten the connecting rod bolts to
the specified torque (page 15-10).
Remove the connecting rod cap assembly, and set a
plastigauge [1] on the crank pin as shown
• Set the plastigauge in the axial direction.
• Avoid the oil passage in the bearing journal to set
the plastigauge.
Reinstall the connecting rod cap assembly on the [2]
connecting rod, and tighten the connecting rod bolts to [1]
the specified torque (page 15-13).
• Tighten the connecting rod bolts with care not to turn
the crankshaft and/or the connecting rod.
Remove the connecting rod cap assembly.
Measure the compressed width of the plastigauge [1]
using the scale [2] printed on the bag of the
plastigauge.
• Measure the widest width on the plastigauge.
STANDARD:
0.020 – 0.038 mm (0.0008 – 0.0015 in)
SERVICE LIMIT:
0.050 mm (0.0020 in)
with an undersize bearing by referring to the connecting
rod bearing selection table (page 15-27).
Recheck the connecting rod bearing oil clearance.
replacing the connecting rod bearing, replace the
crankshaft with a new one.
15-24
dummyhead
CYLINDER BLOCK
CYLINDER BLOCK WARPAGE
Take care not to damage (scores, scratches, etc.) the
mating surface with the cylinder head gasket.
Measure the surface warpage using a straight edge and
a feeler gauge as shown
STANDARD:
0.07 mm (0.003 in) max.
SERVICE LIMIT:
0.10 mm (0.004 in)
BEARING SELECTION
CRANKSHAFT MAIN BEARING
When replacing the main bearing, check the crankshaft
main journal code number and the cylinder block I.D.
code letter, and select the correct bearing by referring
to the bearing selection table.
• If the code letter and/or number is not clear, clean
the area with a cleaning solvent and check again.
Do not scrub with a stiff wire brush or screwdriver to
clean.
Check each crankshaft main journal code number [1] in No.1 No.2 No.3 No.4 No.5
the position shown, and record them. (No.1 journal and subsequent numbers
• The main journals are the No.1 and the subsequent viewed from the alternator side)
number journals when viewed from the alternator
rotor side.
• The crankshaft main journal code numbers are for
the No.1 and the subsequent number journals when
viewed from the right side.
Crankshaft main journal O.D.: 50 mm (2.0 in)
Code
Tolerance
number
4 –0.024 – –0.018 mm (–0.0009 – –0.0007 in)
3 –0.018 – –0.012 mm (–0.0007 – –0.0005 in) No.5 MAIN No.1 MAIN
2 –0.012 – –0.006 mm (–0.0005 – –0.0002 in) JOURNAL JOURNAL
1 –0.006 – ±0.000 mm (–0.0002 – ±0.0000 in)
[1]

15-25
dummyhead
CYLINDER BLOCK
Check each cylinder block I.D. code letter [1] in the
position shown, and record it.
• The cylinder block I.D. code letters are for the No.1 [1]
and the subsequent number journals when viewed
from the left side.
Cylinder block I.D.: 54 mm (2.1 in)
Code
Tolerance
letter
A –0.004 – +0.002 mm (–0.0002 – +0.0001 in)
B +0.002 – +0.008 mm (+0.0001 – +0.0003 in)
C +0.008 – +0.014 mm (+0.0003 – +0.0006 in)
D +0.014 – +0.020 mm (+0.0006 – +0.0008 in) No.1 MAIN No.5 MAIN
JOURNAL JOURNAL
Select the correct bearing by referring to the crankshaft

main journal code number and the cylinder block I.D.
code letter.
Crankshaft main bearing selection table:
Crankshaft Cylinder block I.D. code letter
main journal A B C D
code number Bearing identification color
1 White Red Pink Yellow
2 Red Pink Yellow Green
3 Pink Yellow Green Brown
4 Yellow Green Brown Black
Selection table:
Code
I.D. color Tolerance
letter
–0.004 – –0.001 mm
H White
(–0.0002 – –0.00004 in)
–0.001 – +0.002 mm
G Red
(–0.00004 – +0.0001 in)
+0.002 – +0.005 mm
F Pink
(+0.0001 – +0.0002 in)
+0.005 – +0.008 mm
E Yellow
(+0.0002 – +0.0003 in)
+0.008 – +0.011 mm
D Green
(+0.0003 – +0.0004 in)
+0.011 – +0.014 mm
C Brown
(+0.0004 – +0.0006 in)
+0.014 – +0.017 mm
B Black
(+0.0006 – +0.0007 in)
Main bearing center thickness: 2.0 mm (0.08 in)
The main bearings are available in the seven I.D. colors
(Black, Brown, Green, Yellow, Pink, Red and White in [2]
this order) [1] at intervals of 0.003 mm (0.0001 in) in
tolerance.
Select the bearings so that the oil clearance is 0.018 –
0.036 mm (0.0007 – 0.0014 in).
Align the projection [2] on the bearing with the cutout in
the cylinder block and in the crankcase.
Install the bearing with care not to damage the sliding
surface.
Check the crankshaft main bearing oil clearance after
installing the selected bearing (page 15-23).
[1]
15-26
dummyhead
CYLINDER BLOCK
CONNECTING ROD BEARING
When replacing the connecting rod bearing, check the
crank pin code letter and the connecting rod code
number, and select the correct bearing by referring to
the bearing selection table.
• If the code letter and/or number is not clear, clean
the area with a cleaning solvent and check again.
Do not scrub with a stiff brush or screwdriver to
clean.
Check each crank pin code letter [1] in the position
shown and record them.
• The crank pins are the No.1 and the subsequent
number crank pins when viewed from the alternator No.1 No.3 No.4
No.2
rotor side.
• The crank pin code letters are for the No.1 and the (No.1 journal and subsequent numbers
subsequent number journals when viewed from the viewed from the alternator side)
right side.
Crank pin O.D.: 40 mm (1.6 in)
Code
Tolerance
letter
D –0.024 – –0.018 mm (–0.0009 – –0.0007 in)
C –0.018 – –0.012 mm (–0.0007 – –0.0005 in)
B –0.012 – –0.006 mm (–0.0005 – –0.0002 in)
A –0.006 – ±0.000 mm (–0.0002 – ±0.0000 in)
[1]
No.4 No.1
Check each connecting rod code number [1] in the

position shown and record them.
• The connecting rod code numbers are for the No.1
and the subsequent number journals when viewed
from the alternator rotor side.
Connecting rod big end I.D.: 43 mm (1.7 in)
Code
Tolerance
number
1 ±0.000 – +0.006 mm (±0.0000 – +0.0002 in)
2 +0.006 – +0.012 mm (+0.0002 – +0.0005 in)
3 +0.012 – +0.018 mm (+0.0005 – +0.0007 in)
4 +0.018 – +0.024 mm (+0.0007 – +0.0009 in)
[1]

15-27
dummyhead
CYLINDER BLOCK
Select the correct bearing by referring to the crank pin
code letter and the connecting rod code number.
Connecting rod bearing selection table:
Connecting rod code number
Crank pin
1 2 3 4
code letter
Bearing identification color
A Red Pink Yellow Green
B Pink Yellow Green Brown
C Yellow Green Brown Black
D Green Brown Black Blue
Selection table:
Code
I.D. color Tolerance
letter
–0.005 – –0.002 mm
G Red
(–0.0002 – –0.0001 in)
–0.002 – +0.001 mm
F Pink
(–0.0001 – +0.00004 in)
+0.001 – +0.004 mm
E Yellow
(+0.00004 – +0.0002 in)
+0.004 – +0.007 mm
D Green
(+0.0002 – +0.0003 in)
+0.007 – +0.010 mm
C Brown
(+0.0003 – +0.0004 in)
+0.010 – +0.013 mm
B Black
(+0.0004 – +0.0005 in)
+0.013 – +0.016 mm
A Blue
(+0.0005 – +0.0006 in)
Connecting rod bearing center thickness: 1.5 mm (0.06
in)
The connecting rod bearings are available in the seven

I.D. colors (Blue, Black, Brown, Green, Yellow, Pink [2]
and Red in this order) [1] at intervals of 0.003 mm
(0.0001 in) in tolerance.
Select the bearings so that the oil clearance is 0.020 –
0.038 mm (0.0008 – 0.0015 in).
Align the projection [2] on the bearing with the cutout in
the connecting rod and in the connecting rod cap.
Install the bearing with care not to damage the sliding
surface.
Check the connecting rod bearing oil clearance after
installing the selected bearing (page 15-24).
[1]
15-28
dummytext
16. GEAR CASE
COMPONENT LOCATION ····················· 16-2 VERTICAL SHAFT/FORWARD BEVEL

GEAR REMOVAL/INSTALLATION ········ 16-25
PROPELLER REMOVAL/
INSTALLATION ··································· 16-3 PROPELLER SHAFT HOLDER
DISASSEMBLY/ASSEMBLY················· 16-30
ANODE METAL/WATER SCREEN
REMOVAL/INSTALLATION ··················· 16-4 VERTICAL SHAFT DISASSEMBLY/
ASSEMBLY ······································· 16-33
GEAR CASE/EXTENSION SEPARATOR
(XRT TYPE ONLY) REMOVAL/ SHIM SELECTION ······························ 16-36
INSTALLATION ··································· 16-5
BACKLASH INSPECTION···················· 16-41
EXTENSION CASE/LOWER RUBBER
REMOVAL/INSTALLATION ··················· 16-9 GEAR CASE PRESSURE
INSPECTION ····································· 16-42
SHIFT ROD REMOVAL/ 16
INSTALLATION ··································16-14 PROPELLER SHAFT INSPECTION ······· 16-44
PROPELLER SHAFT HOLDER VERTICAL SHAFT INSPECTION··········· 16-45

CLUTCH SHIFTER INSPECTION··········· 16-45
SHIFT SLIDER/PROPELLER SHAFT
GEAR CASE NEEDLE BEARING
REPLACEMENT ································· 16-46

16-1
dummyhead
GEAR CASE
COMPONENT LOCATION
GEAR CASE
34 N·m (3.5 kgf·m, 25 lbf·ft)
12 N·m (1.2 kgf·m, 9 lbf·ft)

83 N·m (8.5 kgf·m, 61 lbf·ft)
34 N·m (3.5 kgf·m, 25 lbf·ft)
1 N·m (0.10 kgf·m, 0.7 lbf·ft)

MAX. TORQUE:
44.1 N·m (4.5 kgf·m, 33 lbf·ft)
16-2
dummyhead
GEAR CASE
PROPELLER REMOVAL/INSTALLATION
3-BLADE PROPELLER
(Optional part)
SPLIT PIN (4.0 mm)

INSTALLATION:
Be sure to use a Honda Genuine
part (stainless steel).
Bend the pin ends as shown to
secure the nut.
SPLIT PIN (4.0 mm)
(Spline and threads)
PROPELLER THRUST WASHER

INSTALLATION:
Install the thrust washer in the direction as
shown.
GEAR CASE PROPELLER

SIDE SIDE
WASHER (18.5 mm)
PROPELLER CASTLE NUT (18 mm)

TORQUE:
1 N·m (0.10 kgf·m, 0.7 lbf·ft)
Tighten the castle nut to the specified
torque. If the split pin cannot be set,
tighten the nut additionally until the split
pin can be set.
MAX. TORQUE:
44.1 N·m (4.5 kgf·m, 33 lbf·ft)

16-3
dummyhead
GEAR CASE
ANODE METAL/WATER SCREEN REMOVAL/INSTALLATION
GEAR OIL CHECK BOLT
6.5 N·m (0.66 kgf·m, 4.8 lbf·ft)
ANODE METAL (2)

GEAR CASE GROMMET
BOLT (6 x 35 mm) O-RING
BOLT (8 x 25 mm)
WASHER (8 mm) R. WATER

SCREEN
SCREW (5 x 55 mm)
1.0 N·m (0.10 kgf·m, 0.7 lbf·ft)
L. WATER SCREEN
SELF-LOCKING
NUT (6 mm)
O-RING
SELF-LOCKING NUT (6 mm)

TRIM TAB
GEAR OIL DRAIN PLUG BOLT
Installation: 6.5 N·m (0.66 kgf·m, 4.8 lbf·ft)
Align the " " marks.
" " marks
16-4
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GEAR CASE
GEAR CASE/EXTENSION SEPARATOR (XRT TYPE ONLY)
REMOVAL
Move the shift to the "N" (Neutral) position.
Tilt up the outboard motor to the uppermost position.
Pull the tilt stopper down to secure the outboard motor.
Remove the socket bolt [1], gear case cover B [2], and
distance collar [3].
[3]
[2]
[1]
Remove the four bolt/washers [1], bolt [2], washer

[3] and gear case [4] (LRT/LHT/LHG type).
Remove the five self-locking nuts, five washers, and
gear case (XRT type). [5]
Remove the two dowel pins [5].

[4]
[1]
[3]
[2]
Remove shift rod A [1] from the shift shaft [2].

[2]
Pull the tilt stopper up and tilt the outboard motor down
to the lowest position.
[1]

16-5
dummyhead
GEAR CASE
EXPLODED VIEW
CIRCLIP (40 mm)

STUD BOLT (Spline)
(10 x 202 mm)
WASHER (26 mm)
SHIFT ROD A
VERTICAL
SHAFT BUSHING
DOWEL PIN (2)
STUD BOLT
(10 x 164 mm) (4)
(Shift rod spline)
DOWEL PIN (2)
(Water tube seal ring

inner surface)
XRT type only

GEAR CASE
EXTENSION SEPARATOR
XRT type only DISTANCE COLLAR

(6.5 x 9 x 3 mm)
34 N·m (3.5 kgf·m, 25 lbf·ft)
BOLT/WASHER (10 x 40 mm) (4) GEAR CASE

COVER B SOCKET BOLT
34 N·m (3.5 kgf·m, 25 lbf·ft) BOLT (10 x 80 mm)
(6 x 16 mm)
12 N·m (1.2 kgf·m, 34 N·m (3.5 kgf·m, 25 lbf·ft)
9 lbf·ft)
16-6
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GEAR CASE
INSTALLATION
Move the shift to the “N” (Neutral) position.
Check that the shift rod [1] in the gear case is in the “N”
(Neutral) position.
• Check whether the cutout [2] of the shift rod spline [1]
faces in the direction shown. [It indicates that the [2]
shift rod is in the “N” (Neutral) position.]
CRUISING
DIRECTION
If the cutout [1] of the shift rod spline is not in the

direction shown, protect the spline with a shop towel or
equivalent material [2] and turn the shift rod right and [1]
left with a wrench until the cutout faces in the direction
shown.
[2]
Tilt up the outboard motor to the uppermost position.

Pull the tilt stopper down to secure the outboard motor.
Apply marine grease to the spline [1] of shift rod A [2].
Securely install shift rod A by aligning the cutout [3] on the spline of shift rod A with the projection [4] on the shift
shaft. Check that the cutout on the spline of shift rod A faces in the forward cruising direction [5].
[3]
[5]
[4] [1]
[2]

16-7
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GEAR CASE
Apply marine grease to the vertical shaft spline [1] and
shift rod spline [2].
Apply marine grease to the water tube insertion part [3] [7]
[3]
and water tube seal ring inner surface [4].
Install the vertical shaft bushing with the groove toward
the extension separator.
Apply marine grease to the inner surface to the vertical [1]
shaft bushing (page 16-6). [5]
Install the two dowel pins [5] on the gear case.
While aligning the water tube with the water tube seal
ring of the impeller housing, install the gear case [6] on
[4]
the outboard motor by aligning the vertical shaft with the [2]
boss on the flywheel and aligning the shift rod spline
with the shift rod A spline [7].
Loosely tighten the for bolt/washers [8], bolt [9], and
washer [10] (LRT/LHT/LHG type only). [6]
Loosely tighten the five self-locking nuts and five
washers (XRT type only).
Lower the outboard motor to the lowest position. [10]
Tighten the bolts to the specified torque (LRT/LHT/LHG
type only).
Tighten the self-locking nuts to the specified torque
(XRT type only). [8]
[9]
Install the distance collar [1] and gear case cover B [2],
and tighten the socket bolt [3] to the specified torque.
[1]
[2]
[3]
After installing the gear case, check that the tip [1] of
the neutral switch is set in the detent assisted spring [2]
securely and the detent spring roller [3] is set in the [4]
groove [4] in the shift arm.
If the detent spring roller is not in the groove in the shift
arm, loosen the bolt [5] and move the detent spring right
or left to set the detent spring roller in the groove [1]
securely.
Tighten the bolt.
Adjust the shift control cable (page 3-32).
[5] [3]
[2]
16-8
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GEAR CASE
EXTENSION CASE/LOWER RUBBER
– Engine cover
– Gear case/Extension case (XRT type only)(page 16-
5) [4]
Tilt up the outboard motor and hold it in position by [2]
hooking the engine hanger chain on each of the two
engine hangers.
Remove the three bolt/washers [1] and lower mount
housing [2].
Remove the bolt [3] and lead wire [4].
[1] [3]
Remove the nut [1] while holding the bolt [2] with a
wrench, and then remove the bolt and washer [3].
Remove the lower mount stopper [4], lower rubber [3]
mount [5], and lower mount collar [6].
[1]
[2]
[6]
[5] [4]
Remove the eight bolts [1], and remove the extension

case [2].
• Remove the extension case, being careful not to
drop it.
[4]
Remove the two dowel pins [3].
Remove the under cover rubber [4], extension case
grommet [5], and lid clip [6]. [3]
[5]
Remove the screw [7] and lead wire [8].
[2]
[6]
[8]
[7]
[1]

16-9
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GEAR CASE
Remove the bolt [1], water tube plate [2], water tube [3],
and the water tube grommet [4].
[4]
[2]
[3]
[1]
EXPLODED VIEW
WATER TUBE (Inner surface)

BOLT (12 x 186 mm) (2) WATER TUBE GROMMET
PLATE
UNDER COVER RUBBER
LID CLIP (7 mm)
DOWEL PIN
(6 x 10 mm) (2)
LOWER MOUNT
COLLAR (2)
WASHER (12 mm) (2)
BOLT (6 x 12 mm) NUT (12 mm) (2)

83 N·m (8.5 kgf·m, 61 lbf·ft)
LOWER RUBBER
(Tip area) MOUNT (2)
WATER TUBE
LEAD WIRE
BOLT (10 x 40 mm) (8)
(Inner surface) BOLT (6 x 12 mm) SCREW (6 x 8 mm)
EXTENSION CASE
GROMMET LOWER MOUNT
HOUSING (2)
BOLT/WASHER
(8 x 30 mm) (6)
16-10
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GEAR CASE
INSTALLATION
Tilt up the outboard motor and hold it in position by
hooking the engine hanger chain on each of the two
engine hangers.
Apply marine grease to the inner surface of the water
tube grommet [1], and install it on the water tube [2].
Connect the water tube to the oil case, noting the
installation direction as shown.
Set the water tube plate [3] and tighten the bolt [4].
[1]
[3]
[2]
[4]
Install the under cover rubber [1] to the extension case

[2].
[3] [2]
• Install the under cover rubber under the projection
[3] on the extension case.
Apply marine grease to the inner surface of the
extension case grommet [4] and install it to the
extension case.
Install the two dowel pins [5].
Install the lid clip [6] on the extension case, and check
that the clip seat is in contact with the extension case.
[1]
[4]
[5]
[6]

16-11
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GEAR CASE
While pushing the lead wire [1] against the projection [2]
on the lower mount center housing as shown, tighten
the screw [3].
[2]
[3]
[1]
[2]
[3]
[1]
Clean the extension case /oil case mating surfaces [1]

thoroughly using a shop towel and degreasing cleaning
solvent.
Apply sealant (ThreeBond® #5222L or equivalent) to the
entire sealing surface on the oil case side of the
extension case.
10 – 15 mm
(0.4 – 0.6 in)
(ThreeBond® #5222L
or equivalent)
Application area
[1]
16-12
dummyhead
GEAR CASE
Apply marine grease to the water tube end [1].
Install the extension case [2] on the outboard motor,
aligning the water tube with the extension case
grommet [3].
Tighten the eight bolts [4].
[1]
[3]
[2]
[4]
Install the lower mount collar [1], lower rubber mount

[2], and the lower mount stopper [3] on the extension
[6] [4]
case [4].
Note the installation direction of the lower mount collar.
Install the washer [5] and bolt [6].
Tighten the nut [7] to the specified torque while holding
the bolt with a wrench.
[5]
[1]
[2]
[3]
[7]
[1]
LOWER MOUNT LOWER RUBBER

CENTER HOUSING MOUNT SIDE:
SIDE:

16-13
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GEAR CASE
Attach the lead wire [1] to the extension case [2], and
tighten the bolt [3].
Install the lower mount housing [4] on the extension
case, and tighten the three bolt/washers [5]. [2]
Remove the engine hangar chain from the engine
hangers, and lower the outboard motor to the
lowermost position.
– Gear/case/extension separator (XRT type only)
(page 16-7)
– L./R. engine under cover(page 6-7)
– Engine cover
[1]
[5] [4] [3]
SHIFT ROD REMOVAL/INSTALLATION

REMOVAL
[2]
– Water pump (page 11-6)
Wrap a shop towel [1] around the shift rod spline, and
use pliers to turn the shift rod [2] in the direction shown
(toward the reverse side).
[1]
Remove the bolt [1], washer [2], and shift rod holder [3].
Remove the shift rod [4]. [3]
[4]
[1]
[2]
16-14
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GEAR CASE
Remove the shift rod spring [1], washer [2], and E-ring
[3]. [2] [1]
[3]
Remove the two water seals [1].

[1]
Remove the O-ring [2].
[2]
EXPLODED VIEW
SHIFT ROD HOLDER

WATER SEAL
(12 x 21 x 6 mm) (2)
O-RING
WASHER (12 mm)
E-RING (10 mm)
SHIFT ROD SPRING
SHIFT ROD
BOLT (6 x 12 mm)
WASHER (6 mm)

16-15
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GEAR CASE
INSTALLATION
Apply soapy water to the outer circumference of new
water seals [1].
Drive the water seals one by one into the shift rod
holder [2] using the special tool. Note the installation
direction of the water seals. [1]
TOOL:
Installer/remover, 07ZPF-ZW90300
14.5 x 18.5 mm [3]
After installing the water seals, apply marine grease to
the water seal lips.
[3]
[2]
[1]
Install the E-ring [1], washer [2], and the shift rod spring
[3] on the shift rod [4]. [2]
[1] [3]
[4]
16-16
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GEAR CASE
Insert the shift rod [1] into the gear case, aligning the
cam of the shift rod with the "A" point [2] of the gear [1]
case as shown.
Install the shift rod on the shift slider [3], aligning the
cam of the shift rod with the grooves in the shift slider.
[2]
[1]
[3]
Apply marine grease to the circumference of a new O-

ring [1], and install it on the shift rod holder [2]. [2]
[1]
Install the shift rod holder [1] in the gear case, aligning
the projection [2] of the shift rod holder with the recess [4]
[3] in the gear case. [1]
Install the bolt [4] and washer [5] and tighten the bolt.
After installation, check that the cutout in the shift rod
spline is in the cruising direction (page 16-7).
[2] [5]
[3]

16-17
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GEAR CASE
PROPELLER SHAFT HOLDER
– Water pump (page 11-6) [2]
– Shift rod (page 16-14)
Remove the two bolt/washers.
Insert the screwdriver or equivalent tool into the recess
[1] in the propeller shaft holder [2], and remove the
propeller shaft holder from the gear case.
Installation is in the reverse order of removal. Note the
following:
• Check that the shift slider of the propeller shaft
holder is set on the reverse side (page 16-24).
• After installation, check the gear case pressure [1]
inspection (page 16-42).
O-RING
PROPELLER SHAFT
HOLDER
GEAR CASE
BOLT
(O-ring and gear
(10 x 40 mm) (2)
case insertion part.)
16-18
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GEAR CASE
SHIFT SLIDER/PROPELLER SHAFT
REMOVAL
Remove the shift shaft holder (page 16-18).
[1]
Remove the propeller shaft [1], two ball bearings [2],
and O-ring [3] from the propeller shaft holder [4].
Remove the two water seals [5] from the propeller shaft [2]
holder.
[3]
[5] [4]
Remove the cross pin ring [1] and shifter pin [2], and
then remove the clutch shifter [3]. [1]
[2]
[3]
Remove the shift slider [1] and the two steel balls (#7)
[2] from the propeller shaft [3]. Take care not to let the [2]
steel balls pop out of the shift slider.
[1]
[3]

16-19
dummyhead
GEAR CASE
Remove the circlip [1] from the shift slider [2].
[2]
[1]
Remove the roller [1] from the shift slider [2] using a
commercially available pin driver [3]. [3]
• Take care not to let the shift springs and the steel
balls pop out of the shift slider during removal of the
roller. [1]
[2]
Remove the shift plate [1] from the shift slider [2], and
then remove the two shift springs [3] and the two steel [1]
balls (#11) [4].
• Take care not to let the shift springs and the steel [4]
balls pop out of the shift slider during removal of the
shift plate.
[2]
[3]
16-20
dummyhead
GEAR CASE
EXPLODED VIEW
SHIFT SPRING (2)

STEEL BALL (#11) (2)
STEEL BALL (#7) (2)

SHIFT PLATE
CROSS PIN RING ROLLER
SHIFT SLIDER
SHIFTER PIN PROPELLER SHAFT
CLUTCH SHIFTER
CIRCLIP
BALL BEARING (2)
O-RING (94 x 4.1 mm)
PROPELLER
SHAFT HOLDER
WATER SEAL (30 x 45 x 7 mm) (2)

16-21
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GEAR CASE
INSTALLATION
Set a wood block [1] under the reverse bevel gear [2].
Apply soapy water to the outer circumference of new <Water seal installation direction>
water seals [3].
Drive the water seals one by one into the propeller shaft [3]
holder using the special tool. Note the installation
direction of the water seals.
TOOL:
Oil seal driver [4] 07947-SB04100
After installing the water seals, apply marine grease to
the water seal lips. [4]
[1]
[2]
Install a shift spring [1], two steel balls (#11) [2], the
other shift spring, and the shift plate [3] in this order in [3]
the shift slider [4].
[2]
Install the roller [5] by aligning the hole in the shift slider [5]
with the hole in the shift plate, and then install the circlip
[6].
[4]
• Do not align the end gap of the circlip with the hole
of the shift slider.
[1]
[6]
Set the two steel balls (#7) [1] in the steel ball
installation holes in the shift slider [2], and push the shift
slider slowly into the propeller shaft [3]. [2]
• Push the shift slider into the propeller shaft with care
not to allow the steel balls to pop out.
[3]
[1]
16-22
dummyhead
GEAR CASE
With the "F" mark [1] on the clutch shifter toward the
forward bevel gear (i.e. toward front), assemble the
clutch shifter with the propeller shaft while aligning the
shifter pin installation hole [2] with the long slot [3] in the Reverse bevel
propeller shaft. gear side:
Forward bevel
gear side:
[1]
[2]
Forward bevel [3]

gear side:
Install the shifter pin [1] while aligning the hole [2] in the
clutch shifter with the hole [3] in the shifter slider. [1]
[2]
[3]
Install the cross pin ring [1] on the clutch shifter [2].
[1]
• Check that the coils of the cross pin ring do not
overlap each other.
[2]

16-23
dummyhead
GEAR CASE
Push the shift slider [1] into the propeller shaft [2]
slowly, and set the steel balls (#7) [3] in the positions [2] [1]
shown.
• Note that the shift rod cannot be installed unless the
shift slider is on the reverse side. Set the shift slider
on the reverse side securely.
[3]
Apply marine grease to outer circumference of a new

O-ring [1], and install it on the propeller shaft holder [2]. [4]
Apply gear oil to the ball bearings [3], and install them
on the propeller shaft [4].
[3]
Install the propeller shaft, taking care not to let the ball
bearings fall out of position.
– Propeller shaft holder (page 16-18)
[1]
[2]
16-24
dummyhead
GEAR CASE
VERTICAL SHAFT/FORWARD BEVEL
GEAR REMOVAL/INSTALLATION
REMOVAL
[2]
[1]
[4]
Attach the special tool to the vertical shaft end
(Flywheel installation side) [1].
TOOL:
Vertical shaft holder [2] 07SPB-ZW10200
Place a shop towel or equivalent [3] to protect the gear
case. [4]
Holding the vertical shaft with the special tool, remove
the pinion gear nut [5] from the vertical shaft.
[5]
[3]
Remove the lock nut using the special tool as shown.

