F425 Service Manual Lit - 18616-03-83

Worldwide:
(6GT)
-
(6GU)
(6GR)
(6GS)
USA, CAN, EUR, AUS, and NZL:

(6GT)
(6GR)
6GR-28197-ZX-11
LIT-18616-03-83
6GR-28197-ZX-11
LIT-18616-03-83
Preface
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained tech-
nicians when performing maintenance procedures and repairs to Yamaha equipment. It has been writ-
ten to suit the needs of persons who have the Bronze Technical Certificate of the YTA (Yamaha
Technical Academy) marine or the equivalent basic understanding of the mechanical and electrical
concepts and procedures inherent in the work, for without such knowledge attempted repairs or service
to the equipment could render it unsafe or unfit for use.
Because Yamaha has a policy of continuously improving its products, models may differ in detail from
the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Au-
thorized Yamaha dealers are notified periodically of modifications and significant changes in specifica-
tions and procedures, and these are incorporated in subsequent editions of this manual. Also, up-to-
date parts information is available on YMBS (Yamaha Marine Business System, USA only) or YPEC-
web (except USA). Additional information and up-to-date information on Yamaha products and services
are available on YMBS, YMPE (Yamaha Multimedia Product Encyclopedia, Canada only), or Yamaha
Service Portal (except USA and Canada).
Important information
Particularly important information is distinguished in this manual by the following notations:
: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey
all safety messages that follow this symbol to avoid possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could result in death or se-
rious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to the outboard
motor or other property.
TIP:
A TIP provides key information to make procedures easier or clearer.
F375A, FL375A, F425A, FL425A, XF375, XF425

SERVICE MANUAL
©2018 by Yamaha Motor Co., Ltd.
1st Edition, June 2018
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
6GR-28197-ZX-11
LIT-18616-03-83
Contents
General information 0
Specification 1
Technical feature and description 2
Rigging information 3
Troubleshooting 4
Electrical system 5
Fuel system 6
Power unit 7
Lower unit 8
Bracket unit 9
Maintenance 10
Appendix A
General information
Model information .............................................................. 0-1

Applicable model ........................................................................ 0-1 0
Model name designation ............................................................ 0-1
Important safety and service information........................ 0-3

Rotating parts ............................................................................. 0-3
Hot parts..................................................................................... 0-3
Electric shock ............................................................................. 0-3
Propeller ..................................................................................... 0-3
Handling of gasoline................................................................... 0-3
Ventilation................................................................................... 0-3
Self-protection ............................................................................ 0-3
Lifting outboard motors............................................................... 0-4
Handling of gas torch ................................................................. 0-4
Parts, lubricants, and sealants ................................................... 0-4
Handling of lubricants and sealants ........................................... 0-4
Special service tools................................................................... 0-5
Tightening torque ....................................................................... 0-5
Non-reusable parts..................................................................... 0-5
Disassembly and assembly........................................................ 0-5
Disposal of used components and chemicals ............................ 0-5
How to use this manual ..................................................... 0-6

Manual format ............................................................................ 0-6
Conditions when testing and adjusting....................................... 0-7
Abbreviation ............................................................................... 0-7
Color code .................................................................................. 0-8
Specified tightening torque............................................... 0-9

General tightening torque........................................................... 0-9
Symbol .............................................................................. 0-10

Specification symbol................................................................. 0-10
Lubricant, sealant, and thread locking agent symbol ............... 0-10
Special service tool.......................................................... 0-12

Model information
Model information
Applicable model
This manual applies to the following models.
Worldwide
Model name Approved model code Starting serial No.

F425AST 6GR 1000001–
FL425AST 6GS 1000001–
F375AST 6GT 1000001–
FL375AST 6GU 1000001–
USA, CAN, EUR, AUS, and NZL

Model name Approved model code Starting serial No.
XF425NSA 6GR 1000001–
XF375NSA 6GT 1000001–
Model name designation

Worldwide
FL 425 A ST 2 X
1 2 3 4 5 6
F: 4-stroke
1 Model category
L: Counter rotating propeller
2 Output horsepower 375/425
A: 1st change on motor
B: 2nd change on motor
3 Model generation
C: 3rd change on motor
Etc.
Level 1: Starting method
E: Electric start
Level 2: Control method

4 Model variation None: Remote control without tiller handle
S: Built-in SBW and electric start
Level 3: Trim and tilt method

T: PT/T (Power trim and tilt)
None: Gray
5 Color code 2: White
7: Unpainted
0-1
Model information
X (25 in)
6 Motor transom height U (30 in)
E (35 in)
USA, CAN, EUR, AUS, and NZL
XF 425 N SA2
1 2 3 4 5 6 7
X: XTO offshore series

1 Model category
F: 4-stroke
2 Horsepower 375/425
3 Motor transom height N: Without lower unit
4 Starting method/PTT Blank: PTT and electric start
Blank: Remote control
5 Control method
S: Built-in SBW and electric start
A: 1st change on motor
B: 2nd change on motor
6 Generation
C: 3rd change on motor
Etc.
None: Gray
7 Color code 2: White
7: Unpainted
0-2
Important safety and service information
Important safety and service Handling of gasoline

information • Gasoline is highly flammable. Keep gasoline
To prevent an accident or injury and to provide and all flammable products away from heat,
quality service, observe the following informa- sparks, and open flames.
tion. • Gasoline is poisonous and can cause injury
or death. Handle gasoline with care. Never
Rotating parts siphon gasoline by mouth. If you swallow
• Hands, feet, hair, jewelry, clothing, personal some gasoline, inhale a lot of gasoline vapor,
flotation device straps, and so on, can be- or get some gasoline in your eyes, see your
come entangled with internal rotating parts of doctor immediately. If gasoline spills on your
the engine, resulting in serious injury or skin, wash with soap and water. If gasoline
death. spills on your clothing, change your clothes.
• Keep the top cowling installed whenever
possible. Do not remove or install the top
cowling when the engine is running.
• Only operate the engine with the top cowling
removed according to the specific instruc-
tions in the manual. Keep hands, feet, hair,
jewelry, clothing, personal flotation device
straps, and so on, away from any exposed
moving parts.
Hot parts Ventilation

During and after operation, engine parts are • Gasoline vapor and exhaust gases are
hot enough to cause burns. Do not touch any heavier than air and extremely poisonous. If
parts under the top cowling until the engine has gasoline vapor or exhaust gases are inhaled
cooled. in large quantities, it may cause loss of con-
sciousness and death within a short time.
Electric shock • When test running an engine indoors (for ex-
Do not touch any electrical parts while starting ample, in a water tank), make sure to do so
or operating the engine. Otherwise, shock or where adequate ventilation can be main-
electrocution could result. tained.
Propeller
Do not hold the propeller with your hands when
loosening or tightening the propeller nut. Sharp
propeller edges can cause injury. Place a
wood block between the gearcase and propel-
ler to hold the propeller for removal and instal-
lation.
Self-protection
• Protect your eyes by wearing safety glasses
or safety goggles during all operations involv-
ing drilling and grinding, or when using an air
compressor.
0-3
• Protect your hands and feet by wearing pro-
tective gloves and safety shoes when neces-
sary.
Parts, lubricants, and sealants

Use only genuine Yamaha parts, lubricants,
and sealants, or those recommended by
Lifting outboard motors Yamaha, when servicing or repairing the out-
• Outboard motors weighing 18 kg (40 lb) and board motor. Failures caused by the use of
over must be carried by a crane or equiva- parts, lubricants, or sealants that are not equiv-
lent. alent in design and quality to genuine Yamaha
• Use a wire cable lifting harness of adequate parts, lubricants, or sealants will not be cov-
strength to lift up the outboard motor in a sta- ered by warranty.
ble manner.
• Lift and suspend the outboard motor in a sta-
ble manner using the designated lifting at-
tachment points.
• Do not work on or under an outboard motor
while it is suspended from a lifting device. Se-
curely mount the motor on a suitable work
stand or place it on a stable work surface as
soon as possible.
Handling of lubricants and sealants

• Follow all instructions and safety precautions
provided on the product label and the materi-
al safety data sheet (MSDS/SDS) for lubri-
cants, sealants, and other shop chemicals.
• Wear impervious gloves, eye protection, or
other protective apparel when required.
• Wash skin thoroughly after contact with lubri-
cants, sealants, and other shop chemicals,
Handling of gas torch and change clothing if contaminated with
• Improper handling of a gas torch may result them.
in burns. For information on the proper han-
dling of the gas torch, see the operation man-
ual issued by the manufacturer.
• When using a gas torch, keep it away from
gasoline and oil to prevent a fire.
• Components become hot enough to cause
burns. Do not touch any hot components di-
rectly.
0-4
Special service tools

For safety and to help protect parts from dam-
age, use the recommended special service
tools.
• During disassembly, cover all openings,

such as intake and exhaust ports, to prevent
foreign materials from entering the engine.
Foreign materials could cause severe inter-
nal damage when the engine is started.
Tightening torque • Install bearings so that the bearing identifica-
When tightening nuts, bolts, and screws, follow tion mark is facing in the direction indicated in
the tightening instructions provided throughout the installation procedure. In addition, make
the manual. If the tightening order is not speci- sure to lubricate the bearings liberally.
fied, tighten the large sizes first, and then tight- • Apply a thin coat of water resistant grease to
en the small sizes, starting from the center and the lip and periphery of an oil seal before in-
moving outward. stallation.
• Check that moving parts operate normally af-
Non-reusable parts ter assembly.
Always use new gaskets, seals, O-rings, cotter • When starting the engine after reassembly,
pins, and so on, when installing or assembling check for fuel and water leaks from hoses
parts. and pipes that were disconnected or re-
moved while servicing.
• When assembling the PTT/PT unit, do not
use a rag. Otherwise, dust and particles
could get on the PTT/PT unit components,
causing poor performance.
Disposal of used components and

chemicals
Obey all federal, state and local regulations
when disposing of used components and/or
Disassembly and assembly chemicals such as crate frames, replaced
• Use compressed air to remove dust and dirt parts, gaskets, oil, and so on.
during disassembly.
• Apply engine oil to the contact surfaces of
moving parts before assembly.
0-5
How to use this manual

Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the following information as a guide for effective and quality service.
• Parts are shown and detailed in an exploded diagram and are listed in the component list (see “1” in
the following figure for an example page).
• The component list consists of the basic removal or disassembly order (“ ”), part names, quantities,
and remarks, which indicate the bolt and screw dimensions and other information (see “2” in the fol-
lowing figure). For the installation or assembly procedure, reverse the order.
• Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
the lubrication points (see “3” in the following figure).
• Tightening torque specifications are provided in the exploded diagrams (see “4” in the following fig-
ure), and in the related detailed instructions. Some torque specifications are listed in stages as torque
values or angles in degrees.
• Separate procedures and illustrations are used to explain the details of removal, checking, and instal-
lation where necessary (see “5” in the following figure for an example page). Detailed explanations of
the procedures are enclosed in (see “6” in the following figure for an example page).
• Numbers enclosed in brackets are used to indicate the removal or tightening order of bolts, screws,
and other parts (see “7” in the following figure).
TIP:
For troubleshooting procedures, see Chapter 4, “Troubleshooting”.
4 3 1 7 5
Cylinder block
Cylinder block
1 13 N·m (1.3 kgf·m, 9.6 lb·ft) 24 New
2 28 N·m (2.8 kgf·m, 21 lb·ft)
New 25 Cylinder block
3 90°
17 17 26
E
E [19] [9] [10] [20]
15 New 14 3
E
E [35]
[35] [36]
[36]
1 1
E [31]
[31] [15][5] [6][16] 3
New 25 28
E 19 22 2 [32]
[32]
16 27 1 1
15 New [25] [11][1] [2][12] [26]
18 3
1 14 N·m (1.4 kgf·m, 10 lb·ft)
1 1
2 28 N·m (2.8 kgf·m, 21 lb·ft) [21] [14][4] [3]
3][13
[13]
[] [22]
11 New 3 Journal oil clearance
E 6 20 [24] 1 1 [[23
23]] 0.029–0.053 mm (0.0011–
[[18
18][8]
] 8] [7[][17]
8 23 New 3 0.0021 in)
E
7 3
21 E 1 1 Limit
12 [30]
[30] [27]
32 0.073 mm (0.0029 in)
9 13 31 [[28
28]]
3 [29]
E
[34]
[34] 2 [33]
33] [ Selecting the crankshaft journal
10 6 bearing
4 30
E When replacing the crankshaft journal bearing,
1 2 3
1 40 N·m (4.0 kgf·m, 30 lb·ft)
select the bearing as follows.
E
5 New 2 90° 29 a 1. Check:
2 90° • Stamped mark “a” (on the crank web)
1 14 N·m (1.4 kgf·m, 10 lb·ft) E 1 40 N·m (4.0 kgf·m, 30 lb·ft)
2 27.5 N·m (2.75 kgf·m, 20.28 lb·ft) • Stamped mark “b” (on the cylinder block)
New 1 2 90°
1 J1 J2 J3 J4 J5
Part name Q’ty Remarks Part name Q’ty Remarks

1 Bolt M10 × 50 mm 8 Crankshaft journal
18 5
2 Flange 1 bearing
3 Bolt M8 × 50 mm 26 19 Crankshaft 1 Crankcase bolt (M10) “1” [1]–[20]
4 Crankcase cover 1 20 Thrust bearing 1 1st: 40 N·m (4.0 kgf·m, 30 lb·ft)
T.
R.
5 Gasket 1 21 Thrust bearing 1 2nd: 90°

J5
6 Dowel 2 Crankshaft journal Crankcase bolt (M8) “2”, “3” [21]– J4
22 5
bearing [36]
7 Bolt M8 × 50 mm 10 J3
23 Oil seal 1 1st: 14 N·m (1.4 kgf·m, 10 lb·ft) J2 a
8 Bolt M8 × 70 mm 6
24 Oil seal 1 2nd: 28 N·m (2.8 kgf·m, 21 lb·ft) J1
9 Bolt M10 × 103 mm 20
25 Clip 16
10 Crankcase 1
26 Piston pin 8
11 O-ring 1
27 Piston ring set 8
12 Thrust bearing 1 5. Remove:
28 Piston 8
13 Thrust bearing 1 • Crankcase
29 Bolt M6 × 14 mm 6
14 Dowel 10
30 Drive gear 1
15 Bolt M9 × 42mm 16 6. Measure:
31 Pickup rotor 1
Connecting rod as- • Width of the compressed Plastigauge
16 8 32 Dowel 1
sembly (PG-1)
17 Crankshaft pin bearing 16 Out of specification → Replace the crank-
shaft journal bearing. b
7-78 J1 J2 J3 J4 J5
2. Select:
• Crankshaft journal bearing
7-90
2 6
0-6
Conditions when testing and adjusting

Conditions can affect specifications when checking, measuring, and making certain adjustments. Ser-
vice data in this manual was determined under the following conditions:
• Electrical resistance for components such as ignition coils and sensors was measured at 20 °C (68
°F).
• Engine compression was measured at:
• Sea level
• 20 °C (68 °F)
• All spark plugs removed
• Throttle valve at WOT (depending on model specification)
• Trim/tilt angles shown are when the transom angle is 12 degrees.
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
ABYC American Boat and Yacht Council
APS Accelerator Position Sensor
ECM Electronic Control Module
EN European Norm (European standard)
EPA Environmental Protection Agency
ETV Electronic Throttle Valve
HCU Helm Control Unit
ISC Idle Speed Control
LPS Lever Position Sensor
OCV Oil Control Valve
OS Offshore
PCU Power-train Control Unit
PTT Power Trim and Tilt
SBW Steer by Wire
SCU Steering Control Unit
SDS Shift Dampener System
SPS Shift Position Sensor
TPS Throttle Position Sensor
VCT Variable Camshaft Timing
Y-COP Yamaha Customer Outboard Protection
YDIS Yamaha Diagnostic System
XTO Xtreme Thrust Output
WOT Wide Open Throttle
0-7
Color code
B Black Lg Light green Sb Sky blue
Br Brown Or Orange W White
G Green P Pink Y Yellow
Gy Gray Pu Purple
L Blue R Red
TIP:
For example, “R/Y” stands for a Red with Yellow tracer stripe wire.
0-8
Specified tightening torque
Specified tightening torque

Specified tightening torques are provided for specific nuts, bolts, and screws. Specified tightening
torque specifications are provided in the exploded diagrams and in the related working instructions.
When tightening these fasteners, follow the tightening torque specifications and procedures indicated
throughout the manual to meet the design aims of the outboard motor.
General tightening torque

This chart indicates the tightening torques for standard fasteners with a standard ISO thread pitch.
General torque specifications
Width across flats (A) Thread size (B)
N·m kgf·m lb·ft
8 mm M5 5 0.5 3.7
10 mm M6 8 0.8 5.9
12 mm M8 18 1.8 13
14 mm M10 36 3.6 27
17 mm M12 52 5.2 38
0-9
Symbol
Symbol
Specification symbol
Illustrated symbols are used to identify the specifications which appear.
Symbol Definition Symbol Definition
Filling fluid Lubricant
Special tool Tightening torque
T.
R.
Wear limit, clearance Engine speed
Electrical data New Replace the part with a new one.
Lubricant, sealant, and thread locking agent symbol

Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication points.
Symbol Name Application
YAMALUBE 4 or YAMALUBE 4M FC-W Lubricant
YAMALUBE outboard gear oil or Yamalube Ma-

Lubricant
rine Gearcase Lube
Water resistant grease
Lubricant
(Yamaha grease A or Yamalube Marine Grease)
Molybdenum disulfide grease
Lubricant
(Yamalube Molybdenum Disulfide grease)
Corrosion resistant grease
Lubricant
(Yamaha grease D or Yamalube Marine Grease)
Low temperature resistant grease
(Yamaha grease C or Yamalube Molybdenum Di- Lubricant
sulfide grease)
Epnoc grease AP #0 Lubricant
YAMAHA WR-No.2 grease Lubricant
ThreeBond 1901 Lubricant
Symbols in an exploded diagram or illustration indicate the type of sealant or thread locking agent and
the application points.
0-10
Symbol
Symbol Name Application

YAMAHA Gasket Maker Sealant
ThreeBond 1280B
Sealant
(Yamabond 4 Marine)
ThreeBond 1322 Thread locking agent
ThreeBond 1386B Sealant
ThreeBond 1377B Thread locking agent
LOCTITE 1342 Thread locking agent
ThreeBond 1530D Sealant
ThreeBond 1303 Thread locking agent
LOCTITE 271 (red) Thread locking agent
LOCTITE 242 (blue) Thread locking agent
LOCTITE 572 (white) Sealant
0-11
Special service tool

Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division.
USA and Canada tool numbers (YB/YM/YS/YU-*****) are distributed by K&L Supply Co.
Some of the special service tools are only available from the Marine Service Division.
WW SST No.
Liftting eye Bolt hexagon with Liftting hanger Drilling plate

90890-06953 washer 90890-06951 90890-06783
90890-06821
YDIS2 Hardware Kit Digital circuit tester Test harness (3 pins) Ignition checker (Spark
90890-06884 90890-03243 90890-06869 gap tester)
90890-06754
Vacuum/pressure Injector remover Fuel injection meter Stopper

pump gauge set 90890-06696 FIM20000ME 90890-06699
90890-06945
Seal fitter Nozzle cap Seal installer Compression gauge

90890-06708 90890-06697 90890-06698 90890-03160
Compression gauge Balance hanger Bolt set Rotor holder

extension M10 90890-06954 90890-06969 90890-01235
90890-06582
0-12
Flywheel stopper Flywheel guide Shaft holder Valve spring compres-

90890-06598 90890-06955 90890-06949 sor
90890-04019
Valve spring compres- Lever assy Support assy 3 Valve spring compres-
sor attachment 90890-06956 90890-06952 sor
90890-06320 90890-06689
Valve guide remover/ Valve guide reamer Valve lapper Valve seat cutter hold-
installer 90890-06804 90890-04101 er
90890-06801 90890-06316
Valve seat cutter 30– Valve seat cutter 45– Valve seat cutter 60° Valve seat cutter 30°
38 38 90890-06324 90890-06326
90890-06817 90890-06816
Valve seat cutter 45° Valve seat cutter 60° Oil filter wrench Piston slider 96 mm
90890-06325 90890-06323 90890-06874 90890-06684
Driver rod L3 Needle bearing attach- Leakage tester Shift rod socket
90890-06652 ment 90890-06840 90890-06950
90890-06608
0-13
Needle bearing attach- Needle bearing attach- Ring nut wrench Ring nut wrench exten-
ment ment 90890-06932 tion 2
90890-06614 90890-06609 90890-06784
Stopper guide plate Bearing housing puller Center bolt Ball bearing attach-
90890-06501 claw L 90890-06504 ment
90890-06502 90890-06657
Driver rod LL Needle bearing attach- Bearing inner race at- Bearing outer race at-
90890-06605 ment tachment tachment
90890-06933 90890-06658 90890-06621
Driver rod LS Bearing outer race at- Ring nut wrench Drive shaft holder
90890-06606 tachment 90890-06934 90890-06935
90890-06623
Pinion nut holder Socket adapter Holder guide Needle bearing attach-
90890-06715 90890-06936 90890-06937 ment
90890-06967
Needle bearing attach- Bearing outer race Stopper guide plate Bearing inner race at-
ment puller assembly 90890-06939 tachment
90890-06938 90890-06523 90890-06639
0-14
Bearing outer race at- Backlash indicator Magnet base plate Dial gauge set
tachment 90890-06836 90890-07003 90890-03238
90890-06628
Magnet base B Ring nut extension Pinion shimming Pinion shimming

90890-06844 90890-06968 gauge gauge rod
90890-06948 90890-06676
Slide hammer handle Puller head Needle bearing attach- Ball bearing attach-
90890-06531 90890-06514 ment ment
90890-06616 90890-06630
Bearing inner race at- Ring nut wrench 2 Needle bearing attach- Ball bearing attach-
tachment 90890-06823 ment ment
90890-06644 90890-06654 90890-06636
Bearing puller assem- Stopper guide stand Cylinder end screw Cylinder end screw
bly 90890-06538 wrench wrench
90890-06535 90890-06958 90890-06959
Gear oil attachment kit Oil socket Air socket Joint

90890-06963 90890-06964 90890-06965 90890-06966
0-15
US SST No.
Bolt hexagon with Drilling plate YDIS2 Hardware Kit Digital multimeter
washer YB-34465-A LIT-YDIS2-01-KT YU-34899-A
YB-06821
Test harness (3 pins) Spark checker Pressure/vacuum tes- Compression gauge

YB-06869 YM-34487 ter YU-33223
YB-35956-B YU-33223
Universal magneto and Flywheel stopper Valve spring compres- Valve spring compres-
rotor holder YB-06598 sor sor adaptor
YU-01235 YM-04019 YB-06320
Valve spring compres- Valve guide remover Valve guide reamer Valve lapping tool
sor YB-06801 YB-06804 YM-A8998
YB-06689
Neway valve seat kit Oil filter wrench Piston slider 96 mm Driver handle (large)
YB-91044 YB-06874 YB-06684 YB-06071
0-16
Driveshaft bearing in- Driver handle (small) Oil seal installer re- Driveshaft seal install-
staller YB-06229 verse gear bearing er
YB-06110 housing YB-06348
YB-06021
Ring nut wrench exten- Universal Puller Bearing housing puller Prop end seal bearing
sion YB-06117 YB-06207 driver
YB-06784 YB-42227
Driver rod LL Taper roller bearing in- Forward gear bearing Forward gear bearing
YB-06605 staller installer cup installer
YB-06431 YB-06276 YB-06277-A
Bearing inner race at- Bearing cup installer Backlash indicator Backlash adjustment
tachment YB-06167 YB-06836 plate
YB-06639 YB-07003
Dial indicator gauge Magnetic base stand Pinion shimming Slide hammer
YU-03097 YU-A8438 gauge YB-06096
YB-06835
0-17
Propeller shaft and Oil seal installer Forward gear needle Bearing inner race at-
bearing housing re- YB-06023 bearing installer tachment
mover YB-06261 YB-06644
YB-06335
Ring nut wrench Driveshaft needle Needle bearing install- Driveshaft needle
YB-06823 bearing installer and er bearing installer
remover YB-06434 YB-06231
YB-06196
0-18
Specification
Specification data .............................................................. 1-1
External dimensions .......................................................... 1-2

1
Clamp bracket dimensions ............................................... 1-3
Specification data
Specification data
For specification data, see Appendix, “Specification” (A-1).
1-1
External dimensions
External dimensions
TIP:
The dimension values may include reference values.
mm (in)
554 (21.8)
31°
723.9 (28.5)
T1*1
326 (12.8)
X:1291 (50.8)
U:1412 (55.6)
708 (27.9) E:1533 (60.4)
198 (7.8) 1019 (40.1)
X:390 (15.4)
47 (1.9) U:391 (15.4)
E:392 (15.4)
1286 (50.6)
959 (37.8)
720 (28.3)
36 (1.4)
E:894 (35.2) 101 (4.0)
*4
U:767 (30.2)
X:640 (25.2)
X:115 (4.5)
U:83 (3.3)
295 (11.6)
E:49 (1.9)
U:1227 (48.3)
X:1100 (43.3)
E:1354 (53.3)
H*2
U:1079 (42.5)
E:1167 (45.9)
X:991 (39.0)
230 (9.1)
33 (1.
3)
U 42:(1.7)
X 42:(1.7)
E 41:(1.6)
3
°*
12° 4° 77
66 (2.6) 861 (33.9)
*1. Minimum distance between the outboard motors in twin, triple, or quad engine application
*2. Motor transom height
*3. Fully tilt-up angle (Not tilt support angle)
*4. Gravity point
1-2
Clamp bracket dimensions
Clamp bracket dimensions

TIP:
The dimension values may include reference values.
mm (in)
222 (8.7) 222 (8.7)
163.5 (6.4) 163.5 (6.4)

50.8 (2.0)
254 (10.0)
18.5 (0.7)
405 (15.9)
)
.5
(0
13
92.5 (3.6)
24 (0.9)
21 (0.8)
45 (1.8)
125.4 (4.9) 125.4 (4.9)
1-3
Technical feature and description
Model feature ...................................................................... 2-1

General feature .......................................................................... 2-1
Model comparison table ............................................................. 2-2
Rigging information ........................................................... 2-2

Crate top cover........................................................................... 2-2
Power unit ........................................................................... 2-3

2
Sleeveless cylinder..................................................................... 2-4
Heat exhaust fan and heat vent ................................................. 2-4
Direct fuel injection ..................................................................... 2-5
Crankshaft .................................................................................. 2-6
Camshaft .................................................................................... 2-7
Cowlings..................................................................................... 2-8
Bracket unit ........................................................................ 2-9

Upper mount............................................................................. 2-10
SBW (Steer by Wire) system.................................................... 2-11
System diagram ....................................................................... 2-12
Structure................................................................................... 2-14
Operation.................................................................................. 2-15
Outboard motor manual steering method................................. 2-16
PTT unit.................................................................................... 2-17
PTT sensor............................................................................... 2-18
Lower unit ......................................................................... 2-19

Lower case ............................................................................... 2-20
Gear oil changing method ........................................................ 2-21
Reverse thrust .......................................................................... 2-23
Propeller (XTO offshore series)................................................ 2-23
Electrical system .............................................................. 2-24

Charging system ...................................................................... 2-24
Knocking detection ................................................................... 2-25
Overheat detection ................................................................... 2-25
Electronic control system ............................................... 2-26

Electrical components .............................................................. 2-28
Fail-safe.................................................................................... 2-30
Technical feature and description
Fuel system ...................................................................... 2-34

Fuel diagram ............................................................................ 2-34
High-pressure fuel pump control .............................................. 2-37
Low-pressure fuel pump control ............................................... 2-37
Vapor separator........................................................................ 2-38
Fuel strainer ............................................................................. 2-39
Direct injection pump................................................................ 2-40
Lubrication system .......................................................... 2-41

Lubrication diagram.................................................................. 2-41
Dual rotor oil pump ................................................................... 2-43
Oil drain plug ............................................................................ 2-44
Cooling system ................................................................ 2-45

Cooling diagram ....................................................................... 2-45
Dual water pump ...................................................................... 2-48
Engine anode ........................................................................... 2-49
Thermostat ............................................................................... 2-50
Intake and exhaust system ............................................. 2-51

Intake and exhaust diagram ..................................................... 2-51
Hose routing ..................................................................... 2-52

Fuel hose and blowby hose...................................................... 2-52
Cooling water hose................................................................... 2-53
New special service tool.................................................. 2-54

Model feature
Model feature
General feature
• High-torque engine with the world’s highest output for a naturally aspirated outboard motor engine
• Newly designed 4-stroke, V8, 5559 cm³ (339.2 cu. in) engine
• High output due to the direct fuel injection system
• Easy operation of the high-output engine due to the SBW (Steer by Wire) system
• New packaging method for models for North America, Europe, and Oceania
• Various transom heights available for larger boats (X: 25”, U: 30”, E: 35”)
• Enhanced reverse thrust at low speeds
a. Power unit
• Direct fuel injection
• Sleeveless cylinders
• Increased thrust strength of the crankshaft
• New camshaft layout b
• Flywheel with a heat exhaust fan
• Top cowling with a heat vent
• Easier removal and installation of the top a
cowling
• Dual rotor oil pump
b. Electrical
• Electronic fuel injection control
• Digital ignition control
• ETV control
• VCT control (IN)
c
• Shift actuator control
d
• Twin sensor knock control
• Over-revolution control
• High-capacity charging system
c. Bracket unit
• New clamp brackets
• Vibration-isolation upper mounts e
• SBW (Steer by Wire) system
• New PTT unit
d. Upper case
• New bottom cowlings
e. Lower unit
• New lower case
• Dual water pump
• Gear oil changing system on the water
• XTO offshore series propeller with SDS
2-1
Rigging information
Model comparison table

375- and 425-horsepower 4-stroke models have been newly added to the Yamaha outboard motor line-
up. Almost all of the components are the same as those for the 375- and 425-horsepower models; how-
ever, only the ECM that controls the engine power output is different.
F375A/FL375A/XF375 F425A/FL425A/XF425
Type 4-stroke DOHC V8 32 valves
Total displacement 5559 cm³ (339.2 c.i.)
Bore × stroke 96.0 × 96.0 mm (3.78 × 3.78 in)
Compression ratio 12.2:1
Maximum generator output 90 A
Rated power 279.6 kW (375 hp) 316.9 kW (425 hp)
Full throttle operating range 5000–6000 r/min
Maximum fuel consumption at 6000 r/min
121.0 L/h 142.0 L/h
(reference data)
Idle speed (in neutral) 650–750 r/min
Rigging information
Crate top cover
The material of the crate top cover, which is used for shipping, has been changed from cardboard to
polyethylene (PE).
Because the cover is semi-transparent, the contents of the crate can be seen through the cover, which
helps to prevent the forklift operator from accidentally damaging the product with the forklift forks. In
addition, a recyclable material was selected in consideration of the environment.
2-2
Power unit
Power unit
Outline
The outboard motor has the world’s highest output for a naturally aspirated outboard motor engine. The
engine is a newly designed, electronically controlled, direct-injection V8 engine. By using a high com-
pression ratio and direct injection and by optimizing the engine layout, the fuel economy has been im-
proved compared to the F350B (F350CA) while increasing the engine displacement, and the size has
been kept to approximately the same size.
The engine uses sleeveless cylinders (spray-coated cylinders). Due to the use of valve lifters with DLC
(diamond-like carbon) coating, the interval for checking the valve clearance has been extended. The
split-type bottom cowling is equipped with seals between the sections of the bottom cowling to prevent
the entry of water inside the cowling.
In addition, serviceability has been improved through various measures such as the ability to connect
the cooling water passages of the outboard motors and perform the flushing for multiple outboard mo-
tors simultaneously.
2-3
Power unit
Sleeveless cylinder
The newly designed cylinder block has adopted spray-coated cylinders instead of sleeved cylinders.
By using spray-coated cylinders, the weight of the cylinder block is decreased, cooling performance is
increased, and so on.
The inner walls of the cylinders are spray-coated using metal powder.
Heat exhaust fan and heat vent

The flywheel is equipped with a heat exhaust fan and the top cowling is equipped with a heat vent.
By controlling the temperature increase in the top cowling due to the generation of a large amount of
electricity and stabilizing the intake air temperature, high output can be produced.
In addition, the heat vent is located on the front of the top cowling to prevent water from entering the
cowling.
A
A. Warm air flow
2-4
Power unit
Direct fuel injection

The direct injection pumps “1” further increase the pressure of the fuel from the fuel tank, low-pressure
fuel pump, and vapor separator. The fuel pressure sensors (fuel rails) “2” are used to detect the fuel
pressure in the fuel rails, and the injector drivers operate the direct injection pumps and fuel injectors
based on information from the ECM to inject the optimum amount of fuel at the optimum timing.
1
A
A. Fuel flow
Because the intake air can be cooled, the output is increased due to the improved charging efficiency.
In addition, the compression ratio can be increased because knocking is reduced, which increases the
thermal efficiency and fuel economy.
Because the fuel injectors are located in the center of the combustion chambers, the size of the overall
system is compact, and the overall width of the outboard motor and the distance between outboard mo-
tors for multiple engine applications is approximately the same as for previous models.
2-5
Power unit
Crankshaft
The size of the journals is the same as for the F300B (F300CA) and the amount of overlap between the
crankpins has been increased to ensure sufficient durability for offshore use.
In addition, by increasing the surface area of the thrust bearings and reducing the friction by adding a
surface treatment to the portion that engages the drive shaft splines, the durability in the thrust direction
is increased. By reducing the length of the crankshaft as much as possible, the height of the engine has
also been kept low.
Also, the spline portion that engages the drive shaft can be removed and installed, which reduces the
frequency of replacing the crankshaft.
2-6
Power unit
Camshaft
The timing belt is located on the top of the engine and the timing chains and VCT assemblies are locat-
ed at the bottom of the engine for increased engine reliability. In addition, the overall width of the out-
board motor is compact and the distance between outboard motors for multiple engine applications is
approximately the same as for previous models.
While the engine is running, the VCT assemblies advance or retard the intake camshafts according to
the engine speed in order to control the opening and closing timing of the intake valves to improve the
intake efficiency.
2-7
Power unit
Cowlings
The cowling lock levers, which were located on the rear of the outboard motor for previous models,
have been moved closer to the top of the top cowling and the rear portion of the top cowling is shorter.
As a result, it is easier to access the cowling lock levers from the boat and remove and install the top
cowling. In addition, the cowling lock levers can be released using a simple 2-step operation. By using
a lightweight SMC (sheet molding compound) material, the weight of the cowlings has been reduced
by 4.3 kg (9.5 lb) compared to the F350B (F350CA).
The bottom cowling cover and bottom cowlings can also be removed and installed while the boat is
docked for improved serviceability. The bottom cowling cover and bottom cowlings use anti-detach-
ment bolts except for 1 location at the front of each bottom cowling.
2-8
Bracket unit
Bracket unit
Outline
The upper mounts use outward-positioned, vibration-isolation upper mounts. The swivel bracket is
equipped with the new SBW (Steer by Wire) system for easier operation at low to high speeds as well
as easier rigging.
The PTT-related parts have also been newly designed for increased durability as well as easier removal
and installation of the PTT unit itself.
2-9
Bracket unit
Upper mount
This model is the first Yamaha large outboard motor to use a layout with the vibration-isolation upper
mounts positioned on the outside of the upper case.
The installation location of the upper mounts has been changed from being secured inside the exhaust
guide to being secured to the left and right sides of the upper case. The upper mounts are positioned
at a wider pitch and slightly lower toward the rear of the outboard motor compared to previous models.
As a result, the height of the outboard motor is minimized and the full tilt-up angle is increased. This
helps to prevent the lower unit from being submerged when the outboard motor is tilted up while the
boat is moored.
The upper mounts are also easier to replace and have a lighter weight.
2-10
Bracket unit
SBW (Steer by Wire) system

Outline
The steering system has been changed from a mechanical system that was used for previous models
to an electronically controlled power-operated steering system. Because the steering system has been
designed with a sufficient margin for use with large boats, the system is responsive and provides a sta-
ble feeling when steering the boat.
The system is comprised of an integrated unit that is simple and compact. Because the system has an
easy-to-use design that can be used just by connecting the wiring, the time required for rigging is re-
duced and space is used more efficiently.
For multiple engine applications, because the system is always monitoring the positions of the outboard
motors, the system controls the outboard motors to ensure that the appropriate distance is maintained
between the outboard motors.
In addition, because the system includes a dual monitoring system, the boat can still be steered using
the backup system if a malfunction occurs. Even if a malfunction occurs that prevents the power-oper-
ated steering of the boat, the system includes a mechanism for adjusting the steering angle manually.
2-11
Bracket unit
System diagram
When the signals from the steering wheel and joystick are input into the steering control unit (SCU), the
SCU uses that information together with the information from other sensors to calculate the optimal
steering control and operates the steering motor to match the intended steering angle of the operator.
For multiple engine applications, the system controls the steering angle of each outboard motor so that
the boat moves in the intended direction.
Digital Electronic Control model
1. Helm unit
3. Engine ECM
2. Digital Electronic Control 4. Position sensor
5. SCU
6. Steering motor
7. Steering actuator
1. Helm unit
2. Digital Electronic Control
3. Engine ECM
4. Position sensor
5. SCU
6. Steering motor
A. Electronic signal
2-12
Bracket unit
Helm Master model
1. Helm unit / joystick
2. Digital Electronic Control

(HCU) 4. Engine ECM
3. PCU 5. Position sensor
6. SCU
7. Steering motor
A
1. Helm unit/joystick
2. Digital Electronic Control (HCU)
3. PCU
4. Engine ECM
5. Position sensor
6. SCU
7. Steering motor
A. Electronic signal
2-13
Bracket unit
Structure
The steering actuator “1” is an integrated unit with a built-in steering control unit (SCU) and a built-in
steering motor and cannot be disassembled. The steering motor, which has an integrated pipe, is lo-
cated inside the actuator on one end and a shaft runs through the center of that pipe. The pipe is sup-
ported by a bearing on the other end. When the motor is supplied with power, the pipe turns inside the
actuator. The inside of the pipe and the outside of the shaft have threads, which are engaged using
planetary gears. The brackets “2” are installed to both ends of the shaft, and the steering actuator is
suspended inside the swivel bracket “3”. In addition, the rear of the actuator is connected to the steering
arm “4” through the ball joint “5”.
5
2
2
3
2-14
Bracket unit
Operation
When power is supplied to the steering motor inside the steering actuator “1”, the pipe integrated with
the motor turns. The rotational speed of the pipe is reduced as it is transmitted through the planetary
gears to the shaft in the center of the pipe. Because both ends of the shaft are secured to the swivel
bracket, the steering actuator moves 2 mm (0.08 in), which is the internal thread pitch distance, in a
straight line in the shaft direction for each turn of the pipe. The movement direction of the actuator
changes according to the turning direction of the motor. When the steering actuator moves toward the
starboard side, the outboard motor is steered to the port side and when the steering actuator moves
toward the port side, the outboard motor is steered to the starboard side. Because the rear of the actu-
ator is connected to the steering arm “2”, the linear movement of the actuator is converted into turning
movement (with the steering arm shaft as the axis) in order to steer the outboard motor.
1 1
PORT STBD
2 2
31° 31°
2-15
Bracket unit
Outboard motor manual steering method

If the SBW (Steer by Wire) system does not operate due to a malfunction, the outboard motor can be
steered manually.
Usually, the pipe inside the steering actuator moves as it is turned by the motor force, but when the
outboard motor is steered manually, the shaft is turned to move the pipe.
[Steering the outboard motor manually]

1. Remove the clamp bracket cover (PORT) “1” by removing the bolts.
2. Loosen the nut “2” until it contacts the cotter pin.
3. Turn the lever “3” that is installed to the shaft.
TIP:
When the lever is turned clockwise, the steering actuator “4” moves toward the port side and the out-
board motor is steered to the starboard side.
4. When the outboard motor is positioned at the desired steering angle, tighten the nut “2”.
3
2
1
2-16
Bracket unit
PTT unit
The material of the PTT motor has been changed to plastic to increase corrosion resistance. In addition,
the PTT relay is a built-in component of the electrical management unit and is controlled by the micro-
computer. As a result, the operation of the PTT motor can be controlled according to the trim and tilt
angles. Malfunctions can also be determined easily and durability is increased.
2-17
Bracket unit
PTT sensor
This model is equipped with a PTT sensor that detects the trim and tilt angle of the outboard throughout
the full range of movement from fully tilted down to fully tilted up. The end of the pin on the tilt rod fits
into the PTT sensor that is installed to the swivel bracket. The pin is secured in the tilt rod and when the
swivel bracket moves vertically, the relative angle between the pin and the sensor changes. This
change is used to detect the trim and tilt angles of the outboard motor. While the outboard motor is tilted
up from the fully tilted down position “A”, the relative angle becomes smaller. When the outboard motor
is in the fully tilted up position “B”, the PTT sensor is almost parallel to the tilt rod.
In addition, because the sensor is completely waterproof due to its mounting structure, durability is in-
creased.
A B
2-18
Lower unit
Lower unit
Outline
The lower case has been newly designed to increase the size of the case itself and increase the max-
imum speed and stability. The oil passages inside the case have also been revised and stainless steel
parts with high strength and high corrosion resistance are used. In addition, because the lower unit is
equipped with hoses for changing the gear oil, the gear oil can be changed even when the outboard
motor is mounted to the boat for improved serviceability when the boat is docked.
2-19
Lower unit
Lower case
The lower case for this model has a new shape with low resistance. The maximum speed and stability
are increased due to the newly shaped strut and skeg. In addition, by increasing the length of the anti-
cavitation plate, the anti-cavitation performance of the propeller is increased.
Because the diameter of the torpedo is increased, there is sufficient space for the proper gear size in-
side the lower case.
A
A. Water flow
2-20
Lower unit
Gear oil changing method

There are 2 methods that can be used for changing the gear oil of this model. One method, which is
similar to the method for previous models, uses the oil level plug, gear oil drain bolt, and oil filler bolt of
the lower case, and one method uses a pump and the hoses on the side of the engine.
Changing the gear oil using the lower case

Although previous models used 1 bolt hole (M8) to drain and fill the lower unit with gear oil, this model
is equipped with 2 holes: 1 hole (M18) “a” for draining the gear oil and 1 hole (M8) “b” for filling the lower
unit with gear oil. Because the hole for draining the gear oil is larger, the time required to drain the gear
oil is reduced and serviceability is improved.
Because the drain plug “1” is larger, the size of the magnet is also larger. A new type of magnet is used.
Because the direction of the magnetic force of the magnet is different from that of previous models, a
large amount of metal particles “c” become attached to the sides of this new type of magnet. As a result,
this magnet is able to collect metal particles using a larger area than the type of magnet used for pre-
vious models.
The lower unit is filled with gear oil through the oil filler hole. Because the hole has the same diameter
as the hole for previous models, the same gear oil pump can be connected to the hole. Because the oil
surface level is lower than that for previous models, the oil level plug “2” was moved to a lower location
compared to previous models.
For the changing procedure, see “Changing the gear oil by removing the drain screw” (10-21).
2
b
1 c
2-21
Lower unit
Changing the gear oil using the hoses on the side of the engine
The gear oil can be changed using the hoses that are routed from the lower unit to the port side of the
engine without removing the boat from the water, such as when the boat is docked. The “AIR” hose is
connected to the upper portion of the lower case and the “OIL” hose is connected to the end of the tor-
pedo from the front portion of the lower case. When the outboard motor is tilted up, the gear oil that
collects in the end of the torpedo is extracted from this hose and the lower unit is filled with gear oil from
this hose. When the lower unit is filled with gear oil while the outboard motor is tilted up 60° or more,
the lower unit will be filled with gear oil up to the specified level. Therefore, if the outboard motor cannot
be tilted up 60° or more, fill the lower unit with the specified amount of gear oil while being careful not
to overfill the lower unit.
For the changing procedure, see “Changing the gear oil using an oil changer” (10-18).
AIR
OIL
2-22
Lower unit
Reverse thrust
The outboard motor has a structure that discharges the exhaust gas from above the anti-cavitation
plate when the remote control lever is in the R position and the engine speed is 2000 r/min or less. As
a result, propeller cavitation can be prevented when the outboard motor is operating in reverse. In ad-
dition, thrust when operating in reverse is increased, stopping performance is increased, and vibration
and noise are lower. For boats that are equipped with Helm Master, performance when moving side-
ways is increased.
A
B
A. Exhaust gas flow
B. Water flow
Propeller (XTO offshore series)

To ensure that the output, which is larger than that of previous models, is converted into thrust, a large-
boat series of propellers with a new blade shape has been added to the lineup. Due to this 3-blade pro-
peller with good grip, the large output of the outboard motor is transmitted to the water with no waste.
The propeller is also equipped with the Shift Dampener System (SDS) to reduce the shock when shift-
ing.
In addition, the propeller is made of duplex stainless steel to increase rust resistance.
2-23
Electrical system
Electrical system
Charging system
This model is equipped with a 3-phase AC magneto type generator. In addition, because the cooling
efficiency of the rectifier/regulator “1” is increased and the temperature increase is controlled by the fan
“3” on top of the stator assembly “2”, 55 A of electric current is generated at engine idle speed and 72
A is generated at 3000 r/min.
A circuit for detecting the battery voltage has been added to the rectifier/regulator. Because the
charging of the house battery circuit is cut off when an instantaneous voltage drop occurs when the
SBW (Steer by Wire) system or PTT unit is operated, stable power can be supplied to the electrical
components of the engine. As a result, this model can use the same batteries as those of previous mod-
els. (This function operates when the boat is equipped with an engine battery and a house battery, and
the isolator lead is connected.)
2-24
Electrical system
Knocking detection
Although previous models were equipped with 1 knock sensor, the number of sensors for this model
was increased to 2 knock sensors. Because the sensitivity for detecting knocking is increased, the min-
imum amount of fuel within the range that does not produce knocking can be injected to generate the
maximum output.
Overheat detection
Although previous models detected overheating using the engine temperature and thermo switch, this
model detects overheating using the thermo sensor and water pressure sensor. As a result, the warning
can be activated at an early stage.
1. Thermo sensor
3. ECM
2. Water pressure sensor 4. Gauge
1. Thermo sensor 4. Gauge

2. Water pressure sensor
3. ECM
2-25
Electronic control system

This model uses an electronic direct injection control, digital ignition control, Digital Electronic Control,
electronic shift control, ETV control, VCT control, knock control, over-revolution control, alert control,
and fail-safe control.
The engine ECM performs these controls based on data received from each sensor and switch.
The engine ECM is equipped with a self-diagnosis function. This function can be used to check trouble
codes on the YDIS.
It is also equipped with Y-COP as an anti-theft measure (optional).
21. OCV
22. Ignition coil 16. TPS
23. Direct injection
pump 17. ETV
18. High-
24. Fuel injector pressure
fuel pump
24. Fuel injector

23. Direct injection 19. Low-
pump pressure
fuel pump
22. Ignition coil
21. OCV
20. Shift actuator
5. Cam position sensor

25. ETV control
6. Crankshaft position sensor
26. Shift control
7. Intake air pressure
27. Digital ignition control / temperature sensor
28. Valve control 8. Oil pressure sensor
9. Engine temperature sensor
29. Fuel injection 36. Engine 10. Fuel pressure sensor
control ECM
30. Injector (high-pressure fuel pump)
driver 11. Fuel pressure sensor
31. YDIS (direct injection pump)
12. Knock sensor
32. CL7 display 13. Thermo sensor
14. Water detection switch
33. Y-COP *1 34. Multi-hub 15. Water pressure sensor
1. LPS
35. Battery 2. Digital Electronic Control ECM

3. Engine shut-off switch
4. Engine start switch
2-26
1. LPS
2. Digital Electronic Control ECM
3. Engine shut-off switch
4. Engine start switch
7. Intake air pressure/temperature sensor
8. Oil pressure sensor
10. Fuel pressure sensor (high-pressure fuel pump)
11. Fuel pressure sensor (direct injection pump)
12. Knock sensor
13. Thermo sensor
16. TPS
17. ETV
18. High-pressure fuel pump
19. Low-pressure fuel pump
20. Shift actuator
21. OCV
22. Ignition coil
23. Direct injection pump
24. Fuel injector
25. ETV control
26. Shift control
27. Digital ignition control
28. Valve control
29. Fuel injection control
30. Injector driver
31. YDIS
32. CL7 display
33. Y-COP *1
34. Multi-hub
35. Battery
36. Engine ECM
*1. Optional
2-27
Electrical components
6
8
5 9
4
3 10
2
1 11
12
13
8 21 22 6 23
15
16 14
17
18
17
24
19 21
13
20 18 25
17 19 17
Part name Function

1 Low-pressure fuel pump Sends the fuel from the fuel tank to the vapor separator.
High-pressure fuel pump
2
(sub) Pressurizes the fuel and sends the fuel to the direct injection
High-pressure fuel pump pump.
3
(main)
Intake air pressure/tem-
4 Detects the intake air pressure and intake air temperature.
perature sensor
5 ETV Opens and closes the throttle valve using an electric motor.
6 Thermo sensor Detects cooling water temperature.
2-28
Part name Function

Contains various relays and fuses, and controls the power sup-
7 Electrical management box
ply for the electrical components of the outboard motor.
Determines the stroke of each cylinder according to the signals
Cam position sensor (PORT
8 from both the crankshaft position sensor and the cam position
EX)
sensor (PORT EX).
Cam position sensor (PORT
9 Detects the advance angle on the intake camshaft.
IN)
Determines the engine operating conditions according to the
input signals from the sensors and switches which are installed
10 Engine ECM
at various locations on the engine, and sends output signals to
operate the actuators to perform the various control functions.
11 Engine temperature sensor Detects the engine temperature.
Controls the operation of the direct injection pumps and fuel in-
12 Injector driver
jectors.
Advances or retards the intake camshaft timing by switching
the oil passages through which the engine oil is sent into the
13 OCV
advance chamber or the retard chamber in the rotor vane
housing.
Fuel pressure sensor Detects the fuel pressure between the vapor separator and the
14
(high-pressure fuel pump) direct injection pump.
Detects the shift position. SPS 1 is the main sensor and SPS 2
SPS 1
15 is the sub sensor. SPS 1 and SPS 2 mutually monitor each
SPS 2
other for malfunctions.
Drives the motor according to the engine ECM command for
16 Shift actuator
engaging or disengaging the gearshift.
17 Ignition coil Produces high voltage to ignite a spark plug.
Fuel pressure sensor (direct
18 Detects the fuel pressure at the fuel rail.
injection pump)
19 Direct injection pump Pressurize the fuel and sends the fuel to the fuel rail.
20 Water pressure sensor Detects the cooling water pressure.
21 Fuel injector Injects fuel.
22 Knock sensor Detects engine knocking.
Cam position sensor (STBD
23 Detects the advance angle on the intake camshaft.
IN)
Detects the engine speed.
24 Crankshaft position sensor
Detects the crankshaft angle and piston positions.
25 Oil pressure sensor Detects the oil pressure.
2-29
Fail-safe
In the fail-safe control, the engine ECM enters the fail-safe control mode when an electrical component
malfunctions.
The fail-safe control system records the trouble codes according to the engine trouble conditions.
*: For applications with multiple outboard motors
Item Trouble conditions to be detected Controls performed by ECM
There are 7 signals from cam posi- Set VCT in full retard position.
Crankshaft position
tion sensor (PORT EX), but no sig- Stop engine synchronization con-
sensor
nal from crankshaft position sensor. trol.*
High engine idle speed.
Ignition timing advance angle is lim-
ited to BTDC 10°.
Perform cylinder position identifica-
Cam position sensor No signal from cam position sensor
tion using cam position sensor
(PORT EX) (PORT EX) for 1 second.
(PORT IN).
Set VCT in full retard position.
Stop engine synchronization con-
trol.*
Cam position sensor No signal from cam position sensor Set VCT in full retard position.
(STBD IN) (STBD IN) for 1 second. Stop engine synchronization con-
trol.*
Perform cylinder position identifica-
tion using cam position sensor
Cam position sensor No signal from cam position sensor
(PORT EX).
(PORT IN) (PORT IN) for 1 second.
trol.*
TPS 1 output voltage is 0.35 V or Engine speed is limited to 4200 r/
less or 4.80 V or more. TPS 2 output min.
voltage is 2.25 V or less or 4.80 V or Stop engine synchronization con-
more. trol.*
TPS
Engine speed is limited to 1500 r/
Difference between TPS 1 and TPS
min.
2 voltages is 1.7 V or less or 2.30 V
or more.
trol.*
Intake air pressure Output voltage is less than 0.20 V or
sensor more than 4.80 V.
trol.*
Set to intake air temperature when
starting.
Set to 40 °C (104 °F) when running.
Engine temperature Output voltage is less than 0.20 V or
sensor more than 4.80 V.
trol.*
2-30

Output voltage is less than 0.20 V or
Thermo sensor Set to 50 °C (122 °F) when running.
more than 4.65 V.
Set to 25 °C (77 °F).
Intake air tempera- Output voltage is less than 0.20 V or High engine idle speed.
ture sensor more than 4.65 V. Stop engine synchronization con-
trol.*
Output voltage is less than 0.20 V,
more than 4.80 V for 260 seconds,
Oil pressure sensor High engine idle speed.
or more than 4.80 V when engine is
stopped.
Reduce engine speed approximate-
Knock sensor ly 300 r/min.
more than 4.80 V.
trol.*
PTT sensor Deactivate tilt limiter.
more than 4.80 V.
Battery voltage is less than 11.99 V,
Low power supply
when the engine speed is 2000 r/
voltage under loaded High engine idle speed.
min or more and running for 120
condition
seconds.
OCV Open or short circuit.
trol.*
Immobilizer (Y-COP) Communication error occurs.
trol.*
ECM input voltage is 3.99 V or more
Main relay —
when the main relay is off.
Water pressure sen- Output voltage is less than 0.20 V or
—
sor more than 4.80 V.
Water detection Operates the buzzer.
Water detection switch is turned on.
switch
Use value for SPS 2 when SPS 1 is
malfunctioning and use value for
Output voltage is less than 0.20 V or SPS 1 when SPS 2 is malfunction-
more than 4.80 V. ing.
SPS trol.*
Output voltages of both SPS 1 and Engine speed is limited to 1500 r/
SPS 2 are less than 0.20 V or more min.
than 4.80 V. Engine cannot be started.
Difference between SPS 1 and SPS Stop engine synchronization con-
2 voltages is 0.3 V or more. trol.*
2-31

Shift actuator Overcurrent or sticking is detected.
trol.*
Communication error between the Engine speed is limited to 600 r/min.
Extension wire har-
engine ECM and Digital Electronic Stop engine synchronization con-
ness
Control. trol.*
LPS 1 is malfunctioning. min.
LPS 2 is malfunctioning. Stop engine synchronization con-
LPS trol.*
LPS characteristics are abnormal. Engine speed is limited to 600 r/min.
Both LPS 1 and LPS 2 are malfunc- Stop engine synchronization con-
tioning. trol.*
min.
Open circuit in the fuel injector cir- Injection to applicable cylinder is cut
Fuel injector
cuit. off.
trol.*
Fuel pressure sensor min.
(direct injection Use fixed start time for fuel injection.
more than 4.80 V.
pump) Stop engine synchronization con-
trol.*
Signals to increase fuel pressure
are sent continuously for approxi-
mately 6 minutes. Engine speed is limited to 2000 r/
Direct injection pump min.
Signals to decrease fuel pressure
feedback Stop engine synchronization con-
are sent continuously for approxi-
trol.*
mately 8 minutes.
Feedback value is abnormal.
Open circuit in the direct injection min.
Direct injection pump
fuel pump circuit. Stop engine synchronization con-
trol.*
Fuel pressure sensor
Output voltage is less than 0.30 V or min.
(high-pressure fuel
more than 4.75 V. Stop engine synchronization con-
pump)
trol.*
2-32

Message is displayed on gauge dis-
play when engine stops.
“Check fuel supply.
Insufficient fuel supply to vapor sep-
High-pressure fuel Outboard starter will not function for
arator.
pump supply abnor- 7 sec.
High-pressure fuel pump is malfunc-
mal 10 or more restart attempts may be
tioning.
required.
When the engine restarts, let it idle
more than 5 min.”
Starter relay Starter relay is malfunctioning. —
PTT relay PTT relay is malfunctioning. —
PTT relay power sup- PTT relay and related parts are mal-
—
ply functioning.
Shift relay Shift relay is malfunctioning.
trol.*
High-pressure fuel High-pressure fuel pump relay is min
pump relay malfunctioning. Stop engine synchronization con-
trol.*
Fuel injector driver min
relay 1 Fuel injector driver relay is malfunc- Injection to applicable cylinder is cut
Fuel injector driver tioning. off.
relay 2 Stop engine synchronization con-
trol.*
Abnormal information from the
SBW steering components is input using —
digital electronic control.
SCU steering components is input using —
HELM steering components is input using —
2-33
Fuel system
Fuel system
Fuel diagram
2-34
Fuel system
7. Vapor separator
6. Relief 11. Check
12. Fuel pressure
valve valve 9. High-pressure
sensor fuel pump 8. Venturi
(high-pressure (sub)
fuel pump)
10. High-pressure 8. Venturi
13. Fuel strainer fuel pump
5. Feed (main)
valve
6. Relief 5. Feed
valve valve
16. Fuel pressure sensor
14. Direct injection (direct injection pump)
pump (PORT) (PORT) 4. Low-pressure
fuel pump
15. Fuel rail (PORT)
3. Fuel filter
20. 20. 20. 20. (water separator)
Fuel Fuel Fuel Fuel
injector #2 injector #4 injector #6 injector #8
2. Primer pump
21. 21. 21. 21.
Combustion Combustion Combustion Combustion
1. Fuel tank
chamber #2 chamber #4 chamber #6 chamber #8
27. Intake air pressure /
temperature sensor
26. Intake port (PORT)
25. Intake port (STBD)
21. 21. 21. 21.

Combustion Combustion Combustion Combustion
chamber #1 chamber #3 chamber #5 chamber #7 24. Surge tank
20. 20. 20. 20.