TOOL: [1]
Lock nut wrench, 30/64 mm [1] 07916-MB00002
Remove the vertical shaft [1] and pinion gear [2].

[1]
Remove the forward bevel gear/taper bearing [3].
[2]
[3]

16-25
dummyhead
GEAR CASE
Set a commercially available universal bearing puller [1]
between the taper bearing (inner race) and forward
bevel gear. [2]
Drive the taper bearing (inner race) out of the forward [3]
bevel gear using the special tools and a hydraulic press
as shown.
TOOLS:
Driver [2] 07749-0010000
Attachment, 42 x 47 mm [3] 07746-0010300
Pilot, 25 mm [4] 07746-0040600
[1]
[4]
Remove the taper bearing (outer race) [1] using the

Replace the taper bearing (outer race) and the inner
race with new ones as a set on assembly. [2] [1]
[3]
TOOLS:
Bearing race puller [2] 07LPC-ZV30101
Remover handle [3] 07936-3710100
Remover weight [4] 07936-371020A
Remove the forward bevel gear shim [5] from the gear
case.
Replace the shim with a new one on assembly.
[4] [5]
16-26
dummyhead
GEAR CASE
EXPLODED VIEW
(Threads and
LOCK NUT (64 mm) seating surface)
123 N·m (12.5 kgf·m, 91 lbf·ft)
VERTICAL SHAFT
TAPER ROLLER
BEARING
(30 x 62 x 40 mm)
OIL SLINGER
FORWARD BEVEL GEAR
GEAR CASE
TAPER BEARING
(50 x 82 x 21.5 mm)
FORWARD BEVEL GEAR SHIM
(Threads and
PINION GEAR PINION GEAR NUT seating surface)
103 N·m (10.5 kgf·m, 76 lbf·ft)

16-27
dummyhead
GEAR CASE
INSTALLATION
Install a new shim [1] on the gear case [2].
• When the gear case, forward bevel gear, or the
taper bearing have been replaced with new ones, [5] [7]
perform shim adjustment and select the appropriate
shim accordingly (page 16-40).
Apply gear oil to a new taper bearing (outer race) [3].
Install the taper bearing (outer race) on the gear case
using the special tools as shown.
• Replace the taper bearing (outer race) and the inner
race with new ones as a set on reassembly.
• Install the taper bearing (outer race) with the smaller
I.D. side toward the shim.
TOOLS:
[2]
Driver handle, 15 x 280 mm [4] 07949-3710001
[6]
Attachment, 52 x 55 mm [5] 07746-0010400
Mandrel [6] 07SPD-ZW0010Z [4]
Pilot, 25 mm [7] 07746-0040600 [3] [1]
Apply gear oil to the inner surface and the rollers of a

new taper bearing (inner race) [1].
Set a wood block [2] under the forward bevel gear [3].
Drive the taper bearing (inner race) into the forward [4]
bevel gear using the special tools and a hydraulic
press.
TOOLS: [5]
Driver [4] 07749-0010000 [1]
Attachment, 52 x 55 mm [5] 07NAD-P200100
[3]
[2]
Install the forward bevel gear/taper bearing [1] in the

gear case.
[2]
Wipe the tapered part of the vertical shaft [2] and pinion
gear [3] with a shop towel and degreasing cleaning
solvent.
Install the pinion gear and vertical shaft.
• Before installing the pinion gear, make sure that the [3]
forward bevel gear/taper bearing is positioned in the
gear case correctly.
[1]
16-28
dummyhead
GEAR CASE
Apply gear oil to the threads and seating surface of the
lock nut [1].
[3]
Tighten the lock nut to the specified torque using the [2]
TOOL:
Lock nut wrench, 30/64 mm [2] 07916-MB00002
• Make sure the torque wrench [3] stays perpendicular

[4] to the special tool. If the torque wrench is not held
90 degrees to the tool, the torque reading will be
incorrect.
[1]
[2]
[3]
[4]
Attach the special tool to the end of the vertical shaft [1]
as shown. [1]
[2]
TOOL:
Vertical shaft holder [2] 07SPB-ZW10200
Place a shop towel [3] in the gear case [4] as shown to
protect it.
Apply gear oil to the threads and seating surface of the
pinion gear nut [5].
Holding the pinion gear nut as shown, turn the vertical
shaft and tighten the pinion gear nut to the specified
torque.
[4]
[5]
[3]

16-29
dummyhead
GEAR CASE
PROPELLER SHAFT HOLDER
DISASSEMBLY
Remove the needle bearing [1] from the propeller shaft
holder [2] using the special tool as shown.
TOOLS: [4]
Bearing remover, 30 mm [3] 07936-8890300
Remover handle [4] 07936-3710100 [5]
Remover weight [5] 07936-371020A
[2]
[3]
[1]
Remove the reverse bevel gear/bearing [1] from the

propeller shaft holder [2] using the special tools and a
hydraulic press as shown.
[3]
TOOLS:
Driver [3] 07749-0010000
[2]
Attachment, 24 x 26 mm [4] 07746-0010700
Pilot, 17 mm [5] 07746-0040400 Hydraulic
Bearing remover [6] 07936-8890300 press table
[4]
[5]
[1]
[6]
16-30
dummyhead
GEAR CASE
Attach a commercially available universal bearing puller
[1] between the reverse bevel gear and the reverse
bearing.
Remove the ball bearing from the reverse bevel gear
using the special tools and hydraulic press as shown.
TOOLS: [1] [2]
Driver [2] 07749-0010000
Attachment, 37 x 40 mm [3] 07746-0010200
Pilot, 30 mm [4] 07746-0040700
[3]
[4]
EXPLODED VIEW
BALL BEARING (6208)
NEEDLE BEARING
(30 x 37 x 26 mm)
REVERSE BEVEL GEAR
PROPELLER SHAFT
HOLDER

16-31
dummyhead
GEAR CASE
ASSEMBLY
Apply gear oil to the circumference of a new ball
bearing [1].
Drive the ball bearing into the reverse bevel gear using
the special tool and a hydraulic press as shown. [4]
TOOL:
Driver, 40 mm I.D. [4] 07746-0030100
[3] [1]
[2]
Soak the propeller shaft holder [1] in a container filled

with oil with the reverse bevel gear/bearing installation Thermometer [1]
side down.
Heat the oil up to 80 – 90 °C (176 – 194 °F).
Do not heat the oil above 90 °C (194 °F)

After the entire propeller shaft holder becomes hot,
remove the holder from the container and install the
reverse bevel gear/bearing quickly [2] on the propeller
shaft holder.
• The entire propeller shaft holder becomes hot. Wear
groves during the operation.
Heat the oil up to 80 – 90 °C (176 – 194 °F)
[2]
[1]
16-32
dummyhead
GEAR CASE
Apply gear oil to the circumference of a new needle
bearing [3].
Drive the needle bearing into the propeller shaft holder
[4] using the special tools and a hydraulic press as [5]
shown.
• Install the needle bearing with the stamped side [4]
toward the special tools. [6]
TOOLS: [7]
Driver [5] 07749-0010000
Attachment, 37 x 40 mm [6] 07746-0010200
Pilot, 30 mm [7] 07746-0040700
[3]
[2]
[1]
VERTICAL SHAFT DISASSEMBLY/

ASSEMBLY
DISASSEMBLY
Remove the oil slinger [1] from the vertical shaft [2] by
expanding the cut in the oil slinger with a screwdriver
[3].
[3]
[1]
[2]

16-33
dummyhead
GEAR CASE
Check the taper roller bearing for abnormal sound and
play. Replace the inner race and outer race as a set if
necessary.
Set a commercially available universal bearing puller [1]
on the taper roller bearing (inner race) [2], and install
the vertical shaft [3] on the hydraulic press with the
flywheel boss installation side facing up.
Remove the taper roller bearing from the vertical shaft
using a hydraulic press. [3]
Remove the pinion gear shim [4] from the vertical shaft.
[1] [2]
[4]
EXPLODED VIEW
TAPER ROLLER BEARING

(30 x 62 x 40 mm)
VERTICAL SHAFT (Inner race) (2)

(30 x 62 x 40 mm)
(Outer race)
OIL SLINGER
PINION GEAR SHIM
16-34
dummyhead
GEAR CASE
ASSEMBLY
Set the pinion gear [1] on the vertical shaft [2], and
loosely tighten the pinion gear nut [3] by hand.
Apply gear oil to the inner wall of new taper roller
bearing inner races [4], roller and the circumference of [2]
[5]
new outer race [5].
Assemble the inner races and the outer race.
Install new pinion gear shim [6] and taper roller bearing
on the vertical shaft. [4]
• When the gear case, vertical shaft, pinion gear, or
taper roller bearing is replaced with a new one,
perform the shim adjustment and select the
appropriate shim accordingly (page 16-37).
• Set the taper roller bearing with the side on which [1]
the "D" dimension was measured during shim
adjustment toward the pinion gear. [6]
[3]
Set the special tool on the vertical shaft [1].

TOOL:
Disassembly tool, B [2] 07964-MB00200 [6]
Set the vertical shaft on the hydraulic press with the
pinion gear [3] side facing up as shown. [3]
[1]
• Check that the ends of the special tool [4] are set on
the taper roller bearing inner race and on the
hydraulic press table [5] securely.
• Do not damage the threads at the end of the vertical
shaft (pinion gear nut installation part [6]).
After installation, turn the outer race ten to twenty turns
and check that the bearing turns smoothly.
Remove the pinion gear nut and pinion gear from the
vertical shaft. [2]
[4]
[5]
Install the oil slinger [1] on the vertical shaft [2] by

aligning the projection [3] on the inside of the oil slinger [2]
[4]
with the recess [4] on the pinion gear installation side of
the vertical shaft.
[3]
[1]

16-35
dummyhead
GEAR CASE
SHIM SELECTION
• Use shims to adjust the position of each gear so that
they engage properly. Perform shim adjustment if
the backlash of a gear is outside the specification or
after replacing the gear case, vertical shaft, propeller
shaft, or bearing with a new one.
SHIM LOCATION

(30 x 62 x 40 mm)
(Inner race) GEAR CASE

(30 x 62 x 40 mm)
(Outer race)
COLLAR
D
Sp (SHIM THICKNESS)
PINION GEAR SHIM

C
VERTICAL SHAFT
PINION GEAR
FORWARD BEVEL
E Sf (SHIM THICKNESS) GEAR SHIM
FORWARD BEVEL
GEAR
TAPER BEARING (50 x 82 x 21.5 mm)

(Inner race)
TAPER BEARING (50 x 82 x 21.5 mm)

(Outer race)
16-36
dummyhead
GEAR CASE
PINION GEAR SHIM
Remove the taper roller bearing (30 x 62 x 40 mm) if it
is mounted on the vertical shaft [1] (page 16-33). [3]
Clean the tapered surface [2] of the vertical shaft and [1]
the tapered surface of the pinion gear [3] thoroughly
using a shop towel and degreasing cleaning agent.
Install the pinion gear on the vertical shaft.
Tighten the pinion gear nut [4] to the specified torque
using the special tool (vertical shaft holder) (page 16-
29). [4]
TOOL:
Vertical shaft holder 07SPB-ZW10200
[2]
Use a vernier caliper [1] to measure distance (C) [2]

from the end of the pinion gear to the end of the collar of Distance C:
the vertical shaft as shown. Record this measurement.
[2]
[1]
If you have a gauge adapter special tool, place the disc

that is included with that tool on a flat surface. Distance D’:
Make sure the side marked with the tool number is on
the bottom so the smooth side is up. [4]
If you do not have a gauge adapter special tool, use any [3]
flat, hard surface for this procedure.
TOOL:
Gauge adapter, 100 mm [1] 070PJ-ZY30100
Place one new pinion gear inner race [2] on the smooth
side of the gauge adapter special tool (or flat, hard
surface).
Press a new outer race [3] down over the inner race
and turn it several times to seat the rollers.
[1] [2]
There are differences in the way bearings fit together.
Keep the inner race you are measuring in the same
relationship to the outer race you are measuring. Install
the assembled bearing with the race you measure next
to the pinion gear.
Measure the height of the assembled outer race/inner
race (Distance D’) [4] and record it.

16-37
dummyhead
GEAR CASE
Lift the outer race [1], remove the inner race, and
Distance D’’:
replace the outer race on the gauge adapter special tool
[2].
[1] [3]
Measure the height of the outer race (Distance D’’) [3]
and record it.
[2]
Calculate the length from the inner race end to the outer
race end (D) by determining the gap between the
measurements D’ and D’’ using the following formula.
Formula: D= D’ - D’’
Example:
When measurement (D’) from the outer race end to the
inner race end is 34.90 mm (1.374 in), and outer race
height (D’’) is 29.58 mm (1.165 in):
E= 34.90 - 29.58 = 5.32
The gap (D) from the inner race end to the outer race
end is 5.32 mm (0.209 in).
Determine the tolerance and record it using the
measurement (C), calculation (D) and the following
formula.
Formula: Tolerance = C + D - 147.45
Example:
When measurement (C) from the pinion gear end to the
end of the vertical shaft collar is 141.95 mm (5.589 in),
and calculation (D) from the inner race end to the outer
race end is 5.32 mm (0.209 in):
141.95 + 5.32 - 147.45 = -0.18
The tolerance is -0.18 mm (-0.007 in).
[2]
Cross reference the engagement mark [1] located on
the trim tab installation part of the gear case [2] and the
tolerance calculated in the previous step, and refer to
the pinion gear shim selection table to determine the
required thickness of the shim (Sp).
[1]
16-38
dummyhead
GEAR CASE
Pinion gear shim selection table
Unit: mm
Calculation value
-0.31 -0.25 -0.20 -0.15 -0.10 -0.05 0
– – – – – – –
-0.25 -0.20 -0.15 -0.10 -0.05 0 +0.05
F 1.00 0.95 0.90 0.85 0.80 0.75 0.70
E 0.95 0.90 0.85 0.80 0.75 0.70 0.65
engagement
Gear case D 0.90 0.85 0.80 0.75 0.70 0.65 0.60
C 0.85 0.80 0.75 0.70 0.65 0.60 0.55
B 0.80 0.75 0.70 0.65 0.60 0.55 0.50
A 0.75 0.70 0.65 0.60 0.55 0.50 0.45
Unit: mm
Calculation value
+0.05 +0.10 +0.15 +0.20 +0.25 +0.30 +0.35
– – – – – – –
+0.10 +0.15 +0.20 +0.25 +0.30 +0.35 +0.41
F 0.65 0.60 0.55 0.50 0.45 0.40 0.35
E 0.60 0.55 0.50 0.45 0.40 0.35 0.30
engagement
D 0.55 0.50 0.45 0.40 0.35 0.30 0.25

Gear case
C 0.50 0.45 0.40 0.35 0.30 0.25 0.20

B 0.45 0.40 0.35 0.30 0.25 0.20 0.15
A 0.40 0.35 0.30 0.25 0.20 0.15 0.10
Select the shims from the pinion gear shims of different
thickness to obtain the required thickness (Sp) by
combining the shims.
Shim type table
Shim type Thickness
Shim A 0.10 mm
Shim B 0.15 mm
Shim C 0.30 mm
Shim D 0.50 mm
Install the trim tab (page 16-4).
After adjustment, inspect the forward bevel gear
backlash (page 16-41).
HOW TO READ SHIM SELECTION TABLE
When the engagement mark on the gear case housing
is E and the tolerance is -0.18 mm (-0.007 in), the shim
selection table shows that the required shim thickness
is 0.85 mm (0.033 in). (See the table shown below).
Pinion gear shim selection table
Unit: mm
Calculation value
-0.31 -0.25 -0.20 -0.15 -0.10 -0.05 0
– – – – – – –
-0.25 -0.20 -0.15 -0.10 -0.05 0 +0.05
F 1.00 0.95 0.90 0.85 0.80 0.75 0.70
engagement
Gear case
E 0.95 0.90 0.85 0.80 0.75 0.70 0.65

D 0.90 0.85 0.80 0.75 0.70 0.65 0.60
C 0.85 0.80 0.75 0.70 0.65 0.60 0.55
B 0.80 0.75 0.70 0.65 0.60 0.55 0.50
A 0.75 0.70 0.65 0.60 0.55 0.50 0.45
HOW TO SELECT SHIM COMBINATION

To obtain 0.85 mm (0.033 in) of shim thickness,
combine two gear shim A, one gear shim B, and one
gear shim D, or combine one gear shim A, one gear
shim B and two gear shim C.

16-39
dummyhead
GEAR CASE
FORWARD BEVEL GEAR SHIM
If you have a gauge adapter special tool, place the disc
that is included with that tool on a flat surface.
Make sure the side marked with the tool number is on [5]
the bottom and the smooth side is up.
If you do not have a gauge adapter special tool, use any [4]
flat, hard surface for this procedure.
TOOL:
[2]
Gauge adapter, 100 mm [1] 070PJ-ZY30100
Assemble the outer race [2] and the inner race [3] of a
new taper bearing (50 x 82 x 21.5 mm).
Place the bearing assembly on the smooth side of the
gauge adapter special tool (or flat, hard surface).
Press the outer race down over the inner race, and turn
the outer race two or three turns.
[1] [3]
Measure the bearing height (E) [4] from the outer race
end to the inner race end using a regular vernier caliper
[5] as shown, and record the measurement.
Calculate the tolerance using the measurement E
obtained in the previous step and the following formula.
Formula: Tolerance = E - 21.5
Example:
When measurement (E) from the outer race end to the
inner race end is 21.54 mm (0.848 in):
Tolerance = 21.54 - 21.5 = 0.04
The tolerance is 0.04 mm (0.002 in).
[1]
Cross reference the engagement mark [1] located on
the trim tab installation part of the gear case [2] and the
tolerance calculated in the previous step, and refer to
the forward bevel gear shim selection table to
determine the required thickness of the shim (Sf).
[2]
Forward bevel gear shim selection table

Unit: mm
Calculation value
0 +0.05 +0.10 +0.15
– – – –
+0.05 +0.10 +0.15 +0.20
1 0.60 0.55 0.50 0.45
2 0.55 0.50 0.45 0.40
engagement
3 0.50 0.45 0.40 0.35

Gear case
4 0.45 0.40 0.35 0.30

5 0.40 0.35 0.30 0.25
mark
6 0.35 0.30 0.25 0.20

Refer to page 16-39 for information on how to read the
shim selection table and shim combination.
16-40
dummyhead
GEAR CASE
Select the shims from the forward bevel gear shims of
different thickness to obtain the required thickness (Sf)
by combining the shims.
Shim type table
Shim type Thickness
Shim A 0.10 mm
Shim B 0.15 mm
Shim C 0.30 mm
Shim D 0.50 mm
Install the trim tab on the gear case (page 16-4).
After adjustment, inspect the forward bevel gear
backlash (page 16-41).
BACKLASH INSPECTION
FORWARD BEVEL GEAR BACKLASH
Backlash adjustment must be made after adjustment of
each gear shim (page 16-36).
Install the following parts except the water pump. [1]
– Vertical shaft/forward bevel gear (page 16-28)
Hold the propeller shaft securely with the 2 jaw puller
(commercially available) [1] as shown, and tighten the
puller to the specified torque.
TOOL (commercially available):
Puller, 2 jaw
Pins (2 required) CJ-105-11
Pressure screw CJ-105-3
Jaws CJ-105-6
Tip CJ-66-15-3
Yoke CJ-86-1

Turn the vertical shaft five to ten turns clockwise to fit
the taper bearing.

16-41
dummyhead
GEAR CASE
Attach the special tool to the vertical shaft [1] as shown,
and adjust the dial gauge [2] so its needle is at line "1"
of the special tool (backlash indicator tool). [1]
[4]
TOOL:
Backlash indicator tool [3] 07SPJ-ZW0030B
Backlash indicator attachment [4] 07SPK-ZW10100 90° 90°
Turn the vertical shaft lightly right and left and record
the dial indicator reading.
Measure the backlash at four points (by turning the 90° 90°
vertical shaft in increments of 90°) in the same manner.
Do not turn the propeller shaft when turning the vertical
shaft.
Obtain the forward bevel gear backlash using the dial
gauge runout and the following formula.
Formula:
Backlash = Dial gauge runout x 0.80 [3]
Example:
[2]
When dial gauge runout is 0.30 mm (0.012 in),
Backlash =
0.30 mm (0.012 in) x 0.80 = 0.24 mm (0.009 in)
STANDARD VALUE:
0.10 – 0.28 mm (0.004 – 0.011 in)
If the backlash is too large, increase the forward bevel
gear shim thickness and recheck the backlash.
If the backlash is too small, reduce the forward bevel
gear shim thickness and recheck the backlash.
• Use special tool when taper bearing (50 x 82 x 21.5
mm) [outer race] is removed to adjust the backlash
again.
Install the water pump (page 11-9).
After water pump installation, inspect the gear case
pressure inspection (page 16-42).
GEAR CASE PRESSURE INSPECTION

• Perform the gear case pressure check and check for
pressure leakage after disassembling and
reassembling the gear case.
• In principle, the pressure check should be made on
the gear case before filling it with gear oil and before [2]
installing it on the outboard motor. However, the
check can be made with the gear case filled with
gear oil.
[1]
Remove the oil check bolt [1] and the O-ring [2].
Install the adapter [3] (STV-334Y: commercially
available) in the oil check bolt hole. [3]
Attach the hose end of the pressure tester [4] (STV-
V34: commercially available) to the adapter.
Do not screw in the adapter and the hose end with
force.
[4]
16-42
dummyhead
GEAR CASE
While watching pressure tester gauge [1], apply the
specified air pressure to the gear case by pumping the
handle slowly.
Do not apply excessive air pressure.
AIR PRESSURE:
0.029 MPa (0.3 kgf/cm2, 4.3 psi)
[1]
While applying the specified air pressure to the gear

case, move the shift rod [1] right and left five or six [1]
times using pliers.
• Wrap a shop towel [2] around the shift rod spline to
move the shift rod with pliers.
[2]

case, turn the vertical shaft [1] five or six turns [1]
clockwise.
Be sure to turn the vertical shaft clockwise, or damage

to the water pump impeller can occur.

case, turn the propeller shaft [1] right and left two or
three turns.
Leave the gear case for five minutes and then check
that the air pressure is maintained.
[1]

16-43
dummyhead
GEAR CASE
If the air pressure drops, place the gear case in a
container filled with a water. Apply the specified air
pressure to the gear case again, move the shift rod,
vertical shaft and the propeller shaft, and locate the
point where the air is leaking.
Remove the gear case from the water and replace the
water seal or O-ring where the air is leaking.
After the replacing the water seal or O-ring, perform the
pressure check again and be sure that air is not leaking.
Remove the gear case pressure tester and the adapter
from the gear case.
Install a new O-ring on the oil check bolt, and tighten
the oil check bolt to the specified torque.
PROPELLER SHAFT INSPECTION

PROPELLER SHAFT O.D.
Measure the O.D. of the propeller shaft where the
[1]
bearings ride.
STANDARD:
At bevel gear [1]: 24.987 – 25.000 mm
(0.9837 – 0.9843 in)
At needle bearing [2]: 30.007 – 30.020 mm
(1.1814 – 1.1819 in)
SERVICE LIMIT:
At bevel gear: 24.966 mm (0.9829 in)
At needle bearing: 29.986 mm (1.1805 in) [2]

replace the propeller shaft with a new one.
PROPELLER SHAFT RUNOUT

Support each journal with V-blocks as shown.
Set the dial indicator and measure the propeller shaft
runout while turning the shaft.
STANDARD: 0.02 mm (0.001 in) or below
If the measurement is out of the standard, replace the
propeller shaft with a new one.
167 mm (6.6 in)
16-44
dummyhead
GEAR CASE
VERTICAL SHAFT INSPECTION
VERTICAL SHAFT O.D.
(At needle bearing)
Measure the O.D. of the vertical shaft where the needle
bearing [1] rides.
STANDARD: 28.566 – 28.575 mm
(1.1246 – 1.1250 in)
replace the vertical shaft with a new one.
[1]
VERTICAL SHAFT RUNOUT

Support each journal with V-blocks as shown.
Set the dial indicator and measure the vertical shaft 124 mm *1: 570 mm (22.4 in)
runout while turning the shaft. (4.9 in) *2: 684 mm (26.9 in)
STANDARD: 0.30 mm (0.012 in) or below
If the measurement is out of the standard, replace the
vertical shaft with a new one.
*1: 359.5 mm (14.15 in)

*2: 447.5 mm (17.62 in)
*1: LRT/LHT/LHG type
*2: XRT type
CLUTCH SHIFTER INSPECTION

Check the clutch parts [1] on both the forward and
reverse sides for wear and damage. [1]

16-45
dummyhead
GEAR CASE
GEAR CASE NEEDLE BEARING
REPLACEMENT
Remove the vertical shaft (page 16-25)
[3]
Set the special tools on the needle bearing [1], and
place a shop towel [2] or equivalent material under the
needle bearing as shown.
TOOLS:
Bearing driver attachment, 07ZMD-MBW0200
37 mm [4] [4]
Pilot, 28 mm [5] 07746-0041100
[1]
[5]
[2]
Before removing the needle bearing, mark [1] the

special tool [2] at a point level to the gear case end [2]
using a straight edge [3] as shown.
• The mark on the special tool is used for installation
of the needle bearing. Do not erase the mark before
installation.
[1]
Remove the needle bearing from the gear case using
the special tool.
• Remove the needle bearing, taking care not to
damage the gear case.
[3]
Apply gear oil to the outer circumference of a new

[3]
needle bearing [1].
Drive the needle bearing into the gear case [2] up to the
mark made on the special tool during vertical shaft/ [4]
bevel gear removal using the same tool used for
removal.
TOOLS:
Bearing driver attachment, 07ZMD-MBW0200
37 mm [4]
Pilot, 28 mm [5] 07746-0041100
After installation, check that the bottom surface of the
needle bearing is flush with the bottom of the gear case.
Install the vertical shaft (page 16-28) [2]
[1]
[5]
16-46
dummytext
17. MOUNT
MOUNT CASE REMOVAL/ MOUNT CASE ASSEMBLY/

INSTALLATION ··································· 17-2 DISASSEMBLY ··································· 17-3
17

17-1
dummyhead
MOUNT
MOUNT CASE REMOVAL/
MOUNT
INSTALLATION
Remove the engine from the mount case (page 13-3).
UPPER RUBBER MOUNT (2)

INSTALLATION:
Mounting direction as shown.
LONG SHORT
BOLT (8 x 25 mm) (8)

UPPER MOUNT
NUT (12 mm) (2) STOPPER RUBBER (2)
83 N·m (8.5 kgf·m, 61 lbf·ft) UPPER MOUNT
STOPPER (2)
UPPER MOUNT
COVER
UPPER MOUNT
COVER SEAL
BOLT (12 x 186 mm) (2)
UNDER COVER SEAL A
MOUNT CASE ASSEMBLY
17-2
dummyhead
MOUNT
MOUNT CASE ASSEMBLY/
DISASSEMBLY
EXPLODED VIEW
Remove the mount case (page 17-2).
SIDE WASHER (14 mm)
SHIFT SHAFT ASSEMBLY E-RING (12 mm)
SHIFT SHAFT WASHER
FLANGE BUSHING
(14 x 16 x 22.5 mm) WATER SEAL
(22 x 35 x 7 mm) (2)
OIL SEAL
(14 x 26 x 6 mm)
WASHER (14 mm)
WASHER (13 mm)
EXTERNAL
CIRCLIP (12 mm)
WATER TUBE A TUBE CLIP (B10) (2)
FLANGE BUSHING (14 x 16 x 22.5 mm)

REMOVAL
Remove the oil seal (14 x 26 x 6 mm) from mount case
assembly.
[2]
Remove the flange bushing [1] using the special tool
and a hydraulic press as shown.
TOOL:
MT. assembly holder [2] 07KPF-VD60100
[1]

17-3
dummyhead
MOUNT
FLANGE BUSHING (14 x 16 x 22.5 mm)
INSTALLATION
Set a thick wood block [1] under the oil seal (14 x 26 x 6
mm) installation part [2] of the mount case as shown.
[4]
Apply engine oil to the circumference of a new flange
bushing [3].
Drive the flange bushing into the mount case using the
special tools and a hydraulic press as shown.
TOOLS: [3] [5]
Driver [4] 07749-0010000
Attachment, 22 x 24 mm [5] 07746-0010800
Pilot, 14 mm [6] 07746-0041200 [2]
[6]
[1]
OIL SEAL/WATER SEAL