Fuel Fuel Fuel Fuel 23. ETV
injector #1 injector #3 injector #5 injector #7
18. Fuel rail (STBD) 22. Intake silencer
17. Direct injection 19. Fuel pressure sensor

pump (STBD) (direct injection pump) A B C
(STBD)
2-35
Fuel system
1. Fuel tank
2. Primer pump
3. Fuel filter (water separator)
5. Feed valve
6. Relief valve
7. Vapor separator
8. Venturi
9. High-pressure fuel pump (sub)
10. High-pressure fuel pump (main)
11. Check valve
12. Fuel pressure sensor (high-pressure fuel pump)
13. Fuel strainer
14. Direct injection pump (PORT)
15. Fuel rail (PORT)
16. Fuel pressure sensor (direct injection pump) (PORT)
17. Direct injection pump (STBD)
18. Fuel rail (STBD)
19. Fuel pressure sensor (direct injection pump) (STBD)
20. Fuel injector
21. Combustion chamber
22. Intake silencer
23. ETV
24. Surge tank
25. Intake port (STBD)
26. Intake port (PORT)
A. Fuel flow
B. Vapor gas flow
C. Air flow
2-36
Fuel system
High-pressure fuel pump control

The vapor separator contains 2 high-pressure fuel pumps: a main pump without a check valve and a
sub pump with a check valve. When the engine load is low, only the main pump operates, and when
the engine load is high, the sub pump also operates.
The high-pressure fuel pumps are controlled by the ECM using feedback based on information from
the fuel pressure sensor (high-pressure fuel pump). The drive force of the fuel pumps changes dynam-
ically and the fuel pumps may stop when the engine load is small. This prevents vapor gas from col-
lecting in the vapor separator and contributes to more efficient operation.
Low-pressure fuel pump control

When the engine load is low, the pump will cycle ON for 10 seconds and OFF for 20 seconds.
When the engine load is high, the pump is ON continuously.
2-37
Fuel system
Vapor separator
This model is equipped with a newly designed vapor separator, which has been changed to a sealed
type that eliminates the structure for discharging the vapor gas. Because venturi tubes “a” were added
to control the amount of vapor gas so that it does not exceed a certain level, the vapor gas can be han-
dled inside the vapor separator. When the liquid fuel is drawn from below the high-pressure fuel pumps,
the pressure of the fuel decreases when it passes through the venturi tubes because its flow rate in-
creases. As a result, it draws in the vapor gas from the passage at the top of each venturi tube. Although
this mixture of liquid fuel and vapor gas is drawn into the high-pressure fuel pumps in this state, the
vapor gas is compressed by the high-pressure fuel pumps into a liquid state and is discharged as a
liquid.
In addition, because the fuel pressure after the vapor separator is stabilized using feedback control, the
fuel return passage was eliminated.
As a result, the canister, return hoses, and other parts were eliminated, which reduced the number of
parts and improved serviceability.
Also, because the vapor gas is not released into the atmosphere, the outboard motor is friendlier on the
environment.
A
B
C
A. Liquid fuel flow

B. Vapor gas flow
C. Mixture of liquid fuel and vapor gas
2-38
Fuel system
Fuel strainer
This model is equipped with a fuel strainer “1” between the vapor separator and the direct injection
pumps.
The strainer prevents clogging of the filters in the direct injection pumps and fuel injectors, extending
the replacement intervals for the parts. In addition, because the fuel strainer element “2” can be re-
placed easily without removing the fuel hose, serviceability is improved.
2-39
Fuel system

Each direct injection pump “1”, which has a mechanically driven built-in plunger “2” and an electrically
driven built-in solenoid “3”, pressurizes the fuel to the high pressure required for direction injection.
The fuel inside the pump is sent through the mesh filter “4” and damper “5” to the solenoid chamber
and plunger chamber. The pressure of the fuel is increased by the plunger that is driven by the camshaft
“6” and the fuel is sent to the fuel rail through the check valve “7”. To prevent the fuel from flowing back
from the inlet of the plunger chamber at this time and reducing the pressure, the solenoid blocks the
passage at the inlet “a” of the plunger chamber while the fuel is being pressurized. During 1 turn of the
camshaft, the fuel is pressurized 4 times and the solenoid repeatedly opens and closes the passage
each time. Conversely, if the fuel pressure in the fuel rail is too high, the fuel returns through the return
valve “8”.
In addition, feedback control is carried out based on the information from the fuel pressure sensor (di-
rect injection pump), and the operation of the solenoid is controlled to change the flow volume and ad-
just the fuel pressure.
1
A
4 5 8
a
2 7
3
C
A. From vapor separator
B. To fuel rail
C. Fuel flow
2-40
Lubrication system
Lubrication system
Lubrication diagram
2-41
Lubrication system
16. Piston 9. Exhaust camshaft
17. Cylinder block 15. Crankshaft pin 8. Intake camshaft

(oil cooler) 12. VCT 13. Valve and
related parts
14. Crankshaft
journal 10. OCV
18. Crank case cover
11. Cam chain tensioner
(water jacket)
7. Main gallery

5. Oil filter
4. Relief valve
3. Oil pump
2. Oil strainer
1. Oil pan
A
1. Oil pan 16. Piston

2. Oil strainer 17. Cylinder block (oil cooler)
3. Oil pump 18. Crank case cover (water jacket)
4. Relief valve
A. Engine oil flow
5. Oil filter
7. Main gallery
8. Intake camshaft
9. Exhaust camshaft
10. OCV
11. Cam chain tensioner
12. VCT
13. Valve and related parts
14. Crankshaft journal
15. Crankshaft pin
2-42
Lubrication system
Dual rotor oil pump

The dual rotor oil pump is driven using the crankshaft gear. The pump has 2 built-in rotors and while
maintaining its compact size, the flow volume has been increased from 100 L/min to 140 L/min com-
pared to previous models.
A
A. Engine oil flow
2-43
Lubrication system
Oil drain plug

The diameter of the oil drain plug “1” has been increased, and the oil strainer “2” can be removed from
and installed in the drain hole. As a result, the oil strainer can be checked and cleaned without disas-
sembling the upper case.
1
2
A. Engine oil
2-44
Cooling system
Cooling system
Cooling diagram
2-45
Cooling system
29. Thermostat 24. Thermostat 17. Thermostat 18. Thermostat

(water jacket) (oil cooler) (PORT) (STBD)
15. Thermo 16. Thermo

28. Water jacket 23. Oil cooler sensor (PORT) sensor (STBD)
(upper)
30. Vapor
separator 12. Cylinder 13. Cylinder (PORT) 14. Cylinder (STBD)
(fuel cooler) block
11. Cooling water
27. Rectifier/regulator pilot hole
26. Water jacket (lower) 9. Cylinder 10. Cylinder

head (PORT) head (STBD)
25. Crankcase
7. Exhaust joint
8. Water pressure
sensor
6. Exhaust guide
5. Oil pan
B 4. Muffler 22. PCV 19. Upper case

31. Flushing device
3. Water pump 20. Lower case
32. Multi engines
flushing adapter 2. Water inlet 21. Propeller boss
1. Water
A
2-46
Cooling system
1. Water
2. Water inlet
3. Water pump
4. Muffler
5. Oil pan
6. Exhaust guide
7. Exhaust joint
9. Cylinder head (PORT)
10. Cylinder head (STBD)
11. Cooling water pilot hole
12. Cylinder block
13. Cylinder (PORT)
14. Cylinder (STBD)
15. Thermo sensor (PORT)
16. Thermo sensor (STBD)
17. Thermostat (PORT)
18. Thermostat (STBD)
19. Upper case
20. Lower case
21. Propeller boss
22. PCV
23. Oil cooler
24. Thermostat (oil cooler)
25. Crankcase
26. Water jacket (lower)
27. Rectifier/regulator
28. Water jacket (upper)
29. Thermostat (water jacket)
30. Vapor separator (fuel cooler)
31. Flushing device
32. Multi engines flushing adapter
A. Cooling water flow

B. When flushing the cooling water passages
2-47
Cooling system
Dual water pump

This model is equipped with a dual water pump to ensure sufficient cooling water for the higher output
engine. The water pump can discharge 1.3 times the water that the pump for the F350B (F350CA)
could discharge, which helps to control the increase in engine temperature when the outboard motor is
operating under a high load. In addition, although the amount of cooling water has increased, the du-
rability is equivalent to or higher than that of the F350B (F350CA).
A
A. Cooling water flow
2-48
Cooling system
Engine anode
The locations of the anodes in the engine cooling water passages have been optimized. As a result,
checking the anodes at 1000 hours is no longer necessary and the anodes must be replaced only
during major maintenance work.
2-49
Cooling system
Thermostat
In addition to the thermostat in each cylinder bank of the F350B (F350CA), a thermostat has been add-
ed to the crankcase and cylinder block for a total of 4 thermostats.
Because the cooling water passages have been divided into 2 sections that are controlled separately,
the engine temperature and output are stabilized, the warming-up time is reduced, the fuel consumption
is lower, and condensation in the lubrication system is prevented.
In addition, the high-temperature water that passes through the thermostats is discharged instead of
flowing through the cooling water passages, which reduces the amount of corrosion.
Specifications 1 2 3
58–62 °C 58–62 °C 58–62 °C
Valve opening temperature
(136–143 °F) (136–143 °F) (136–143 °F)
Fully open temperature 70 °C (158°F) 70 °C (158°F) 70 °C (158°F)
Fully open stroke 5.0 mm (0.20 in) 3.0 mm (0.12 in) 3.0 mm (0.12 in)
Diameter “a” 45.65 mm (1.797 in) 27.3 mm (1.075 in) 27.3 mm (1.075 in)
Flow rate at a pressure dif-
ference of 19.6 kPa (0.196 2.8 L/min 0.3–0.4 L/min 0.1–0.2 L/min
kgf/cm², 2.8 psi)
2-50
Intake and exhaust system
Intake and exhaust system

Intake and exhaust diagram
1. Intake silencer A. Intake air flow

2. ETV B. Exhaust gas flow
4. Intake manifold (PORT)
5. Intake manifold (STBD)
6. Exhaust joint
7. Oil pan
8. Muffler
9. Propeller boss
10. Idle exhaust hole
2-51
Hose routing
Hose routing
Fuel hose and blowby hose
1. Joint to fuel filter assembly 12. Relief valve to joint

2. Fuel filter assembly to joint 13. Relief valve to fuel pressure sensor
3. Joint to low-pressure fuel pump 14. Fuel pressure sensor to fuel strainer
4. Low-pressure fuel pump to fuel feed 15. Fuel strainer to joint
valve 16. Joint to direct injection pump (PORT)
5. Fuel feed valve to vapor separator 17. Joint to direct injection pump (STBD)
6. Vapor separator to relief valve 18. Cylinder head cover (PORT) to intake
7. Relief valve to joint silencer
8. Vapor separator to drain joint 19. Cylinder head cover (STBD) to cylinder
9. Vapor separator to joint head cover (PORT)
10. Joint to fuel feed valve
11. Fuel feed valve to relief valve
2-52
Hose routing
Cooling water hose
1. Crankcase to vapor separator (fuel 13. Joint to cooling water pilot hole
cooler) 14. Water jacket cover to joint
2. Vapor separator (fuel cooler) to 15. Joint to joint
thermostat housing 16. Joint to joint
3. Thermostat housing to joint 17. Flushing hose adapter to joint
4. Joint to thermostat housing (oil cooler)
5. Joint to joint
6. Thermostat housing to joint
7. Joint to joint
8. Joint to upper case
9. Thermostat housing to joint
10. Joint to upper case
11. Exhaust guide to joint
12. Exhaust guide to joint
2-53
New special service tool
New special service tool

Special service tools for new uses have been established.
Balance hanger (SST No.: 90890-06954) “1”

Install this special service tool to the exhaust joint and use it together with the lifting eye (90890-06953)
“2” to support the power unit when suspending it. Because the power unit can be suspended horizon-
tally when using the balance hanger, it is easier to remove and install the power unit.
See “Removing the power unit” (7-15).
Lifting hanger (SST No.: 90890-06951) “3”

Install this special service tool to the propeller shaft and use the tool to support the lower unit when re-
moving and installing it. Because the lower unit can be suspended using a crane, it is easier to remove
and install the lower unit.
See “Uncrating procedure (outboard motor without lower unit)” (3-3) and “Removing the lower unit”
(8-6).
2
3
2-54
Rigging information
Important reminder on rigging.......................................... 3-1

Outboard motor mounting instructions ....................................... 3-1
Crate handling .................................................................... 3-2

Crate top cover symbol description ............................................ 3-2
Uncrating ............................................................................ 3-3

Uncrating procedure (outboard motor without lower unit) .......... 3-3
Uncrating procedure (outboard motor with lower unit) ............... 3-4
Outboard motor mounting................................................. 3-9

3
Installing the outboard motor...................................................... 3-9
Outboard motor mounting height.............................................. 3-12
Rigging grommet mounting ............................................ 3-14

Rigging grommet description.................................................... 3-14
Installing the battery cable........................................................ 3-14
Installing the main wire harness ............................................... 3-14
Installing the rigging grommet .................................................. 3-14
Connecting the fuel hose.......................................................... 3-15
Optional equipment ......................................................... 3-16

Installing the isolator lead......................................................... 3-16
Installing the SCU communication lead.................................... 3-16
Installing Y-COP....................................................................... 3-17
Registering the receiver ID to the ECM.................................... 3-17
Battery installation ........................................................... 3-19

Battery wiring without house battery ........................................ 3-19
Battery wiring with house (accessory) battery.......................... 3-24
System diagram ............................................................... 3-30

Single outboard motor application (single station) ................... 3-30
Twin outboard motor application (single station)...................... 3-33
Triple outboard motor application (single station) .................... 3-36
Quad outboard motor application (single station)..................... 3-39
Single outboard motor application (dual station) ...................... 3-42
Twin outboard motor application (dual station) ........................ 3-45
Triple outboard motor application (dual station) ....................... 3-48
Quad outboard motor application (dual station) ....................... 3-51
Rigging information
Digital Electronic Control ................................................ 3-54

Digital Electronic Control system reset..................................... 3-54
Tilt limiter .......................................................................... 3-55

Setting the tilt limiter ................................................................. 3-55
Clearing the tilt limiter............................................................... 3-56
Deactivating the tilt limiter ........................................................ 3-57
Calibration (6X6 Digital Electronic Control)................... 3-58

Configuring the number of outboard motors............................. 3-58
Accessing the calibration menu................................................ 3-58
Steering sensor ........................................................................ 3-59
Toe Adjust ................................................................................ 3-62
Lock to Lock ............................................................................. 3-63
Friction Set ............................................................................... 3-64
Rigging recommendation ................................................ 3-66

Battery cable length.................................................................. 3-66
Extension length recommendation for battery cable ................ 3-66
Propeller selection ........................................................... 3-68

Propeller size............................................................................ 3-68
Selection................................................................................... 3-68
Fuel line air purging ......................................................... 3-70

Air purging during initial priming ............................................... 3-70
Important reminder on rigging
Important reminder on rigging

Outboard motor mounting instructions
• Overpowering a boat could cause severe instability. Do not install an outboard motor with
more horsepower than the maximum rating on the capacity plate of the boat. If the boat does
not have a capacity plate, consult the boat manufacturer.
• Improper mounting of the outboard motor could result in hazardous conditions, such as poor
handling, loss of control, or fire hazards.
Too much weight on the transom can change the center of gravity, buoyancy, operating bal-
ance, or performance of the boat, which could cause loss of control or swamping. Consult the
boat manufacturer for the maximum engine weight allowable on the transom, which is different
from the overall boat capacity. Overloading the transom with an outboard motor that is too
heavy could also damage the hull, transom, deck, or helm area, as well as the outboard motor
and other equipment.
Before mounting the outboard motor, consult the manufacturer of the engine jack plates or
brackets. Excessive loads could damage the engine jack plates, brackets, boat transom, steer-
ing system, or engine. These damages could cause loss of control.
This outboard motor is designed exclusively for use with the Digital Electronic Control and CL7
display. Do not use this outboard motor with other control equipment or measuring devices.
3-1
Crate handling
Crate handling
Crate top cover symbol description
The following symbol are important when handling the crate.
Read the notice and understand what each symbol means to prevent damage to the outboard motor
when handling, transporting, and storing the crate.
1
A
B
6 7
10 8
9
3 IMPORTANT
This unit delivered to carrier in a good condition.
For protection against loss due to damage, inspect thoroughly.
If damage is noted, make note on freight bill.
Shipper assumes no further liability to the transportation company.
Your claim should be filed against carrier for damage of any nature.
A. Outboard motor without lower unit 3. IMPORTANT

B. Outboard motor with lower unit This unit delivered to carrier in a good
condition.
1. WARNING For protection against loss due to
Wear suitable protective gear such as damage, inspect thoroughly.
gloves and eye protection when handling If damage is noted, make note on freight
and opening crate. bill.
2. NOTICE Shipper assumes no further liability to
• Use forklifts with forks that are at least 1 the transportation company.
m (40 in) in length. Your claim should be filed against carrier
• Only stack with crates of the same size. for damage of any nature.
• Be sure unit is stacked securely (all four 4. Lifting fork insert position
corners fit securely on unit below it). 5. Crate barycentric position
• Stack Limit - 2 units (at handling). 6. Stack limit: Maximum 4 units for storage
7. Upward indication
8. Care handling indication
9. Recycling indication
10. Water avoidance indication
3-2
Uncrating
Uncrating
Uncrating procedure (outboard motor
without lower unit)
Wear gloves to avoid injury from sharp

steel edges while uncrating.
1. Check:
• Crate for shipping damage
If any damage is found, consult your
Yamaha distributor.
2
2. Remove:
• Top cover
5. Install:
• Frame
• Special service tools “1” and “2”
• Wrapping
When lifting the outboard motor, make sure

Be careful not to damage the outboard mo-
to use the specified special service tool.
tor.
Other bolts and hanging jigs could bend or
break, causing the outboard motor to fall.
3. Check:
• Outboard motor for concealed damage
If any damage is found, consult your
Yamaha distributor. 2
4. Remove:
• Top cowling “1”
• Shroud cover “2”
Liftting eye “1”

90890-06953
Bolt hexagon with washer “2”
90890-06821
YB-06821
3-3
Uncrating
• Mount bolts “2”
Lifting eye bolt
• Bottom frame
36 N·m (3.6 kgf·m, 27 lb·ft)
T.
R.
6. Install:
• Lifting harness “1”
(to the lifting eye “2”)
7. Apply tension to the lifting harness.
Make sure that the lifting harness does not 1

contact the bottom cowling rear cover.
Uncrating procedure (outboard motor

8. Lift up the outboard motor carefully along with lower unit)
with the bottom frame “1”. This procedure includes only the information
that is different from the information in the pro-
cedure for the outboard motor without the low-
Make sure that the lifting harnesses do not
er unit. For the procedure of unpacking and
damage any parts of the outboard motor.
lifting up the outboard motor, see “Uncrating
procedure (outboard motor without lower unit)”
1 (3-3).
Wear gloves to avoid injury from sharp

steel edges while uncrating.
9. Remove:
• Skeg holder “1”
3-4
Uncrating
1. Remove: 3. Mount:
• Top cowling “1” • Outboard motor
• Shroud cover “2” (to the boat or maintenance stand)
See “Installing the outboard motor” (3-9).
1
4. Remove:
• Lifting harness
• Special service tool
5. Install (for U- or E-transom model):

• Stud bolts “1”
• Dowels “2”
• Rubber seal “3”
• O-rings “4”
• Extension “5”
• Extension mounting bolt “6”
TIP:
2 Point the flat end of the stud bolt up.
2. Remove: 1 LT
• Skeg holder “1” 3 572

• Mount bolts “2”
2
• Bottom frame
4
4
2
1 6
LT
5 572
3-5
Uncrating
B c. Install the special service tool “1” onto the
lower unit “2”.
LT
1 572 d. Hook a lifting harness onto the special ser-

3 vice tool “1”.
2
e. Tilt the outboard motor up so that the mat-
ing surface of the outboard motor is paral-
4 lel to the mating surface of the lower unit.
4
2 3
2 1
5
4
4
2 LT
2
5 6 572
A. U-transom model Liftting hanger “1”

B. E-transom model 90890-06951
Stud bolt “1” f. Install the lower unit “1”

23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
Extension mounting bolt “6”

42 N·m (4.2 kgf·m, 31 lb·ft) • Make sure to disconnect the battery ca-
bles from the battery, and remove the clip
6. Install: from the engine shut-off switch.
• Water pipe • When removing or installing the lower
• Dowel unit with the power unit installed, make
• Lower unit sure to suspend the outboard motor. Oth-
• Splash plates erwise, the outboard motor could fall sud-
• Lower unit mounting bolts (for X-transom denly and result in severe injuries.
model)
• Washers (for U- or E-transom model)
TIP:
• Lower unit mounting nuts (for U- or E-tran-
• Align the check valves “2” and “3” with the
som model)
holes “a” in the joint. (For X-transom model)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the water pipe. • Align the check valves “2” and “3” with the
holes “b” in the extension. (For U- or E-tran-
TIP: som model)
• Check that the rubber seal where the water • If the lower unit cannot be installed properly
pipe is inserted is installed properly, there is to the outboard motor, check that the protrud-
no foreign material on the rubber seal, and so ing portions are aligned properly with their
on. corresponding openings.
• Install the water pipe completely.
b. Install the dowels to the lower unit.
3-6
Uncrating
A A
LT
572
1
a 3
2
2 LT
572
B
3 2
A. For X-transom model

2 B. For U- or E-transom model
1
Lower case mounting bolt (for X-
A. For X-transom model transom model)
T.
R.
B. For U- or E-transom model 47 N·m (4.7 kgf·m, 35 lb·ft)

Lower case mounting nut (for U-
g. Install the splash plates “1”, and then tight- or E-transom model)
en the bolts “2”. (For X-transom model) 47 N·m (4.7 kgf·m, 35 lb·ft)
Install the splash plates “1”, and then tight-
en the nuts “2”. (For U- or E-transom mod- h. Remove the special service tool.
el) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-7
Uncrating
7. Install:
• Lower case mounting bolts “1”, “2”
• Anode “3”
• Washer “4”
• Anode bolt “5”
1 2
3
4
Lower case mounting bolt

47 N·m (4.7 kgf·m, 35 lb·ft)
T.
R.
Lower case anode bolt

42 N·m (4.2 kgf·m, 31 lb·ft)
3-8
Outboard motor mounting
Outboard motor mounting For a twin outboard motor application,

Installing the outboard motor place the outboard motors so that the dis-
tance from the C/L of each outboard motor
Properly mounting the outboard motor will re-
to the C/L of the boat transom are equal on
sult in better engine performance, product reli-
both sides.
ability, fuel economy, customer satisfaction,
etc. This chapter provides a brief summary of TIP:
the procedures for mounting the outboard mo- • Make sure that the distance “e” is equal to
tor. The first requirement is to make sure the distance “f”.
outboard motor has clearance for full move- • For the distance (T1), see “External dimen-
ment, from port to starboard, as well as during sions” (1-2).
tilt operation. For the motor dimensions, see
“External dimensions” (1-2).
1. For a single outboard motor application, C/L
place the outboard motor on the vertical
e f
centerline of the boat transom. For a hull
without strakes, make the same radius (R)
at both sides of the hull, and use another
measurement point.
TIP:
Make sure that distance “a” is equal to distance
“b”, and distance “c” is equal to distance “d”.
T1
A C/L
C/L.Centerline of the transom

For a triple outboard motor application,
R a b R place the center outboard motor so that
the C/L of the outboard motor is aligned
with the C/L of the boat transom. Place the
c d other two outboard motors on both sides
so that the distance from the C/L of each
B outboard motor to the C/L of the boat tran-
C/L
som are equal.
TIP:
• Make sure that the distance “g” is equal to
a b distance “h”.
c d • If the boat has a V shape hull, the center out-
board motor should have a longer transom
height than the outboard motors on both
sides.
A. Hull without strakes • For the distance (T1), see “External dimen-
B. Hull with strakes sions” (1-2).
3-9
2. Adjust the position of the outboard motor
C/L so that the height of the anti-cavitation
g h plate “1” is equal to the bottom of the boat
transom.
TIP:
This mounting height information is for refer-
ence only. It is impossible to provide complete
instructions for every possible boat and out-
board motor combination.
A
T1 T1

For a quad outboard motor application,
place the outboard motors so that the dis-
tance from the C/L of each outboard motor
to the C/L of the boat transom are equal on 1
both sides.
TIP: B
• Make sure that the distance “i” is equal to dis-
tance “j”.
• Make sure that the distance “k” is equal to
distance “l”.
• If the boat has a V shape hull, the center out-
board motors should have a longer transom
height than the outboard motors on both
1 1
sides.
• For the distance (T1), see “External dimen-
sions” (1-2).
C
C/L
k i j l
1 1
1
(T1) (T1) (T1)

3-10
D
2 1
1
1
1 1
3
A. Single outboard motor application
B. Twin outboard motor application H
C. Triple outboard motor application
D. Quad outboard motor application a
2
TIP:
The mounting height of an outboard motor var- C/L
ies based on the boat and engine model com-
bination. For more information for your specific
boat package, contact your boat manufacturer. 6. Apply sealant to the mounting holes, and
then secure the outboard motor using the
3. Install: included mounting bolts “1” and “2”, small
• Special service tool “1” washers “3”, large washers “4”, and nuts
“5”.
Drilling plate “1”
90890-06783
Drilling plate “1” Make sure that there is no clearance be-
YB-34465-A tween the surfaces of the boat transom and
the clamp brackets. Otherwise, the clamp
4. Adjust the height of the scale “2” to the brackets or boat transom may be damaged.
transom height (H), and place it on the
special service tool “1”. Secure the special TIP:
service tool “1” to the boat transom using The second hole from the top of each clamp
screws or vises. bracket is recommended for the upper mount-
ing bolt.
TIP:
For the transom height (H), see “External di-
mensions” (1-2).
5. When the outboard motor mounting posi-

tion has been determined, mark the best
suited 6 symmetrical mounting holes on
the boat transom “3”. Drill the mounting
holes perpendicular to the surface of the
boat transom using a 13.0 mm (0.5 in) “a”
drill bit.
3-11
Lower mounting bolt “2”
1
3 Boat transom Mounting
4 3 Part number
5 thickness (D) bolt size
M12 × 150
75–95 mm
1 mm 90101-12031
(3.0–3.7 in)
3 (5.91 in)
5
4 3 M12 × 170
1 95–115 mm
mm 90101-12036
(3.7–4.5 in)
SS (6.69 in)
2 M12 × 180
D 2 mm 90101-12054
3 (7.09 in)
4 3
5 M12 × 200
mm 90101-12055
115 mm (7.87 in)
(4.5 in) or
more M12 × 210
Upper mounting bolt “1” mm 90101-12056
(8.27 in)
Boat transom Mounting
Part number M12 × 230
thickness (D) bolt size
mm 90101-12057
M12 × 170
(9.06 in)
mm 90101-12036
75–95 mm (6.69 in)
7. Install the mounting bolts, and then tighten
(3.0–3.7 in) M12 × 180 the nuts firmly.
mm 90101-12054
(7.09 in)
M12 × 200 Make sure that the clamp brackets do not
95–115 mm bite into the boat transom.
mm 90101-12055
(3.7–4.5 in)
(7.87 in)
M12 × 210 8. Tighten the locknuts firmly.
mm 90101-12056
115 mm (8.27 in)
(4.5 in) or
more M12 × 230
mm 90101-12057
(9.06 in)
Outboard motor mounting height

4-stroke engines are heavier than 2-stroke en-
gines of the same horsepower. Therefore, if a
2-stroke outboard motor is replaced with a 4-
stroke outboard motor, the boat will become
“stern heavy”. Also, the water line will rise and
become closer to the power unit. If the water
3-12
line is too close to the power head, poor engine
performance could result, and water could en-
ter the cylinders and damage the engine.
When mounting a 4-stroke outboard motor to a
boat, make sure that the mounting height be-
tween the water surface and the clamp bracket
seating point is not less than the specified min-
imum mounting height “a”. Measure the
mounting height when the boat is moored and
carrying the maximum load.
Minimum mounting height “a”

100 mm (3.9 in)
3-13
Rigging grommet mounting

TIP:
Rigging grommet description Make sure that the hole in the end of the nega-
Pass all the control components through the tive battery cable terminal fits over the projec-
proper holes in the rigging grommet. tion.
6 2
1
5 3
1
4
2
1. Main wire harness

2. SCU communication lead (for multiple ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
engine applications)
Installing the main wire harness
3. Flushing hose
1. Install:
4. Fuel hose
• Main wire harness
5. Battery cable
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
6. Isolator lead (optional) a. Connect the main wire harness coupler
1. Remove the grommet holder “1” and rig- “a”, and then fasten it using the holder “1”.
ging grommet “2”.
a
2
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Installing the battery cable Installing the rigging grommet

1. Remove: 1. Install:
• Bottom cowling cover • Rigging grommet
See “Bottom cowling cover and apron cov- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
er” (9-1). a. Route each harness through the proper
• Bottom cowling (STBD) hole in the rigging grommet. See “Rigging
See “Bottom cowling (PORT and STBD)” grommet description” (3-14).
(9-3).
b. Align the tape “a” on the battery cable “1”
2. Install and mark “b” on the flushing hose “2” with
• Battery cable the outer end of the rigging grommet.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert the battery cables into the bottom c. Align the tape “c” on the SCU communica-
cowling so that the positive battery cable tion lead with the outer end of the rigging
“1” is routed above the negative battery ca- grommet. (For multiple engine applica-
ble “2”. tions)
3-14
b
2
d. Install the rigging grommet “1” along with

the grommet holder “2”.
1 2
e. Install the rigging tube retainer “1”, and

then fasten it using the plastic tie “2”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Connecting the fuel hose

• When connecting the fuel hose, bleed the
boat fuel line.
See “Air purging during initial priming” (3-70).
• The engine idle speed may be unstable after
the engine is started until the air is bled from
the high-pressure line, but this is not a mal-
function.
3-15
Optional equipment
Optional equipment
Installing the isolator lead
1. Install
• Isolator lead
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert the isolator lead into the bottom
cowling.
b. Remove the isolator terminal cover.

b a
c. Install the isolator lead “1” and square c. Disconnect the SCU signal coupler “1”.
washer to the isolator terminal.
d. Remove the coupler cap from the SCU
1 communication lead coupler (4P) “2”, and
then install the cap to the SCU signal cou-
pler (4P) “1” (female section).
d. Install the rubber cap.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Installing the SCU communication 1 2

lead a. For the port or starboard outboard motor
To improve working efficiency for the rigging of of multiple engine applications only
multiple engine applications, start from the out-
board motor on the port side of the boat. e. Connect the SCU signal coupler (male
1. Install: section) to the SCU communication lead
• SCU communication lead coupler (4P) “1”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert the SCU communication lead into
the bottom cowling.
b. Install the SCU communication lead cou-

pler. a
TIP:
• For the port or starboard outboard motor of
multiple engine applications, install the cou- 1
pler (6 pins) onto the tab “a” and install the
coupler (4 pins) onto the tab “b”. a. For the port or starboard outboard motor
• For the center outboard motor of multiple en- of multiple engine applications only
gine applications, install the coupler (4 pins) f. Fasten the SCU communication lead us-
onto the tab “b”. ing the holder “1” shown in the illustration.
3-16
Optional equipment
TIP: TIP:
Make sure that there is no slack in the wire har- Mount the receiver within 3 m (10 ft) from the
ness. steering position.
1
1
g. Fasten the SCU communication lead us-

ing the plastic ties “1”, “2”, and “3” at the 4
locations shown in the illustration.
TIP: 2. Connect the Y-COP wires. See “System

• Make sure that the SCU communication lead diagram” (3-30).
does not contact the oil filter.
• Make sure that there is no slack in the wire Registering the receiver ID to the ECM
harness. 1. Check that the engine start switch is OFF.
2. Push the unlock button “1” of the transmit-

ter. The buzzer of the receiver will sound 2
short beeps.
2
3
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Installing Y-COP 1
3. Turn the engine start switch to ON. The

• Install the receiver so that the “UP” mark buzzer of the receiver will sound 1 medium
is facing up. beep.
• Do not install the receiver in a location
where it will be exposed to water. 4. Turn the engine start switch to OFF. Initial
• Do not cover the receiver with metal ob- registration is complete. Y-COP is un-
jects. Otherwise, signals may not be re- locked.
ceived.
5. Push the lock button “1” of the transmitter.
1. Install: Check that the buzzer of the receiver will
• Receiver “1” sound 1 short beep.
3-17
Optional equipment
1 a
6. Turn the engine start switch to ON.
TIP:
If the outboard motor is equipped with the CL7
display, Y-COP mark “a” is displayed on the
gauge when the engine start switch is turned to
ON.
7. Push the unlock button “1” of the transmit-

ter. Check that the buzzer of the receiver
will sound 2 short beeps.
TIP:
If the outboard motor is equipped with the CL7
display, Y-COP mark “a” will not be displayed
when the engine start switch is turned to ON.
3-18
Battery installation
• Make sure to connect the battery properly and select the proper cable sizes. Otherwise, a fire
could result.
• If an optional isolator lead is installed and connected to a house battery, overcurrent protec-
tion in compliance with ABYC (E-11) or equivalent must be provided.
• Do not reverse the battery connections. Otherwise, the charging system could be damaged.
• Route the positive battery cable and negative battery cable next to each other.
• For excess portions of the battery cables, do not coil the cables more than is necessary.
Battery wiring without house battery
When using a dual battery installation, a negative battery cable must be installed between both
engine batteries. This cable must be sized equivalent to the engine battery cables or larger AWG
cable size in accordance with ABYC specifications.
1. Outboard motor
2. Red
3. Black
1. Outboard motor
2. Red
3. Black
3-19
STBD PORT
1. Outboard motor 1. Outboard motor
2. Red 2. Red
3. Black 3. Black
3. Black
1. Outboard motor 3. Black

2. Red
1. Outboard motor
3. Red
4. Black
2. Battery switch
ON/OFF
1. Outboard motor
2. Battery switch
3. Red
4. Black
3-20
STBD PORT
3. Red 3. Red
4. Black 4. Black
ON/OFF ON/OFF
2. Battery switch
2. Battery switch
4. Black
1. Outboard motor 3. Red

2. Battery switch 4. Black
STBD PORT
2. Battery switch
2. Battery switch 3. Navigation system 4. Boat system
5. Black 5. Black
ON/OFF ON/OFF
6. Red
6. Red
6. Red 6. Red
5. Black 5. Black 5. Black

1. Outboard motor 4. Boat system
3. Navigation system 6. Red
3-21
1. Outboard motor 1. Outboard motor 1. Outboard motor

2. Isolator lead 2. Isolator lead 2. Isolator lead
STBD CENTER PORT
4. Red 4. Red 4. Red

ON/OFF ON/OFF ON/OFF
5. Black 5. Black
3. Battery switch 3. Battery switch 3. Battery switch

2. Isolator lead 5. Black
3. Battery switch
2. Battery switch 1. Outboard motor 7. Isolator lead 1. Outboard motor
STBD CENTER PORT

1. Outboard motor
2. Battery switch
3. Navigation system 4. Boat system
6. Red 6. Red
ON/OFF ON/OFF
5. Black 6. Red
5. Black ON/OFF
6. Red
5. Black 5. Black 5. Black 2. Battery switch
1. Outboard motor 4. Boat system

3. Navigation system 6. Red
3-22
1. Outboard motor 1. Outboard motor 1. Outboard motor 1. Outboard motor

2. Isolator lead 2. Isolator lead 2. Isolator lead 2. Isolator lead
STBD CS CP PORT
4. Red 4. Red 4. Red 4. Red
5. Black 5. Black 5. Black 5. Black

ON/OFF ON/OFF ON/OFF ON/OFF
3. Battery switch 3. Battery switch 3. Battery switch 3. Battery switch

3. Battery switch
7. Isolator lead 7. Isolator lead

STBD CS 1. Outboard motor CP PORT
2. Battery switch
5. Black 5. Black
3. Navigation system 4. Boat system
6. Red 5. Black
ON/OFF ON/OFF
6. Red 6. Red
ON/OFF ON/OFF
6. Red 5. Black 5. Black 5. Black 5. Black 6. Red 5. Black

2. Battery switch 6. Red 2. Battery switch
2. Battery switch
2. Battery switch 6. Red
3. Navigation system 7. Isolator lead
4. Boat system
3-23
Battery wiring with house (accessory) battery
• When only one battery is used for one engine, connect the positive battery cable and isolator
lead to the positive battery terminal. If the isolator lead is left unconnected, accidental contact
of the isolator lead with the negative terminal of the battery can cause a short circuit, which
may result in a fire.
• When using a house battery, a negative battery cable must be installed between the house
battery and the engine battery. This cable must be sized equivalent to the engine battery ca-
bles or larger AWG cable size in accordance with ABYC specifications.
• Battery switches must be capable of meeting intermittent and continuous current ratings for
engines and accessories.
1. Outboard motor
2. Isolator lead
3. Battery switch
4. Red
3. Battery switch
ON/OFF
1 2
5. Black
4. Red
6. House battery

3. Battery switch 6. House battery
3-24
1. Outboard motor
2. Isolator lead
3. Red
4. Black
4. Black
5. House battery

2. Isolator lead 5. House battery
3. Red
1. Outboard motor
2. Isolator lead
3. Black
4. Red
5. Battery switch
1 2
3. Black
4. Red
6. House battery

2. Isolator lead 5. Battery switch
3. Black 6. House battery
3-25
STBD 1. Outboard motor PORT

1. Outboard motor

3. Black
4. Battery switch 5. Red 3. Black

5. Red
4. Battery switch
ON/OFF
5. Red ON/OFF
1 2 3. Black
4. Battery switch
6. House battery
3. Black
1. Outboard motor 4. Battery switch
2. Isolator lead 5. Red

1. Outboard motor
3. Black
4. Battery switch
4. Battery switch 5. Red 5. Red 3. Black
ON/OFF
5. Red 5. Red
1 2 1 2
3. Black
4. Battery switch
6. House battery
3. Black
3-26

1. Outboard motor
3. Black
4. Battery switch 5. Red 3. Black

5. Red
4. Battery switch
5. Red
5. Red 1 2 1 2
6. House battery
3. Black 3. Black


1. Outboard motor

3. Battery switch 3. Battery switch
ON/OFF 5. Black
3. Battery switch
4. Red ON/OFF 4. Red
4. Red ON/OFF
5. Black 6. House battery 6. House battery

3-27
2. Isolator lead
STBD CENTER PORT

4. Battery switch
4. Battery switch
6. House battery
1 2 1 2 1 2
5. Red 5. Red
5. Red 3. Black
3. Black


STBD 2. Isolator lead CENTER PORT 2. Isolator lead
3. Black
5. Red 5. Red
3. Black 3. Black
ON/OFF ON/OFF ON/OFF
1 2 5. Red 5. Red 1 2
5. Red

4. Battery switch 6. House battery 4. Battery switch

3-28

STBD CS CP PORT
2. Isolator lead
5. Black
ON/OFF 5. Black
4. Red
ON/OFF ON/OFF
5. Black ON/OFF
4. Red
ON/OFF 4. Red
4. Red
5. Black ON/OFF
4. Red 4. Red
4. Red 5. Black 5. Black 5. Black 5. Black

3. Battery switch 6. House battery 6. House battery 3. Battery switch
2. Isolator lead 2. Isolator lead 2. Isolator lead 2. Isolator lead

STBD CS CP PORT
5. Red

5. Red 5. Red
1 2 1 2 1 2 1 2

6. House battery
4. Battery switch 4. Battery switch 4. Battery switch 4. Battery switch

3-29
System diagram
System diagram
Single outboard motor application (single station)
17
DC 12V
GPS
16
15
14
13
12
6
13
8
11
10
7
b
c
c
c
a
9
8
10 19
5
3
2
4
18
1
3-30
System diagram
Ref.
Part name Part No. Remarks
No.
1 Engine ECM —
6X6-8258A-50 3.7 m (12 ft)
6X6-8258A-60 5.2 m (17 ft)
6X6-8258A-00 6.1 m (20 ft)
2 Main wire harness (16P) 6X6-8258A-10 7 m (23 ft)
6X6-8258A-20 8 m (26 ft)
6X6-8258A-30 10 m (32 ft)
6X6-8258A-40 12 m (38 ft)
6GR-8258A-00 0.91 m (3 ft)
3 Extension wire harness
6GR-8258A-40 1.83 m (6 ft)
4 HELM unit 6GR-615A0-00
5 Digital Electronic Control 6X6-42805-61
6 Main switch 6X6-82570-33
7 Conversion harness 1 6Y9-83553-10 0.3 m (1 ft)
6Y8-82553-01 0.3 m (1 ft)
6Y8-82553-50 3 m (10 ft)
6Y8-82553-11 4.6 m (15 ft)
8 Main bus wire
6Y8-82553-21 6.1 m (20 ft)
6Y8-82553-31 7.6 m (25 ft)
6Y8-82553-41 9.1 m (30 ft)
9 Multi-hub 6Y8-81920-01 w/ resistor cap, gray
10 Waterproof cap 6Y8-82582-11 4P, white
11 Resistor cap 6Y8-85371-01 6P, gray
12 Power supply wire 6Y8-83553-01 w/ 10 A fuse, 2.4 m (8 ft)
6Y8-82521-01 0.3 m (1 ft)
6Y8-82521-11 0.6 m (2 ft)
6Y8-82521-21 0.9 m (3 ft)
13 Pigtail bus wire
6Y8-82521-31 1.8 m (6 ft)
6Y8-82521-41 2.7 m (9 ft)
6Y8-82521-51 3.6 m (12 ft)
6Y8-86254-03 For Europe
14 Y-COP
6Y8-86254-22 For USA and Oceania
15 Wire lead for CL7 Display 6YD-83553-00 2.4 m (8 ft)
6YD-83710-01 Wi-Fi
16 CL7 Display 6YD-83710-11 Chart/Wi-Fi
6YD-83710-21
17 Tank wire 6YD-8356N-00 1.06 m (3 ft)
3-31
System diagram
Ref.
No.
18 Fuel tank —
19 Single (inline) hub 6Y8-81920-11 w/ resistor, 4–6P, white
a. Power port
b. Bus port
c. Device port
TIP:
The part numbers are subject to change without notice. Make sure to confirm the latest part numbers.
3-32
8
22
9
23
7
13 GPS
15 DC 12V
6 6
10 18
P 1 11 11
14 24
2 3 b
16
c
5 c
4 12 16
c 14
b 13
3-33
19
a
20
Twin outboard motor application (single station)
S 1
2
3
17
13
21
System diagram
System diagram
Ref.
No.
1 Engine ECM —
2 SCU —
6GR-81115-00 w/ resistor cap, 1.5 m (5 ft)
3 SCU communication lead
6GR-81115-10 w/ resistor cap, 3 m (10 ft)
6Y8-82521-01 0.3 m (1 ft)
6Y8-82521-11 0.6 m (2 ft)
6Y8-82521-21 0.9 m (3 ft)
4 SCU communication extension lead
6Y8-82521-31 1.8 m (6 ft)
6Y8-82521-41 2.7 m (9 ft)
6Y8-82521-51 3.6 m (12 ft)
6X6-8258A-50 3.7 m (12 ft)
6X6-8258A-60 5.2 m (17 ft)
6X6-8258A-00 6.1 m (20 ft)
6X6-8258A-20 8 m (26 ft)
6X6-8258A-30 10 m (32 ft)
6X6-8258A-40 12 m (38 ft)
6GR-8258A-10 0.91 m (3 ft)
6GR-8258A-50 1.55 m (5 ft)
6Y8-82553-01 0.3 m (1 ft)
6Y8-82553-50 3 m (10 ft)
6Y8-82553-11 4.6 m (15 ft)
11 Main bus wire
6Y8-82553-21 6.1 m (20 ft)
6Y8-82553-31 7.6 m (25 ft)
6Y8-82553-41 9.1 m (30 ft)
15 Immobilizer power distribution wire 6Y8-83553-01 w/ 10 A fuse, 2.4 m (8 ft)
3-34
System diagram
Ref.
No.
6Y8-82521-01 0.3 m (1 ft)
6Y8-82521-11 0.6 m (2 ft)
6Y8-82521-21 0.9 m (3 ft)
16 Pigtail bus wire
6Y8-82521-31 1.8 m (6 ft)
6Y8-82521-41 2.7 m (9 ft)
6Y8-82521-51 3.6 m (12 ft)
17 Y-COP
6YD-83710-01 Wi-Fi
6YD-83710-21
20 Tank wire 6YD-8356N-00 1.06 m (3 ft)
21 Fuel tank —
22 All start/stop button 6X6-82570-D0
23 Start/stop button 6X6-82570-60
a. Power port P. port
b. Bus port S. starboard
c. Device port
TIP:
3-35
9
23
10
15 d 24
8
GPS
P 1 d
16 DC 12V
2 7 7
3 11 19
d 12
14 25 12
4
6 b
1 17
C c
3-36
5 c
2 13 14 17 19
c
6 b 15 21
Triple outboard motor application (single station)
4 a
18
S 1
2 22
3
15
System diagram
System diagram
Ref.
No.
1 Engine ECM —
2 SCU —
6Y8-82521-01 0.3 m (1 ft)
6Y8-82521-11 0.6 m (2 ft)
6Y8-82521-21 0.9 m (3 ft)
6Y8-82521-31 1.8 m (6 ft)
6Y8-82521-41 2.7 m (9 ft)
6Y8-82521-51 3.6 m (12 ft)
6GR-81115-20 1.5 m (5 ft)
6GR-81115-30 3 m (10 ft)
6X6-8258A-50 3.7 m (12 ft)
6X6-8258A-60 5.2 m (17 ft)
6X6-8258A-00 6.1 m (20 ft)
6X6-8258A-20 8 m (26 ft)
6X6-8258A-30 10 m (32 ft)
6X6-8258A-40 12 m (38 ft)
6GR-8258A-10 0.91 m (3 ft)
6GR-8258A-50 1.55 m (5 ft)
10 Main switch 6X6-82570-50 Main station helm
6Y8-82553-01 0.3 m (1 ft)
6Y8-82553-50 3 m (10 ft)
6Y8-82553-11 4.6 m (15 ft)
12 Main bus wire
6Y8-82553-21 6.1 m (20 ft)
6Y8-82553-31 7.6 m (25 ft)
6Y8-82553-41 9.1 m (30 ft)
16 Immobilizer power distribution wire 6Y8-81315-00 w/ 10 A fuse, 2.4 m (8 ft)
3-37
System diagram
Ref.
No.
6Y8-82521-01 0.3 m (1 ft)
6Y8-82521-11 0.6 m (2 ft)
6Y8-82521-21 0.9 m (3 ft)
17 Pigtail bus wire
6Y8-82521-31 1.8 m (6 ft)
6Y8-82521-41 2.7 m (9 ft)
6Y8-82521-51 3.6 m (12 ft)
18 Y-COP
6YD-83710-01 Wi-Fi
6YD-83710-21
21 Tank wire 6YD-8356N-00 1.06 m (3 ft)
22 Fuel tank —
b. Bus port C. center
c. Device port S. starboard
d. For sub station helm
TIP:
3-38
24
GPS
DC 12V
25
23
21
P CP 10
d
P 1
3 15
2 19 14
4
18 17 11
21 22 22
CP 1
16
5
a b c c c b 22 26 17 CS S 12
2
6 20
3-39
P/CP
4
Quad outboard motor application (single station)
13 9
CS 1
5
2
CS/S
6
4
7 7
S 1
2 8
3
21
d
System diagram
System diagram
Ref.
No.
1 Engine ECM —
2 SCU —
6Y8-82521-01 0.3 m (1 ft)
6Y8-82521-11 0.6 m (2 ft)
6Y8-82521-21 0.9 m (3 ft)
6Y8-82521-31 1.8 m (6 ft)
6Y8-82521-41 2.7 m (9 ft)
6Y8-82521-51 3.6 m (12 ft)
6GR-81115-20 1.5 m (5 ft)
6GR-81115-30 3 m (10 ft)
6X6-8258A-50 3.7 m (12 ft)
6X6-8258A-60 5.2 m (17 ft)
6X6-8258A-00 6.1 m (20 ft)
6X6-8258A-20 8 m (26 ft)
6X6-8258A-30 10 m (32 ft)
6X6-8258A-40 12 m (38 ft)
6GR-8258A-10 0.91 m (3 ft)
6GR-8258A-50 1.55 m (5 ft)
10 Start/stop button 6X6-82570-J0
11 Main switch 6X6-82570-G0
12 Start/stop button 6X6-82570-K0
13 PTT switch 6X6-82570-N1
6YD-83710-01 Wi-Fi
6YD-83710-21
3-40
System diagram
Ref.
No.
6Y8-82553-01 0.3 m (1 ft)
6Y8-82553-50 3 m (10 ft)
6Y8-82553-11 4.6 m (15 ft)
17 Main bus wire
6Y8-82553-21 6.1 m (20 ft)
6Y8-82553-31 7.6 m (25 ft)
6Y8-82553-41 9.1 m (30 ft)
6Y8-82521-01 0.3 m (1 ft)
6Y8-82521-11 0.6 m (2 ft)
6Y8-82521-21 0.9 m (3 ft)
18 Pigtail bus wire
6Y8-82521-31 1.8 m (6 ft)
6Y8-82521-41 2.7 m (9 ft)
6Y8-82521-51 3.6 m (12 ft)
24 Tank wire 6YD-8356N-00 1.06 m (3 ft)
25 Fuel tank —
b. Bus port CP. center port
c. Device port CS. center starboard
d. For sub station helm S. starboard
TIP:
3-41
23 5 B
24
4 DC 12V
25
b 11
c
c 10 14 16
9 17
22 c 10
b
21 a
A
6
5 12 GPS
20
4 DC 12V
3-42
16
Single outboard motor application (dual station)
8
7 7
3 13
2
1
b 17
c 14
18
c
9 10 14
c
b 15
a
7
19
10 26
System diagram
System diagram
Ref.
No.
1 Engine ECM —
6X6-8258A-50 3.7 m (12 ft)
6X6-8258A-60 5.2 m (17 ft)
6X6-8258A-00 6.1 m (20 ft)
6X6-8258A-20 8 m (26 ft)
6X6-8258A-30 10 m (32 ft)
6X6-8258A-40 12 m (38 ft)
6GR-8258A-00 0.91 m (3 ft)
6GR-8258A-40 1.83 m (6 ft)
5 Station selector switch 6X6-82570-B0
6Y8-82553-01 0.3 m (1 ft)
6Y8-82553-50 3 m (10 ft)
6Y8-82553-11 4.6 m (15 ft)
7 Main bus wire
6Y8-82553-21 6.1 m (20 ft)
6Y8-82553-31 7.6 m (25 ft)
6Y8-82553-41 9.1 m (30 ft)
6Y8-82521-01 0.3 m (1 ft)
6Y8-82521-11 0.6 m (2 ft)
6Y8-82521-21 0.9 m (3 ft)
14 Pigtail bus wire
6Y8-82521-31 1.8 m (6 ft)
6Y8-82521-41 2.7 m (9 ft)
6Y8-82521-51 3.6 m (12 ft)
15 Y-COP
6YD-83710-01 Wi-Fi
6YD-83710-21
3-43
System diagram
Ref.
No.
18 Tank wire 6YD-8356N-00 1.06 m (3 ft)
19 Fuel tank
6X6-8258A-G1 5 m (16 ft)
2nd station helm extension harness
20 6X6-8258A-H1 8 m (26 ft)
(3/4/6P)
6X6-8258A-J1 12.2 m (38 ft)
21 2nd station helm harness (3/4/6P) 6GR-8258A-20 0.77 m (2.5 ft)
6X6-8258A-B1 5 m (16 ft)
22 2nd station helm harness (2-12P) 6X6-8258A-D1 8 m (26 ft)
6X6-8258A-F1 12.2 m (38 ft)
25 Engine shut-off switch 6X6-82570-90
a. Power port A. Main station
b. Bus port B. Sub station
c. Device port
TIP:
3-44
26 8 B
27
7 DC 12V
28
b 14
c
c 13 15 17
12
c 13
b 20
25 a 29
24
24 23
23
A
30
8 9
15
31
7
GPS
3-45
14
6 6 DC 12V
16
Twin outboard motor application (dual station)
19
1 11
P 10
3
2 10
5 b
17
4 c
5 c
12 17 20
c 13
b 18
S 1
a
2 10 21
3
14 13 32
22
System diagram
System diagram
Ref.
No.
1 Engine ECM —
2 SCU —
6Y8-82521-01 0.3 m (1 ft)
6Y8-82521-11 0.6 m (2 ft)
6Y8-82521-21 0.9 m (3 ft)
6Y8-82521-31 1.8 m (6 ft)
6Y8-82521-41 2.7 m (9 ft)
6Y8-82521-51 3.6 m (12 ft)
6X6-8258A-50 3.7 m (12 ft)
6X6-8258A-60 5.2 m (17 ft)
6X6-8258A-00 6.1 m (20 ft)
6X6-8258A-20 8 m (26 ft)
6X6-8258A-30 10 m (32 ft)
6X6-8258A-40 12 m (38 ft)
6GR-8258A-10
6GR-8258A-50
6Y8-82553-01 0.3 m (1 ft)
6Y8-82553-50 3 m (10 ft)
6Y8-82553-11 4.6 m (15 ft)
10 Main bus wire
6Y8-82553-21 6.1 m (20 ft)
6Y8-82553-31 7.6 m (25 ft)
6Y8-82553-41 9.1 m (30 ft)
16 Immobilizer power distribution wire 6Y8-81315-00 w/ 5 A fuses, 2.4 m (8 ft)
3-46
System diagram
Ref.
No.
6Y8-82521-01 0.3 m (1 ft)
6Y8-82521-11 0.6 m (2 ft)
6Y8-82521-21 0.9 m (3 ft)
17 Pigtail bus wire
6Y8-82521-31 1.8 m (6 ft)
6Y8-82521-41 2.7 m (9 ft)
6Y8-82521-51 3.6 m (12 ft)
18 Y-COP
6YD-83710-01 Wi-Fi
6YD-83710-21
21 Tank wire 6YD-8356N-00 1.06 m (3 ft)
22 Fuel tank
6X6-8258A-G1 5 m (16 ft)
24 6X6-8258A-H1 8 m (26 ft)
(3/4/6P)
6X6-8258A-J1 12.2 m (38 ft)
6X6-8258A-B1 5 m (16 ft)
6X6-8258A-F1 12.2 m (38 ft)
27 Start/stop button 6X6-82570-E0
29 Waterproof cap 6Y8-82582-01 2P, red
b. Bus port S. starboard
c. Device port
A. Main station
B. Sub station
TIP:
3-47
27 9 B
28
DC 12V
8 29
b 15
c
c 14 18 20
9 21
c 14
26 b
a 30
11
25 A
24 9 10
25 31
16
25
15 32
GPS
1
3-48
P
3 DC 12V
2
Triple outboard motor application (dual station)
17
20
4 8
7 7
C 1
5
2 21
6 12
6
4
11 22
b
c
S 1 c 18
13
2 c 14 18 19
3 b
23
a
15 11
14 33
System diagram
System diagram
Ref.
No.
1 Engine ECM —
2 SCU —
6Y8-82521-01 0.3 m (1 ft)
6Y8-82521-11 0.6 m (2 ft)
6Y8-82521-21 0.9 m (3 ft)
6Y8-82521-31 1.8 m (6 ft)
6Y8-82521-41 2.7 m (9 ft)
6Y8-82521-51 3.6 m (12 ft)
6GR-81115-20 1.5 m (5 ft)
6GR-81115-30 3 m (10 ft)
6X6-8258A-50 3.7 m (12 ft)
6X6-8258A-60 5.2 m (17 ft)
6X6-8258A-00 6.1 m (20 ft)
6X6-8258A-20 8 m (26 ft)
6X6-8258A-30 10 m (32 ft)
6X6-8258A-40 12 m (38 ft)
6GR-8258A-10 0.91 m (3 ft)
6GR-8258A-50 1.55 m (5 ft)
6Y8-82553-01 0.3 m (1 ft)
6Y8-82553-50 3 m (10 ft)
6Y8-82553-11 4.6 m (15 ft)
11 Main bus wire
6Y8-82553-21 6.1 m (20 ft)
6Y8-82553-31 7.6 m (25 ft)
6Y8-82553-41 9.1 m (30 ft)
17 Immobilizer power distribution wire 6Y8-81315-00 w/ 5 A fuses, 2.4 m (8 ft)
3-49
System diagram
Ref.
No.
6Y8-82521-01 0.3 m (1 ft)
6Y8-82521-11 0.6 m (2 ft)
6Y8-82521-21 0.9 m (3 ft)
18 Pigtail bus wire
6Y8-82521-31 1.8 m (6 ft)
6Y8-82521-41 2.7 m (9 ft)
6Y8-82521-51 3.6 m (12 ft)
19 Y-COP
6YD-83710-01 Wi-Fi
6YD-83710-21
22 Tank wire 6YD-8356N-00 1.06 m (3 ft)
23 Fuel tank, and so on
6X6-8258A-G1 5 m (16 ft)
24 6X6-8258A-H1 8 m (26 ft)
(3/4/6P)
6X6-8258A-J1 12.2 m (38 ft)
25 2nd station helm harness (3/4/6P) 6GR-8258A-30 0.91 m (3 ft)
6X6-8258A-B1 5 m (16 ft)
6X6-8258A-F1 12.2 m (38 ft)
28 Start/stop button 6X6-82570-F0
b. Bus port C. center
c. Device port S. starboard
A. Main station
B. Sub station
TIP:
3-50
24 A
B
GPS 15
DC 12V
17
25 DC 12V
23 23
P CP
10 30
36 22 29
17
14 30
19 15
P 1 21
P CP
31
2 18
3 11
17
4 32
18 CS S 26
16
22 22 35 22 22 21
12 26
CP 1
5 a b c c c b a b c c c b
2 20 20
P/CP P/CP
4
3-51
6 13 9 13 33
Quad outboard motor application (dual station)
CS 1 CS/S CS/S
5
2
7 7 27
4
31
S 1
2
3 CS S
34
30
21
29
8
8
28
28
System diagram
System diagram
Ref.
No.
1 Engine ECM —
2 SCU —
6Y8-82521-01 0.3 m (1 ft)
6Y8-82521-11 0.6 m (2 ft)
6Y8-82521-21 0.9 m (3 ft)
6Y8-82521-31 1.8 m (6 ft)
6Y8-82521-41 2.7 m (9 ft)
6Y8-82521-51 3.6 m (12 ft)
6GR-81115-20 1.5 m (5 ft)
6GR-81115-30 3 m (10 ft)
6X6-8258A-50 3.7 m (12 ft)
6X6-8258A-60 5.2 m (17 ft)
6X6-8258A-00 6.1 m (20 ft)
6X6-8258A-20 8 m (26 ft)
6X6-8258A-30 10 m (32 ft)
6X6-8258A-40 12 m (38 ft)
6GR-8258A-10 0.91 m (3 ft)
6GR-8258A-50 1.55 m (5 ft)
11 Main switch 6X6-82570-G0
13 PTT switch 6X6-82570-N1
15 CL7 Display 6YD-83710-01 Wi-Fi
6Y8-82553-01 0.3 m (1 ft)
6Y8-82553-50 3 m (10 ft)
6Y8-82553-11 4.6 m (15 ft)
17 Main bus wire
6Y8-82553-21 6.1 m (20 ft)
6Y8-82553-31 7.6 m (25 ft)
6Y8-82553-41 9.1 m (30 ft)
3-52
System diagram
Ref.
No.
6Y8-82521-01 0.3 m (1 ft)
6Y8-82521-11 0.6 m (2 ft)
6Y8-82521-21 0.9 m (3 ft)
18 Pigtail bus wire
6Y8-82521-31 1.8 m (6 ft)
6Y8-82521-41 2.7 m (9 ft)
6Y8-82521-51 3.6 m (12 ft)
24 Tank wire 6YD-8356N-00 1.06 m (3 ft)
25 Fuel tank
26 Station selector switch 6X6-82570-L0
6X6-8258A-R0 5 m (16 ft)
27 2nd station helm harness (3-12P) 6X6-8258A-S0 8 m (26 ft)
6X6-8258A-T0 12.2 m (38 ft)
6X6-8258A-B1 5 m (16 ft)
6X6-8258A-F1 12.2 m (38 ft)
6X6-8258A-G1 5 m (16 ft)
30 6X6-8258A-H1 8 m (26 ft)
(3/4/6P)
6X6-8258A-J1 12.2 m (38 ft)
b. Bus port CP. center port
c. Device port CS. center starboard
S. starboard
A. Main station
B. Sub station
TIP:
3-53
Digital Electronic Control
Digital Electronic Control

Digital Electronic Control system
reset R/C System Reset
R/C Reset
A Digital Electronic Control system reset is re-

quired after the replacement of the Digital Elec- Do you wish to reset the remote control system?
tronic Control ECM or the engine ECM.

1. Connect the YDIS to display “Boat Sys- ere are no problems.
1. Before resetting the remote contorol system, check that there
2. Select the [Reset] button below to reset the remote controll system.
system.
tem” menu. To connect and operate the

YDIS, see the YDIS (Ver. 2.33 or later) in-
struction manual.
2. Click the “R/C Reset” button or “OK” but-

ton, or select “R/C Reset” using the arrow
keys, and then press the Enter key on the
keyboard. 5. Click the “OK” button or press the Enter
key on the keyboard.
OutboardMotorSetting R/C Reset
R/C Reset
R/C System Reset

1) Boat Setting
2) OutboardMotorSetting Tilt Limiter

Remote control system reset completed.
Turn off the main switch and quit YDIS.
When the main switch is turned on again, remote control

system identification will be performed automatically.
3) Watercraft Setting R/C Reset
Rotor Reset ere are no problems.