INSTALLATION
Apply soapy water to the circumference of the new oil <Oil seal installation direction>
seal (14 x 26 x 6 mm) [1].
Install the oil seal as shown using the special tools.
• Note the installation direction of the oil seal as [2]
shown.
TOOLS:
Driver [2] 07749-0010000
Attachment, 24 x 26 mm [3] 07746-0010700
After installing the oil seal, apply grease to the oil seal
lip and the area around the lip. [3] [1]
[1]
Apply soapy water to the circumference of the two new

water seals (22 x 35 x 7 mm) [1]. <Water seal installation direction>
Install the water seals one by one in the mount case

using the special tools as shown.
• Note the installation direction of the water seals as [1]
shown. [2]
TOOLS:
Driver [2] 07749-0010000
Attachment, 32 x 35 mm [3] 07746-0010100
[3]
After installing the water seal, apply grease to the water
seal lip and the area around the lip.
[1]
17-4
dummyhead
MOUNT
SHIFT SHAFT INSTALLATION
Apply marine grease to the shift shaft assembly
installation part [1] in the mount case.
Set the shift shaft washer [2] on the mount case.
Install shift shaft A [3] and shift shaft B [4] of the shift [9]
shaft assembly in the mount case in this sequence.
• Install shift shaft A with care not to turn up the water [4]
seal (14 x 26 x 6 mm).
• Check that the shift shaft washer is set in position
under shift shaft B securely. [8]
Install the washer (14 mm) [5], washer (13 mm) [6], and
the external circlip [7] on shift shaft A.
[1]
Install the E-ring [8] and the side washer (14 mm) [9] on
shift shaft B.
[2]
Install the engine on the mount case (page 13-8). [3]
[5]
[6]
[7]

17-5
dummyhead
MEMO

dummytext
18. TRIM/TILT
COMPONENT LOCATION ····················· 18-2 POWER TRIM/TILT DISASSEMBLY/

ASSEMBLY ······································· 18-23
ATF LINE DESCRIPTION ······················ 18-4
POWER TILT MOTOR DISASSEMBLY/
POWER TRIM/TILT/SWIVEL CASE ASSEMBLY ······································· 18-41
(EXCEPT LHGX TYPE) ························· 18-6 POWER TILT MOTOR INSPECTION ······ 18-46
SWIVEL CASE/MOUNT FRAME GAS ASSISTED DAMPER/SWIVEL

DISASSEMBLY/ASSEMBLY·················18-15 CASE/STERN BRACKET REMOVAL/
INSTALLATION·································· 18-48
18

18-1
dummyhead
TRIM/TILT
COMPONENT LOCATION
TRIM/TILT
Except LHGX type:
34 N·m (3.5 kgf·m, 25 lbf·ft)
34 N·m (3.5 kgf·m, 25 lbf·ft)
18-2
dummyhead
TRIM/TILT
LHGX type only:
34 N·m (3.5 kgf·m, 25 lbf·ft)
34 N·m (3.5 kgf·m, 25 lbf·ft)

18-3
dummyhead
TRIM/TILT
ATF LINE DESCRIPTION
Trim/tilt up:
DOWN RELIEF VALVE

PISTON ROD A
POWER TILT MOTOR
PUMP
Discharge
Charge
LOWER CHAMBER
SPOOL VALVE
OIL TANK
PISTON ROD B
MANUAL
VALVE
LOWER CHAMBER
CHECK VALVE
UPPER CHAMBER
SPOOL VALVE
UPPER CHAMBER
CHECK VALVE
18-4
dummyhead
TRIM/TILT
Trim/tilt down:
DOWN RELIEF VALVE
POWER TILT MOTOR

PISTON ROD A
PUMP
Discharge
Charge
LOWER CHAMBER
SPOOL VALVE
OIL TANK
MANUAL
VALVE PISTON ROD B
LOWER CHAMBER
CHECK VALVE
UPPER CHAMBER
SPOOL VALVE
UPPER CHAMBER
CHECK VALVE

18-5
dummyhead
TRIM/TILT
POWER TRIM/TILT/SWIVEL CASE REMOVAL/INSTALLATION
(EXCEPT LHGX TYPE)
REMOVAL
Remove the following
– Engine (page 13-3) [1]
– Mount (page 17-2)
Connect the battery positive (+) cable to the Green
terminal [1] of the power tilt motor 2P connector [2] and
the battery negative (-) cable to the Blue terminal [3].
Raise the swivel case to the uppermost position (the
position rod of the power trim/tilt is extended fully).
• Connect the power tilt motor 2P connector to the

battery with care no to short-circuit it.
After raising the swivel case to the uppermost position, [2] [3]
disconnect the battery cables from the connector
terminals, and secure the swivel case using the tilt
stopper.
Open the wire harness clip [1] and release the trim
angle sensor wire and the power tilt motor wire. [1]
Remove the spiral tube [2] from the trim angle sensor
wire and the power tilt motor wire.
[2]
Remove the tie-wrap band [1] from the under case

[3]
grommet C [2], and remove the trim angle sensor wire [4]
[3] and power tilt motor wire [4] out of the hole in the
under cover front bracket. [1]
[2]
Remove the motor wire bushing [1] from the L. stern

bracket [2]. [2] [1]
18-6
dummyhead
TRIM/TILT
Remove the screws [1] and ground wire [2].
Remove the two bolts [3], ground wire, and the anode [4]
metal [4] from the stern brackets.
• Check the anode metal for corrosion. If it is corroded
excessively, replace with a new one.
[2]
[1]
[3]
Remove the two E-rings [1] from the upper cylinder pin
[2].
Remove the upper cylinder pin and piston rod [3] from [1]
the swivel case [4].
Check the upper cylinder bushings mounted on the
[4]
piston rod of the power trim/tilt. Replace the upper
cylinder bushings with new ones if they are worn, [1]
damaged or deformed.
Remove the upper cylinder bushing [5] from the piston
rod.
[2]
[5]
[3]
Remove the two bolts [1] and the trim angle sensor [2]
from the L. stern bracket.
[2]
[1]
Remove the tilting bolt cap [1] and the loosen the self-
locking nut (25 X 2.0 mm) [2] fully. [1]
• The self-locking nut (25 X 2.0 mm) must not come

off the tilting shaft.
[2]

18-7
dummyhead
TRIM/TILT
While pushing the L./R. stern brackets lightly against
the swivel case, remove the self-locking nut [1], washer
[2], and bolt [3] from the R. stern bracket.
[1]
[3]
[2]
While holding the power trim/tilt [1] with your hand,

remove the locking nut (25 X 2.0 mm) [2] from the tilting
shaft [3].
Pull the power tilt motor wire and the trim angle sensor [3]
wire out of the hole in the L. stern bracket [4].
Remove the L. stern bracket from the tilting shaft and
the lower cylinder collar [5].
[2]
• The power trim/tilt is heavy. Take care not to
drop it.
Remove the power trim/tilt.
[5]
Remove the lower cylinder collar from the power trim/
tilt.
Check the lower cylinder bushings [6] mounted on the
power trim/tilt. Replace the lower cylinder bushings with
new ones if they are worn, damaged or deformed.
Remove the lower cylinder bushings.
• Do not push in the piston rod after removing the
power trim/tilt.
If the piston rod has been pushed down, set it in the
fully extended position (page 18-6).
[4] [1]
• After removing the power trim/tilt, store it while [6]
holding it upright with the upper cylinder pin
installation part [7] up. Never lay the power trim/tilt
on its side or hold it upside down (with the lower
cylinder collar installation part [8] up).
[7]
[8]
18-8
dummyhead
TRIM/TILT
Remove the self-locking nut (7/8-14 UNF) [1] from the
tilting shaft [2].
[6]
Remove the swivel case [3] from the tilting shaft, and [3]
then remove the wave washer (26 mm) [4] and the
tilting shaft from the R. stern bracket [5]. [6]
Check the swivel case bushings [6] mounted on the
swivel case. Replace the swivel case bushings with
new ones if they are worn, damaged or deformed. [1]
Remove the two swivel case bushings [6].
Remove the tilting shaft O-ring [7].
Remove the wire harness clip from the L. stern bracket.
[2]
[7]
[4]
[5]

18-9
dummyhead
TRIM/TILT
EXPLODED VIEW
SWIVEL CASE
SWIVEL CASE
BUSHING (2)
UPPER CYLINDER PIN TILTING SHAFT
E-RING (15 mm) (2)

TILTING BOLT
CAP
UPPER CYLINDER
BUSHING (2)
SELF-LOCKING NUT (7/8-14 UNF)

34 N·m (3.5 kgf·m, 25 lbf·ft)
TRIM BOLT
WAVE WASHER ANGLE (6 X 20 mm) (2)
O-RING
(26 mm) (2) SENSOR
R. STERN
BRACKET
SELF-LOCKING NUT
(25 X 2.0 mm)
34 N·m (3.5 kgf·m, 25 lbf·ft)
WASHER
WIRE HARNESS (10 mm)
CLIP
LOWER CYLINDER
COLLAR
POWER TRIM/TILT
L. STERN
BRACKET
MOTOR CORD LOWER CYLINDER

BUSHING BUSHING (2)
ANODE METAL
GROUND CABLE
BOLT
(10 X 235 mm) BOLT
(6 X 23 mm) (2) SCREW (6 X 8 mm)
18-10
dummyhead
TRIM/TILT
INSTALLATION
• Check that the piston rod of the power trim/tilt is extended fully.
Apply marine grease to the inner wall and outer surface
of the swivel case bushings [1] and install them on the [6] [5] [9]
swivel case [2].
Apply marine grease to the circumference of a new O-
ring [3], and install it in the groove [4] in the tilting shaft
[5] securely.
• Install the O-ring in the groove inside the tilting shaft
that is on the side of the short threaded end [6] of the
tilting shaft.
Apply marine grease to the tilting shaft bearing area. [4]
Apply marine grease to the swivel case and to the shaft [2]
installation part on the L. /R. stern bracket [7].
[1]
Tighten new self-locking nut (7/8-14 UNF) [8] on the
long threads end [9] of the tilting shaft.
• Tighten the self-locking nut (7/8-14 UNF) fully to the
end of the threaded part of the tilting shaft.
Apply marine grease to the wave washer [10]. [8]
Set the R. stern bracket and the wave washer on the
tilting shaft.
Pass the tilting shaft through the swivel case.
[3]
[5]
[10] [7]
Apply marine grease to the wave washer [1] and install

it on the tilting shaft [2].
[2] [6]
of the lower cylinder bushings [3], and install them on
the power trim/tilt [4].
Apply marine grease to the outer surface of the lower [1]
cylinder collar [5] and install it in the power trim/tilt. [8]
Raise the swivel case [6] to the uppermost position and
secure it in the position using the tilt stopper.
Route the trim angle sensor wire and the power tilt
motor wire through the hole in the L. stern bracket [7]. [5]
Install the lower cylinder collar, which has been

installed in the power trim/tilt, in the R. stern bracket [8].
Install the L. stern bracket on the tilting shaft.
[9]
Loosely tighten new self-locking nut (25 X 2.0 mm) [9]
on to the tilting shaft.
[7]
[4]
[3]

18-11
dummyhead
TRIM/TILT
While pushing the L./R. stern brackets lightly toward the
swivel case side, install the bolt [1] and the washer [2],
and loosely tighten the self-locking nut (10 mm) [3].
[3]
[1]
[2]
Install the trim angle sensor [1] and tighten the two bolts
[2].
[1]
[2]
Tighten the self-locking nut (7/8-14 UNF) [1] to the

specified torque.

Tighten the self-locking nut (25 x 2.0 mm) [2] to the [1] [3]
specified torque so that the tilting shaft end is flush with
the nut end.
Tighten the self-locking nut (Bolt 10 x 235 mm side).
Apply marine grease to the threads of both sides of the
tilting shaft.
Install the tilting bolt cap [3].
18-12
dummyhead
TRIM/TILT
Pass the trim angle sensor wire [1] and the power tilt
motor wire [2] through the motor wire bushing [3] in the [4]
[5]
positions shown.
Install the motor wire bushing in the L. stern bracket,
aligning the projection [4] on the motor wire bushing
with the concave [5] in the L. stern bracket.
• Check that the trim angle sensor wire is on the right
side of the power tilt motor wire by viewing from the
backside of the L. stern bracket.
[3]
<Viewing L. stern bracket from the backside>
Up (engine side)
[1]
[3]
Rear
[2]
Install the wire harness clip [1] on the L. stern bracket

[2].
Check that the corrugated tube [3] on the power tilt [1] [8]
motor wire stands erect as shown.
Install the power tilt motor wire, aligning the end of the [2]
taped part [4] of the power tilt motor wire with the end
[5] of the motor wire bushing. [7]
Wind the spiral tube [6] onto the trim angle sensor wire
[7] and the power tilt motor wire so the end of the spiral [3]
tube aligns with the end of the taped part [8] of the [6]
power tilt motor wire.
Close the wire harness clip on the spiral tube.
[4]
[5]

[5]
of the upper cylinder bushings [1] and install them on
the piston rod [2] of the power trim/tilt.
Apply marine grease to the outer surface of the upper
cylinder pin [3]. [5] [4]
Align the hole in the piston rod with the hole in the
swivel case [4] and insert the upper cylinder pin into the
hole.
Install the E-rings [5] to the groove on the outer end of
the upper cylinder pin.
[3]
[1]
[2]

18-13
dummyhead
TRIM/TILT
Set the lead wire [1] between the projections [2] on the
anode metal [3], and install them with the two bolts [4].
Tighten the bolts. [3]
• Before installation, check the anode metal for

corrosion and replace it with a new one if necessary.
Set the lead wire as shown and install the screw [5].
Tighten the screw.
[1]
[5]
[4]
[1]
90°
[2]
Route the trim angle sensor wire [1] and the power tilt
motor wire [2] through under case grommet C [3]. [1] [2]
Align the end of the taped part [4] of the power tilt motor
wire with the end [5] of under case grommet C and [5]
[4]
secure with the new tie-wrap band [5].
Cut off any excess tie-wrap band.
[3]
Loosen the manual valve [1] fully.

Raise the swivel case a little, unlock the tilt stopper, and
Tighten Loosen
lower the swivel case to the lowermost position. [1]
Tighten the manual valve to the specified torque.
– Mount case (page 17-2)
– Engine (page 13-8)
18-14
dummyhead
TRIM/TILT
SWIVEL CASE/MOUNT FRAME DISASSEMBLY/ASSEMBLY
DISASSEMBLY
Remove the swivel case/stern bracket (page 18-6).
Remove the external circlip [1] from the swivel shaft.
[1]
Mark [1] the mount frame [2] so that it aligns with the
" " mark [3] on the lower mount center housing [4]. [3]
[1]
[2]
[4]
Warm up the lower mount center housing [1] and mount

frame [2] using a heat gun (ETB1600: commercially [1] [3]
available) [3].
• Wear gloves to protect your hands when handling
the lower mount center housing.
Screw in the shaft of the bearing puller (commercially
available: OTC 1035) [4] and remove the lower mount
center housing.
TOOL:
[2]
Puller adapter [5] 07APF-ZY3A200
• If it is hard to remove the lower center housing, heat
the lower mount center housing and mount frame
again.
[5]
[4]

18-15
dummyhead
TRIM/TILT
Remove the mount frame [1], washer [2], and the wave
washer [3] from the swivel case [4].
[4]
[1]
[2]
[3]
Remove the oil seal [1] from the swivel case [2].
Check the swivel case liners [3] mounted on the swivel
case and replace them with new ones if they are worn, [2]
damaged, or deformed. [3]
Remove the two swivel case liners from the swivel

case.
[3]
[1]
18-16
dummyhead
TRIM/TILT
Remove the three grease fittings [1] from the swivel
case [2]. [1]
Remove the two self-locking nuts [3], washers [4], and

thrust receivers [5]. [2]
[3]
[5]
[4]
[1]
Remove the bolt [1], detent spring [2], and detent

assisted spring [3]. [1]
Using a commercially available pin driver (2.5 mm) [4], [5]
drive out the spring pin (2.5 X 20 mm) [5] up to the
position where if does not interfere with the swivel case. [3]
Remove the spring pin (2.5 X 20 mm) that was just [7]
driven out using pliers or an equivalent tool.
Remove the spring pin located on the other side, [2] (8)
following the same procedure.
Remove the two tilt stoppers [6] and the tilting bracket
[7]. [6]
Check the cam and bearing of the tilting bracket for

wear, damage, or deformation. Replace the tilting
bracket with a new one if necessary.
Check the tilt arm bushings [8] on the swivel case for
wear, damage, or deformation. Replace the tilt arm
bushings with new ones if necessary. [6]
Remove the two tilt arm bushings. [8]
[4]
[5]

18-17
dummyhead
TRIM/TILT
EXPLODED VIEW
BOLT
(6 X 14 mm)
DETENT ASSIST
SPRING SWIVEL CASE
SPRING PIN LINER (2)
(2.5 X 20 mm) (2)
DETENT
SPRING
TILTING
BRACKET
TILT STOPPER (2)
MOUNT FRAME SELF-LOCKING

NUT (10 mm) (2)
TILT ARM
BUSHING (2)
THRUST RECEIVER (2)
WASHER
(10 mm) (2)
SWIVEL CASE
THRUST WASHER
(34 mm)
GREASE FITTING (3)
3 N·m (0.31 kgf·m, 2.2 lbf·ft) SWIVEL CASE LINER
WAVE WASHER
OIL SEAL (40 mm)
(39.5 X 52 X 6 mm)
EXTERNAL CIRCLIP
(Spline part) (39 mm)
LOWER MOUNT
CENTER HOUSING
18-18
dummyhead
TRIM/TILT
ASSEMBLY
Install the detent assist spring [1], detent spring [2], and
bolt [3]; tighten the bolt. [3]
Apply marine grease to the detent spring roller. [1]
[6]
Apply marine grease to the circumference of the tilt
stoppers [4] and tilt arm bushings [5]. [2]
Apply marine grease to the tilting bracket cam [6].

Install the two tilt arm bushings to the swivel case [7], [7] [5]
and then install the tilt stoppers and tilting bracket.
[5]
[4]
[4]
Check that the projection [1] of the tilting bracket is in

the position shown.
Using a commercially available pin driver (2.5 mm) [2],
drive the spring pins (2.5 X 20 mm) [3] into the tilting
bracket until the pins protrude by 1.0 – 2.0 mm (0.04 – [2]
0.08 in) from the other side of the tilting bracket as
shown.
• Do not drive in the spring pins excessively, or the tilt
stopper cannot operate properly.
[1]
[3]
1.0 – 2.0 mm (0.04 – 0.08 in)
Install the two thrust receivers [1], washers [2], and self- [5]
locking nuts [3] to the swivel case [4] and tighten the
self-locking nuts. [4]
Apply marine grease to the sliding surface of the thrust
receivers.
Install the three grease fittings [5] on the swivel case,
and tighten them to the specified torque.
[3]
[1]
[2]
[5]

18-19
dummyhead
TRIM/TILT
Apply marine grease to the circumference of the swivel
case liners [1]. [2]
Install the swivel case liners by aligning the projection

[2] on each swivel case liner with the recess [3] in the
swivel case. [1]
[3]
[3]
[1]
[2]
Apply marine grease to the circumference of a new oil

seal [1].
Install the oil seal in the bottom of the swivel case using
the special tool. Note the installation direction of the oil [2]
seal.
TOOL:
Driver [2] 07749-0010000
Attachment, 52 X 55 mm [3] 07746-0010400 [3]
Apply marine grease to the lip of the oil seal.
[1]
18-20
dummyhead
TRIM/TILT
Apply marine grease to the circumference of the thrust
washer [1] and install it to the mount frame [2].
Apply marine grease to the circumference of the mount
frame shaft and install the mount frame on the swivel
case [3].
[3]
• Install the mount frame with care not to push the
swivel case liner out of the swivel case. [2]
Apply marine grease to the wave washer [4] and install
it on the mount frame.
[1]
[4]
Warm up the lower mount center housing [1] using a

heat gun (ETB1600: commercially available) [2].
[1]
• Wear gloves to protect your hands when handling
the lower mount center housing.
Apply marine grease to the spline of the lower mount
center housing.
Set the lower mount center housing to the mount frame
[3] by aligning the " " mark [4] on the lower mount
center housing with the mark [5] on the mount frame [2]
that was made during disassembly.
Drive in the lower mount center housing until it does not
come off using the special tools as shown. [4]
TOOLS: [5]
Driver [6] 07749-0010000
Attachment, 52 x 55 mm [7] 07746-0010400
• Drive in the lower mount center housing at right
angles to the swivel shaft.
[1] [3]
[7]
[6]

18-21
dummyhead
TRIM/TILT
Set the nut [1], washer [2], and bearing driver
attachment, 30 X 37 mm [3] on the threaded shaft [4] Mount frame side:
(special tool).
TOOLS:
Threaded shaft 07APF-ZY3A300 [4]
Bearing driver attachment, 070PD-ZY6A200
30 x 37 mm
[2]
Install the threaded shaft (special tool) on the mount
frame as shown. Note the installation direction of the [1]
[3]
nut of the threaded shaft and the bearing attachment,
30 X 37 mm (special tool).
Set the driver attachment, 50 mm [5] (special tool),
washer [6], and nut [7] on the threaded shaft in this
order. Note the installation direction of the nut of the
bearing attachment, 50 mm and nut of the threaded
shaft.
TOOL:
Bearing driver attachment, 07APF-ZY3A100
50 mm
Tighten the nut of the lower mount center housing side
while holding the nut of the mount frame side.
• Check that the lower mount center housing [8] is set [9]
at right angles to the mount frame [9].
Tighten the nut in several steps while checking that the
external circlip installation groove [10] in the mount [8]
frame is in alignment with the surface of the lower [5]
mount center housing as shown.
After installation, check that the mount frame turns [7]
smoothly. Check that the external circlip is set in the [6]
designated position securely.
Adjust if the mount frame does not turn smoothly or if Lower mount center housing side:
the circlip installation groove in the mount frame is not
exposed properly (page 18-22).
[10]
[8]
If the nut is tightened excessively and the lower mount

center housing [1] does not turn smoothly, perform the [1]
following adjustment.
[3]
Install the bearing puller (commercially available: OTC
1035) [2] and the special tool on the lower mount center
housing.
TOOL:
Puller adapter [3] 07APF-ZY3A200
Tighten the puller bolt and align the circlip installation
groove in the mount frame with the surface of the lower
mount center housing.
Remove the puller and special tool. [2]
18-22
dummyhead
TRIM/TILT
If the mount frame turns smoothly and the circlip can be
installed in the groove, install the external circlip [1] in
the designated position and apply marine grease to the
part A [2] shown.
Install the swivel case/stern bracket (page 18-11).
[1]
[2]
POWER TRIM/TILT DISASSEMBLY/

ASSEMBLY
DISASSEMBLY
• Do not disassemble the pump. If it is faulty, replace it
as an assembly.
• Do not use a shop towel, cloth, or gloves during
removal.
• Use the recommended automatic transmission fluid
(ATF).
Recommended ATF: Genuine Honda Automatic
Transmission Fluid (ATF), DEXRON® or equivalent.
• Do not reuse the drained ATF.
• Do not tighten the vise excessively when holding the
power trim/tilt in a vise during operation.
• Clean the removed parts in fresh ATF, and blow
each port of the parts with compressed air. Set the
parts neatly in a suitable container with care not to
contaminate them with dust and dirt.
• Do not reuse O-rings and oil seals.
• Take care not to damage the sliding surface of the
piston rod when removing them.
Remove the power trim/tilt (page 18-6).
Operate the power tilt motor until the each rod reach the
fully extended position (page 18-6).
Remove the oil tank cap [1], and drain the ATF from the
oil tank.
Do not drain the ATF by pushing the piston rod in.
Loosely install the oil tank cap on the oil tank.
[1]

18-23
dummyhead
TRIM/TILT
Remove the three oil tank mounting bolt/washers (6 x 8
mm) [1] and oil tank [2] from the cylinder. Remove the
O-ring [3] from the cylinder. [2]
Drain the residual ATF from the oil tank.

[1]
[3]
Remove the four power tilt motor mounting bolt/

washers (6 x 34 mm) [1] and power tilt motor [2] from [1]
[2]
the pump.
Remove the O-ring [1] from the power tilt motor [2].
[1]
[2]
Remove the drive joint [1] and filter B [2] from the pump
[3]. [1]
Check the mesh of filter B for blockage and tears.

If it is torn, replace filter B with a new one.
If it is clogged with dust and dirt, blow the mesh with air [2]
to remove the blockage.
Take care not to damage the mesh.
[3]
18-24
dummyhead
TRIM/TILT
Remove socket bolt A (8 x 84 mm) [1], two socket bolts
B (8 x 23 mm) [2], and the pump [3]. Remove the five O- [6]
rings [4] and orifice collar [5] from the cylinder [6]. [7]
[4]
Remove the reservoir valve [7] from the cylinder.
[3]
• Take care not to lose the pins and steel balls in the
reservoir valve.
[1]
[5]
[2]
Remove the internal circlip [1] and manual valve [2]

[3]
from the pump [3].
Check the manual valve and O-ring for deterioration,
wear, and damage.
Replace the manual valve with a new one if necessary.
[1]
[2]
Hold the cylinder [1] in a vise [2] with a shop towel or

[1]
soft jaws as shown.
Do not tighten the vise excessively, as it can damage

the cylinder.
[2]
• Make sure the right and left piston rod B are fully
extended. [1]
• Do not push piston rod B into the trim cylinder.
Remove the rod guide [1] using the special tool as
shown.
TOOL:
Trim cap wrench, 4 mm [2] 070PA-001A100
[2]

18-25
dummyhead
TRIM/TILT
Remove the rod guide [1] and piston rod B [2] from the
[2]
trim cylinder slowly.
• Do not push piston rod B into the trim cylinder
chamber during removal.
Remove the rod guide from piston rod B.
Drain the ATF from the trim cylinders.
[1]
Remove the O-ring [1] from the rod guide [2].

Insert a sharp-end screwdriver [3] into the gap between [4]
the dust seal [4] and the rod guide.
Lift the dust seal and remove it from the rod guide. [5]
Take care not to damage inside the rod guide during
this operation.
Remove the oil seal [5] in the rod guide in the same
manner.
• Be careful not to damage the oil seal installation
surface of the rod guide.
Replace the rod guide with a new one, if damaged.
[2]
[1]
[3]
[4]
Remove the O-ring [1] and backup ring [2] from piston
[3]
rod B [3].
[2]
[1]
18-26
dummyhead
TRIM/TILT
Hold the cylinder with a vise (page 18-25).
[1]
Make sure that piston rod A [1] is in the fully extended
position.
Set the special tool on the cylinder cap [2] as shown, [3]
and remove piston rod A.
TOOL:
Pin wrench, 6 mm [3] 07SPA-ZW1010A
[2]
Remove piston rod A [1] from the cylinder [2].