1. Before resetting the remote contorol system, check that there
2. Select the [Reset] button below to reset the remote controll system.
system.
3. Click the “Reset” button or press the Enter

key on the keyboard. 6. Turn the engine start switch to OFF, and
then remove the extension wire harness of
the Digital Electronic Control.
R/C System Reset

R/C Reset
TIP:
The outboard motor will automatically identify
the newly connected Digital Electronic Control
under any of the following conditions:
1. Before resetting the remote contorol system, check that there are no problems.
2. Select the [Reset] button below to reset the remote control system.
• When the extension wire harness is connect-
ed and the engine start switch is turned to
ON again.
• When the engine start switch is turned to
OFF, and then turned to ON again after wait-
ing for about 10 seconds until the power to
the engine ECM is shut off.
4. Click the “OK” button or press the Enter

3-54
Tilt limiter
Tilt limiter
Setting the tilt limiter
• Check that the outboard motor is mount-

ed on the boat or on a stand securely.
• Never get under the outboard motor while
it is tilted.
If there is interference between the top cowling

and the motor well when the outboard motor is
tilted up, adjust the setting angle of the tilt lim-
iter using the following procedures.
1. Fully tilt the outboard motor down.
5. Operate the PTT switch on the bottom
2. Connect the YDIS to display “Boat Sys-
cowling to tilt the outboard motor up to the
position where the tilt limiter is to be acti-
vated.
struction manual.
TIP: • Do not use the PTT switch on the Digital

It is not possible to set or clear the tilt limiter if
Electronic Control during the tilt limiter
there is any problem with the PTT sensor or the
setting to avoid interference between the
wiring. In that case, correct the problem first,
motor well and the top cowling.
and then set or clear the tilt limiter.
• Make sure to keep the clearance “a” of
50.8 mm (2.0 in) or more between the out-
3. Click the “Tilt Limiter” button or “OK” but- board motor and the motor well.
ton, or select the “Tilt Limiter” using the ar-
row keys, and then press the Enter key on TIP:
the keyboard. The tilt up angle can be set at any tilt setting
range “b”.
OutboardMotorSetting Tilt Limiter
1) Boat Setting
2) OutboardMotorSetting Tilt Limiter

a
3) Watercraft Setting R/C Reset
Rotor Reset
4. Click the “Next” button or press the Enter

b
3-55
Tilt limiter
6. Click the “Set” button or press the Enter
key on the keyboard. TIP:
It is not possible to set or clear the tilt limiter if
there is any problem with the PTT sensor or the
wiring. In that case, correct the problems be-
fore setting or clearing the tilt limiter.
2. Click the “Reset” button or press the F1



8. Check that the outboard motor stops at the

set position.
TIP:
• If the tilt limiter does not operate at the set po-
sition, or to change the setting position, clear
the tilt limiter setting, and then reset it.
• If the tilt limiter is set to a position where the
tilt support lever cannot be engaged, or if the
outboard motor is tilted up with the tilt support
lever released for a long time, the outboard TIP:
motor can fall under its own weight. To reset the tilt limiter setting, see “Setting the
tilt limiter” (3-55).
Clearing the tilt limiter
1. Connect the YDIS to display “Boat Sys-
struction manual.
3-56
Tilt limiter
Deactivating the tilt limiter

The tilt limiter can be deactivated temporarily
without using the YDIS for services or mainte-
nance. Deactivate the tilt limiter using the fol-
lowing procedure.
1. Disconnect the PTT sensor (sub lead)
coupler “a”.
TIP:
When the engine start switch is turned to ON
with the PTT sensor coupler disconnected, di-
agnosis code 83 (PTT sensor malfunction) will
be recorded in the engine ECM. Make sure to
connect the PTT sensor coupler and delete the
diagnosis code after services or maintenance
is complete.
3-57
Calibration (6X6 Digital Electronic Control)
Calibration (6X6 Digital Electronic

Control)
• If the steering actuator is removed, the steer-
ing sensor must be calibrated after the unit is
installed.
• Check that the battery is fully charged before
performing the calibration. Otherwise, the
calibration cannot be performed properly.
• Do not turn the steering wheel while the cali-
bration is being performed.
5. Select the number of outboard motors
Configuring the number of outboard mounted on the boat.
motors
• If the number of outboard motors mounted
on the boat is changed, change the gauge
setting.
• Perform this procedure before performing
the calibration.
1. Turn the main switch to “ON”.
2. Tap “Menu”.
6. Tap “Engine” to confirm that the number of

outboard motors has been changed.
3. Tap “Reset”.
Accessing the calibration menu

1. Tap “Engine” on the screen, and then tap
“Menu” to display the “Engine Menu”
screen.
4. Tap “Number of Engines”.
3-58
4. The “Technician Settings” menu will ap-
pear.
2. Tap and hold the center “a” of the “Engine

Menu” bar for 10 seconds. The “Techni-
cian Settings” item will be added to the Steering sensor
menu. During this process, only the corresponding
steering actuator will operate as the steering
a
sensor is being calibrated.
1. Before performing this procedure, switch
the battery switch(es) to the “ALL” position.
2. From the “Technician Settings” menu, se-

lect “Steer Sensor”, and then tap “YES”.
TIP:
When the engine is running, this function is not
available.
3. When the “Technician Settings” message

appears, tap “OK”.
3. Fully tilt the outboard motor down.
3-59
4. Remove the side cowlings (bottom cowl-

ings).
TIP:
• For triple engine applications, perform this
5. Turn the steering wheel clockwise until the step for the center outboard motor after com-
starboard outboard motor is turned com- pleting this step for the starboard outboard
pletely to starboard and the message ap- motor.
pears. • For quad engine applications, perform this
Confirm that the starboard outboard motor step on the center port outboard motor first,
is turned completely to starboard, and then and then the center starboard outboard mo-
tap “SET”. tor.
6. Turn the steering wheel clockwise until the

port outboard motor is turned completely
to starboard and the message appears.
Confirm the port engine is turned com-
pletely to starboard, and then tap “SET”.
3-60
8. Turn the steering wheel counterclockwise

until starboard outboard motor is turned
completely to port and the message ap-
pears. Confirm that the starboard outboard
motor is turned completely to port, and
then tap “SET”.
7. Turn the steering wheel counterclockwise

until the port outboard motor is turned
completely to port and the message ap-
pears. Confirm that the port outboard mo-
tor is turned completely to port, and then
tap “SET”.
3-61
9. Once the calibration is complete, a mes-
sage will appear verifying that the proce-
dure is completed.
2. Check that the outboard motors do not

contact each other during steering opera-
tion, and tap the “Toe Angle”. (For multiple
10. During the steering sensor calibration pro- engine applications)
cedure, if there is an invalid value when
calibrating the steering sensor, a notifica-
tion will appear. Perform the complete cal-
ibration procedure again.
11. If the steering system still requires calibra-

tion, a warning notification will appear. The
engine will not start until the calibration is
performed again.
3. Adjust the toe angle, and tap “Done” to

confirm.
TIP:
• –2.0° to +2.0° in 0.2° increments (up to 0.2
in).
• Minus (–) degrees equals toe-in.
• Plus (+) degrees equals toe-out.
• For quad engine application, the toe angle of
Toe Adjust C PORT and C STBD engines can be syn-
This should be determined by on-water testing. chronously adjusted independent of the
1. From the “Technician Settings” menu, se- PORT and STBD engines.
lect “Toe Adjust”.
3-62
Single engine
Triple/Twin engine
a
b
P 0.0 S 0.0
a. Toe angle inside

b. Toe angle outside
Lock to Lock
lect “Lock to Lock”.
Quad engine
TIP:
available.
P 0.0 CP CS S 0.0
2. Select the “Constant” or “Variable”.
TIP:
• When “Constant” is selected, perform step 3.
• When “Variable” is selected, perform step 4.
3-63
Regardless of the setting chosen, the steering
still increases and decreases the friction based
on the engine speed.
lect “Friction Set”.
TIP:
available.
3. Select the steering wheel’s rotation range.

Tap to confirm your setting.
TIP:
This setting allows you to adjust the number of
turns from “Lock to Lock”.
• Minimum: 4 turns
• Maximum: 9 turns
• Default: 4 turns
2. First choose “Regular” or “Heavy”, then

adjust the percentage of friction. Tap “Do-
ne” to confirm.
TIP:
The setting choices allow you to choose be-
4. Select the steering wheel’s rotation ranges tween “Regular” and “Heavy”. In each of those
at the specified engine speeds. Tap to settings it is adjustable between 100% and
confirm your setting. 200% in 10% increments. The default setting is
100%.
Friction Set
The steering will automatically adjust the fric-
tion setting depending on engine speed. At
higher engine speeds, the friction increases. At
lower engine speeds, the friction decreases.
3-64
7.0
6.0 a
5.0
4.0 b
A
3.0
c
2.0 d
1.0
0.0
1000 2000 3000 4000 5000 6000
B
A. Steering friction (N·m)
B. Engine speed (r/min)
a. Heavy 200%
b. Regular 200%
c. Heavy 100%
d. Regular 100%
3. When the “Friction Set” setting is complet-

ed, tap “Back” to return to the “Technician
Settings” menu.
3-65
Rigging recommendation
Battery cable length
The table below shows the battery cable length from the negative terminal of the battery cable to the
rigging grommet.
The positive battery cable is 100 mm (3.9 in) longer than the negative battery cable.
Length (L)
3.55 m (11.6 ft)
(L)
100 mm
(3.9 in)
Extension length recommendation for battery cable
Do not exceed the recommended extension length for the battery cable. Otherwise, the electri-
cal system could be damaged or operate improperly.
To extend the length of battery cables, follow the requirements in the tables for battery capacity, cable
size, and ambient temperature.
The maximum total extension length is the total combined length of the positive and negative battery
cables.
Select an extension battery cable and terminal that meet ABYC requirements or the equivalent.
Select the battery stud that is best-suited to the terminal size.
Solder the cable and terminal connections to prevent them from corroding.
Ambient temperature is 0 °C (32 °F) and above
Battery requirements Cable specifications
Maximum total extension length
(Positive battery cable + Negative battery cable)
Unit Rating
20 mm² 30 mm² 50 mm² 60 mm²
(AWG4) (AWG2) (AWG1/0) (AWG2/0)
CCA/SAE 700 A
MCA/ABYC 900 A
RC/SAE 170 minutes 6.4 m 10.0 m 11.8 m
–
CCA/EN 670 A (21 ft) (33 ft) (39 ft)
20HR/IEC 110 Ah
JIS 120E41
3-66
Ambient temperature is below 0 °C (32 °F)

Battery requirements Cable specifications
Maximum total extension length
(Positive battery cable + Negative battery cable)
Unit Rating
20 mm² 30 mm² 50 mm² 60 mm²
(AWG4) (AWG2) (AWG1/0) (AWG2/0)
CCA/SAE 700 A
MCA/ABYC 900 A
–
CCA/EN 670 A (9 ft) (15 ft) (16 ft)
20HR/IEC 110 Ah
JIS 120E41
CCA/SAE 800 A
MCA/ABYC 960 A
–
CCA/EN 750 A (10 ft) (15 ft) (18 ft)
20HR/IEC 120 Ah
JIS 130E41
1. Extension battery cable 2. Battery switch
ON/OFF
3. Battery 4. Original battery cable
1. Extension battery cable

2. Battery switch
3. Battery
4. Original battery cable
3-67
Propeller selection
Propeller selection
The size and type of propeller that is used will affect the performance of a boat and outboard motor
critically. Propellers greatly affect boat speed, acceleration, engine life, fuel economy, and even boating
and steering capabilities. An incorrect choice could adversely affect performance and could also dam-
age the engine seriously.
Use the following information as a guide for selecting a propeller that meets the operating conditions of
the boat and outboard motor.
Propeller size
The size of the propeller is indicated on the side of the propeller boss.
b
a
c
a. Propeller diameter (in inches) c. Propeller type (propeller mark)

b. Propeller pitch (in inches)
Selection
With the engine speed at full throttle operating range and under a maximum boat load, the engine
speed should be within the upper half of the full throttle operating speed range.
Full throttle operating range
5000–6000 r/min
Regular rotation model
Blade Dia. (in) Pitch (in) Mark Material Part number Remarks
3 17 1/8 15 Y Stainless steel 6GR-45970-10 *1, *2
3 16 25 Y Stainless steel 6GR-45930-10 *1, *2
*1. Shift Dampener System (SDS) propellers

*2. XTO offshore series propellers (“XTO OS” is indicated on the side of the propeller boss.)
TIP:
3-68
Propeller selection
Counter rotation model
Blade Dia. (in) Pitch (in) Mark Material Part number Remarks
3 17 1/8 15 YL Stainless steel 6GS-45970-10 *1, *2
3 16 25 YL Stainless steel 6GS-45930-10 *1, *2
*1. Shift Dampener System (SDS) propellers

*2. XTO offshore series propellers (“XTO OS” is indicated on the side of the propeller boss.)
TIP:
3-69
Fuel line air purging
Fuel line air purging

Air purging during initial priming
• When mounting a new outboard motor to a
new boat, the fuel line must be bled.
• Cover the fuel components using a rag to
prevent fuel from spilling out.
Never get under the outboard motor while it

is tilted.
1
1. Fully tilt the outboard motor up, and then
support it using the tilt support lever “1”.
1 6. Install the plug into the drain hose, and

then fasten the drain hose using the holder
on the vapor separator cover.
7. Disconnect the quick connector.

1 See “Disconnecting the quick connector”
(6-1).
8. Install the band to the fuel pipe, and then

2. Disconnect the quick connector “1”. connect the quick connector.
See “Disconnecting the quick connector”
(6-1). 9. Squeeze the primer pump until it becomes
firm.
3. Remove the band “2” from the fuel pipe
“a”, and then connect the quick connector
“1”.
1 a 2
4. Remove the drain hose “1” from the holder

on the vapor separator cover.
5. Remove the plug from the drain hose, and

then squeeze the primer pump until fuel
flows from the drain hose.
3-70
Troubleshooting
YDIS ..................................................................................... 4-1

Basic components ...................................................................... 4-2
Function...................................................................................... 4-3
Connecting the communication cable ...................................... 4-10
Outboard motor troubleshooting.................................... 4-11

Troubleshooting procedure ...................................................... 4-11
Troubleshooting the power unit using the YDIS ....................... 4-11
Trouble code and checking step .............................................. 4-15
Troubleshooting procedure (trouble code not detected) .......... 4-37
Troubleshooting the power unit ................................................ 4-37
Troubleshooting the PTT unit ................................................... 4-45
Troubleshooting the lower unit ................................................. 4-46
4
YDIS
YDIS
The Yamaha Diagnostic System uses precision fault diagnosis to offer better serviceability at a time
when there is increasing demand for service tools for electronically controlled products. It provides
quick, reliable, safe, and reasonable service, and is intended to obtain customer satisfaction. The
Yamaha Diagnostic System features updated software and expanded tool functions that allow it to re-
spond to new models and technologies, maintaining compatibility with regulations. This manual con-
tains the model-specific information. See YDIS (Ver. 2.33 or later) instruction manual for detailed
information.
4-1
YDIS
Basic components
YDIS2 Hardware Kit
90890-06884
YDIS2 Hardware Kit
LIT-YDIS2-01-KT
TIP:
The software is available through YMAN (Yamaha Marine Associate Network).
1 2 4
3
5 6
9 10
8
No. Part name Q’ty Remarks

1 Adapter interface 1
2 USB cable 1 5 m (16.4 ft)
3 Adapter cap 1
4 AD harness 1 For external input
5 CAN-Line harness 1
6 K-Line harness 1
7 Power supply harness 1
8 Trigger switch harness 1
9 Trigger switch extension harness 1
10 Reprogramming harness 1
4-2
YDIS
Function
YDIS version 2.33 is comprised of the following items.
1. Start 2. Boat System 3. Boat Setting
4.Outboard Motor 5. Tilt Limiter

Setting
6. R/C Reset
7. Rotor Reset
8. DI Fuel System 9. Fuel System
11. Watercraft Setting Maintenance Air Purge
12. R/C & Steering 13. Diagnosis
14. Diag. Record 10. Reduce DI
Fuel Pressure
15. Monitor
16. System Record
17. Engine 18. Diagnosis 19. Diagnosis
20. Diag. Record
21. Diag. Record 2
22. Engine Record
23. Operating Hrs
24. Eng. Monitor 25. Digital Disp.
26. Analog Disp.
27. Graph Disp.
28. Input Setting
29. Component Test 30. Stationary Test
31. Active Test
32. Data Logger 33. Logger Graph
34. ECM Rec Graph
35. Logging 36. Normal set
40. Oil Change Rec
37. Repeat set
41. Maintenance 38. Show Data
39. Clear Data
4-3
YDIS
42. Update 43. Online Update

45. Setting 44. Offline Update
46. Off Line 47. Show Graph
Normal Logging
48. Record set K-LINE
49. Record set 6Y8
Repeat Logging
50. Record set K-LINE
51. Record set 6Y8 52. Show Data
54. Check Engine 53. Clear Data
55. Special Function 56. Boat System 57. 6X6/6X7 Remote Control
58. 6YD Gauge
59. 6YG Gateway
60. Engine 61. ONLINE

62. OFFLINE 63. Download
64. Programming
66. History 65. Report
67. Maintenance 68. Correction of

ENG serial No.
69. BPS Scan 70. Registration
74. CAN Information 75. Communication List 71. Replacement

72. Report
76. Bus Statistics
73. History
77. Virtual Engine
78. Virtual Remote Control
79. Check 6X6 RC System
4-4
YDIS
1. Start 50. Record set K-LINE (Repeat Logging)

2. Boat System 51. Record set 6Y8 (Repeat Logging)
3. Boat Setting 52. Show Data
4. Outboard Motor Setting 53. Clear Data
5. Tilt Limiter 54. Check Engine
6. R/C Reset 55. Special Function
7. Rotor Reset 56. Boat System
8. DI Fuel System Maintenance 57. 6X6/6X7 Remote Control
9. Fuel System Air Purge 58. 6YD Gauge
10. Reduce DI Fuel Pressure 59. 6YG Gateway
11. Watercraft Setting 60. Engine
12. R/C & Steering 61. ONLINE
13. Diagnosis 62. OFFLINE
14. Diag. Record 63. Download
15. Monitor 64. Programming
16. System Record 65. Report
17. Engine 66. History
18. Diagnosis 67. Maintenance
19. Diagnosis 68. Correction of ENG serial No.
20. Diag. Record 69. BPS Scan
21. Diag. Record 2 70. Registration
22. Engine Record 71. Replacement
23. Operating Hrs 72. Report
24. Eng. Monitor 73. History
25. Digital Disp. 74. CAN Information
26. Analog Disp. 75. Communication List
27. Graph Disp. 76. Bus Statistics
28. Input Setting 77. Virtual Engine
29. Component Test 78. Virtual Remote Control
30. Stationary Test 79. Check 6X6 RC System
31. Active Test
32. Data Logger
33. Logger Graph
34. ECM Rec Graph
35. Logging
36. Normal set
37. Repeat set
38. Show Data
39. Clear Data
40. Oil change Rec
41. Maintenance
42. Update
43. Online Update
44. Offline Update
45. Setting
46. Off Line
47. Show Graph
48. Record set K-LINE (Normal Logging)
49. Record set 6Y8 (Normal Logging)
4-5
YDIS
5. Tilt Limiter
The tilt limiter allows the tilt-up action to be halted at a set angle, preventing the top cowling from coming
into contact with the motor well when the outboard motor is tilted up.
6. R/C Reset
When the Digital Electronic Control and engine combination has been changed (when active indicator
is off), the engine authorization ID has to be reset to default.
9. Fuel System Air Purge

Bleeds the fuel system. Because the fuel pumps operate while the fuel injectors are opened, the fuel is
pressure fed while the fuel system is bled.
10. Reduce DI Fuel Pressure

Prevents fuel from spraying out when a fuel rail or fuel injector is removed. Because the fuel injectors
are opened, the fuel pressure in the fuel rails is reduced.
19. Diagnosis
Displays diagnosis codes recorded in the engine ECM, item names, and current item conditions.
This can identify components and/or systems with problems. The trouble codes displayed are the same
as those described in this chapter. See “Trouble code and checking step” (4-15).
20. Diag. Record

Displays diagnosis codes recorded in the engine ECM, item names, and when problems are detected.
The fault diagnosis history can be erased. The trouble codes displayed are the same as those de-
scribed in this chapter. See “Trouble code and checking step” (4-15).
22. Engine Record

Data recorded on the engine ECM related to various controls for engine speed (max.) and engine
speed, and the time and the number of times the controls occurred is displayed as a list.
Engine speed (max.) Knock control count Knock learning minimum value
Over-rev. count Shift count Rapid acceleration count
Overheat count Start count Total hours of operation
Low oil pressure count Reverse rotation count
24. Eng. Monitor

Displays engine ECM conditions (sensor information) in real time. “25. Digital Disp.” displays these in
digital form, and “27. Graph Disp.” displays these in graph form. Additionally, connecting a commercially
available external device and configuring “28. Input Setting” enables display of the Engine Monitor.
Engine speed Cooling water temperature (S) Main switch signal
Intake air pressure Ignition timing Start/stop button
TPS1 Engine temperature Possibility to start
Throttle valve opening angle Intake air temperature Main relay
TPS2 Oil pressure ETV relay
Throttle request Intake cam timing (S bank) Starter relay
LPS CP 1 Intake cam timing (P bank) VST fuel pump relay *1
4-6
YDIS
LPS CP 2 PTT sensor Low pressure fuel pump relay

LPS CS 1 Cooling water pressure EDU relay
LPS CS 2 DI fuel pressure P *2 Shift actuator relay
Active remote control DI fuel pressure S *3 PTT UP relay
SPS 1 Feed fuel pressure *4 PTT DOWN relay
SPS 2 Trim Level Immobilizer
Shift request Fuel flow PTT switch UP
Atmospheric pressure Engine shut-off switch PTT switch DOWN
Battery voltage Shift position judgment A/D (CH1)
Accessory Battery voltage Multi-engine system A/D (CH2)
Fuel injection duration Shift cut-off A/D (CH3)
Cooling water temperature (P) R/C ECM signal *5 A/D (CH4)
*1. High-pressure fuel pump relay
*2. Fuel pressure (direct injection pump) (PORT)
*3. Fuel pressure (direct injection pump) (STBD)
*4. Fuel pressure (high-pressure fuel pump)
*5. Digital Electronic Control ECM signal
30. Stationary Test

When the engine is stopped and the shift is in the N position, certain engine components can be oper-
ated to check the component operation and component circuits.
Activate ignition coil (#1–#8) Activate VST fuel pump 1 *1 Activate DI fuel pump (S) *5
Activate injector (#1–#8) Activate VST fuel pump 2 *2
Activate low pressure fuel
Activate OCV (S bank)
pump *3
Activate OCV (P bank) Activate DI fuel pump (P) *4
*1. Activate high-pressure fuel pump (main)

*2. Activate high-pressure fuel pump (sub)
*3. Activate low-pressure fuel pump
*4. Activate direct injection pump (PORT)
*5. Activate direct injection pump (STBD)
31. Active Test

When the engine is running, certain components can be operated to check the component operation,
the component circuits and/or the engine condition.
Drop cylinder (#1–#8) No idle control mode *1
*1 This function operates only when the shift is in the N position.
4-7
YDIS
33. Logger Graph
Displays in graph form engine operation data stored in the ECM for the last 19 minutes in 1-minute in-
tervals.
Engine speed Engine temperature Throttle request
Battery voltage Intake air pressure SPS
TPS Oil pressure
34. ECM Rec Graph

When a problem occurs in the electronic throttle system, the data for 2 seconds before and after the
problem, for a total of 4 seconds. The recorded data is displayed in graph form.
Engine speed Ref. TPS voltage *2 Overheat warning
Throttle request Target TPS voltage for ISC *3 Low oil pressure
TPS 1 Engine stop mode Total hours of operation
TPS 2 Engine start mode Trigger
Intake air pressure Engine shut-off switch Code
Battery voltage Main relay Active Remote Control
Target TPS voltage *1 ETV relay
*1. This item shows the target output voltage of the TPS.
This value is the control voltage that the engine ECM requires to set the target opening angle
of the throttle valve.
*2. Reference TPS voltage
This item shows the judgment output voltage of the TPS.
This value is used to detect the TPS output voltage during engine operation.
*3. Engine ECM controls the engine idle speed using the throttle valve that is connected to the
TPS.
This target voltage is used by the engine ECM to obtain the target opening angle of the throt-
tle valve at engine idle speed.
35. Logging
Use “36. Normal set” or “37. Repeat set” to set items to record. “38. Show Data” saves logged data in
the computer, and displays this data in graph form. “39. Clear Data” deletes data and conditions stored
in the adapter. While the computer and the outboard motor are not connected, records “Engine Monitor”
data using the adapter.
40. Oil Change Rec

It is possible to maintain oil change records using this function.
43. Online Update

It is possible to update data while the computer is connected to the Internet and the adapter. This func-
tion compares the latest data available in YMAN (Yamaha Marine Associate Network) with the data
stored in the computer. If any updates are available, the data stored in the computer will be updated
automatically.
4-8
YDIS
44. Offline Update
It is possible to update the database when update information is provided. To update the database, you
need to download the necessary data from YMAN (Yamaha Marine Associate Network) first.
45. Setting
Switches the language to use in the YDIS.
It is possible to select units when connected via the CAN-Line.
46. Off Line

Displays saved graph data in the Engine Monitor (Graph Display) and Logging menus when the com-
puter is not connected to the outboard motor.
Record settings for logging, deleting data, and data playback are possible even when the computer is
not connected to the outboard motor.
75. Communication List

Displays the name of Yamaha genuine parts connected to the Digital Network by connecting the YDIS
to a multi-hub via a CAN-Line. This function can be used to check that the connections are correct.
76. Bus Statistics

Displays the bus load connected to the Digital Network by connecting the YDIS to a multi-hub via a
CAN-Line. If the bus load is higher than 40%, then check the connection status.
4-9
YDIS
Connecting the communication cable

CAN-Line
3. Adapter interface
1. CAN-Line harness 4. USB cable
2. Adapter cap
6. Single (inline) hub
5. Main bus wire
7. Multi-hub
1. CAN-Line harness 5. Main bus wire

2. Adapter cap 6. Single (inline) hub
3. Adapter interface 7. Multi-hub
4. USB cable
K-Line
a. YDIS coupler
2. Adapter cap
1. Adapter interface
3. USB cable 4. K-Line harness

1. Adapter interface a. YDIS coupler (gray)
2. Adapter cap
3. USB cable
4. K-Line harness
4-10
Outboard motor troubleshooting

Troubleshooting procedure
1. Before troubleshooting the outboard motor, check that fresh fuel of the specified type has been
used.
2. Check that all electrical connections are secure and free from corrosion, and that the battery is fully
charged.
3. Check the trouble code using the YDIS first, and then check the electronic control system following
the trouble code chart.
4. When a trouble code is detected, check the data logger of the engine ECM record graph as well.
5. If a trouble code is not detected, check the power unit according to “Troubleshooting the power unit”
(4-37).
6. Before using the YDIS to check the power unit, check the engine ECM circuit. See “Checking the
engine ECM circuit” (5-19).
TIP:
• When deleting the diagnosis record on the YDIS, make sure to check the time that the trouble codes
were detected.
• When checking the input voltage of a part, the coupler or connector must be disconnected. As a re-
sult, the engine ECM determines that the part is disconnected and a trouble code is detected. There-
fore, make sure to delete the diagnosis record after checking the input voltage.
• Since the main relay comes on for approximately 10 seconds after the engine start switch is turned
to OFF, the power of the engine ECM cannot be turned off. Therefore, if the engine start switch is
turned to ON within 10 seconds after it was turned to OFF, the trouble codes cannot be deleted.
Troubleshooting the power unit using the YDIS

1. Use the trouble codes, displayed by the YDIS, to check each part according to the table of “Trouble
code and checking step” (4-15).
2. Delete the trouble codes after checking, repairing, or replacing a part and check that the trouble
codes are not detected again. If the same trouble codes are detected, the engine ECM may be
faulty.
3. Check the items listed in the table. If all of the items are in good condition, delete the trouble codes,
and then check the trouble codes again. If the same trouble codes are detected again, the engine
ECM is faulty.
TIP:
When using a K-Line connection, trouble codes for code number 300 and higher are not displayed.
4-11
Trouble code table
To display trouble codes (code number 300 and higher) for the SBW system, connect using the CAN-
Line harness.
*1: Crankshaft position sensor
*2: Fuel pressure sensor (high-pressure fuel pump)
: Indicated
—: Not indicated
YDIS diagnosis
Code No. Item YDIS diagnosis
record
13 Pulser coil *1  
15 Engine temperature sensor  
17 Knock Sensor 1  
19 Battery voltage  
20 Knock Sensor 2  
23 Air temperature sensor  
24 Cam position sensor (EX)  
27 Water in fuel filter  
29 Air pressure sensor  
39 Oil pressure sensor  
42 Thermo sensor (P)  
43 Thermo sensor (S)  
44 Engine shut-off switch  —
56 Main power supply  
57 Starter magnet power supply  
71 Cam position sensor (S bank IN)  
72 Cam position sensor (P bank IN)  
73 OCV (S bank)  
74 OCV (P bank)  
83 PTT sensor  
86 Immobilizer — 
112, 113,
114, 115,
116, 117,
119, 123, ETV  
138, 141,
142, 143,
144, 145
124, 125,
126, 127, TPS  
128
4-12
YDIS diagnosis
record
146, 147,
148, 149,
SPS  
150, 153,
154, 155
156, 157 Engine-R/C communication  
160, 161,
162, 163,
164, 165,
166, 167,
168, 169,
170, 171,
172, 173, Remote control system  
174, 175,
176, 177,
178, 179,
180, 181,
183, 184,
186, 187
190 PTT relay  
191 PTT relay power  
192 Shift actuator power supply  
193 VST fuel pump power supply  
194 Water pressure sensor  
195 Medium pressure fuel pressure sensor *2  
196 Fuel system  
210 Engine-FuseBox communication  
213 EDU power supply 1  
214 EDU power supply 2  
215 DI fuel pressure sensor (P)  
216, 217 DI fuel pressure (P)  
DI fuel pump (P)
218  
(DI fuel pressure pump P)
219 DI fuel pressure sensor (S)  
220, 221 DI fuel pressure (S)  
222 DI fuel pump (S)  
223 Steering system  
224 Steering system–Outboard (SCU)  
225 Steering system–Helm (HELM)  
4-13
YDIS diagnosis
record
241, 242,
243, 244,
Injector#1–Injector#8  
245, 246,
247, 248
321 R/C to Steering Communication  
322, 323 Remote Control System  
512, 513 System Voltage Low  
514 System Voltage High  
515, 517,
518, 519, Steering System–Position Sensor  
520, 521
516 Steering Sensor(s) Calibration  
522 Steering System–Actuator Temp.  
523, 524 Steering System–Temperature Sensor  
525, 526,
Steering System–Actuator Current  
527
528, 529 Steering System–Control Unit  
530 Steering System–Current Sensor  
531 Steering System–Brake Current  
532, 533 Steering System–Actuator  
534 R/C to Steering Communication  
535 Steering to Steering Communication  
536 Steering System Communication  
537, 538 Steering System–Main Helm  
539, 540 Steering System–2nd Helm  
541 Steering System–Control Unit  
542 Incompatible Hardware  
543 Steering System–Control Unit  
544 Steering to R/C Communication  
545 Incompatible Software  
546 Steering System–Configuration  
547 Outboard to Steering Communication  
4-14
Trouble code and checking step

To display trouble codes (code number 300 and higher) for the SBW system, connect using the CAN-
Line harness.
The descriptions enclosed by < > are applicable to the twin, triple, and quad engine installations.
*1: Crankshaft position sensor
*2: See the Digital Electronic Control service manual.
—: Not applicable
Trou-
Item (Condi- See
ble Symptom Checking steps
tion) page
code
Measure the crankshaft posi-
5-35
tion sensor input voltage.
“Check Engine” is displayed.
Pulser coil *1 Check for wiring continuity be-
Engine does not restart.
13 (Irregular sig- tween the crankshaft position A-14
<Engine speeds do not syn-
nal) sensor and the engine ECM.
chronize>
Check the protrusions on the
7-78
pickup rotor for damage.
“Check Engine” is displayed. Measure the engine tempera-

5-37
Degraded acceleration perfor- ture sensor input voltage.
Engine tem-
mance. Measure the engine tempera-
perature sensor 5-37
15 Declining maximum engine ture sensor resistance.
(Out of specifi-
speed. Check for wiring continuity be-
cation)
<Engine speeds do not syn- tween the engine temperature A-14
chronize> sensor and the engine ECM.
“Check Engine” is displayed. Measure the knock sensor re-
5-39
High engine idle speed. sistance.
Knock Sensor 1
Reduce engine speed approx-
17 (Irregular sig- Check for wiring continuity be-
imately 300 r/min.
nal) tween the knock sensor and A-14
chronize> the engine ECM.
Check the battery capacity

10-7
and specific gravity.
5-10
Check the fuse.
A-16
Battery voltage and battery Check the battery cable and
Battery voltage alert are displayed. terminals for proper connec- 10-7
19 (Below speci- High engine idle speed. tion.
fied voltage) Engine does not restart (de- Measure the lighting coil resis-
pends on battery condition). 5-34
tance.
Measure the rectifier/regula-
5-34
tor output voltage.
Check the rectifier/regulator
5-34
for continuity.
4-15
Trou-
Item (Condi- See
tion) page
code
Measure the knock sensor re-
“Check Engine” is displayed. 5-39
Knock Sensor 2 sistance.
20 (Irregular sig- Check for wiring continuity be-
nal) tween the knock sensor and A-14
chronize>
the engine ECM.
Check the intake air tempera-
5-36
ture using the YDIS.
Measure the intake air tem-
5-36
Air tempera- “Check Engine” is displayed. perature sensor input voltage.
ture sensor High engine idle speed. Measure the intake air tem-
23 5-36
(Out of specifi- <Engine speeds do not syn- perature sensor resistance.
cation) chronize>
Check for wiring continuity be-
tween the intake air tempera-
A-14
ture sensor and the engine
ECM.
Measure the cam position
5-23
“Check Engine” is displayed. sensor input voltage.
High engine idle speed. Measure the cam position
Degraded acceleration perfor- 5-23
Cam position sensor output voltage.
mance.
24 sensor (EX) (Ir- Check for wiring continuity be-
Declining maximum engine
regular signal) tween the cam position sensor A-10
speed.
<Engine speeds do not syn- and the engine ECM.
chronize> Check the brim of the cam-
7-50
shaft.
Check the fuel filter for water. —
Measure the water detection
5-28
switch input voltage.
Water in fuel fil- “Water in fuel” is displayed.
27 ter (Water in Alert buzzer comes on while Check the water detection
5-28
fuel filter) the shift is in the N position. switch for continuity.
tween the water detection A-12
switch and the engine ECM.
Measure the intake air pres-
sure sensor input voltage.
Air pressure Measure the intake air pres-
Declining maximum engine 5-36
29 sensor (Out of sure sensor output voltage.
speed.
specification) Check for wiring continuity be-
chronize> tween the intake air pressure A-14
sensor and the engine ECM.
4-16
Trou-
Item (Condi- See
tion) page
code
Check the oil pressure using
7-1
the YDIS.
Measure the oil pressure sen-
Oil pressure sor input voltage.
39 sensor (Out of Measure the oil pressure sen-
Declining maximum engine 5-26
specification) sor output voltage.
speed.
tween the oil pressure sensor A-10
and the engine ECM.
Check the thermo sensor us-
5-38
ing the YDIS.
“Check Engine” is displayed. Measure the thermo sensor
5-38
Thermo sensor Set to 50 °C (122 °F) when input voltage.
42 (P) (Out of running. Measure the thermo sensor
specification) <Engine speeds do not syn- 5-38
resistance.
chronize>
tween the thermo sensor and A-14
the engine ECM.
Check the thermo sensor us-
5-38
ing the YDIS.
“Check Engine” is displayed. Measure the thermo sensor
5-38
Thermo sensor Set to 50 °C (122 °F) when input voltage.
43 (S) (Out of running. Measure the thermo sensor
specification) <Engine speeds do not syn- 5-38
resistance.
chronize>
tween the thermo sensor and A-14
the engine ECM.
Check for wiring short be-
tween the engine start switch A-16
“Check Engine” is displayed. and the engine ECM.
Main power Main relay is not turned off Check for wiring short be-
56 supply (Irregu- even if the engine start switch tween the electrical manage-
A-16
lar signal) is OFF. ment box and the engine
Battery discharges. ECM.
Replace the electrical man-
7-22
agement box.
4-17
Trou-
Item (Condi- See
tion) page
code
Check the fuse. 5-10
Check for wiring open or short
between the engine start A-16
switch and the engine ECM.
tween the engine start switch
A-16
and the electrical manage-
Starter magnet “Check Engine” is displayed. ment box.
power supply Engine does not crank.
57 Check for wiring open or short
(Irregular sig- Starter motor cannot be
nal) turned on or off. between the electrical man- A-16
agement box and the ground.
Check for wiring open or short
between the electrical man-
A-16
agement box and the engine
ECM.
Replace the electrical man-
7-22
agement box.
5-23
Cam position Degraded acceleration perfor- 5-23
sensor output voltage.
sensor (S bank mance.
71 Check for wiring continuity be-
IN) (Irregular Declining maximum engine
signal) speed. tween the cam position sensor A-10
7-50
shaft.
5-23
Cam position Degraded acceleration perfor- 5-23
sensor output voltage.
sensor (P bank mance.
72 Check for wiring continuity be-
IN) (Irregular Declining maximum engine
signal) speed. tween the cam position sensor A-10
7-50
shaft.
4-18
Trou-
Item (Condi- See
tion) page
code
Check the OCV operation us-
5-25
ing the YDIS.
Measure the OCV input volt-
age.
Degraded acceleration perfor- Measure the OCV resistance. 5-25
OCV (S bank)
mance. Check for wiring continuity be-
73 (Irregular load
Declining maximum engine tween the OCV and the main A-10
current value)
speed. relay.
chronize>
tween the OCV and the en- A-10
gine ECM.
Check the OCV filter. 7-59
Check the OCV operation us-
5-25
ing the YDIS.
Measure the OCV input volt-
age.
Degraded acceleration perfor- Measure the OCV resistance. 5-25
OCV (P bank)
mance. Check for wiring continuity be-
74 (Irregular load
Declining maximum engine tween the OCV and the main A-10
current value)
speed. relay.
chronize>
tween the OCV and the en- A-10
gine ECM.
Check the OCV filter. 7-59
Check the PTT sensor using
5-50
the YDIS.
Measure the PTT sensor input
5-50
PTT sensor voltage.
83 (Out of specifi- “Check Engine” is displayed. Measure the PTT sensor out-
cation) 5-50
put voltage.
tween the PTT sensor and the A-18
engine ECM.
“Check Engine” is displayed. Check that Y-COP is connect-

3-30
Immobilizer Declining maximum engine ed properly.
86 (Communica- speed. Measure the remote control
—
tion error) <Engine speeds do not syn- receiver input voltage.
chronize> Check the Y-COP circuit. —
4-19
Trou-
Item (Condi- See
tion) page
code
ETV (Engine
ECM internal
112 Throttle does not operate. Replace the engine ECM. 7-37
circuit malfunc-
Engine speed is set at approx-
tion)
imately 1500 r/min.
Measure the TPS output volt-
age using the YDIS.
ETV (Throttle High engine idle speed.
113 valve malfunc- Throttle does not operate. Check the ETV circuit. A-10
tion) Engine speed is set at approx- Check the fuse. 5-10
imately 1500 r/min.
Check the ETV motor relay. 5-21
ETV (Engine
ECM internal
114 Engine will not start. Replace the engine ECM. 7-37
circuit malfunc-
tion)
“Check Engine” is displayed. Check the ETV circuit. A-10
115
valve malfunc- Throttle does not operate.
116
tion) Engine speed is set at approx- Check the ETV. 6-29
imately 1500 r/min.
ETV (Throttle High engine idle speed. Check the fuse. 5-10
117 valve malfunc- Throttle does not operate.
Check the ETV motor relay. 5-21
tion) Engine speed is set at approx-
imately 1500 r/min. Check the ETV. 6-29
imately 1500 r/min.
High engine idle speed. Check the fuse. 5-10
ETV (Out of
123 Throttle does not operate.
specification)
Engine speed is set at approx- Check the ETV motor relay. 5-21
imately 1500 r/min.
“Check Engine” is displayed. Measure the TPS output volt-
5-21
High engine idle speed. age using the YDIS.
124 TPS (Out of Degraded acceleration perfor-
125 specification) mance.
Declining maximum engine Check the ETV circuit. A-10
speed.
4-20
Trou-
Item (Condi- See
tion) page
code

5-21
High engine idle speed. age using the YDIS.
TPS (Out of
126 Throttle does not operate. Measure the TPS input volt-
specification) 5-21
Engine speed is set at approx- age.
imately 1500 r/min. Check the ETV circuit. A-10
5-21
Degraded acceleration perfor- age using the YDIS.
127 TPS (Out of
mance.
128 specification)
Declining maximum engine Check the ETV circuit. A-10
speed.
ETV (Engine
ECM internal
circuit malfunc-
tion)
imately 1500 r/min.
imately 1500 r/min.
ETV (Throttle “Check Engine” is displayed. Check the throttle valve opera-
6-29
142 valve malfunc- Declining maximum engine tion.
tion) speed. Replace the ETV. 6-28
ETV system
(Engine ECM
internal circuit
malfunction)
imately 1500 r/min.
Check the battery cable and
terminals for proper connec- 10-7
tion.
“Check Engine” is displayed. Check the fuse. 5-10
Measure the lighting coil resis-
144 valve malfunc- Throttle does not operate. 5-34
tance.
imately 1500 r/min. Measure the rectifier/regula-
5-34
tor output voltage.
Check the rectifier/regulator
5-34
for continuity.
4-21
Trou-
Item (Condi- See
tion) page
code
Check that other trouble
ETV (Throttle codes (112–144) are detect- 4-11
145 valve malfunc- High engine idle speed. ed.
tion) Check the throttle valve opera-
6-29
tion.
Measure the SPS input volt-
5-22
“Check Engine” is displayed. age.
Engine operates normally un- Measure the SPS output volt-
less it is stopped. 5-22
age.
146 SPS (Out of Engine does not restart (No
147 specification) cranking). Check for wiring continuity be-
Alert indicator is ON. tween the SPS and the engine A-10
<Engine speeds do not syn- ECM.
chronize> Measure the shift actuator rod
5-23
stroke.
“Check Engine” is displayed. Measure the SPS input volt-
5-22
Normal operation is possible. age.
Shift actuator does not oper- Measure the SPS output volt-
ate. 5-22
age.
SPS (Center (When either one of the trou-
148 outboard motor ble codes 146 and 147, and
tween the SPS and the engine A-10
149 [Out of specifi- either one of the trouble codes
ECM.
cation]) 148 and 149 took place simul-
taneously)
Alert indicator is ON. Measure the shift actuator rod
5-23
<Engine speeds do not syn- stroke.
chronize>
“Check Engine” is displayed. Measure the SPS input volt-
5-22
High engine idle speed. age.
Engine does not restart (In a Measure the SPS output volt-
shift-in position). 5-22
SPS (Out of age.
150 Shift actuator does not oper-
specification)
ate. Check for wiring continuity be-
Alert indicator is ON. tween the SPS and the engine A-10
<Engine speeds do not syn- ECM.
chronize>
4-22
Trou-
Item (Condi- See
tion) page
code
5-10
Check the fuse.
A-10
Measure the shift actuator mo-
5-23
“Check Engine” is displayed. tor resistance.
High engine idle speed. Check for wiring continuity be-
Engine does not restart (In a tween the shift actuator and A-10
SPS (Out of shift-in position). the engine ECM.
153
specification) Throttle does not operate.
Check that the gear shift oper-
Alert indicator is ON. 10-8
ates properly.
chronize> Measure the shift actuator rod
5-23
stroke.
Check the shift mechanism. 9-12
Check the lower unit. 8-5
5-10
Check the fuse.
A-14
Measure the shift actuator re-
5-22
lay input voltage.
5-23
tor resistance.
“Check Engine” is displayed. tween the shift actuator and A-14
Engine does not restart. the engine ECM.
SPS (Out of
154 Shift does not disengage from Check the shift actuator relay. 5-23
specification)
the shift-in position. Check for wiring continuity be-
Alert indicator is ON. tween the shift actuator relay A-14
and the engine ECM.
Measure the shift actuator rod
5-23
stroke.
8-11
8-52
4-23
Trou-
Item (Condi- See
tion) page
code
5-10
Check the fuse.
A-14
Measure the shift actuator re-
5-23
lay input voltage.
5-23
tor resistance.
Engine does not restart (In a Check for wiring continuity be-
shift-in position). tween the shift actuator and A-14
SPS (Out of the engine ECM.
155 Gear shift does not operate.
specification)
Alert indicator is ON. Check the shift actuator relay. 5-23
<Engine speeds do not syn- Check for wiring continuity be-
chronize> tween the shift actuator relay A-14
and the engine ECM.
Measure the shift actuator rod
5-23
stroke.
Check the extension wire har-
ness proper connection and —
“Check Engine” is displayed. damage.
Alert indicator is ON. Check for wiring continuity be-
<Engine speeds do not syn- tween the engine ECM and A-14
chronize> the engine main harness.
Check the Digital Electronic
*2
Control circuit.
Engine does not restart. Check that the extension wire
Engine–R/C
Fully closed throttle. harness is connected proper-
156 communication —
Shift actuator rod returns to ly and that there is no dam-
157 (Communica-
the N position. age.
tion error)
CL7 gauge does not operate. Check for wiring continuity be-
Trouble codes 156 and 157 tween the engine ECM and A-14
detected simultaneously. engine main harness.
Alert indicator is ON.
chronize>
Unable to switch the active Check the Digital Electronic
*2
station in the case of dual sta- Control circuit.
tion arrangement (trouble
code 186).
4-24
Trou-
Item (Condi- See
tion) page
code
Measure the LPS output volt-
“Check Engine” is displayed. age using the YDIS.
<Engine speeds do not syn- Check for wiring continuity be-
chronize> tween the LPS and the Digital
Electronic Control ECM.
Locked at engine idle speed. Measure the LPS output volt-
160 Remote control Shift actuator rod returns to age using the YDIS.
161 system (Main the N position. *2
162 station [LPS Ir- Alert indicator is ON.
163 regular signal]) <Engine speeds do not syn-
chronize> Check for wiring continuity be-
When either one of the trouble tween the LPS and the Digital
codes 160 and 161, and either Electronic Control ECM.
one of the trouble codes 162
and 163 took place simultane-
ously.
Remote control
system (Main “Check Engine” is displayed. Replace the Digital Electronic
station LPS Ir- Locked at engine idle speed. Control ECM.
regular signal Shift actuator rod returns to (When replacing the Digital
164 [Digital Elec- the N position. Electronic Control ECM with a *2
tronic Control Shift actuator can be operated new one, resetting of Digital
ECM internal manually. Electronic Control ECM is
circuit malfunc- Alert indicator is ON. necessary)
tion])
“Check Engine” is displayed. Measure the LPS output volt-
Locked at engine idle speed. age using the YDIS.
Shift actuator rod returns to
Remote control
the N position.
system (Main
165 Alert indicator is ON. Check for wiring continuity be- *2
station [LPS Ir-
<Difference in engine idle tween the LPS and the Digital
regular signal])
speeds> Electronic Control ECM.
chronize>
4-25
Trou-
Item (Condi- See
tion) page
code
Locked at engine idle speed. Check for wiring continuity be-
Alert indicator is ON. tween the LPS and the Digital
Remote control Electronic Control ECM.
166 system (Main Locked at engine idle speed. Measure the LPS output volt-
167 station, center Shift actuator rod returns to age using the YDIS. *2
168 outboard motor the N position.
169 [LPS Irregular Alert indicator is ON.
signal]) When either one of the trouble Check for wiring continuity be-
codes 166 and 167, and either tween the LPS and the Digital
one of the trouble codes 168 Electronic Control ECM.
ously.
Remote control age using the YDIS.
Locked at engine idle speed.
system (Main
170 Shift actuator rod returns to Check for wiring continuity be- *2
station [LPS Ir-
the N position. tween the LPS and the Digital
regular signal])
Alert indicator is ON. Electronic Control ECM.
Electronic Control ECM.
171 Remote control Locked at engine idle speed. Measure the LPS output volt-
172 system (Sub Shift actuator rod returns to age using the YDIS. *2
173 station [LPS Ir- the N position.
174 regular signal]) Alert indicator is ON.
When either one of the trouble Check for wiring continuity be-
ously.
Remote control
system (LPS Ir- Replace the Digital Electronic
regular signal “Check Engine” is displayed. Control ECM.
[Sub station Locked at engine idle speed. (When replacing the Digital
175 Digital Elec- Shift actuator rod returns to Electronic Control ECM with a *2
tronic Control the N position. new one, resetting of Digital
ECM internal Alert indicator is ON. Electronic Control ECM is
circuit malfunc- necessary.)
tion])
4-26
Trou-
Item (Condi- See
tion) page
code
Remote control Measure the LPS output volt-
system (Sub age using the YDIS.
Locked at engine idle speed.
station, center
176 Shift actuator rod returns to Check for wiring continuity be- *2
outboard motor
the N position. tween the LPS and the Digital
[LPS Irregular
signal])
Remote control Electronic Control ECM.
177 system (Sub Locked at engine idle speed. Measure the LPS output volt-
178 station, center Shift actuator rod returns to age using the YDIS. *2
179 outboard motor the N position.
180 [LPS Irregular Alert indicator is ON.
signal]) When either one of the trouble Check for wiring continuity be-
ously.
Remote control Locked at engine idle speed. age using the YDIS.
system (Sub Throttle does not operate.
181 Check for wiring continuity be- *2
station [LPS Ir- Shift actuator rod returns to
regular signal]) the N position. tween the LPS and the Digital
Remote control Replace the Digital Electronic

system (LPS Ir- Control ECM of the main sta-
regular signal “Check Engine” is displayed. tion.
[Digital Elec- Station selection is impossi- (When replacing the Digital
183 *2
tronic Control ble. Electronic Control ECM with a
ECM internal Alert indicator is ON. new one, resetting of Digital
circuit malfunc- Electronic Control ECM is
tion]) necessary.)
Remote control Replace the Digital Electronic
system (LPS Ir- Control ECM of the main sta-
regular signal “Check Engine” is displayed. tion.
[Digital Elec- Engine selection is impossi- (When replacing the Digital
184 *2
tronic Control ble. Electronic Control ECM with a
ECM internal Alert indicator is ON. new one, resetting of Digital
circuit malfunc- Electronic Control ECM is
tion]) necessary.)
4-27
Trou-
Item (Condi- See
tion) page
code
Sub station Digital Electronic Turn off the engine start switch
—
Control does not operate. once, and turn it on again.
Unable to change to the sub
Remote control
station Digital Electronic Con-
system (Main
186 trol Locked at engine idle Check the extension wire har-
station [LPS Ir-
speed. ness for proper connection —
regular signal])
Shift actuator rod returns to and damage.
the N position.
Remote control
Replace the Digital Electronic
system (LPS Ir-
Control ECM.
regular signal
“Check Engine” is displayed. (When replacing the Digital
[Digital Elec-
187 Engine does not restart. Electronic Control ECM with a *2
tronic Control
Alert indicator is ON. new one, resetting of Digital
ECM internal
Electronic Control ECM is
circuit malfunc-
necessary.)
tion])
PTT relay
190 Stop engine synchronization — —
(—)
control.
Check the wiring is connected
properly and that there is no A-12
PTT relay pow- “Check Engine” is displayed. damage.
191 er Stop engine synchronization 9-44
Check the PTT motor.
(—) control. 9-51
Check the power supply and
A-12
electrical management box.
Check the fuse of shift actua-
5-22
tor relay.
Shift actuator “Check Engine” is displayed.
192 power supply Stop engine synchronization
(—) control.
damage.
Check the shift actuator relay. 5-22
Check the fuse of high-pres-
5-31
sure fuel pump relay.
VST fuel pump “Check Engine” is displayed. Check the wiring is connected
193 power supply Engine speed is limited to properly and that there is no A-12
(—) 2000 r/min. damage.
Check the high-pressure fuel
5-31
pump relay.
4-28
Trou-
Item (Condi- See
tion) page
code
Check the water pressure
4-3
sensor using the YDIS.
Water pres-
“Check Engine” is displayed. Measure the water pressure
sure sensor 5-26
194 Stop engine synchronization sensor output voltage.
(Out of specifi-
control. Check the wiring is connected
cation)
damage.
Check the fuel pressure sen-
Fuel pressure sor (high-pressure fuel pump) 4-3
“Check Engine” is displayed. using the YDIS.
sensor
195 Engine speed is limited to
(Out of specifi- Check the wiring is connected
2000 r/min.
cation) properly and that there is no A-12
damage.
4-3
sor using the YDIS.
Fuel system
“Check Engine” is displayed. Check the wiring and fuel pipe
(Low-pressure —
196 Can not start 7 seconds after for damage or bends.
fuel pump mal-
engine stall. Check the operation of fuel
function)
pump in the YDIS “Stationary 5-29
test”.
Engine-Fuse- Check the wiring is connected
Box communi- “Check Engine” is displayed. properly and that there is no A-12
210 cation Stop engine synchronization damage.
(Communica- control. Check the input voltage to
tion error) 5-20
Check the fuse of injector driv-
er relay.
EDU power “Check Engine” is displayed.
213 supply 1 Engine speed is limited to A-12
properly and that there is no
(—) 2000 r/min.
damage.
Check the injector driver relay.
Check the fuse of injector driv-
er relay.
EDU power “Check Engine” is displayed.
214 supply 2 Engine speed is limited to A-12
(—) 2000 r/min.
damage.
Check the injector driver relay.
4-29
Trou-
Item (Condi- See
tion) page
code
DI fuel pressure sor (direct injection pump) 4-3
“Check Engine” is displayed. (PORT) using the YDIS.
sensor (P)
2000 r/min.
damage.
DI fuel pressure Check fuel pipe for damage or
—
(P) bends.
(DI fuel pres-
216 Engine speed is limited to Check the operation of the di-
sure drop P)
2000 r/min. rect injection pump (PORT) in 5-30
(Out of specifi-
cation) the YDIS “Stationary test”.
DI fuel pressure Check fuel pipe for be

—
(P) clogged.
(DI fuel pres-
217 Engine speed is limited to Check the operation of the in-
sure rise P)
2000 r/min. jector in the YDIS “Stationary 5-29
(Out of specifi-
cation) test”.

DI fuel pump damage.
(P) Check the injector driver input
218 Engine speed is limited to 5-28
(Irregular sig- voltage.
2000 r/min.
nal) Check the operation of the di-
rect injection pump (PORT) in 5-30
the YDIS “Stationary test”.
DI fuel pressure sor (direct injection pump) 4-3
“Check Engine” is displayed. (STBD) using the YDIS.
sensor (S)
2000 r/min.
damage.
DI fuel pressure Check fuel pipe for damage or
—
(S) bends.
(DI fuel pres-
220 Engine speed is limited to Check the operation of the di-
sure drop S)
2000 r/min. rect injection pump (STBD) in 5-30
(Out of specifi-
cation) the YDIS “Stationary test”.
4-30
Trou-
Item (Condi- See
tion) page
code
DI fuel pressure Check fuel pipe for be
—
(S) clogged.
(DI fuel pres-
221 Engine speed is limited to Check the operation of the in-
sure rise S)
2000 r/min. jector in the YDIS “Stationary 5-29
(Out of specifi-
cation) test”.

DI fuel pump damage.
(S) Check the injector driver input
222 Engine speed is limited to 5-28
(Irregular sig- voltage.
2000 r/min.
nal) Check the operation of the di-
rect injection pump (STBD) in 5-30
the YDIS “Stationary test”.
Steering sys-
tem Stop engine synchronization Check detail by using YDIS
223 —
(Irregular sig- control. CAN communication cable.
nal)
Steering sys-
tem–Outboard
Stop engine synchronization Check detail by using YDIS
224 (SCU) —
control. CAN communication cable.
(Irregular sig-
nal)
Steering sys-
tem–Helm
Stop engine synchronization Check detail by using YDIS
225 (HELM) —
control. CAN communication cable.
(Irregular sig-
nal)
241, Check the wiring is connected
242, properly and that there is no A-12
243, Injector#1–In- damage.
244, jector#8 Check the operation of the in-
Engine speed is limited to
245, (Irregular sig- jector in the YDIS “Stationary 5-29
2000 r/min.
246, nal) test”.
247,
248 Check the injector driver. 5-28
R/C to Steer- *2
ing Communi- A-18
damage.
321 cation —
(Communica- Check the input voltage of the
5-49
tion error) remote control system and
*2
steering actuator.
4-31
Trou-
Item (Condi- See
tion) page
code
Remote Control properly and that there is no *2
System damage.
322 —
(Communica-
tion error) Check the input voltage of the
*2
remote control system.
Remote Control properly and that there is no *2
System damage.
323 —
(Communica-
tion error) Check the input voltage of the
*2
remote control system.
System Volt- damage.
age Low SBW system does not oper-
512 Check the battery voltage us-
(Low battery ate. 4-3
ing the YDIS.
voltage)
Turn off the engine start switch
—
once and turn it on again.
age Low
513 Operation is slow. Check the battery voltage us-
(Weak battery 4-3
ing the YDIS.
voltage)
—
age High SBW system does not oper-
514 Check the battery voltage us-
(High battery ate. 4-3
ing the YDIS.
voltage)
—
Steering Sys-
tem–Position
515 Sensor — —
(Irregular sig-
nal)
Steering Sen-
sor(s) Calibra-
SBW system does not oper- Calibrate the steering system
516 tion 3-58
ate. by using CL7 gauge function.
(Calibration un-
set)
4-32
Trou-
Item (Condi- See
tion) page
code
Steering Sys-
tem–Position
517 Sensor — —
(Irregular sig-
nal)
Steering Sys-
tem–Position
Sensor
SBW system does not oper- Turn off the engine start switch
518 (Position sen- —
ate. once and turn it on again.
sor and Hall
sensor mal-
function)
Steering Sys-
tem–Position
519 Sensor —
(Sensor value
mismatch)
Steering Sys-
tem–Position
520 Sensor — —
(Hall sensor
malfunction)
Steering Sys-
tem–Position
521 Sensor —
(Calibration un-
set)
Steering Sys- Check the wiring is connected
tem–Actuator properly and that there is no A-18
522 Temp. — damage.
(Irregular sig- Check the battery voltage us-
nal) 4-3
ing the YDIS.
Steering Sys-
tem–Tempera-
523 ture Sensor — —
(Irregular sig-
nal)
Steering Sys-
tem–Tempera-
ture Sensor Turn off the engine start switch
524 Operation is slow. —
(Temperature once and turn it on again.
Sensor mal-
function)
4-33
Trou-
Item (Condi- See
tion) page
code
525 Current Operation is slow. damage.
(Out of specifi- Check the battery voltage us-
cation) 4-3
ing the YDIS.
Current SBW system does not oper- damage.
526
(Motor or bat- ate.
tery short cir- Turn off the engine start switch
—
cuit) once and turn it on again.
Steering Sys-
tem–Actuator
527 Current —
(Motor circuit
fault)
Steering Sys-
tem–Control
528 Unit —
(Motor circuit
fault)
Steering Sys-
tem–Control
529 Unit — —
(Motor circuit
fault)
Steering Sys-
tem–Current
Sensor Turn off the engine start switch
530 Operation is slow. —
(Current sen- once and turn it on again.
sor malfunc-
tion)
Steering Sys-
tem–Brake Cur-
531 rent —
(Brake malfunc-
tion)
Steering Sys-
tem–Actuator Turn off the engine start switch
532 — —
(Irregular sig- once and turn it on again.
nal)
4-34
Trou-
Item (Condi- See
tion) page
code
Steering Sys-
tem–Actuator SBW system does not oper- Turn off the engine start switch
533 —
(Irregular sig- ate. once and turn it on again.
nal)
R/C to Steer- properly and that there is no —
ing Communi- damage.
534 cation —
5-49
tion error) remote control system and
*2
steering actuator.
Steering to Check the wiring is connected
Steering Com- properly and that there is no A-18
535 munication — damage.
tion error) 5-49
steering actuator.
tem Communi- properly and that there is no A-18
SBW system does not oper- damage.
536 cation
ate.
tion error) 5-49
steering actuator.
properly and that there is no 3-30
Steering Sys- damage.
tem–Main Helm
537 — Check the input voltage of the
(Communica- 3-30
main helm components.
tion error)
—
Steering Sys- Locked at engine idle speed. damage.
tem–Main Helm Outboard motor cannot be
538 Check the input voltage of the
(Main helm steered by the power-operat- 3-30
main helm components.
malfunction) ed steering system.
—
Steering Sys- damage.
tem–2nd Helm
539 — Check the input voltage of the
(Communica- 3-30
2nd helm components.
tion error)
—
4-35
Trou-
Item (Condi- See
tion) page
code
Steering Sys- Locked at engine idle speed. damage.
tem–2nd Helm Outboard motor cannot be
540 Check the input voltage of the
(2nd helm mal- steered by the power-operat- 3-30
2nd helm components.
function) ed steering system.
—
Steering Sys-
tem–Control Check the wiring is connected
SBW system does not oper- A-18
541 Unit properly and that there is no
ate. 3-30
(Out of specifi- damage.
cation)
Incompatible
Hardware SBW system does not oper- Turn off the engine start switch
542 —
(Out of specifi- ate. once and turn it on again.
cation)
Steering Sys-
tem–Control
543 Unit — —
(Irregular sig-
nal)
Steering to R/C
Communication SBW system does not oper- Turn off the engine start switch
544 —
(Irregular sig- ate. once and turn it on again.
nal)
Incompatible damage.
Software SBW system does not oper- Turn off the engine start switch
545 —
(Out of specifi- ate. once and turn it on again.
cation) Check the situation of system
devices by using “BPS Scan” 4-3
function of YDIS.
Steering Sys-
tem–Configura-
SBW system does not oper- Reset the steering system by
546 tion 3-58
ate. using CL7 gauge function.
(Irregular sig-
nal)
Outboard to Check the wiring is connected
Steering Com- Steering friction adjustment properly and that there is no A-18
547 munication function depending on the en- damage.
(Communica- gine speed is disabled. Check the input voltage of the
tion error) A-18
steering actuator.
4-36
Troubleshooting procedure (trouble code not detected)

Troubleshooting consists of the following 5 items:
Symptom 1: Specific trouble conditions
Symptom 2: Trouble conditions of an area or individual part
Cause: Trouble causes of symptom 2
Checking steps: Method for checking
See page: Reference page
—: Not applicable
Troubleshooting the power unit

Symptom 1: Engine does not crank.
See
Symptom 2 Cause Checking steps
page
Gear shift not in the N posi-
Set the gear shift to the N position. 5-22
tion
Blown fuse Check the fuse. 5-10
Engine start switch mal- Check the engine start switch. 5-40
function Check the engine start/stop button. 5-40
Starter motor does LPS malfunction Check the LPS. —
not operate
Short, open, or loose con-
Check the wire harness for continui-
nection in starter motor cir- A-16
ty.
cuit
Disassemble and check the starter
Starter motor malfunction 5-44
motor.
Y-COP is locked Unlock Y-COP. —
Disassemble and check the power
Stuck piston or crankshaft 7-78
Starter motor oper- unit.
ates, but the engine Check the drive shaft bushing. 9-27
does not crank Stuck drive shaft Disassemble and check the lower 8-27
unit. 8-58
4-37
Symptom 1: Engine will not start (engine cranks).
See
page
Check the electrical management
Main relay malfunction 5-19
box.
Check for wire harness continuity
Short, open, or loose con- between the electrical management A-10
nection in the engine ECM box and the engine ECM.
Engine ECM does circuit Check for continuity between the en-
5-19
not operate gine ECM and ground.
Engine ECM ID and Digital
Reset the Digital Electronic Control
Electronic Control ECM ID —
system using the YDIS.
do not match.
Engine ECM malfunction Replace the engine ECM. 7-37
Extension wire harness Check the extension wire harness
5-48
malfunction for continuity.
Crankshaft position sensor Measure the crankshaft position
5-35
malfunction sensor input voltage.
Spark plug does not
Short, open, or loose con- Check the wire harness continuity
produce a spark (all
nection in the pulser coil between the crankshaft position A-12
cylinders)
circuit sensor and the engine ECM.
Y-COP is locked Unlock Y-COP. —
4-38
See
page
— Measure the fuel pressure. 6-2
Pinched or kinked fuel hose Check the fuel hose. 2-52
Fuel leakage Check the fuel line for leakage. 2-52
Check the fuel filter element for dirt
Clogged fuel filter element 6-4
and obstructions.
Check the fuel strainer for dirt and
Clogged fuel strainer 6-14
obstructions.
Direct injection pump mal-
Check the direct injection pump. 6-19
function
Check the high-pressure fuel pump
5-29
High-pressure fuel pump operation using the YDIS.
malfunction Measure the high-pressure fuel
5-29
pump resistance.
Check the high-pressure fuel pump
5-29
input voltage.
Check for wiring continuity between
Fuel not supplied (all the high-pressure fuel pump and the A-12
nection in high-pressure
cylinders) engine ECM.
fuel pump circuit
the high-pressure fuel pump and the A-12
Check the low-pressure fuel pump
5-29
input voltage.
the low-pressure fuel pump and the A-12
nection in low-pressure fuel
engine ECM.
pump circuit
the low-pressure fuel pump and the A-12
Check the low-pressure fuel pump
5-29
Low pressure fuel pump operation using the YDIS.
malfunction Check the low-pressure fuel pump
5-29
resistance.
Relief valve malfunction Check the relief valve. 6-14
Feed valve malfunction Check the feed valve. 6-15
Injector driver malfunction Check the injector driver circuit. 5-28
4-39
See
page
Check the valve timing. 7-43
Check the timing belt. 7-43
Improper valve timing Check the cam chain. 7-49
Check the chain tensioner. 7-50
Compression pres- Check the VCT for sticking. 7-48
sure is low
Check the valve for bends and stick-
7-62
ing.
Compression leakage Check the piston and piston rings for
7-78
damage.
Check the cylinder for scratches. 7-80
Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited engine
speed.
See
page
Spark plug malfunction Check the spark plug. 7-41
Measure the ignition coil input volt-
5-35
age.
the ignition coil and the engine A-14
nection in ignition coil cir-
Spark plug does not ECM.
cuit
produce a spark Check for wiring continuity between
(some cylinders) the ignition coil and the electrical A-14
management box.
Exchange the ignition coil with a dif-
Ignition coil malfunction ferent one, and then check the igni- 5-35
tion spark.
4-40
See
page
Fuel leakage Check for fuel leakage. 2-52
Check the fuel filter for dirt and ob-
Clogged fuel filter 6-4
structions.
Check the fuel strainer for dirt and
Clogged fuel strainer 6-14
obstructions.
Direct injection pump mal-
Check the direct injection pump. 6-19
function
Cam lobe (direct injection
Fuel pressure is low Check the cam shaft. 7-50
pump) wear
High-pressure fuel pump Measure the high-pressure fuel
5-29
malfunction pump resistance.
Fuel pressure sensor mal-
Check the fuel pressure sensor. 5-32
function
Check the fuel injector operation us-
5-29
Fuel injector malfunction ing the YDIS.
Measure the fuel injector resistance. 5-29
the fuel injector and the electrical A-12
Short, open, or loose con- management box.
nection in fuel injector cir-
Fuel not supplied cuit Check for wiring continuity between
(some cylinders) the fuel injector and the engine A-12
ECM.
Clogged fuel injector Replace the fuel injector. 6-18
Check the valve timing. 7-43
Check the timing belt. 7-43
Improper valve timing Check the cam chain. 7-49
Check the chain tensioner. 7-50
Compression pres- Check the VCT for sticking. 7-48
sure is low
Check the valve for bends and stick-
7-62
ing.
Compression leakage Check the piston and piston rings for
7-78
damage.
Check the cylinder for scratches. 7-80
4-41
Symptom 1: High engine idle speed.
See
page
Air leakage (ETV–cylinder Check the gaskets of the intake 6-25
—
head) manifolds, surge tank, and ETV. 6-28
Symptom 1: Engine stalls, unstable engine idle speed, or poor acceleration.
See
page
Check the OCV operation using the
5-25
Stuck OCV plunger YDIS.
Check the OCV plunger. 5-25
Clogged OCV filter Replace the OCV filter. 7-59
Improper intake cam
Clogged oil passage Check the oil passage. 2-41
timing
Stuck VCT Replace the VCT assembly. 7-46
Cam chain wear
Check the cam chain. 7-49
Cam chain stretch
Cam chain tension Check the cam chain tensioner. 7-50
4-42
Symptom 1: Limited engine speed (below 2000–3000 r/min).
See
page
Measure the thermo senor input
5-38
voltage.
Measure the thermo sensor resis-
Thermo sensor malfunction 5-38
tance.
Check for continuity between the
A-14
thermo sensor and the engine ECM.
Measure the engine temperature
5-37
sensor input voltage.
Check the engine temperature sen-
Engine temperature sen- 5-37
sor resistance.
sor malfunction
Check for continuity between the en-
gine temperature sensor and the en- 5-37
gine ECM.
Measure the water pressure sensor
5-26
Buzzer comes on. input voltage.
Overheat alert indica- Check the water pressure sensor
Water pressure sensor 5-26
tor comes on. out put voltage.
malfunction
Check for continuity between the
water pressure sensor and the en- 5-26
gine ECM.
Clogged cooling water inlet Check the cooling water inlet. 2-45
Check the impeller. 8-13
Check the impeller key. 8-13
Water pump malfunction Check the water pump housing. 8-13
Check the insert cartridge. 8-13
Check the outer plate cartridge. 8-13
Clogged cooling water pas-
Check the cooling water passage. 2-45
sage
Open PCV Check the PCV. 9-27
Thermostat malfunction Check the thermostat. 7-74
4-43
See
page
Check the engine oil level. 10-7
Check for engine oil leakage. 2-41
Insufficient engine oil Check the valve stem seals and
7-64
valves.
Check the piston rings. 7-80
Buzzer comes on. — Measure the oil pressure. 7-1
Oil pressure alert in-
dicator comes on. Check the oil pump. 7-71
Check the oil strainer. 9-27
Engine oil pressure de- Check the relief valve. 7-78
crease Check the oil passage (power unit
2-41
and oil pump).
Replace the oil filter. 10-17
Symptom 1: Discharged battery.
See
page
Check the battery capacity and spe-
10-7
Battery performance de- cific gravity.
crease Check the proper connection of bat-
—
tery cables and terminals.
Short, open, or loose con- Check the proper connection of the
A-16
nection in charging circuit charging circuit and for damage.
Low voltage indicator
Stator assembly malfunc-
activates on the Measure the lighting coil resistance. 5-34
tion
gauge
Rectifier/regulator malfunc- Check the rectifier/regulator for con-
5-34
tion tinuity.
Check the rectifier/regulator output
5-34
Electrical management box voltage.
malfunction Check the electrical management
A-16
box terminal and wire harness.
Symptom 1: Y-COP lock and unlock do not function.
See
page
Check the button cell battery volt-
—
Y-COP remote control age.
There is an answer- transmitter malfunction Replace with a spare remote control
—
back (beep) transmitter.
Check the Y-COP circuit. —
nection of the wire harness
4-44
Symptom 1: Y-COP lock and unlock function, but there is no answer-back (beep).
See
page
Buzzer malfunction Check the buzzer. —
— Short, open, or loose con- Measure the buzzer input voltage. —
nection of the wire harness Check the Y-COP circuit. —
Troubleshooting the PTT unit

Symptom 1: PTT unit does not operate.
See
page
5-10
Blown fuse Check the fuse.
A-18
PTT switch malfunction Check the PTT switch. 5-50
Check the electrical management
PTT relay malfunction 5-20
box.
Measure the PTT switch input volt-
5-50
PTT relay does not age.
operate Measure the electrical manage-
5-50
ment box input voltage.
nection of the wire harness Check for continuity between the
PTT switch and the electrical man- A-18
agement box.
A-18
the PTT switch and the ECM.
PTT motor malfunction Check the PTT motor. 9-50
Short, open, or loose con- Check for wiring continuity between
nection of the PTT motor the PTT motor and the electrical A-18
lead management box.
PTT motor does not
Electrical management box Check the electrical management
operate A-18
malfunction box.
Bent tilt ram or trim ram Check the tilt ram and trim ram. 9-60
Disassemble and check the PTT
Stuck tilt ram or trim ram 9-60
unit.
4-45
See
page
Open manual valve Check the manual valve. 9-46
Insufficient PTT fluid Add sufficient PTT fluid. 10-24
PTT fluid leakage Check for PTT fluid leakage. 10-24
Disassemble and check the PTT 9-55
unit. 9-60
PTT fluid pressure Check the filter for dirt and obstruc- 9-52
does not increase Clogged fluid passage tions. 9-57
Check the valves for damage. 9-57
Check the fluid passages for ob- 9-55
structions. 9-60
PTT motor malfunction Check the PTT motor. 9-50
Gear pump malfunction Check the gear pump assembly. 9-57
Symptom 1: PTT unit does not hold the outboard motor up.
See
page
Open manual valve Check the manual valve. 9-46
Insufficient PTT fluid Add sufficient PTT fluid. 10-24
Decrease in PTT fluid PTT fluid leakage Check for PTT fluid leakage. 10-24
pressure in lower Disassemble and check the PTT 9-55
chamber of PTT cyl- unit. 9-60
inders Clogged or open fluid pas-
Check the valves for damage. 9-57
sage
Check the fluid passages for ob- 9-55
structions. 9-60
Troubleshooting the lower unit

Symptom 1: Shift mechanism of the forward gear and reverse gear does not operate properly.
See
page
Check the shift actuator operation. 5-23
Check that the shift rod, shift actua- 9-13

Shift rod does not operate
tor bracket, and shift actuator are in- 8-15
properly
stalled properly. 8-16
Check the shift rod for wear. 8-13
—
Check the shift rod connection. 8-13
Check the dog clutch and related
8-21
Shift mechanism malfunc- parts.
tion (in lower unit) Check the forward gear, reverse 8-30
gear, and pinion for damage and 8-22
wear. 8-30
4-46
Electrical system
Electrical component and wire harness routing ............. 5-1

Port............................................................................................. 5-1
Starboard.................................................................................... 5-3
Rear............................................................................................ 5-5
Front ........................................................................................... 5-7
Top ............................................................................................. 5-8
Fuse holder (Electrical management box)................................ 5-10
Bottom cowling ......................................................................... 5-11
ECM circuit diagram ........................................................ 5-12
ECM coupler layout.......................................................... 5-15
Checking the electrical component................................ 5-18

Using the YDIS......................................................................... 5-18
Using the digital tester.............................................................. 5-18
5
Engine control unit and component............................... 5-19
Checking the main relay........................................................... 5-19
Checking the engine ECM circuit ............................................. 5-19
Checking the electrical management box ................................ 5-20
Checking the ETV and TPS ..................................................... 5-21
Checking the ETV motor relay ................................................. 5-21
Checking the SPS .................................................................... 5-22
Checking the shift actuator relay .............................................. 5-22
Checking the shift actuator....................................................... 5-23
Checking the cam position sensor ........................................... 5-23
Checking the OCV.................................................................... 5-25
Checking the oil pressure sensor ............................................. 5-26
Checking the water pressure sensor........................................ 5-26
Fuel control unit and component ................................... 5-28

Checking the injector driver circuit ........................................... 5-28
Checking the water detection switch ........................................ 5-28
Checking the fuel injector ......................................................... 5-29
Checking the low-pressure fuel pump and high-pressure fuel
pump ........................................................................................ 5-29
Checking the direct injection pump .......................................... 5-30
Checking the low-pressure fuel pump relay ............................. 5-31
Checking the high-pressure fuel pump relay............................ 5-31
Checking the fuel pressure sensor........................................... 5-32
Electrical system
Charging unit and component ........................................ 5-34

Checking the lighting coil (stator assembly) ............................. 5-34
Checking the rectifier/regulator ................................................ 5-34
Ignition unit and component ........................................... 5-35

Checking the ignition spark ...................................................... 5-35
Checking the ignition coil.......................................................... 5-35
Checking the crankshaft position sensor.................................. 5-35
Checking the intake air pressure/temperature sensor.............. 5-36
Checking the engine temperature sensor ................................ 5-37
Checking the thermo sensor .................................................... 5-38
Checking the knock sensor ...................................................... 5-39
Checking the engine shut-off switch......................................... 5-39
Starting unit and component .......................................... 5-40

Checking the starter relay ........................................................ 5-40
Checking the engine start switch and main switch................... 5-40
Checking the engine start/stop button...................................... 5-40
Checking Y-COP ...................................................................... 5-41
Starter motor .................................................................... 5-43

Removing the starter motor...................................................... 5-44
Checking the starter motor pinion ............................................ 5-44
Disassembling the starter motor............................................... 5-44
Checking the armature (starter motor) ..................................... 5-45
Checking the brush holder ....................................................... 5-45
Assembling the starter motor ................................................... 5-46
Installing the starter motor........................................................ 5-47
Outboard motor and Digital Electronic Control

connection ........................................................................ 5-48
Checking the extension wire harness....................................... 5-48
Checking the main harness...................................................... 5-48
Steering unit ..................................................................... 5-49

Checking the steering actuator................................................. 5-49
PTT system ....................................................................... 5-50

Checking the PTT switch (on bottom cowling) ......................... 5-50
Checking the PTT sensor......................................................... 5-50
Electrical component and wire harness routing

Port
1 2 3 A 4 B 5 6 C 7
Q
R
Q
10
P P
12
O O
11 S S
N
10
9 G F E 8 D
13 14 14 L M
14 K
15 15
15
O-O Q-Q S-S
H C
13
14
I J
N P-P R T
5-1
1. ETV (TPS)
2. Low-pressure fuel pump relay
3. YDIS coupler
4. ECM
5. Thermo sensor (PORT)
7. Cam position sensor (PORT IN)
8. OCV (PORT)
9. Fuel pressure sensor (high-pressure fuel
pump)
10. Injector driver
13. Lighting coil lead
14. Wire harness
15. Ground lead
A. Install the holder as shown, and then

fasten the lighting coil leads using the
holder.
B. Install the holder on the wire harness to
the bracket.
C. Fasten the coupler using the plastic tie at
the location shown. Cut off the excess
end of the plastic tie to 1 mm or less.
D. Position the slack in the PTT motor lead
and PTT sensor lead between the
holders.
E. Install the ground lead terminals so that
they contact the stoppers.
F. Make sure that the ground leads are not
pinched between the intake manifold and
the cylinder head. Route the ground
leads between the wire harness and the
bracket.
G. Install the ground lead terminal so that it
contacts the stopper.
H. Fasten the wire harness with the fuel
hose using the holder.
I. Route the short lighting coil lead to the
front of the other leads.
J. Position the buckle of the plastic tie
within the range shown.
K. Route the wire harness to the inside of
the gear oil change hose.
L. Install the holder on the wire harness to
the bracket.
M. Do not route the PTT sensor lead and
injector lead between the wire harness
and the fuel hose.
5-2
Starboard
1 B 2 C D
A Q
R
F E
R
G
S S
Z
T U U
Z
T
F
N
V V
F
W W
M
L
X
Y H
I
3
K 4 J
8 9 5 5 5 5
5 10 L
7 7 O 6 7
X
U-U V-V W-W S-S
5 11
B
5 J
12
5
C 7 13
P O
6
R-R Q T-T Y
5-3
1. Cam position sensor (STBD IN) J. Fasten the cooling water hose, OCV
2. Starter motor lead, oil pressure sensor lead, and
3. Oil pressure sensor dipstick guide at the location shown
4. OCV (STBD) using the plastic tie. Do not cut off the
5. Extension wire harness excess end of the plastic tie.
6. Starter motor lead K. Position the slack in the SCU positive
7. Crankshaft position sensor lead lead between the exhaust guide and the
8. Shift actuator lead holder.
9. Low-pressure fuel pump lead L. Install the ground lead terminal so that it
10. SCU negative lead contacts the stopper.
11. Dipstick M. Route the ground lead through the
12. Cooling water hose opening in the wire harness guide.
13. OCV lead N. Route the wire harness so that the split
where the ground lead branches off from
A. Fasten the SCU positive lead at the white the harness is facing to starboard.
tape using the holder at the top of the O. Route the starter motor lead to the
guide plate, and then fasten the leads outside of the extension wire harness.
using the other holder as shown. P. Position the buckle of the plastic tie
B. Fasten the coupler using the plastic tie at within the range shown.
the location shown. Cut off the excess
end of the plastic tie to 1 mm or less.
C. Install the lead terminals to the electrical
management box, and then fasten the
leads using the plastic tie. Point the end
of the plastic tie in the direction shown.
Do not cut off the excess end of the
plastic tie.
D. Install the ground lead terminals so that
they contact the stoppers. Make sure to
match the numbers on the ground leads
to the numbers on the bracket terminals.
E. Route the high-pressure fuel pump lead
under the low-pressure fuel pump
coupler.
F. Install the ground lead terminal, and then
connect the rectifier/regulator couplers.
G. Position the slack in the fuel pump lead
between the holder and the coupler.
H. Fit the protrusions on the wire harness
holders into the holes in the brackets,
and then install the ground lead terminal.
Make sure that the crimped sections of
the terminals that secure the rectifier/
regulator leads are facing away from
each other and that the terminals contact
the stopper.
I. Install the extension wire harness
terminal that is identified by white tape on
the lead to the center terminal.
5-4
Rear
11 1 A 2 12
10 13
H-H 4
K L 3 K-K
B
H H 13 12
4
K L 7
4
I I M M
11 L-L
10
15 4
11
5
5
I-I 15
4
4
10 M-M
15 J J
O
6 14
J-J
O N N 11
6
N-N
D
11
2 C E
P
G 16 F 16
O-O
7
7 7
8 8 8
9 9 9
17
P P P
5-5
1. Cam position sensor (PORT EX)

2. Knock sensor
4. Ignition coil
5. Fuel pressure sensor (direct injection
pump)
7. Knock sensor coupler
8. SCU coupler (3P)
9. SCU coupler (4P)
10. PTT lead
11. Wire harness
12. Cam position sensor lead
13. Blowby hose
14. SCU positive lead
15. Fuel injector sub-wire harness
16. SCU communication lead coupler (4P)
17. SCU communication lead coupler (6P)
A. Route the knock sensor lead so that it

does not protrude above the blowby
hose.
B. Fit the protrusion on the wire harness
holder into the hole in the guide plate.
C. Fasten the water pressure sensor lead
and cooling water pilot hose using the
holder.
D. Fasten the wire harness at the white tape
using the holder.
E. For single outboard motor.
F. For port outboard motor and starboard
outboard motor.
G. For center outboard motor.
5-6
Front
B B-B
B
4
3
1
1. High-pressure fuel pump (main)

4. High-pressure fuel pump (sub)
A. Do not route the intake air pressure/

temperature sensor lead between the 2
main portions of the wire harness.
5-7
Top
B 3 C
2
J
I I
1 M
A L L
M
K K
F
E
D
9 8 9
H 8
H G 14
13
10 10
I-I J-J K-K
12 8
11
10
H
L-L M-M
7 6 5
5-8

2. Lighting coil (stator assembly)
3. Thermo sensor (STBD)
4. Electrical management box
5. Bonder (black leads with white tape)
6. Bonder (orange leads)
7. Bonder (black leads)
8. Wire harness (to the main wire harness)
9. Cooling water hose
10. Wire harness (to the PTT switch lead)
11. Rectifier/regulator lead
12. Lighting coil lead
13. PTT ground lead
14. PTT lead
A. Fasten the wire harness at the white tape

using the holder.
B. Fit the protrusion on the wire harness
holder into the hole in the wire harness
guide, and then install the lead terminals
to the electrical management box.
C. Route the wire harness under the
D. Fit the protrusion on the wire harness
guide.
E. Position the slack in the wire harness
between these holders.
F. Position the slack in the lighting coil
leads between the rectifier/regulator and
the holder.
G. Fit the protrusion on the wire harness
guide.
H. Route the hose and leads in the order
shown.
5-9
Fuse holder (Electrical management box)
1 2 3 4 5 6
10 9 8
7 8 9
10 11 12
18
19
1 2 3 4 5 6 7
13 14 15 16 17
1. Fuse (15A) (fuel pump 2) 11. Fuse (30A) (engine ECU/ignition coil)
2. Fuse (15A) (fuel pump 1) 12. Fuse (10A) (fuel feed pump)
3. Fuse (30A) (fuel pumps) 13. Fuse (100A) (power STRG)
4. Fuse (10A) (RC-ECU) 14. Fuse (70A) (engine main 1)
5. Fuse (20A) (main switch/PTT switch) 15. Fuse (70A) (engine main 2)
6. Fuse (10A) (ETV) 16. Fuse (70A) (isolator 2)
7. Fuse (15A) (shift actuator) 17. Fuse (70A) (isolator 1)
8. Fuse (30A) (starter relay) 18. Fuse (100A, 70A, 70A) (spare)
9. Fuse (20A) (DI system 2) 19. Fuse (30A, 20A, 15A, 10A) (spare)
10. Fuse (20A) (DI system 1)
5-10
Bottom cowling
1
2
1. SPS
2. Shift actuator
3. PTT switch
5-11
ECM circuit diagram
ECM circuit diagram

, , a: Indicate a connection between the symbols.
The circled numbers in the illustration indicate the engine ECM terminal numbers.
<INPUT> <OUTPUT>
19. Injector driver relay

5V
98
1. Crankshaft position sensor 128 72
17. Ground
125
5V
21 35 21. Fuel injector #1
2. Cam position sensor (PORT EX) 74 34
22. Fuel injector #4
44
82 20. Injector 23. Fuel injector #7
(PORT IN) 43
driver
19 24. Fuel injector #6
(STBD IN)
81 20
14 25. Direct injection
P
5V pump (PORT)
100 22
5. Intake air pressure/
temperature sensor(pressure)
87
19. Injector driver relay
6. Fuel pressure sensor(direct

injection pump)(PORT)
56
7. Fuel pressure sensor(direct

injection pump)(STBD)
55
18. Engine
8. Fuel pressure sensor 54 ECM
(high-pressure fuel pump) 15
20. Injector 28. Fuel injector #3
9. Oil pressure sensor 122 24
driver
5V 10 29. Fuel injector #8
59 11
10. Water pressure sensor 120 13 30. Direct injection
P
pump (STBD)
12
11. PTT sensor 123
31. Ignition coil #1
12. Intake air pressure/
temperature sensor(temperature) 32. Ignition coil #2
77 38
13. Engine temperature 33. Ignition coil #3
sensor 37
68 34. Ignition coil #4
14. Thermo sensor 39
(PORT)
66 40
15. Thermo sensor
(STBD)
16. Water detection switch 36. Ignition coil #6

121 41
17. Ground
28
29
17. Ground
127
30
a
5-12
ECM circuit diagram
, , a: Indicate a connection between the symbols.

The circled numbers in the illustration indicate the engine ECM terminal numbers.
<INPUT> <OUTPUT> a
39. Knock sensor 58. High-pressure fuel

56. High-pressure
71 pump relay
fuel pump (main)
39. Knock sensor 93 P
80 57. High-pressure
5V fuel pump (sub)
101
91 P
40. SPS 1 111
73
17. Ground 59. Low-pressure fuel pump
116
P
5V
102 57
41. SPS 2 110 60. Low-pressure fuel
17. Ground pump relay
107 61. OCV (PORT)
5V 26
99 62. OCV (STBD)
42. TPS 1 109 17
43. TPS 2 108 27

17. Ground 63. PTT relay
126 36
44. PTT switch(UP)
104
45. PTT switch(DN)
112
46. Engine shut-off switch 49
79 18. Engine 48
ECM
105 47
114 46
48. Main 47. Digital
switch Electronic 62 103 64. ETV relay
Control ECM 53 97
49. Engine 106
start switch
88
50. Starter relay 89
M 65. ETV motor
9 90
51. Starter
M
motor
115
124
96
52. Main relay
63 66. Shift relay
95
2
45
1
18
8
∼ M 67. Shift actuator
6
53. Rectifier/regulator 58
4
3
54. Engine battery 60
55. House battery 131
68. YDIS
132
5-13
ECM circuit diagram
1. Crankshaft position sensor 45. PTT switch (DN)

2. Cam position sensor (PORT EX) 46. Engine shut-off switch
3. Cam position sensor (PORT IN) 47. Digital Electronic Control ECM
4. Cam position sensor (STBD IN) 48. Main switch
5. Intake air pressure/temperature sensor 49. Engine start switch
(pressure) 50. Starter relay
6. Fuel pressure sensor (direct injection 51. Starter motor
pump) (PORT) 52. Main relay
7. Fuel pressure sensor (direct injection 53. Rectifier/regulator
pump) (STBD) 54. Engine battery
8. Fuel pressure sensor (high-pressure fuel 55. House battery
pump) 56. High-pressure fuel pump (main)
9. Oil pressure sensor 57. High-pressure fuel pump (sub)
10. Water pressure sensor 58. High-pressure fuel pump relay
11. PTT sensor 59. Low-pressure fuel pump
12. Intake air pressure/temperature sensor 60. Low-pressure fuel pump relay
(temperature) 61. OCV (PORT)
13. Engine temperature sensor 62. OCV (STBD)
14. Thermo sensor (PORT) 63. PTT relay
15. Thermo sensor (STBD) 64. ETV relay
16. Water detection switch 65. ETV motor
17. Ground 66. Shift relay
18. Engine ECM 67. Shift actuator
19. Injector driver relay 68. YDIS
20. Injector driver
25. Direct injection pump (PORT)
30. Direct injection pump (STBD)
39. Knock sensor
40. SPS 1
41. SPS 2
42. TPS 1
43. TPS 2
44. PTT switch (UP)
5-14
ECM coupler layout
ECM coupler layout
44 43 42 41 40 39 38 37 36 88 87 86 85 84 83 82 81 80 132 131 130 129128127126125124

35 34 33 32 31 30 29 28 27 79 78 77 76 75 74 73 72 71 123 122 121 120119118117116115
26 25 24 23 22 21 20 19 18 70 69 68 67 66 65 64 63 62 114113112 111110109 108107106
17 16 15 14 13 12 11 10 9 61 60 59 58 57 56 55 54 53 105104103 102101100 99 98 97
8 7 6 5 4 3 2 1 52 51 50 49 48 47 46 45 96 95 94 93 92 91 90 89
No. Connecting part Color No. Connecting part Color

1 Shift power source Red/Blue Injector driver (direct
13 injection pump Red
2 Shift power source Red/Blue
[STBD])
3 Shift ground Black
Injector driver (direct
4 Shift ground Black 14 injection pump Red
5 — — [PORT])
6 Shift actuator – Green/Black Injector driver (fuel in-
15 White
7 — — jector #3)
8 Shift actuator + Green/Yellow Injector driver (fuel in-

16 Black
jector #2)
9 Starter relay Brown/White
17 OCV (STBD) Purple
Injector driver (fuel in-
10 Red 18 Main relay Yellow/Green
jector fail #2, #5)
Injector driver (fuel in- Injector driver (fuel in-
11 Green 19 Red
jector fail #3, #8) jector fail #1, #4)
Injector driver (direct Injector driver (fuel in-
20 Green
12 injection pump fail Green jector fail #6, #7)
[STBD]) 21 Sensor power source Orange
5-15
ECM coupler layout

Injector driver (direct Fuel pressure sensor
22 injection pump fail Green 55 (direct injection White
[PORT]) pump) (STBD)
23 — — Fuel pressure sensor
24 Fuel injector #8 Black 56 (direct injection White
pump) (PORT)
25 Fuel injector #5 White
Low-pressure fuel
26 OCV (PORT) Purple 57 Blue/Yellow
pump relay
27 PTT relay (UP) Sky blue
Power source man-
28 Ignition coil #6 Black/Red 58 White/Green
agement
29 Ignition coil #7 Black/Orange 59 Sensor power source Orange
30 Ignition coil #8 Black/White House battery power
60 Red
31 — — source
32 — — 61 — —
33 — — Digital Electronic
62 White
Control 2 (H)
34 Fuel injector #4 White
63 Shift relay Yellow/Green
35 Fuel injector #1 Black
64 — —
36 PTT relay (DN) Light green
65 — —
37 Ignition coil #2 Black/White
Thermo sensor
38 Ignition coil #1 Black/Orange 66 Black/Yellow
(PORT)
39 Ignition coil #3 Black/Yellow
Thermo sensor
40 Ignition coil #4 Black/Blue 67 Black/Yellow
(STBD)
41 Ignition coil #5 Black/Blue Engine temperature
68 Black/Yellow
42 — — sensor
43 Fuel injector #6 Black 69 — —
44 Fuel injector #7 White 70 — —
45 Unit ground Black 71 Knock sensor Green
46 Ground Black 72 Injector driver relay Yellow/Red
47 Ground Black High-pressure fuel
73 Yellow/Green
48 Ground Black pump relay
49 Ground Black Cam position sensor
74 White/Blue
(PORT EX)
50 — —
75 — —
51 — —
76 — —
52 — —
Intake air pressure/
Digital Electronic
53 Blue 77 temperature sensor Black/Yellow
Control 2 (L)
(temperature)
Fuel pressure sensor
78 — —
54 (high-pressure fuel White
pump) Engine shut-off
79 White
switch
5-16
ECM coupler layout

80 Knock sensor Green/White 111 SPS 1 Pink/Blue
Cam position sensor 112 PTT switch (DN) Light green
81 White/Black
(STBD IN) 113 — —
Cam position sensor Digital Electronic
82 White/Green 114 Blue
(PORT IN) Control 1 (L)
83 — — 115 ETV ground Black
84 — — 116 SPS 1 ground Black
85 — — 117 Sensor ground Black
86 — — 118 — —
Intake air pressure/ 119 — —
87 temperature sensor Yellow/Green
Water pressure sen-
(pressure) 120 Blue/Black
sor
Wake up pulse (Digi-
88 Yellow Water detection
tal Electronic Control) 121 Blue/White
switch
89 ETV motor (+) Green/Red
122 Oil pressure sensor Pink/Blue
90 ETV motor (-) Green/Black
123 PTT sensor Pink
High-pressure fuel
91 Blue/Red 124 ETV ground Black
pump (sub)
Crankshaft position
92 — — 125 Black
sensor ground
High-pressure fuel
93 Blue/Red 126 TPS ground Black
pump (main)
127 Sensor ground Black
94 — —
Crankshaft position
95 Battery power source Red/Yellow 128 White/Black
sensor
96 Battery power source Red/Yellow
129 — —
97 ETV power source Red/Green
130 — —
98 Sensor power source Orange
YDIS (communica-
99 TPS power source Orange 131 White/Black
tion)
100 Sensor power source Orange Green/Or-
132 YDIS (VPP)
101 SPS 1 power source Orange ange
102 SPS 2 power source Orange
103 ETV relay Yellow/Green
104 PTT switch (UP) Sky blue
Digital Electronic
105 White
Control 1 (H)
106 ETV power source Red/Green
107 SPS 2 ground Black
108 TPS 2 Pink/Blue
109 TPS 1 Pink
110 SPS 2 Pink
5-17
Checking the electrical component
Checking the electrical

component
Using the YDIS
When checking the ETV, TPS, SPS, OCV, ig-
nition spark, high-pressure fuel pump, fuel in-
jector, and related sensors, use the YDIS. 1 2
TIP:
• When deleting the diagnosis record in the
YDIS, make sure to check the time that the
trouble codes were detected. Digital circuit tester
• When checking the input voltage of a part, 90890-03243
the coupler or connector must be disconnect- Digital multimeter
ed. As a result, the engine ECM determines YU-34899-A
that the part is disconnected and a trouble Test lead
code is detected. Therefore, make sure to Terminal, male “1”
delete the diagnosis record after checking (commercially available)
the input voltage. Terminal, female “2”
• To connect and operate the YDIS, see the (commercially available)
YDIS (Ver. 2.33 or later) instruction manual.
• The software is available through YMAN
(Yamaha Marine Associate Network).
YDIS2 Hardware Kit

90890-06884
YDIS2 Hardware Kit
LIT-YDIS2-01-KT
Using the digital tester

The electrical technical data applies to the
measurements taken using the Yamaha rec-
ommended tester.
The resistance values shown are the values
taken before the engine is started. The actual
resistance may vary depending on the environ-
mental conditions and ambient temperature.
The input voltage changes depending on the
battery voltage. Check the battery and wire
harness if the input voltage is less than the
specified value. Check the components be-
tween the battery and the input voltage mea-
suring point if there is no problem with the
battery and wire harness.
If the tester probe cannot be inserted into the
coupler, prepare a test lead suitable for the
measurement.
5-18
Engine control unit and component
Engine control unit and

a b
component
Checking the main relay
The main relay cannot be removed for testing
or replaced as a single unit because it is a com-
ponent part of the electrical management box.
1. Check:
• Main relay
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the YDIS to display “Main relay”.
b. Check the wire harness for continuity.
b. Turn the engine start switch to ON, and
then check that “ON” is displayed for the
main relay on the YDIS screen.
c. Measure the input voltage between the

main fuse “a” and ground. b 46 47 48 49
Wire harness continuity

Terminal 46–Ground
Input voltage c. Measure the input voltage between the en-

12 V gine ECM coupler terminal 18 and ground.
Main fuse “a”–Ground
d. Turn the engine start switch to OFF.
e. Install the fuse cover. 18

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a
Checking the engine ECM circuit

1. Check:
• Engine ECM
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the engine ECM couplers “a” Input voltage
and “b”. 12 V
d. Turn the engine start switch to ON, and

then measure the input voltage between
the engine ECM coupler terminal 88 and
ground.
5-19
a b c
88
Input voltage c. Disconnect the electrical management box

12 V coupler “d”.
d
e. Turn the engine start switch to OFF.
f. Connect the engine ECM couplers.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the electrical management

box
1. Check:
• Electrical management box d. Check the wire harness for continuity.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the YDIS and check that trouble
codes for code number 190 and higher are
not displayed. 72 73
Trouble codes for code number 190 and 18 63
a 9 b
higher are displayed → See “Trouble code 1 2
and checking step” (4-15).

Trouble codes for code number 190 and
higher are not displayed → Check the en-
gine ECM and electrical management box
for continuity.
TIP:
To connect the YDIS, use the CAN-Line com- 106 7 6
97 103
munication cable. c 95 96 d 16 15 13 12 9
23 22 21 20 18
b. Disconnect the engine ECM couplers “a”,

“b”, and “c”.
5-20
c. Turn the engine start switch to ON, and
then measure the TPS output voltages
a Terminal 1–d Terminal 13
when the Digital Electric Control lever is at
the fully closed position.
a Terminal 18–d Terminal 21 TPS 1 output voltage at throttle
b Terminal 63–d Terminal 22 valve fully closed (reference data)
b Terminal 72–d Terminal 2 0.850 V
b Terminal 72–d Terminal 20 TPS 2 output voltage at throttle
b Terminal 73–d Terminal 16 valve fully closed (reference data)
c Terminal 95–d Terminal 18 2.840 V
c Terminal 96–d Terminal 9 TPS 1 output voltage at throttle
c Terminal 97–d Terminal 7 valve fully open (reference data)
c Terminal 103–d Terminal 23 4.340 V
c Terminal 106–d Terminal 15 TPS 2 output voltage at throttle
valve fully open (reference data)
e. Measure the input voltage at the engine 4.640 V
ECM.
See “Checking the engine ECM circuit” d. Turn the engine start switch to OFF.
(5-19).
e. Disconnect the ETV coupler “a”.
f. No problems were found in the preceding
step → Replace the electrical manage- f. Turn the engine start switch to ON, and
ment box. then measure the TPS input voltage at the
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ETV coupler.
Checking the ETV and TPS Or B

TPS 1 and TPS 2 are components of the ETV,
which cannot be disassembled.
Do not loosen the throttle stop screw nut or

turn the throttle stop screw.
a
Input voltage
5V
Orange (Or)–Black (B)
g. Turn the engine start switch to OFF.
h. Connect the ETV coupler.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1. Check:
• TPS 1 and TPS 2
Checking the ETV motor relay
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
The ETV motor relay cannot be removed for
a. Connect the YDIS to display “TPS 1” and testing or replaced as a single unit because it
“TPS 2”. is a component part of the electrical manage-
ment box.
b. Start the engine, warm it up for 5–10 min- 1. Check:
utes, and then stop it. • ETV relay
5-21
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the YDIS to display “ETV relay”. SPS output voltage
F 1.170 V
N 2.540 V
then check that “ON” is displayed for “ETV
relay” on the YDIS screen. R 3.780 V
c. Remove the fuse cover. c. Turn the engine start switch to OFF, and
then disconnect the SPS coupler “a”.
d. Measure the input voltage between the
ETV relay fuse “a” and ground. d. Turn the engine start switch to ON, and
then measure the input voltage at the SPS
a coupler.
B
Or
B
Input voltage a
12 V
ETV fuse “a”–Ground
f. Install the fuse cover. Input voltage

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5V
Checking the SPS A. SPS 1

1. Check: B. SPS 2
• SPS
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ e. Turn the engine start switch to OFF, and
a. Connect the YDIS to display “SPS”. then connect the SPS coupler.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Operate the Digital Electronic Control lever
to measure the output voltage at the F, N, Checking the shift actuator relay
and R positions. The shift actuator relay cannot be removed for
N testing or replaced as a single unit because it
F R is a component part of the electrical manage-
ment box.
1. Check:
• Shift actuator relay
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the YDIS to display “Shift actuator
relay”.

then check that “ON” is displayed for “Shift
actuator relay” on the YDIS screen.
5-22
c. Remove the fuse cover.
d. Measure the input voltage between the

shift fuse “a” and ground.
a
b
Motor resistance (reference data)

1.2 Ω
c. Connect the shift actuator coupler.

Input voltage
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
12 V
Shift fuse “a”–Ground Checking the cam position sensor
1. Check:
e. Turn the engine start switch to OFF. • Cam position sensor
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
f. Install the fuse cover. a. Disconnect the cam position sensor cou-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ plers “a”, “b”, and “c”.
Checking the shift actuator b. Turn the engine start switch to ON, and
1. Check: then measure the input voltage at the cam
• Shift actuator position sensor coupler.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Operate the Digital Electronic Control to PORT IN
check the shift actuator rod stroke “a” at
the positions F, N, and R. Or W/G B
a
STBD IN
b
Or W/B B
Shift actuator rod stroke “a”
F 82.0 mm (3.23 in)
N 60.0 mm (2.36 in)
R 37.0 mm (1.46 in)
b. Disconnect the shift actuator coupler “b”,

and then measure the shift actuator motor
resistance.
5-23
f. Connect the test leads to the cam position
PORT EX c
sensor “1” and cam position sensor cou-
pler.
Or W/L B
Make sure that the test leads do not contact

each other and cause a short circuit. Other-
wise, the fuse could blow when the engine
start switch is turned to ON.
Input voltage g. Connect the tester probes to the test

5V leads.
Orange (Or)–Black (B) W/B
White/Green (W/G)–Black (B) 1 W/G
(PORT IN) R/Y W/L
White/Black (W/B)–Black (B)
(STBD IN)
White/Blue (W/L)–Black (B) B
(PORT EX)
c. Turn the engine start switch to OFF.
d. Make 3 test leads.
3 h. Turn the engine start switch to ON, and

then measure the output voltage when
b moving a screwdriver close to the cam po-
a sition sensor “1”.
Out of specification → Replace.
1 TIP:
1 Using an analog circuit tester is recommended.
c
1
Test lead
Terminal, male “1”
9E212-10303
Terminal, female “2”
a b c
9E212-11303
Terminal, female “3”
(commercially available)
“a” = 100 mm (3.94 in)
“b” = 50 mm (1.97 in)
“c” = Cutout area
e. Remove the cam position sensors “1”.
5-24
Output voltage b STBD

R/Y
White/Black (W/B)–Black (B)
(STBD IN)
White/Green (W/G)–Black (B)
(PORT IN)
White/Blue (W/L)–Black (B)
(PORT EX)
Position Voltage
“a”, “c” More than 4.8
“b” Less than 1.0 Input voltage
12 V
i. Turn the engine start switch to OFF. Red/Yellow (R/Y)–Ground
j. Disconnect the test leads, and then install
d. Turn the engine start switch to OFF.
the cam position sensors.
k. Connect the cam position sensor couplers. e. Remove the OCVs.
f. Measure the OCV resistance.

l. Install new plastic ties.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the OCV

1. Check:
• OCV
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the operation of the OCV using the
YDIS “Stationary test” and check the oper-
ating sound.
b. Disconnect the OCV couplers “a” and “b”.

Resistance
c. Turn the engine start switch to ON, and 6.7–7.7 Ω
the OCV coupler and ground. g. Connect the battery leads to the terminals
and check the operation of the spool valve.
PORT a R/Y Does not operate → Replace the OCV.
h. Disconnect the battery leads.
5-25
i. Install the OCVs, and then connect the
Pressure pump “1”
OCV couplers.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Test harness (3 pins) “2”
Checking the oil pressure sensor 90890-06869
1. Check: Test harness (3 pins) “2”
• Oil pressure sensor YB-06869
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the oil pressure sensor coupler Output voltage at 392 kPa (3.92
“a”. kgf/cm², 56.8 psi)
2.5 V
Output voltage at 784 kPa (7.84
then measure the input voltage at the oil
kgf/cm², 113.7 psi)
pressure sensor coupler.
4.5 V
Pink/Blue (P/L)–Black (B)
B Or
e. Turn the engine start switch to OFF, and
then disconnect the special service tool
a and pressure pump.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the water pressure sensor

1. Check:
• Water pressure sensor
Input voltage ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
5V a. Disconnect the water pressure sensor
Orange (Or)–Black (B) coupler “a”.
c. Remove the oil pressure sensor, and then B Or

connect a pressure pump “1” and the spe- a
cial service tool “2”.
d. Apply positive pressure to the oil pressure

sensor slowly, and then measure the out-
put voltage at the specified pressures.
P/L
B
Or b. Turn the engine start switch to ON, and
G/W B G
then measure the input voltage at the wa-
ter pressure sensor coupler.
2
Input voltage
5V
c. Remove the water pressure sensor, and

1 then connect a pressure pump “1” and the
2 special service tool “2”.
5-26
d. Apply positive pressure to the water pres-
sure sensor slowly, and then measure the
output voltage at the specified pressures.
L /B
B
Or
G/W B G

90890-06869
YB-06869

kgf/cm², 56.8 psi) (reference data)
2.5 V
kgf/cm², 113.7 psi) (reference da-
ta)
4.5 V
Blue/Black (L/B)–Black (B)
e. Turn the engine start switch to OFF, and

then disconnect the special service tool
and pressure pump.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-27
Fuel control unit and component
Fuel control unit and component Input voltage

Checking the injector driver circuit 12 V
1. Remove: Terminal 1–Ground
• Intake manifold (PORT)
See “Intake manifold” (6-25). d. Turn the engine start switch to OFF.
2. Check: e. Connect the injector driver couplers.

• Injector driver ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the injector driver couplers “a” Checking the water detection switch
and “b”. 1. Check:
• Water detection switch
a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the water detection switch
coupler “a”.
b
a then measure the input voltage at the wa-
ter detection switch coupler.
b
a B L/W
b. Check the wire harness for continuity.
3
Input voltage
5V
Blue/White (L/W)–Black (B)
Terminal 3–Ground c. Turn the engine start switch to OFF, and
then remove the fuel filter assembly.
c. Turn the engine start switch to ON, and d. Check that the float “1” moves smoothly.
the injector driver coupler terminal 1 and e. Check the water detection switch for conti-
ground. nuity when the float “1” is in positions “A”
and “B”.
Out of specification → Replace the fuel
cup assembly.
1 Do not remove the clip and float.
5-28
A PORT STBD
1 a
a
B 4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
1 Resistance (reference data)

1.74–2.04 Ω
Fuel injector #1, #2 terminal 4–8
Water detection switch continuity
No continuity d. Connect the fuel injector sub-wire harness
Float position “A” couplers.
Continuity ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Float position “B”
Checking the low-pressure fuel pump
f. Install the fuel filter assembly. See “Fuel fil- and high-pressure fuel pump
ter assembly” (6-3). 1. Check:
• Low-pressure fuel pump
g. Connect the water detection switch cou- • High-pressure fuel pump
pler. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a. Check the operation of the low-pressure
fuel pump and high-pressure fuel pump
Checking the fuel injector using the YDIS “Stationary test” and check
1. Check: the operating sound.
• Fuel injector
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ b. Disconnect the high-pressure fuel pump
a. Check the operation of the fuel injector us- couplers “a” and “b”.
ing the YDIS “Stationary test” and check
the operating sound. c. Connect the tester probes to the terminals
of the high-pressure fuel pump couplers,
b. Disconnect the fuel injector sub-wire har- and then measure the input voltage.
ness couplers “a”.
c. Measure the fuel injector resistance.

Out of specification → Replace the fuel in-
jector.
5-29
B B
L/R Y/R L/R Y/R
a
b
A. Low-pressure fuel pump

B. High-pressure fuel pump
Low-pressure fuel pump

High-pressure fuel pump Resistance (reference data)
Input voltage 0.6 Ω
12 V High-pressure fuel pump
Yellow/Red (Y/R)–Blue/Red (L/R) Resistance (reference data)
0.3 Ω
d. Disconnect the low-pressure fuel pump
coupler “c”. f. Connect the low-pressure fuel pump cou-
pler and high-pressure fuel pump cou-
e. Measure the resistance of the fuel pump plers.
motors. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the direct injection pump
c 1. Check:
• Direct injection pump
A ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the operation of the direct injection
pump using the YDIS “Stationary test” and
check the operating sound.
b. Disconnect the direct injection pump cou-

plers “a” and “b”.
a b
5-30
c. Measure the resistance of the fuel pump e. Connect the positive battery lead to the
solenoid. terminal “b” and the negative battery lead
Out of specification → Replace the direct to the terminal “c”, and then check for con-
injection pump. tinuity between the terminals “d” and “e”.
If there is no continuity → Replace.
Do not reverse the battery leads.
a
b c

d e
Resistance (reference data)
0.45-0.55 Ω
d. Connect the direct injection pump cou- Terminal

plers. Battery lead
d e
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Connect
Disconnect
relay
1. Check: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Low-pressure fuel pump relay
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Checking the high-pressure fuel
a. Disconnect the low-pressure fuel pump re- pump relay
lay coupler “a”. The high-pressure fuel pump relay cannot be
removed for testing or replaced as a single unit
b. Turn the engine start switch to ON, and because it is a component part of the electrical
then measure the low-pressure fuel pump management box.
relay input voltage. 1. Check:
• High pressure fuel pump relay
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Y/R
a. Connect the YDIS to display “VST fuel
pump relay”.

then check that “ON” is displayed for “VST
fuel pump relay” on the YDIS screen.
a c. Remove the fuse cover.
Input voltage d. Measure the input voltage between the

12 V high-pressure fuel pump fuse “a” and
Yellow/Red (Y/R)–Ground ground.
c. Turn the engine start switch to off.
d. Remove the low-pressure fuel pump relay.
5-31
B
a
Or B
Input voltage C
12 V
High-pressure fuel pump fuse “a”– Or B
Ground
f. Install the fuse cover.

a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the fuel pressure sensor

Before checking the fuel pressure sensor, A. Fuel pressure sensor (direct injection
make sure that there are no other problems in pump [STBD])
the fuel system. B. Fuel pressure sensor (direct injection
1. Check: pump [PORT])
• Fuel pressure sensor (high-pressure fuel C. Fuel pressure sensor (high-pressure fuel
pump) pump)
• Fuel pressure sensor (direct injection
pump) c. Turn the engine start switch to OFF, and
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ then connect the fuel pressure sensor cou-
a. Stop the engine, and then disconnect the plers.
fuel pressure sensor couplers “a”.
Fuel pressure sensor (direct injec-
b. Turn the engine start switch to ON, and tion pump)
then measure the fuel pressure sensor in- Input voltage
put voltage. 5V
A
Fuel pressure sensor (high-pres-
a sure fuel pump)
Or B Input voltage
5V
5-32
d. Measure the fuel pressure.
See “Measuring the fuel pressure” (6-2).
Out of specification → Replace the fuel rail
assembly.
Fuel pressure at idle speed (high-
pressure fuel pump)
330-400 kPa (3.3-4.0 kgf/cm²,
47.9-58.0 psi)
Fuel pressure at idle speed (DI
pump)
8.00 Mpa (80.0 kgf/cm², 1160.0
psi)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-33
Charging unit and component
Charging unit and component Charging voltage

Checking the lighting coil (stator Engine battery More than 13.0 V
assembly)
House battery
1. Check: More than 14.0 V
(Accessary battery)
• Lighting coil
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the intake manifold (PORT).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
See “Intake manifold” (6-25).
2. Remove:
b. Disconnect the lighting coil couplers “a”, • Intake manifolds
“b” and “c”. See “Intake manifold” (6-25).
• Surge tank
c. Measure the lighting coil resistance at
See “ETV” (6-28).
each coupler.
3. Check:
a • Rectifier/regulator continuity
Out of specification → Replace the rectifi-
b d e f er/regulator.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the rectifier/regulator couplers.
b. Set the digital circuit tester to the diode

c
mode.
c. Check the rectifier/regulator for continuity.

Resistance (reference data) See “Rectifier/regulator continuity table”
0.0904–0.1356 Ω (A-20).
Terminal “d”–Terminal “e”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Terminal “d”–Terminal “f”
Terminal “e”–Terminal “f”
d. Connect the lighting coil couplers.
e. Install the intake manifold (PORT).

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the rectifier/regulator

1. Check:
• Rectifier/regulator (trigger leads)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the YDIS to display “Battery volt-
age” and “Accessary battery voltage”.
b. Start the engine, and measure the battery

charging voltages.
Engine battery changing voltage is out of
specification → Check the lighting coil and
rectifier/regulator continuity.
House battery (accessary battery)
charging voltage is low → Replace the rec-
tifier/regulator.
5-34
Ignition unit and component

Checking the ignition spark
1. Check:
• Ignition coil
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the ignition coils.
a
a
b. Connect the special service tool “1” to the
ignition coil.
TIP:
Repeat steps (b)–(d) for each ignition coil.
R/Y B
c. Check the ignition spark using the YDIS
“Stationary test”.
Do not touch any of the connections of the

special service tool. Input voltage
12 V
1 Red/Yellow (R/Y)–Black (B)
OK c. Turn the engine start switch to OFF.
d. Connect the ignition coil couplers.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the crankshaft position

0 5
sensor
1. Remove:
Ignition checker (Spark gap tes- • Intake manifold (STBD)
ter) “1”
90890-06754 2. Check:
Spark checker “1” • Crankshaft position sensor
YM-34487 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the crankshaft position sensor
coupler “a”.
d. Disconnect the special service tool.
e. Install the ignition coils.
then measure the input voltage at the
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
crankshaft position sensor coupler.
Checking the ignition coil
1. Check:
• Ignition coil B Or
a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ignition coil couplers “a”.

then measure the input voltage at the igni-
tion coil coupler.
5-35
Input voltage Input voltage

5V 5V
Orange (Or)–Black (B) Orange (Or)–Black (B)
c. Turn the engine start switch to OFF. f. Turn the engine start switch to OFF.
d. Connect the crankshaft position sensor g. Make 3 test leads.

coupler.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2
Checking the intake air pressure/
3
temperature sensor
1. Check: b
• Intake air pressure/temperature sensor
a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the ambient temperature.
1
b. Connect the YDIS to display “Intake air 1
temperature”.
c. Check that the difference between the am-

bient temperature and the displayed intake
air temperature is within ± 5 °C (± 9 °F). Test lead
Terminal, male “1”
TIP: 8100-1466
• Check the intake air pressure/temperature Terminal, female “2”
sensor when the engine is cold. 8100-2567
• When checking the intake air pressure/tem- Terminal, female “3”
perature sensor, remove the top cowling and (commercially available)
do not start the engine. “a” = 100 mm (3.94 in)
“b” = 50 mm (1.97 in)
d. Disconnect the intake air pressure/tem-
perature sensor coupler “a”.
Make sure that the test leads do not contact
e. Turn the engine start switch to ON, and
each other and cause a short circuit. Other-
then measure the input voltage at the in-
wise, the fuse could blow when the engine
take air pressure/temperature sensor cou-
start switch is turned to ON.
pler.
a h. Remove the intake air pressure/tempera-

ture sensor.
B Or See “ETV” (6-28).
i. Connect the special service tool “1” and

test leads “2” to the intake air pressure/
temperature sensor.
5-36
2 1 B B/Y
B/Y o. Measure the intake air pressure/tempera-

Or
B ture sensor resistance.
Y/G
Resistance at 0 °C (32 °F)
5.4-6.6 kΩ
0.28-0.38 kΩ
Black/Yellow (B/Y)–Black (B)
Vacuum/pressure pump gauge

p. Install the intake air pressure/temperature
set “1”
sensor and connect the coupler.
90890-06945
See “ETV” (6-28).
Pressure/vacuum tester “1”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
YB-35956-B
Checking the engine temperature
j. Turn the engine start switch to ON. sensor
1. Remove:
k. Apply negative pressure to the intake air
pressure/temperature sensor slowly, and
then measure the output voltage at the
specified pressure. 2. Check:
Output voltage at -20.0 kPa (-0.20 • Engine temperature sensor
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
kgf/cm², -2.9 psi) a. Disconnect the engine temperature sensor
0.79 V coupler “a”.
Output voltage at -46.7 kPa (-0.47
kgf/cm², -6.8 psi) b. Turn the engine start switch to ON, and
1.84 V then measure the input voltage at the en-
Yellow/Green (Y/G)–Black (B) gine temperature sensor coupler.
l. Turn the engine start switch to OFF. B B/Y

m. Disconnect the test leads and special ser-
vice tool. a
n. Place the intake air pressure/temperature

sensor in a container of water and heat the
water slowly.
5-37
Input voltage
then measure the input voltage at the ther-
5V
mo sensor coupler.
Black/Yellow (B/Y)–Black (B)
c. Turn the engine start switch to OFF. a

d. Remove the engine temperature sensor. B B/Y
e. Place the engine temperature sensor in a

container of water and heat the water
slowly.
f. Measure the engine temperature sensor

resistance. a
B B/Y
Input voltage
Resistance at 20 °C (68 °F) (refer- 5V
ence data) Black/Yellow (B/Y)–Black (B)
2.51–2.77 kΩ
Resistance at 100 °C (212 °F) c. Turn the engine start switch to OFF.
(reference data)
0.21–0.22 kΩ d. Remove the thermo sensor.
e. Place the thermo sensor in a container of

g. Install the engine temperature sensor and
water and heat the water slowly.
connect the coupler.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the thermo sensor

1. Remove:
• Shroud cover
• Terminal covers
See “Shroud cover and terminal cover”
(7-5).
2. Check:
• Thermo sensor f. Measure the thermo sensor resistance.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the thermo sensor couplers Resistance at 20 °C (68 °F)
“a”. 2.25–2.65 kΩ
0.31-0.33 kΩ
5-38
g. Install the thermo sensor and connect the Checking the engine shut-off switch
coupler. 1. Check:
See “Shroud cover and terminal cover” • Engine shut-off switch
(7-5). ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a. Disconnect the main switch coupler or en-
gine start switch coupler.
Checking the knock sensor
1. Check: b. Turn the engine start switch to ON, and
• Knock sensor then check the engine shut-off switch for
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ continuity. Replace if out of specification.
a. Disconnect the knock sensor couplers “a”
and “b”. A 2. ON B 2. ON
1. OFF 3. START 1. OFF
b b
a
a
a
A. Engine start switch

b B. Main switch
Switch posi- Terminal

b. Measure the knock sensor resistance. Re- tion a b
place if out of specification.
Clip removed
Clip installed
d. Connect the main switch coupler or engine

start switch coupler.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Resistance
504–616 kΩ
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-39
Starting unit and component

Checking the starter relay A B 2. ON
2. ON
The starter relay cannot be removed for testing 1. OFF 3. START 1. OFF
or replaced as a single unit because it is a com-
ponent part of the electrical management box.
1. Check:
• Starter relay b d b
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
d
a. Connect the YDIS to display “Starter re- a
a
lay”. e
c c
then check that “ON” is displayed for
“Starter relay” on the YDIS screen.
A. Engine start switch
c. Remove the fuse cover. B. Main switch
d. Measure the input voltage between the Terminal
Switch
starter fuse “a” and ground.
position a b c d e
a
OFF
ON
START
*1
*1. Engine start switch only
c. Connect the engine start switch coupler or

main switch coupler.
Input voltage ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
12 V Checking the engine start/stop button

Starter motor fuse “a”– Ground 1. Check:
• Engine start/stop button
e. Turn the engine start switch to OFF. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the engine start/stop button
f. Install the fuse cover. coupler.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Check the engine start/stop button for con-
Checking the engine start switch and tinuity at the engine start/stop button cou-
main switch pler.
1. Check:
A
• Engine start switch
• Main switch
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a
a. Disconnect the engine start switch coupler
or main switch coupler.
b
b. Check the engine start switch or main
switch for continuity at the engine start
switch coupler or main switch coupler.
5-40
B
G i j
c d
k l
e f
C c d
m
A. Single type (sub station)

B. Twin type (main station)
e f C. Twin type (sub station)
D. Triple type (main station)
D E. Triple type (sub station)
c d F. Quad type (main station)
G. All start/stop button
f
e Engine start/stop button continuity
g h Button pushed in:
Terminal a–Terminal b
E Terminal c–Terminal d
c
d Terminal e–Terminal f
Terminal g–Terminal h
f
Terminal l–Terminal i
Terminal l–Terminal j
h
Terminal l–Terminal k
e g
Terminal l–Terminal m
F
c. Connect the engine start/stop button cou-
c d
pler.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking Y-COP
1. Check:
e f
• Y-COP
c d
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the Y-COP coupler “a”, and
then measure the Y-COP input voltage.
e f
5-41
Input voltage
12 V
Red (R)–Black (B)
b. Connect the Y-COP coupler “a”.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-42
Starter motor
Starter motor
1
8
19 6
12
23 C 7
13
21 New
17 New 14
22
2
20 15 11
M
3 5
16
18 10
4 9
24

1 Screw set M6 × 25 mm 2 Pinion shaft M5 × 127
15 1
Magnet switch assem- mm
2 1
bly 16 Planetary gear 3
Shim for pin- 17 O-ring 1
3 Shim 1 ion gap ad- 18 Screw set M5 × 11 mm 1
justment 19 Armature 1
4 Bolt M6 × 150 mm 2 20 Stator 1
5 Lever assembly 1 21 O-ring 1
6 Pinion stopper set 1 22 Bracket 1
7 Pinion set 1 23 Brush holder 1
8 Cover assembly 1 24 Nut 1
9 Center bracket 1
Ball 6.33 mm (0.25 in)
10 1
(reference data)
Starting motor gear
11 1
assembly
12 Stopper set 1
13 Clutch assembly 1
14 Bracket M4 × 16 mm 1
5-43
Starter motor
Removing the starter motor