Remove the two O-rings [3] from the cylinder cap [4]. [1]
[2]
[4]
[3]
Remove the free piston [1], backup ring [2], and O-ring
[1] [2]
[3] from the cylinder [4].
Check the sliding surface of the free piston for wear and
damage and replace if necessary.
[3]
[4]

18-27
dummyhead
TRIM/TILT
EXPLODED VIEW
PISTON ROD A
CYLINDER CAP
POWER TILT MOTOR 207.5 N·m (21.2 kgf·m, 153 lbf·ft)
O-RING
(3.5 X 41.7 mm) BACKUP RING
FREE PISTON
POWER TILT MOTOR O-RING (2)
MOUNTING BOLT/WASHER (4) (3.5 X 38.7 mm)
4.9 N·m (0.50 kgf·m, 3.6 lbf·ft)
O-RING
(1.9 X 11 mm)
OIL TANK MOUNTING BOLT/
WASHER (6 x 8 mm) (3)
4.9 N·m (0.50 kgf·m, 3.6 lbf·ft)
OIL TANK CAP
O-RING 2.5 N·m (0.26 kgf·m, 1.8 lbf·ft)
(1.8 X 69.6 mm) OIL
RESERVOIR TANK
VALVE
O-RING
DRIVE JOINT (1.8 X 7.7 mm)
FILTER B
DUST SEAL (2)
PUMP
OIL SEAL (2)
MANUAL VALVE
3.4 N·m (0.35 kgf·m, ROD GUIDE
2.5 lbf·ft) 139.5 N·m (14.2 kgf·m,
103 lbf·ft)
O-RING (2)
ORIFICE (3.5 X 35.7 mm)
INTERNAL COLLAR
CIRCLIP PISTON ROD B (2)
SOCKET BOLT A (8 X 84 mm)

O-RING (5) BACKUP RING (2)
8.3 N·m (0.85 kgf·m, 6.1 lbf·ft)
(1.8 X 7.7 mm) O-RING (2)
(3.5 X 31.7 mm)
SOCKET BOLT B (8 X 23 mm) (2)
8.3 N·m (0.85 kgf·m, 6.1 lbf·ft)
CYLINDER
18-28
dummyhead
TRIM/TILT
ASSEMBLY
• Do not reuse O-rings and oil seals.
• Do not use a shop towel or equivalent cloth, and do
not wear gloves during this operation.
• Do not reuse the drained ATF.
• When holding the cylinder in a vise, do not tighten
the vise excessively.
• Add ATF slowly.
• Assemble the power trim/tilt with piston rod A and
piston rod B fully extended. Do not push in piston rod
A and piston rod B.
• Do not allow dust, dirt, and other foreign material to
enter the cylinder and the pump during assembly.
• After assembly, coat the joints or mating sections of
the parts and any sections where the paint came off
with rust preventive paint of the same color.
Clean the parts with fresh ATF and blow each port with
[1]
compressed air to remove dust and dirt. Check that the
parts are clean before assembly.
Hold the cylinder [1] in a vise [2] with a shop towel or
soft jaws as shown.
[2]
Do not tighten the vise excessively, as it can damage
the cylinder.
Pour approximately 30 cm3 (1.0 fl oz) of ATF into the [4]

piston rod chamber of the cylinder [1].
RECOMMENDED OIL: [3]

Genuine Honda Automatic Transmission Fluid
(ATF) DEXRON®, or equivalent [2]
Apply ATF to a new O-ring [2] and new backup ring [3].
Install the backup ring and O-ring on the free piston [4].
Install the backup ring on the free piston with care not to
break it. [1]
Apply ATF to the circumference of the free piston and

push it in the piston rod chamber slowly until it bottoms Pour slowly up to the
out. top of the piston rod
chamber
After fully installing the free piston, pour fresh ATF
slowly up to the top of the piston rod chamber of the
cylinder.

18-29
dummyhead
TRIM/TILT
Apply ATF to a new O-ring [1] and Install it on the
[5]
bottom (i.e. nut side) of piston rod A [2].
[2]
Apply ATF to a new O-ring [3] and Install it on the
cylinder cap [4] of piston rod A.
Apply marine grease to the cylinder cap threads. [4]
With piston rod A fully extended, install piston rod A
slowly in the piston rod chamber of the cylinder [5].
Loosely tighten the cylinder cap.
[1]
Do not install piston rod A by pushing it in the piston rod
chamber.
[3]
Tighten the cylinder cap [1] to the specified torque using

the special tool as shown.
[3] [2]
TOOL:
Pin wrench, 6 mm [2] 07SPA-ZW1010A

incorrect. [1]
[2] [3]
[4]
Pour fresh ATF in the right and left trim cylinder

Pour slowly up to the top
chambers up to the top of the trim cylinder chamber.
of the trim cylinder
chamber
18-30
dummyhead
TRIM/TILT
Apply ATF to a new O-ring [1] and new backup ring [2],
[3]
and install them on piston rod B [3].
• Install the backup ring on piston rod B with care not

to break it.
[2]
[1]
Apply ATF to a new oil seal [1].

Holding the oil seal in the shape of a "U" with your
fingers, install it in the lower groove in the rod guide [2], [3]
taking care not to damage the oil seal.
Apply ATF to a new dust seal [3].
Holding the dust seal in the shape of a "U" with your
fingers, install it in the upper groove in the rod guide, [1]
taking care not to damage the dust seal.
Apply ATF to a new O-ring [4] and install it on the rod
guide.
[2]
[4]
Push in at an angle.
[1] Push i by deforming

Hold in the shape "U". it slightly.
[3]
[4]
[2]
[1]

18-31
dummyhead
TRIM/TILT
Apply marine grease to the rod guide threads [1].
[2]
Install the rod guide on piston rod B [2].
Extend piston rod B fully and hold it in that position.
Set one piston rod B in the left cylinder chamber and
one in the right cylinder chamber.
Do not install either piston rod B by pushing it into the
trim cylinder.
[1]
Holding each piston rod B in place, loosely tighten the
rod guides on the cylinders.
Do not install either piston rod B by pushing it into the
trim cylinder.
Using the special tool, tighten the left and right rod
guides [1] to the specified torque as shown.
[3]
TOOL:
Trim cap wrench, 4 mm [2] 070PA-001A100

incorrect.
[1] [2]
[2]
[3]
[4]
Apply ATF to the manual valve O-rings [1].

[3]
Install the manual valve [2] to the pump [3] and tighten it
to the specified torque.
[4] [2]
Install the internal circlip [4].
[1]
18-32
dummyhead
TRIM/TILT
Apply ATF to five new O-rings [1] and orifice collar [2].
Install the reservoir valve [3] into the cylinder [4].
Pump side: Cylinder side:
• Note the installation direction of the reservoir valve.
• Take care not to let the pin and steel ball come out
of the reservoir valve. [3]
Install the five O-rings and orifice collar in the cylinder
and install the pump [5] on the cylinder.
Install and tighten socket bolts A [6] and B [7] to the
[1] [3]
specified torque. [4]
[5]
[6]
[7] [2]
Fill the pump [1] fully with fresh ATF.

Do not fill up the pump quickly. Pour ATF in the pump
slowly.
[1]
Install filter B [1] and the drive joint [2] on the pump [3].
[2]
[1]
[3]

18-33
dummyhead
TRIM/TILT
After installation, check filter B for bubbles. Remove the
bubbles with an oil bottle [1] or an equivalent tool if
necessary.
Be sure to remove the air bubbles, or they will cause air
in the system.
After removing the air bubbles, fill the pump fully with
ATF again.
[1]
Apply ATF to a new O-ring [1] and install it on the power

tilt motor [2].
[1]
[2]
Install the power tilt motor on the pump by aligning the

projection [1] on the motor with the cutout in the drive
joint [2].
Set the motor wire of the power tilt motor facing toward [1]
the manual valve side.
Tighten the four power tilt motor mounting bolt/washers
[4] to the specified torque.
[2]
[3]
18-34
dummyhead
TRIM/TILT
Apply ATF to a new O-ring [1] and install it on the
cylinder.
[2]
Install the oil tank [2] on the cylinder and tighten the
three oil tank mounting bolt/washers [3] to the specified
torque. [3]
[1]
Remove the oil tank cap [1]. Pour fresh ATF to the
upper limit [2] of the oil tank filler port.
OIL CAPACITY:
0.68 liter (0.72 US qt, 0.6 Imp qt) [2]
• Do not overfill with ATF; that will damage the oil seal
of the motor when each rod is compressed.
After filling the oil tank with ATF, bleed air from the
power tilt/trim (without mounting on the outboard motor)
(page 18-36). [1]
Install the oil tank cap and tighten it to the specified
torque.

18-35
dummyhead
TRIM/TILT
AIR BLEEDING
• Bleed air from the unit whenever the power trim/tilt is
assembled.
• Perform the following procedure to bleed air:
1. Bleed air without mounting the unit on the outboard
motor.
2. Check hydraulic pressure (page 18-38).
3. Bleed air after mounting the unit on the outboard
motor (page 18-37).
Power trim/tilt not mounted on the outboard motor
1. Hold the power trim/tilt vertically.
2. Operate the power tilt motor to compress each rod
fully (Connect the battery [1] negative (–) cable to <To extend the rods>
the Green terminal [1] of the power tilt motor 2P [1]
connector [2], and the battery positive (+) cable to
the Blue terminal [3].)
3. Operate the power tilt motor to extend each rod fully
(Connect the battery positive (+) cable to the Green
terminal of the power tilt motor 2P connector, and
the battery negative (–) cable to the Blue terminal.)
[3]
• Connect the battery cables to the power tilt motor 2P

connector terminals with care not to short-circuit the
connector.
<To compress the rods>
[2]
[1]
[3]
4. Remove the oil tank cap with each rod extended

[1]
fully. Check whether the Automatic Transmission
Fluid (ATF) is at the upper limit [1] of the filler port.
If ATF does not flow out of the filler port, add ATF
until it flows out.
Check the fluid level with the rods fully extended.
Note that ATF will spurt out when the oil tank cap is
removed with the rods fully compressed.
5. After adding ATF, repeat the procedure from step 2
through 4 two or three times to bleed air from the
unit.
6. Be sure that the rods fully extend and compress
during the step 5 operation.
When the rods fully extend and compress fully,
perform the hydraulic pressure check (page 18-38).
If the rods do not compress fully, perform the
following procedure.
18-36
dummyhead
TRIM/TILT
7. With the rods extended fully, operate the power tilt
motor to extend each rod until the relief valve opens
again. Operate the power tilt motor to compress
each rod and be sure that the rods compress (page
18-38).
If the rods extend and compress fully, go to the
[1]
hydraulic pressure check (page 18-38).
8. If the rods do not compress after the step 7
operation, operate the power tilt motor to compress
each rod (page 18-36) while pushing piston rod B
[1], and check whether the rods compress.
9. If the rods still do not compress after the step 8
operation, loosen the manual valve [2] and
compress each rod. Tighten the manual valve
securely again. Operate the power tilt motor to
extend each rod fully, and then operate the power tilt
motor to compress the each rod and check whether
the rods compress fully (page 18-36).
10.If the rods do not compress after the above
operations, perform the following.
– Disassemble and assemble the power trim/tilt (page
18-41). [2]
– Bleed air with the power trim/tilt not mounted on the
outboard motor (page 18-37).
Air bleeding with the power trim/tilt on the outboard

motor
Perform the following procedure after bleeding air
without mounting the power trim/tilt on the outboard
motor and after checking the hydraulic pressure.
1. Install the power trim/tilt on the outboard motor
securely (page 18-11).
2. Push the "UP" side of the power trim/tilt switch, and
raise the outboard motor to the uppermost position.
3. Remove the oil tank cap [1], and check whether the
ATF is at the upper limit [2] of the oil filler port. Add
ATF if necessary. [2]
[1]

18-37
dummyhead
TRIM/TILT
4. Lower the outboard motor slowly to the lowermost
position by loosening the manual valve [1]. [1]
5. Tighten the manual valve to the specified torque. Tighten Loosen
6. Hold the outboard motor in the lowermost position
for five minutes.
7. Then, push the "UP" side of the power trim/tilt
switch, and raise the outboard motor to the
uppermost position. Hold the outboard motor in this
position for five minutes. After five minutes, check
the fluid level in the oil tank.
8. Repeat the procedure from step 4 through 7 five
times.
HYDRAULIC PRESSURE CHECK

After bleeding air from the power trim/tilt without
installing on the outboard motor and checking each rod
for proper compression, perform the following operation
in the same manner as bleeding air without installing on
the outboard motor.
– Be sure each rod is extended fully.
– Check the hydraulic pressure both at the upper and
lower chambers.
Lower chamber hydraulic pressure
Remove the internal circlip [1] and manual valve [2]
from the power trim/tilt.
A small amount of oil will flow out when the manual
valve is removed. Catch it with a container. [2]
Install the special tool where the manual valve was

removed as shown and tighten it to the specified torque.
TOOL:
Oil pressure gauge joint B [3] 07SPJ-ZW1020A

Attach the special tool to gauge joint B as shown.
[1]
TOOL:
Pressure gauge, 0 – 5,000 psi [4] 07KPJ-VD6020B
[3]
[4]
18-38
dummyhead
TRIM/TILT
Remove the oil tank cap [1] and check wether the ATF
is at the upper limit of the filler port [2].
[2]
[1]
Operate the power tilt motor to compress the each rod

(page 18-36) fully.
Operate the power tilt motor to extend each rod (page
18-36) fully again, and read the pressure gauge [1] to
measure the lower chamber hydraulic pressure.
LOWER CHAMBER HYDRAULIC PRESSURE:
8,826 – 11,768 kPa
(90 – 120 kgf/cm2, 1,280 –1,707 psi)
If a sharp pressure drop is observed, check the power
tilt motor for a damaged oil seal (page 18-28).
If the hydraulic pressure is lower than the specified
pressure, check for oil leaks.
Measure the upper chamber hydraulic pressure (page
18-39).
[1]
Upper chamber hydraulic pressure

After measuring the lower chamber hydraulic pressure,
remove the special tools (oil pressure gauge joint B [1] [2]
and oil pressure gauge [2]) with each rod fully
extended. [1]
Install the special tool and tighten the specified torque.
TOOL:
Oil pressure gauge joint A [3] 07SPJ-ZW1010A

Attach the pressure gauge to the special tool (oil
pressure gauge joint A).
[3]

18-39
dummyhead
TRIM/TILT
Remove the oil tank cap [1] and check wether the ATF
is at the upper limit of the filler port [2].
[2]
[1]
Operate the power tilt motor to compress the each rod

(page 18-36) fully, and read the pressure gauge [1] to
measure the upper chamber hydraulic pressure.
UPPER CHAMBER HYDRAULIC PRESSURE:

3,923 – 7,355 kPa (40 – 75 kgf/cm2, 569 –1,067 psi)
If the hydraulic pressure is lower than the specified
pressure, check for oil leaks.
[1]
After checking, operate the power tilt motor to extend

each rod (page 18-36). With each rod extended fully,
remove the special tools (oil pressure gauge [1] and oil [1]
pressure gauge joint A [2]).
Install the manual valve [3] to the pump and tighten it to
the specified torque.
[2]
Install the internal circlip [4].
Recheck the ATF level.
[4] [3]
18-40
dummyhead
TRIM/TILT
POWER TILT MOTOR DISASSEMBLY/
ASSEMBLY
DISASSEMBLY
Untape the corrugated teflon tube [1], and pull the tube
to the opposite side of the wire holder. [1]
[3] [2]
Remove the wire holder screw (stainless steel screw: 4
x 16 mm) [2]. Pull out the wire holder [3] and the two
grommets [4] from the yoke [5], and move them to the
tube side. [4]
[5]
• Pull out the grommets with care not to damage

them.
Remove the two screws (4 x 16 mm) [1] from the front

[2] [7]
bracket [2].
Wrap the armature shaft [3] with a shop towel [4] or
equivalent material to protect, and hold the shaft with
pliers [5]. [4]
Pushing the two motor wires [6] toward the yoke [7],
remove the armature/front bracket from the yoke.
Do not allow the commutator to become contaminated
with oil or grease.
[6]
[5] [3] [1]

18-41
dummyhead
TRIM/TILT
Pull the brushes [1] from the brush holders and remove
the two brush springs [2]. [1] [4]
Disconnect the motor wire (Blue wire) terminal [3] from [9] [6]
the breaker [4] while holding the breaker with a
screwdriver.
[5]
• Do not disconnect the Blue wire terminal without

holding the breaker, or it can cause damage to the [8]
breaker. Be sure to disconnect the terminal while
holding the breaker. [5]
• Take care not to touch the bimetal part of the [7]
breaker during removal. [3] [6]
Remove the two screws (4 x 10 mm) [5], brush terminal [10] [5]
[6], motor wire (Green wire) [7], brush holders A [8] and
B [9], and breaker.
Remove the O-ring [10] from the front bracket groove. [3]
[7]
Check the oil seal [11] for damage or wear.
Replace the oil seal with a new one if necessary.
Check the metal part [12] of the front bracket for
damage and wear.
Replace the front bracket assembly if necessary.
[12]
[2]
[11]
18-42
dummyhead
TRIM/TILT
EXPLODED VIEW
WIRE HOLDER SCREW

(STAINLESS STEEL: 4 x 16 mm)
1.4 N·m (0.14 kgf·m, 1.0 lbf·ft)
YOKE
ARMATURE
BLUE WIRE
SCREW (4 x 10 mm) (2)

GREEN WIRE
BRUSH HOLDER B
BRUSH HOLDER A
BREAKER
Do not touch the bimetal part.
BRUSH
BRUSH SPRING (2)
O-RING
FRONT BRACKET
OIL SEAL SCREW (4 x 16 mm) (2)

18-43
dummyhead
TRIM/TILT
ASSEMBLY
Apply grease to the oil seal lips.
[4]
Apply grease to a new O-ring [1] and install it to the [6]
front bracket groove [2]. [1]
Set brush holder A [3] and brush terminal [4] above the
motor wire (Green wire) terminal [5] and loosely tighten [11] [5]
the screw (4 x 10 mm) [6].
Be sure that the motor wire (Green wire) terminal and
the brush assembly wire terminal contact the respective
projections [7] on brush holder A, and then tighten the
screw.
Install the breaker [8] and brush holder B [9], and
tighten the screw (4 x 10 mm) [10].
Do not touch the bimetal part of the breaker.

Connect the motor wire (Blue wire) terminal [11] to the
breaker. [12]
[2]
Install the two springs [12] in place under the brush
holders A and B. [13] [8]
Set the two brushes [13] on the brush holders.
[9] [4]
[7]
[1]
[3]
[10]
[11] [5]
Apply grease to the sliding surface of the armature shaft

[1], taking care that the commutator surface [2] is not [1]
contaminated with grease.
Install the armature on the front bracket while pushing
the brush terminal into the holder.
• Be careful not to damage the brushes when
installing the armature into the front bracket.
[2]
[1]
18-44
dummyhead
TRIM/TILT
Make sure that there is no washer, etc. on the magnet
[6] [1]
in the yoke [1].
Wrap the armature shaft [2] with a shop towel [3] or
equivalent material, and hold the shaft with pliers [4].
[3]
Pulling the two motor wires [5] of the yoke side slowly,
install the armature/front bracket [6] on the yoke.
If it is hard to install the armature/front bracket in the
yoke, check whether the metal of the yoke (i.e. where
the armature shaft is installed) is out of position and
repeat. [5]
After installation, check that the armature turns
smoothly and tighten the two screws (4 x 16 mm) [7].
[4] [2] [7]
After tightening the two screws, connect the battery to
the power tilt motor 2P connector and check whether
the motor turns (page 18-46). If the motor does not turn,
disassemble the power tilt motor again, and check
whether the motor wire (Blue wire) terminal is
disconnected.
Install the two grommets [1] and wire holder [2] on the
yoke [3]. [2]
Tighten the screw (stainless steel screw: 4 x 16 mm) [4]
to the specified torque. Do not overtighten it.
[4]
[3]
[1]
Tape the corrugated teflon tube [1] with heat resisting

tape [2] so that the distance from the wire holder end to [2]
the tube end is 30 mm (1.2 in) or less as shown. [1]
Bleed air from the power trim/tilt without mounting on Wrap by two or three
the outboard motor (page 18-36). turns.
30 mm
(1.2 in) or
less

18-45
dummyhead
TRIM/TILT
POWER TILT MOTOR INSPECTION
OPERATION INSPECTION
Connect the battery [1] to the power tilt motor 2P
[2]
connector terminals [2] and check that the motor turns.
Connect the battery in reverse and check that the motor
turns in the opposite direction.
Connect the battery, being very careful not to cause a

short-circuit.
Disassemble and inspect the components of the motor
if there is any abnormality.
[1]
BRUSH LENGTH
Measure the brush length.

If brush length is less than the service limit, replace the
brush assembly.
BREAKER
Check for continuity between the brush and terminal.
If there is no continuity, replace the brush assembly.
18-46
dummyhead
TRIM/TILT
MICA DEPTH
Check the grooves of the commutator and measure the
mica depth [1].

If the grooves are clogged or mica depth is less than the
service limit, recut the grooves using a hacksaw blade
or a small file.
[1]
ARMATURE
Check for continuity between each segment.
If an open circuit exists between any two segments,
replace the armature.

armature coil core.

armature shaft.

18-47
dummyhead
TRIM/TILT
Place the armature on an armature tester (commercially
available.)
Hold a hacksaw blade close to the armature core.
If the blade is attracted to the core or vibrates when the
core is turned, the armature is shorted. Replace the
armature.
GAS ASSISTED DAMPER/SWIVEL CASE/STERN BRACKET

REMOVAL
[1]
– Engine (page 13-3)
– Mount case (page 17-2)
Raise the swivel case to the uppermost position (the
piston rod of the gas assisted damper is extended fully).
[2]
Remove the tilting bolt cap [1] and loosen the self-
locking nut [2] fully.
• The self-locking nut must not come off the tilting
shaft.
Remove the screw [1] and spacer [2].

Remove the two bolts [3], lead wire [4], and anode [5]
metal [5].
• Check the anode metal for corrosion. If it is corroded
excessively, replace with a new one. [3]
[2]
[4] [1]
Remove the nut [1], washer [2], and adjusting bolt [3].
[5] [4]
Remove the self-locking nut [4] and washer [5], and
remove the bolt [6].
[6] [3]
[1] [2]
18-48
dummyhead
TRIM/TILT
Remove the two E-rings [1], and upper cylinder pin [2].
[1]
[2]
[1]
Remove the self-locking nut [1] from the tilting shaft.

While holding the gas assisted damper [2], remove the L. stern bracket [3] and wave washer [4].
Remove the gas assisted damper and wave washers [5].
Remove the lower cylinder collar [6] and spacers [7].
Check the upper cylinder bushings [8] and lower cylinder bushings [9]. Replace the upper and lower cylinder
bushings with new ones if they are worn, damaged, or deformed.
• Store the gas assisted damper while holding it upright with the upper cylinder pin installation part up.
[8]
[4]
[5]
[3]
[1]
[6]
[5]
[7]
[9]
[9]
[7] [2]

18-49
dummyhead
TRIM/TILT
Remove the self-locking nut (7/8-14 UNF) [1] from the
tilting shaft [2].
Remove the swivel case [3] from the tilting shaft. [3]
[6]
Remove the wave washer [4] and tilting shaft from the
R. stern bracket [5].
• Check the bushings [6] mounted on the swivel case
and replace the them with new ones if they are worn,
damaged, or deformed.
Remove the swivel case bushings. [1]
Remove the O-ring [7] from the tilting shaft.
[7]
[2]
[4]
[5]
Store the gas assisted damper while holding it upright
with the upper cylinder pin installation part up.
[2]
[1]
• Never heat the gas assisted damper, as it can

explode.
• Never disassemble the gas assisted damper, as
it is filled with high pressured nitrogen gas.
• Be sure to release the gas from the gas assisted
damper before disposing of it.
Loosen the bolt [1], nut [2], and tilt lever [3].
[3]
Install the tilt lever by aligning the index mark [4] with
the punch mark [5] on the shaft. [4] [5]
Install the bolt and nut, and tighten the nut.
18-50
dummyhead
TRIM/TILT
DISPOSAL
The gas assisted damper assembly is filled with the
high pressured gas. Observe the following instructions.
[1]
• Never heat the gas assisted damper, as it can

explode.
• Never disassemble the gas assisted damper, as
it is filled with high pressured nitrogen gas.
• Be sure to release the gas from the gas assisted
damper before disposing of it.
[2]
Move the tilt lever to the "FREE" position with the piston
rod of the gas assisted damper assembly extended
fully.
Wrap the gas assisted damper in a vinyl bag [1], and
hold it upright in a vise as shown.
Inflate the vinyl bag with the cooling air from the drill
motor.
While releasing air from the bag to prevent the bag from
bursting, release the gas from the gas assisted damper
by drilling it at the plug bolt [2] (specified drill point).
Wear goggles during drilling and drill with care not to let
the vinyl bag get caught with the drill bit.
• Drill the gas assisted damper at the specified drill
point.
• Be sure to wear goggles during drilling.
The gas and drill chips will spurt out and scatter
when drilling through the gas assisted damper.

18-51
dummyhead
TRIM/TILT
EXPLODED VIEW
SCREW (6 x 8 mm)
SWIVEL CASE LEAD WIRE (137 mm)
SWIVEL CASE
BUSHING (2)
WAVE WASHER (26 mm) (4)
UPPER CYLINDER PIN TILTING SHAFT
E-RING (15 mm) (2)
TILTING CAP
SELF-LOCKING NUT
NUT (6 mm) (7/8-14 UNF mm)
34 N·m (3.5 kgf·m, 25 lbf·ft)
O-RING
UPPER CYLINDER
BUSHING (2) TILT LEVER
SELF-LOCKING NUT (25 x 2.0 mm) ADJUSTING BOLT

34 N·m (3.5 kgf·m, 25 lbf·ft)
SELF-LOCKING
NUT (10 mm)
WASHER (10 mm)

R. STERN BRACKET
L. STERN BRACKET BOLT (6 X 25 mm)
LOWER CYLINDER
BOLT (10 x 235 mm) LOWER CYLINDER
BUSHING (2)
COLLAR
SPACER (2)
NUT ANODE METAL
WASHER (6 mm)
WASHER
SCREW (6 mm)
BOLT (6 x 23 mm) (2)
LEAD WIRE (137 mm)
18-52
dummyhead
TRIM/TILT
INSTALLATION
of the swivel case bushings [1] and install them on the [6] [9]
swivel case [2].
Apply marine grease to the circumference of the new O-
ring [3], and install it in the groove [4] in the tilting shaft
[5] securely.
• Install the O-ring in the groove inside the tilting shaft
that is on the side of the short threaded end [6] of the
tilting shaft.
Apply marine grease to the tilting shaft bearing area. [4]
Apply marine grease to the swivel case and to the shaft [2]
installation part on the R. stern bracket [7].
[1]
Tighten a new self-locking nut (7/8-14 UNF) [8] on the
long threads end [9] of the tilting shaft.
• Tighten the self-locking nut (7/8-14 UNF) fully to the
[3]
end of the threaded part of the tilting shaft.
Apply marine grease to the wave washer [10].
Set the R. stern bracket and the wave washer on the
tilting shaft. [8]
Pass the tilting shaft through the swivel case.
[5]
[10] [7]
Check that the piston rod [1] of the gas assisted damper
is extended fully. [3]
of the lower cylinder bushings [2] and upper cylinder
bushings [3], and install them on the gas assisted
damper.
[1]
[2]

18-53
dummyhead
TRIM/TILT
Install the E-ring [1] in the upper cylinder pin [2].
[7]
Apply marine grease to the outer surface of the upper
cylinder pin.
[2]
Apply marine grease to the outer surface of the lower
cylinder collar [3], and install it in the gas assisted
damper [4]. [1]
Apply marine grease to the inner wall of the spacers [5]
and install them on the lower cylinder collar.
Apply marine grease to the wave washers [6].
Align the holes of the upper mount of the gas assisted
damper and wave washers with the hole in the swivel
case.
[6]
Insert the upper cylinder pin into the hole and install the
E-ring [7] in the groove on the other end of the upper
cylinder pin.
[4] [3]
[5]
Apply marine grease to the shaft installation part on the

L. stern bracket [1].
Apply marine grease to the wave washer [2] and install [2]
it on the tilting shaft.
Install the L. stern bracket on the tilting shaft.
Loosely tighten a new self-locking nut [3] on the tilting
shaft.
[3]
[1]
18-54
dummyhead
TRIM/TILT
While pushing the L./R. stern brackets lightly toward the
swivel case side, install the bolt [1] and the washer [2],
and loosely tighten the self-locking nut (10 mm) [3].
Tighten the self-locking nut (25 x 2.0 mm) [4] to the
specified torque so that the tilting shaft end is flush with
the nut end.