Bolt “2”
M5 × 35 mm
Before removing the starter motor, make Nut “3”
sure to disconnect the negative battery ter- M5
minal. Washer “4”
Inside diameter = 6.5 mm (0.24 in)
Outside diameter = 16.0 mm (0.63 in)
Checking the starter motor pinion
1. Check: b. Place a pipe “1” on the pinion stopper “2”.
• Teeth of the pinion Tap the pipe “1” using a plastic hammer to
Crack/wear → Replace the pinion. push down the pinion stopper “2”, and then
• Turn the pinion counterclockwise to check remove the clip “3”.
that it operates smoothly and turn it clock-
wise to check that it locks in place.
1
Not smooth → Replace the pinion. a
1 2
Disassembling the starter motor
1. Remove: b
• Magnet switch assembly 3
2
TIP:
Some starter motors do not have a shim.
Pipe “1”
2. Remove: (commercially available)
• Pinion “a” = 22.0 mm (0.87 in)
• Lever “b” = 50.0 mm (1.97 in)
• Starting motor gear assembly
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. Fix the lever “1” in the pulled-out position
using the bolt “2”. 3. Remove:
• Clutch assembly
• Bracket
Be careful not to break the lever. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the cap “1”.
2 b. Place a pipe “2” on the pinion shaft stopper
1 “3”. Tap the pipe “2” using a plastic ham-
3 mer to push down the pinion shaft stopper
“3”, and then remove the clip “4”.
4 b
2 2
a
1
4 3
5-44
Starter motor
b. Check the armature for continuity.
Pipe “2”
“a” = 12.0 mm (0.47 in)
“b” = 17.0 mm (0.67 in)
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ d
b c
4. Remove:
• Bracket
• Armature
• Brush holder
Armature for continuity
Do not scratch or damage the brushes “a” “b” “c” “d”

when removing the armature.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the armature (starter motor)
Checking the brush holder
1. Check the commutator for dirt. Clean with
1. Check:
600-grit sandpaper and compressed air if
• Brush holder continuity
necessary.
a
d
b
2. Check:
• Armature
Out of specification → Replace. “a” “b” “c” “d”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the commutator diameter “a”.
2. Measure:
• Brush length “a”
Standard commutator diameter

32.0 mm (1.26 in)
Wear limit
31.4 mm (1.24 in)
5-45
Starter motor
c. Align the protrusion “a” on the stator “3”
with the protrusion “b” in the bracket “4”,
and then install the bracket “4”.
b a 1
4
3
a. Standard brush length a
b. Wear limit
2 b
Standard brush length
18.0 mm (0.71 in)
Wear limit
11.0 mm (0.43 in)
Assembling the starter motor

1. Install:
• Brushes
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Brushes holder
• Armature 2. Assemble:
• Stator • Bracket
• Bracket • Clutch assembly
• O-ring New • Pinion shaft
• Stopper
• Clip
Do not apply grease or oil to the commuta- • Planetary gear
tor of the armature. • Ball
• Center bracket
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the brushes “1” of the stator to the a. Install the stopper “1” and clip “2” to the
brush holder “2”. pinion shaft “3”.
b. Set the bearing separator on the bottom

face of the clutch, and then insert the clip
“2” into the groove in the stopper “1” by
tapping the pinion shaft “3”.
1 2
b. Push the brushes into the holders, and

then install the armature “1” to the brush
holder “2”.
5-46
Starter motor
c. Install the cap “5”.
3 5
2 4
3 4
1 3
2
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• Magnet switch assembly
c. Install the planetary gear “1”, ball “2”, and
center bracket “3”. TIP:
Some starter motors do not have a shim.
Installing the starter motor

1. Install:
• Starter motor
1 3 See “Installing the starter motor” (7-29).
2. Install:
2
• Intake manifolds
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Assemble:
• Starting motor gear assembly
• Lever assembly
• Cover
• Starting motor body
• O-ring New
4. Install:
• Spring
• Pinion
• Pinion stopper
• Clip
• Cap
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the spring “1”, pinion “2”, pinion
stopper “3”, and clip “4”.
b. Insert a flat-head screwdriver between the

pinion “2” and the pinion stopper “3” to
raise the pinion stopper “3” and push in the
clip “4”.
5-47
Outboard motor and Digital Electronic Control connection
Outboard motor and Digital c. Disconnect the electrical management box

Electronic Control connection coupler “d”.
Checking the extension wire harness

1. Check:
• Extension wire harness d
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the extension wire harness for con-
tinuity. Check the wire terminal numbers
from “a” to “p”.
a b c a b c d. Check the wire harness for continuity.

d e f d e f
g h k m g h k m 88
4 3 2 79
n p n p 8 7 6 62
a 12 11 10 9 b 53
15 14
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the main harness

1. Check: 114
105
• Main harness 3 2 1
c d 6
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 9
a. Disconnect the main wire harness coupler
“a”.
a Wire harness continuity

a Terminal 2–c Terminal 114
a Terminal 3–c Terminal 105
a Terminal 4–b Terminal 79
a Terminal 6–Ground
b. Disconnect the engine ECM couplers “b” a Terminal 9–Ground
and “c”. a Terminal 10–d Terminal 6
a Terminal 11–Ground
b c a Terminal 12–d Terminal 9
e. Connect the electrical management box

coupler, ECM couplers, and main wire har-
ness coupler.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-48
Steering unit
Steering unit Wire harness continuity

Checking the steering actuator a Terminal 53–c Terminal 4
1. Check: a Terminal 62–c Terminal 3
• Steering actuator a Terminal 88–c Terminal 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a Terminal 88–d Terminal 3
a. Disconnect the engine ECM couplers “a” b Terminal 105–d Terminal 2
and “b”. b Terminal 114–d Terminal 1
a b
the electrical management box terminal
“1” and ground.
1
b. Disconnect the SCU signal couplers “c”
and “d”.
Input voltage
12 V
Terminal 1–Ground

d c
f. Connect the engine ECM couplers and
c. Check the wire harness for continuity. SCU signal couplers.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
88
62 114
a 53 b 105
1 2 1
c d
4 3 3
5-49
PTT system
PTT system b. Tilt the outboard motor up and down, and

Checking the PTT switch (on bottom measure the PTT sensor output voltage at
the specified positions.
cowling)
1. Check: Output voltage
• PTT switch Position Voltage
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the PTT switch coupler “a”. Tilt support lever up-
4.07
per position
b. Measure the input voltage between the Tilt support lever
PTT switch coupler terminal and ground. 3.57
lower position
R Fully tilted-down po-
0.93
sition
a
c. Disconnect the PTT sensor (sub lead)
coupler “a”.

then measure the input voltage at the PTT
sensor coupler.
PTT switch input voltage

12.0 V (battery voltage)
Red (R)–Ground B Or
a
c. Check the PTT switch for continuity. Re-
place if out of specification.
PTT sensor input voltage

a b c 5V
Sb
R
Lg e. Turn the engine start switch to OFF, and
then connect the PTT sensor (sub lead)
coupler.
Switch Terminal ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
position “a” “b” “c”
UP
Free
DN
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the PTT sensor

1. Check:
• PTT sensor
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the YDIS to display “PTT sensor”.
5-50
Fuel system
Fuel system basic procedure............................................ 6-1

Starting the engine after running out of fuel ............................... 6-1
Reducing the fuel pressure ........................................................ 6-1
Disconnecting the quick connector............................................. 6-1
Measuring the fuel pressure....................................................... 6-2
Fuel filter assembly............................................................ 6-3

Checking the fuel filter assembly................................................ 6-4
Checking the fuel filter element .................................................. 6-4
Checking the fuel cup assembly................................................. 6-4
Checking the primer pump ......................................................... 6-4
Assembling the fuel filter ............................................................ 6-5
Installing the fuel filter................................................................. 6-5
Low-pressure fuel pump ................................................... 6-6

Checking the low-pressure fuel pump ........................................ 6-7
Checking the feed valve (low-pressure fuel pump) .................... 6-7
Checking the relief valve (low-pressure fuel pump) ................... 6-7
Installing the low-pressure fuel pump......................................... 6-8
Vapor separator and high-pressure fuel pump ............... 6-9

Draining the fuel ....................................................................... 6-10
6
Removing the vapor separator ................................................. 6-10
Checking the high-pressure fuel pump..................................... 6-10
Assembling the vapor separator............................................... 6-10
Installing the vapor separator ................................................... 6-11
Fuel hose assembly ......................................................... 6-12
Fuel hose, feed valve, relief valve, and fuel strainer .... 6-13
Disassembling the fuel hose assembly .................................... 6-14
Checking the fuel strainer......................................................... 6-14
Checking the relief valve (high-pressure fuel pump) ................ 6-14
Checking the feed valve (high-pressure fuel pump)................. 6-15
(high-pressure fuel pump) ........................................................ 6-16
Assembling the fuel hose assembly ......................................... 6-16
Installing the fuel hose assembly ............................................. 6-17
Direct injection pump and fuel injector.......................... 6-18

Removing the fuel rail............................................................... 6-19
Fuel system
Removing the fuel injector........................................................ 6-19

Checking the fuel pressure sensor (direct injection pump) ...... 6-19
Checking the direct injection pump .......................................... 6-19
Checking the fuel rail and fuel injector ..................................... 6-19
Installing the fuel injector and fuel rail ...................................... 6-20
Intake manifold ................................................................. 6-25

Checking the intake manifold ................................................... 6-26
Installing the intake manifold .................................................... 6-26
ETV .................................................................................... 6-28

Checking the ETV .................................................................... 6-29
Checking the intake air pressure/temperature sensor.............. 6-29
Installing the ETV and surge tank ............................................ 6-29
Fuel system basic procedure
Fuel system basic procedure 3. Start the engine.

Starting the engine after running out TIP:
of fuel Wait until the engine stalls.
Use the following procedure to start the engine
after running out of fuel.
4. After the engine stalls, crank the engine 2

1. Check: or 3 times.
• Fuel supply
Fuel is not supplied → Check and repair 5. Reduce the fuel rail fuel pressure using the
the fuel system. YDIS “Stationary test” or “Reduce DI Fuel
Pressure”. See the YDIS (Ver. 2.33 or lat-
2. Start the engine and let it idle for 5 min- er) instruction manual.
utes.
TIP:
TIP: When using “Stationary test”, activate the in-
• After the engine stops due to a lack of fuel, it jector for 1 cylinder on each side of the engine.
cannot be cranked for 7 seconds.
• To start the engine, it may be necessary to
crank the engine 10 or more times. 6. Check:
• The engine idle speed may be unstable after • Fuel pressure
the engine is started until the air is bled from Does not decrease → Repeat steps 4 and
the high-pressure line, but this is not a mal- 5.
function.
7. Install:
• Fuse (30 A) (high-pressure fuel pump sys-
Reducing the fuel pressure tem)
• Fuse cover
Before servicing the high-pressure fuel line Disconnecting the quick connector
or vapor separator, make sure to reduce
the fuel pressure in the fuel line. Otherwise,
pressurized fuel could spray out. Before disconnecting the quick connector,
reduce the fuel pressure. Otherwise, pres-
1. Connect the YDIS to display “DI fuel pressurized fuel could spray out.
sure P”, “DI fuel pressure S”, and “Feed
fuel pressure”. 1. Reduce the fuel pressure. See “Reducing
the fuel pressure” (6-1).
2. Remove:
• Fuse cover 2. Disconnect:
• Fuse (30 A) (high-pressure fuel pump sys- • Quick connector
tem) “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wrap a rag around the quick connector “1”.
6-1
Fuel system basic procedure
b. Spread apart the ends of the retainer “a”,
and then pull the retainer.
c. Disconnect the quick connector “1” from

the fuel pipe “b” directly.
TIP:
Cover the quick connector and fuel pipe with a
plastic bag to prevent damage and to prevent
dirt from entering them.
b
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Measuring the fuel pressure

1. Connect the YDIS to display “DI fuel pres-
sure P”, “DI fuel pressure S” and “Feed
fuel pressure”.
2. Measure:
• Fuel pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Start the engine and warm it up until the
engine idle speed stabilizes at the speci-
fied engine idle speed range.
Idle speed (in neutral)
650–750 r/min
b. Measure the fuel pressure.

Fuel pressure at idle speed (high-
pressure fuel pump)
330-400 kPa (3.3-4.0 kgf/cm²,
47.9-58.0 psi)
Fuel pressure at idle speed (DI
pump)
8.00 Mpa (80.0 kgf/cm², 1160.0
psi)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-2
Fuel filter assembly
5 N·m (0.5 kgf·m, 3.7 lb·ft)

1
13 21
18
1 New 15
2 12 14 16
3 7 E
19
20
6 18
17
5
4
New 8
9
10
11

1 Bolt M6 × 16 mm 3 20 Clamp 1
2 Cover 1 21 Bracket 1
3 Plastic tie 1
4 Retainer 1
5 Bolt M6 × 20 mm 2
6 Grommet holder 1
7 Rigging grommet 1
8 Plastic tie 2
9 Hose 1
10 Clamp 1
11 Joint 1
12 Fuel filter assembly 1
13 Cap 1
14 Fuel filter element 1
15 O-ring 1
16 Holder 1
17 Fuel cup assembly 1
18 Bolt M6 × 16 mm 2
19 Holder 1
6-3
Checking the fuel filter assembly ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Connect the special service tool “1” to the
1. Check:
fuel outlet “a”.
• Fuel inlet holding pressure
Out of specification → Replace the O-ring, b. Block the fuel inlet “b” using a rubber plug
cup assembly, or fuel filter assembly. “2”, and then apply the specified negative
Fuel inlet holding pressure (posi- pressure for 15 seconds or more.
tive pressure)
200.0 kPa (2.00 kgf/cm², 29.0
psi)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1
fuel inlet “a”.
b. Block the fuel outlet “b” using a rubber plug OUT IN

“2”, and then apply the specified positive a b
pressure for 15 seconds or more.
1 Vacuum/pressure pump gauge

set “1”
90890-06945
OUT IN Pressure/vacuum tester “1”
YB-35956-B
b a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2
Checking the fuel filter element
1. Check:
• Fuel filter element
Vacuum/pressure pump gauge Dirt/residue → Replace.
set “1”
90890-06945 Checking the fuel cup assembly
Pressure/vacuum tester “1” 1. Check:
YB-35956-B • Fuel filter cup assembly
Foreign material → Clean.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Cracked → Replace.
2. Check:
• Fuel outlet holding pressure (negative 2. Check:
pressure) • Electrical performance of the water detec-
Out of specification → Replace the O-ring, tion switch.
cup assembly, or fuel filter assembly. See “Checking the water detection switch”
(5-28).
Fuel outlet holding pressure (neg-
ative pressure) Checking the primer pump
-80.0 kPa (-0.80 kgf/cm², -11.6 1. Check:
psi) • Positive pressure
6-4
Installing the fuel filter

Positive pressure
166.7 kPa (1.67 kgf/cm², 24.2 1. Install:
psi) • Fuel filter bracket
• Clamps
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Holder
a. Connect the special service tool “1” to the • Fuel filter assembly
fuel inlet “a”. • Fuel hose
See “Hose routing” (2-52).
b. Block the fuel outlet “b” using a rubber plug
“2”, and then apply the specified positive TIP:
pressure for at least 30 seconds. Fit the rib “a” on the fuel cup “1” into the slit “b”
in the holder “2”.
2 b a b
2
1
2. Check:
• Fuel flow
Vacuum/pressure pump gauge Leak/clog → Replace the fuel filter assem-
set “1” bly.
90890-06945
YB-35956-B
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Pump operation
Fuel is not sent to the outboard motor even
after priming the pump. → Replace
Assembling the fuel filter

1. Install:
• Fuel cup assembly
• Fuel filter element
• O-ring New
• Fuel filter cap
Fuel filter cap
5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
R.
6-5

7
14
19
18
14
7
20 12
17
11
New 4
14
6
16
12
14
6
8 15
9
5 New
21
1
22
1
12
12 mm 12 mm 9 mm 12 14
(0.47 in) (0.47 in) (0.35 in) 23 13
24 23
10
3 3
12 mm 23
(0.47 in) 6 7 2
2

1 Bolt M6 × 25 mm 3 20 Feed valve 1
2 Collar 3 Low-pressure fuel
21 1
3 Grommet 3 pump
4 Plastic tie 1 22 Bushing 2
5 Plastic tie 3 23 Bolt M6 × 16 mm 3
6 Holder 3 24 Bracket 1
7 Holder 2
8 Bolt M6 × 12 mm 2
9 Holder 1
10 Holder 1
11 Hose 1
12 Clamp 4
13 Hose 1
14 Clamp 4
15 Hose 1
16 Relief valve 1
17 Hose 1
18 Quick connector 1
19 Hose 1
6-6

1. Check:
• Electrical performance of the low-pres-
sure-fuel pump
See “Checking the low-pressure fuel pump
and high-pressure fuel pump” (5-29).
Checking the feed valve (low- a 1

pressure fuel pump)
1. Check:
• Feed valve air flow Vacuum/pressure pump gauge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ set “1”
a. Connect the special service tool “1” to the 90890-06945
fuel inlet “a”. Pressure/vacuum tester “1”
YB-35956-B
b. Apply positive pressure and check that air
comes out of the opposite end of the feed ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
valve.
No air comes out → Replace. Checking the relief valve (low-
pressure fuel pump)
1. Check:
• Relief valve opening pressure
Opening pressure (positive pres-
sure)
a 1 72.5-93.5 kPa (0.73-0.94 kgf/
cm², 10.5-13.6 psi)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Vacuum/pressure pump gauge a. Connect the special service tool “1” to the
set “1” relief valve inlet “a”.
90890-06945
b. Apply the positive pressure, and check
that the relief valve opens at the specified
YB-35956-B
pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Feed valve holding pressure
Holding pressure (positive pres-
sure)
200.0 kPa (2.00 kgf/cm², 29.0
a
psi) 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
fuel outlet “a”.
b. Apply the specified positive pressure.

Cannot be maintained for 15 seconds or
more → Replace.
6-7
• Low-pressure fuel pump holders “8”, “9”
• Clamps
set “1”
90890-06945 • Plastic ties New
1 6
YB-35956-B
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1
2. Check: 5
• Relief valve holding pressure 7
sure) 4 2
200.0 kPa (2.00 kgf/cm², 29.0
psi) 8
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
relief valve outlet “a”. 3
b. Apply the specified positive pressure, and 9

check that the specified pressure is main-
tained. 2. Install:
• Low-pressure fuel pump bracket “1”
• Low-pressure fuel pump assembly “a”
(along with feed valve, relief valve, and
fuel hoses)
a
a 1

set “1” 1
90890-06945
YB-35956-B
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Installing the low-pressure fuel pump

1. Assemble:
• Holders “1”, “2”
• Bushings “3”
• Low-pressure fuel pump “4”
• Feed valve “5”
• Fuel hoses
• Quick connector “6”
• Relief valve “7”
6-8
Vapor separator and high-pressure fuel pump

2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
A
4
10
11
18
17
12 New
3
2 13
5 New 19
15 New 4
4
14 7 A
3
4
8 3
16 4
1 New
New 15
6
9 20

1 Plastic tie 2 High-pressure fuel Main, gray in-
18 1
2 Bolt M6 × 35 mm 4 pump let
3 Collar 4 19 Damper 2
4 Grommet 4 20 Case 1
5 Vapor separator 1
6 Clamp 2
7 Plug 1
8 Quick connector 1
9 Hose 1
10 Screw M4 × 12 mm 8
11 Cover 1
12 Gasket 1
13 Rubber damper 2
14 Bracket 1
15 O-ring 4
16 Pipe 1
High-pressure fuel Sub, white in-
17 1
pump let
6-9
Draining the fuel 6. Install:

Cover the fuel components using a rag to pre- • Plug
vent fuel from spilling out. • Drain hose
(onto the holder on the vapor separator
cover)
Never get under the outboard motor while it • Band
is tilted.
7. Connect:
1. Fully tilt the outboard motor up, and then • Quick connector
Removing the vapor separator
Cover the fuel components using a rag to pre-
1 vent fuel from spilling out.
1. Reduce:
• Fuel pressure
See “Reducing the fuel pressure” (6-1).
1
Checking the high-pressure fuel
pump
1. Check:
2. Disconnect: • Electrical performance of the high-pres-
• Quick connector “1” sure fuel pump
See “Disconnecting the quick connector” See “Checking the low-pressure fuel pump
(6-1). and high-pressure fuel pump” (5-29).
3. Remove: Assembling the vapor separator

• Band
1. Install:
• Drain hose
• Dampers
(from the holder on the vapor separator
• High-pressure fuel pump cover (to the sub
cover)
pump)
4. Set the drain hose “2” into a drain pan. • High-pressure fuel pump (main) “1”
(gray inlet)
5. Remove the plug in the drain hose, and • High-pressure fuel pump (sub) “2”
then drain the fuel into the drain pan. (white inlet)
• O-rings New
• Fuel cooler pipe
• High-pressure fuel pump brackets
1 • Rubber damper
• Vapor separator cover gasket New
2 • Vapor separator cover
• Vapor separator drain hose
• Quick connector
• Plug
6-10
Vapor separator cover screw

2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
T.
R.
Installing the vapor separator

1. Install:
• Vapor separator
2. Connect:
• Quick connector
• Cooling water hoses
• High-pressure fuel pump couplers
6-11
Fuel hose assembly
Fuel hose assembly
6
23 N·m (2.3 kgf·m, 17 lb·ft)
5 1
7
10 11
6
11 7
6
22
21
New 20 23
4
19 3
12 18
14 6
8
12
16 2 5
17
1
7 10 11 12 13
9
6 6
13 15
16
14 15 16 17

1 Bolt M6 × 25 mm 2 20 Plastic tie 1
2 Cover (PORT) 1 21 Cover 1
3 Cover (STBD) 1 Fuel pres-
22 Sensor 1
4 Collar 2 sure
5 Grommet 2 23 Joint 1
6 Grommet 6
7 Holder 2
8 Fuel hose assembly 1
9 Fuel hose assembly 1
10 Holder 1
11 Holder 2
12 Holder 2
13 Holder 1
14 Holder 1
15 Holder 1
16 Holder 2
17 Holder 1
18 Bolt M6 × 16 mm 1
19 Ground lead 1
6-12
Fuel hose, feed valve, relief valve, and fuel strainer
14 14
1 New New 1
14
New 1
15 16
21
20
18
1 New
New 17
2
19 4
3 1 New
1 New
1 New
4
5 6 New
7
New 1 10 8
9 1 New
11
12
13
New 1
New 6
14

1 Clamp 18 20 Hose 1
2 Quick connector 1 21 Hose 1
3 Hose 1
4 Joint 2
5 Hose 1
6 Plastic tie 2
7 Cover 1
8 Feed valve 1
9 Hose 1
10 Hose 1
11 Cover 1
12 Relief valve 1
13 Hose 1
14 Quick connector 4
15 Hose 1
16 Fuel strainer 1
17 O-ring 1
18 Element 1
19 Hose 1
6-13
Disassembling the fuel hose

c.
assembly
1. Remove:
• Clamps “1”
TIP:
Make sure that the protrusion “a” on the clamp
fits in the slot “b” in the tool “2”.
c a
b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• Holding pressure
Out of specification → Replace the fuel
2 strainer.
sure)
300.0 kPa (3.00 kgf/cm², 43.5
psi)
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a pressure pump “1” to the fuel in-
2 let “a”.
b b. Block the fuel outlet “b” using a rubber plug

“2”, and then apply the specified positive
1 a pressure.
300
Checking the fuel strainer 400
1. Check: 500
a
• Fuel strainer 2 b
Cracked/damaged → Replace.
2. Check:
• Strainer element
1
Dirt/residue → Replace.
TIP:
It is not necessary to remove the fuel strainer (commercially available)
from the fuel hose when checking the strainer
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
element.
Checking the relief valve (high-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slide the retainer “a” outward. pressure fuel pump)
1. Check:
b. Remove the cap “b”, and then remove the • Relief valve holding pressure
strainer element “c”. Out of specification → Replace.
6-14
Holding pressure (positive pres- 1

sure)
490.0 kPa (4.90 kgf/cm², 71.1
psi)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a
a. Connect a pressure pump “1” to the fuel 2 b
outlet “a”.
b. Apply the specified positive pressure for

15 seconds or more.
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the feed valve (high-

pressure fuel pump)
a 1. Check:
• Feed valve holding pressure
Pressure pump “1” sure)
(commercially available) 490.0 kPa (4.90 kgf/cm², 71.1
psi)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a pressure pump “1” to the fuel
• Relief valve opening pressure
outlet “a”.
Opening pressure (positive pres- b. Apply the specified positive pressure for
sure) 15 seconds or more.
445.0-455.0 kPa (4.45-4.55 kgf/
cm², 64.5-66.0 psi) a 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
let “a”.
b. Block the fuel outlet “b” using a rubber plug

“2”.
c. Apply the specified positive pressure, and

check that the relief valve opens at the Pressure pump “1”
specified pressure. (commercially available)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Feed valve opening pressure
6-15
Opening pressure (positive pres- TIP:

sure) Make sure to face the crimped section of the
9.3-12.6 kPa (0.09-0.13 kgf/cm², clamp in the direction shown in the illustration.
1.3-1.8 psi)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
let “a”.
b. Apply the specified positive pressure and

check that the feed valve opens at the
specified pressure.
2
a 1
2. Assemble:
• Fuel hoses
• Clamps
Vacuum/pressure pump gauge • Fuel strainer “1”
set “1” • Joint
90890-06945 • Quick connectors
TIP:
YB-35956-B
Make sure to face the crimped section of the
clamp in the direction shown in the illustration.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

(high-pressure fuel pump)
1. Check:
• Electrical performance of the fuel pressure
sensor (high-pressure-fuel pump). 1
See “Checking the fuel pressure sensor”
(5-32).
Assembling the fuel hose assembly

1. Assemble:
• Fuel hoses 3. Tighten:
• Clamps • Clamps “1”
• Joint
TIP:
• Quick connectors
• Push the protrusion “a” on the clamp using
• Relief valve “1”
the side “b”, which does not have a slot, of
• Fuel feed valve “2”
the tool.
• Covers
• Make sure that the ends “c” of the clamp are
• Plastic ties New hooked securely onto the portion “d” of the
clamp.
6-16
b
1 a
Installing the fuel hose assembly

1. Install:
• Fuel pressure sensor (high-pressure fuel
pump)
• Fuel hose assemblies
• Holders
• Fuel rail covers
Fuel pressure sensor (fuel hose
assembly)
T.
R.
23 N·m (2.3 kgf·m, 17 lb·ft)
6-17
Direct injection pump and fuel injector

23 19 22 21 20
18
28 N·m (2.8 kgf·m, 21 lb·ft)
24
14 N·m (1.4 kgf·m, 10 lb·ft) A
E 16 12
New 13
23 New
5
24 New 4
16 12
19 22 New 15
New 1
21 New
20 New
8 6
9 New 2
16 7
E A
12 New 10
11 11
13 14,15 3,5
10 New
14 E
8
17 16 9 New A
12 3 New
7 E
A
3,5
28 N·m (2.8 kgf·m, 21 lb·ft)
6
1 New
A
48 N·m (4.8 kgf·m, 35 lb·ft) 6 2 7

1 Plastic tie 2 16 Stud bolt M8 × 65 mm 4
2 Cover 2 Sub-wire harness
17 1
3 Fuel pipe (PORT) 1 (PORT)
4 Bolt M6 × 14 mm 1
18
Sub-wire harness
1
5 Fuel pipe (STBD) 1 (STBD)
6 Bolt M6 × 35 mm 4 19 Fuel injector 8
7 Direct injection pump 2 20 Stopper 8
8 Lifter 2 21 O-ring 8
9 O-ring 2 22 Backup ring 8
10 Plastic tie 2 23 Seal 8
11 Cover 2 24 Spring 8
12 Nut M6 4
13 Bolt M6 × 50 mm 4
With fuel
14 Fuel rail (PORT) 1 pressure
sensor
With fuel
15 Fuel rail (STBD) 1 pressure
sensor
6-18
Removing the fuel rail
Do not remove the fuel pressure sensor

from the fuel rail. Otherwise, fuel could leak 1
when the fuel pressure sensor is rein-
stalled to the fuel rail.
Removing the fuel injector

1. Remove: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Fuel injector
3. Remove:
TIP: • Stopper “1”
• Remove the fuel injector along with the fuel • O-ring “2”
rail. • Backup ring “3”
• If the fuel injectors remain installed to the cyl-
inder head, remove them using the special
Be careful not to scratch the installation
service tool.
area of the O-ring.
3
2
1
Injector remover “1”

90890-06696
(direct injection pump)
1. Check:
2. Remove:
• Electrical performance of the fuel pressure
• Nozzle seal
sensor (direct injection pump).
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Stretch the nozzle seal “1” by pulling it See “Checking the direct injection pump”
away from the nozzle using needle-nose (6-19).
pliers.
Checking the direct injection pump
b. Cut the nozzle seal. 1. Check:
• Electrical performance of the direct injec-
tion pump.
If the nozzle seal is cut without pulling it, See “Checking the direct injection pump”
the fuel injector could be damaged. (6-19).
Checking the fuel rail and fuel injector

1. Check:
• Fuel rail
Crack/deformed → Replace.
6-19
2. Check:
Fuel injection volume
• Electrical performance of the fuel injectors.
108–124 cm³ (108–124 cc)/30
See “Checking the fuel injector” (5-29).
sec
3. Measure: Test fuel
• Injection volume Dry sorbent (viscosity: 1.2 ±
See the “Fuel Injection Meter Operation 0.03 mm²/s, specific gravity:
Manual” (90894-62982-85). 0.774 [15 °C])
Test fuel temperature 22–24 °C
(room temperature and test fuel
Do not use gasoline when measuring the temperature should be the
fuel injection volume. Otherwise, the cylin- same)
der could be damaged, which can cause a Test fuel pressure
gasoline leakage. Make sure to follow the 300 ± 1.5 kPa
instructions for operation of the fuel injec- Measuring cylinder internal pres-
tion meter. sure (standard atmosphere pres-
sure)
960–1060 hPa
TIP:
• When measuring, obtain a result from the av-
erage of 4 measurements. Installing the fuel injector and fuel rail
• It is not possible to obtain correct measure-
ments under different test conditions.
• Make sure to fully charge the battery. Be careful not to scratch the installation
• The cylinder is graduated in increments of area of the O-ring or the nozzle.
2.5 cm³ (2.5 cc). 1. Clean the fuel injector and special service
• Exchange the 5 A fuse with the 10 A fuse. tool to remove any foreign material.
• Use the special attachment (FIM20000ME-
14) for this model. 2. Install:
• Make sure to comply with the laws and regu- • Spring New
lations of the region when disposing of the
• Backup ring New
used test fuel.
• O-ring New
Fuel injection meter • Stopper New

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
FIM20000ME a. Install a new backup ring “1” and O-ring
“2”.
TIP:
Make sure to face the tapered end of the back-
up ring “1” toward the O-ring.
b. Put a new stopper “3” into the hole in the

special service tool “4”.
TIP:
Install the stopper so that the side of the stop-
per with the notch is facing toward the special
service tool.
6-20
c. Fit the injector end into the stopper, and
then push the injector down to install it. 3
4
1
3
1 2 Stopper “1”
90890-06699
Seal fitter “2”
90890-06708
1 Nozzle cap “3”
90890-06697
2
3 4 c. Install the nozzle seal “1” onto the special
service tool “2” up to the bottom of the tool
using the special service tool “3”.
d. Push the nozzle seal into the groove “a”

Stopper “4” using your fingers.
90890-06699
TIP:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ At this time, the nozzle seal is larger than its
original size.
3. Install:
• Nozzle seal New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 3 2
a. Set the fuel injector onto the special ser-
3
vice tool “1”.
1
b. Install the special service tools “2” and “3”
a
and a new nozzle seal “4”.
TIP:
• Make sure to face the stepped section of
special service tool “2” toward the injector
body. Seal installer “3”
• Make sure that the special service tool “3” 90890-06698
does not contact the end of the nozzle.
• Make sure that the nozzle seal “4” is not de- e. Remove the special service tools “1” and
formed. “2”, and then pull up the special service
tool “3” gradually.
f. Keep the special service tool “3” for 30

seconds or more.
6-21
g. Remove the special service tool “3”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the fuel injector to the fuel rail so that
the protrusion “a” on the fuel injector spring
Make sure that the nozzle seal has returned is aligned with the slot “b” in the fuel rail.
to its original size. Otherwise, the seal
could be pinched when the fuel injector is
installed. • Install the fuel injector straight into the
fuel rail so that it is not positioned at an
angle.
• Be careful not to damage the O-ring on
1 the fuel injector.
3
2
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• Stud bolts b
• Fuel injectors
(to the fuel rail) b. Connect the sub-wire harness to the fuel
• Fuel injector sub-wire harnesses injector.
(to the fuel injector)
c. Apply engine oil to the fuel injector hole in
• Fuel rails
the cylinder head.
• Fuel pressure sensor covers
• Plastic ties New d. Install the fuel rail onto the stud bolts by
pushing in the fuel rail until the threads of
the bolts for the nuts are visible.
• If a fuel injector is dropped, replace it.
• Make sure that there is no foreign material
or damage on the installation area of the • Push in the fuel rail gradually and evenly
fuel injector. so that the fuel rail is not positioned at an
angle.
Fuel rail stud bolt • Be careful not to damage the end of the
14 N·m (1.4 kgf·m, 10 lb·ft) fuel injector nozzle or the nozzle seal.
T.
R.
Fuel rail bolt

28 N·m (2.8 kgf·m, 21 lb·ft) e. Tighten the fuel rail nuts “1” and fuel rail
Fuel rail nut bolts “2” to the specified torque evenly in
28 N·m (2.8 kgf·m, 21 lb·ft) the order [1], [2], and so on.
Make sure that the fuel rail is not positioned

at an angle.
6-22
PORT [4] STBD TIP:

[4]
Tighten the bolts temporarily to a level that
1 1
[2] does not compress the direct injection pump
[2] spring.
2 2
[1]
[1]
2 2 d. Install a new fuel pipe.
[3]
[3]
1 1
• Make sure that there is no foreign material
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ or damage on the mating surfaces of the
5. Install: fuel rail, direct injection pump, and fuel
• Lifters pipe.
• O-rings New • Apply grease to the fuel pipe nipples, and
• Direct injection pumps all around the threaded portions of the di-
rect injection pump and fuel rail. Other-
• Fuel pipes New
wise, the parts could seize when
• Direct injection pump covers
tightened, causing fuel to leak.
• Plastic ties New
Fuel pipe flare nut
48 N·m (4.8 kgf·m, 35 lb·ft)
T.
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft so that the flat portion
A
”a” of the fuel pump cam on the camshaft
is facing toward the direct injection pump
hole in the cylinder head cover.
TIP:
Because the fuel pump cams for the left and A
right cylinder banks have different positions,
rotate the crankshaft to position each camshaft
separately.
e. Tighten the flare nuts “a” on both ends of
b. Install the lifter “1”. the fuel pipe temporarily until the distances
are within specification.
TIP:
• It is easier to perform the work by gradually
tightening the nuts on both ends of the pipe
alternately.
• If the nuts cannot be tightened temporarily
a until the distances are within specification,
E
E
the fuel pipe may be connected improperly.
1
c. Install a new O-ring and the direct injection

pump, and tighten the bolts temporarily.
6-23
A B
a
c
a
b
A. Fuel rail end of the fuel pipe

B. Direct injection pump end of the fuel pipe
Distance “b”
5.0 mm (0.20 in) or less
Distance “c”
9.5 mm (0.37 in) or less
f. Tighten the direct injection pump bolts

evenly.
g. Tighten the fuel pipe bolt (starboard fuel

pipe).
h. Tighten the flare nuts on both ends of the

fuel pipe to the specified torque.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-24
Intake manifold
Intake manifold
16 24 N·m (2.4 kgf·m, 18 lb·ft)
25 New 25 New New 20
29 11 N·m (1.1 kgf·m, 8.1 lb·ft)
27
23 New
7 New
28 New 19
26 9
8 New
New 22 18
24 17
16
New 7
7 New
10 21
17
7 New
3 15
13
11 4
15 14
A
5
New 2 12 4 6 New
7 New
1 New

1 Plastic tie 1 19 Gasket 1
2 Plastic tie 1 20 Gasket 1
3 Oil dipstick 1 Intake manifold
21 1
4 Bolt M6 × 16 mm 3 (STBD)
5 Dipstick guide 1 22 Gasket 1
6 O-ring 1 23 Gasket 1
7 Plastic tie 6 24 Holder 2
8 Plastic tie 1 25 Plastic tie 5
9 Hose 1 26 Hose 1
10 Hose 1 27 Hose 1
11 Joint 1 28 Joint 1
12 Hose 1 29 Hose 1
13 Bolt M6 × 12 mm 2 A. For multiple engine applications
14 Bracket 1
15 Holder 2
16 Bolt M8 × 35 mm 10
17 Bolt M6 × 40 mm 10
Intake manifold
18 1
(PORT)
6-25
Intake manifold
Checking the intake manifold 3. Install:

1. Check: • Intake manifolds
• Intake manifold (temporarily)
4. Tighten:
Installing the intake manifold • Intake manifold bolts
1. Install: TIP:
• Cooling water hoses “1”, “2”, “3” Tighten the intake manifold bolts “1” and “2” to
• Joint the specified torque in the order [1], [2], and so
• Plastic ties New on.
PORT 1 1 STBD
3
2 [5] [5]
[3] [3]
1 [1] [1]
2. Install: [2] [2]

• Gaskets New
TIP: [4] [4]

Make sure to fit the tabs on the gaskets “1” and
“2” properly and firmly with the grooves “a” and
PORT STBD
“b” in the intake manifold.
2 2
1
[5] [2] [2] [5]
[1] [1]
[6] [6]
a
[4] [3] [3] [4]
a
2 Intake manifold bolt “1” (M8)

24 N·m (2.4 kgf·m, 18 lb·ft)
T.
R.
Intake manifold bolt “2” (M6)

11 N·m (1.1 kgf·m, 8.1 lb·ft)
5. Install:
b
• Holders
b • Bracket
• Hoses
• Joint
6-26
Intake manifold

• O-ring New
• Dipstick guide
• Oil dipstick
TIP:
• Make sure that the paint marks “a” on the
cooling water hoses face outward.
• Tighten the dipstick guide bolts “1” in the or-
der [1], [2], and so on.
STBD
a
[3] [2]
[1]
1
a
a
6-27
ETV
ETV
2
3 7 N·m (0.7 kgf·m, 5.2 lb·ft)
17
7 New 16
2
15
1 New 8 New
14
13
6 New 11
12 10
9
14
18
3.5 N·m (0.35 kgf·m, 2.6 lb·ft) 24 N·m (2.4 kgf·m, 18 lb·ft)
New 16

1 Plastic tie 1 18 Hose 1
2 Bolt M6 × 20 mm 2
3 Intake silencer 1
4 Joint 1
5 Bolt M8 × 60 mm 4
6 Bracket 1
7 ETV 1
8 Gasket 1
9 Screw M5 × 16 mm 2
Intake air
10 Sensor 1 pressure/
temperature
11 O-ring 1
12 Bolt M8 × 35 mm 6
13 Surge tank 1
14 Dowel 2
15 Holder 2
16 Plastic tie 2
17 Hose 1
6-28
ETV
Checking the ETV

1. Check: [5]
• ETV [6]
Cracked → Replace.
2. Check: [1]
• Throttle valve movement
• Rough movement → Replace the ETV.
[2]
[4] [3]
Surge tank bolt

24 N·m (2.4 kgf·m, 18 lb·ft)
T.
R.
Intake air pressure/temperature
sensor bolt
3. Check: 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
• Electrical performance of the TPS.
See “Checking the ETV and TPS” (5-21). 2. Install:
• Gasket New
Checking the intake air pressure/
• ETV
temperature sensor
• Bracket
1. Check: • Joint
• Plastic tie New
• Intake silencer
2. Check:
• Electrical performance of the intake air
TIP:
Make sure to fit the tab on the ETV gasket “1”
pressure/temperature sensor.
properly and firmly with the groove “a” in the
See “Checking the intake air pressure/
surge tank.
temperature sensor” (5-36).
Installing the ETV and surge tank

1. Install:
• Dowel
• Surge tank 1
1
• O-ring New
TIP: a
Tighten the surge tank bolts to the specified
torque in the order [1], [2], and so on.
Intake silencer bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
6-29
Power unit
Power unit (check and adjustment).................................. 7-1

Checking the compression pressure .......................................... 7-1
Checking the oil pressure........................................................... 7-1
Checking the valve clearance .................................................... 7-2
Adjusting the valve clearance..................................................... 7-3
Shroud cover and terminal cover ..................................... 7-5

Installing the shroud cover and terminal cover........................... 7-6
Exhaust joint....................................................................... 7-7

Removing the exhaust joint ........................................................ 7-9
Checking the exhaust joint ......................................................... 7-9
Checking the exhaust joint anode .............................................. 7-9
Checking the water pressure sensor.......................................... 7-9
Installing the exhaust joint .......................................................... 7-9
Power unit assembly ....................................................... 7-13

Removing the power unit.......................................................... 7-15
Installing the power unit............................................................ 7-17
Electrical management box............................................. 7-22

Installing the electrical management box ................................. 7-23
Flywheel magneto ............................................................ 7-24

7
Removing the flywheel magneto .............................................. 7-25
Installing the flywheel magneto ................................................ 7-25
Starter motor and extension wire harness .................... 7-28

Installing the starter motor........................................................ 7-29
Installing the extension wire harness ....................................... 7-29
Wire harness..................................................................... 7-30

Removing the wire harness...................................................... 7-31
Installing the wire harness........................................................ 7-33
ECM, injector driver, and rectifier/regulator .................. 7-37

Removing the rectifier/regulator ............................................... 7-38
Checking the rectifier/regulator anode ..................................... 7-38
Installing the ECM and injector driver....................................... 7-38
Power unit
Installing the rectifier/regulator ................................................. 7-38
Ignition coil and spark plug ............................................ 7-40

Checking the spark plug........................................................... 7-41
Installing the ignition coil and spark plug.................................. 7-41
Timing belt ........................................................................ 7-42

Removing the timing belt.......................................................... 7-43
Checking the timing belt ........................................................... 7-43
Installing the timing belt............................................................ 7-43
Camshaft ........................................................................... 7-46

Removing the camshaft, VCT assembly, and driven
sprocket.................................................................................... 7-48
Checking the sprocket.............................................................. 7-49
Checking the cam chain ........................................................... 7-49
Checking the cam chain tensioner ........................................... 7-50
Checking the valve lifter ........................................................... 7-50
Checking the camshaft............................................................. 7-50
Checking the camshaft journal oil clearance............................ 7-51
Checking the camshaft journal outside diameter and
camshaft journal inside diameter.............................................. 7-52
Installing the camshaft, VCT assembly, and driven sprocket... 7-53
Cylinder head ................................................................... 7-59

Removing the cylinder head..................................................... 7-60
Disassembling the cylinder head.............................................. 7-60
Checking the cylinder head ...................................................... 7-60
Checking the cylinder head bolt ............................................... 7-61
Checking the valve spring ........................................................ 7-61
Checking the valve ................................................................... 7-62
Checking the valve guide ......................................................... 7-62
Replacing the valve guide ........................................................ 7-63
Checking the valve seat ........................................................... 7-64
Refacing the valve seat ............................................................ 7-65
Checking the cylinder head anode ........................................... 7-67
Checking the cam position sensor ........................................... 7-67
Checking the OCV.................................................................... 7-67
Assembling the cylinder head .................................................. 7-67
Installing the cylinder head....................................................... 7-69
Oil pump assembly .......................................................... 7-71

Removing the oil pump assembly ............................................ 7-72
Power unit
Removing the oil filter............................................................... 7-72

Installing the oil filler neck and relief valve ............................... 7-72
Installing the oil pump assembly .............................................. 7-72
Installing the oil filter................................................................. 7-72
Oil cooler and water jacket.............................................. 7-73

Checking the thermostat .......................................................... 7-74
Checking the oil cooler cover anode and water jacket
anode ....................................................................................... 7-74
Installing the cylinder block thermostat .................................... 7-74
Installing the water jacket cover ............................................... 7-74
Installing the oil cooler cover .................................................... 7-75
Cylinder block sensor...................................................... 7-76

Checking the cylinder block anode........................................... 7-77
Installing the cylinder block anode ........................................... 7-77
Installing the cylinder block sensor........................................... 7-77
Cylinder block .................................................................. 7-78

Disassembling the cylinder block ............................................. 7-79
Checking the piston diameter................................................... 7-79
Checking the cylinder bore....................................................... 7-80
Checking the piston clearance ................................................. 7-80
Checking the piston ring........................................................... 7-80
Checking the piston ring end gap............................................. 7-81
Checking the piston ring groove............................................... 7-81
Checking the piston ring side clearance................................... 7-82
Checking the piston pin boss inside diameter .......................... 7-82
Checking the piston pin diameter ............................................. 7-82
Checking the connecting rod small end inside diameter and
big end inside diameter ............................................................ 7-83
Checking the connecting rod big end side clearance............... 7-83
Checking the crankshaft........................................................... 7-83
Checking the crankcase bolt .................................................... 7-84
Checking the big end oil clearance .......................................... 7-84
Selecting the crankshaft pin bearing ........................................ 7-86
Crankshaft pin bearing selection table ..................................... 7-88
Checking the journal oil clearance ........................................... 7-89
Selecting the crankshaft journal bearing .................................. 7-90
Crankshaft journal bearing selection table ............................... 7-92
Assembling the cylinder block .................................................. 7-93
Power unit (check and adjustment)
Power unit (check and Compression pressure

adjustment) Minimum (reference data)
Checking the compression pressure 947.9 kPa (9.48 kgf/cm², 137.4
1. Start the engine, warm it up for 5–10 min- psi)
utes, and then stop it.
5. Remove:
2. Remove: • Special service tools
• Clip
(from the engine shut-off switch) 6. Install:
• Fuel rail covers • Spark plugs
See “Fuel hose assembly” (6-12). • Ignition coils
• Ignition coils See “Ignition coil and spark plug” (7-40).
• Spark plugs • Clip
See “Ignition coil and spark plug” (7-40). (to the engine shut-off switch)
Spark plug
Before removing the spark plugs, remove 11 N·m (1.1 kgf·m, 8.1 lb·ft)
T.
R.
any dirt or dust in the spark plug wells that Ignition coil bolt
could fall into the cylinders. 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Checking the oil pressure

3. Install:
1. Connect the YDIS to display “Oil pres-
• Special service tools
sure”.
2
1 2. Start the engine and warm it up until the
engine idle speed stabilizes at the speci-
fied engine idle speed range.
Idle speed (in neutral)
650–750 r/min
3. Measure:
• Oil pressure
Compression gauge “1” Below specification → Check the engine
90890-03160 internal parts.
Compression gauge extension Engine oil pressure at idle speed
M10 “2” (reference data)
90890-06582 492.0 kPa (4.92 kgf/cm², 71.3
Compression gauge “1” psi)
YU-33223 Engine oil pressure at 3000 r/min
(reference data)
4. Measure: 676.0 kPa (6.76 kgf/cm², 98.0
• Compression pressure psi)
Below specification → Check the engine
internal parts.
TIP:
Crank the engine until the reading on the com-
pression gauge stabilizes.
7-1
Checking the valve clearance

Measure the valve clearances when the en- TIP:
• Turn the crankshaft gradually until the cam
gine is cold.
nose for each valve is positioned within the
range “b”, and then measure the valve clear-
Do not turn the flywheel magneto counter- ance for that valve.
clockwise. Otherwise, the water pump im- • Write down the measurement data.
peller could be damaged.
1. Reduce: IN EX EX IN
• Fuel pressure
See “Reducing the fuel pressure” (6-1). #1
#2
2. Remove:
• Bottom cowling cover #3
#4
See “Bottom cowling cover and apron cov-
er” (9-1).
#5
• Bottom cowlings #6
See “Bottom cowling (PORT and STBD)”
(9-3). #7
• Shroud cover and terminal covers #8
(7-5).
• Electrical management box
See “Electrical management box” (7-22).
PORT STBD
See “Fuel hose assembly” (6-12).
b
• Exhaust joints
See “Exhaust joint” (7-7).
• Ignition coils
• Spark plugs
See “Ignition coil and spark plug” (7-40).
• Fuel hoses
(from the direct injection pump) a
• Fuel rails
See “Direct injection pump and fuel injec-
tor” (6-18).
• Wire harness guide
See “Timing belt” (7-42).
• Cylinder head covers
See “Camshaft” (7-46). b. 60°
3. Measure: Valve clearance IN (cold engine)

• Valve clearance “a” 0.17–0.24 mm (0.0067–0.0094
Out of specification → Adjust. in)
See “Adjusting the valve clearance” (7-3). Valve clearance EX (cold engine)
0.37–0.44 mm (0.0146–0.0173
in)
7-2
4. Install: • Flywheel magneto
• Cylinder head covers See “Removing the flywheel magneto”
See “Camshaft” (7-46). (7-25).
• Wire harness guide • Timing belt
See “Timing belt” (7-42). See “Removing the timing belt” (7-43).
• Fuel rails • Chain tensioners
• Fuel hoses • Camshafts
(from the direct injection pump) (with driven sprocket and VCT assembly)
See “Direct injection pump and fuel injec- • Valve lifters
tor” (6-18). See “Removing the camshaft, VCT as-
• Spark plugs sembly, and driven sprocket” (7-48).
• Ignition coils
See “Ignition coil and spark plug” (7-40). 2. Measure:
• Exhaust joints • Valve lifter thickness “a”
See “Installing the exhaust joint” (7-9).
TIP:
• Make sure to keep the parts in the order of re-
moval.
• Write down the measurement data.
See “Installing the electrical management
box” (7-23).
• Shroud cover and terminal covers
a
(7-5).
• Bottom cowlings
(9-3).
• Bottom cowling cover
er” (9-1).
3. Select:
Adjusting the valve clearance
• Valve lifter
Adjust the valve clearances when the engine is ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
cold. a. Select the necessary valve lifter by calcu-
lating its thickness using the following for-
mula.
• Do not turn the flywheel magneto coun-
terclockwise. Otherwise, the water pump Calculation formula:
impeller could be damaged. Necessary valve lifter thickness =
• Do not turn the flywheel magneto, VCT Removed valve lifter thickness +
assembly or driven sprocket when the Measured valve clearance –
timing belt is not installed. Otherwise, the Specified valve clearance
pistons and valves, or intake and exhaust
valves will collide with each other and be
damaged.
1. Remove:
• Fuel hose assembly
7-3
Example:
Removed valve lifter thickness = 3.000
mm
Measured valve clearance = 0.255 mm
Specified valve clearance = 0.205 mm
Necessary valve lifter thickness
= 3.000 mm + 0.255 mm – 0.205 mm
= 3.050 mm
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• Valve lifters
• Camshafts
• Chain tensioners
See “Installing the camshaft, VCT assem-
bly, and driven sprocket” (7-53).
• Timing belt
See “Installing the timing belt” (7-43).
• Flywheel magneto
See “Installing the flywheel magneto”
(7-25).
7-4
Shroud cover and terminal cover
1 1
5
1 3
6
5 4
9 2 3
8
5 7
3
9
8
9
8
9
8
10
10
10
Part name Q’ty Remarks

1 Bolt M6 × 12 mm 5
2 Shroud cover 1
3 Rivet 5
4 Damper 1
5 Bolt M6 × 25 mm 4
6 Terminal cover (PORT) 1
7 Terminal cover (STBD) 1
8 Collar 4
9 Grommet 4
10 Grommet 4
7-5
Installing the shroud cover and terminal

cover
1. Install:
• Grommets
• Terminal cover grommets
• Terminal cover collars
• Terminal covers
• Shroud cover damper
• Shroud cover
7-6
Exhaust joint
Exhaust joint
1 14 N·m (1.4 kgf·m, 10 lb·ft) New 3 55 N·m (5.5 kgf·m, 41 lb·ft)
2 21 N·m (2.1 kgf·m, 15 lb·ft) 2 5 1 14 N·m (1.4 kgf·m, 10 lb·ft)
2 7 17
14 N·m (1.4 kgf·m, 10 lb·ft) 2 21 N·m (2.1 kgf·m, 15 lb·ft)
6 3 New
3 New 4 16 New
New 15 25
1 22 12
E
23 24
42
40 New 37 New 14
3 New
30 New
32 29 E
41 New
30 New 26 12
31 27 30 New 12
29
31 32 28 31 29
37 41 32
38 36 New
41 35 33
39 34 8 11 30
E
New 40 19 N·m (1.9 kgf·m, 14 lb·ft) 31
32 12
10 29
41 9 21 New
32 12
New 30 E
29 19 20 New
31 35
E 36 1 14 N·m (1.4 kgf·m, 10 lb·ft)
1303 E
New 30 2 21 N·m (2.1 kgf·m, 15 lb·ft)
31 2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
32 17 17 13
29 1 14 N·m (1.4 kgf·m, 10 lb·ft)
18 N·m (1.8 kgf·m, 13 lb·ft) 2 21 N·m (2.1 kgf·m, 15 lb·ft) 18 New

1 Holder 1 19 Exhaust joint (lower) 1
2 Holder 2 20 O-ring 1
3 Plastic tie 6 21 O-ring 1
4 Hose 1 22 Plug M18 × 17 mm 1
5 Hose 1 23 Washer 1
6 Hose 1 24 Bolt M8 × 130 mm 4
7 Joint 1 25 Exhaust joint (upper) 1
8 Bolt M6 × 16 mm 1 26 Gasket 1
9 Bracket 1 27 Dowel 2
10 Holder 1 28 Exhaust joint (center) 1
11 Holder 1 29 Plug M16 × 11 mm 6
12 Bolt M8 × 70 mm 11 30 O-ring 6
13
Exhaust joint assem-
1 31 Screw M5 × 25 mm 6
bly 32 Anode 6
14 Gasket 1 33 Coupler 1
15 O-ring 2 Water pres-
16 Gasket 1 34 Sensor 1
sure
17 Dowel 4 35 Bolt M8 × 50 mm 14
18 Gasket 1
7-7
Exhaust joint
1 14 N·m (1.4 kgf·m, 10 lb·ft) New 3 55 N·m (5.5 kgf·m, 41 lb·ft)

2 21 N·m (2.1 kgf·m, 15 lb·ft) 2 5 1 14 N·m (1.4 kgf·m, 10 lb·ft)
2 7 17
14 N·m (1.4 kgf·m, 10 lb·ft) 2 21 N·m (2.1 kgf·m, 15 lb·ft)
6 3 New
3 New 4 16 New
New 15 25
1 22 12
E
23 24
42
40 New 37 New 14
3 New
30 New
32 29 E
41 New
30 New 26 12
31 27 30 New 12
29
31 32 28 31 29
37 41 32
38 36 New
41 35 33
39 34 8 11 30
E
New 40 19 N·m (1.9 kgf·m, 14 lb·ft) 31
32 12
10 29
41 21 New
12 9
New 30 32 E
29 19 20 New
31 35
E 36 1 14 N·m (1.4 kgf·m, 10 lb·ft)
1303 E
New 30 2 21 N·m (2.1 kgf·m, 15 lb·ft)
31 2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
32 17 17 13
29 1 14 N·m (1.4 kgf·m, 10 lb·ft)
18 N·m (1.8 kgf·m, 13 lb·ft) 2 21 N·m (2.1 kgf·m, 15 lb·ft) 18 New

36 Bolt M8 × 155 mm 12
37 Nut M8 4
38 Exhaust joint (PORT) 1
39 Exhaust joint (STBD) 1
40 Gasket 2
41 Dowel 4
42 Stud bolt M8 × 65 mm 4
7-8
Exhaust joint
Removing the exhaust joint Checking the exhaust joint anode

1. Remove: 1. Check:
• Bottom cowling cover • Anode
See “Bottom cowling cover and apron cov- Eroded (1/2 or more worn out) → Replace.
er” (9-1). Adhered grease, oil, or scales → Clean.
• Bottom cowlings
See “Removing the bottom cowling” (9-4).
• Fuel rail covers Do not apply grease, oil, or paint to the an-
See “Fuel hose assembly” (6-12). odes.
2. Remove:
• Exhaust joint (lower) “1” Checking the water pressure sensor
1. Check:
TIP: • Exterior
Use suitable bolts “2” to separate the exhaust Cracked → Replace.
joint (lower) “1” and exhaust joint (center) “3”. • Electrical performance
Screw in the bolts “2” evenly. See “Checking the water pressure sensor”
(5-26).
Installing the exhaust joint

1. Install:
• Stud bolts
Stud bolt
14 N·m (1.4 kgf·m, 10 lb·ft)
T.
R.
2 2. Install:
3 2
• Dowels
2 2
• Gaskets New
• Exhaust joint (PORT) “1”
1 • Exhaust joint (STBD) “2”
Bolt “2” TIP:

Tighten the exhaust joint bolts “3” and “4” and
exhaust joint nuts “5” to the specified torques in
M6 × 40 mm (1.57 in)
2 stages and in the order [1], [2], and so on.
Checking the exhaust joint

1. Check:
• Exhaust joints
Corroded/cracked → Replace.
7-9
Exhaust joint
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3 4 a. Install the dowels “1”, new gasket “2”, ex-
a haust joint (upper) “3”, and exhaust joint
b (center) “4”, and then tighten the exhaust
E E joint bolts “5” to the specified torques in 2
5 stages.
4 1 1 a
3 5
E E
5 2 2
3
3 4
4
1
a. 130 mm (5.12 in)
Exhaust joint bolt “5”

a. 50 mm (1.97 in)
1st: 14 N·m (1.4 kgf·m, 10 lb·ft)
b. 155 mm (6.10 in)
T.
R.
2nd: 21 N·m (2.1 kgf·m, 15 lb·ft)
[13] [13] b. Install new O-rings “1” and “2” and exhaust
[9] [10] [9] [10] joint (lower) “3” to the exhaust joint (center)
“4”.
[5] [6] [5] [6]
TIP:
[1] [2] [1] [2] • Use suitable bolts “5” to install the exhaust
[4] [3] [4] [3] joint (lower) “3” to the exhaust joint (center)
[8] [7] [8] [7] “4”. Screw in the bolts “5” evenly.
• Do not remove the bolts “5” until step (d) is
[12] [11] [12] [11] completed.
[15] [14] [15] [14]
PORT STBD
Exhaust joint bolt “3”, “4” 4

3
1st: 14 N·m (1.4 kgf·m, 10 lb·ft)
T.
R.
2nd: 21 N·m (2.1 kgf·m, 15 lb·ft)

Exhaust joint nut “5” 1
1st: 14 N·m (1.4 kgf·m, 10 lb·ft)
2nd: 21 N·m (2.1 kgf·m, 15 lb·ft) 2
3. Assemble:
• Dowels
• Gaskets New
• O-rings New
• Exhaust joint (upper)
• Exhaust joint (center)
• Exhaust joint (lower)
7-10
Exhaust joint
TIP:
Tighten the bolts on the starboard side “a”, then
the bolts on the port side “b”, in each stage.
f. Tighten the exhaust joint assembly bolts (low-

er) “c” to the specified torques in 2 stages.
PORT STBD
5 b a
5
4 a
5
5
b
3 a
Bolt “5”
M6 × 40 mm (1.57 in)
b a
c. Install the dowels “1”, new O-rings “2” and
new gaskets “3”, “4”, and “5”.
3
1
2 1 c
c c
5
2 4
c
d. Install the exhaust joint assembly “1” that was
assembled in steps (a) and (b), and then tight- Exhaust joint assembly bolt
en the exhaust joint assembly bolts “2” tem- 1st: 14 N·m (1.4 kgf·m, 10 lb·ft)
T.
R.
porarily. 2nd: 21 N·m (2.1 kgf·m, 15 lb·ft)
2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
2
4. Install:
a
• Water pressure sensor
E
• Exhaust joint plug washer
• Exhaust joint plug
2 • Pilot hoses
• Pilot hose joint
a. 70 mm (2.76 in) Water pressure sensor

19 N·m (1.9 kgf·m, 14 lb·ft)
T.
R.
e. Tighten the exhaust joint assembly bolts Exhaust joint plug

(PORT and STBD) to the specified torques in 55 N·m (5.5 kgf·m, 41 lb·ft)
2 stages.
7-11
Exhaust joint
5. Connect:
• Water pressure sensor coupler
6. Install:
• Exhaust joint anodes
• O-rings New
• Exhaust joint anode plugs
Exhaust joint anode screw
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
T.
R.
Exhaust joint anode plug

18 N·m (1.8 kgf·m, 13 lb·ft)
7. Install:
• Holder bracket
• Fuel hose holder
• Wire harness holder
• Pilot hose holders
8. Install:
• Bottom cowlings
See “Installing the bottom cowling” (9-5).
See “Bottom cowling cover and apron cover”
(9-1).
7-12
Power unit assembly
Power unit assembly