[1]
Tighten the self-locking nut (7/8-14 UNF) [5] to the
[2]
specified torque.
Tighten the self-locking nut (10 mm).
Apply marine grease to the threads of both sides of the
tilting shaft. [6]
[5]
Install the tilting bolt cap [6].
[4]
Set the lead wire [1] between the projections [2] on the
anode metal [3], and install them with the two bolts [4].
Tighten the bolts. [3]
• Before installation, check the anode metal for

corrosion and replace it with a new one if necessary.
Set the lead wire as shown and install the spacer [5]
and screw [6].
Tighten the screw.
[1]
[5]
[6]
[4]
[1]
[2]

18-55
dummyhead
TRIM/TILT
Install the adjusting bolt [1] and the washer [2], and
tighten the self-locking nut [3].
[1]
[2]
[3]
18-56
dummytext
19. CONTROLS
COMPONENT LOCATION ····················· 19-2 STEERING FRICTION SHAFT/ROD

REMOVAL/INSTALLATION (
REMOTE CONTROL CABLE/GROMMET TILLER HANDLE TYPE) ······················ 19-20
TILLER HANDLE REMOVAL/
SHIFT LINK BRACKET/NEUTRAL INSTALLATION·································· 19-21
SWITCH REMOVAL/INSTALLATION ······ 19-8
TILLER HANDLE DISASSEMBLY/
SEAL HOLDER REMOVAL/ ASSEMBLY ······································· 19-23
INSTALLATION ··································19-12
COMBINATION SWITCH INSPECTION ·· 19-45
SHIFT LINK BRACKET DISASSEMBLY/
ASSEMBLY ·······································19-13 WARNING BUZZER INSPECTION ········· 19-46
SEAL HOLDER WATER SEAL EMERGENCY STOP SWITCH

REPLACEMENT ·································19-14 INSPECTION ····································· 19-46
STEERING ROD REMOVAL/INSTALLATION INDICATOR LIGHT INSPECTION ·········· 19-47

(REMOTE CONTROL TYPE)·················19-14
POWER TRIM/TILT SWITCH INSPECTION
REMOTE CONTROL BOX (REMOTE CONTROL/ 19
DISASSEMBLY/ASSEMBLY·················19-15 TILLER HANDLE SIDE) ······················· 19-48

19-1
dummyhead
CONTROLS
COMPONENT LOCATION
CONTROLS
2.5 N·m (0.26 kgf·m, 1.8 lbf·ft)
19-2
dummyhead
CONTROLS
REMOTE CONTROL CABLE/GROMMET
REMOVAL
Remove the following part,
[2]
– Engine cover
Loosen the under case grommet band [1] and remove it
from the remote control cable grommet [2].
[1]
Remove the remote control cable (shift side) shift pivot

[1] from the shift link pin [2]. [3] [5] [6]
Remove the remote control (throttle side) shift pivot [3] [7]
from the throttle arm link pin [4].
Remove the bolt [5] and remove the remote control
cable cover [6].
Remove the remote control cables (shift side and
throttle side) [7] from the remote control cable plate and [1]
the remote control cable grommet.
[4] [2]
Open the harness band clip [1] positioned on the

remote control cable plate. [3]
Remove the remote control cable plate [2].
Release the 14P connector [3] and 6P connector [4]
from the relay bracket [5] and disconnect each
connector.
Remove the indicator light wire, remote control cable,
starter cable, and fuel tube A from the remote control
[2]
cable grommet [6]. (Remote control type only)
[4]
Remove the handle cable, starter cable, and fuel tube A
from the remote control cable grommet. (Tiller handle
type only)
[1]
[5] [6]

19-3
dummyhead
CONTROLS
COMPONENTS DRAWING
BOLT REMOTE CONTROL CABLE

(6 x 16 mm) (2) (THROTTLE SIDE)
REMOTE CONTROL
CABLE COVER
REMOTE CONTROL
CABLE (SHIFT SIDE)
REMOTE CONTROL
CABLE GROMMET
SHIFT PIVOT/
LOCK PLATE
14P
CONNECTOR
6P
CONNECTOR
UNDER CASE
GROMMET BAND
HARNESS BAND
CLIP
REMOTE CONTROL
CABLE PLATE
FUEL TUBE A
THROTTLE ARM
LINK PIN
SHIFT LINK PIN
STARTER CABLE
19-4
dummyhead
CONTROLS
INSTALLATION
Set the starter cable [1] on the front bracket [2].
• Align the tape end [3] on he starter cable with the
end of the front bracket.
[3]
[1]
[2]

Route the starter cable [1], fuel tube [2], 14P connector [5]
wire harness [3], and 6P connector wire harness [4]
through the cable grommet [5].
• Align the tie wrap band [6] on each of the 14P
connector wire harness and 6P connector wire [4]
harness with the end of the cable grommet. [3]
[1] [2]
[4] [6]
[3] [6] [5]

19-5
dummyhead
CONTROLS
Long tiller handle type:
[4]
Route the starter cable [1], fuel tube [2], and 14P/6P
connector wire harness [3] through the cable grommet
[4].
• Align the tape [5] on the 14P/6P connector wire [3]
harness with the end of the cable grommet.
[1] [2]
[5]
[3]
[4]
Install the cable grommet [1] in the groove in the front

bracket [2], aligning the flat part [3] of the front bracket
with the flat part [4] of the cable grommet.
[1]
[4]
[2] [3]
19-6
dummyhead
CONTROLS
Connect the 14P connector [1] and 6P connector [2] to
the engine side connectors [3] and secure the [1] [3]
connectors to the connector holders [4]. [8]
Install the remote control cable plate [5] and tighten the [7]
bolt [6].
[6]
Secure the 14P connector wire harness [7] and 6P
connector wire harness [8] with the new harness band
clip [9] and install it to the remote control cable plate.
After securing the 14P/6P connector wire harness, cut [5]
off the excess of the band so it does not interfere with [2]
the neighboring parts.
[9]
[4]
Route the throttle control cable [1] and shift control

cable [2] through the cable grommet [3]. [2] [1]
Align the groove [4] in the remote control cables (shift
and throttle) with the groove [5] in the remote control
cable plate.
Install the remote control cable cover [6] on the remote
control cable plate with the projection [7] on the remote
control cable cover set in the cutout [8] in the remote
control cable plate.
Tighten the bolt [9].
[3]
Install the lock nuts [10] and shift pivots [11] on the
remote control cables.
[14] [11]
Apply marine grease to the link pin installation port of [9] [6]
[10]
the shift pivot.
[4]
Connect the shift pivots to the shift link pin [12] and the
throttle arm link pin [13]. (Slide the lock plates [14] to
connect the remote control cables and lock.)
[14]
[13] [12] [5]
[7]
[8]

19-7
dummyhead
CONTROLS
Check that each cable and tube is set in the holes in the
cable grommet securely.
Secure the cable grommet [1] with the grommet band
[2].
[1]
Adjust the following parts.
– Throttle control cable(page 3-9)
– Shift control cable
Install the following parts.
– Engine cover
[2]
SHIFT LINK BRACKET/NEUTRAL

SWITCH REMOVAL/INSTALLATION
REMOVAL
Be sure that the remote control lever or shift lever is in
the "N" (Neutral) position. [2]
Remove the following parts:
– Engine cover
– R. engine under cover(page 6-5)
– Remote control cable/grommet (page 19-3)
– Stater cable/fuse cable (page 10-6)
Remove the two bolts [1] from the shift link bracket [2]
and remove the starter cable holder [3].
[1] [3]
Remove the throttle rod linkage pivot [1] from the

throttle plate [2]. [1]
Remove the two bolts [3] from the shift link bracket [4]. [2]
Remove the link pin of the shift link bracket [5] from the
shift arm [6], and remove the shift link bracket.
[5] [6]
[3] [4]
19-8
dummyhead
CONTROLS
Remove the snap pin [1] and remove the shift arm [2]
from the sift shaft. [1]
• Remove the snap pin with care not to move the shift
arm out of the “N” (Neutral) position. [2]
Release the neutral switch 2P connector [1] from the

neutral switch bracket [2] and disconnect the connector. [3]
Remove the harness band clip [3] that clamps the fuse [1]
cable from the neutral switch bracket.
Remove the bolt [4] from the neutral switch bracket, and
remove the neutral switch bracket.
[2] [4]
Remove clip A [1] from the neutral switch bracket [2].

Remove the nut [3] from the neutral switch [4]. Remove [4]
[1]
the neutral switch from the neutral switch bracket.
[2]
[3]

19-9
dummyhead
CONTROLS
REMOVAL
SNAP PIN
SHIFT ARM
THROTTLE ROD
CLIP A
NEUTRAL SWITCH
BRACKET
NUT (20 mm)

2.5 N·m (0.26 kgf·m, 1.8 lbf·ft)
BOLT BOLT (6 x 14 mm)
(6 x 18 mm) (2)
SHIFT LINK BRACKET
BOLT
(6 x 20 mm) (2)
STARTER CABLE HOLDER
19-10
dummyhead
CONTROLS
INSTALLATION
Set the neutral switch [1] on the neutral switch bracket
[2] and tighten the nut [3] to the specified torque. [1]
[4]
[2]
Set clip A [4] on the neutral switch wire and install clip A
on the neutral switch bracket.
[3]
Install the neutral switch bracket [1], aligning the two

holes [2] in the neutral switch bracket with the two [6] [5]
projections [3] on the crankcase as shown.
Tighten the bolt [4] securely.
Install the harness band clip [5] that clamps the fuse [3]
[3]
cable on the neutral switch bracket.
Connect the neutral switch 2P connector [6] and install
the connector on the neutral switch bracket.
[1] [4]
[2]
Apply marine grease the following part.

[4] [2]
– Shift shaft spline portion
– Detent spring roller/link pin contact portion
Install the shift arm [1] on the shift shaft, aligning the
projection on the shift arm [2] with the recess in the shift
shaft [3] as shown.
Set the snap pin [4] on the shift shaft securely as
shown.
[3]
[1]

19-11
dummyhead
CONTROLS
Apply marine grease to the following part.
[5]
– Circumference of the link pin of the shift link bracket
– Throttle plate (linkage pivot installation part)
– linkage pivot (throttle rod)
Install the shift link bracket [1], aligning the link pin [2]
with the long hole in the shift arm [3] and secure the
shift link bracket by tightening the two bolts [4].
Install the linkage pivot [5] on the throttle plate.
[2] [3]
[4] [1]
Check that the tip of the neutral switch [1] is pushed in [4]
the detent assisted spring [2] securely.
Check that the detent spring roller [3] is in the groove in
the shift arm [4] securely.
[3]
• Tighten the loosely tightened bolt [5] securely. [1]
[5]
[2]
Install the starter cable holder [1] on the shift link

bracket using the two bolts [2].
Install the following parts:
– Stater cable/fuse cable (page 10-8)
– Remote control cable/grommet (page 19-5)
– Engine cover
[2] [1]
SEAL HOLDER REMOVAL/

INSTALLATION
Remove the shift link bracket (page 19-8).
[1] [2]
Remove the two bolts [1] from the seal holder [2].
• Remove the seal holder, being careful not to allow
the shift shaft to come out of position in the mount
case.
Remove the seal holder while pushing the shift shaft
toward the mount case side.
• If required, replace the seal (page 19-14).
Remove the O-ring [3] from the seal holder. [3]
Apply marine grease to a new O-ring and install it to the
seal holder groove.
Insert the seal holder into the shift shaft slowly, and
tighten the two bolts securely.
Install the shift link bracket (page 19-11).
19-12
dummyhead
CONTROLS
SHIFT LINK BRACKET DISASSEMBLY/
ASSEMBLY
Remove the shift link bracket (page 19-8).
THROTTLE PLATE
(SLIDING SURFACE)
E-RING (4 mm) (3)
(WASHER MATING SURFACE) INSTALLATION

(MOUNTING
DIRECTION: (SEAT)
PORTION)
CHAMFER
BUSHING A (2)
(MATING SURFACE)
SHIFT PIVOT PLATE
(THROTTLE LINK
THROTTLE ARM
MATING SURFACE/
BEARING PORTION)
(SLIDING SURFACE)
LINK PIN
WASHER (6 mm)
(MOUNTING PORTION)
BOLT (6 X 12 mm)
PIVOT WASHER
THROTTLE LINK
DETENT SPRING
SHIFT LINK BRACKET
BOLT (6 X 16 mm)
INSTALLATION:
Loosely tighten.
Install the shift link bracket, DETENT ASSISTED WASHER (8 mm)
check that the detent spring SPRING
roller is in the groove in the
shift arm securely, and then
tighten the loosely tightened
bolt securely. SHIFT LINK PIN
SHIFT SLIDE PIVOT E-RING (6 mm)
LINK PIN

19-13
dummyhead
CONTROLS
SEAL HOLDER WATER SEAL REPLACEMENT
Remove the seal holder (page 19-12).
Remove the water seal (14 X 26 X 6 mm) [1] from the [2]
seal holder [2] using the commercially available oil seal
remover.
Apply soapy water to the circumference of a new water
seal (14 X 26 X 6 mm), and install it on the seal holder.
• The marked side of the water seal is faces the seal
holder.
Apply marine grease to the water seal lip.
Install the seal holder (page 19-12).
[1]
STEERING ROD REMOVAL/INSTALLATION (REMOTE CONTROL

TYPE)
BOLT (3/8-24 UNF)

22 N·m (2.2 kgf·m, 16 lbf·ft) TILTING BOLT CAP
STEERING CABLE
(Commercially available)
STEERING ROD COLLAR
STEERING ROD
SELF-LOCKING NUT (3/8-24 UNF) (2)

22 N·m (2.2 kgf·m, 16 lbf·ft)
WASHER (10 mm) (3)
19-14
dummyhead
CONTROLS
REMOTE CONTROL BOX DISASSEMBLY/ASSEMBLY
SHIFT PIVOT (2)
INSTALLATION:
Screw in the shift pivot 8 mm (0.3 in) or more onto the
threaded end of the cable.
8 mm (0.3 in)
REMOTE CONTROL
BOX COVER C
LOCK NUT
(10-32 UNF) (2)
LOCK PIN (6 mm) (2) SCREW (5 X 25 mm) (7)
SCREW (5 X 12 mm) (2) 2.5 N·m (0.26 kgf·m, 1.8 lbf·ft)
4.9 N·m (0.50 kgf·m, 3.6 lbf·ft)
FAST IDLE LEVER WASHER (6 mm) (2) REMOTE CONTROL

CABLE (THROTTLE SIDE)
CABLE CLAMP
SPACER
REMOTE CONTROL
BOX COVER B REMOTE CONTROL
CABLE (SHIFT SIDE)

19-15
dummyhead
CONTROLS
ELECTRIC COMPONENTS
EMERGENCY STOP
SWITCH
WARNING
BUZZER COMBINATION
SWITCH
SCREW (5 X 8 mm) (2) POWER TRIM/TILT SWITCH WIRE

0.7 N·m (0.07 kgf·m, 0.5 lbf·ft)
INSTALLATION:
Route the power trim/tilt switch wire and
POWER TILT set the power tilt cord clamp as shown.
CORD CLAMP
POWER TRIM/
TILT SWITCH
SPARE EMERGENCY WIRE
STOP SWITCH CLIP
POWER TILT
CORD CLAMP
NUT (16 mm) NUT (22 mm)

4.9 N·m (0.50 kgf·m, 3.6 lbf·ft)
1.5 N·m (0.15 kgf·m, 1.1 lbf·ft)
INDICATOR LIGHT
19-16
dummyhead
CONTROLS
SLIDING PLATE
SCREW
(5 X 10 mm)
LINK JOINT
WASHER (5 mm)
BRACKET
E-CLIP (4 mm)
NUT (5 mm)
FAST IDLE SPRING E-CLIP (7 mm)
4.9 N·m (0.50 kgf·m,
WASHER (6 mm) (2) 3.6 lbf·ft)
WASHER (8 mm)
BOLT
(5 X 16 mm)
FAST IDLE WHEEL
FAST IDLE DETENT

ROLLER (13 X 13 mm)
SCREW (6 X 10 mm)
5.9 N·m (0.60 kgf·m,
SCREW (5 X 10 mm) 4.4 lbf·ft)
2.5 N·m (0.26 kgf·m, 1.8 lbf·ft)
SPRING
SETTING PLATE
LINK JOINT ARM
FAST IDLE DETENT
SPRING (12.7 X 23.9 mm)
LINK JOINT
COLLAR (2)
WASHER (6 mm)
SLIDING PLATE/PLATE COLLAR

INSTALLATION:
Install the sliding plate with the “UP”
mark facing up.
PIN (6 X 6 mm) Attach the sliding plate collar to the
INSTALLATION: sliding plate with its wider side toward
the “UP” mark of the sliding plate.
Install in the concave area of the
control wheel as shown. PLATE COLLAR “UP” MARK
SLIDING PLATE
CONTROL WHEEL

19-17
dummyhead
CONTROLS
REMOTE CONTROL LEVER/CONTROL WHEEL
BOLT (8 X 35 mm) SCREW (5 X 10 mm)

23.5 N·m (2.4 kgf·m, 17 lbf·ft) NUT (6 mm) 2.5 N·m (0.26 kgf·m, 1.8 lbf·ft)
WASHER (4 mm) (2) WASHER (5 mm)
(Journal/hole)
CONTROL WHEEL
NEUTRAL SWITCH
SPACER
WASHER (28 mm)
FRICTION
SHIFT LINK ARM ADJUSTING BOLT
THROTTLE
FRICTION BLOCK
*1
SHIFT DETENT
SPRING E-RING (3 mm)
SHIFT DETENT SCREW (5 X 10 mm)

ROLLER 2.5 N·m (0.26 kgf·m, 1.8 lbf·ft)
SPRING SETTING
REMOTE CONTROL BOX PLATE
HOUSING A
WASHER (5 mm)
HARNESS GUIDE
PIPE SCREW (6 X 16 mm)
2.5 N·m (0.26 kgf·m, 1.8 lbf·ft)
NEUTRAL LOCK
BLOCK
*1: Use molybdenum disulfide grease (containing more than 3%

molybdenum disulfide, NLGI #2 or equivalent).
Example: REMOTE CONTROL
• Molykote® BR-2 plus manufactured by Dow Corning U.S.A. LEVER
• Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
19-18
dummyhead
CONTROLS
REMOTE CONTROL LEVER
NEUTRAL RELEASE
REMOTE CONTROL LEVER
LEVER SPRING
SCREW (5 X 10 mm)
4.9 N·m (0.50 kgf·m, 3.6 lbf·ft)
LEVER SETTING
REMOTE CONTROL PLATE
LEVER GRIP
SCREW (5 X 12 mm)
POWER TRIM/TILT 2.5 N·m (0.26 kgf·m, 1.8 lbf·ft)
SWITCH
REMOTE CONTROL
LEVER
WIRE HARNESS CLIP
HARNESS CLAMP
LEVER CAP

19-19
dummyhead
CONTROLS
STEERING FRICTION SHAFT/ROD REMOVAL/INSTALLATION
(TILLER HANDLE TYPE)
O-RING
STEERING
STEERING FRICTION ROD
FRICTION BLOCK
WASHER (8 mm)
(2)
STEERING
SELF-LOCKING
NUT (6 mm) FRICTION SHAFT
NUT (8 mm) (2)
SPLIT PIN
(2.0 mm) FRICTION BOLT
POSITION VARIATIONS OF STEERING FRICTION ROD

• Note that the steering friction rod [1] installation
position varies, depending on the installation Figure 1: Steering bracket
direction of the steering friction shaft [2]. side
Install the steering friction rod in the direction shown in Short
Figure 1.
Install the steering friction rod on the steering bracket
[3] in the position shown in Figure 2 or 3.
Tighten the self-locking nut so that there is no play in [1] Long
the steering friction rod. Steering friction
After tightening, check that the steering friction shaft shaft side
and the steering friction rod move smoothly with the
friction bolt [4] loosened.
Figure 2:
[2]
[4]
[3] [1]
Figure 3:
[2]
[1]
[4] [3]
19-20
dummyhead
CONTROLS
TILLER HANDLE REMOVAL/INSTALLATION
REMOVAL
Remove the control cables (page 19-3).
Remove the two self-locking nuts [1] and two washers
[2]. [1]
[2]
[2]
[1]
Remove the two bolts [1] and two washers [2] from the steering bracket [3], and remove the tiller handle [4] and
friction rod [5].
[4]
[3]
[2]
[5]
[1]

19-21
dummyhead
CONTROLS
INSTALLATION
Set the steering bracket [1] of the tiller handle [2] on the mount frame [3] and install the two washers [4] and two
bolts [5]. loosely tighten the bolts.
Apply marine grease to the seating area (at two places) of the steering friction rod [6]. Install the steering friction
rod on the steering bracket and the steering friction shaft as shown. Note the installation direction of the
steering friction rod.
Install and tighten the bolts.
[3]
[2]
[1]
[4]
Steering bracket
side
Short
[6]
[5]
[6] Long
Steering friction
shaft side
Install the two washers [1] and two self-locking nuts [2].
Tighten the self-locking nuts.
• Note that the steering friction rod [3] installation [2]
position varies, depending on the installation
direction of the steering friction shaft [4] (page 19- [1]
20).
Install the control cables (page 19-5).
[3]
[4]
[1]
[2]
19-22
dummyhead
CONTROLS
TILLER HANDLE DISASSEMBLY/ASSEMBLY
DISASSEMBLY
Remove the tiller handle (page 19-21).
[1] [2]
Remove the six screws [1] and under cover [2].
Remove the grommet [1] from the tiller handle.

[4]
Remove the two E-rings [2] from each of the two remote
control cables [3], and disconnect the remote control [5] [1]
cables from the throttle arm and the shift frame.
Remove the two bolt/washers [4] and remove the cable [6]
bracket [5] and clamp bracket [6].
[3]
[2]
Open the harness band clip [1] that clamps tube B [2].
[1] [2]
Remove tube B and disconnect the three power trim/tilt [4]
switch connectors (Except LHGX type) [3].
Disconnect the two emergency stop switch connectors
[4].
[3]

19-23
dummyhead
CONTROLS
Remove the harness band clip [1] that clamps the cord
tube (40 mm) [2] from the connector bracket [3] as [1]
shown. [2]
[3]
Remove the switch clip [1] from the emergency stop

switch [2].
Remove the nut [3] from the emergency stop switch, [1]
[3]
and push the emergency stop switch into the housing.
[2]
Remove the nut [4] from the combination switch, and
push the combination switch [5] into the housing.
[4] [5]
19-24
dummyhead
CONTROLS
Remove the bolt [1] from the connector bracket [2], and remove the harness and the connector bracket as a set
from the tiller handle.
Remove the harness band clip [3], which clamps tube A [4], from the connector bracket.
Remove the warning buzzer [5] from the housing.
[4]
[3]
[2]
[1]
[5]
Open the harness band clip [1] that clamps the cord
tube (40 mm) [2]. [1]
Remove all the connectors [3] from the cord tube (40
mm).
[2]
[3]

19-25
dummyhead
CONTROLS
Open the harness band clip [1] that clamps tube A [2].
Disconnect all the combination switch connectors [3].
Disconnect the two warning buzzer connectors [4].
[3] [1]
[2]
[4]
Disconnect all the indicator light connectors [1].

Remove the indicator light [2] from the tiller handle by
pushing the retaining tabs [3] on the right and left sides
to the indicator light as shown.
[1]
[2]
[3] [3]
19-26
dummyhead
CONTROLS
Remove the bolt [1] and height adjust block [2].
Remove the nut (small) [3] that tightens the steering bracket.
Remove the bolt [4], nut (large) [5], wave washer [6], distance collar [7], and washer (12 mm small) [8].
Remove the steering bracket [9] and washer (12 mm large) [10].
Check the steering handle bushings [11] mounted on the steering bracket installation part of the tiller handle for
wear, damage, or deformation. Replace the bushings with new ones if necessary.
[7]
[6] [9]
[5]
[3]
[8]
[2]
[4]
[1]
[10]
[11]
[11]
Remove the grip rubber [1] and bolt [2].
[1]
[2]

19-27
dummyhead
CONTROLS
Loosen the throttle friction grip [1] of the grip pipe [2],
and turn the grip pipe clockwise to remove it from the
tiller handle.
[2]
[1]
Remove the throttle friction grip [1], throttle friction pad,

[2] and the throttle friction block [3] from the grip pipe [4]
[4].
[2]
[3]
[1]
• Except LHGX type:

Open the two harness bands [1] of the wire cover [2].
[2] [3]
Remove the two screws [3], and remove the wire cover.
Remove the bolt [4] and the washer [5], and remove the [1]
power trim/tilt switch [6].
Remove the switch grommet [7] and the switch holder
[8] from the power trim/tilt switch. [4]
• LHGX type only:

Remove the bolt [4] and the washer [5], and remove the
switch holder [8].
Remove the switch hole grommet [9].
[5]
[8]
[9]
[6]
[7]
19-28
dummyhead
CONTROLS
Remove the cap [1].
[1]
Loosen the socket bolt [2] by approximately 10 mm (0.4 [2]
in). [4]
Remove the shift lever [3] from the tiller handle by
lightly tapping the bolt head with a plastic hammer. [5]
Remove the socket bolt and the washer [4] from the
shift lever, and remove the lever stopper [5] and the
shift lever from the tiller handle.
Remove the O-ring [6] from the shift lever.
Check the bushing [7] for wear or damage and replace
it with a new one if necessary.
[7]
[6]
[3]
Remove the two bolt/washers [1] from the shift frame [2].
Remove the three bolts [3], three washers [4], and the guide plate [5], and then remove the throttle arm [6]/
throttle rod [7] and the shift frame as a set.
Remove the E-ring [8], and remove the throttle rod and the two washers [9].
Remove the steel ball [10] from the shift frame.
[10]
[6] [7]
[9]
[3]
[8]
[9]
[1]
[4]
[5]
[2]

19-29
dummyhead
CONTROLS
Remove the throttle cable pin [1] from the throttle cable
pivot [2]. [1] [4]
Loosen the nut [3] of the throttle cable pivot, and [3]
remove the throttle cable pivot, nut, and rod grommet
[4] from the throttle rod [5].
[5]
[2]
Remove the two screws [1] and remove the lock plate [2].
Remove the two screws [3], and remove the spring guide [4], spring [5], shift arm pin [6], and the roller [7].
Remove the shift gear [8] and the bushing [9] from the shift frame [10].
[1]
[2]
[7] [6]
[8]
[5]
[4]
[9] [3]
[10]
19-30
dummyhead
CONTROLS
EXPLODED VIEW
UNDER COVER/CABLE/STEERING BRACKET
SCREW (5 x 12 mm) (6)

2.4 N·m (0.24 kgf·m, 1.8 lbf·ft)

(THROTTLE SIDE)
UNDER COVER
REMOTE CONTROL BOLT/WASHER (6 X 12 mm) (2)

CABLE (SHIFT SIDE)
7 N·m (0.71 kgf·m, 5.2 lbf·ft)
STEERING BRACKET
CABLE BRACKET
E-RING (4 mm) (2)

WAVE WASHER
(14 mm)
CLAMP BRACKET
DISTANCE COLLAR
NUT
(12 mm SMALL) WASHER
(12 mm SMALL)
BOLT (12 X 80 mm)

NUT 29 N·m (3.0 kgf·m,
(12 mm LARGE) 21 lbf·ft)
GROMMET
HEIGHT ADJUST
BRACKET
BOLT (8 X 28 mm)
STEERING HANDLE
BUSHING (2)
WASHER
(12 mm LARGE)

19-31
dummyhead
CONTROLS
ELECTRIC PARTS
HARNESS BAND
CLIP (3) EMERGENCY
TUBE B STOP SWITCH
POWER TRIM/TILT
SWITCH WIRE
(Except LHGX type)
GROMMET
INDICATOR
WARNING LIGHT WIRES
BUZZER WIRE
COMBINATION
SWITCH
BOLT (6 X 12 mm)
7 N·m (0.71 kgf·m,
5.2 lbf·ft)
TUBE A
SWITCH CLIP CORD TUBE

(40 mm)
NUT
CONNECTOR
3.9 N·m (0.40 kgf·m, BRACKET
2.9 lbf·ft)
NUT (16 mm)

1.2 N·m (0.12 kgf·m,
0.9 lbf·ft)
WARNING INDICATOR
BUZZER LIGHT
19-32
dummyhead
CONTROLS
POWER TRIM/TILT SWITCH/THROTTLE
SCREW (5 X 10 mm) (2)

(Except LHGX TYPE)
WIRE COVER
(Except LHGX TYPE)
SWITCH HARNESS BAND (2)
HOLDER (Except LHGX TYPE)
BOLT (5 X 8 mm)
4.5 N·m (0.46 kgf·m,
3.3 lbf·ft)
SWITCH HOLE GROMMET

(LHGX TYPE ONLY)
WASHER

(Except LHGX TYPE)
SWITCH GROMMET
(Except LHGX TYPE)
THROTTLE
FRICTION BLOCK
GRIP PIPE
THROTTLE
FRICTION PAD
THROTTLE
FRICTION GRIP
BOLT (6 X 12 mm)
GRIP RUBBER
7 N·m (0.71 kgf·m, 5.2 lbf·ft)

19-33
dummyhead
CONTROLS
SHIFT LEVER/SHIFT GEAR
BOLT (5 X 12 mm) (3)

4.5 N·m (0.46 kgf·m, 3.3 lbf·ft)
WASHER (5 mm) (3) THROTTLE ARM
THROTTLE ROD
WASHER
GUIDE PLATE (10 mm) (2) STEEL BALL
ROD GROMMET E-RING (9 mm)

NUT (5 mm)
1.3 N·m (0.13 kgf·m, 1.0 lbf·ft)
SCREW (5 X 14 mm) (2)
BOLT/WASHER
THROTTLE (6 X 12 mm) (2)
CABLE PIN 7 N·m (0.71 kgf·m,
5.2 lbf·ft)
SHIFT ARM PIN
THROTTLE ROLLER LOCK

CABLE PIVOT PLATE
SHIFT GEAR
SPRING
GUIDE
SPRING
CAP
BUSHING
SOCKET BOLT
(8 X 50 mm) SCREW
(5 X 14 mm) (2)
SHIFT FRAME
WASHER (8 mm)
(Side and upper surface)

LEVER STOPPER
SHIFT LEVER
BUSHING
O-RING
19-34
dummyhead
CONTROLS
ASSEMBLY
Install the lock plate [1] on the spring guide [2].
Install and tighten the two screws [3]. [3]
[5] [1]
Apply marine grease to the outer surface of the spring [4]
[4], shift arm pin [5], and the roller [6].
[6]
Install the shift arm pin and spring on the spring guide
by noting the shift arm pin installation direction as [2]
shown. [9]
Apply marine grease to the outer surface of the bushing
[7], and install it on the shift frame [8].
[7]
[12]
[11]
[8]
UP
Apply marine grease to the shift gear [9] in the positions
shown. [5]
[6]
Install the roller of the spring guide on the roller
[9]
installation part of the shift gear as shown.
Apply marine grease to the gear [10] of the arm [11] of
the shift frame.
Set the shift frame so that the arm is at right angles to
the horizontal line as shown.
Install the shift gear/spring guide assembly on the shift [1]
frame with care not to move the arm of the shift frame.
• If the arm of the shift frame moved, remove the shift [2] [4]
gear/spring guide assembly once and install them [11]
again.
Install and tighten the two screws [12] on the shift [10]
frame.
[8]
Apply marine grease to the sliding surface of the throttle

cable pivot [1]. [3]
Apply marine grease to the sliding surface of the throttle [4]
rod [2].
Install the rod grommet [3] on the throttle rod and
Tighten the nut [4] on the throttle rod.
Tighten the throttle cable pivot on the throttle rod.
[2]
[1]

19-35
dummyhead
CONTROLS
Set the steel ball [1] in the position as shown.
Apply marine grease to the pin of the throttle arm [2].
Apply marine grease to the throttle rod [3] at position as shown.
Set the two washers [4] and the throttle rod on the throttle arm, and install the E-ring [5] securely as shown.
Apply marine grease to the pivot points of the throttle arm.
Set the throttle arm in the cutout [6] in the guide plate [7] as shown.
Assemble the throttle arm/throttle rod assembly with the shift frame [8].
Set the throttle arm/throttle rod/shift frame assembly on the tiller handle [9] while aligning the steel ball with the
groove [10] in the housing.
Install the three bolts [11] and washers [12], and tighten them to the specified torque. Note that the throttle arm
does not interfere with the cutout in the guide plate.
Install and tighten the two bolt/washers [13] to the specified torque.
Tighten the nut [14] of the throttle rod to the specified torque.
Apply marine grease to the side and upper of the shift frame.
[1]
[1]
[2] [3] [4]

[11]
[5]
[4]
[12] [13]
[6]
[7]
[14]
[8]
[10]
[9]
19-36
dummyhead
CONTROLS
Apply marine grease to the indicated position of the
housing [1] and to the outer surface of the bushing [2], [8] [6]
and then install the bushing on the housing.
[7]
Apply marine grease to the new O-ring [3] and install it
[5]
on the shift lever [4].
Apply marine grease to the sliding surfaces of the shift
lever and lever stopper [5].
Install the shift lever and the lever stopper, aligning the
square parts of both the shift lever and lever stopper
with the square holes in the shift gear as shown.
Install the socket bolt [6] and washer [7] and tighten it.
Install the cap [8] on the housing.
[1]
[2]
[3] [4]
• Except LHGX type:

[1]
Install the switch holder [1] on the power trim/tilt switch [5]
[2] with the "UP" mark [3] on the power trim/tilt switch
toward the bolt installation hole [4] in the switch holder
as shown.
Install the switch grommet [5] on the power trim/tilt
switch.
Install the power trim/tilt switch, bolt [6], and washer [7]. [4]
Tighten the bolt to the specified torque.
[2]
• Check that the power trim/tilt switch wire does not
interfere with the throttle rod and the bolt.
Install the wire cover [8], and tighten the two screws [9]. [8] [9]
Set the two new harness bands [10] in the recess on [10]
both ends of the wire cover, and secure the power trim/
tilt switch wire and the wire cover together using the
harness bands. [6]
Cut off the excess of each band so it does not interfere
with a neighboring part.
• LHGX type only:

Set the switch hole grommet [11] on the switch holder.
Install the switch holder, bolt, and washer.
Tighten the bolt to the specified torque. [7]
[1]
[11]
[2]
[5]

19-37
dummyhead
CONTROLS
Apply marine grease to the grip pipe installation part of
the tiller handle. [1]
Install the throttle friction block [1] on the tiller handle by

aligning the wide projection [2] on the tiller handle with
the wide recess [3] in the friction block.
[3]
[2]
Apply marine grease to the outer surface of the throttle

cable pin [1].
Install the throttle cable pin on the throttle cable pivot so [1]
that the pin ends protrude from the throttle cable pivot
by the dimensions shown. 3 mm (0.12 in)
7 mm (0.28 in)
Apply marine grease to the inner wall of the grip pipe

[1], circumference of the throttle friction pad [2].
[6]
Install the throttle friction pad on the grip pipe.
Install the grip pipe on the tiller handle by turning the
grip pipe counterclockwise slowly.
Tighten the throttle friction grip [3] against the throttle 3 mm (0.12 in)
friction block [4], aligning the recess [5] in the throttle
friction pad with the projection [6] on the throttle friction
block.
[4]
[5] [1]
[2]
[3]
19-38
dummyhead
CONTROLS
Install and tighten the bolt [1] to the specified torque.

Check that the grip pipe is tightened securely by turning
it clockwise fully (full close position), and tighten the
throttle friction grip securely.
Install the grip rubber [2] on the grip pipe with the " "
mark [3] facing up. [3]
[1]
[2]
After installing the grip rubber [1], operate the throttle

grip and check that the " " mark [2] on the grip rubber
aligns with the fully open position or full close position [2]
(" " mark) [3] of the throttle mark.
If not, remove the grip rubber and install it again.
[1]
[3]

19-39
dummyhead
CONTROLS
Apply marine grease to the side and outer surface of the steering handle bushings [1] and to the inner wall of
the housing.
Install the steering handle bushings on the tiller handle.
Apply marine grease to the washer (large) [2].
Set the washer (large) in the position shown, and install the steering bracket [3] on the tiller handle.
Apply marine grease to the wave washer [4].
Install the washer (small) [5], bolt [6], distance collar [7], wave washer and the nut (large) [8], and tighten the
bolt to the specified torque.
• Check that the threads of the bolt are not contaminated with marine grease.
Install the nut (small) [9].
Holding the bolt, tighten the nut (small).
Set the height adjusting block [10] and bolt [11] on the steering bracket, and tighten the bolt.
[7]
[3]
[8] [4]
[9]
[5]
[10]
[6]
[11]
[2]
[1]
Install the indicator light [1] on the tiller handle so the display appears as shown.
• Install the indicator light by pushing the frame [2] on both ends of the display. Do not install the indicator light
by pushing the center of the display.
• After installation, check that the retaining tabs [3] of the indictor light are locked on the tiller handle securely.
[2]
[3]
[1]
19-40
dummyhead
CONTROLS
Connect the connectors to the indicator light connectors [1], combination switch connectors [2], and warning
buzzer connectors [3].
Set tube A [4] over the connectors that were just connected, and clamp tube A at the connectors securely using
a new harness band clip [5].
After clamping with the harness band clip, cut off the excess band at 15 – 20 mm (0.6 – 0.8 in) from the fastener
end.
• Do not set the Black connector [6] of the combination switch connector in tube A.
[5]
[2] [5]
[6]
15 – 20 mm
(0.6 – 0.8 in)
[4]
[3]
[1]
Set the connectors [1] in the cord tube (40 mm) [2] and
clamp the tube using a new harness band clip [3] as
shown. [3]
After clamping with the harness band clip, cut off the
excess band at 15 – 20 mm (0.6 – 0.8 in) from the [2]
fastener end.
[1]

19-41
dummyhead
CONTROLS
Install the combination switch [1] on the tiller handle [2],
aligning the cutout [3] in the combination switch with the [3]
flat part [4] in the switch installation part of the tiller
handle as shown. [4]
Install the emergency stop switch [5] on the tiller
handle, aligning the cutout [6] in the emergency stop
switch with the flat part [7] in the switch installation part
of the tiller handle as shown.
[1]
[2]
[5]
[6]
[2]
[7]
Install the connector bracket [1] and bolt [2], and tighten it to the specified torque.
Install tube A [3] and set the harness band clips [4] to the connector bracket.
[3]
[4]
[1]
[4]
[2]
19-42
dummyhead
CONTROLS
Install the warning buzzer [1] in the housing.
Route the warning buzzer wire [2] between the [1]
projections [3] in the housing as shown.
• Operate the throttle arm and check that it does not
interfere with the warning buzzer wire.
[3] [2]
Install the nut [1] on the combination switch and tighten

the nut to the specified torque.
[3]
Install the nut (16 mm) [2] on the emergency stop
switch and tighten the nut to the specified torque.
Set the switch clip [3] to the emergency stop switch.
[1]
Connect the power trim/tilt switch connectors [1]

(except LHGX type). [5] [4]
[2]
Connect the emergency stop switch connectors [2].
Fold back the power trim/tilt switch wire [3] and set it in
tube B [4] as shown (Except LHGX type).
Holding the emergency stop switch connectors in tube
B, clamp tube B at the connectors securely using a new
harness band clip [5].
After clamping with the harness band clip, cut off the
excess band at 15 – 20 mm (0.6 – 0.8 in) from the
fastener end.
• Check that the wires are not interfering with the tiller
handle.
[1]
[3]

19-43
dummyhead
CONTROLS
Apply thread locking agent (LOCTITE® 242 or
equivalent) to the threads of the two bolt/washers [1]. [1]
Install the cable bracket [2] and clamp bracket [3], and [2] [5]
tighten the two bolt/washers to the specified torque.
TORQUE: 7 N·m (0.71 kgf·m, 5.2 lbf·ft) [3]
Set the shift side remote control cable [4] in the handle
cable installation hole in the grommet [5], and set the
throttle side remote control cable [6] in the handle cable
installation hole by viewing the grommet from the
outboard motor side as shown.
Install the grommet on the tiller handle.
• Note that the longer remote control cable is the shift [4]
side cable, while the shorter cable is the throttle side
cable.
Set the shift side and throttle side remote control cables [6]
on the shift frame and the throttle arm respectively, and
install the two E-rings [7] securely. [7]
• Check that the throttle side remote control cable
[4]
does not interfere with the power trim/tilt switch [5]
(except LHGX type only).
[6]
Viewing the grommet from the outboard motor side:
Set the tiller handle harness [1] through the grommet [2]
with the bands [3] on either side of the grommet. [1]
[2]
Viewing the grommet from the outboard motor side:
[3] [2]
[1]
19-44
dummyhead
CONTROLS
Clean the housing and under cover mating surfaces
thoroughly using a shop towel and degreasing cleaning 20 mm
solvent. (0.8 in)
Apply liquid gasket (ThreeBond® #1216E or equivalent)
to the housing in the areas shown.
9 mm
(0.4 in)
Install the under cover [1] and six screws [2] and tighten
them to the specified torque. [2] [1]

Install the tiller handle (page 19-22).
COMBINATION SWITCH INSPECTION

Check for continuity between the terminals with the
switch in each position. Black/
White
Color IG BAT LOAD ST
E
Black/ White/ Black/ Black/ White/
Black
Position Red Black Yellow White Black
OFF
Black/
ON Yellow
START Black
: Continuity Black/Red

19-45
dummyhead
CONTROLS
WARNING BUZZER INSPECTION
Connect the Black/Yellow terminal of the warning
buzzer to the positive (+) terminal of the 12 V battery
and the Yellow/Green terminal to the negative (–)
terminal of the battery. The warning buzzer should
sound.
Black/ Yellow/
Yellow Green
12V
EMERGENCY STOP SWITCH

INSPECTION
Attach the tester leads [1] to the two terminals of the
emergency stop switch [2] and check for continuity. [1] <Remote control type>
Black
Switch clip position Continuity
Switch clip set No [2]
Switch clip not set Yes
Switch clip set and switch pushed Yes
Black/Red
<Tiller handle type>
Black/Red
Black
Switch clip set and Switch clip not set.

switch pushed.
19-46
dummyhead
CONTROLS
INDICATOR LIGHT INSPECTION
Route the indicator light wires as shown. Connect
switch A [1] and switch B [2], which are connected to [1]
the battery negative (–) terminal, to the Black and [2]
Yellow terminals. Black/Yellow
Connect the battery positive (+) terminal to the Black/ Black
Yellow terminal.
Check that the oil indicator light (Green light) [3] comes Yellow
ON when switch A is ON.
Check that the oil indicator light (Green light) goes OFF
when switch A and switch B are ON.
12V
[3]
Connect the battery positive (+) terminal to the indicator

light Black/Yellow terminal and the battery negative (–)
terminal to the White/Blue terminal as shown. Alternator
indicator light (Red light) [1] should come ON.
Red White/Blue
Connect the battery positive (+) terminal to the indicator Red/Blue Black/Yellow
terminal to the Red terminal as shown. Overheat
indicator light (Red light) [2] should come ON.
Connect the battery positive (+) terminal to the indicator
terminal to the Red/Blue terminal as shown. MIL (Red
12V
light) [3] should come ON.
[1]
[2] [3]

19-47
dummyhead
CONTROLS
INSPECTION (REMOTE CONTROL/
TILLER HANDLE SIDE)
Check for continuity between the terminals with the
switch in each position. <Remote control type>
White/Black Light green

Light White/
Light blue
green Black Light blue
NORMAL
UP
DOWN
: Continuity
<Tiller handle type>
White/Black
Light green
Light blue
19-48
dummytext
20. TECHNICAL FEATURES
OIL PRESSURE ALERT SYSTEM ·········· 20-2 COMPACT & HIGH POWER ALTERNATOR +
DIRECT WATER-COOLED REGULATOR/
CAM CHAIN TENSION ADJUSTMENT RECTIFIER ········································· 20-6
SYSTEM & LUBRICATION
MECHANISM ······································ 20-5 LOW SPEED SIDE INTAKE ROCKER ARM
STRUCTURE (BF90D/BF100A ONLY)····· 20-7
20

20-1
dummyhead
TECHNICAL FEATURES
OIL PRESSURE ALERT SYSTEM
TECHNICAL FEATURES
SYSTEM DESCRIPTION
This model utilizes an oil pressure alert system with the EOP sensor, which detects the oil pressure linearly, instead of a
conventional system that uses two EOP switches (high pressure side/low pressure side).
This system enables more accurate control of pressure alert, depending on the engine speed and engine temperature, which
realizes an enhanced reliability of the whole system.
CONVENTIONAL SYSTEM WITH EOP SWITCHES: NEW SYSTEM WITH EOP SENSOR:
EOP SWITCH (HIGH

PRESSURE SIDE)
EOP SENSOR
EOP SWITCH (LOW

PRESSURE SIDE)
CONVENTIONAL SYSTEM NEW SYSTEM
DETECTION OPERATION
CONTROL DETECTION CONTROL OPERATION
EOP SWITCH
(LOW ECM ECM
PRESSURE SIDE)
P OPSL
OIL OIL
INDICATOR POIL INDICATOR
LIGHT EOP SENSOR LIGHT
EOP SWITCH
(HIGH Bu
PRESSURE SIDE)
Y/R VCC2
Y/R OPSH WARNING WARNING
BUZZER G SG2 BUZZER
G/R SG2
ENGINE ENGINE
SPEED ENGINE SPEED ENGINE
SPEED SPEED
CONTROL CONTROL
ENGINE ENGINE
TEMPERATURE TEMPERATURE
20-2
dummyhead
TECHNICAL FEATURES
EOP SENSOR
A conventional EOP switch is an ON/OFF pressure switch, which includes a mechanical contact, that turns ON when the oil
pressure is below a specified value and turns OFF when the pressure is above a specified value.
The EOP sensor includes a piezoelectric device which converts the electronic signals into voltage, which ranges from 0 to 5 V, and
transmits to the ECM. The electronic resistance of the piezoelectric device changes in accordance with the oil pressure, sending a
smaller signal when the oil pressure is low and a larger signal when the oil pressure is high.
CONVENTIONAL SYSTEM NEW SYSTEM WITH EOP SENSOR:

WITH EOP SWITCHES:
CYLINDER BLOCK CYLINDER BLOCK

PIEZOELECTRIC
DIAPHRAGM DEVICE
CONTACT
EOP SENSOR
TERMINAL
EOP SWITCH
EOP SENSOR
EOP SWITCH TERMINAL OIL PASSAGE OIL PASSAGE
5V
ON
VOLTAGE
OFF
FIXED OIL
PRESSURE VALUE 0V
LOW HIGH LOW HIGH

OIL PRESSURE OIL PRESSURE

20-3
dummyhead
TECHNICAL FEATURES
ABNORMAL OIL PRESSURE DETECTION
In a conventional system, the ECM uses two EOP switches (low/high pressure) in order to detect an abnormal oil pressure
according to the operating condition that varies with the engine speed and engine temperature.
On this newly introduced oil pressure alert system, the ECM detects linear change of oil pressure by the EOP sensor, constantly
compares the constantly changing detected value with the normal value depending on engine speed and temperature, in order to
find an abnormal oil pressure.
EOP SWITCH EOP SENSOR

SPECIFIED VALUE
OIL PRESSURE
DETECTED VALUE
OIL PRESSURE
Alert system
operates if the
(3) detected value is
lower than specified.
(2)
ENGINE
(1) SPEED
NE1 NE2 ENGINE SPEED
(1): Controlled by the EOP switch (low pressure side)

(2): Intermediate area (low/high switches depending ENGINE
on operating condition) TEMPERATURE
(3): Controlled by the EOP switch (high pressure side)
FAIL-SAFE OPERATION WHEN ABNORMAL OIL PRESSURE IS DETECTED

When the ECM detects an abnormal oil pressure, it conducts the following fail-safe operations.
1. Turns OFF the oil indicator light (Green)
2. Sounds the warning buzzer continuously
3. Limits the engine speed below 1,800 min-1 (rpm)
When the abnormal oil pressure is cleared, the ECM will turn ON the oil indicator light (Green) and stops the warning buzzer, then
gradually increases the engine speed to normal operating speed.
Abnormal oil pressure detected:

ECM conducts the fail-safe operations.
CRUISING 1) Turns OFF the oil indicator light (Green):
SPEED 2) Sounds the warning buzzer continuously:
3) Limits the engine speed below 1,800 min-1 (rpm)
ENGINE SPEED
1,800 min-1
(rpm)
Oil pressure returns to normal

ECM conducts the normal operation.
1) Turns ON the oil indicator light (Green):
2) Stops the warning buzzer:
3) Increases the engine speed to normal speed
Time
20-4
dummyhead
TECHNICAL FEATURES
CAM CHAIN TENSION ADJUSTMENT SYSTEM & LUBRICATION
MECHANISM
OUTLINE
The BF75D/BF80A/BF90D/BF100A are equipped with a cam chain tensioner and a cam chain tensioner slider to constantly
maintain the cam chain tension at the proper level.
The oil injected from the oil pipe drips down from the ribs located in the chain case, then lubricates the cam chain driven sprocket,
cam chain drive sprocket, cam chain, cam chain tensioner, and the cam chain tensioner slider.
STRUCTURE
OIL SPLASH OIL SPLASH

PREVENTION RIB PREVENTION RIB
(CYLINDER HEAD (CHAIN CASE)
COVER) CAM CHAIN GUIDE
OIL PIPE
CAM CHAIN TENSIONER

SLIDER OIL SPLASH
OIL DRIPPING RIBS CAM CHAIN TENSIONER
(CHAIN CASE) PREVENTION LIB
(CHAIN CASE)

20-5
dummyhead
TECHNICAL FEATURES
COMPACT & HIGH POWER ALTERNATOR + DIRECT WATER-
COOLED REGULATOR/RECTIFIER
OUTLINE
The BF75D/BF80A/BF90D/BF100A are each equipped with an alternator that uses a permanent magnet. By adoption of this type of
alternator, the number of parts could be reduced significantly, compared to the existing models equipped with the self-exciting
alternator, and high output power is achieved as well.
The heat generated in the regulator/rectifier is discharged efficiently by adoption of the water-cooled regulator/rectifier.
STRUCTURE AND FEATURES
• The alternator rotor is equipped with a neodymium magnet of high magnetic power. The cooling air inlet ports are made on the
top of the rotor to cool the stator core.
• The alternator stator is equipped with a 3-phase alternator stator coil.
• The regulator/rectifier is installed on the water jacket cover so it is structured to cool both the regulator and rectifier
simultaneously with the engine cooling water.
INLET PORT OF
COOLING AIR PASSAGE OF ENGINE
ALTERNATOR ROTOR COOLING WATER
NEODYMIUM
MAGNET
REGULATOR/RECTIFIER
ALTERNATOR STATOR WATER JACKET COVER
20-6
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TECHNICAL FEATURES
LOW SPEED SIDE INTAKE ROCKER ARM STRUCTURE
(BF90D/BF100A ONLY)
STRUCTURE AND FEATURES
The low speed side (low lift side) intake rocker arm was changed to the integral fork end type, which contributed to reduction in the
number of parts.
Existing model (BF150A):
LOW SPEED SIDE

INTAKE ROCKER
ARMS
BF90D/BF100A:
LOW SPEED SIDE

INTAKE ROCKER
ARMS
LOW SPEED SIDE

INTAKE ROCKER
ARMS HIGH SPEED SIDE
INTAKE ROCKER
ARMS
EXHAUST
ROCKER ARM
PISTON ROCKER PISTON ROCKER

EXHAUST
STOPPER ARM PISTON STOPPER ARM PISTON
ROCKER ARM

20-7
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MEMO

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21. WIRING DIAGRAMS
WIRING DIAGRAMS SYSTEM DIAGRAM ····························· 21-5

(REMOTE CONTROL TYPE)·················· 21-3
CONNECTOR GENERAL
WIRING DIAGRAMS LAYOUT DRAWING ····························· 21-6
(TILLER HANDLE TYPE) ······················ 21-4
21

21-1
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WIRING DIAGRAMS (REMOTE CONTROL TYPE)

WIRING DIAGRAMS
FUSE BOX FUEL PUMP 29 ECM

EQUIPPED TYPE OPTIONAL PART
ALTERNATOR MAIN FUEL FUEL FUEL FUEL
TACHO METER TRIM METER ALTERNATOR W INJECTOR #4 INJECTOR #3 INJECTOR #2 INJECTOR #1 IGNITION COIL #4 IGNITION COIL #3 IGNITION COIL #2 IGNITION COIL #1 W/Bu ACGLP
COMBINATION SWITCH FUSE 70 A 30 A 6
2
Bu/Y
VOLT HOUR GND IG BAT LOAD ST W R/Bu WARNL
Bl
R/C
3
METER METER W/Bl Gr TACHO
COLOR Bl Bl/R W/Bl Bl/Y Bl/W 10 A 2
4
OFF W/Bl 5 1 2 37 1 2 36 1 2 35 1 2 34 1 2
FI 2 3 1 2 3 1 2 3 1 2 3 1
33 32 31 30
ON T5 T6 Y Y/Bu TRMA
15 A 3
To LIGHTING
6
W/Bl R/W TE
SWITCH START IGP
W/Bu
SPARK SPARK SPARK SPARK
Bu/R
Bu/R
7
W/G
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Bu
Bu
Br
Bl
Bl
Bl
Bl
Bl
R
Y
Y R/Bl THL
Y/Bu
R/W
R/W
R/W
R/W
Bl/Y
Bl/Y
15 A 5 PLUG PLUG PLUG PLUG

Gr
C2
Bl
Bl
Bl
Bl
C3
Bl
Bl
Bl
Bl
8
Y
W/G W/R PB
W
W
W
W
Bl
SUB
9
COLOR Bl/R Bl Y Y/R
1 2 POIL
C10
C11
C12
C13
C14
C15
C16
C17
C18
C22
C23
C24
C25
C26
C27
C28
C29
10 A 4
C4
C5
C6
C7
C8
C9
10
PUSH or REMOVE THE CLIP 1 2 3 1 2 GND1 W/R Bu K-LINE
FFP
11
SET THE CLIP
Y/Bu
R/W
R/W
R/W
R/W
Bl/Y
Y/Bl
Bl/Y
Bl/Y
Bl/Y
R/W
R/W
W W/Bu
Gr
W/Bu IGN2
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Y
10 A 1
REGULATOR/
12
Bl W W/Bu Lg FLR1
C19
NEAUTRAL SWITCH RECTIFIER
13
C30
Bl Bl Bl T3 T4 Lg FLR2
To SPEED COLOR Bl/Bu Bl
14
C20 C31 METER GEAR IN Bu IGN1
LIGHT W
15
R/W R/W R/W
C21 NEUTRAL C1
Bl/Y Y T1 G PG3
W 3
17
Br POWER TRIM/TILT SWITCH W/Bl
Bl/Y
TROLLING STARTER O2HT

3
Bl/W Bl/W
18
Bl CONTROL COLOR Lg W/Bl Lb Y/G BUZZ
5
SWITCH BATTERY
2
Lg/Bl Bl/Bu Bu
19
NORMAL Bu
1
CRK
6
10 A Bu/R Bu/R
20
38 UP STARTER
3
DOWN T2 MOTOR Lg/R Lg

R/Bl TOH1
1
Bl
Bl Bl
22
Y/Bu
Lg/Bl
Bl/Y
FUEL R/Y TA
4
TROLLING CONTROL SWITCH

Gr
Br
Bl
Bl
GND2 Bl/Y Bl/Y
23
6 MAIN G TDC
2
COLOR Lg/Bl Bl Br
24
C32
C33
C34
C35
C36
C37
C38
C39
C40
4 1 3 2 5 6 NEUTRAL W/Bu W/Bu

REMOTE CONTROL BOX R TOH2
1
UP W/Y W
26
W/Bu
R/Bu
Y/Bl
Bl/Y
5
DOWN O2
Bu
Bl
G
Bl W/Bl W/Bl
27
EMERGENCY
Lg/Bl
Y/Bu
Bl/Y
Bl/Y
STOP SWITCH
Gr
Br
C41
Bl
R
R
Y
Y
W/G W/G
Bl/R Bl/R
2
C42 W/R W/R

Y/G Y/G WARNING W/G IGN3
3
NMEA
30
Bl/Y BUZZER 2000 1 PGM-FI/MAIN RELAY 4 Y OPL
31
C43 O/Bu R
R OHL
Lb Lb
3
32
C44 POWER W/Bu Bl Bu/R IGN4
W/Bl W/Bl TRIM/TILT
2
33
C45 SWITCH Y Y G FUP
4
34
Lg Lg
C46 W W G PG4
6
35
Bl/Y Bl/Y O
C47
Bu
5
Bl/Y Bl/Y LOAD

C48 SHIELD
Bl Bl NMEA2000 W CAN1H
C49
1
Bl Bl GND COMBINATION R CAN 12V
SWITCH
2
C50 2
Bl/R Bl/R IG Bu Bl CAN GND
Bl/R Bl
3
C51
1
Bl/W Bl/W ST Gr
C52 Bu LG1
2
W/Bl W/Bl BAT ENGINE SPEED CHECK CONNECTOR
5
W/Bl
C53 3 Br/Y VCC1
Bl
Bl
6
Bl
C54 Y/Bl Bu VCC2
Bl R
3
7
Bl GND Bu Y/Bl IGP1
C55
Bl/Y
1
8
Bl/Y Bl/Y BAT Lg IGP2
Y/Bl
C56
4
9
R R OHL INDICATOR Bl G/Y VTS
C57 LIGHT
2
10
Y Y OPL G DLC G/Bl TLUP
C58
11
4
R/Bu R/Bu WARNL Br TLDN
G G
12
C59
Y INJ4
3
W/Bu W/Bu ACGLP