7.6 N·m (0.76 kgf·m, 5.6 lb·ft)
1 2
48
4
6 3
5 5
7
30 New
31
D 44 34
6 23 33
22 32
5 43 15 13
11 18
21 42 16 17
10 18
12 19 41
8 18 14
7 20
WR-No.2
WR-No.2
New 35 51 New
7 38 9
36 46
A 7 49 New
37 39
26
40
B New 24 LT
37 25 47 572
50 50
C New 24
26
28 37 25 LT LT
27 45 572 572
46
26 1 42 N·m (4.2 kgf·m, 31 lb·ft) 1 42 N·m (4.2 kgf·m, 31 lb·ft)

1 Hose 1 20 Cap 1
2 Hose 1 21 Battery cable 1
3 Bolt M6 × 16 mm 1 22 Washer 1
4 Guide 1 23 Lead 1
5 Nut M6 3 24 Plastic tie 2
6 Cap 3 25 Plastic tie 1
7 Holder 7 26 Coupler 1
8 Holder 1 27 Lead 1
9 Holder 1 28 Cap 1
10 Lead 1 29 Lead 1
11 Holder 1 30 Plastic tie 1
12 Lead 1 31 Hose 1
13 Plastic tie 1 32 Holder 1
14 Retainer 1 33 Coupler 1
15 Bolt M6 × 20 mm 2 34 Coupler 1
16 Grommet holder 1 35 Plastic tie 2
17 Grommet 1 36 Bolt M6 × 16 mm 1
18 Bolt M8 × 16 mm 4 37 Coupler 1
19 Cap 1 38 Coupler 1
7-13
Power unit assembly
7.6 N·m (0.76 kgf·m, 5.6 lb·ft)

1 2
48
4
6 3
5 5
7
30 New
31
D 44 34
6 23 33
22 32
5 43 15 13
11 18
21 42 16 17
10 18
12 19 41
8 18 14
7 20
WR-No.2
WR-No.2
New 35 51 New
7 38 9
36 46
A 7 49 New
37 39
26
40
B New 24 LT
37 25 47 572
50 50
C New 24
26
28 37 25 LT LT
27 45 572 572
46
Part name Q’ty Remarks A. For the single engine applications

39 Fuel hose 1 B. For the port or starboard outboard motor of
40 Wire harness 1 multiple engine applications
41 Coupler 1 C. For the center outboard motor of multiple en-
42 Holder 1 gine applications
43 Holder 1 D. Optional (isolator lead)
44 Coupler 1
45 Bolt M10 × 35 mm 4
46 Bolt M10 × 70 mm 6
47 Bolt M10 × 130 mm 4
48 Power unit assembly 1
49 Gasket 1
50 Dowel 2
51 O-ring 1
7-14
Power unit assembly
Removing the power unit 3. Remove:

1. Remove: • PTT motor lead “1”
• Bottom cowling cover and apron cover • SCU positive lead “2”
er” (9-1).
• Bottom cowlings
(9-3).
• Aprons
See “Apron” (9-7).
• Dipstick
1 2
• Gear oil changing system hoses
See “Cooling water hose and gear oil 4. Disconnect:
changing hose” (9-8). • Flushing hose “1”
• Fuel rail covers (from the joint)
• Low-pressure fuel pump holder 1
(from the low-pressure fuel pump bracket)
See “Low-pressure fuel pump” (6-6).
TIP:
After removing the low-pressure fuel pump
holder, support the low-pressure fuel pump,
such as by securing it to the power unit assem-
bly using a string, and so on.
5. Disconnect:
2. Remove: • Cooling water hoses “1”, “2”
• Exhaust joint assembly (from the joint)
TIP:
Use a suitable bolt “1” to secure the exhaust
1
joint (lower) “2” and exhaust joint (center) “3”
so that they do not become misaligned.
3
PORT
1 2
2
Bolt “1”
(commercially available) STBD
M6 × 40 mm (1.57 in)
7-15
Power unit assembly
6. Disconnect: c. Hook a lifting harness onto the special ser-
• PTT sensor coupler “1” vice tools “1” and “3”.
• Fuel hose “2” 2
(from the holder bracket)
• Wire harness “3” 6
(from the holder bracket) 5
3
4 1
1
4
1
2 3
7. Disconnect:
3
• SPS lead coupler “1”
1
90890-06953
90890-06821
Balance hanger “3”
90890-06954
8. Remove: Bolt set “4”
• PTT switch lead “1” 90890-06969
YB-06821
1

36 N·m (3.6 kgf·m, 27 lb·ft)
T.
R.
Bolt set “4”

18 N·m (1.8 kgf·m, 13 lb·ft)
d. Remove the bracket “1”.
9. Remove:
• Power unit 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the special service tools “1” and “2”
to the flywheel magneto.

to the exhaust joints “5” and “6”.
7-16
Power unit assembly
e. Remove the power unit mounting bolts “1”,
“2”, and “3”, and then remove the power
unit.
2
WR-No.2 1
1 1
PORT 2

to the flywheel magneto.
c. Install the special service tools “3” and “4”

to the exhaust joints “5” and “6”.
d. Hook a lifting harness onto the special ser-

3 3 vice tools “1” and “3”.
2
6
5
3
4 1
1 1
4
STBD 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
Installing the power unit
1. Clean:
• Power unit matching surface 3
2. Install:
• O-ring New
• Dowels
• Gasket New
• Power unit
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a new O-ring “1” into the flange “2”
and install the dowels and new gasket onto
the exhaust guide.
7-17
Power unit assembly
f. Tighten the power unit mounting bolts “1”,
“2” and “3” to the specified torques in 2
90890-06953
stages and in the order [1], [2], and so on.
90890-06821 [10][17] [7][18] [8][19]
2
Balance hanger “3” [9][16] [11][20]
90890-06954 3
[6][15] 1
Bolt set “4” [12][21]
90890-06969 1
[13][22]
Bolt hexagon with washer “2” [1][28] 1
YB-06821 3
[4][27] [14][23]
2
Bolt hexagon with washer “2” [5][26] [2][25] [3][24]
36 N·m (3.6 kgf·m, 27 lb·ft)
Power unit mounting bolt “1”, “2”,
T.
R.
Bolt set “4”

“3”
T.
18 N·m (1.8 kgf·m, 13 lb·ft)
R.
1st: 42 N·m (4.2 kgf·m, 31 lb·ft)
2nd: 42 N·m (4.2 kgf·m, 31 lb·ft)
e. Install the power unit, and then tighten the
power unit mounting bolts “1”, “2” and “3”
g. Install the bracket “1”
temporarily.
1 1
PORT 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• PTT switch lead “1”
• Holders “2”, “3”
3 3
1
3
2
4. Connect:
• SPS lead coupler “1”
1 1
STBD 2
7-18
Power unit assembly
7. Install:
• SCU signal coupler (4 pins)
• SCU signal coupler (3 pins)
1
TIP:
For single engine applications, connect the
SCU signal coupler (4 pins) to the wire har-
ness, and for multiple engine applications, con-
nect the coupler to the SCU communication
lead (optional). See “Electrical component and
5. Connect: wire harness routing” (5-1).
• Cooling water hoses “1”, “2”
(to the joint) 8. Connect:
• Plastic ties “3” New • SCU negative terminal “1”
3
1
PORT
9. Install:
• Shift actuator motor coupler “1”
• Main wire harness coupler “2”
2
2
3
STBD
6. Connect: 1
• PTT sensor coupler “1”
• Fuel hose “2”
(to the holder bracket) 10. Connect:
• Wire harness “3” • Flushing hose “1”
(to the holder bracket) (to the joint)
• Plastic tie “2” New
2 3
7-19
Power unit assembly
14. Install:
• Caps
1
• PTT motor lead “1”
• SCU positive lead “2”
When tightening the electrical management

box terminal nuts, do not exceed the specified
torque. Otherwise, the base of the electrical
2
management box could be damaged.
11. Install:
• Isolator lead “1” TIP:
• Washer • Route the PTT lead and SCU lead. See “Electri-
(equipped with optional isolator lead) cal component and wire harness routing” (5-1).
• Positive battery cable “a” • Connect the specified leads to the terminals of
• Negative battery cable “b” the electrical management box.
TIP:
When installing the battery cables, make sure that
the flushing hose is not pulled or twisted and does
not contact other parts.
1 2
1
a
b a
12. Install (for multiple engine applications):

• SCU communication lead
• Plastic tie New b
See “Installing the SCU communication lead”
(3-16).
13. Install:
• Rigging grommet
• Rigging grommet holder
• Rigging grommet retainer
See “Installing the rigging grommet” (3-14).
TIP:
Route each harness through the proper hole in
a. Lead color
the rigging grommet. See “Rigging grommet de-
b. Tape color
scription” (3-14).
7-20
Power unit assembly
Electrical management box termi-

nal nut
T.
R.
7.6 N·m (0.76 kgf·m, 5.6 lb·ft)
15. Install:
• Blowby hose guide
• Holders
• Blowby hoses
16. Install:
• Exhaust joint assembly
TIP:
After installing the exhaust joint assembly, re-
move the bolt “1” that was used to secure the
exhaust joint (lower) “2” and exhaust joint (cen-
ter) “3”.
1 2
17. Install:
• Low-pressure fuel pump holder
(to the low-pressure fuel pump bracket)
• Gear oil changing system hoses
See “Cooling water hose and gear oil
changing hose” (9-8).
• Dipstick
• Aprons
• Bottom cowlings
(9-3).
• Bottom cowling cover and apron cover
er” (9-1).
7-21
Electrical management box

7.6 N·m (0.76 kgf·m, 5.6 lb·ft) 6 3.2 N·m (0.32 kgf·m, 2.4 lb·ft) 10* 11*
2 8
6
1 6
A A
3 B
4 16 15* 14* 13*12*

2 A
9
4 1
7
14 15 13
15 13 12 12 14
14
13
12
10 11 11
B
Part name Q’ty Remarks *The locations of the spare fuses are not speci-
1 Nut M6 7 fied.
2 Cap 7
3 Lead 1
4 Coupler 2
Extension wire har-
5 1
ness
6 Bolt M6 × 16 mm 4
Electrical manage-
7 1
ment box
8 Cover 1
9 Screw M5 × 10 mm 10
10 Fuse 2 100 A
11 Fuse 6 70 A
12 Fuse 4 10 A
13 Fuse 4 30 A
14 Fuse 4 20 A
15 Fuse 4 15 A
16 Fuse puller 1
7-22
Installing the electrical management

box nal nut
T.
1. Install:
R.
7.6 N·m (0.76 kgf·m, 5.6 lb·ft)
• Fuses
Fuse screw
3.2 N·m (0.32 kgf·m, 2.4 lb·ft)
T.
R.
2. Install:
• Fuse cover
• Caps
• Extension wire harness
• PTT ground lead (wire harness)
• Couplers
When tightening the electrical management

box terminal nuts, do not exceed the spec-
ified torque. Otherwise, the base of the
electrical management box could be dam-
aged.
TIP:
Connect the specified leads to the terminals of
the electrical management box.
a. Lead color
b. Tape color
7-23
Flywheel magneto
Flywheel magneto
2 3 2
12
13 14 14
2 15
LT
4
242 1 11
5
11
6
New 7
17
16
E
10
1 8 N·m (0.8 kgf·m, 5.9 lb·ft)

8 2 8 N·m (0.8 kgf·m, 5.9 lb·ft)
1 40 N·m (4.0 kgf·m, 30 lb·ft)
2 90°

1 Holder 1
2 Bolt M6 × 16 mm 3
3 Air shroud 1
4 Bolt M6 × 16 mm 4
5 Fan 1
6 Plate 1
7 Bolt M10 × 50 mm 6
8 Flywheel magneto 1
9 Dowel 1
10 Holder 1
11 Holder 2
12 Bolt M6 × 35 mm 6
13 Stator assembly 1
14 Bolt M6 × 30 mm 3
15 Base assembly 1
16 Bolt M6 × 16 mm 1
17 Bracket 1
7-24
Flywheel magneto
Removing the flywheel magneto 3. Remove:

1. Remove: • Flywheel magneto
See “Fuel hose assembly” (6-12). TIP:
Install the guide bolts “a” to the crankshaft, and
then install the guide plate “b” to the flywheel
magneto “1” using the flywheel magneto fan
2. Remove: bolts “2”. Turn the center bolt “c” clockwise us-
Flywheel magneto bolts “1” ing a wrench to remove the flywheel magneto
“1”.
Apply force in the direction of the arrow to

prevent the special service tool “2” from c
slipping off easily. a
2
A 1
1
b
Flywheel guide
90890-06955
2
Installing the flywheel magneto
B 1. Install:
• Holder bracket
1 • Base assembly
• Holders
• Stator assembly
TIP:
Route the stator assembly leads. See “Electri-
3
cal component and wire harness routing” (5-1).
A. Conventional special service tool 2. Install:

B. New special service tool • Dowel
• Flywheel magneto
Rotor holder “2” • Flywheel magneto bolts New
90890-01235 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Flywheel stopper “3” a. Check the mating surfaces of the flywheel
90890-06598 magneto and crankshaft for dirt and other
Universal magneto and rotor hold- foreign material. Clean if there is dirt or
er “2” other foreign material.
YU-01235
b. Install the flywheel magneto using the spe-
Flywheel stopper “3”
cial service tool.
YB-06598
7-25
Flywheel magneto
TIP: TIP:
• Install the guide bolts “a” to the crankshaft, and In the second tightening stage for the flywheel
then install the guide plate “b” to the flywheel magneto bolts “1”, mark the bolts and flywheel
magneto “1” using the flywheel magneto fan magneto with identification marks “a”, and then
bolts “2”. Turn the center bolt “c” counterclock- tighten the bolts 90° from the marks on the fly-
wise using a wrench to install the flywheel mag- wheel magneto.
neto “1”.
• Align the hole “d” in the guide plate “b” with the A
dowel hole “e” in the flywheel magneto “1”.
a 90° 1
d b E
2
e
1
1 B
a 90° 1
c
E
a
2
1
3 1
b
A. Conventional special service tool
B. New special service tool
Flywheel guide
90890-06955
c. Remove the special service tool and flywheel [1] [6]

magneto fan bolts.
[3] [4]
d. Install new flywheel magneto bolts “1”, and
then tighten the bolts to the specified torques
in 2 stages and in the order [1], [2], and so on. [5] [2]
Apply force in the direction of the arrow to pre-

vent the special service tool “2” from slipping
off easily.
7-26
Flywheel magneto
Rotor holder “2”

90890-01235 c d
Flywheel stopper “3” 3
90890-06598
Universal magneto and rotor hold-
er “2”
YU-01235
2
Flywheel stopper “3”
YB-06598
Flywheel magneto bolt “1” 4

1st: 40 N·m (4.0 kgf·m, 30 lb·ft) [3]
T.
R.
2nd: 90° [1]
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Flywheel magneto fan plate “1” [2]
[4]
• Flywheel magneto fan “2”
• Air shroud
Flywheel magneto fan bolt “4”
TIP:
1st: 8 N·m (0.8 kgf·m, 5.9 lb·ft)
• Align the notches “a” in the flywheel magneto
T.
R.
2nd: 8 N·m (0.8 kgf·m, 5.9 lb·ft)

fan plate “1” with the marks “b” on the fly-
wheel magneto “3”.
• Align the “8.0 N·m” mark “c” on the flywheel 4. Install:
magneto fan “2” with the mark “d” on the fly- • Intake manifold (PORT)
wheel magneto “3”. See “Intake manifold” (6-25).
• Tighten the flywheel magneto fan bolts “4” to • Fuel hose assembly
the specified torques in 2 stages and in the See “Fuel hose assembly” (6-12).
order [1], [2], and so on.
LT
242
2
a
1 a
7-27
Starter motor and extension wire harness
14
13
11 N·m (1.1 kgf·m, 8.1 lb·ft)
12
13
19
7 3
9 2
18
10
3
18
3 16
1
11 19
15
8
15 A
17
4
5
4 6
4 11 N·m (1.1 kgf·m, 8.1 lb·ft)

1 Plastic tie 1 19 Bracket 2
2 Holder 1
A. When an isolator lead is not installed.
3 Holder 5
4 Bolt M8 × 16 mm 3
5 Cap 3
6 Bolt M6 × 16 mm 1
Extension wire har-
7 1
ness
8 Holder 2
9 Nut M8 1
10 Cap 1
11 Cable 1
12 Coupler 1
13 Bolt M8 × 45 mm 3
14 Starter motor 1
15 Bolt M8 × 20 mm 2
16 Terminal 1
17 Cover 1
18 Bolt M6 × 16 mm 4
7-28
Installing the starter motor

1. Install:
• Holder brackets
• Battery cable terminal
• Terminal cover
(when an isolator lead is not installed)
• Starter motor
• Holders
• Cap
• Starter motor cable
• Starter motor coupler
Starter motor cable nut
11 N·m (1.1 kgf·m, 8.1 lb·ft)
T.
R.
Starter motor cable bolt

11 N·m (1.1 kgf·m, 8.1 lb·ft)
Installing the extension wire harness

1. Install:
• Holders
• Extension wire harness
• Caps
• Extension wire harness bolts
• Ground lead
(extension wire harness)
• Plastic tie
TIP:
Route the extension wire harness. See “Elec-
trical component and wire harness routing”
(5-1).
Extension wire harness bolt

11 N·m (1.1 kgf·m, 8.1 lb·ft)
T.
R.
7-29
Wire harness
Wire harness
8 New
13
11 12
7
4
11
8 New
10
4
9 9
5
3
2
6 4 4
1

1 Bolt M6 × 16 mm 2
2 Bracket 1
3 Holder 1
4 Bolt M6 × 16 mm 6
5 Holder 2
6 Holder 1
7 Holder 1
8 Plastic tie 2
9 Holder 3
10 Holder 1
11 Holder 3
12 Holder 1
13 Wire harness 1
7-30
Wire harness
Removing the wire harness

1. Disconnect: a
• Crankshaft position sensor coupler “a” b
c
d
a
5. Disconnect:
• ECM couplers “a”, “b”, “c”
• Thermo sensor coupler (PORT) “d”
2. Disconnect:
• Ground leads “a”, “b”, “c” TIP:
While pushing the tab “e” of the ECM coupler,
move the lock lever “f” in the direction shown to
a disengage the coupler.
d
b
3. Disconnect:
a b c
• Low-pressure fuel pump coupler “a”
• High-pressure fuel pump couplers “b”, “c”
coupler “d”
f
a b
d e
f
c
6. Disconnect:
• Wire harness “a”
4. Disconnect: (from the guide)
• ETV coupler “a” • Plastic tie “1”
• Rectifier/regulator coupler “b” • Cam position sensor coupler (PORT IN)
• YDIS coupler “c” “b”
• Low-pressure fuel pump relay coupler “d” • Joint connector “c”
7-31
Wire harness
g
1 g
a
1
e f e
b b
7. Disconnect: 9. Disconnect:
• Ignition coil couplers (PORT) “a” • Ground leads “a”, “b”
• Fuel pressure sensor (direct injection • OCV coupler (PORT) “c”
pump) coupler (PORT) “b”
c
a
a
a b
10. Disconnect:
8. Disconnect: • PTT sensor coupler “a”
• Wire harness “a” (from the bracket)
(from the bracket) • Sub-wire harness coupler (PORT) “b”
• Engine temperature sensor coupler “b” • Direct injection pump coupler (PORT) “c”
• Injector driver couplers “c”, “d”, “e”
TIP:
While pushing the tab “f” of the injector driver
coupler “e”, move the lock lever “g” in the direc-
tion shown to disengage the coupler.
c
a
a b
b
c
d 11. Disconnect:
e • Cam position sensor coupler (PORT EX)
“a”
c • Knock sensor coupler (upper) “b”
d • Water pressure sensor coupler “c”
e
7-32
Wire harness
b
a a a
b
c
b
c
12. Disconnect: 15. Disconnect:

• Direct injection pump coupler (STBD) “a” • Wire harness “a”
• Sub-wire harness coupler (STBD) “b” (from the guides)
• Joint connector “c” • Plastic tie “1”
(from the bracket) • Cam position sensor coupler (STBD IN)
• Knock sensor coupler (lower) “d” “b”
• SCU couplers “e”, “f” • Thermo sensor coupler (STBD) “c”
(from the bracket)
c
a 1
c b
a
c
e b
d a b
f
Installing the wire harness

13. Disconnect: Route the wire harness.
• Oil pressure sensor coupler “a” See “Electrical component and wire harness
• OCV coupler (STBD) “b” routing” (5-1).
1. Connect:
b • Holder “1”
• Wire harness “a”
(to the guides)
• Cam position sensor coupler (STBD IN)
a “b”
• Thermo sensor coupler (STBD) “c”
1 c
14. Disconnect:
• Ground lead “a” 2
• Ignition coil couplers (STBD) “b”
• Fuel pressure sensor (direct injection a
pump) coupler (STBD) “c”
b
a b
7-33
Wire harness
2. Connect:
• Holders “1”
• Ground lead “a” a
• Ignition coil couplers (STBD) “b”
b
pump) coupler (STBD) “c”
1 a
b a a
1 6. Connect:
c • Wire harness “a”
b (to the guide)
• Cam position sensor coupler (PORT IN)
1 “b”
3. Connect: • Joint connector “c”
• Oil pressure sensor coupler “a”
• OCV coupler (STBD) “b” c
b 1
a
1
a
b b
7. Connect:
• Holders “1”
4. Connect: • Wire harness “a”
• Cam position sensor coupler (PORT EX) (to the bracket)
“a” • Engine temperature sensor coupler “b”
• Knock sensor coupler (upper) “b” • Injector driver couplers “c”, “d”, “e”
• Water pressure sensor coupler “c”
TIP:
Fit the injector driver coupler “e” onto the injec-
tor driver, and then move the lock lever “f” in
a
the direction shown to engage the coupler.
b Make sure that the tab “g” is securely locked in
place.
5. Connect:
• Ignition coil couplers (PORT) “a”
pump) coupler (PORT) “b”
7-34
Wire harness
a
b
1
c
d
e c
1
c a b
d
e 10. Connect:
1
• Holder “1”
• SCU couplers “a”, “b”
(to the bracket)
• Knock sensor coupler (lower) “c”
• Joint connector “d”
(to the bracket)
f
• Sub-wire harness coupler (STBD) “e”
• Direct injection pump coupler (STBD) “f”
e d f
g e
d
8. Connect: 1
• Ground leads “a”, “b” b
c
• OCV coupler (PORT) “c”
a
c 11. Connect:
• Holder “1”
• ECM couplers “a”, “b”, “c”
• Thermo sensor coupler (PORT) “d”
TIP:
a b Fit the ECM coupler onto the ECM, and then
move the lock lever “e” in the direction shown to
9. Connect: engage the coupler. Make sure that the tab “f” is
• PTT sensor coupler “a” securely locked in place.
(to the bracket)
• Sub-wire harness coupler (PORT) “b”
• Direct injection pump coupler (PORT) “c” d
1
a b c
7-35
Wire harness
TIP:
Connect the ground leads so that they contact
the stoppers. Make sure to match the numbers
“d” on the ground leads to the numbers “e” on
e
the oil filler neck.
f
e
e a
d
12. Connect: 1
• Holder “1” 2 2
• ETV coupler “a” 3 b

• Rectifier/regulator coupler “b”
3
• YDIS coupler “c” c
• Low-pressure fuel pump relay coupler “d”
15. Connect:
a • Crankshaft position sensor coupler “a”
b
1
c
d
a
13. Connect:
• Holders “1”
• Low-pressure fuel pump coupler “a” 16. Install:
• High-pressure fuel pump couplers “b”, “c” • Holder bracket
• Intake air pressure/temperature sensor • Holder
coupler “d”
1 1
a b
14. Connect:
• Ground leads “a”, “b”, “c”
7-36
ECM, injector driver, and rectifier/regulator

3.9 N·m (0.39 kgf·m, 2.9 lb·ft)
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
11 10 7
18
6
17
12 10
14
5
4
9
LT
242
15
16 8
2
3 New 13
1 14 N·m (1.4 kgf·m, 10 lb·ft)

2 28 N·m (2.8 kgf·m, 21 lb·ft) 8
1

1 Bolt M8 × 50 mm 10
2 Rectifier/regulator 1
3 Gasket 1
4 Screw M6 × 25 mm 1
5 Anode 1
6 Bolt M6 × 20 mm 4
7 ECM 1
8 Bolt M6 × 16 mm 8
9 Injector driver 2
10 Screw M6 × 20 mm 2
11 Bracket 1
12 Relay 1
13 Bolt M6 × 35 mm 6
14 Bracket 1
15 Collar 6
16 Grommet 6
17 Bolt M6 × 16 mm 2
18 Bracket 1
7-37
Removing the rectifier/regulator

1. Remove: TIP:
• Install the rectifier/regulator “4” so that its
side with the “OUTSIDE” mark “a” is facing
outward.
• Vapor separator assembly
• Tighten the rectifier/regulator bolts “5” to the
See “Removing the vapor separator”
specified torques in 2 stages and in the order
(6-10).
[1], [2], and so on.
• Surge tank
See “ETV” (6-28).
a
Checking the rectifier/regulator anode
1. Check:
• Anode
Eroded (1/2 or more worn out) → Replace. 3
Adhered grease, oil, or scales → Clean.
Do not apply grease, oil, or paint to the an- 5 1

odes. 2
LT
Installing the ECM and injector driver 242
1. Install: 4
• Holder bracket
• Grommets
• Collars a
• ECM/injector driver bracket
• Coupler bracket
• Low-pressure fuel pump relay
• Injector drivers
[5] [6] [7]
• ECM
Coupler bracket screw
2.5 N·m (0.25 kgf·m, 1.8 lb·ft) [1] [2]
T.
R.
Low-pressure fuel pump relay

screw [4] [3]
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
[10] [9] [8]
Installing the rectifier/regulator
1. Install:
• Rectifier/regulator anode “1”
• Rectifier/regulator anode screw “2” Rectifier/regulator anode screw
• Gasket “3” New “2”
T.
R.
• Rectifier/regulator “4” 3.9 N·m (0.39 kgf·m, 2.9 lb·ft)

• Rectifier/regulator bolts “5” Rectifier/regulator bolts “5”
1st: 14 N·m (1.4 kgf·m, 10 lb·ft)
2nd: 28 N·m (2.8 kgf·m, 21 lb·ft)
7-38
2. Install:
• Surge tank
See “Installing the ETV and surge tank”
(6-29).
• Vapor separator assembly
See “Installing the vapor separator” (6-11).
See “Installing the low-pressure fuel pump”
(6-8).
7-39
Ignition coil and spark plug
5
4
3
2
5
3
4
2
1
10 N·m (1.0 kgf·m, 7.4 lb·ft)

11 N·m (1.1 kgf·m, 8.1 lb·ft)

1 Bolt M6 × 30 mm 8
2 Ignition coil 8
3 Spark plug 8
4 Bolt M6 × 20 mm 16
5 Bracket 8
7-40
Checking the spark plug

1. Check:
• Electrode “1”
Damaged/worn → Replace.
• Insulator “2”
Abnormal color → Replace.
(Normal color: Medium-to-light tan)
2. Clean:
• Spark plug
(with a spark plug cleaner)
Do not use a wire brush to clean the spark

plugs, as it will damage the iridium coating
on the electrode.
3. Measure:
• Spark plug gap “a”
(with a wire thickness gauge)
2 a
Spark plug (NGK)

ILMAR7E-9
Spark plug gap
0.8–0.9 mm (0.031–0.035 in)
Installing the ignition coil and spark

plug
1. Install:
• Spark plugs
• Ignition coil brackets
• Ignition coils
Spark plug
11 N·m (1.1 kgf·m, 8.1 lb·ft)
T.
R.
Ignition coil bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
7-41
Timing belt
Timing belt
1 5 1 39 N·m (3.9 kgf·m, 29 lb·ft)
5 10
2
9
4
7 6
3
8
4
4
3 4
6
3 8
3

1 Bolt M6 × 35 mm 4
2 Wire harness guide 1
3 Collar 4
4 Grommet 4
5 Holder 2
6 Grommet 2
7 Bolt M6 × 16 mm 2
8 Bracket 2
9 Tensioner 1
10 Timing belt 1
7-42
Timing belt
Removing the timing belt

Shaft holder “1”
90890-06949
When the timing belt is not installed, do not
turn the crankshaft or driven sprocket. Other- c. Turn the timing belt tensioner gradually clock-
wise, the pistons and valves could collide with wise using a hexagon wrench, and then insert
each other and be damaged. a 5.0 mm (0.2 in) diameter pin “1” into the hole
“a”.
1. Remove:
• Timing belt TIP:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • When turning the timing belt tensioner, apply a
a. Align the “ ” mark “a” on the crankshaft with force of 15 N·m (1.5 kgf·m, 11 lb·ft) or less.
the protrusion “b” on the cylinder block. • Leave the pin “1” inserted into the hole “a” of the
timing belt tensioner until the timing belt is in-
TIP: stalled again.
Turn the crankshaft clockwise using the special
service tool “1”.
1
b. Check that the “ ” mark “c” on the driven

sprocket (PORT) and the “ ” mark “d” on
the cylinder head (PORT) are aligned, and
check that the “ ” mark “e” on the driven
sprocket (STBD) and the “ ” mark “f” on the
cylinder head (STBD) are aligned. a
d. Remove the timing belt.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the timing belt

1
1. Check:
• Interior and exterior of the timing belt
Cracked/damaged/worn → Replace.
Installing the timing belt

c d
f e
turn the crankshaft or driven sprocket. Other-
wise, the pistons and valves could collide with
each other and be damaged.
1. Install:
• Timing belt
• Timing belt tensioner
b
TIP:
a Check that the alignment marks on the crankshaft
and driven sprockets are positioned in the proper
locations. See “Removing the timing belt” (7-43).
7-43
Timing belt
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ c. Turn the timing belt tensioner “1” so that the
a. Install the timing belt “1” onto the crankshaft hole “a” in the timing belt tensioner fits onto
so that the part number “a” is in the upright po- the protrusion “b” on the cylinder block, and
sition and the belt position mark “b” is aligned then tighten the timing belt tensioner bolt “2”.
with the mark “c” on the crankshaft.
1 2
1
c
b
a b a b
Timing belt tensioner bolt “2”

39 N·m (3.9 kgf·m, 29 lb·ft)
T.
R.
d. Adjust the timing belt installation heights “a”,
“b”, and “c” to specification.
b. Working in a counterclockwise manner, install
the timing belt by aligning the belt position
mark “a” with the “ ” mark “b” on the driven 1 3
sprocket (PORT) and aligning the belt posi- b c
tion mark “c” with the “ ” mark “d” on the driv- a
en sprocket (STBD).
TIP: 2
After installing the timing belt, temporarily install
the timing belt tensioner “1” to remove the slack in
the timing belt. Do not pull out the pin that was in-
serted when removing the timing belt tensioner 1. Crankshaft
“1”. 2. Driven sprocket (PORT)
3. Timing belt tensioner
b a Installation height
c d “a”: 3.25 mm (0.1280 in)
“b”: 0.75 mm (0.0295 in)
“c”: 6.75 mm (0.2657 in)
e. Turn the timing belt tensioner gradually clock-

wise using a hexagon wrench, and then re-
move the pin “1”. After removing the pin,
slowly move the timing belt tensioner back to
1
its original position.
7-44
Timing belt
TIP:
• When turning the timing belt tensioner, apply
a force of 15 N·m (1.5 kgf·m, 11 lb·ft) or less.
• Make sure that the belt position marks are
aligned with the marks on the crankshaft and
driven sprockets. See steps (a) and (b).
f. Turn the crankshaft clockwise 2 full turns

until the “ ” mark “a” on the crankshaft is
aligned with the protrusion “b” on the cylin-
der block. Check that the “ ” mark “c” on
the driven sprocket (PORT) and the “ ”
mark “d” on the cylinder head (PORT) are
aligned, and check that the “ ” mark “e” on
the driven sprocket (STBD) and the “ ”
mark “f” on the cylinder head (STBD) are
aligned.
c d
f e
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
• Brackets
• Grommets
• Collars
• Wire harness guide
7-45
Camshaft
Camshaft
60 N·m (6.0 kgf·m, 44 lb·ft) 28 25 13 New 9
17 14
1
38 19
39
1386B
29 New 30 35
37 24
5
27
33 26 16 1
37 23 21 24 11 4
29 31 2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
20 36
14
28 1280B
17 37 25
1377B
18
29 29 New 12 15
New 30
E 1280B
37 New 8
E E
E
E
28 32 E
27 7
34 1280B
31 E 3 10 6
22 1 9
E
E 2
24 1
21
E 25 E 28 1 8 N·m (0.8 kgf·m, 5.9 lb·ft)
E
36 E 26 2 8 N·m (0.8 kgf·m, 5.9 lb·ft)
20
1 8 N·m (0.8 kgf·m, 5.9 lb·ft)
E 2 17 N·m (1.7 kgf·m, 13 lb·ft)
60 N·m (6.0 kgf·m, 44 lb·ft) 24 25

1 Bolt M6 × 16 mm 13 Driven sprocket
19 1
2 Bracket 1 (STBD)
3 Guide 1 Left-hand
20 Bolt M12 × 35 mm 2
4 Bracket 1 threads
5 Guide 1 21 Bolt M6 × 25 mm 4
6 Bolt M6 × 25 mm 1 22 Tensioner (PORT) 1
7 Hose nipple 1 23 Tensioner (STBD) 1
8 O-ring 1 24 Bolt M7 × 48 mm 8
9 Bolt M6 × 30 mm 44 25 Bolt M7 × 37 mm 36
10 Cover 1 26 Camshaft cap 2
11 Cover 1 27 Camshaft cap 2
12 Gasket 1 28 Camshaft cap 18
13 Gasket 1 29 Dowel 8
14 Screw M4 × 7 mm 16 30 Oil seal 2
15 Plate 1 31 Chain 2
16 Plate 1 32 Camshaft (PORT EX) 1
17 Bolt M10 × 35 mm 2 33 Camshaft (STBD EX) 1
34 Camshaft (PORT IN) 1
Driven sprocket
18 1 35 Camshaft (STBD IN) 1
(PORT)
7-46
Camshaft
60 N·m (6.0 kgf·m, 44 lb·ft) 28 25 13 New 9

17 14
1
38 19
39
1386B
29 New 30 35
37 24
5
27
33 26 16 1
37 23 21 24 11 4
29 31 2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
20 36
14
28 1280B
17 37 25
1377B
18
29 29 New 12 15
New 30
E 1280B
37 New 8
E E
E
E
28 32 E
27 7
34 1280B
31 E 3 10 6
22 1 9
E
E 2
24 1
21
E 25 E 28 1 8 N·m (0.8 kgf·m, 5.9 lb·ft)
E
36 E 26 2 8 N·m (0.8 kgf·m, 5.9 lb·ft)
20
1 8 N·m (0.8 kgf·m, 5.9 lb·ft)
E 2 17 N·m (1.7 kgf·m, 13 lb·ft)
60 N·m (6.0 kgf·m, 44 lb·ft) 24 25

36 VCT assembly 2
37 Valve lifter 32
38 Bolt M8 × 20 mm 2
39 Bracket 1
7-47
Camshaft
Removing the camshaft, VCT

assembly, and driven sprocket TIP:
After removing the timing belt, secure the cam-
shaft using a wrench, and then remove the
When the timing belt is not installed, do not driven sprocket bolts “3”.
turn the crankshaft or camshaft. Otherwise,
the pistons and valves could collide with 2 1
1. Remove:
• Exhaust joints (PORT and STBD)
• Direct injection pumps
• Fuel rails
• Fuel injectors 3
See “Direct injection pump and fuel injec-
tor” (6-18).
2. Turn:
• Crankshaft
4. Loosen:
• VCT bolts “1”
Do not turn the crankshaft counterclock-
wise more than 45°. Otherwise, the pistons
and valves could collide with each other When loosening or tightening the VCT bolt,
and be damaged. do not secure the VCT assembly. Other-
wise, the VCT assembly could be damaged.
TIP:
Turn the crankshaft counterclockwise 45° TIP:
gradually until the “ ” mark “a” on the crank- Secure the camshaft using a wrench, and then
shaft is aligned with the“” mark “b” on the cyl- loosen the VCT bolt “1”.
inder block.
45°
b a
5. Remove:
• Cam chain tensioners
6. Remove:
• Camshaft caps
3. Remove:
• Driven sprocket (PORT) “1”
• Driven sprocket (STBD) “2”
7-48
Camshaft
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
TIP: a. Measure the distances “a” and “b” for a 12-
Remove the camshaft caps “1”, “2”, and “3” in link section of the cam chain, and then cal-
the order [1], [2], and so on. culate the chain length using the following
formula.
PORT STBD TIP:

1 1 When measuring the chain length, make sure
[1] [1] that the chain is sufficiently taut without any
[4] [5] [4] slack.
[5]
[3] [4] [3]
[4] Calculation formula:
Chain length of the measured section =
[5] [6] [5] (Distance “a” between the inner edges of
[6] the rollers + Distance “b” between the out-
[2] [3] [2] er edges of the rollers)/2
[3] 2 Example:
3 3 Distance “a” between the inner edges of
2 [2] the rollers = 108.25 mm
[1] [2] [1] Distance “b” between the outer edges of
the rollers = 120.55 mm
Chain length of the measured section =
7. Remove: (108.25 mm + 120.55 mm)/2 = 114.40 mm
• Camshafts
b. Measure the distances of 3 different sec-
• Valve lifters
tions of the cam chain, and then calculate
TIP: the average chain length.
Make sure to keep the parts in the order of re- Example:
moval. (mm)
Chain length of mea-
114.40
Checking the sprocket sured section 1
1. Check: Chain length of mea-
114.50
• Driven sprocket sured section 2
• Camshaft (EX) Chain length of mea-
• VCT assembly 114.45
sured section 3
Cracked/damaged/worn → Replace the
Average 114.45
driven sprocket, camshaft (EX), or VCT
assembly.
1 3 ..... 11
Checking the cam chain
1. Check:
Chain length
2 12
Above specification → Replace.
Limit
114.85 mm (4.5216 in) a
b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-49
Camshaft
Checking the cam chain tensioner

1. Measure: TIP:
• Be careful not to scratch or damage the face
• Wear depth
of the flange.
• If there is a scratch that is more than 0.2 mm
TIP: (0.008 in) deep or more than 0.5 mm (0.020
Measure the wear depth “a” on the guide sur- in) wide on the surface of the flange, an error
face of the cam chain tensioner. may occur in the cam position sensor signal.
IN
Maximum wear depth

1.00 mm (0.0394 in)
Checking the valve lifter

1. Check:
• Valve lifter
Damaged/scratched/worn → Replace.
2. Measure: EX
• Valve lifter outside diameter “a”
2. Measure:
• Cam lobe height “a”
• Fuel pump cam width across corners (di-
rect injection pump) “b”
a a
Outside diameter
30.964–30.980 mm (1.2191–
1.2197 in)
Checking the camshaft

1. Check:
• Pulser rotor
Damaged/rough/scratched → Replace.
7-50
Camshaft
Checking the camshaft journal oil

clearance
1. Install:
• Camshafts
b • Plastigauge (PG-1) “1”
Do not place the Plastigauge (PG-1) over

the oil hole in each camshaft journal.
b
Cam lobe height IN TIP:

47.011–47.111 mm (1.8508– Place the camshafts onto the cylinder head,
1.8548 in) and then place a piece of Plastigauge (PG-1)
Limit “1” onto each camshaft journal, parallel to the
46.961 mm (1.8489 in) camshaft.
Cam lobe height EX
46.600–46.700 mm (1.8346–
1.8386 in) 1
Limit
46.550 mm (1.8327 in)
Fuel pump cam width across cor-
ner (DI pump)
49.350-49.450 mm (1.9429-
1.9468 in)
3. Measure:
• Camshaft runout 2. Install:
Out of specification → Replace. • Dowels
• Camshaft caps “1”, “2”, “3”
• Camshaft cap bolts (M7 × 48 mm) “4”
(temporarily)
• Camshaft cap bolts (M7 × 36 mm) “5”
(temporarily)
TIP:
Install the camshaft caps “1”, “2”, and “3” in
their proper positions so that the stamped
numbers are upside down.
Runout
0.030 mm (0.0012 in)
7-51
Camshaft
PORT 3 4 STBD Camshaft cap bolt “1”, “2”

1 3 51
5 4 6S 1st: 8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
6P
7S 1S 2nd: 17 N·m (1.7 kgf·m, 13 lb·ft)
1P 7P
8S 2S 4. Remove:
2P 8P • Camshaft caps
See step 6 in “Removing the camshaft,
9S 3S
3P 9P VCT assembly, and driven sprocket”
(7-48).
10S 4S
10P
4P 5S 5. Measure:
5P 11S
11P • Width of the Plastigauge “1”
Out of specification → Check the camshaft
journal outside diameter and camshaft
4 5 2
2 4 journal inside diameter. See “Checking the
4 camshaft journal outside diameter and
E E camshaft journal inside diameter” (7-52).
3. Tighten:
1
• Camshaft cap bolts “1”, “2”
TIP:
• Tighten the camshaft cap bolts “1” and “2” to
the specified torques in 2 stages and in the
• Do not turn the camshafts when measuring
the camshaft journal oil clearance using the
Plastigauge.
Camshaft journal oil clearance
0.020–0.061 mm (0.0008–
PORT STBD 0.0024 in)
1 2 2 Limit
1
[6] [6] 0.080 mm (0.0032 in)
[2] [2] [2]
[2] Checking the camshaft journal
[3] [3] [3] outside diameter and camshaft
[3] journal inside diameter
[1] [1] [1] 1. Measure:
[1] • Camshaft journal outside diameter “a”
[4] [4] [4] Out of specification → Replace.
[4]
[5]
[5] [5] [5]
2 2
7-52
Camshaft
Installing the camshaft, VCT

a assembly, and driven sprocket
If the valve clearances are adjusted or any
parts related to valve movement are replaced
after installing the timing belt, check the valve
clearances. See “Checking the valve clear-
ance” (7-2).
a

turn the crankshaft or camshaft. Otherwise,
the pistons and valves could collide with
1. Install:
Journal diameter
• Wire harness guide bracket
24.960–24.980 mm (0.9827–
0.9835 in) 2. Check:
• Crankshaft position
2. Install:
• Camshaft caps TIP:
See steps 2–3 in “Checking the camshaft Check that the “ ” mark “a” on the crankshaft
journal oil clearance” (7-51). is aligned with the “” mark “b” on the cylinder
block.
3. Measure:
• Camshaft journal inside diameter “a”
Out of specification → Replace the cylin-
der head and camshaft cap as a set.
b a
a
3. Install:
• Valve lifters
Journal inside diameter

TIP:
Install the valve lifters in their original positions.
25.000–25.021 mm (0.9843–
0.9851 in)
4. Assemble:
• VCT assemblies
• VCT bolts (temporarily)
• Camshafts (IN)
5. Install:
• Oil seals New
• Camshafts (IN) (along with cam chain)
• Camshafts (EX)
7-53
Camshaft
TIP: 1386B 1386B a

Align the mark “a” on the VCT assembly and a a
a
the big slot “b” on the camshaft (EX) with the
gold-colored plates “c” on the cam chain “1”.
c 1 c a
E E
PORT
b. Install the camshaft caps “1”, “2”, and “3” in
their proper positions so that the stamped
a c 1 c numbers are upside down, and then install
the camshaft cap bolts “4” and “5” tempo-
b rarily.
PORT 3 4 STBD
1 3 51
5 4 6S
6P
7S 1S
E E
1P 7P
STBD 8S 2S
2P 8P
6. Install:
• Camshaft caps 9S 3S
3P 9P
• Camshaft cap bolts
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 10S 4S
a. Apply a thin, even coat of sealant to the 4P 10P 5S
mating surfaces “a” of the camshaft caps 5P 11S
11P
and cylinder heads.
TIP: 4 5 2
Do not block the oil passages or oil holes with 2 4
4
the sealant.
E E
c. Tighten the camshaft cap bolts “1” and “2”

to the specified torques in 2 stages and in
the order [1], [2], and so on.
7-54
Camshaft
8. Install:
PORT STBD
• Cam chain tensioner (PORT) “1”
1 2 2 • Cam chain tensioner (STBD) “2”
1
[6] [6]
[2] [2] [2] TIP:
[2] • Use plastic ties “3” to hold the cam chain ten-
[3] sioners in the retracted position. Remove the
[3] [3]
[3] plastic ties “3” after installing the cam chain ten-
sioners.
[1] [1] [1] • Make sure that the cam chain “4” is properly po-
[1] sitioned on the guide surface “a” of the cam
[4] [4] [4] chain tensioner.
[4]
3 3
[5]
[5] [5] [5]
2 2
Camshaft cap bolt “1”, “2”

1st: 8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
2nd: 17 N·m (1.7 kgf·m, 13 lb·ft)

1 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
PORT
7. Tighten:
• VCT bolts 4
When loosening or tightening the VCT bolt, do

not secure the VCT assembly. Otherwise, the a
VCT assembly could be damaged.
TIP:
Secure the camshaft using a wrench, and then STBD
tighten the VCT bolt “1” to the specified torque.
1
a
9. Install:
• Driven sprocket (PORT) “1”
• Driven sprocket (STBD) “2”
VCT bolt “1”
60 N·m (6.0 kgf·m, 44 lb·ft)
T.
R.
7-55
Camshaft
11. Turn:
TIP: • Crankshaft
Secure the camshaft using a wrench, and then
tighten the driven sprocket bolts “3” to the
specified torque. Do not turn the crankshaft clockwise more
than 45°. Otherwise, the pistons and valves
could collide with each other and be dam-
2
aged.
TIP:
3 Turn the crankshaft clockwise 45° gradually
1 until the “ ” mark “a” on the crankshaft is
aligned with the protrusion “b” on the cylinder
block.
Driven sprocket bolt “3”

60 N·m (6.0 kgf·m, 44 lb·ft)
T.
R.
10. Check:
b a
• Camshaft positions
TIP: 45°
• Check that the “ ” mark “a” on the driven
sprocket (PORT) is aligned with the “ ”
mark “b” on the cylinder head (PORT).
• Check that the “ ” mark “c” on the driven
sprocket (STBD) is aligned with the “ ” mark
“d” on the cylinder head (STBD).
12. Install:
a • Breather plate (PORT)
• Breather plate (STBD)
b TIP:
• Apply a thin, even coat of sealant onto the
cylinder head covers “1” and “2”.
• Make sure to apply sealant only to the por-
tions of the cylinder head covers that will con-
tact the breather plates.
c
d
7-56
Camshaft
PORT 1280B 2
4
1280B
1
1280B
1280B
1
3
1280B
STBD Cylinder head cover bolt

1st: 8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
2nd: 8 N·m (0.8 kgf·m, 5.9 lb·ft)
1280B
14. Install:
• O-ring “1” New
2 • Hose nipple “2”
• Guide (PORT) “3”
• Bracket (PORT) “4”
• Guide (STBD) “5”
• Bracket (STBD) “6”
5
Breather plate screw 1

2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 6
T.
R.
E
13. Install: 3 2
• Gaskets “1”, “2” New
• Cylinder head cover (PORT) “3”
• Cylinder head cover (STBD) “4” 4
TIP:
Tighten the cylinder head cover bolts to the
specified torques in 2 stages.
7-57
Camshaft
15. Install:
• Fuel injectors
• Fuel rails
• Direct injection pumps
See “Installing the fuel injector and fuel
rail” (6-20).
• Exhaust joint (PORT and STBD)
7-58
Cylinder head
Cylinder head
25 N·m (2.5 kgf·m, 18 lb·ft) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 9
12 10
13 11 New
7 23 24 New
1
22 20
21 19
New 6 14 17 16 25 New 18
7 24 New
14
17 15 New 25 19
16 New 20 18
1303 21 27 New
22
8 E 3 26
23 12
5
12 2
13 13
8 7 4 25 N·m (2.5 kgf·m, 18 lb·ft)
7 E
25 New
New 24 New
New 25 21
27 20
New 24 21 26 19
1377B 20
19 18
9 18 25 N·m (2.5 kgf·m, 18 lb·ft)
6.5 N·m (0.65 kgf·m, 4.8 lb·ft) 10 E
11 New 1
1 39 N·m (3.9 kgf·m, 29 lb·ft) 1 14 N·m (1.4 kgf·m, 10 lb·ft)
2 180° 3 E 2 2 28 N·m (2.8 kgf·m, 21 lb·ft)

1 Bolt M8 × 50 mm 2 19 Spring retainer 32
2 Bolt M8 × 70 mm 8 20 Valve spring 32
3 Bolt M11 × 120 mm 20 21 Spring seat 32
4 Cylinder head (PORT) 1 22 Intake valve 16
5 Cylinder head (STBD) 1 23 Exhaust valve 16
6 Gasket 2 24 Valve seal 32
7 Dowel 4 25 Valve guide 32
8 Grommet 2 26 Plug M21 × 14 mm 6
9 Bolt M6 × 35 mm 6 27 O-ring 6
10 OCV assembly 2
11 Gasket 2
12 Bolt M6 × 20 mm 3
13 Cam position sensor 3
14 Plug 6
15 O-ring 6
16 Screw M5 × 21 mm 6
17 Anode 6
18 Valve cotter 64
7-59
Cylinder head
Removing the cylinder head

B 5 4
1. Remove:
• Cylinder head 3
Do not scratch or damage the mating sur-

faces of the cylinder head and cylinder
4 2
block.
TIP:
Remove the M11 cylinder head bolts using a A. Conventional special service tool
triple square socket. B. New special service tool
Conventional special service tools
Disassembling the cylinder head Valve spring compressor “1”

1. Remove: 90890-04019
• Intake valves Valve spring compressor attach-
• Exhaust valves ment “2”
90890-06320
TIP: Valve spring compressor “1”
Make sure to keep the parts in the order of re- YM-04019
moval. Valve spring compressor adaptor
“2”
A YB-06320
1 New special service tools
2 Valve spring compressor attach-

ment “2”
90890-06320
Lever assy “3”
90890-06956
Support assy 3 “4”
90890-06952
Valve spring compressor “5”
90890-06689
Valve spring compressor adaptor
“2”
YB-06320
YB-06689
Checking the cylinder head

1. Remove:
• Combustion chamber carbon deposits
7-60
Cylinder head
2. Check:
• Cylinder head
Damaged/scratched → Replace.
b a
• Cylinder head warpage
TIP: d c
Check the cylinder head warpage using a
straightedge “1” and a thickness gauge “2” in 6
directions.
Cylinder head bolt (M11) diameter
2 difference limit
1
“a” – “b” = Less than 0.20 mm
(0.0079 in)
Measuring point “c”: 10.0 mm
(0.39 in)
Measuring point “d”: 85.0 mm
(3.35 in)
Checking the valve spring

1. Measure:
• Free length “a”
Below specification → Replace.
Warpage limit
0.10 mm (0.0039 in)
Checking the cylinder head bolt a

1. Measure:
Free length IN
• Cylinder head bolt diameter
48.08 mm (1.89 in)
Limit
TIP: 45.68 mm (1.80 in)
Measure the diameters “a” and “b” of the cylin- Free length EX
der head bolt (M11) at the specified measuring 48.08 mm (1.89 in)
points “c” and “d”. Limit
45.68 mm (1.80 in)
2. Measure:
• Spring tilt “a”
7-61
Cylinder head
a
a
Tilt limit IN Diameter IN

1.7 mm (0.07 in) 5.477–5.492 mm (0.2156–
Tilt limit EX 0.2162 in)
1.7 mm (0.07 in) Limit
5.447 mm (0.2144 in)
Checking the valve Diameter EX
1. Check: 5.464–5.479 mm (0.2151–
• Valve face 0.2157 in)
Pitted/worn → Replace. Limit
5.434 mm (0.2139 in)
2. Measure:
• Margin thickness “a” 4. Measure:
Out of specification → Replace. • Stem runout
a
Margin thickness IN
0.50–0.90 mm (0.0197–0.0354 Runout limit IN
in) 0.01 mm (0.0004 in)
Margin thickness EX Runout limit EX
0.90–1.30 mm (0.0354–0.0512 0.01 mm (0.0004 in)
in)
Checking the valve guide
3. Measure: Before checking the valve guides, make sure
• Stem diameter “a” that the valve stem diameter is within specifica-
Out of specification → Replace. tion.
1. Measure:
• Inside diameter “a”
7-62
Cylinder head
2
a
1
Inside diameter IN Valve guide remover/installer “2”

5.504–5.522 mm (0.2167– 90890-06801
0.2174 in) Valve guide remover “2”
Inside diameter EX YB-06801
5.504–5.522 mm (0.2167–
0.2174 in) 2. Install:
• Valve guide “1” New
2. Calculate: (from the camshaft side)
• Valve stem to valve guide clearance
Out of specification → Replace the valve TIP:
and valve guide. Make sure that the valve guide installation
height “a” is within specification.
Valve stem to valve guide clear-
ance = valve guide inside diameter
– valve stem diameter
2
Clearance IN
0.012–0.045 mm (0.0005–
0.0018 in) a
Limit
0.070 mm (0.0028 in)
Clearance EX
0.025–0.058 mm (0.0010– 1
0.0023 in)
Limit
Valve guide remover/installer “2”
0.080 mm (0.0032 in)
90890-06801
Valve guide remover “2”
Replacing the valve guide YB-06801
After replacing a valve guide, check the valve
seat contact area. Installation height
1. Remove: 11.30–11.70 mm (0.4449–
• Valve guide “1” 0.4606 in)
(from the combustion chamber side)
3. Ream:
• Valve guide “1”
7-63
Cylinder head
c. Press the valve lightly against the valve
TIP: seat using the special service tool “1”.
• To ream the valve guide “1”, turn the valve
guide reamer “2” clockwise. 1
• When removing the valve guide reamer “2”,
do not turn it counterclockwise.
• After reaming the valve guide “1”, make sure
to clean it.
Valve lapper “1”

90890-04101
Valve lapping tool “1”
YM-A8998
1
E
d. Measure the valve seat contact width “a”
where the blue layout fluid is adhered to
Valve guide reamer “2”
the valve face.
90890-06804
Valve guide reamer “2” TIP:
YB-06804 Reface the valve seat if the valve is not seated
properly or if the valve seat contact width is out
4. Measure: of specification. Check the valve guide if the
• Inside diameter valve seat contact width is uneven.
Inside diameter IN
5.504–5.522 mm (0.2167–
0.2174 in)
Inside diameter EX
5.504–5.522 mm (0.2167–
0.2174 in)
a
Checking the valve seat

1. Remove:
• Carbon deposit
2. Measure:
• Valve seat contact width
Not seated properly/out of specification →
Reface the valve seat.
Uneven → Check the valve guide.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the carbon deposits from the
valve.
b. Apply a thin, even layer of blue layout fluid

(Dykem) onto the valve seat.
7-64
Cylinder head
30 45 60
30
45
A. Worldwide
B. USA and Canada
Valve seat cutter holder

90890-06316
Seat contact width IN
Intake:
1.10–1.40 mm (0.0433–0.0551
Valve seat cutter 30–38
in)
90890-06817
Limit
Valve seat cutter 45–38
1.850 mm (0.0728 in)
90890-06816
Seat contact width EX
Valve seat cutter 60°
1.40–1.70 mm (0.0551–0.0669
90890-06324
in)
Exhaust:
Limit
Valve seat cutter 30°
2.150 mm (0.0846 in)
90890-06326
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Valve seat cutter 45°
90890-06325
Refacing the valve seat Valve seat cutter 60°
90890-06323
Neway valve seat kit
After every lapping procedure, make sure YB-91044
to clean off any remaining lapping com-
pound from the cylinder head and valves.
b. Cut the surface of the valve seat using a
1. Reface: 45° cutter by turning the cutter clockwise
• Valve seat until the valve seat face has become
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ smooth.
a. Reface the valve seat using the special
service tools.
Do not overcut the valve seat. To prevent
A
chatter marks, make sure to turn the cutter
evenly using a downward force of 40–50 N
(4.0–5.0 kgf, 8.8–11.0 lbf).
30 45 60
7-65
Cylinder head
A
a
60°
a. Previous contact width

B
e. Adjust the valve seat contact width to
specification using a 45° cutter.
a
b
A. Worldwide
B. USA and Canada 45°
45° a. Previous contact width

a b. Specified contact width
f. Check the valve seat contact area of the

valve. See “Checking the valve seat”
(7-64).
Example:
• If the valve seat contact area is too wide and
situated in the center of the valve face, cut
a. Slag or rough surface the top edge of the valve seat using a 30° cut-
ter, and then cut the bottom edge using a 60°
c. Adjust the top edge of the valve seat con-
cutter to center the area and set its width.
tact width using a 30° cutter.
30°
30°
a
a
60°

d. Adjust the bottom edge of the valve seat

contact width using a 60° cutter.
7-66
Cylinder head
• If the valve seat contact area is too narrow and
situated near the top edge of the valve face, cut
the top edge of the valve seat using a 30° cutter 1
to center the area, and then set its width using a
45° cutter.
30°
a
Valve lapper “1”

90890-04101
Valve lapping tool “1”
YM-A8998
a. Previous contact width 3. Measure:

• If the valve seat contact area is too narrow and • Valve seat contact width
situated near the bottom edge of the valve face, See step 2 in “Checking the valve seat”
cut the bottom edge of the valve seat using a (7-64).
60° cutter to center the area, and then set its
width using a 45° cutter. Checking the cylinder head anode
1. Check:
• Anode
a Eroded (1/2 or more worn out) → Replace.
Do not apply grease, oil, or paint to the an-

60° odes.
Checking the cam position sensor

1. Check:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Electrical performance
2. Lap: See “Checking the cam position sensor”
• Valve (5-23).
Checking the OCV

Do not get the lapping compound on the valve 1. Check:
stem and valve guide. • Electrical performance
See “Checking the OCV” (5-25).
TIP: Assembling the cylinder head
After refacing the contact width of the valve seat
1. Install:
to specification, apply a thin, even layer of lapping
compound onto the valve seat, and then lap the • O-rings New
valve using the special service tool “1”. • Plugs
• Cam position sensors
• OCV gaskets New
• OCV assemblies
7-67
Cylinder head
Plug B 9 8
25 N·m (2.5 kgf·m, 18 lb·ft)
T.
R.
OCV bolt 7
6.5 N·m (0.65 kgf·m, 4.8 lb·ft) 4
1
2. Install:
3 8 6
• Valve stem seals New
E
• Exhaust valves
2
• Intake valves
• Spring seats A. Conventional special service tool
• Valve springs B. New special service tool
• Spring retainers
• Valve cotters Conventional special service tools
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Valve spring compressor “5”
a. Install a new valve seal “1” onto the valve
90890-04019
guide “2”.
Valve spring compressor attach-
ment “6”
1
90890-06320
YM-04019
2 “6”
YB-06320
New special service tools
b. Install the valve “1”, valve spring seat “2”, Valve spring compressor attach-
valve spring “3”, and valve spring retainer ment “6”
“4” in this order, and then install the special 90890-06320
service tools. Lever assy “7”
90890-06956
A Support assy 3 “8”
5 90890-06952
4 Valve spring compressor “9”
6 90890-06689
3 “6”
YB-06320
2 YB-06689
c. Compress the valve spring, and then in-

stall the valve cotters “1”.
1
7-68
Cylinder head
Installing the cylinder head

Before assembling the cylinder head, check the
cylinder head bolts. See “Checking the cylinder
head bolt” (7-61).
1. Install:
• Grommets
1
TIP:
Align the protrusion “a” on the grommet with the
rib “b” on the cylinder block. Make sure that no
d. Tap the valve spring retainer lightly using a portion of the grommet, except the protrusion,
plastic hammer to seat the valve cotters “1” protrudes above the mating surface of the cylinder
securely. block.
1 1
2. Install:
• Dowel
• Gaskets New
• Cylinder head (PORT)
• Cylinder head (STBD)
• Cylinder head bolts (M11)
• Cylinder head bolts (M8)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Tighten the cylinder head bolts (M11) “1” to
3. Install: the specified torques in 2 stages and in the or-
• Cylinder head anodes der [1], [2], and so on.
• O-rings New
• Cylinder head anode plugs TIP:
• Tighten the M11 bolts using a triple square
socket.
Do not apply grease, oil, or paint to the an- • In the 2nd stage, mark the M11 bolts and cylin-
odes. der head with paint marks “a”, and then tighten
the M11 bolts 180° from the marks on the cylin-
Cylinder head anode screw der head.
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
T.
R.
Cylinder head anode plug

b. Tighten the cylinder head bolts (M8) “2” and
25 N·m (2.5 kgf·m, 18 lb·ft)
“3” to the specified torques in 2 stages and in
the order [11], [12], and so on.
7-69
Cylinder head
PORT a 180° STBD

3 1 1 3
[15] [15]
[10] [10]
[9]
[9]
[6] [5] [6]
[5]
[2] [1] [2]
[1]
[3] [4] [3]
[4]
[8]
[7] [8] [7]
2 2
2 [14] [14] 2
[11] 2 1 2 3 2 [11]
[12] [13] [13] [12]
E E E
Cylinder head bolt (M11) “1” [1]–