Bu Bu
13
Bu INJ3
2
Bl Bl
14
R INJ2
1
Y/Bl Y/Bl Y/Bl
15
Br INJ1
1
W/Bu W/Bu W/Bu W/Bu
16
G PG1
2
R/Bu R/Bu R/Bu R/Bu
17
G EACVP
3
39 INDICATOR LIGHT
18
Bu CAN1L
Lg Lg 5
19
Y SHIELD
1
Lb Lb Lg Lg
20
2
7 11 10
R R Lb Lb
VCC3
3
Br/W
Y Y R R
22
4
40 Bu LG2
Y Y
23
Bl/W Bl/W G SG1
6
Bl/W Bl/W
3
24
Y/G Y/G G SG2
8
Y/G Y/G
2
25
Bl Bl
4
Bl Bl
4
Br Br Bu NT SW
3
Br Br
1
27
Y/Bu Y/Bu Br FFD
5 13
Y/Bu Y/Bu
5
28
Bl/Y Bl/Y R/Bu KS
Bl/Y
6
Bl/Y
29
41
Bl/R EMS1
2
W/Bl W/Bl W/Bl W/Bl
30
EMS2
1
Bl/R
1
Bl/R Bl/R Bl/R Bl/R
31
3
Gr Gr Gr Gr
Lg SCS
4
12 14
Lg/Bl Lg/Bl Lg/Bl G/Bl
33
2
Lb
Lg
W
Bl
42
REMOTE CONTROL
W/Bl
G/Y
Lb
Lg
Bl 7 8 G PG2
CABLE 9 11
35
Bl EACVM
Bl 3 2 1 1
36
G 3 2 1 1
6 Bl
R/Bu
Bu
W/Bl
Br
Bl/Y
Y/Bl
Bl
Bu 28
Br/W
Y/Bu
G
W
Bl
G G
25
W/Bl
10 Bu
G/W
1
Lb
Lg
Lb
Lg
Bu Bu
Bl 14 2 1 16 2 1
2
1 1 2 4 3
15 1 2 3
Bl/Bu
Bl
G/R
Gr
R/W
G/Bl
G/Bl
W/R
Br/Y
R/Bl
R/Bl
Y/Bl
Y/Bl
W
W
R/Y
Y/R
Br
Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Bu
Bu
Bu
Bl
Bu
Bu
G
R
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Y
G
G
G
G
G
G
G
G
G
Bl BLACK Br BROWN EQUIPPED TYPE

Lg/Bl
Y/Bu
12 13
Bl
17 18 19 20 21 22 23 24 26 27
Y YELLOW O ORANGE
KNOCK VTEC 21 17 23 15 24 13 22 19 18 1 2 3 6 5 4 8 9 12 11 10 4 6 1 9 3 8 7 2 5 21 20 19 18 24 23 22 15 14 16 17
Bu BLUE Lb LIGHT BLUE GND4 GND5 GND6 GND7 2 1 2 1 2 1 2 1 3 1 2 3 1 2 3 2 1 3 2 1 2 1 3 2 1
REMOTE CONTROL TYPE (When using the SENSOR SOLENOID
G GREEN Lg LIGHT GREEN POWER
side mount remote control box) R RED P PINK TRIM/TILT VALVE
GROUND GROUND NEUTRAL TRIM WATER LEVEL ECT ECT IAT EBT TP EOP CKP CMP H02S SENSOR MAP IAC
POWER POWER TILT RELAY
GND3
SWITCH SWITCH ANGLE SENSOR SENSOR 2 SENSOR 3 SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR
W WHITE Gr GRAY TILT MOTOR BF90/100 only VALVE
GROUND JOINT CONNECTOR 2 JOINT CONNECTOR 1 SENSOR
21-3

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WIRING DIAGRAMS (TILLER HANDLE TYPE)

FUSE BOX FUEL PUMP 29 ECM
OPTIONAL PART
ALTERNATOR MAIN FUEL FUEL FUEL FUEL
TACHO METER TRIM METER ALTERNATOR W INJECTOR #4 INJECTOR #3 INJECTOR #2 INJECTOR #1 IGNITION COIL #4 IGNITION COIL #3 IGNITION COIL #2 IGNITION COIL #1 W/Bu ACGLP
COMBINATION SWITCH FUSE 70 A 30 A 6
2
Bu/Y
GND IG BAT LOAD ST W R/Bu WARNL
Bl
R/C
3
VOLT METER HOUR METER W/Bl Gr TACHO
COLOR Bl Bl/R W/Bl Bl/Y Bl/W 10 A 2
4
OFF W/Bl 5 1 2 37 1 2 36 1 2 35 1 2 34 1 2
FI 2 3 1 2 3 1 2 3 1 2 3 1
33 32 31 30
ON T5 T6 Y Y/Bu TRMA
To LIGHTING 15 A 3
6
SWITCH START W/Bl
IGP
R/W TE
W/Bu
SPARK SPARK SPARK SPARK
Bu/R
Bu/R
7
W/G
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Bu
Bu
Br
Bl
Bl
Bl
Bl
Bl
R
Y
Y R/Bl THL
Y/Bu
R/W
R/W
R/W
R/W
C2
C3
Bl/Y
Bl/Y
15 A 5 PLUG PLUG PLUG PLUG

Gr
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
8
Y
W/G W/R PB
W
W
W
W
Bl
SUB
9
COLOR Bl/R Bl Y Y/R
1 2 POIL
C4
C10
C11
C12
C13
C14
C15
C16
C17
C18
C22
C23
C24
C25
C26
C27
C28
C29
10 A 4
C5
C6
C7
C8
C9
10
PUSH or REMOVE THE CLIP 1 2 3 1 2 GND1 W/R Bu K-LINE
FFP
11
SET THE CLIP
Y/Bu
R/W
R/W
R/W
R/W
Bl/Y
Y/Bl
Bl/Y
Bl/Y
Bl/Y
R/W
R/W
W W/Bu
Gr
W/Bu IGN2
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Y
10 A 1
REGULATOR/
12
TO NEAUTRAL SWITCH Bl W W/Bu Lg FLR1
C19 SPEED RECTIFIER
13
C30
Bl Bl Bl T3 T4 Lg FLR2
METER COLOR Bl/Bu Bl
14
C20 C31 LIGHT GEAR IN Bu IGN1
W
15
R/W R/W R/W
C21 NEUTRAL C1
Bl/Y
Bl/Y Y T1 G PG3
6 4 W 3
17
POWER TRIM/TILT SWITCH W/Bl O2HT
STARTER
Bl/W Bl/W
18
10 A COLOR Lg W/Bl Lb Y/G BUZZ
5
BATTERY Bl/Bu Bu
19
NORMAL Bu CRK
6
Bu/R Bu/R
20
UP STARTER
3
Y/Bu
Bl/Y
MOTOR
Gr
Bl
DOWN T2 Lg/R Lg
R/Bl TOH1
1
Bl
Bl Bl
22
C43
C44
FUEL R/Y
C32
C33
C34
C35
C36
C37
C38
C39
C40
C41
C42
TA
4
TROLLING CONTROL SWITCH GND2 Bl/Y Bl/Y
23
MAIN G TDC
2
TILLER HANDLE COLOR Lg/Bl Bl Br
24
Bl
NEUTRAL W/Bu W/Bu
EMERGENCY R TOH2
1
UP
W/Bu
W/Bu
R/Bu
R/Bu
Y/Bu
W/Bl
W/Bl
Bl/Y
Bl/Y
STOP SWITCH W/Y W

Bu
Gr
Lb
Lg
C45
26
Bl
Bl
G
R
R
Y
Y
Bl/R Bl/R Bl/Y

5
DOWN W/Bl W/Bl

O2
27
C46
4
Y/G Y/G WARNING W/G W/G

2
Bl/Y BUZZER W/R W/R

NMEA W/G IGN3
3
2000 1
30
C47 4 Y OPL
O/Bu R PGM-FI/MAIN RELAY
Lb
31
Lb
3
C48 POWER W/Bu Bl

R OHL
32
W/Bl W/Bl TRIM/TILT
2
Bu/R IGN4
SWITCH Y Y
33
(Except
4
C49 G FUP
W W
LGHX type)
34
Lg
6
Lg G PG4
O Bu
35
C50
5
Bl/Y Bl/Y
SHIELD
C51 NMEA2000
Bl/Y Bl/Y LOAD
C52 2 W CAN1H
Bl Bl Bu
1
C53 Bl R CAN 12V
COMBINATION
1
2
Bl Bl GND Gr Bl CAN GND
Bl/R
C54 SWITCH
2
3
Bl/R IG
Bl/R
C55 ENGINE SPEED
Bl/W Bl/W ST CHECK CONNECTOR Bu LG1
C56 3
5
W/Bl W/Bl BAT
W/Bl Br/Y VCC1
Y/Bl
6
C57 R
3
Bl Bu VCC2
Bl Bl GND Bu
7
C58
1
Bl/Y Y/Bl IGP1

Bl/Y BAT Lg
8
Bl/Y
4
C59 Y/Bl IGP2

R R OHL INDICATOR Bl
9
2
C60 LIGHT DLC G/Y VTS

Y Y OPL
10
G G/Bl TLUP
C61
11
R/Bu R/Bu WARNL 4
C62 Br TLDN
G G
12
W/Bu W/Bu ACGLP Y INJ4
3
Bu Bu
13
Bu INJ3
2
Bl
14
R INJ2
1
Y/Bl
15
Br INJ1
4
W/Bu W/Bu
16
G PG1
5
R/Bu R/Bu
17
G EACVP
6
INDICATOR LIGHT
18
Bu CAN1L
5
19
Y SHIELD
Lg Lg
20
7 11 10
Lb Lb
Br/W VCC3
R R
22
Bu LG2
Y Y
23
G SG1
6
Bl/W Bl/W
24
G SG2
8
Y/G Y/G
25
4
Bl Bl
Bu NT SW
3
Br
27
Br FFD
5 13
Y/Bu Y/Bu
28
R/Bu KS
Bl/Y Bl/Y
29
Bl/R EMS1
2
W/Bl W/Bl
30
Bl/R EMS2
1
Bl/R Bl/R
31
9
Gr Gr
Lb
Lg
W
Bl
Lg SCS
12 14
G/Bl
33
W/Bl
G/Y
Lb
Lg
Bl HANDLE CABLE 7 8 G PG2

9 11
35
Bl 3 2 1 1 Bl EACVM
6 G
36
3 2 1 1
Bl
R/Bu
Bu
W/Bl
Br
Bl/Y
Y/Bl
Bl
G G
G
Bu
W
28
Br/W
G
Y/Bu
1
Bl
Lb
Lg
Bu Bu
EQUIPPED TYPE 25
W/Bl
10 Bu
G/W
Lb
Lg
Bl
2
14 2 1 16 2 1
1 1 2 4 3
15 1 2 3
Bl/Bu
Bl
G/R
Gr
R/W
G/Bl
G/Bl
W/R
Br/Y
R/Bl
R/Bl
Y/Bl
Y/Bl
W
W
R/Y
Y/R
Br
Bl
Bl BLACK Br BROWN
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Y/Bl
Bu
Bu
Bu
Bl
Bu
Bu
G
R
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Bl
Y
G
G
G
G
G
G
G
G
G
Lg/Bl
Y/Bu
Y YELLOW O ORANGE 12 13
Bl
17 18 19 20 21 22 23 24 26 27
Bu BLUE Lb LIGHT BLUE 21 17 23 15 24 13 22 19 18 1 2 3 6 5 4 8 9 12 11 10 4 6 1 9 3 8 7 2 5 21 20 19 18 24 23 22 15 14 16 17
KNOCK VTEC GND4 GND5 GND6 GND7 2 1 2 1 2 1 2 1 3 1 2 3 1 2 3 2 1 3 2 1 2 1 3 2 1
SENSOR SOLENOID
R RED P PINK POWER GND3 POWER
TILT MOTOR GROUND TRIM/TILT VALVE
W WHITE Gr GRAY POWER TILT RELAY GROUND GROUND NEUTRAL TRIM WATER LEVEL ECT ECT IAT EBT TP EOP CKP CMP H02S SENSOR MAP IAC
SWITCH SWITCH ANGLE SENSOR SENSOR 2 SENSOR 3 SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR VALVE
TILLER HANDLE TYPE EXCEPT LHGX TYPE BF90D/100A only JOINT CONNECTOR 2 JOINT CONNECTOR 1 SENSOR
21-4

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SYSTEM DIAGRAM
CHECK VALVE REGULATOR/
RECTIFIER IG6 IG3 IG2 IG1
10A
BF90D/BF100A Only PGM-FI/MAIN RELAY
AIR VENT 30A 10A
STRAINER
70A
10A LO
ALTERNATOR MAIN 15A
BAT
ST 15A
PRESSURE
REGULATOR COMBINATION FFP
VAPOR SWITCH ECM
SEPARATOR
To ST
STARTER IGP1 PG1
FUEL MOTOR IGP2 PG2
STRAINER FLR1 PG3
(HIGH) FLR2 PG4
BATTERY
FUEL
PUMP NTSW
(HIGH) VCC3 LG1
NEUTRAL
SWITCH LG2
TRIM
ANGLE
TRIM SENSOR
METER
TRMA
INJ4
INJ3
INJ2
INJ1
IGN1
IGN2
IGN3
IGN4
#4 #3 #2
FUEL INJECTORS VTS
IGNITION IGNITION IGNITION

COIL #2 COIL #3 COIL #4 VTEC SOLENOID
FUEL VALVE
WATER STRAINER
SEPARATOR (LOW) INDICATOR IG6
LIGHTS
SG1 ALTERNATOR
PB ACGLP
VCC1
THL PGM-FI
VCC2 WARNL
FUEL PUMP TP SG2
(LOW) SENSOR
OHL
WATER LEVEL OVERHEAT
SENSOR IGNITION
COIL #1 OPL
MAP OIL
ECT INTAKE MANIFOLD SENSOR
SENSOR 3 FUEL INJECTOR #1 WARNING
BUZZER
TA BUZZ
HO2S SENSOR TACHOMETER

IG3
IAT TACHO
EBT SENSOR
SENSOR KNOCK THROTTLE
SENSOR BODY EMS1
SILENCER EMS2
ECT IG3
SENSOR 2 IAC VALVE
IG1 EMERGENCY
STOP SWITCH
SCS
DLC
IG1 EOP
SENSOR K-LINE
CMP
SENSOR
TDC
EACVP
CKP EACVM
ENGINE
SENSOR FUEL CONSUMPTION SPEED
METER (OP) CHECK
CONNECTOR
TOH1 FUP
KS
CRK
UP
TLUP
POIL TLDN
TE DOWN
TROLLING
O2HT CONTROL SWITCH
(OP)
O2
CAN 1H
TOH2
CAN 12V
FFD CAN GND NMEA 2000
CAN 1L
SHIELD
21-5

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CONNECTOR GENERAL LAYOUT DRAWING
Terminal Wire color Terminal Wire color

number number
JOINT JOINT
1 W 1 W/Bu
CONNECTOR 1 CONNECTOR 2 Main wire harness side 2 W 2 Bl
STATOR 3P Main wire harness side
3 W 3 Y/Bl
CONNECTOR
No.1 IGNITION COIL
3P CONNECTOR

number number
1 G 1 Bu
2 G/Bl 2 Bl
3 Y/Bl 3 Y/Bl
Main wire harness side Main wire harness side
No.2 IGNITION COIL
3P CONNECTOR
Terminal Wire color

ECT SENSOR 3 number
2P CONNECTOR 1 Bu/R Terminal Wire color Terminal Wire color Terminal Wire color Terminal Wire color
2 Bl number number number number
Main wire harness side 3 Y/Bl 1 Bl 7 Bl 17 Y/Bl 23 Y/Bl
2 Bl 8 Bl 18 Y/Bl 24 Y
3 Bl 9 Bl 19 Y/Bl
No.3 IGNITION COIL 4 Bl 14 Y/Bl 20 Y/Bl
3P CONNECTOR 5 Bl 15 Y/Bl 21 Y/Bl
Main wire harness side
6 Bl 16 Y 22 Y/Bl
Terminal Wire color

number
1 W/G
2 Bl
Main wire harness side 3 Y/Bl
No.4 IGNITION COIL Terminal Wire color Terminal Wire color Terminal Wire color Terminal Wire color
3P CONNECTOR number number number number
1 Bl 8 Y 15 G 23 G
2 Bl 9 Y/Bl 17 G 24 G
3 Bl 10 Y/Bl 18 G
Terminal Wire color 4 Bl 11 Y/Bl 19 G
number 5 Bl 12 Y/Bl 21 G
Bl BLACK Br BROWN 1 R Main wire harness side 6 Bl 13 G 22 G
CMP 3P Y YELLOW O ORANGE
Main wire harness side 2 G
CONNECTOR
R RED P PINK
W WHITE Gr GRAY
21-6

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ECM 36P ECM 36P

CONNECTOR B (Black) CONNECTOR A (Gray) Terminal Wire color Terminal Wire color
HO2S 4P ENGINE SPEED CHECK number number
CONNECTOR 2P CONNECTOR (Blue) 1 Bl/Y 1 Lg
2 G 2 W/Bl
3 W/Bl 3 Lb
Main wire harness side 4 Y/Bl Main wire harness side

number number
1 Bl 1 Lg
Power trim/tilt switch side 2 W/Bl
2 Gr
3 W 3 Lb
4 W
HO2S side
Terminal Wire color Terminal Wire color Terminal Wire color Terminal Wire color
number number number number
1 W 11 G/Bl 20 Y 31 Bl/R
2 R 12 Br 22 Br/W 33 Lg
3 Bl 13 Y 23 Bu 35 G
5 Bu 14 Bu 24 G 36 Bl
6 Br/Y 15 R 25 G
7 Bu 16 Br 27 Bu
Main wire harness side 8 Y/Bl 17 G 28 Br *: BF90D/BF100A only
9 Y/Bl 18 G 29* R/Bu
10* G/Y 19 Bu 30 Bl/R
POWER TRIM/TILT
SWITCH 3P CONNECTOR
DLC 4P (Red)
(Except LHGX type)
Terminal Wire color Terminal Wire color Terminal Wire color Terminal Wire color
number number number number
2 W/Bu 12 W/Bu 23 R/Y 35 G
3 R/Bu 13 Lg 24 G
4 Gr 14 Lg 26 R
6 Y/Bu 15 Bu 27 Bl/Y
7 R/W 17 G 30 W/G
8 R/Bl 18 W/Bl 31 Y
Main wire harness side 9 W/R 19 Y/G 32 R
10 Y/R 20 Bu 33 Bu/R
11 Bu 22 R/Bl 34 G

number Terminal Wire color Terminal Wire color Bl BLACK Br BROWN
number number Y YELLOW O ORANGE
1 Bu number
1 Bl Bl
2 Bl W G GREEN Lg LIGHT GREEN
2 Gr W R RED P PINK
3 Y/Bl W WHITE Gr GRAY
Main wire harness side 4 Lg
21-7

dummytext
GROUND
CABLE Terminal Wire color
number
FUSE BOX GROUND
5P CONNECTOR CABLE 1 W/Bu
GROUND 2 W/G
CABLE 3 W/R
4 W/Bl
Main wire harness side 5 W
GROUND
CABLE
Terminal Wire color

number
1 W/Bu
2 W/G
3 W/R
Main relay side 4 W/Bl
5 W/Y
PGM-FI/MAIN RELAY
6P CONNECTOR
Terminal Wire color
number
Bl
Bl
PGM-FI/MAIN RELAY Bu
5P CONNECTOR Bl
Bl
Bu
NMEA 2000 6P
REGULATOR/
CONNECTOR
RECTIFIER 3P
ECT SENSOR 2 CONNECTOR
2P CONNECTOR Terminal Wire color
number
1 Lg
2 Bl/Y
3 Bu/R
4 Bl
Main wire harness side 5 Bl/W
6 Bu

number Terminal Wire color number
Terminal Wire color W number 2 Bl
number W 1 W 3 R
Bl BLACK Br BROWN Terminal Wire color 1 Lg/R 3 Bl 4 Y
Y YELLOW O ORANGE
number Main wire harness side
Bu BLUE Lb LIGHT BLUE 2 Bl/Y 5 Bu
G GREEN Lg LIGHT GREEN 1 R/Bl 6 W
R RED P PINK
3 Bu/R
W WHITE Gr GRAY Main wire harness side 2 G 4 Bl Main wire harness side
Main relay side
5 Bl/W Terminal Wire color
6 Bl/Bu number
Bl
Bl
21-8

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Terminal Wire color

number
1 Bl
REMOTE CONTROL CABLE 2 Bu
or TILLER HANDLE 14P 3 G
IAT SENSOR 2P CONNECTOR 4 Y/Bl
CONNECTOR INDICATOR LIGHT 5 W/Bu
Terminal Wire color 6P CONNECTOR 6 R/Bu
MAP SENSOR 3P
CONNECTOR number
1 Br/Y EXCEPT LHGX TYPE
2 W/R
Main wire harness side Terminal Wire color Terminal Wire color
3 G
number number
WATER LEVEL SENSOR 1 W/Bl 8 Bl/W
2P CONNECTOR 2 Bl/Y 9 Bl/R
3 Bl 10 Lg
4 Y/G 11 Lb
IAC VALVE 2P 5 Y/Bu 12 G/Bl
Terminal Wire color
CONNECTOR 6 Y 13 Br
number
1 R/Y TRIM ANGLE 7 R 14 Gr
2 G SENSOR 3P Main wire harness side
Main wire harness side CONNECTOR
(Except LHGX
type) LHGX TYPE ONLY
number number
1 W/Bl 9 Bl/R
2 Bl/Y 12 G/Bl
3 Bl 13 Br
4 Y/G 14 Gr
6 Y
Terminal Wire color 7 R
number 8 Bl/W
1 Bl
2 G Main wire harness side

Terminal Wire color
number
POWER TILT MOTOR 1 Br
POWER TILT RELAY
2P CONNECTOR 2 G
NEUTRAL SWITCH 2P 2P CONNECTOR (Except LHGX type) Main wire harness side
CONNECTOR (Except LHGX type)
Terminal Wire color
number
1 Bu Terminal Wire color
2 R/Bl number
3 G 1 Br
Water level sensor side
2 G/R
Terminal Wire color
Terminal Wire color number
number 1 G
TP SENSOR 3P Terminal Wire color
1 Bu 2 Bu
CONNECTOR number
2 Bl
Power tilt relay side 1 Bl
Main wire harness side 2 Y/Bu
Bl BLACK Br BROWN
Y YELLOW O ORANGE
3 Br/W
Bu BLUE Lb LIGHT BLUE Main wire harness side
R RED P PINK Terminal Wire color
W WHITE Gr GRAY number
1 Bl Terminal Wire color
Neutral switch side number
2 Bl/Bu
1 Bl
Power tilt motor side Trim angle sensor side 2 Y/Bu
3 Lg/Bl
21-9

dummytext
EOP SENSOR 3P CKP SENSOR 3P

CONNECTOR CONNECTOR
FUEL PUMP (HIGH) Terminal Wire color
2P CONNECTOR number
Terminal Wire color 1 Bu
POWER TILT RELAY number 2 Y/R Terminal Wire color
3P CONNECTOR 1 W Main wire harness side 3 G number
FUSE CABLE 1P (Except LHGX type) No.1 FUEL 1 G/Y
CONNECTOR Fuse cable side INJECTOR 2P Main wire harness side
CONNECTOR
POWER TILT RELAY
1P CONNECTOR Terminal Wire color
(Except LHGX type) number
Terminal Wire color 1 G/W
No.2 FUEL number
VTEC solenoid valve side
INJECTOR 2P 1 Bu
CONNECTOR 2 G/Bl
Power tilt relay side Main wire harness side 3 Y/Bl
Terminal Wire color

number
No.3 FUEL
1 R/W
INJECTOR 2P
2 G
CONNECTOR Terminal Wire color
Terminal Wire color Main wire harness side
number
number
1 Y/Bl
1 Bu/R
2 Br
2 Bl
Main wire harness side Main wire harness side
Terminal Wire color No.4 FUEL

number INJECTOR 2P Terminal Wire color
1 Bu/Y number
CONNECTOR
Fuel pump side Terminal Wire color 1 R/Bu
2 Bl number Main wire harness side
1 Y/Bl
2 R
Terminal Wire color

number
1 Bl
2 Lg
3 Lb Terminal Wire color
Main wire harness side number
1 Y/Bl
2 Bu
Terminal Wire color
number
2 Lg
Power tilt relay side 3 Lb
Bl BLACK Br BROWN
Terminal Wire color Y YELLOW O ORANGE
number Bu BLUE Lb LIGHT BLUE
1 Y/Bl R RED P PINK
2 Y W WHITE Gr GRAY
Terminal Wire color Main wire harness side
number
Bl
VTEC SOLENOID 1P
KNOCK SENSOR 1P EBT SENSOR 2P
CONNECTOR
CONNECTOR CONNECTOR
(BF90D/BF100A only)
(BF90D/BF100A only)
21-10

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REMOTE CONTROL TYPE (Side mount remote control box) [Equipped type only]
WIRING DIAGRAM:
POWER TRIM/TILT REMOTE CONTROL
C55
SWITCH CABLE B
REMOTE C56 INDICATOR
TACHO METER TRIM METER INDICATOR LIGHT Terminal Wire color Terminal Wire color
CONTROL C57 LIGHT
Terminal Wire color number number
CABLE B C54
number C43 Lb C32 R
C53
C53 Bl C44 W/Bl C33 Y
C54 Bl C45 Lg C34 Gr
To LIGHTING
SWITCH C55 Bl/Y C35 Bl/Y
Y/Bu
R/W
R/W
Bl/Y
Bl/Y
Gr
Bl
Bl
Bl
Bl
C56 R C36 Lg/Bl

C2
Terminal Wire color

C3
number C57 Y C37 Y/Bu

C10
C11
C12
C13
C14
C15
C16
C17
C18
C4
C5
C7
C8
C9
C6
C53 Bl C58 R/Bu C38 Br

Y/Bu
R/W
R/W
R/W
R/W
Bl/Y
Y/Bl
Bl/Y
Bl/Y
Bl/Y
Gr
Bl
Bl
Bl
Bl
Bl
Bl
C19
C54 Bl C59 W/Bu C39 Bl
Bl
C55 Bl/Y C41 Bl/R
C20
R/W
C21
C56 R C42 Y/G
Bl/Y C57 Y C43 Lb
C44 W/Bl
%O<
C45 Lg
2
COMBINATION SWITCH
1
10 A
38 C47 Bl/Y
Terminal Wire color
C49 Bl
number
Y/Bu
Lg/Bl
Bl/Y
C50 Bl/R
Gr
Br
Bl
Bl
6 C46 Bl/Y
C51 Bl/W
C32
C33
C34
C35
C36
C37
C38
C39
C40
4 1 3 2 5 6 C47 Bl/Y
REMOTE CONTROL BOX C52 W/Bl
C48 Bl
C53 Bl
W/Bu
R/Bu
Y/Bl
Bu
Bl
G
Bl
EMERGENCY C49 Bl
Lg/Bl
Y/Bu
C54 Bl
Bl/Y
Bl/Y
STOP SWITCH
Gr
Br
C41
Bl
R
R
Y
Y
Bl/R Bl/R C50 Bl/R

C42 C55 Bl/Y
Y/G Y/G WARNING C51 Bl/W
Bl/Y BUZZER C56 R
C43 EMERGENCY STOP C52 W/Bl
Lb Lb C57 Y
C44 POWER SWITCH
W/Bl W/Bl TRIM/TILT C58 R/Bu
C45 SWITCH Terminal Wire color
Lg
C46
Lg
number C59 W/Bu
Bl/Y Bl/Y
Bl/Y
C47 C41 Bl/R
Bl/Y LOAD
Bl
C48
Bl C48 Bl
C49
Bl Bl GND COMBINATION
Bl/R
C50 SWITCH 2
Bl/R IG
Bl/R
C51
Bl/W Bl/W ST
C52
W/Bl W/Bl BAT
W/Bl
C53
Bl
Bl Bl
C54 C33
Bl
Bl GND
C55 C32
Bl/Y
Bl/Y Bl/Y BAT
C56
R R OHL INDICATOR
C57 LIGHT WARNING BUZZER
Y Y OPL G
C58 4 Terminal Wire color
R/Bu R/Bu WARNL C39
C59 G
C38 REMOTE number
3
W/Bu W/Bu ACGLP

Bu
REMOTE C42 Y/G
METER C37
CONTROL
2
Bl
CONTROL C46 Bl/Y
1
Y/Bl Y/Bl HARNESS A CABLE B

CABLE B
1
W/Bu
W/Bu W/Bu
(Equipped type C34
5
2
R/Bu R/Bu R/Bu

only)
3
39
C35
Lg Lg 5
1
Lb Lb Lg
7 11 10
WARNING
2
R R Lb C36 C42
3
Y Y R BUZZER Terminal Wire color

4
40
Bl/W Bl/W
Y
number
6
Bl/W REMOTE POWER C46

3
Y/G Y/G
Terminal Wire color
C45
C41 Bl/R
8
Y/G C47
CONTROL TRIM/TILT
2
Bl Bl C44
C42 Y/G
4
Bl number C43
C52
4
Br Br CABLE B SWITCH REMOTE

3
Br
C32 R COMBINATION C46 Bl/Y
1
Y/Bu Y/Bu
CONTROL
5 13
Y/Bu C50
C33 Y C47 Bl/Y
5
Bl/Y Bl/Y
CABLE B SWITCH
Bl/Y
Terminal Wire color
6
41
C34 Gr C48 Bl
2
W/Bl W/Bl W/Bl C51

number
1
C35 Bl/Y C49 Bl

1
Bl/R Bl/R Bl/R C49

Bl BLACK Br BROWN
C43 Lb
9
3
C48
Gr Gr Gr
C36 Lg/Bl C50 Bl/R Y YELLOW O ORANGE
12 14
C44 W/Bl
4
Lg/Bl Lg/Bl Lg/Bl

C37 Y/Bu EMERGENCY C51 Bl/W Bu BLUE Lb LIGHT BLUE
2
42
C45 Lg STOP SWITCH C52 W/Bl
Bl
C38 Br C41
R RED P PINK
C39 Bl C58 R/Bu W WHITE Gr GRAY
C58 INDICATOR C59 W/Bu

C59 LIGHT
21-11

dummytext
• Connectors are viewed from the terminal side

TACHO METER METER HARNESS A
Terminal Wire color Terminal Wire color (Equipped type only) (Equipped type only)
Terminal Wire color Terminal Wire color number number Terminal Wire color Terminal Wire color
number number 1 W/Bl 1 Y/Bl number number
1 W/Bl 8 Bl/W 2 Lg/Bl 2 W/Bu C9 R/W C2 R/W
2 Bl/Y 9 Bl/R 3 Bl/R Indicator wire side 3 R/Bu C10 Bl C3 Bl/Y
3 Bl 10 Lg 4 Gr C11 Gr C4 R/W
Remote control C12 Bl/Y C5 Bl
4 Y/G 11 Lb cable A side
5 Y/Bu 12 G/Bl C13 Bl C6 Y/Bl
6 Y 13 Br C7 Bl/Y
Terminal Wire color
7 R 14 Gr C8 Bl
number TRIM METER C9 R/W
Terminal Wire color 1 — (Equipped type only)
Main wire harness side number C10 Bl
2 W/Bu Terminal Wire color
1 W/Bl C11 Gr
3 R/Bu number
2 Lg/Bl C12 Bl/Y
Remote control C14 Bl/Y
3 Bl/R C13 Bl
cable B side C15 Y/Bu
4 Gr C14 Bl/Y
C16 Bl
C15 Y/Bu
C17 Bl
Terminal Wire color Terminal Wire color Remote control C16 Bl
Terminal Wire color C18 R/W
number number cable B side number C17 Bl
1 W/Bl 8 Bl/W 1 Bl C18 R/W
2 Bl/Y 9 Bl/R 2 Bu C19 Bl
3 Bl 10 Lg Terminal Wire color C20 R/W
number 3 G
4 Y/G 11 Lb 4 Y/Bl C21 Bl/Y
5 Y/Bu 12 Lg/Bl 1 Br C22 R/W
2 Y/G 5 W/Bu
6 Y 13 Br Remote control C23 Bl
3 Bl/W cable A side 6 R/Bu
7 R 14 Gr C24 Y
Remote control cable A side 4 Bl C25 Bl
5 Y/Bu C26 Y
Remote control 6 Bl/Y
cable A side C27 Bl
Terminal Wire color C28 R/W
number C29 Bl
Terminal Wire color 4 Y/Bl C30 Bl
number Terminal Wire color C31 R/W
1 Bl number
2 Bu Meter harness A side
1 Br
3 G 2 Y/G
4 Y/Bl 3 Bl/W
Main wire 5 W/Bu
harness side 4 Bl
6 R/Bu Remote control 5 Y/Bu Terminal Wire color
cable B side 6 Bl/Y number
1 Lg/Bl
Terminal Wire color 2 Bl
number Terminal Wire color 3 Br
1 Bl number Meter wire harness
1 Lg side
2 Bu
3 G 2 Lb
4 Y/Bl 3 R
5 W/Bu 4 Y Terminal Wire color
Indicator wire side number
6 R/Bu
Remote control 1 Lg/Bl
cable A side 2 Bl
Trolling control 3 Br
switch side
[Optional part]
Terminal Wire color
number
1 Lg
2 Lb
3 R
4 Y
Bl BLACK Br BROWN
Y YELLOW O ORANGE Remote control
Bu BLUE Lb LIGHT BLUE cable B side
R RED P PINK
W WHITE Gr GRAY
21-12

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TILLER HANDLE TYPE [Equipped type only]

WIRING DIAGRAM:
HANDLE CABLE POWER TRIM/TILT Connectors in 40 mm cord tube:

40 mm CORD
Terminal Wire color SWITCH TUBE
number (EQUIPPED TYPE ONLY)
Terminal Wire color
C32 Bu Terminal Wire color
number
C33 G number
C32 Bu
C34 W/Bu C47 Lb
C33 G
C35 R/Bu C48 W/Bl
C43
C44
C32
C33
C34
C35
C36
C37
C38
C39
C40
C41
C42
C34 W/Bu
TILLER HANDLE C36 R C49 Lg
C35 R/Bu
Bl
EMERGENCY C37 Y C36 R
W/Bu
W/Bu
R/Bu
R/Bu
Y/Bu
W/Bl
W/Bl
Bl/Y
Bl/Y
STOP SWITCH
Bu
Gr
Lb
Lg
C45
Bl
Bl
G
R
R
Y
Y
Bl/R
C46
Bl/R C38 Bl/Y C37 Y
Y/G Y/G WARNING C39 Gr C38 Bl/Y
Bl/Y BUZZER
C40 Y/Bu C39 Gr
Lb
C47 C43 W/Bl WARNING BUZZER C40 Y/Bu
Lb
W/Bl
C48
W/Bl
POWER
TRIM/TILT
C44 Bl C43 W/Bl
C49
SWITCH C45 Bl/R C44 Bl
Lg Lg C46 Y/G
C50
Bl/Y
C51
Bl/Y C47 Lb
Bl/Y
C52
Bl/Y LOAD C48 W/Bl
Bl Bl
C53 C49 Lg
Bl Bl GND COMBINATION
Bl/R
C54
Bl/R IG
SWITCH C50 Bl/Y
Bl/R
Bl/W
C55
Bl/W ST C53 Bl
C56
W/Bl
W/Bl W/Bl BAT C54 Bl/R
C57 INDICATOR LIGHT
Bl
Bl
C58
Bl GND C55 Bl/W
Bl/Y
Bl/Y
C59
Bl/Y BAT C56 W/B
R INDICATOR
C60
R OHL
LIGHT C57 Bl COMBINATION SWITCH
Y Y OPL
R/Bu
C61
R/Bu WARNL
G
4
C58 Bl/Y
W/Bu
C62
W/Bu ACGLP
G C59 R
3
Bu
C60 Y
2
C61 R/Bu
1
C62 W/Bu
4
W/Bu
5
R/Bu
6
5
Lg
Connectors in tube B:
7 11 10
Lb
R
Y
6
Bl/W
8
Y/G
TUBE B Terminal Wire color
4
Bl
EMERGENCY STOP number
3
C41 Lb
5 13
Y/Bu SWITCH
Bl/Y
C42 Lg
Connectors in tube A:
2
W/Bl
C45 Bl/R
1
Bl/R
C47 Lb
9
Gr
12 14
Terminal Wire color C48 W/Bl

Bl number C49 Lg
TUBE A C46 Y/G C52 Bl
C50 Bl/Y
C51 Bl/Y
HANDLE CABLE
C53 Bl
Bl BLACK Br BROWN C54 Bl/R
Y YELLOW O ORANGE
Bu BLUE Lb LIGHT BLUE C55 Bl/W
G GREEN Lg LIGHT GREEN C56 W/B
R RED P PINK
W WHITE Gr GRAY
C57 Bl
INDICATOR C58 Bl/Y
LIGHT C59 R
CONNECTORS
C60 Y
WARNING C61 R/Bu
BUZZER C62 W/Bu
CONNECTORS
21-13

dummytext
• Connectors are viewed from the terminal side

number number
Terminal Wire color
1 W/Bl 8 Bl/W number
2 Bl/Y 9 Bl/R 4 Y/Bl
3 Bl 10 Lg
4 Y/G 11 Lb
5 Y/Bu 12 G/Bl Meter harness
6 Y 13 Br A side
Main wire harness side 7 R 14 Gr
Except LHGX Type

number number
1 W/Bl 8 Bl/W
2 Bl/Y 9 Bl/R
3 Bl 10 —
4 Y/G 11 —
5 — 12 G/Bl
6 Y 13 Br
Main wire harness side 7 R 14 Gr
LHGX Type only

number number
1 W/Bl 8 Bl/W
2 Bl/Y 9 Bl/R
3 Bl 10 Lg
4 Y/G 11 Lb
5 Y/Bu 12 —
6 Y 13 —
7 R 14 Gr
Handle cable side
(Equipped type only)
Terminal Wire color

number
1 Bl
2 Bu
3 G
4 Y/Bl
5 W/Bu
Main wire
harness side 6 R/Bu
Terminal Wire color

number
1 —
2 Bu Bl BLACK Br BROWN
Y YELLOW O ORANGE
3 G Bu BLUE Lb LIGHT BLUE
4 — G GREEN Lg LIGHT GREEN
Handle cable 5 W/Bu R RED P PINK
W WHITE Gr GRAY
side 6 R/Bu
21-14

INDEX
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INDEX
70 A FUSE BOX/FUSE INSPECTION ··················· 10-14 ENGINE SIDE STOPPER REMOVAL/
Numerics
AIR VENT STRAINER/CHECK VALVE REMOVAL/ INSTALLATION ·············································· 6-11

A
INSTALLATION··············································· 5-86 ENGINE TROUBLESHOOTING ·······························4-2

ALERT SYSTEM/WARNING SYSTEM EOP SENSOR REMOVAL/INSTALLATION ·············· 5-84
TROUBLESHOOTING······································ 4-16 EXTENSION CASE/LOWER RUBBER REMOVAL/
ALTERNATOR COVER ··········································7-5 INSTALLATION ·············································· 16-9
ALTERNATOR INSPECTION ································ 7-13 FLUSH VALVE DISASSEMBLY/ASSEMBLY ·········· 11-12
F
ALTERNATOR REMOVAL/INSTALLATION················7-6 FLYWHEEL INSPECTION ···································· 9-22

ANODE METAL CHECK (INNER SIDE)··················· 3-19 FLYWHEEL REMOVAL/INSTALLATION····················9-8
ANODE METAL CHECK (OUTER SIDE)·················· 3-17 FRAME TROUBLESHOOTING ······························ 4-23
ANODE METAL/WATER SCREEN REMOVAL/ FRONT SEPARATE COVER REMOVAL/
INSTALLATION··············································· 16-4 INSTALLATION ················································6-4
ATF LINE DESCRIPTION ····································· 18-4 FUEL FILTER (HIGH PRESSURE SIDE)
BACKLASH INSPECTION ·································· 16-41 INSPECTION/REPLACEMENT ·························· 3-28
B
BEARING SELECTION ······································ 15-25 FUEL INJECTOR INSPECTION ··························· 5-103

BEFORE TROUBLESHOOTING ······························4-2 FUEL INJECTORS REMOVAL/INSTALLATION ········ 5-73
CABLE/HARNESS ROUTING ································ 2-18 FUEL LINE CHECK/REPLACEMENT······················ 3-30
C
CAM CHAIN TENSION ADJUSTMENT SYSTEM & FUEL PRESSURE MEASUREMENT ······················ 5-97
LUBRICATION MECHANISM····························· 20-5 FUEL PRESSURE REGULATOR INSPECTION ········ 5-98
CHAIN CASE/CAM CHAIN REMOVAL/ FUEL PRESSURE RELIEVING······························ 5-66
INSTALLATION··············································· 14-4 FUEL PUMP (HIGH PRESSURE SIDE)
CHARGING SYSTEM TROUBLESHOOTING ·············7-3 INSPECTION ················································· 5-99
CIRCUIT DIAGRAM···············································5-8 FUEL PUMP (HIGH PRESSURE SIDE)/VAPOR
CKP SENSOR REMOVAL/INSTALLATION ·············· 5-83 SEPARATOR DISASSEMBLY/ASSEMBLY ·········· 5-91
CLUTCH SHIFTER INSPECTION························· 16-45 FUEL PUMP (HIGH PRESSURE SIDE)/VAPOR
CMP SENSOR REMOVAL/INSTALLATION·············· 5-83 SEPARATOR REMOVAL/INSTALLATION············ 5-76
COMBINATION SWITCH INSPECTION················· 19-45 FUEL PUMP (LOW PRESSURE SIDE)
COMPACT & HIGH POWER ALTERNATOR + DIRECT INSPECTION ················································· 5-99
WATER-COOLED REGULATOR/RECTIFIER ······· 20-6 FUEL PUMP (LOW PRESSURE SIDE) REMOVAL/
COMPONENT LOCATION INSTALLATION ·············································· 5-67
CHARGING SYSTEM·········································7-4 FUEL STRAINER (LOW PRESSURE SIDE)
CONTROLS ··················································· 19-2 INSPECTION/CLEANING ································· 3-25
COOLING SYSTEM ········································· 11-2 FUEL TANK/FILTER CLEANING···························· 3-29
CYLINDER BLOCK·········································· 15-2 FUEL TANK/FUEL TANK TUBE DISASSEMBLY/
CYLINDER HEAD············································ 14-2 ASSEMBLY···················································· 5-96
ENGINE COVER ···············································6-2 FUSE BOX INSPECTION ··································· 10-14
ENGINE REMOVAL/INSTALLATION··················· 13-2 FUSE/ELECTRIC POWER LINE
GEAR CASE ·················································· 16-2 TROUBLESHOOTING······································ 4-12
LUBRICATION SYSTEM··································· 12-2 GAS ASSISTED DAMPER/SWIVEL CASE/STERN
G
TRIM/TILT······················································ 18-2 BRACKET REMOVAL/INSTALLATION ·············· 18-48

CONNECTOR GENERAL LAYOUT DRAWING ········· 21-6 GEAR CASE NEEDLE BEARING REPLACEMENT·· 16-46
CRANKCASE BREATHER CHECK ························ 3-31 GEAR CASE OIL CHANGE·····································3-6
CRANKCASE/CRANKSHAFT/CYLINDER BLOCK/ GEAR CASE PRESSURE INSPECTION················ 16-42
PISTON DISASSEMBLY/ASSEMBLY·················· 15-3 GEAR CASE/EXTENSION SEPARATOR
CRANKSHAFT/PISTON/CYLINDER BLOCK (XRT TYPE ONLY) REMOVAL/INSTALLATION ···· 16-5
INSPECTION················································ 15-18 HO2S INSPECTION ·········································· 5-108
H
CYLINDER COMPRESSION TEST······················· 14-32 HO2S REMOVAL/INSTALLATION·························· 5-82

CYLINDER HEAD ASSEMBLY/DISASSEMBLY ······ 14-22 IAC VALVE INSPECTION ··································· 5-107
I
CYLINDER HEAD COVER REMOVAL/ IAC VALVE REMOVAL/INSTALLATION ·················· 5-82

INSTALLATION············································· 14-15 IAT SENSOR INSPECTION ································ 5-107
CYLINDER HEAD INSPECTION ·························· 14-32 IAT SENSOR REMOVAL/INSTALLATION················ 5-81
CYLINDER HEAD REMOVAL/INSTALLATION········ 14-19 IDLE SPEED CHECK/ADJUSTMENT······················ 3-20 22
DIMENSIONAL DRAWING······································1-7 IGNITION SYSTEM TROUBLESHOOTING ················8-3
D
DTC TROUBLESHOOTING ·································· 5-13 INDICATOR LIGHT INSPECTION ························ 19-47

EBT SENSOR REMOVAL/INSTALLATION··············· 5-84 INTAKE MANIFOLD REMOVAL/INSTALLATION······· 5-69
E
EBT SENSOR/ECT SENSOR 2/3 INSPECTION······ 5-106 KNOCK SENSOR REMOVAL/INSTALLATION

K
ECM TERMINAL ARRANGEMENT ························· 5-11 (BF90D/BF100A ONLY)···································· 5-84

ECM, PGM-FI/MAIN RELAY REMOVAL/ L./R. ENGINE UNDER COVER REMOVAL/
L
INSTALLATION··············································· 10-3 INSTALLATION ················································6-5

ECT SENSOR 2 REMOVAL/INSTALLATION ············ 5-85 LOW SPEED SIDE INTAKE ROCKER ARM
ECT SENSOR 3 REMOVAL/INSTALLATION ············ 5-85 STRUCTURE (BF90D/BF100A ONLY) ················ 20-7
EMERGENCY STOP SWITCH CHECK ··················· 3-31 LUBRICATION ··················································· 3-22
EMERGENCY STOP SWITCH INSPECTION ········· 19-46 LUBRICATION & SEAL POINT ································2-8
ENGINE & FRAME TORQUE VALUES······················2-4 LUBRICATION SYSTEM DIAGRAM ······················· 12-3
ENGINE COVER REMOVAL/INSTALLATION ·············6-3 MAINTENANCE SCHEDULE···································3-2
M
ENGINE INSTALLATION ······································ 13-8 MAINTENANCE STANDARDS ································2-2

ENGINE OIL FILTER CHANGE································3-5 MAP SENSOR REMOVAL/INSTALLATION ·············· 5-81
ENGINE OIL LEVEL CHECK/OIL CHANGE················3-4 MIL TROUBLESHOOTING···································· 5-43
ENGINE REMOVAL············································· 13-3 MOUNT CASE ASSEMBLY/DISASSEMBLY············· 17-3
22-1
dummytext
INDEX
MOUNT CASE REMOVAL/INSTALLATION ············· 17-2 STARTER MOTOR INSPECTION ···························9-19
NEUTRAL SWITCH INSPECTION ························· 9-22 STARTER MOTOR REMOVAL/INSTALLATION ········· 9-5
N
NUTS, BOLTS, FASTENERS································ 3-31 STARTING PROCEDURE AFTER INSTALLING

OIL CASE REMOVAL/INSTALLATION···················· 12-5 MAJOR ASSEMBLIES ······································12-4
O
OIL PRESSURE ALERT SYSTEM ························· 20-2 STARTING SYSTEM TROUBLESHOOTING·············· 9-3
OIL PRESSURE CHECK·····································12-10 STEERING FRICTION SHAFT/ROD REMOVAL/
OIL PUMP DISASSEMBLY/ASSEMBLY·················· 12-8 INSTALLATION (TILLER HANDLE TYPE) ·········· 19-20
OIL PUMP INSPECTION·····································12-10 STEERING ROD REMOVAL/INSTALLATION
OIL PUMP REMOVAL/INSTALLATION ··················· 12-7 (REMOTE CONTROL TYPE) ··························· 19-14
PGM-FI/MAIN RELAY INSPECTION ·····················10-13 SWIVEL CASE/MOUNT FRAME DISASSEMBLY/
P
PIPING CONNECTIONS ········································ 5-7 ASSEMBLY ·················································· 18-15

POWER TILT MOTOR DISASSEMBLY/ SYSTEM DIAGRAM
ASSEMBLY ··················································18-41 CHARGING SYSTEM ········································ 7-2
POWER TILT MOTOR INSPECTION·····················18-46 IGNITION SYSTEM··········································· 8-2
POWER TILT RELAY INSPECTION ······················10-15 STARTING SYSTEM ········································· 9-2
POWER TILT RELAY/RELAY BRACKET REMOVAL/ WIRING DIAGRAMS ········································21-5
INSTALLATION ·············································10-11 SYSTEM LOCATION
POWER TRIM/TILT CHECK ································· 3-32 CHARGING SYSTEM ········································ 7-2
POWER TRIM/TILT DISASSEMBLY/ASSEMBLY·····18-23 FUEL SYSTEM ···············································5-10
POWER TRIM/TILT SWITCH INSPECTION IGNITION SYSTEM··········································· 8-2
OUTBOARD MOTOR SIDE ·····························10-16 OTHER ELECTRICAL ······································10-2
REMOTE CONTROL/TILLER HANDLE SIDE ······19-48 STARTING SYSTEM ········································· 9-2
POWER TRIM/TILT/SWIVEL CASE REMOVAL/ THERMOSTAT INSPECTION ······························ 11-12
T
INSTALLATION (EXCEPT LHGX TYPE) ············· 18-6 THERMOSTAT/WATER JACKET COVER REMOVAL/
PROPELLER AND SPLIT PIN CHECK···················· 3-17 INSTALLATION ···············································11-4
PROPELLER REMOVAL/INSTALLATION ··············· 16-3 THROTTLE BODY INSPECTION·························· 5-105
PROPELLER SHAFT HOLDER DISASSEMBLY/ THROTTLE CONTROL CABLE/THROTTLE LINK
ASSEMBLY ··················································16-30 CHECK/ADJUSTMENT······································ 3-9
PROPELLER SHAFT HOLDER REMOVAL/ TILLER HANDLE DISASSEMBLY/ASSEMBLY ········ 19-23
INSTALLATION ·············································16-18 TILLER HANDLE REMOVAL/INSTALLATION ········· 19-21
PROPELLER SHAFT INSPECTION ······················16-44 TOOLS ······························································2-12
R. ENGINE UNDER COVER DISASSEMBLY/ TRIM ANGLE SENSOR INSPECTION ··················· 10-16
R
ASSEMBLY ··················································· 6-18 TUBE ROUTING ·················································2-43

REGULATOR/RECTIFIER INSPECTION················· 7-13 UNDER COVER FRONT BRACKET DISASSEMBLY/
U
REGULATOR/RECTIFIER/FUSE BOX/70 A FUSE BOX ASSEMBLY ····················································6-17

REMOVAL/INSTALLATION ······························ 10-4 UNDER COVER FRONT BRACKET REMOVAL/
RELIEF VALVE REMOVAL/INSTALLATION ···········11-11 INSTALLATION ···············································6-12
REMOTE CONTROL BOX DISASSEMBLY/ UNDER COVER REAR BRACKET DISASSEMBLY/
ASSEMBLY ··················································19-15 ASSEMBLY ····················································6-18
REMOTE CONTROL CABLE/GROMMET REMOVAL/ UNDER COVER REAR BRACKET REMOVAL/
INSTALLATION ·············································· 19-3 INSTALLATION ···············································6-15
ROCKER ARMS/SHAFT DISASSEMBLY/ VALVE CLEARANCE CHECK/ADJUSTMENT ···········3-12
V
ASSEMBLY ··················································14-30 VALVE GUIDE REPLACEMENT··························· 14-40

SEAL HOLDER REMOVAL/INSTALLATION ···········19-12 VALVE SEAT RECONDITIONING························· 14-41
S
SEAL HOLDER WATER SEAL REPLACEMENT······19-14 VAPOR SEPARATOR INSPECTION ····················· 5-102
SERIAL NUMBER LOCATION ································ 1-2 VERTICAL SHAFT DISASSEMBLY/ASSEMBLY······ 16-33
SERVICE PRECAUTIONS ····································· 5-2 VERTICAL SHAFT INSPECTION·························· 16-45
SHIFT CONTROL CABLE CHECK/ADJUSTMENT ···· 3-32 VERTICAL SHAFT/FORWARD BEVEL GEAR
SHIFT LINK BRACKET DISASSEMBLY/ REMOVAL/INSTALLATION ····························· 16-25
ASSEMBLY ··················································19-13 VTEC SOLENOID VALVE INSPECTION
SHIFT LINK BRACKET/NEUTRAL SWITCH (BF90D/BF100A ONLY) ·································· 5-107
REMOVAL/INSTALLATION ······························ 19-8 VTEC SOLENOID VALVE REMOVAL/INSTALLATION
SHIFT ROD REMOVAL/INSTALLATION ················16-14 (BF90D/BF100A ONLY) ····································5-82
SHIFT SLIDER/PROPELLER SHAFT REMOVAL/ WARNING BUZZER INSPECTION························ 19-46
W
INSTALLATION ·············································16-19 WATER LEVEL SENSOR INSPECTION ················ 5-106

SHIM SELECTION·············································16-36 WATER LINE DESCRIPTION ································11-3
SILENCER CASE DISASSEMBLY/ASSEMBLY ········ 5-90 WATER PUMP CHECK ········································3-31
SILENCER CASE REMOVAL/INSTALLATION ········· 5-67 WATER PUMP REMOVAL/INSTALLATION ··············11-6
SPARK PLUG CHECK/REPLACEMENT ················· 3-15 WATER SEPARATOR CHECK·······························3-25
SPECIFICATIONS ················································ 1-2 WATER SEPARATOR DISASSEMBLY/ASSEMBLY ···5-89
STANDARD TORQUE VALUES ······························ 2-7 WATER SEPARATOR REMOVAL/INSTALLATION ····5-87
STARTER CABLE/FUSE CABLE REMOVAL/ WIRING DIAGRAMS
INSTALLATION ·············································· 10-6 REMOTE CONTROL TYPE ·······························21-3
STARTER MOTOR DISASSEMBLY/ASSEMBLY ······ 9-10 TILLER HANDLE TYPE ····································21-4
22-2
BFT 75A/90A
BFT 75A
BFT 90A
BFT 75A
BFT 90A OB No.62ZY950US
14-01 NB OB No.62ZY950US
Printed in Japan 14-01 NB

BFT 75 A

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BFT 75A/90A

BFT75-90AUS_Cover_140207.indd 1 14/02/07 10:56

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Change model names with "BF" to "BFT".

Add "HCO-" at the beginning of part numbers of special tools.

BFT75-90AUS_Cover_140207.indd 2 14/02/10 9:43

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Improper service or repairs can create an unsafe

For Your Safety

Failure to properly follow instructions and

Important Safety Precautions

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You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.

You CAN be HURT if you don’t follow instructions.

© Honda Motor Co., Ltd.

How to use this manual

Replace the part(s) with new one(s) before assembly.

Use the recommend engine oil, unless otherwise specified.

Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

Use marine grease (water resistant urea based grease).

Use automatic transmission fluid.

( x )( ) Indicates the diameter, length, and quantity of metric bolts used.

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Bl Black G Green Br Brown Lg Light green

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FEMALE CONNECTOR VIEWING DIRECTION

VIEWING DIRECTION MALE CONNECTOR

TERMINAL ARRANGEMENT CONNECTOR No.

FEMALE CONNECTOR DRAWING

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: Connector that joins a harness to a harness (Circled No. in black background)

SERIAL NUMBER LOCATION ················· 1-2 DIMENSIONAL DRAWING ······················ 1-7

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ENGINE SERIAL NUMBER PRODUCT IDENTIFICATION NUMBER

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Model BF75DK3 BF90DK4

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Model BF75DK3 BF80A BF90DK4 BF100A

365 (14.4) Unit: mm (in)

746 (29.4) 449 (17.7)

76.2 (3.0) 48.4 (1.91)

X type: 664 (26.1)

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76.2 (3.0) 449 (17.7)

ANSI INV.S.16/32 x 15T x 30°

28.5 mm 57.5 ± 0.5 mm 60 mm

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MAINTENANCE STANDARDS ················· 2-2 TOOLS ·············································· 2-12

STANDARD TORQUE VALUES ··············· 2-7 TUBE ROUTING ·································· 2-43

LUBRICATION & SEAL POINT ················ 2-8

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ENGINE & FRAME TORQUE VALUES

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POWER TRIM/TILT (Except LHGX type)

STANDARD TORQUE VALUES

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