[10]
T.
R.
1st: 39 N·m (3.9 kgf·m, 29 lb·ft)

2nd: 180°
Cylinder head bolt (M8) “2”, “3”
[11]–[15]
1st: 14 N·m (1.4 kgf·m, 10 lb·ft)
2nd: 28 N·m (2.8 kgf·m, 21 lb·ft)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-70
Oil pump assembly
Oil pump assembly
7
New 8
10
E
New 11
9
E
E
E
6 New
E
4 14
5 2 13
15 New
3 1
E
E
18 N·m (1.8 kgf·m, 13 lb·ft)
12
49 N·m (4.9 kgf·m, 36 lb·ft)
18 N·m (1.8 kgf·m, 13 lb·ft) 11 N·m (1.1 kgf·m, 8.1 lb·ft) 12

1 Oil filter 1
2 Union bolt 1
3 Sensor 1 Oil pressure
4 Bolt M6 × 40 mm 3
5 Bracket 1
6 Gasket 1
7 Oil filler cap 1
8 O-ring 1
9 Bolt M6 × 25 mm 3
10 Oil filler neck 1
11 O-ring 1
12 Bolt M6 × 75 mm 4
13 Oil pump assembly 1
14 Relief valve 1
15 O-ring 1
7-71
Oil pump assembly
Removing the oil pump assembly

Oil pump assembly bolt
11 N·m (1.1 kgf·m, 8.1 lb·ft)
T.
R.
Do not disassemble the oil pump assembly.
Installing the oil filter
1. Install:
Removing the oil filter
• Gasket New
1. Remove:
• Oil filter bracket
• Oil filter “1”
• Union bolt “1”
• Oil pressure sensor “2”
TIP:
Install the longer threaded portion “a” of the union
bolt “1” into the oil filter bracket “3”.
1
3
2
E
Oil filter wrench “2”

90890-06874 2
Oil filter wrench “2” a
YB-06874 1
Installing the oil filler neck and relief

Union bolt “1”
valve
49 N·m (4.9 kgf·m, 36 lb·ft)
T.
1. Install:
R.
Oil pressure sensor “2”

• O-rings New 18 N·m (1.8 kgf·m, 13 lb·ft)
• Oil filler neck
• Oil filler cap 2. Install:
• Relief valve • Oil filter “1”
Installing the oil pump assembly
1. Install:
• Oil pump assembly
TIP: E
Fill the oil pump assembly with engine oil through 1
both the inlet hole and outlet hole. 1
2

90890-06874
YB-06874
Oil filter
18 N·m (1.8 kgf·m, 13 lb·ft)
T.
R.
7-72
Oil cooler and water jacket

18
New 21
20 19
3 20
3.9 N·m (0.39 kgf·m, 2.9 lb·ft)
New 21
19 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
2 12 N·m (1.2 kgf·m, 8.9 lb·ft)
3 18 11 New
10
New 4
6 New
2
17 1
1 1 16
7
15 New
9 New
17 16
LT
LT
242 8
242 1 8
14
5
12
13
3.9 N·m (0.39 kgf·m, 2.9 lb·ft) 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
1 2 12 N·m (1.2 kgf·m, 8.9 lb·ft)

1 Bolt M6 × 25 mm 32 20 Thermostat 2
2 Thermostat cover 1 21 Gasket 2
3 Thermostat 1
4 Gasket 1
5 Cover 1
6 Gasket 1
7 Thermostat cover 1
8 Thermostat 1
9 Gasket 1
10 Cover 1
11 Gasket 1
12 Clamp 1
13 Hose 1
14 Cover 1
15 Gasket 1
16 Screw M6 × 25 mm 2
17 Anode 2
18 Bolt M6 × 40 mm 4
19 Thermostat cover 2
7-73
Checking the thermostat Checking the oil cooler cover anode and
1. Measure: water jacket anode
• Valve opening “a” 1. Check:
(at the specified water temperatures) • Anode
Out of specification → Replace. Eroded (1/2 or more worn out) → Replace.
TIP:
• Suspend the thermostat in a container of water.
• Place a thermo meter in the water, and then Do not apply grease, oil, or paint to the an-
heat the water slowly. odes.
Installing the cylinder block thermostat

1. Install:
• Gaskets New
• Cylinder block thermostats
• Thermostat housings
Installing the water jacket cover

1. Install:
• Water jacket anode
• Gasket New
a • Water jacket cover (lower)
TIP:
Tighten the water jacket cover (lower) bolts to the
Water jacket anode screw

3.9 N·m (0.39 kgf·m, 2.9 lb·ft)
T.
R.
Cylinder block thermostat Water jacket cover (lower) bolt

1st: 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Water temperature Valve opening “a”
2nd: 12 N·m (1.2 kgf·m, 8.9 lb·ft)
58–62 °C
Starts opening
(136–144 °F) 2. Install:
above 70 °C 5.0 mm (0.20 in) or • Hose “1”
(158 °F) above • Clamp “2”
Oil cooler thermostat and water jacket ther- TIP:
mostat Point the end of the clamp forward.
Water temperature Valve opening “a”
58–62 °C
Starts opening
(136–144 °F)
above 70 °C 3.0 mm (0.12 in) or
(158 °F) above
7-74
Oil cooler cover anode screw

3.9 N·m (0.39 kgf·m, 2.9 lb·ft)
T.
R.
1 2
3. Install:
• Gasket New
• Water jacket cover (upper)
TIP:
Tighten the water jacket cover (upper) bolts to
the specified torques in 2 stages.
Water jacket cover (upper) bolt

1st: 6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
2nd: 12 N·m (1.2 kgf·m, 8.9 lb·ft)
4. Install:
• Gasket “1” New
• Water jacket thermostat “2”
• Water jacket thermostat housing
TIP:
Fit the protrusion “a” on the thermostat into the
cut-out “b” in the water jacket cover (upper).
2
1
Installing the oil cooler cover

1. Install:
• Oil cooler cover anode
• Gasket New
• Oil cooler cover
• Gasket New
• Thermostat
• Thermostat cover
7-75
Cylinder block sensor

A 18 N·m (1.8 kgf·m, 13 lb·ft)
New 10 9 2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 12 18 N·m (1.8 kgf·m, 13 lb·ft)
4 1303 9 A
11
10 New
New 5 12 6
18 N·m (1.8 kgf·m, 13 lb·ft) 1303
32 N·m (3.2 kgf·m, 24 lb·ft)
11 7
8
7
32 N·m (3.2 kgf·m, 24 lb·ft)
6
2
1 5 New
4
E
18 N·m (1.8 kgf·m, 13 lb·ft)

1 Bolt M6 × 20 mm 1
Crankshaft
2 Sensor 1
position
Engine tem-
3 Sensor 1
perature
4 Sensor 2 Thermo
5 Gasket 2
6 Knock sensor 2
7 Bolt M6 × 25 mm 8
8 Bracket 2
9 Plug M16 × 11 mm 2
10 O-ring 2
11 Screw M5 × 25 mm 2
12 Anode 2
7-76
Checking the cylinder block anode 2

1. Check:
• Anode 1
Eroded (1/2 or more worn out) → Replace.

odes.
1
Installing the cylinder block anode 2
1. Install: 3
• Cylinder block anodes
• O-rings New
• Anode plugs
a
Cylinder block anode screw 2 3
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
T.
R.
Anode plug
18 N·m (1.8 kgf·m, 13 lb·ft)
Installing the cylinder block sensor

1. Install:
• Knock sensor brackets Knock sensor
• Knock sensors 32 N·m (3.2 kgf·m, 24 lb·ft)
T.
R.
• Gaskets “1” New Thermo sensor

• Thermo sensors “2” 18 N·m (1.8 kgf·m, 13 lb·ft)
• Engine temperature sensor “3” Engine temperature sensor
• O-ring New 18 N·m (1.8 kgf·m, 13 lb·ft)
• Crankshaft position sensor
TIP:
Be sure to install the thermo sensor (with the
O-ring “a”) “2” and engine temperature sensor
(without O-ring) “3” in the proper locations.
7-77
Cylinder block
Cylinder block
1 13 N·m (1.3 kgf·m, 9.6 lb·ft) 24 New
2 28 N·m (2.8 kgf·m, 21 lb·ft)
3 90° New 25
17 17 26
E
E
15 New 14
E
E
E
New 25 28
E 19 22
16 27
15 New
18
1 14 N·m (1.4 kgf·m, 10 lb·ft)
2 28 N·m (2.8 kgf·m, 21 lb·ft)
11 New
E 6 20
8 23 New
E
7 21 E
12
32
9 13 31
3
E
10 6
4 E 30
1 40 N·m (4.0 kgf·m, 30 lb·ft) E

5 New 2 90° 29
2
1 14 N·m (1.4 kgf·m, 10 lb·ft) E 1 40 N·m (4.0 kgf·m, 30 lb·ft)
2 27.5 N·m (2.75 kgf·m, 20.28 lb·ft) 2 90°
New 1

1 Bolt M10 × 50 mm 8 Crankshaft journal
18 5
2 Flange 1 bearing
3 Bolt M8 × 50 mm 26 19 Crankshaft 1
4 Crankcase cover 1 20 Thrust bearing 1
5 Gasket 1 21 Thrust bearing 1
6 Dowel 2 Crankshaft journal
22 5
bearing
7 Bolt M8 × 50 mm 10
23 Oil seal 1
8 Bolt M8 × 70 mm 6
24 Oil seal 1
9 Bolt M10 × 103 mm 20
25 Clip 16
10 Crankcase 1
26 Piston pin 8
11 O-ring 1
27 Piston ring set 8
12 Thrust bearing 1
28 Piston 8
13 Thrust bearing 1
29 Bolt M6 × 14 mm 6
14 Dowel 10
30 Drive gear 1
15 Bolt M9 × 42mm 16
31 Pickup rotor 1
Connecting rod as-
16 8 32 Dowel 1
sembly
17 Crankshaft pin bearing 16
7-78
Cylinder block
Disassembling the cylinder block

1. Remove: a
• Flange “1” 1
TIP:
2
Install the special service tool “2” to the flange
“1”, secure the tool using a wrench, and then
remove the flange bolts “3”.
1 2
2
1 3 3
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Remove:
• Crankshaft journal bearings (crankcase
side) “1”
• Crankshaft “2”
Shaft holder “2” • Crankshaft journal bearings (cylinder
90890-06949 block side) “3”
2. Remove: TIP:
• Connecting rod assemblies Make sure to keep the crankshaft journal bear-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ings in the order of removal.
a. Remove the connecting rod caps “1”, and
then remove the crankshaft pin bearings
“2” and connecting rods (along with the 1
piston) “3”.
TIP:
• To prevent mixing the piston, connecting rod 2
assemblies “3”, and connecting rod caps “1”,
mark each with an identification number “a”
3
of the corresponding cylinder.
3
• Make sure to keep the crankshaft pin bear-
ings in the order of removal.
Checking the piston diameter

1. Measure:
• Piston diameter “a”
(at the specified measuring point “b”)
7-79
Cylinder block
Checking the piston clearance

1. Measure:
• Piston diameter
See “Checking the piston diameter” (7-79).
• Cylinder bore
b
See “Checking the cylinder bore” (7-80).
a
2. Calculate:
• Piston clearance
Out of specification → Replace the piston
Piston or cylinder block.
Diameter Piston clearance = maximum cylin-
95.945–95.960 mm (3.7774– der bore – piston outside diameter
3.7779 in) Piston clearance
Limit 0.040–0.067 mm (0.0016–
95.905 mm (3.7758 in) 0.0026 in)
Measuring point Limit
14.5 mm (0.57 in) 0.167 mm (0.0066 in)
Checking the cylinder bore Checking the piston ring

1. Measure: 1. Measure:
• Cylinder bore (D1–D6) • Piston ring dimension
(at measuring points “a”, “b”, and “c”, and Out of specification → Replace.
in directions “d” [D1, D3, D5] and “e” [D2,
D4, D6]) a b
Out of specification → Replace the cylin- B B
der block.
T T
a
b D2 D1 c B
c d
D4 D3 e T
D6 D5 a. Top ring
b. 2nd ring
c. Oil ring
a. 7.0 mm (0.28 in)

b. 52.0 mm (2.05 in)
c. 111.0 mm (4.37 in)
d. Parallel to the crankshaft
e. At a right angle to the crankshaft
Cylinder
Bore
96.000–96.012 mm (3.7795–
3.7800 in)
Limit
96.072 mm (3.7824 in)
7-80
Cylinder block
Piston ring dimensions Piston ring end gap

Top ring Measuring point
Height (B) 10.0 mm (0.39 in)
1.170–1.185 mm (0.0461– Top ring
0.0467 in) End gap
Width (T) 0.20–0.30 mm (0.0079–
2.800–3.000 mm (0.1102– 0.0118 in)
0.1181 in) Limit
2nd ring 0.470 mm (0.0185 in)
Height (B) 2nd ring
1.170–1.190 mm (0.0461– End gap
0.0469 in) 0.60–0.75 mm (0.0236–
Width (T) 0.0295 in)
3.800–4.000 mm (0.1496– Limit
0.1575 in) 0.900 mm (0.0354 in)
Oil ring Oil ring
Height (B) End gap
2.410–2.470 mm (0.0949– 0.15–0.60 mm (0.0059–
0.0972 in) 0.0236 in)
Width (T)
2.350–2.750 mm (0.0925– Checking the piston ring groove
0.1083 in) 1. Measure:
• Piston ring groove
Checking the piston ring end gap Out of specification → Replace.
1. Measure:
• Piston ring end gap “a”
Out of specification → Replace. a
TIP:
b
Level the piston ring “1” in the cylinder using a
piston crown at the specified measuring point
“b”. c
a. Ring groove (Top)

b b. Ring groove (2nd)
c. Ring groove (Oil)
1
Piston ring groove
a
Ring groove (Top)
1.22–1.25 mm (0.0480–0.0492
in)
Ring groove (2nd)
1.22–1.24 mm (0.0480–0.0488
in)
Ring groove (Oil)
2.51–2.53 mm (0.0988–0.0996
in)
7-81
Cylinder block
Checking the piston ring side

clearance TIP:
When measuring the piston pin boss inside di-
1. Measure:
ameter, do not measure it at the ring groove “b”
• Piston ring side clearance
or oil groove “c”.
Out of specification → Check the piston
ring grooves and piston ring.
See “Checking the piston ring groove”
(7-81) and “Checking the piston ring”
(7-80). a
b
a
c c
b
a. Top ring side clearance

Pin boss inside diameter
b. 2nd ring side clearance
22.011–22.018 mm (0.8666–
c. Oil ring side clearance
0.8668 in)
Piston ring side clearance Limit
Top ring 22.038 mm (0.8676 in)
Side clearance
0.03–0.08 mm (0.0014– Checking the piston pin diameter
Limit • Piston pin outside diameter “a”
0.130 mm (0.0051 in) (at measuring points “b”, “c”, and “d”, and
2nd ring in directions “e” and “f”)
Side clearance Below specification → Replace.
0.03–0.07 mm (0.0012–
0.0028 in) a
Limit
0.110 mm (0.0043 in)
Oil ring
Side clearance
0.04–0.12 mm (0.0016–
0.0047 in)
Checking the piston pin boss inside

diameter b
1. Measure: e
Piston pin boss inside diameter “a” c
Out of specification → Replace. f
7-82
Cylinder block
Checking the connecting rod big end

Pin outside diameter
21.996–22.005 mm (0.8660– side clearance
Limit • Big end side clearance “a”
21.986 mm (0.8656 in) Out of specification → Check the crank-
shaft pin width.
See “Checking the crankshaft” (7-83).
Checking the connecting rod small
end inside diameter and big end
a
inside diameter
1. Measure:
• Small end inside diameter “a”
• Big end inside diameter “b”
Out of specification → Replace the con-
necting rod assembly.
TIP:
• When checking the big end inside diameter,
reuse the removed connecting rod bolt.
• Tighten the connecting rod bolts “1” to the
• In the third tightening stage for the connect-
ing rod bolts “1”, mark the connecting rod
bolts and the connecting rod cap with identi-
fication marks “c”, and then tighten the bolts
90° from the marks on the connecting rod
cap. Big end side clearance
0.140–0.310 mm (0.0055–
0.0122 in)
c 90° a
Limit
0.36 mm (0.0142 in)
b
Checking the crankshaft
1. Measure:
• Journal diameters “a”
1 • Crankshaft pin diameters “b”
• Crankshaft pin widths “c”
Out of specification → Replace the crank-
Connecting rod bolt “1” shaft.
1st: 13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
2nd: 28 N·m (2.8 kgf·m, 21 lb·ft)

3rd: 90°
Small end inside diameter

22.008–22.025 mm (0.8665–
0.8671 in)
Big end inside diameter
65.990–66.010 mm (2.5980–
2.5988 in)
7-83
Cylinder block
Checking the crankcase bolt

1. Measure:
• Diameter
TIP:
Measure the diameters “a” and “b” of the
crankcase bolt (M10) at the specified measur-
a
ing points “c” and “d”.
b a
b
d c
c
Journal diameter
72.976–72.996 mm (2.8731–
2.8739 in) Crankcase bolt diameter differ-
Crankshaft pin diameter ence limit
62.980–63.000 mm (2.4795– “a” – “b” = Less than 0.20 mm
2.4803 in) (0.0079 in)
Crankshaft pin width Measuring point “c”: 10.0 mm
21.00–21.10 mm (0.8268– (0.39 in)
0.8307 in) Measuring point “d”: 65.0 mm
(2.56 in)
2. Measure:
• Runout Checking the big end oil clearance
shaft. TIP:
Clean the mating surfaces of the parts in ad-
vance.
1. Install:
Crankshaft pin bearings “1” (into the con-
necting rod “2” and connecting rod cap “3”)
TIP:
Install the crankshaft pin bearings in their orig-
inal positions.
Runout
0.03 mm (0.0012 in)
Limit
0.04 mm (0.0016 in)
7-84
Cylinder block
2 E
1 2
1
3
a
2. Install: 4. Tighten:
• Plastigauge (PG-1) “1” • Connecting rod bolts “1”
TIP:
Do not place the Plastigauge (PG-1) over • Tighten the connecting rod bolts “1” to the
the oil hole in the crankshaft pin of the specified torques in 3 stages.
crankshaft. • In the third tightening stage for the connect-
ing rod bolts “1”, mark the connecting rod
bolts and the connecting rod cap with identi-
TIP:
fication marks “a”, and then tighten the bolts
Place a piece of Plastigauge (PG-1) “1” onto
90° from the marks on the connecting rod
the crankshaft pin, parallel to the crankshaft.
cap.
1
a 90°
1
3. Install:
• Connecting rod “1” Connecting rod bolt “1”
• Connecting rod cap “2” 1st: 13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
• Connecting rod bolts (temporarily) 2nd: 28 N·m (2.8 kgf·m, 21 lb·ft)

3rd: 90°
TIP:
• When checking the oil clearance, reuse the 5. Remove:
removed connecting rod bolts. • Connecting rod bolts
• Make sure that the marks “a” on the connect- • Connecting rod cap
ing rod “1” and connecting rod cap “2” face
toward the flywheel magneto end of the 6. Measure:
crankshaft. • Width of the compressed Plastigauge
• Do not turn the connecting rod until the big (PG-1)
end oil clearance measurement has been Out of specification → Replace the crank-
completed. shaft pin bearing.
7-85
Cylinder block
P1 P2 P5 P6
P3 P4 P7 P8
Big end oil clearance P8

0.026–0.049 mm (0.0010– P7
0.0019 in) P6
Limit P5
P4
0.079 mm (0.0031 in)
P3
a P2
Selecting the crankshaft pin bearing P1
When replacing the crankshaft pin bearing, se-
lect the bearing as follows. 3. Select:
1. Measure: • Crankshaft pin bearing
• Connecting rod big end inside diameter “a”
TIP:
Select the suitable colors “1” for the crankshaft
pin bearing from the “Crankshaft pin bearing
selection table” (7-88).
a 1
Big end inside diameter

65.990–66.010 mm (2.5980– 1
2.5988 in)
Example: Rod side bear- Cap side bear-

Connecting rod big ing color ing color
end inside diameter Number in table “a” Yellow Yellow
“a” “b” Yellow Green
66.005 mm 05 “c” Green Green
2. Check: “d” Blue Green
Stamped mark “a” (on the crank web) “e” Blue Blue
7-86
Cylinder block
Example:
If the connecting rod big end inside diame-
ter is “05” and the crankshaft pin mark is
“81”, select the bearing colors in “e”. The
rod side bearing color is blue and the cap
side bearing color is blue.
90 91 04 05 06 07
80
81
e
82
7-87
Cylinder block
Crankshaft pin bearing selection table
A
90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 10
80
81 e
82
83
84
85
d
86
87
88
89
B 90
c
91
92
93
94
95
b
96
97
98
99 a
00
A. Connecting rod big end inside diameter
B. Crankshaft pin mark
7-88
Cylinder block
Checking the journal oil clearance 3. Install:

• Crankshaft journal bearings
TIP: (into the crankcase)
• After checking the journal oil clearance,
check the crankcase bolts. See “Checking TIP:
the crankcase bolt” (7-84). Install the crankshaft journal bearings in their
• Clean the mating surfaces of the parts in ad- original positions.
vance.
1. Install: 4. Install:
• Crankcase
• Crankshaft journal bearings “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Crankshaft “2” a. Tighten the crankcase bolts (M10) “1” to
(into the cylinder block) “3” the specified torques in 2 stages and in the
TIP:
Install the crankshaft journal bearings “1” in b. Tighten the crankcase bolts (M8) “2” and
their original positions. “3” to the specified torques in 2 stages and
in the order [21], [22], and so on.
3 TIP:
• When checking the oil clearance, reuse the
removed crankcase bolts.
• Do not turn the crankshaft until the journal oil
clearance measurement has been complet-
2
ed.
• In the second tightening stage for the M10
1 crankcase bolts “1”, mark the M10 bolts and
the crankcase with identification marks “a”,
2. Install: and then tighten the bolts 90° from the marks
• Plastigauge (PG-1) “1” on the crankcase.
1 2 3
Do not place the Plastigauge (PG-1) over
the oil hole in each crankshaft journal.
TIP: E
Place a piece of Plastigauge (PG-1) “1” onto E
the crankshaft journal, parallel to the crank-
shaft.
7-89
Cylinder block
[19] [9] [10] [20]

3
[35] [36]
1 1
[31] [15][5]
[15][5] [6][16] 3
2 [32]
1 1
[25] [11][1]
[11][1] [2][12]
[2][12] [26]
3
1 1
[21] [14][4]
[14][4] [3][13]
[3][13] [22]
3 Journal oil clearance
[24] 1 1 [23] 0.029–0.053 mm (0.0011–
[18][8]
[18][8] [7][17]
[7][17]
3 0.0021 in)
3
1 1 Limit
[30] [27] 0.073 mm (0.0029 in)
[29] [28]
[34] 2 [33] Selecting the crankshaft journal
bearing
When replacing the crankshaft journal bearing,
1 2 3
select the bearing as follows.
a 1. Check:
90° • Stamped mark “a” (on the crank web)
• Stamped mark “b” (on the cylinder block)
1 J1 J2 J3 J4 J5
Crankcase bolt (M10) “1” [1]–[20]

1st: 40 N·m (4.0 kgf·m, 30 lb·ft)
T.
R.
2nd: 90°
J5
Crankcase bolt (M8) “2”, “3” [21]– J4
[36] J3
1st: 14 N·m (1.4 kgf·m, 10 lb·ft) J2 a
2nd: 28 N·m (2.8 kgf·m, 21 lb·ft) J1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Remove:
• Crankcase
6. Measure:
• Width of the compressed Plastigauge
(PG-1)
shaft journal bearing. b
J1 J2 J3 J4 J5
2. Select:
• Crankshaft journal bearing
7-90
Cylinder block
TIP:
Select the suitable colors “1” for the crankshaft
journal bearing from the “Crankshaft journal
bearing selection table” (7-92).
Block side bear- Crankcase side

ing color bearing color
“a” Black Black
“b” Blue Blue
“c” Pink Pink
“d” White White
Example:
If the crankshaft journal mark is “77” and
the cylinder block mark is “17”, select the
bearing colors in “d”. The block side bear-
ing color is white and the crankcase side
bearing color is white.
00 01 16 17 18 19 20
76
77
d
78
7-91
Cylinder block
Crankshaft journal bearing selection table
A
00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20
76
77
78 d
79
80
81
82
83
c
84
85
B 86
87
88
b
89
90
91
92
93
a
94
95
96
A. Cylinder block mark

B. Crankshaft journal mark
7-92
Cylinder block
Assembling the cylinder block

1. Install: TIP:
• Make sure that the “2R” mark “a” on the 2nd
• Dowel
ring “2” and “1R” mark “b” on the top ring “3”
• Pickup rotor
are facing up.
• Drive gear
• Make sure that the piston rings move
2. Assemble: smoothly.
• Piston
• Connecting rod c. Offset the piston ring end gaps.
• Piston pin
• Piston clips New 1 a
• Piston rings
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ #5 #4
a. Assemble the piston “1”, connecting rod
“2”, piston pin “3”, and new piston pin clips #3 2
“4”. 3
#2
#1
TIP: 45˚ 45˚
• Face the mark “a” on the connecting rod “2” #5 #2
in the same direction as the mark “b” on the
piston crown. b
E
• Make sure that the clip “4” end is not aligned #1
with the groove “c” in the piston pin boss. #4 #3
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 b
3 3. Install:
4
• Crankshaft journal bearings (cylinder
block side) “1”
E
c TIP:
• Install the crankshaft journal bearings “1” in
their original positions.
1
• Install the crankshaft journal bearings “1” ac-
cording to the specified dimensions.
4
2
b b a
a
b. Install the oil rings “1”, 2nd ring “2”, and top
ring “3”.
1 1 1 1 1
Do not scratch the pistons or break the pis-
ton rings.
7-93
Cylinder block
Distance “a” a
1
0.65–1.25 mm (0.026–0.049 in)
Distance “b”
0.95–1.55 mm (0.037–0.061 in)
4. Install:
• Oil seal (upper) New
• Oil seal (lower) New
• Crankshaft
• Thrust bearings (cylinder block side) “1” Piston slider 96 mm “1”
90890-06684
TIP: Piston slider 96 mm “1”
• Install each thrust bearing with its grooves
YB-06684
facing outward.
• Slide the thrust bearing between the crank-
7. Install:
shaft and the cylinder block.
• Connecting rod caps
• Connecting rod bolts New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the connecting rod caps “1” to the
connecting rods.
TIP:
Make sure that the protrusion “a” on the con-
1 necting rod caps “1” is facing toward the fly-
wheel magneto end “b” of the crankshaft.
5. Install: b. Tighten new connecting rod bolts “2” to the

• Crankshaft pin bearings specified torques in 3 stages.
(into the connecting rod and connecting
rod cap) TIP:
• In the third tightening stage for the connect-
TIP: ing rod bolts “2”, mark the connecting rod
Install the crankshaft pin bearings in the origi- bolts and connecting rod cap with paint
nal positions. marks “c”, and then tighten the bolts 90° from
the marks on the connecting rod cap.
• After tightening the connecting rod bolts “2”,
6. Install: make sure that the crankshaft turns smooth-
• Pistons ly.
TIP:
• Apply engine oil to the side of the piston, pis-
ton rings, and cylinder wall.
• Install the piston so that the mark “a” on the
piston crown is facing toward the flywheel
magneto end of the crankshaft.
7-94
Cylinder block
2 2 a Distance “a”
c 90°
1 0.65–1.25 mm (0.026–0.049 in)
Distance “b”
0.95–1.55 mm (0.037–0.061 in)
E
c. Apply a thin, even layer of sealant onto the

b mating surface of the crankcase.
TIP:
• Do not apply any sealant to the crankshaft
journal bearings.
• When applying sealant to the portion “a” of
the mating surface, be careful not to apply
sealant to an area that will contact the O-ring.
Connecting rod bolt “2” • Install the crankcase within 3 minutes after
1st: 13 N·m (1.3 kgf·m, 9.6 lb·ft) applying the sealant. Tighten the crankcase
T.
R.
2nd: 28 N·m (2.8 kgf·m, 21 lb·ft) bolts to the specified torque within 15 min-
3rd: 90° utes after applying the sealant.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1280B
8. Install:
• Crankcase
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the thrust bearings (crankcase
side).
TIP:
Install each thrust bearing with its grooves fac-
ing outward. a
d. Install a new O-ring, dowels, and the

b. Install the crankshaft journal bearings crankcase, and then tighten the crankcase
(crankcase side) “1”. bolts (M10) “1” to the specified torques in 2
TIP:
Install the crankshaft journal bearings “1” in TIP:
their original positions. In the second tightening stage for the M10
bolts “1”, mark the M10 bolts and the crank-
case with identification marks “a”, and then
b b a
tighten the bolts 90° from the marks on the
crankcase.
1 1 1 1 1 e. Tighten the crankcase bolts (M8) “2” and

“3” to the specified torques in 2 stages and
E TIP:
After tightening the crankcase bolts “1”, “2” and
“3”, make sure that the crankshaft turns
smoothly.
7-95
Cylinder block
[19] [9] [10] [20] [17]

[17][18]
[18] [19] [20]
3
[35] [36]
1 1 [13] [14]
[31] [15][5]
[15][5] [6][16] 3
[9] [10]
2 [32]
1 1 [5] [6]
[25] [11][1]
[11][1] [2][12]
[2][12] [26]
[1] [2]
3
1 1 [4] [3]
[21] [14][4]
[14][4] [3][13]
[3][13] [22]
[8] [7]
3
1 1 [12] [11]
[24] [23]
[18][8]
[18][8] [7][17]
[7][17]
3 3 [16] [15]
1 1 [26] [21]
[30] [27]
[29] [28]
[34] 2 [33] [25] [24] [23] [22]
Crankcase cover bolt [1]–[26]

1 2 3
1st: 14 N·m (1.4 kgf·m, 10 lb·ft)
T.
R.
a 2nd: 27.5 N·m (2.75 kgf·m,

90° 20.28 lb·ft)
E
10. Install:
E
E 1 • Flange “1”
• Flange bolts “2” New
TIP:
Crankcase bolt (M10) “1” [1]–[20] • Clean the mating surface of the crankshaft
1st: 40 N·m (4.0 kgf·m, 30 lb·ft) and flange.
T.
R.
2nd: 90° • Tighten new flange bolts “2” to the specified

Crankcase bolt (M8) “2”, “3” [21]– torques in 2 stages and in the order [1], [2],
[36] and so on.
1st: 14 N·m (1.4 kgf·m, 10 lb·ft) • Install the special service tool “3” to the
2nd: 28 N·m (2.8 kgf·m, 21 lb·ft) flange, secure the tool using a wrench, and
then tighten the flange bolts “2”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9. Install:
• Dowels
• Gasket New
• Crankcase cover
• Crankcase cover bolts
TIP:
Tighten the crankcase cover bolts to the spec-
ified torques in 2 stages and in the order [1], [2],
and so on.
7-96
Cylinder block
1 2
[6] [4]
[1] [8]
[7]
[2]
[3]
[5]
Shaft holder “3”

90890-06949
Flange bolt “2”

1st: 40 N·m (4.0 kgf·m, 30 lb·ft)
T.
R.
2nd: 90°
7-97
Lower unit
Propeller and water inlet cover ......................................... 8-1

Removing the propeller .............................................................. 8-2
Disassembling the propeller (Shift Dampener System [SDS]
propeller) .................................................................................... 8-2
Checking the propeller ............................................................... 8-2
Assembling the propeller (Shift Dampener System [SDS]
propeller) .................................................................................... 8-2
Installing the water inlet.............................................................. 8-3
Installing the propeller ................................................................ 8-3
Lower unit ........................................................................... 8-5

Removing the lower unit............................................................. 8-6
Checking the lower unit anode ................................................... 8-6
Checking the gear oil passage check valve ............................... 8-7
Checking the lower unit for leakage ........................................... 8-7
Installing the lower unit............................................................... 8-7
Extension (except for X-transom model) ......................... 8-9

Checking the extension ............................................................ 8-10
Assembling the extension ........................................................ 8-10
Installing the extension............................................................. 8-10
Water pump and shift rod................................................ 8-11

Removing the shift rod (regular rotation model) ....................... 8-12
Removing the shift rod (counter rotation model) ...................... 8-12
Removing the gear oil passage check valve ............................ 8-13
Checking the water pump......................................................... 8-13
Checking the shift rod............................................................... 8-13
Installing the gear oil passage check valve .............................. 8-13
Assembling the shift rod guide plate ........................................ 8-13
8
Assembling the water pump housing ....................................... 8-14
Installing the water pump and shift rod
(regular rotation model) ............................................................ 8-15
Installing the water pump and shift rod
(counter rotation model) ........................................................... 8-16
Propeller shaft housing (regular rotation model).......... 8-18

Removing the propeller shaft housing assembly...................... 8-19
Disassembling the propeller shaft assembly ............................ 8-20
Disassembling the reverse gear............................................... 8-20
Disassembling the propeller shaft housing assembly .............. 8-20
Checking the propeller shaft..................................................... 8-21
Checking the dog clutch ........................................................... 8-21
Lower unit
Checking the propeller shaft housing ....................................... 8-21

Checking the reverse gear ....................................................... 8-22
Assembling the propeller shaft assembly................................. 8-22
Assembling the reverse gear.................................................... 8-22
Assembling the propeller shaft housing assembly ................... 8-23
Installing the propeller shaft housing assembly........................ 8-25
Drive shaft and lower case (regular rotation model) .... 8-27
Removing the drive shaft.......................................................... 8-28
Disassembling the drive shaft .................................................. 8-28
Disassembling the forward gear............................................... 8-29
Disassembling the lower case.................................................. 8-29
Checking the pinion.................................................................. 8-30
Checking the forward gear ....................................................... 8-30
Checking the drive shaft........................................................... 8-30
Checking the lower case .......................................................... 8-30
Assembling the lower case....................................................... 8-30
Assembling the forward gear.................................................... 8-30
Assembling the drive shaft ....................................................... 8-31
Assembling the oil seal housing ............................................... 8-33
Installing the forward gear ........................................................ 8-34
Installing the drive shaft............................................................ 8-34
Shimming (regular rotation model) ................................ 8-36

Shimming workflow .................................................................. 8-36
Shimming check sheet ............................................................. 8-37
Measuring the forward gear backlash and reverse gear
backlash before disassembly ................................................... 8-39
Shimming procedure ................................................................ 8-43
Shim location............................................................................ 8-43
Selecting the pinion shim (T3).................................................. 8-44
Measuring the forward gear backlash ...................................... 8-46
Adjusting the forward gear shim thickness (T1) ....................... 8-46
Measuring the reverse gear backlash ...................................... 8-47
Adjusting the reverse gear shim thickness (T2) ....................... 8-48
Selecting the propeller shaft shim (T4)..................................... 8-49
Propeller shaft housing (counter rotation model)......... 8-52

Removing the propeller shaft housing assembly...................... 8-53
Disassembling the propeller shaft housing assembly .............. 8-53
Disassembling the forward gear............................................... 8-54
Checking the propeller shaft..................................................... 8-54
Checking the dog clutch ........................................................... 8-55
Checking the propeller shaft housing ....................................... 8-55
Checking the forward gear ....................................................... 8-55
Lower unit
Assembling the propeller shaft housing and forward gear ....... 8-55
Installing the propeller shaft housing assembly........................ 8-57
Drive shaft and lower case (counter rotation model) ... 8-58
Removing the drive shaft.......................................................... 8-59
Disassembling the drive shaft .................................................. 8-59
Disassembling the reverse gear............................................... 8-59
Disassembling the lower case.................................................. 8-59
Checking the pinion.................................................................. 8-59
Checking the reverse gear ....................................................... 8-59
Checking the drive shaft........................................................... 8-59
Checking the lower case .......................................................... 8-59
Assembling the lower case....................................................... 8-59
Assembling the reverse gear.................................................... 8-59
Assembling the drive shaft ....................................................... 8-60
Assembling the oil seal housing ............................................... 8-60
Installing the reverse gear ........................................................ 8-60
Installing the drive shaft............................................................ 8-60
Shimming (counter rotation model) ............................... 8-61

Shimming workflow .................................................................. 8-61
Shimming check sheet ............................................................. 8-62
Measuring the forward gear backlash and reverse gear
backlash before disassembly ................................................... 8-64
Shimming procedure ................................................................ 8-68
Shim location............................................................................ 8-68
Selecting the pinion shim (T3).................................................. 8-69
Selecting the propeller shaft shim (T4)..................................... 8-69
Measuring the reverse gear backlash ...................................... 8-70
Adjusting the reverse gear shim thickness (T1) ....................... 8-71
Measuring the forward gear backlash ...................................... 8-72
Adjusting the forward gear shim thickness (T2) ....................... 8-73
Propeller and water inlet cover
1 New 80 N·m (8.0 kgf·m, 59 lb·ft)

2
3 5
22 New
4
A
10
6 9
7
B
13
14
New 21
8
17 New
16 20 19 New
11
15 18
3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
12

1 Cotter pin 1 Oil level plug
16 1
2 Propeller nut M18 1 M8 × 8 mm
3 Washer 1 17 O-ring 1
4 Spacer 1 Drain screw
18 1
5 Propeller 1 M18 × 12 mm
6 Propeller 1 19 O-ring 1
7 Spacer 1 Oil filler plug
20 1
8 Bolt M6 × 57 mm 1 M8 × 8 mm
Water inlet cover 21 O-ring 1
9 1
(PORT) 22 Damper 1
10 Self-locking nut M6 1
A. For regular rotation model
Water inlet cover
11 1 B. For counter rotation model
(STBD)
12 Bolt M6 × 57 mm 1
Water inlet cover
13 1
(PORT)
14 Self-locking nut M6 1
Water inlet cover
15 1
(STBD)
8-1
Removing the propeller B
4 4 5
5 1
• Make sure to disconnect the battery ca-
from the engine shut-off switch.
• When removing or installing the lower
unit with the power unit installed, make
sure to suspend the outboard motor. Oth-
erwise, the outboard motor could fall sud-
denly and result in severe injuries.
A. Worldwide
1. Remove: B. USA and Canada
• Cotter pin
• Propeller nut Driver rod L3 “2”
• Washer 90890-06652
• Spacer Needle bearing attachment “3”
• Propeller 90890-06608
Driver handle (large) “4”
TIP: YB-06071
• Set the gear shift to the N position. Driveshaft bearing installer “5”
• Place a block of wood between the anticavi- YB-06110
tation plate and the propeller to prevent the
propeller from turning, and then remove the Checking the propeller
propeller nut and propeller.
1. Check:
• Propeller blade
• Damper rubber spline
Cracked/damage/worn → Replace the
propeller.
Assembling the propeller (Shift

Dampener System [SDS] propeller)
1. Install:
• Damper “1” (into the propeller “2”)
TIP:
Disassembling the propeller (Shift • Align the mark “a” on the damper “1” with the
Dampener System [SDS] propeller) mark “b” on the propeller “2”.
1. Remove: • Install the damper “1” using the special ser-
• Damper “1” vice tools and spacer “3” to the specified in-
stallation depth “c”.
A
2 2 3
3 1
8-2
2. Fill:
2 • Gear oil
See step 5 in “Changing the gear oil by re-
1 a b
moving the drain screw” (10-21).
3. Install:
• O-rings New
• Oil level plug
• Oil filler plug
• Lower water inlet covers
A • Upper water inlet covers
3 4
Oil level plug
4
3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
T.
R.
Oil filler plug
3
3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
Lower water inlet cover bolt
3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
c Upper water inlet cover bolt
1
3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
B
3 5 Installing the propeller
5
• Make sure to disconnect the battery ca-
3 bles from the battery, and remove the clip
• When loosening or tightening the propel-
c ler nut, do not hold the propeller using
1 your hands.
A. Worldwide 1. Install:
B. USA and Canada • Spacer “1”
• Propeller “2”
Needle bearing attachment “4” • Spacer “3”
90890-06608 • Washer “4”
Driveshaft bearing installer “5” • Propeller nut “5”
YB-06110
Installation depth “c” 5

13.5–16.3 mm (0.53–0.64 in) 4
3
Installing the water inlet 1

1. Install: 2
• O-ring New
D
• Drain screw
2. Tighten:
Drain screw
• Propeller nut
3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
T.
R.
8-3
TIP:
Place a block of wood between the anticavita-
tion plate and the propeller to prevent the pro-
peller from turning, and then tighten the
propeller nut.
Propeller nut
80 N·m (8.0 kgf·m, 59 lb·ft)
T.
R.
3. Install:
• Cotter pin “1” New
TIP:
If the slots in the propeller nut “2” are not
aligned with the cotter pin hole, tighten the pro-
peller nut until they are aligned.
8-4
Lower unit
Lower unit
A
12 LT
D 47 N·m (4.7 kgf·m, 35 lb·ft)

572
15 A B C
5
4
LT
11 14
572 10 New 19 16
6 7
LT
47 N·m (4.7 kgf·m, 35 lb·ft)
A B C 572
New 17 14
18 5
3
18 2 8 9
LT
1 572
47 N·m (4.7 kgf·m, 35 lb·ft)
12 A
13 D
42 N·m (4.2 kgf·m, 31 lb·ft) 5

LT
572 11
47 N·m (4.7 kgf·m, 35 lb·ft)
10

1 Bolt M10 × 60 mm 1 19 O-ring 1
2 Washer 1
A. For X-transom model
3 Anode 1
B. For U-transom model
4 Bolt M10 × 100 mm 1
C. For E-transom model
5 Bolt M10 × 45 mm 9
D. Except for X-transom model
6 Bolt M10 × 225 mm 1
7 Bolt M10 × 355 mm 1
8 Bolt M10 × 174 mm 1
9 Bolt M10 × 299 mm 1
10 Nut M10 8
11 Washer 8
12 Splash plate 2
13 Lower unit 1
14 Dowel 2
15 Rubber seal 1
16 Plate 1
17 O-ring 1
18 Backup ring 2
8-5
Lower unit
Removing the lower unit
A B C
• Make sure to disconnect the battery ca- 1 33
3
• When removing or installing the lower A B C
2
sure to suspend the outboard motor. Oth- 2 2
denly and result in severe injuries. A. X-transom model
B. U-transom model
C. E-transom model
TIP:
When disassembling the lower unit, measure c. Tilt the outboard motor up, and then install
the backlash before disassembly. See “Mea- the special service tool “1” to the lower unit
suring the forward gear backlash and reverse “2”.
gear backlash before disassembly” (8-39) or
“Measuring the forward gear backlash and re- d. Hook a lifting harness onto the special ser-
verse gear backlash before disassembly” vice tool.
(8-64).
1. Drain: 1
• Gear oil
See steps 1 and 2 in “Changing the gear
oil by removing the drain screw” (10-21).
2. Remove:
• Anode 2
• Lower case mounting bolts
• Lower case mounting nuts (except for X-
transom model) Liftting hanger “1”
• Lower unit 90890-06951
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the outboard motor in an upright po- e. Remove the lower unit.
sition. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Remove the anode “1” and lower case Checking the lower unit anode
mounting bolts “2” and “3”. 1. Check:
• Anode
Adhered grease, oil, paint, or scales →
Clean.

ode.
8-6
Lower unit
Checking the gear oil passage check

valve TIP:
Apply the specified pressure and check that
1. Check:
the pressure is maintained in the lower unit for
• Gear oil passage check valves “1”
10 seconds or more.
Cracked/damaged → Replace the check
valve.
See “Water pump and shift rod” (8-11). Holding pressure
68.6 kPa (0.69 kgf/cm², 9.9 psi)
Installing the lower unit

1
1 • Make sure to disconnect the battery ca-

• When removing or installing the lower
Checking the lower unit for leakage sure to suspend the outboard motor. Oth-
1. Install:
denly and result in severe injuries.
• O-rings New
• Drain screw 1. Install:
• Oil filler plug • O-rings New
• Special service tool “1” (to the oil level plug • Backup rings
hole) • Plate
• Rubber seal
• Dowels
• Lower unit
• Splash plates
• Anode
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the gear shift to the N position.
1
Leakage tester “1”

90890-06840 1
Leakage tester “1”
(commercially available) R
N
2. Check: F
• Holding pressure
Pressure is not maintained → Repair the Shift rod socket “1”
location of the leak. 90890-06950
b. Install the dowels, lower unit “1”, splash

Do not overpressurize the lower unit. Oth- plates “2”, and anode “3”.
erwise, the oil seals could be damaged.
8-7
Lower unit
TIP: Lower case mounting bolt “5”

• To install the lower unit using the lifting hang- 47 N·m (4.7 kgf·m, 35 lb·ft)
T.
R.
er, see step 6 in “Uncrating procedure (out- Lower case mounting nut “6”
board motor with lower unit)” (3-4). 47 N·m (4.7 kgf·m, 35 lb·ft)
• Align the check valves “4” with the holes “a”. Lower case anode bolt “7”
42 N·m (4.2 kgf·m, 31 lb·ft)
A
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a
4
WR-No.2 4
4 LT
5
4 572 3
5
1
7
LT
2
5 572
LT
a 572
a
LT
LT
572
5
4 572 5
C 5
4 WR-No.2
C 5
D
D
4
2 4 3
6
1 LT
2 6 572 7
A. X-transom model
B. U-transom and E-transom model
C. U-transom model
D. E-transom model
8-8
Extension (except for X-transom model)

A 23 N·m (2.3 kgf·m, 17 lb·ft)
18
LT
23 N·m (2.3 kgf·m, 17 lb·ft) 572
13
9
12
New 16
17 New
New 14
LT
572 1322
New 15
7 New 4 12 13
8 New 11
3 12
New 16
New 5
New 6 New 14 17 New
1322
1322 1322
3 New 15
12
1 LT
LT
10 572
2 572 11
47 N·m (4.7 kgf·m, 35 lb·ft) 47 N·m (4.7 kgf·m, 35 lb·ft)

1 Bolt M10 × 45 mm 1
Stud bolt
Point the flat
2 Extension 1 18 8 end of the
M10 × 312 mm
3 Dowel 2 stud bolt up.
4 Rubber seal 1 A. For E-transom model
5 O-ring 1
6 Nipple 1
7 O-ring 1
8 Nipple 1
Point the flat
Stud bolt
9 8 end of the
M10 × 185 mm
stud bolt up.
10 Bolt M10 × 174 mm 1
11 Extension 2
12 Dowel 4
13 Rubber seal 2
14 O-ring 2
15 Nipple 2
16 O-ring 2
17 Nipple 2
8-9
Checking the extension

1. Check:
• Extension
Assembling the extension

1. Install:
• Nipples “1”, “2” New
• O-rings New
2
1 2
1 a a
1322
Installation height “a”

32.2–32.8 mm (1.27–1.29 in)
Installing the extension

1. Install:
• Stud bolts
TIP:
Point the flat end of the stud bolt up.
Stud bolt (lower case mounting)

23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
2. Install:
• Rubber seal(s)
• Dowels
• Extension(s)
Extension mounting bolt
47 N·m (4.7 kgf·m, 35 lb·ft)
T.
R.
8-10
Water pump and shift rod

16 N·m (1.6 kgf·m, 12 lb·ft)
New 31
1
1322
5 28 26
17 LT 27
572
7 29 New
LT 8 New 2
572
25 New
4.5 N·m (0.45 kgf·m, 3.3 lb·ft)
30 New
18 3 9
10 1530D 24
11
3 New 4
19 New
4.5 N·m (0.45 kgf·m, 3.3 lb·ft)
23 14
New 13 15
22 12
16
20
6
12
A B New 32
1322
21 New

1 Bolt M8 × 70 mm 4 20 Plate 1
2 Water pump housing 1 21 Gasket 1
3 Dowel 2 22 Shift rod 1
4 O-ring 1 23 E-clip 1
5 Impeller 1 24 Insert cartridge 1
6 Impeller key 1 25 O-ring 1
7 Outer plate cartridge 1 26 Guide 1
8 O-ring 1 27 Seal 1
9 Bolt M5 × 10 mm 2 28 Cover 1
10 Impeller 1 29 Oil seal 1
11 Water pump housing 1 30 Oil seal 1
12 Dowel 2 31 Check valve 1
13 O-ring 1 32 Check valve 1
14 Bolt M5 × 16 mm 2
A. For regular rotation model
15 Spacer 1
B. For counter rotation model
16 Spacer 1
17 Bolt M8 × 35 mm 6
18 Plate 1
19 O-ring 1
8-11
Removing the shift rod (regular Removing the shift rod (counter
rotation model) rotation model)
1. Remove: 1. Remove:
• Shift rod guide plate • Shift rod guide plate
• Plate • Plate
• Gasket • Gasket
• Shift rod • Shift rod
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the gear shift to the N position. a. Set the gear shift to the N position.
1 1
R R
N N
F F
Shift rod socket “1” Shift rod socket “1”

90890-06950 90890-06950
b. Remove the shift rod guide plate “1”, plate b. Remove the shift rod guide plate “1”, plate
“2”, gasket “3”, and shift rod “4”. “2”, gasket “3”, and shift rod “4”.
4 4
1 1
2 2
4 90° 4
3 3
90°
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-12
Removing the gear oil passage check • Outer plate cartridge

valve Cracked/worn → Replace.
3. Check:
• Use heat-resistant gloves. Otherwise, • Lower impeller
burns could result. • Lower water pump housing
• To prevent fires, remove any flammable Cracked/damaged → Replace.
substances, such as gasoline and oil,
4. Check:
around the working area.
• Impeller key
• Keep good ventilation while working.
• Keyway in the drive shaft
1. Remove: Deformed/worn → Replace.
• Gear oil passage check valve (lower case)
“1” Checking the shift rod
1. Check:
• Shift rod
When heating the lower case, heat the en- Bent/cracked/worn → Replace.
tire installation area evenly. Otherwise, the
paint on the lower case could be burned. Installing the gear oil passage check
valve
TIP: 1. Install:
Heat the installation area of the check valve in • Gear oil passage check valve (lower case)
the lower case “2” using a gas torch, and then “1” New
remove the check valve “1”.
1
1 a
2
1322
Installation height “a”

40.7–41.3 mm (1.60–1.63 in)
Checking the water pump
1. Check: Assembling the shift rod guide plate
• Upper water pump housing 1. Install:
Deformed → Replace.
• Oil seal “1” New
TIP: • O-ring New
If the engine overheats, the inside of the water
pump housing may be deformed. Therefore,
make sure to remove the insert cartridge when
checking the upper water pump housing.
2. Check:
• Upper impeller
• Insert cartridge
8-13
A Assembling the water pump housing
1. Install:
2 • Oil seal “1” New
3 • Seal
1
A
2
3
1
B
4
5
1
B
4
5
1
A. Worldwide
B. USA and Canada
Driver rod L3 “2”

90890-06652
Needle bearing attachment “3” A. Worldwide
90890-06614 B. USA and Canada
Driver handle (small) “4”
YB-06229 Driver rod L3 “2”
Oil seal installer reverse gear 90890-06652
bearing housing “5” Needle bearing attachment “3”
YB-06021 90890-06609
2. Install: YB-06229
• Gear oil passage check valve (shift rod Driveshaft seal installer “5”
YB-06348
guide plate) “1” New
2. Install:
1
• Cover “1”
• Guide “2”
a
TIP:
• Fit the protrusions “a” on the cover “1” into
the holes “b” in the upper water pump hous-
ing “3”.
• Fit the protrusions “c” on the guide “2” into the
holes “d” in the upper water pump housing
Installation height “a” “3”.
21.2–21.8 mm (0.83–0.86 in)
8-14
2 c
1 LT
4 572
a d 2
3
b 90° a 1
3 5
a
3. Install: b
• O-ring New
• Insert cartridge “1”
TIP:
• Fit the protrusions “a” on the insert cartridge
“1” into the slots “b” in the upper water pump
housing “2”.
• Do not apply sealant to the slot “c” in the up- 2. Install:
per water pump housing “2”. • Spacers
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the spacers “1” and “2”.
2 1
c
a TIP:
• Install the spacers “1” and “2” so that the
b punch marks “a” on the spacers are facing
up.
• Align the flat portion “b” of the spacer “1” with
1530D the cutout “c” in the drive shaft “3”.
3 a
a
Installing the water pump and shift
rod (regular rotation model)
1. Install: b
• Dowels
• Gasket “1” New 2
• Plate “2” c
• E-clip 1
• Shift rod “3”
• Shift rod guide plate “4” b. Install the spacer bolts “1” and “2”.
TIP: c. Tighten the spacer bolt “1” temporarily until

Turn the shift rod “3” clockwise 90°, and then the mating surfaces (the ends with the
push it down so that the tip “a” of the shift rod punch marks “a”) of the spacers “3” and “4”
“3” fits into the groove “b” in the shift slider “5”. are contacting, and then tighten the spacer
bolt “2” temporarily.
d. Tighten the spacer bolt “1”, then the spac-

er bolt “2”.
8-15
TIP:
While turning the drive shaft “2” clockwise,
4
push the upper water pump housing “1” down
2
a to install it.
2
3 a LT
572
1
Spacer bolt “1”, “2”

4.5 N·m (0.45 kgf·m, 3.3 lb·ft)
T.
LT
R.
572
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
3. Install:
• O-rings New
• Lower water pump housing
• Lower impeller
• Dowels
• Outer plate cartridge Upper water housing bolt
• Impeller key “1” 16 N·m (1.6 kgf·m, 12 lb·ft)
T.
R.
• Upper impeller “2”
TIP: Installing the water pump and shift

Align the slot “a” in the upper impeller “2” with rod (counter rotation model)
the impeller key “1”. 1. Install:
• Dowels
• Gasket “1” New
2 • Plate “2”
• E-clip
• Shift rod “3”
a • Shift rod guide plate “4”
TIP:
Turn the shift rod “3” counterclockwise 90°,
1
and then push it down so that the tip “a” of the
shift rod fits into the groove “b” in the shift slider
Lower impeller bolt “5”.
4.5 N·m (0.45 kgf·m, 3.3 lb·ft)
T.
R.
4. Install:
• O-ring New
• Upper water pump housing “1”
Do not turn the drive shaft counterclock-

wise. Otherwise, the water pump impeller
could be damaged.
8-16
LT
4 572
2
3
a 1
90° 5
a
b
2. Install:
• Spacers
• O-rings New
• Lower impeller
• Dowels
• Outer plate cartridge
• Impeller key
• Upper impeller
• Upper water pump housing
See steps 2–4 in “Installing the water
pump and shift rod (regular rotation mod-
el)” (8-15).
8-17
Propeller shaft housing (regular rotation model)

15 17 16 12 6
16 14 13
13
1
2
16 6
14
12
17 New 20
16 New 22 21
15 3 D
New 8
4
9
New 5 10 G
New 18 1 155 N·m (15.5 kgf·m, 114 lb·ft)

2 *1
19 D
3 250 N·m (25 kgf·m, 184 lb·ft)
11 G

1 Ring nut M142 1 6.33 mm
2 Claw washer 1 (0.25 in)
16 Ball 2
Propeller shaft hous- (reference
3 1 data)
ing
4 Key 1 17 Shift plunger 1
5 O-ring 1 18 Ball bearing 1
6 Propeller shaft 1 19 Thrust washer 1
Reverse gear shim 20 Oil seal 2
7 — 21 Circlip 1
(T2)
8 Tapered roller bearing 1 22 Needle bearing 1
Propeller shaft shim
9 — *1. Rotate the drive shaft by 10 turns or more.
(T4)
10 Washer 1
11 Reverse gear 1
12 Spring 1
13 Cross pin 1
14 Dog clutch 1
15 Slider 1
8-18
Removing the propeller shaft housing A

assembly 4
1. Remove:
• Ring nut 2 1 a
• Claw washer
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Straighten the bent tab “a” on the claw
washer. 3
B
5
a
1 a
b
b. Loosen the ring nut. 6
A. Worldwide
B. USA and Canada
2
Stopper guide plate “2”
90890-06501
Bearing housing puller claw L “3”
1 90890-06502
Center bolt “4”
90890-06504
Ring nut wrench “1”
Universal Puller “5”
90890-06932
YB-06117
Ring nut wrench extention 2 “2”
Bearing housing puller “6”
90890-06784
YB-06207
Ring nut wrench extension “2”
YB-06784
3. Remove:
• O-ring “1”
c. Remove the ring nut and claw washer.
• Propeller shaft assembly “a”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Reverse gear shims “2”
2. Remove:
• Propeller shaft housing assembly “a” 1
• Key “1”
TIP: 2
Without the attachment “b”.
a
8-19
4. Remove: Disassembling the reverse gear
• Tapered roller bearing inner race “a” 1. Remove:
• Propeller shaft shims “1” • Ball bearing “1”
• Washer “2” • Thrust washer “2”
• Reverse gear assembly “b”
A
3 5
1
3
1
2
5
B
b
2 4 5
1 1
a 4
1
Disassembling the propeller shaft 2
assembly
1. Remove:
• Spring “1”
• Cross pin “2” 5
• Dog clutch “3”
• Slider “4” A. Worldwide
• Balls “5” B. USA and Canada
• Shift plunger “6”
Ball bearing attachment “3”
TIP: 90890-06657
When removing the slider “4”, make sure that Prop end seal bearing driver “4”
the balls “5” do not fall out of position. YB-42227
Bearing splitter plate “5”
1 (commercially available)
5 6
Disassembling the propeller shaft
4 housing assembly
2
• Use heat-resistant gloves. Otherwise,
5 burns could result.
• To prevent fires, remove any flammable
3
1. Remove:
• Oil seals “1”
• Circlip “2”
8-20
1 1
2. Remove: Checking the propeller shaft

• Needle bearing “1” 1. Check:
• Propeller shaft
2
1 Damaged/worn → Replace.
2. Measure:
3 • Propeller shaft runout
3 Above specification → Replace.
1
Driver rod LL “2”

90890-06605
Needle bearing attachment “3”
90890-06933
YB-06605
Runout
3. Remove: 0.02 mm (0.0008 in)
• Tapered roller bearing (outer race) “a”
Checking the dog clutch
1. Check:
When heating the propeller shaft housing,
• Dog clutch
heat the entire installation area evenly. Oth-
• Shift plunger
erwise, the propeller shaft housing could
• Cross pin
be damaged.
• Spring
• Balls
TIP: • Slider
Heat the installation area of the tapered roller Cracked/worn → Replace.
bearing outer race in the propeller shaft hous-
ing “1” using a gas torch, and then remove the Checking the propeller shaft housing
tapered roller bearing outer race “a”. 1. Check:
• Propeller shaft housing
8-21
Checking the reverse gear 2 1

1. Check:
• Teeth and dogs of the reverse gear
Cracked/worn → Replace.
1
Assembling the propeller shaft
assembly 2
1. Install:
• Balls “2”
• Slider “3” Assembling the reverse gear
1. Install:
TIP: • Thrust washer “1”
When installing the slider “3”, make sure that
• Ball bearing “2” New
the balls “2” do not fall out of position.
TIP:
Face the bearing identification mark “a” on the
3 1 2 ball bearing toward the propeller shaft housing.
A
2 2 a
3 1 G
3
2 3
2
2
2. Install:
• Dog clutch “1” 1 1
TIP:
Install the dog clutch “1” so that the hole “a” in B
the dog clutch “1” and the hole “b” in the propel-
ler shaft are aligned with the hole “c” in the slid- a
er “2”.
4
b 4 G
2 2
1
a 1
1
A. Worldwide
2 B. USA and Canada
b c
Bearing inner race attachment “3”
3. Install: 90890-06658
• Cross pin “1” Taper roller bearing installer “4”
• Spring “2” YB-06431
8-22
Assembling the propeller shaft A

housing assembly 1
2
burns could result.
B
1. Install:
• Tapered roller bearing (outer race) New 3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Heat the installation area of the tapered 4
roller bearing outer race in the propeller
shaft housing “1” using a gas torch, and
then install a new tapered roller bearing
outer race “a”.

A. Worldwide
B. USA and Canada
erwise, the propeller shaft housing could
be damaged. Driver rod LL “1”
90890-06605
a Bearing outer race attachment “2”
90890-06621
YB-06071
G
1 Forward gear bearing installer “4”
YB-06276
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
b. While holding the special service tools, • Needle bearing “1” New
strike the tool to check that the tapered roll- • Circlip
er bearing outer race is installed properly.
TIP:
TIP: Face the bearing identification mark “a” on the
If a high-pitched metallic sound is produced needle bearing toward the propeller.
when the special service tool is struck, the out-
er race is installed properly.
8-23
Driver rod LS “2”

2 90890-06606
1 a
Bearing outer race attachment “3”
90890-06623
YB-06071
Forward gear bearing cup installer
“5”
YB-06277-A

Installation depth “a”
90890-06933
12.25–12.75 mm (0.482–0.502
in)
3. Install:
• Oil seals New b. Install a new oil seal “1” in the propeller
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a new oil seal “1” in the propeller shaft housing at the specified installation
shaft housing at the specified installation depth “a”.
depth “a”. A
A 2
3 a
2
1
3
1 a
B
B 4
5 a
4
1
5
1 a
A. Worldwide
A. Worldwide B. USA and Canada
B. USA and Canada
8-24
Driver rod LS “2” TIP:

90890-06606 Make sure to fit the protrusion “a” on the pro-
Bearing outer race attachment “3” peller shaft housing into the slot “b” in the claw
90890-06623 washer “1”.
YB-06071
Forward gear bearing cup installer b
“5”
YB-06277-A a

4.75–5.25 mm (0.187–0.207 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1
Installing the propeller shaft housing 4. Install:

assembly • Ring nut “1”
1. Assemble:
• Propeller shaft assembly TIP:
• Reverse gear assembly Install the ring nut “1” so that the side with the
• Washer mark “a” is toward the propeller.
• Propeller shaft shims
• Tapered roller bearing (inner race) New
• O-ring New a
• Propeller shaft housing assembly
D
TIP:
Position the thickest propeller shaft shim to-
ward the propeller shaft housing.
1
2. Install:
• Reverse gear shims 5. Tighten:
• Propeller shaft/propeller shaft housing as- • Ring nut
sembly ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Key a. Tighten the ring nut to the specified torque.
TIP:
• Position the thickest reverse gear shim to-
ward the lower case. 2
• Turn the drive shaft and check that the pro-
peller shaft/propeller shaft housing assembly
is installed securely. 1
3. Install:
• Claw washer “1”
8-25

90890-06932
90890-06784
YB-06784
Ring nut
1st: 155 N·m (15.5 kgf·m, 114
T.
R.
lb·ft)
2nd: Rotate the drive shaft by 10
turns or more.
3rd: 250 N·m (25 kgf·m, 184
lb·ft)
b. Bend one of the 4 tabs on the claw washer

outward, and then bend the other 3 tabs in-
ward.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-26
Drive shaft and lower case (regular rotation model)

2 1 2
1
LT
EP
New 16 572
3 EP
EP
46 N·m (4.6 kgf·m, 34 lb·ft)

3
17 New 15
240 N·m (24 kgf·m, 177 lb·ft)
18 4 12
13
5 G
14 G
19 New
G
G
23 11
25 New
24 G
8 21
26 20
G
9 7
22 New
10 G
G
6
27 175 N·m (17.5 kgf·m, 129 lb·ft)

1 Cover 1 19 Tapered roller bearing 1
2 Bolt M8 × 20 mm 2 20 Circlip 1
3 Housing 1 21 Washer 1
4 Ring nut M86 1 22 Tapered roller bearing 1
5 Spacer 1 23 Dowel 1
6 Pinion nut M18 1 24 Circlip 1
7 Pinion 1 25 Roller bearing 1
8 Drive shaft 1 26 Needle bearing 1
9 Spacer 1 27 Lower case 1
10 Pinion shim (T3) —
11 Forward gear 1
12 Thrust bearing 1
Forward gear shim
13 1
(T1)
14 Adapter 1
15 O-ring 1
16 Oil seal 2
17 Nut M35 1
18 Claw washer 1
8-27
Removing the drive shaft Disassembling the drive shaft

1. Remove: 1. Remove:
• Cover • Drive shaft nut
• Oil seal housing • Claw washer
• Ring nut “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Spacer “2” a. Straighten the tab “a” on the claw washer
“1”.
a
1
1

b. Secure the drive shaft nut “1” on the drive
90890-06934
shaft.
2. Loosen: c. Loosen the drive shaft nut “1”, and then re-
• Pinion nut “1” move the drive shaft nut “1” and claw
washer “2”.
1
4
3
1 3
2
2
Drive shaft holder “2”

90890-06935 Drive shaft holder “3”
Pinion nut holder “3” 90890-06935
90890-06715
Socket adapter “4” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
90890-06936
2. Remove:
Holder guide “5”
• Tapered roller bearing “1”
90890-06937
3. Remove: Make sure that the inner race of the tapered

• Pinion roller bearing is placed properly on the
• Drive shaft assembly blocks.
• Pinion shims
• Spacer
8-28
Disassembling the lower case

burns could result.
1 • To prevent fires, remove any flammable
1. Remove:
• Needle bearing
1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Heat the installation area of the needle
bearing in the lower case using a gas
Disassembling the forward gear torch.
• Use heat-resistant gloves. Otherwise, When heating the lower case, heat the en-
burns could result. tire installation area evenly. Otherwise, the
• To prevent fires, remove any flammable paint on the lower case could be burned.
1. Remove:
• Circlip
• Dowel “1”
• Roller bearing “2”
When heating the adapter, heat the entire

installation area evenly. Otherwise, the
adapter could be damaged.
TIP:
Heat the installation area of the roller bearing in b. Remove the needle bearing “1”.
the adapter “3” using a gas torch, and then re-
move the roller bearing “2”. TIP:
• Before removing the needle bearing, make
sure to remove the forward gear assembly.
3 • Before installing the special service tool,
make sure that the rollers are installed in the
needle bearing outer race.
8-29
Checking the lower case

2 1. Check:
2 3 • Lower case
1
Assembling the lower case
3 1. Install:
• Needle bearing “1” New
TIP:
Driver rod LL “2” • Make sure to face the bearing identification
90890-06605 mark “a” on the needle bearing toward the
Needle bearing attachment “3” pinion.
90890-06967 • The needle bearing contains 22 rollers.
YB-06605
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4
Checking the pinion 3
1. Check: 1
• Teeth of the pinion
Cracked/worn → Replace. G
2 1
Checking the forward gear
1. Check: 2
• Teeth and dogs of the forward gear
a
Checking the drive shaft
1. Check:
90890-06938
• Drive shaft
Bearing outer race puller assem-
bly “3”
2. Measure: 90890-06523
• Drive shaft runout Stopper guide plate “4”
Above specification → Replace. 90890-06939
Double ended bolt “3”
5/8–18 UNF, 350 mm (13.8 in)
Assembling the forward gear

burns could result.
Runout
1.0 mm (0.039 in)
8-30
1. Install: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Adapter a. Install a new tapered roller bearing inner
race “a”.
• Roller bearing New
• Dowel
• Circlip Do not press the threads “b” of the drive
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
shaft directly. Make sure that the special
a. Heat the installation area of the roller bear-
service tool and blocks do not contact the
ing in the adapter “1” using a gas torch,
threads “c” of the drive shaft.
and then install a new roller bearing “2”.
When heating the adapter, heat the entire

installation area evenly. Otherwise, the b
adapter could be damaged.
b. Install the circlip “3” and dowel “4”.

a G
TIP: a 1
Face the bearing identification mark “a” on the 1
roller bearing toward the circlip.
c
a 3

4 90890-06639
2 Bearing inner race attachment “1”
1 YB-06639
G
Press load (bearing)

50 × 103 N (5000 kgf)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install: b. Install a new tapered roller bearing outer

• Tapered roller bearing New race “a” and the tapered roller bearing in-
• Washer ner race “b”.
• Circlip
Assembling the drive shaft Do not press the threads “c” of the drive
1. Install: shaft directly. Make sure that the special
service tool and blocks do not contact the
• Tapered roller bearing New
threads “d” of the drive shaft.
• Claw washer
• Drive shaft nut
8-31
2
c
a
a
G a
b
1 d
1 b
a
Bearing inner race attachment “1” f. Secure the drive shaft nut “1” on the drive
90890-06639 shaft.
YB-06639 g. Tighten the drive shaft nut “1” to the spec-
ified torque.

50 × 103 N (5000 kgf)
c. Turn the tapered roller bearing 10 turns or

more to seat the bearing, and then press 2
the drive shaft again using the specified
load. 1
50 × 103 N (5000 kgf)
d. Turn the tapered roller bearing 10 turns or

more to seat the bearing.
e. Install the claw washer “1”, and then tight- Drive shaft holder “2”
en the drive shaft nut “2” temporarily. 90890-06935
TIP: Drive shaft nut “1”

Make sure to fit the tab “a” on the claw washer 46 N·m (4.6 kgf·m, 34 lb·ft)
T.
“1” into the slot “b” in the drive shaft.

R.
h. Hold the tapered roller bearing outer race,

and then measure the motive torque of the
drive shaft.
Motive torque
0.3–3.0 N·m (0.03–0.30 kgf·m,
0.22–2.2 lb·ft)
i. Bend the tab “a” on the claw washer “1” to

secure the drive shaft nut “2”.
8-32

90890-06605
2 Bearing outer race attachment “3”
a 90890-06628
1 Driver handle (large) “4”
YB-06071
Bearing cup installer “5”
YB-06167
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Installation depth “a”

8.25–8.75 mm (0.325–0.344 in)
Assembling the oil seal housing
1. Install:
b. Install a new oil seal “1” in the oil seal
• Oil seals New housing at the specified installation depth
• O-ring New “a”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a new oil seal “1” in the oil seal A
housing at the specified installation depth
“a”.
a
A 2
3
EP
a
2
3 1
EP
1
a
B 4
5
EP
a
4
5 1
EP
A. Worldwide
B. USA and Canada
1
A. Worldwide 90890-06605
B. USA and Canada Bearing outer race attachment “3”
90890-06628
YB-06071
Bearing cup installer “5”
YB-06167
8-33

0.75–1.25 mm (0.030–0.049 in)
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
Installing the forward gear
G
1. Install:
• Adapter assembly “a”
• Forward gear shim “1” a
• Thrust bearing “2”
• Forward gear assembly “b” b. Install the pinion “1” and pinion nut “2” tem-
porarily.
TIP:
Make sure to fit the dowel “3” into the slot “c” in TIP:
the lower case. • When installing the pinion, lift up the drive
shaft slightly and align the splines on the
drive shaft with the splines on the pinion.
b c • Tighten the pinion nut “2” temporarily until the
tapered portion of the pinion “1” contacts the
tapered portion of the drive shaft.
G 2
1 c. Tighten the pinion nut “2” to the specified

torque.
G a
1
2
G
3 5
4
Installing the drive shaft
1. Install:
• Pinion shims
• Spacer
• Drive shaft assembly 3
• Pinion
6
• Pinion nut
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the original pinion shims “1”, spacer Drive shaft holder “3”
“2”, and drive shaft assembly “a”. 90890-06935
Pinion nut holder “4”
TIP: 90890-06715
Position the thickest shim on the bottom. Socket adapter “5”
90890-06936
Holder guide “6”
90890-06937
Pinion nut “2”

175 N·m (17.5 kgf·m, 129 lb·ft)
T.
R.
8-34
d. Check that the drive shaft turns smoothly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP:
• Make sure to install the oil seal housing “a” so
2. Install: that the protrusion “b” is facing rearward.
• Spacer “1” • Align the protrusion “c” on the cover “1” with
• Drive shaft ring nut “2” the slot “d” in the oil seal housing “a”.
The correct setting value of the torque

wrench varies depending on its length. a b
When tightening the drive shaft ring nut to
the specified torque, use the following cal-
culation formula to obtain the correct set- 1
ting value.
d c LT
572
3
G 2
0.045 m Am

90890-06934
Torque wrench setting value = 240

N·m ÷ (A + 0.045) × A
T.
R.
Specified tightening torque for

the drive shaft ring nut
0.045 m
Ring nut wrench length
Am
Torque wrench length
3. Install:
• Oil seal housing assembly “a”
• Cover “1”
8-35
Shimming (regular rotation model)

Shimming workflow
1. Remove the water pump assembly,

shift rod guide plate, plate, shift rod, and oil seal housing.
2. Measure the backlash before

disassembly.
4. YES
3. Within specification? 5. Shimming is not required.
6. NO
7. Disassemble the lower unit.
8. Select the pinion shims (T3).
9. Assemble the lower unit.
10. Measure the backlash.
6. NO 11. Adjust the forward gear shim

3. Within specification? thickness (T1) and reverse gear
shim thickness (T2).
4. YES
12. Select the propeller shaft
shims (T4).
13. Install the oil seal housing, shift rod, plate,

shift rod guide plate, and water pump assembly.
1. Remove the water pump assembly, shift 11. Adjust the forward gear shim thickness
rod guide plate, plate, shift rod, and oil (T1) and reverse gear shim thickness
seal housing. (T2).
2. Measure the backlash before 12. Select the propeller shaft shims (T4).
disassembly. 13. Install the oil seal housing, shift rod,
3. Within specification? plate, shift rod guide plate, and water
4. YES pump assembly.
5. Shimming is not required.
6. NO
8. Select the pinion shims (T3).
8-36
TIP:
• Make sure to drain the gear oil before measuring the backlash.
• If the backlash is within specification, shimming is not required.
• When assembling the original inner parts and a new lower case, shimming is required.
• When replacing the pinion, forward gear, reverse gear, bearings, drive shaft, or propeller shaft hous-
ing, shimming is required.
Shimming check sheet

Lower case deviation
Serial number P F R Remarks
Pinion height
Measurements (mm)
Measuring point “a”
Measuring point “b”
Measuring point “c”
Measuring point “d”
Average
Round-down average
Forward gear backlash

Measurements (mm)
Before disassembly After disassembly
Average
Round-down average
Reverse gear backlash

Measurements (mm)
Average
Round-down average
8-37
Forward gear shim (T1) thickness measurement in 2 places
(mm) Number of shim(s) Subtotal
2.00
2.03
2.06
2.09
2.12
2.15
2.18
2.21
Total
Reverse gear shim (T2) thickness measurement in 2 places

0.10
0.12
0.15
0.18
0.30
0.40
0.50
Total
8-38
Measuring the forward gear backlash A

and reverse gear backlash before
disassembly
2
1. Install:
• Lower unit (onto the repair stand)
2. Remove:
• Upper impeller
1 3
• Lower impeller B
• Spacers
• Shift rod guide plate
• Plate
• Shift rod
See “Water pump and shift rod” (8-11). a
• Cover 4
• Oil seal housing
See “Drive shaft and lower case (regular 5 b
rotation model)” (8-27).
A. Worldwide
3. Measure: B. USA and Canada
• Forward gear backlash
Out of specification → Adjust the shim Center bolt “1”
thicknesses. 90890-06504
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Bearing housing puller claw L “2”
a. Install the shift rod and shift rod guide plate 90890-06502
temporarily, and then set the gear shift to Stopper guide plate “3”
the N position. 90890-06501
YB-06207
YB-06117
Center bolt “1” or “a” (shimming)

R 1 4.9 N·m (0.49 kgf·m, 3.6 lb·ft)
T.
R.
N
F
c. Install the special service tool “1” onto the
drive shaft at the lowest possible position
Shift rod socket “1” where the shaft diameter is 26.0 mm
90890-06950 (1.024 in), and then set up the special ser-
vice tools “2”, “3”, and “4”.
b. Set up the special service tools, and then
tighten the center bolt “1” or “a” to the
specified torque.
TIP:
8-39
3 4
2
Backlash indicator “1” e. Turn the drive shaft 180° clockwise, and
90890-06836 then measure the backlash again.
Magnet base plate “2”
90890-07003 TIP:
• Measure the backlash at 4 points: “a”, “b”, “c”,
Dial gauge set “3”
and “d”, turning the drive shaft 180° clock-
90890-03238
wise after each measurement.
Magnet base B “4”
• Write down the measurement data in the
90890-06844
shimming check sheet.
Backlash indicator “1”
YB-06836
Backlash adjustment plate “2”
YB-07003
Dial indicator gauge “3”
YU-03097 a
Magnetic base stand “4”
YU-A8438
b
d
d. Turn the drive shaft slowly clockwise and
counterclockwise, and then measure the
backlash between where the drive shaft
stops in each direction.
c
TIP:
• Do not turn the drive shaft using too much
force. Otherwise, the forward gear will turn, f. Determine the backlash average, and then
leading to incorrect measurements. round down the average to 2 decimal plac-
• A knocking sound may be heard when the es.
drive shaft is rotated, but this is the sound of Example:
the pinion contacting the reverse gear and (mm)
does not affect the backlash measurement.
Measurement point “a” 0.25
Measurement point “b” 0.26
Measurement point “c” 0.26
Measurement point “d” 0.24
Average 0.2525
Round-down average 0.25
g. Check that the forward gear backlash av-

erage is within specification.
8-40
TIP: Shift rod socket “1”

Adjust the shim thicknesses if the forward gear 90890-06950
backlash is out of specification.
c. While turning the shift rod toward the R po-
sition using the specified torque, turn the
drive shaft slowly clockwise and counter-
0.13–0.50 mm (0.0051–0.0197
clockwise and measure the backlash be-
in)
tween where the drive shaft stops in each
direction.
h. Remove the special service tools.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ TIP:
4. Measure: • Do not turn the drive shaft using too much
• Reverse gear backlash force. Otherwise, the reverse gear will turn,
Out of specification → Adjust the shim leading to incorrect measurements.
thickness. • A knocking sound may be heard when the
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ drive shaft is rotated, but this is the sound of
a. Install the special service tools “1”, “2” the pinion contacting the forward gear and
washer “3”, and propeller nut “4”. does not affect the backlash measurement.
2 1
4

90890-06932
Ring nut extension “2”
90890-06968
Specified torque
Propeller nut “4” (shimming)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
50 N·m (5.0 kgf·m, 37 lb·ft)
T.
R.
T.
R.
d. Turn the drive shaft 180° clockwise, and

b. Set the gear shift to the R position.
then measure the backlash again.
TIP:
1
R wise after each measurement.
N shimming check sheet.
8-41
• Plate
• Spacers
a
• Lower impeller
• Upper impeller
b
d • Upper water pump housing
See “Installing the water pump and shift
rod (regular rotation model)” (8-15).
e. Determine the backlash average, and then

round down the average to 2 decimal plac-
es.
Example:
(mm)
Average 0.4525
f. Check that the reverse gear backlash av-

TIP:
Adjust the shim thicknesses if the reverse gear

0.39–0.83 mm (0.0154–0.0327
in)
g. Remove the special service tools.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• Cover
See step 3 in “Installing the drive shaft”
(8-34).
• Shift rod
• Dowels
• Gasket New
8-42
Shimming procedure
• Before selecting the forward gear shim (T1) and reverse gear shims (T2), make sure to select the pin-
ion shims (T3).
• After selecting the pinion shims (T3), do not apply gear oil, grease, or sealant to the lower unit parts
to measure the backlash.
• When assembling the lower unit after shimming is completed, make sure to apply gear oil, grease,
and sealant to the specified areas.
Shim location
T3
T1 T2 T4
8-43
Selecting the pinion shim (T3)

Pinion shimming gauge “1”
• Spray anti-rust lubricant on the gears and 90890-06948
bearings before installation. Do not apply Pinion shimming gauge rod “2”
gear oil to the parts. Otherwise, correct mea- 90890-06676
surements cannot be obtained. Pinion shimming gauge “2”
• Keep the parts free of foreign material, such YB-06835
as dirt and lint.
c. Measure the distance “a” between the
Be careful not to damage the measurement special service tool “1” and the pinion “2”.
plane surface of the special service tool.
Otherwise, correct measurements cannot
be obtained.
1. Install:
a
• Original pinion shims (T3)
• Spacer 2
1
• Drive shaft assembly
• Pinion
1
• Pinion nut
• Spacer d. Turn the drive shaft 90° clockwise and
• Drive shaft ring nut measure the distance again.
See steps 1 and 2 in “Installing the drive
shaft” (8-34). TIP:
• Measure the distance at 4 points: “a”, “b”, “c”,
TIP: and “d”, turning the drive shaft 90° clockwise
• If the original shims are missing, install new after each measurement.
shims with a combined thickness of 0.95 mm. • Write down the measurement data in the
• Do not reuse a shim if deformed or shimming check sheet.
scratched.
a
2. Measure:
• Distance “a”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check that the drive shaft turns smoothly.
d b
b. Set up the special service tools “1” and “2”,
and then remove the special service tool
“2”. c
2 2 e. Determine the distance average, and then
round down the average to the 1/100
1 place.
Example:
(mm)
8-44
Measuring point “a” 0.70 b a

Measuring point “b” 0.71 (mm)
Measuring point “c” 0.71 A 0.51 0.52 0.53

B +0.24 +0.23 +0.22
Measuring point “d” 0.69
Average 0.7025 A 0.74 0.75 0.76
Round-down average 0.70 B +0.01 -0.01
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Select: A. Pinion distance measurement

• Pinion shim (T3) B. Shim thickness adjustment
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Determine the pinion shim (T3) thickness b. Calculate the new pinion shim (T3) thick-
adjustment using the pinion shim (T3) se- ness.
lection table. See “Pinion shim (T3) selec-
tion table” (A-22). TIP:
• Use up to 3 shims to obtain the required shim
TIP: thickness. However, if the pinion shim thick-
• If the shim thickness adjustment value is pos- ness is 1.21 mm or more, 4 shims may be
itive, the current shim thickness must be in- used.
creased by that amount and, if the value is • If the calculated shim thickness cannot be
negative, the current shim thickness must be obtained with a combination of the available
decreased by that amount. shims, increase or decrease the pinion dis-
• The blue-colored cell on the selection table tance measurement by 0.01 mm.
indicates the specified pinion distance. Shim-
ming is not required if the measured pinion
distance is 0.75 mm. Calculation formula:
• The values for the shim thickness adjust- New pinion shim (T3) thickness = Current
ments specified in the selection table are in- pinion shim thickness + Shim thickness
tended to obtain the specified pinion distance adjustment
of 0.75 mm. Example:
Use the following formula when the shim
Example: thickness adjustment value is positive.
Pinion distance measurement = 0.52 mm Current pinion shim thickness = 0.70 mm
“a” Shim thickness adjustment = 0.18 mm
Pinion shim (T3) thickness adjustment = New pinion shim (T3) thickness = 0.70 mm
0.23 mm “b” + 0.18 mm = 0.88 mm
The current shim thickness must be in- Use the following formula when the shim
creased by 0.23 mm. thickness adjustment value is negative.
Current pinion shim thickness = 0.70 mm
Shim thickness adjustment = -0.09 mm
New pinion shim (T3) thickness = 0.70 mm
+ (-0.09) mm = 0.61 mm
Available shim thicknesses
Pinion shims
0.10/0.12/0.15/0.18/0.30/0.40/
0.50 mm
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-45
4. Remove:
• Special service tool TIP:
• If the original reverse gear shims (T2) are
5. Install: missing, install new shims with a combined
• Determined pinion shims (T3) thickness of 0.80 mm.
• Do not reuse a shim if deformed or
Measuring the forward gear backlash scratched.
• Spray anti-rust lubricant on the gear and • Check that the drive shaft turns smoothly.
bearings before installation. Do not apply
gear oil to the parts. Otherwise, correct mea-
3. Install:
surements cannot be obtained.
• Shift rod
• Keep the parts free of foreign material, such
• Shift rod guide plate (temporarily)
as dirt and lint.
See step 1 in “Installing the water pump
• When measuring the forward gear or reverse
and shift rod (regular rotation model)”
gear backlash, use the original bearings and
(8-15).
shims.
1. Install: 4. Measure:
• Adapter assembly • Forward gear backlash (BL 1)
• Original forward gear shim (T1) See step 3 in “Measuring the forward gear
• Thrust bearing backlash and reverse gear backlash be-
• Forward gear assembly fore disassembly” (8-39).
See “Installing the forward gear” (8-34).
• Pinion shims (T3) Forward gear backlash
• Spacer 0.13–0.50 mm (0.0051–0.0197
• Drive shaft assembly in)
• Pinion
• Pinion nut Adjusting the forward gear shim
• Spacer thickness (T1)
• Drive shaft ring nut 1. Remove:
See steps 1 and 2 in “Installing the drive • Shift rod guide plate
shaft” (8-34). • Shift rod
See “Removing the shift rod (regular rota-
TIP:
tion model)” (8-12).
• If the original forward gear shim (T1) is miss-
ing, install a new shim with a thickness of 2. Remove:
2.00 mm. • Ring nut
• Do not reuse a shim if deformed or • Claw washer
scratched. • Propeller shaft housing assembly
• Check that the drive shaft turns smoothly. • Key
• O-ring
2. Install: • Propeller shaft assembly
• Original reverse gear shims • Original reverse gear shim
• Propeller shaft/propeller shaft housing as- See steps 1–3 in “Removing the propeller
sembly shaft housing assembly” (8-19).
• Key
3. Remove:
• Claw washer (do not bend the tabs)
• Drive shaft ring nut
• Ring nut
• Spacer
See steps 2–5 in “Installing the propeller
• Pinion nut
shaft housing assembly” (8-25).
• Pinion
8-46
• Drive shaft assembly Example:
• Spacer Backlash measurement (BL1) = 0.30 mm
• Pinion shims (T3) “a”
See “Removing the drive shaft” (8-28). Current forward gear shim thickness =
• Forward gear assembly 2.06 mm “b”
• Thrust bearing Use the determined shim thickness of 2.03
• Original forward gear shim (T1) mm instead of the current shim thickness.
• Adapter assembly
See “Drive shaft and lower case (regular a
rotation model)” (8-27). (mm)
A
4. Measure: 0.28 0.29 0.30
• Original forward gear shim (T1) thickness 2.00
2.03
B
TIP: 2.06 2.03
• Measure the thickness of original forward 2.09
gear shim (T1) in 2 places. b
scratched. A. Backlash measurement (BL1)
B. Current shim thickness
5. Select: Available shim thicknesses

• Forward gear shim (T1) Forward shims
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2.00/2.03/2.06/2.09/2.12/2.15/
a. Determine the forward gear shim (T1) 2.18/2.21 mm
thickness using the “Forward gear shim
(T1) selection table” according to the back- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
lash measurement (BL1) from “Measuring
6. Install:
the forward gear backlash”. See “Forward
gear shim (T1) selection table” (A-22).
• Determined forward gear shim (T1)
TIP: • Thrust bearing
• The blue-colored cells on the selection table • Forward gear assembly
indicate the range where the shim adjust- See “Installing the forward gear” (8-34).
ment is unnecessary. Shimming is not re- • Pinion shims (T3)
quired if the obtained forward gear shim • Spacer
thickness is indicated by the blue-colored • Drive shaft assembly
cells. • Pinion
• The values for the shim thickness specified in • Pinion nut
the selection table are intended to obtain the • Spacer
median value within the range for the speci- • Drive shaft ring nut
fied forward gear backlash. See steps 1–3 in “Installing the drive shaft”
• If the backlash measurement (BL1) is less (8-34).
than 0.13 mm, install a new shim with a thick-
ness of 2.00 mm. Measuring the reverse gear backlash
• If the backlash measurement (BL1) is more • Spray anti-rust lubricant on the gears and
than 0.51 mm, install a new shim with a thick- bearings before installation. Do not apply
ness of 2.21 mm. gear oil to the parts. Otherwise, correct mea-
• Use only 1 shim to obtain the required shim surements cannot be obtained.
thickness. • Keep the parts free of foreign material, such
as dirt and lint.
8-47
• When measuring the forward gear or reverse • Original reverse gear shims (T2)
gear backlash, use the original bearings and See steps 1–3 in “Removing the propeller
shims. shaft housing assembly” (8-19).
1. Install:
• Original reverse gear shims (T2) 3. Measure:
• Propeller shaft/propeller shaft housing as- • Original reverse gear shim (T2)
sembly
• Key
TIP:
• Measure the thickness of original reverse
gear shim (T2) in 2 places.
• Ring nut
See “Installing the propeller shaft housing
scratched.
assembly” (8-25).
TIP: 4. Select:
Check that the drive shaft turns smoothly. • Reverse gear shim (T2)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Determine the reverse gear shim (T2)
2. Install:
thickness adjustment using the “Reverse
• Shift rod
gear shim (T2) selection chart” according
• Shift rod guide plate (temporarily)
to the backlash measurement (BL2) from
“Measuring the reverse gear backlash”.
and shift rod (regular rotation model)”
See “Reverse gear shim (T2) selection
(8-15).
chart” (A-23).
3. Measure:
TIP:
• Reverse gear backlash (BL 2)
• If the shim thickness adjustment value is pos-
See step 4 in “Measuring the forward gear
itive, increase the current shim thickness by
backlash and reverse gear backlash be-
that amount and, if the value is negative, de-
fore disassembly” (8-39).
crease the current shim thickness by that
Reverse gear backlash amount.
0.39–0.83 mm (0.0154–0.0327 • The blue-colored area on the selection chart
in) indicates the range of the specified backlash.
Shimming is not required if the measured
Adjusting the reverse gear shim backlash is within the blue-colored area.
• The values for the shim thickness adjust-
thickness (T2)
ments specified in the selection chart are in-
1. Remove:
tended to obtain the median value within the
range for the specified reverse gear back-
• Shift rod
lash.
See “Removing the shift rod (regular rota-
• The table that follows the selection chart
tion model)” (8-12).
shows the shim thickness adjustments for
2. Remove: the points marked on the chart.
• Ring nut
Example:
• Claw washer
Backlash measurement (BL2) = 0.10 mm
“a”
• Propeller shaft assembly
Reverse gear shim (T2) thickness adjust-
• Key
ment = 0.56 mm “b”
• O-ring
The current shim thickness must be in-
creased by 0.56 mm.
8-48
0.80 Available shim thicknesses

b Reverse shims
0.60 0.10/0.12/0.15/0.18/0.30/0.40/
B (mm)
0.50 mm
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
–1.60
0 5 10 15 20 25 30 35 40 Selecting the propeller shaft shim (T4)
a A (1/100 mm) 1. Install:
• Propeller shaft assembly
A 0 5 10 15 20 25 30 35 40 • Reverse gear assembly
• Washer
B 0.67 0.62 0.56 0.51 0.45 0.40 0.34 0.29 0.12 • Original propeller shaft shims (T4)
• Tapered roller bearing
A. Backlash measurement (BL2) • Reverse gear shims (T2)
B. Shim thickness adjustment • O-ring
b. Calculate the new reverse gear shim (T2) • Claw washer (do not bend the tabs)
thickness. • Ring nut
See “Installing the propeller shaft housing
TIP:
assembly” (8-25).
thickness. 2. Install:
• If the calculated shim thickness cannot be • Shift rod
obtained with a combination of the available • Shift rod guide plate (temporarily)
shims, increase or decrease the pinion dis- See step 1 in “Installing the water pump
tance measurement by 0.01 mm. and shift rod (regular rotation model)”
(8-15).
Calculation formula: TIP:
New reverse gear shim (T2) thickness = • If the original shims are missing, install new
Current reverse gear shim thickness + shims with a combined thickness of 1.20 mm.
shim thickness adjustment • Do not reuse a shim if deformed or
Example: scratched.
Use the following formula when the shim • Check that there is no free play in the propel-
thickness adjustment value is positive. ler shaft.
Current reverse gear shim thickness =
0.75 mm
Shim thickness adjustment = 0.56 mm 3. Measure:
New reverse gear shim (T2) thickness = • Propeller shaft free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
0.75 mm + 0.56 mm = 1.31 mm a. Set the gear shift to the N position.
thickness adjustment value is negative.
Current reverse gear shim thickness =
0.75 mm
Shim thickness adjustment = –0.26 mm
New reverse gear shim (T2) thickness =
0.75 mm + (–0.26 mm) = 0.49 mm
8-49
TIP:
• Measure the thickness of original propeller
shaft shim (T4) in 2 places.
1 scratched.
R ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Determine the propeller shaft shim (T4)
N
F thickness adjustment using the “Propeller
shaft shim (T4) selection chart” according
Shift rod socket “1” to the propeller shaft motive torque.
90890-06950 See “Propeller shaft shim (T4) selection
chart” (A-24).
b. Turn the propeller shaft 5 turns or more.
TIP:
c. Install the washer “1” and propeller nut “2”. • If the shim thickness adjustment value is pos-
2 that amount and, if the value is negative, de-
1 amount.
• The blue-colored area on the selection chart
indicates the range of the specified motive
torque. Shimming is not required if the mea-
sured motive torque is within the blue-col-
ored area.
d. Measure the motive torque of the propeller ments specified in the selection chart are in-
shaft. tended to obtain the median value within the
range for the specified motive torque.
shows the shim thickness adjustments for
the points marked on the chart.
Example:
Propeller shaft motive torque measure-
ment = 0.2 N·m “a”
Propeller shaft shim (T4) thickness adjust-
ment = 0.05 mm “b”
Motive torque
creased by 0.05 mm.
0.4–1.0 N·m (0.04–0.10 kgf·m,
0.30–0.73 lb·ft)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Select:
• Propeller shaft shim (T4)
8-50
0.07 Available shim thicknesses

b 0.06 Propeller shaft shims
0.05 0.10/0.12/0.15/0.18/0.30/0.40/
B (mm)
0.04 0.50/1.00 mm
–0.07
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
–0.08
0 0.1 0.2
a
A (N·m)
A 0 0.1 0.2
B 0.07 0.06 0.05
b. Calculate the new propeller shaft shim

(T4) thickness.
TIP:
thickness.
• If the calculated shim thickness cannot be
obtained with a combination of the available
shims, increase or decrease the shim thick-
ness by 0.01 mm.
Calculation formula:
New propeller shaft shim (T4) thickness =
Current propeller shaft shim thickness +
shim thickness adjustment
Example:
thickness adjustment value is positive.
Current propeller shaft shim thickness =
1.20 mm
Shim thickness adjustment = 0.04 mm
1.20 mm + 0.04 mm = 1.24 mm
1.30 mm
Shim thickness adjustment = –0.05 mm
1.30 mm + (–0.05 mm) = 1.25 mm
8-51
Propeller shaft housing (counter rotation model)

New 23
24
13
5
7
G
G
10
8
11 6 New 20
10 New 22 21
9 3
16
New 15
4 G
New 12
1
D
14 G
2
G 9 11 10 6 14
D
17 250 N·m (25 kgf·m, 184 lb·ft)

19 New 10 8 7
18

1 Ring nut M142 1 15 Thrust bearing 1
2 Claw washer 1 Propeller shaft shim
16 —
Propeller shaft hous- (T4)
3 1
ing 17 Circlip 1
4 Key 1 18 Washer 1
Forward gear shim 19 Roller bearing 1 Inner race
5 —
(T2) 20 Oil seal 2
6 Spring 1 21 Circlip 1
7 Cross pin 1 22 Needle bearing 1
8 Dog clutch 1 23 Tapered roller bearing 1
9 Slider 1 24 Thrust washer 1
6.33 mm
(0.25 in)
10 Ball 2
(reference
data)
11 Shift plunger 2
12 O-ring 1
13 Forward gear 1
14 Propeller shaft 1
8-52
Removing the propeller shaft housing Disassembling the propeller shaft

assembly housing assembly
1. Remove:
• Ring nut
• Claw washer • Use heat-resistant gloves. Otherwise,
See step 1 in “Removing the propeller burns could result.
shaft housing assembly” (8-19). • To prevent fires, remove any flammable
2. Remove: around the working area.
• Propeller shaft/propeller shaft housing as- • Keep good ventilation while working.
sembly “a”
• Key “1” 1. Remove:
• Spring
A • Cross pin
• Dog clutch
• Slider
• Balls
• Shift plunger
See “Disassembling the propeller shaft as-
sembly” (8-20).
3
2. Remove:
2 1 a • Forward gear assembly
B ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Heat the area of the propeller shaft hous-
ing “1” where the tapered roller bearing
outer race is to be installed using a gas
torch, and then remove the forward gear
assembly “a”.
5
4 1 a erwise, the propeller shaft housing could
A. Worldwide be damaged.
B. USA and Canada
Slide hammer handle “2”

90890-06531 1
Puller head “3”
90890-06514
Slide hammer “4”
YB-06096
Propeller shaft and bearing hous-
ing remover “5” a
YB-06335
3. Remove:
• Forward gear shim
• O-ring ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-53
3. Remove: Disassembling the forward gear
• Propeller shaft 1. Remove:
• Thrust bearing • Tapered roller bearing “1”
• Propeller shaft shims • Thrust washer “2”
• Circlip
A
• Washer
• Roller bearing (inner race) “a” 3 5
1
A 3
1 1
a 2
1 2
2
a
5 5
B
5
4 5
1
B 4
3 1
a 2
3
4
4
a
5 5
A. Worldwide
5
B. USA and Canada
A. Worldwide Ball bearing attachment “3”

B. USA and Canada 90890-06630
Forward gear needle bearing in-
Driver rod L3 “1” staller “4”
90890-06652 YB-06261
Needle bearing attachment “2” Bearing splitter plate “5”
90890-06616 (commercially available)
YB-06229
Checking the propeller shaft
Oil seal installer “4”
1. Check:
YB-06023
• Propeller shaft
Bearing splitter plate “5”
2. Measure:
4. Remove: • Propeller shaft runout
• Oil seals Above specification → Replace.
• Circlip
• Needle bearing
See “Disassembling the propeller shaft
housing assembly” (8-20).
8-54

90890-06644
YB-06644
2. Install:
• Needle bearing New
• Circlip
• Oil seals New
Runout See steps 2 and 3 in “Assembling the pro-
0.02 mm (0.0008 in) peller shaft housing assembly” (8-23).
3. Install:
Checking the dog clutch • Propeller shaft shims “1”
See “Checking the dog clutch” (8-21). • Thrust bearing “2”
Checking the propeller shaft housing TIP:

See “Checking the propeller shaft housing” Position the thickest propeller shaft shim to-
(8-21). ward the propeller shaft housing.
Checking the forward gear 2

1. Check:
• Teeth and dogs of the forward gear
G
Assembling the propeller shaft

housing and forward gear 1
1. Install:
• Roller bearing (inner race) “a” New
• Washer
4. Install:
• Circlip
• Propeller shaft
TIP: • Tapered roller bearing
Face the bearing identification mark “b” on the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the propeller shaft “1” and tapered
roller bearing inner race “a” up.
roller bearing inner race “a”.
1
G
a
1
G
b
8-55
b. Install the tapered roller bearing outer race
Ring nut wrench 2 “4”
“a” using the special service tools.
90890-06823
2 Ring nut wrench extention 2 “5”
1 90890-06784
2
a Ring nut wrench “4”
1 YB-06823
a Ring nut wrench extension “5”
YB-06784
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
G
6. Install:
Ring nut wrench 2 “1”
• Balls “2”
90890-06823
• Slider “3”
90890-06784 TIP:
Ring nut wrench “1” When installing the slider “3”, make sure that
YB-06823 the balls “2” do not fall out of position.
YB-06784
3 2 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• Thrust washer
• Forward gear 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the thrust washer “1” and forward 1
gear “2” using the dog clutch “3” and spe- 2
cial service tools.
3
5 2
5 7. Install:
4 • Dog clutch “1”
4
3 3
2 2 TIP:
1 Make sure that the hole “a” in the dog clutch “1”
1 and the hole “b” in the propeller shaft are
aligned with the hole “c” in the slider “2”.
8-56
a
a
b c
8. Install:
• Cross pin
• Spring
• O-ring New
Installing the propeller shaft housing

assembly
1. Install:
• Forward gear shims
• Propeller shaft/propeller shaft housing as-
sembly
• Key
TIP:
Position the thickest forward gear shim toward
the lower case.
2. Install:
• Claw washer
• Ring nut
Ring nut
250 N·m (25 kgf·m, 184 lb·ft)
T.
R.

8-57
Drive shaft and lower case (counter rotation model)

2 1
1 2
LT
572
New 16 EP
3 EP
EP
46 N·m (4.6 kgf·m, 34 lb·ft)

3
17 New 15 240 N·m (24 kgf·m, 177 lb·ft)
18 4 12
13
5 G
14
19 New
G
G
G
22
24 New
8 23 G 11
9 25 20
G
10
7
New 21 G
G
6 175 N·m (17.5 kgf·m, 129 lb·ft)
26

1 Cover 1 19 Tapered roller bearing 1
3 Housing 1 21 Roller bearing 1 Outer race
4 Ring nut M86 1 22 Dowel 1
5 Spacer 1 23 Circlip 1
6 Pinion nut M18 1 24 Roller bearing 1
7 Pinion 1 25 Needle bearing 1
8 Drive shaft 1 26 Lower case 1
9 Spacer 1
10 Pinion shim (T3) —
11 Reverse gear 1
12 Thrust bearing 1
Reverse gear shim
13 1
(T1)
14 Adapter 1
15 O-ring 1
16 Oil seal 2
17 Nut M35 1
18 Claw washer 1
8-58
Removing the drive shaft

Driver rod L3 “2”
See “Removing the drive shaft” (8-28). 90890-06652
Disassembling the drive shaft
90890-06609
See “Disassembling the drive shaft” (8-28). Driver handle (large) “4”
YB-06071
Disassembling the reverse gear Driveshaft needle bearing installer
1. Remove: and remover “5”
• Circlip YB-06196
• Roller bearing (outer race) “a”
2. Remove:
TIP:
When removing the roller bearing, make sure • Dowel
that the reverse gear shim “1” is installed to the • Circlip
reverse gear. Do not reuse the reverse gear • Roller bearing
shim. See “Disassembling the forward gear”
(8-29).
A
Disassembling the lower case
2 3 a See “Disassembling the lower case” (8-29).
1
2
Checking the pinion
See “Checking the pinion” (8-30).
Checking the reverse gear

1. Check:
3 • Teeth and dogs of the reverse gear
B
4 5 a Checking the drive shaft
1 See “Checking the drive shaft” (8-30).
4
Checking the lower case
See “Checking the lower case” (8-30).
Assembling the lower case

5 See “Assembling the lower case” (8-30).
A. Worldwide Assembling the reverse gear

B. USA and Canada 1. Install:
• Adapter
• Roller bearing New
• Dowel
See step 1 in “Assembling the forward
gear” (8-30).
2. Install:
• Roller bearing (outer race) “a” New
• Reverse gear
• Circlip
8-59
TIP:
Face the bearing identification mark “b” on the
roller bearing (outer race) “a” up.
A
b 1
a
1 G
B
b 2
a
2 G
A. Worldwide
B. USA and Canada

90890-06654
Needle bearing installer “2”
YB-06434
Assembling the drive shaft

See “Assembling the drive shaft” (8-31).
Assembling the oil seal housing

See “Assembling the oil seal housing” (8-33).
Installing the reverse gear

1. Install:
• Reverse gear shim
• Thrust bearing
• Reverse gear assembly
Installing the drive shaft

See “Installing the drive shaft” (8-34).
8-60
Shimming (counter rotation model)

Shimming workflow
1. Remove the water pump assembly,

shift rod guide plate, plate, shift rod, and oil seal housing.

disassembly.
4. YES
3. Within specification? 5. Shimming is not required.
6. NO
8. Select the pinion shims (T3)

and propeller shaft shims (T4).
6. NO 11. Adjust the forward gear shim

3. Within specification? thickness (T2) and reverse gear
shim thickness (T1).
4. YES
12. Install the oil seal housing, shift rod, plate,
shift rod guide plate, and water pump assembly.
1. Remove the water pump assembly, shift 12. Install the oil seal housing, shift rod,
rod guide plate, plate, shift rod, and oil plate, shift rod guide plate, and water
seal housing. pump assembly.
disassembly.
3. Within specification?
4. YES
5. Shimming is not required.
6. NO
8. Select the pinion shims (T3) and
propeller shaft shims (T4).
11. Adjust the forward gear shim thickness
(T2) and reverse gear shim thickness
(T1).
8-61
TIP:
• Make sure to drain the gear oil before measuring the backlash.
• If the backlash is within specification, shimming is not required.
• When assembling the original inner parts and a new lower case, shimming is required.
• When replacing the pinion, forward gear, reverse gear, bearings, drive shaft, or propeller shaft hous-
ing, shimming is required.
Shimming check sheet

Lower case deviation
Serial number P F R Remarks
Pinion height
Measurements (mm)
Average
Round-down average

Measurements (mm)
Average
Round-down average

Measurements (mm)
Average
Round-down average
8-62
Forward gear shim (T2) thickness measurement in 2 places
0.10
0.12
0.15
0.18
0.30
0.40
0.50
Total
Reverse gear shim (T1) thickness measurement in 2 places

2.00
2.03
2.06
2.09
2.12
2.15
2.18
2.21
Total
8-63
Measuring the forward gear backlash A

and reverse gear backlash before
disassembly
2
1. Install:
• Lower unit (onto the repair stand)
2. Remove:
• Upper impeller
1 3
• Lower impeller B
• Spacers
• Plate
• Shift rod
See “Water pump and shift rod” (8-11). a
• Cover 4
See “Drive shaft and lower case (counter 5 b
rotation model)” (8-58).
A. Worldwide
3. Measure: B. USA and Canada
• Forward gear backlash
Out of specification → Adjust the shim Center bolt “1”
thicknesses. 90890-06504
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Bearing housing puller claw L “2”
a. Install the shift rod and shift rod guide plate 90890-06502
temporarily, set the gear shift to the N po- Stopper guide plate “3”
sition. 90890-06501
YB-06207
YB-06117
Center bolt “1” or “a” (shimming)

R 1 4.9 N·m (0.49 kgf·m, 3.6 lb·ft)
T.
R.
N
F
c. Install the special service tool “1” onto the
drive shaft at the lowest possible position
Shift rod socket “1” where the shaft diameter is 26.0 mm
90890-06950 (1.024 in), and then set up the special ser-
vice tools “2”, “3”, and “4”.
b. Set up the special service tools, and then
tighten the center bolt “1” or “a” to the
specified torque.
TIP:
8-64
3 4
2
Backlash indicator “1” e. Turn the drive shaft 180° clockwise, and
90890-06836 then measure the backlash again.
Magnet base plate “2”
90890-07003 TIP:
Dial gauge set “3”
90890-03238
Magnet base B “4”
90890-06844
shimming check sheet.
Backlash indicator “1”
YB-06836
Backlash adjustment plate “2”
YB-07003
Dial indicator gauge “3”
YU-03097 a
Magnetic base stand “4”
YU-A8438
b
d
d. Turn the drive shaft slowly clockwise and
counterclockwise, and then measure the
backlash between where the drive shaft
stops in each direction.
c
TIP:
force. Otherwise, the forward gear will turn, f. Determine the backlash average, and then
leading to incorrect measurements. round down the average to 2 decimal plac-
• A knocking sound may be heard when the es.
drive shaft is rotated, but this is the sound of Example:
the pinion contacting the reverse gear and (mm)
Average 0.2525
g. Check that the forward gear backlash av-

8-65
TIP:
Adjust the shim thicknesses if the forward gear

0.20–0.61 mm (0.0079–0.0240
in)
h. Remove the special service tools from the

propeller shaft.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Measure:
• Reverse gear backlash
Out of specification → Adjust the shim Specified torque
thicknesses. 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the gear shift to the R position. c. Turn the drive shaft 180° clockwise, and
then measure the backlash again.
TIP:
1 • Measure the backlash at 4 points: “a”, “b”, “c”,
R
N shimming check sheet.
Shift rod socket “1”

90890-06950
a
b. While turning the shift rod toward the R po-
sition using the specified torque, turn the
drive shaft slowly clockwise and counter- b
d
clockwise and measure the backlash be-
tween where the drive shaft stops in each
direction.
TIP: c
force. Otherwise, the reverse gear will turn,
leading to incorrect measurements. d. Determine the backlash average, and then
• A knocking sound may be heard when the round down the average to 2 decimal plac-
drive shaft is rotated, but this is the sound of es.
the pinion contacting the forward gear and
8-66
Example:
(mm)
Average 0.4525
e. Check that the reverse gear backlash av-

TIP:
Adjust the shim thicknesses if the reverse gear

0.40–0.81 mm (0.0157–0.0319
in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• Cover
See step 3 in “Installing the drive shaft”
(8-34).
• Shift rod
• Plate
• Spacers
• Lower impeller
• Upper impeller
See “Installing the water pump and shift
rod (counter rotation model)” (8-16).
8-67
Shimming procedure
• Before selecting the forward gear shim (T2) and reverse gear shims (T1), make sure to select the pin-
ion shims (T3).
• After selecting the pinion shims (T3), do not apply gear oil, grease, or sealant to the lower unit parts
to measure the backlash.
• When assembling the lower unit after shimming is completed, make sure to apply gear oil, grease,
and sealant to the specified areas.
Shim location
T3
T1 T2 T4
8-68
Selecting the pinion shim (T3)

2
See “Selecting the pinion shim (T3)” (8-44).
Selecting the propeller shaft shim (T4)

1. Assemble:
1
• Original propeller shaft shims (T4)
• Thrust bearing
• Propeller shaft
• Tapered roller bearing
• Thrust washer Dial gauge set “1”
• Forward gear 90890-03238
• Shift plunger Magnet base B “2”
• Balls 90890-06844
• Slider Dial indicator gauge “1”
• Dog clutch YU-03097
• Cross pin Magnetic base stand “2”
• Spring YU-A8438
• O-ring
See “Assembling the propeller shaft hous- Free play
ing and forward gear” (8-55). 0.42–0.52 mm (0.0165–0.0205
in)
2. Install:
4. Calculate:
sembly
• Propeller shaft shim (T4) thicknesses
• Key
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Claw washer (do not bend the tabs) a. Round the measurement value to the 1/10
• Ring nut place if out of specification.
Ring nut
TIP:
250 N·m (25 kgf·m, 184 lb·ft)
In the “Propeller shaft shim (T4) selection ta-
T.
R.
See steps 2–5 in “Installing the propeller ble”, use the rounded measurement value for
shaft housing assembly” (8-25). the free play measurement.
TIP:
b. Determine the value of propeller shaft
• If the original shims are missing, measure the
free play without any shims. shim (T4) thickness adjustment using the
• Do not reuse a shim if deformed or “Propeller shaft shim (T4) selection table”
according to the free play measurement.
scratched.
See “Propeller shaft shim (T4) selection ta-
ble” (A-25).
3. Measure:
• Propeller shaft free play
8-69
TIP: 0.8 mm
• If the shim thickness adjustment value is pos- Shim thickness adjustment = 0.2 mm
itive, the current shim thickness must be in- New propeller shaft shim (T4) thickness =
creased by that amount and, if the value is 0.8 mm + 0.2 mm = 1.0 mm
negative, the current shim thickness must be Use the following formula when the shim
decreased by that amount. thickness adjustment value is negative.
• The blue-colored cell on the selection table Current propeller shaft shim thickness =
indicates the specified propeller shaft free 0.8 mm
play. Shimming is not required if the mea- Shim thickness adjustment = -0.1 mm
sured propeller shaft free play is 0.42–0.52 New propeller shaft shim (T4) thickness =
mm. 0.8 mm + (-0.1) mm = 0.7 mm
ments specified in the selection table are in- Available shim thicknesses
tended to obtain the specified propeller shaft Propeller shaft shims
free play of 0.50 mm. 0.10/0.12/0.15/0.18/0.30/0.40/
0.50 mm
Example:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Free play measurement = 1.1 mm “a”
Propeller shaft shim (T4) thickness adjust- 5. Remove:
ment = 0.6 mm “b” • Special service tools
creased by 0.6 mm. 6. Install:
• Determined propeller shaft shims
a Measuring the reverse gear backlash

(mm)
• Spray anti-rust lubricant on the gears and
A 1.0 1.1 bearings before installation. Do not apply
B +0.5 +0.6 surements cannot be obtained.
• Keep the parts free of foreign material, such
b
as dirt and lint.
• When measuring the forward gear or reverse
A. Free play measurement gear backlash, use the original bearings and
B. Shim thickness adjustment shims.
1. Install:
c. Calculate the new propeller shaft shim • Adapter assembly
(T4) thickness. • Original reverse gear shim (T1)
• Thrust bearing
TIP: • Reverse gear assembly
Use up to 3 shims to obtain the required shim
thickness.
• Pinion shims (T3)
• Spacer
Calculation formula: • Drive shaft assembly
New propeller shaft shim (T4) thickness = • Pinion
Current propeller shaft shim thickness + • Pinion nut
Shim thickness adjustment • Spacer
• Drive shaft ring nut
Example:
See steps 1 and 2 in “Installing the drive
shaft” (8-34).
8-70
• Shift rod
TIP: See “Removing the shift rod (counter rota-
• If the original reverse gear shim (T1) is miss- tion model)” (8-12).
ing, install a new shim with a thickness of
2.00 mm. 2. Remove:
• Do not reuse a shim if deformed or • Ring nut
scratched. • Claw washer
• Check that the drive shaft turns smoothly. See step 1 in “Removing the propeller
• Key
2. Install:
• Original forward gear shims (T2)
sembly
sembly
See steps 2 and 3 in “Removing the pro-
• Key
peller shaft housing assembly” (8-53).
• Ring nut 3. Remove:
See steps 2–5 in “Installing the propeller • Drive shaft ring nut
shaft housing assembly” (8-25). • Spacer
• Pinion nut
TIP:
• Pinion
• If the original forward gear shims (T2) are
• Drive shaft assembly
missing, install new shims with a combined
• Spacer
thickness of 0.75 mm.
• Pinion shims (T3)
See “Removing the drive shaft” (8-28).
scratched.
• Reverse gear assembly
• Check that the drive shaft turns smoothly.
• Thrust bearing
• Original reverse gear shim (T1)
3. Install: • Adapter assembly
• Shift rod See “Drive shaft and lower case (counter
• Shift rod guide plate (temporarily) rotation model)” (8-58).
and shift rod (counter rotation model)” 4. Measure:
(8-16). • Original reverse gear shim (T1) thickness.
4. Measure: TIP:
• Reverse gear backlash (BL 1) • Measure the thickness of original reverse
See step 4 in “Measuring the forward gear gear shim (T1) in 2 places.
backlash and reverse gear backlash be- • Do not reuse a shim if deformed or
fore disassembly” (8-64). scratched.

0.40–0.81 mm (0.0157–0.0319 5. Select:
in) • Reverse gear shim (T1)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Determine the reverse gear shim (T1)
Adjusting the reverse gear shim thickness using the “Reverse gear shim
thickness (T1) (T1) selection table” according to the back-
1. Remove: lash measurement (BL1) from “Measuring
• Shift rod guide plate the reverse gear backlash”. See “Reverse
gear shim (T1) selection table” (A-26).
8-71
• Thrust bearing
TIP: • Reverse gear assembly
• The blue-colored cells on the selection table See “Installing the forward gear” (8-34).
indicate the range where the shim adjust- • Pinion shims (T3)
ment is unnecessary. Shimming is not re- • Spacer
quired if the obtained reverse gear shim • Drive shaft assembly
thickness is indicated by the blue-colored • Pinion
cells. • Pinion nut
• The values for the shim thickness specified in • Spacer
the selection table are intended to obtain the • Drive shaft ring nut
median value within the range for the speci- See steps 1–3 in “Installing the drive shaft”
fied reverse gear backlash. (8-34).
• If the backlash measurement (BL1) is less
than 0.42 mm, install a new shim with a thick- TIP:
ness of 2.00 mm. Check that the drive shaft turns smoothly.
• If the backlash measurement (BL1) is more
than 0.80 mm, install a new shim with a thick-
ness of 2.21 mm. Measuring the forward gear backlash
• Use only 1 shim to obtain the required shim • Spray anti-rust lubricant on the gear and
thickness. bearings before installation. Do not apply
Example: surements cannot be obtained.
Backlash measurement (BL1) = 0.59 mm • Keep the parts free of foreign material, such
“a” as dirt and lint.
Current reverse gear shim thickness = • When measuring the forward gear or reverse
2.06 mm “b” gear backlash, use the original bearings and
Use the determined shim thickness of 2.03 shims.
mm instead of the current shim thickness. 1. Install:
a • Key
(mm)
A sembly
0.57 0.58 0.59 • Claw washer (do not bend the tabs)
2.00
• Ring nut
2.03
B See steps 2–5 in “Installing the propeller
2.06 2.03
2.09
b 2. Measure:
A. Backlash measurement (BL1) • Forward gear backlash (BL 2)
B. Current shim thickness See step 3 in “Measuring the forward gear
backlash and reverse gear backlash be-
Available shim thicknesses fore disassembly” (8-64).
Reverse shims Forward gear backlash
2.00/2.03/2.06/2.09/2.12/2.15/ 0.20–0.61 mm (0.0079–0.0240
2.18/2.21 mm in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• Determined reverse gear shim (T1)
8-72
Adjusting the forward gear shim

thickness (T2) TIP:
• If the shim thickness adjustment value is pos-
1. Remove:
• Ring nut
that amount and, if the value is negative, de-
• Claw washer
See step 1 in “Removing the propeller
amount.
• The blue-colored area on the selection chart
indicates the range of the specified backlash.
sembly
Shimming is not required if the measured
• Key
backlash is within the blue-colored area.
See steps 2 and 3 in “Removing the pro-
ments specified in the selection chart are in-
peller shaft housing assembly” (8-53).
tended to obtain the median value within the
2. Measure: range for the specified forward gear back-
• Original forward gear shim (T2) thickness lash.
TIP: shows the shim thickness adjustments for
• Measure the thickness of original forward the points marked on the chart.
gear shim (T2) in 2 places.
• Do not reuse a shim if deformed or Example:
scratched. Backlash measurement (BL2) = 0.10 mm
“a”
Forward gear shim (T2) thickness adjust-
3. Select: ment = 0.34 mm “b”
• Forward gear shim (T2) The current shim thickness must be in-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Determine the forward gear shim (T2) creased by 0.34 mm.
B (mm)
thickness adjustment using the “Forward 0.60

gear shim (T2) selection chart” according
to the backlash measurement (BL2) from 0.40
“Measuring the forward gear backlash”. b
See “Forward gear shim (T2) selection 0.20
chart” (A-25).
–1.80
0 5 10 15 20 25 30 35
a A (1/100 mm)
A 0 5 10 15 20 25 30 35
B 0.45 0.40 0.34 0.29 0.27 0.22 0.17 0.12
A. Backlash measurement (BL2)

B. Shim thickness adjustment
b. Calculate the new forward gear shim (T2)

thickness.
8-73
TIP:
thickness.
• If the calculated shim thickness cannot be
obtained with a combination of the available
shims, increase or decrease the pinion dis-
tance measurement by 0.01 mm.
Calculation formula:
New forward gear shim (T2) thickness =
Current forward gear shim thickness +
shim thickness adjustment
Example:
Current forward gear shim thickness =
0.75 mm
Shim thickness adjustment = 0.34 mm
0.75 mm + 0.34 mm = 1.09 mm
Current forward gear shim thickness =
0.75 mm
Shim thickness adjustment = -0.26 mm
0.75 mm + (-0.26 mm) = 0.49 mm
Available shim thicknesses
Forward shims
0.10/0.12/0.15/0.18/0.30/0.40/
0.50 mm
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• Determined forward gear shims (T2)
• Key
sembly
• Claw washer
• Ring nut
8-74
Bracket unit
Bottom cowling cover and apron cover........................... 9-1

Installing the bottom cowling cover ............................................ 9-2
Bottom cowling (PORT and STBD)................................... 9-3

Removing the bottom cowling .................................................... 9-4
Assembling the bottom cowling.................................................. 9-4
Installing the bottom cowling ...................................................... 9-5
Apron................................................................................... 9-7
Cooling water hose and gear oil changing hose............. 9-8

Removing the cooling water hose (oil pan side)......................... 9-9
Installing the gear oil changing hose .......................................... 9-9
Installing the cooling water hose .............................................. 9-11
Shift actuator and shift rod ............................................. 9-12

Installing the shift actuator and shift rod................................... 9-13
Bottom cowling (front) and flushing hose ..................... 9-15

Assembling the bottom cowling (front) ..................................... 9-16
Installing the bottom cowling (front).......................................... 9-16
Installing the flashing hose and PTT switch ............................. 9-16
Upper case assembly and mount ................................... 9-18

Removing the upper case assembly ........................................ 9-19
Installing the upper case assembly .......................................... 9-19
Exhaust guide................................................................... 9-23

Checking the exhaust guide ..................................................... 9-24
9
Installing the exhaust guide...................................................... 9-24
Upper case, muffler, and oil pan..................................... 9-26

Disassembling the upper case ................................................. 9-27
Checking the upper case.......................................................... 9-27
Checking the muffler ................................................................ 9-27
Checking the PCV .................................................................... 9-27
Checking the oil pan and oil strainer ........................................ 9-27
Assembling the oil pan ............................................................. 9-27
Assembling the upper case ...................................................... 9-28
Bracket unit
Installing the muffler and upper case ....................................... 9-28
Steering actuator and steering arm................................ 9-30

Removing the steering actuator (with the power unit
installed) ................................................................................... 9-31
Removing the power steering unit (with the power unit
removed) .................................................................................. 9-32
Removing the steering arm ...................................................... 9-33
Checking the steering arm and steering arm joint.................... 9-34
Installing the steering arm ........................................................ 9-34
Installing the steering actuator (with the power unit
removed) .................................................................................. 9-35
Installing the steering actuator (with the power unit
installed) ................................................................................... 9-37
Clamp bracket and swivel bracket ................................. 9-40

Removing the clamp bracket.................................................... 9-41
Checking the clamp bracket anode .......................................... 9-41
Assembling the swivel bracket ................................................. 9-41
Installing the clamp bracket...................................................... 9-41
PTT unit ............................................................................. 9-43

Removing the PTT unit............................................................. 9-44
Checking the PTT motor electric current when the relief
valve operates .......................................................................... 9-44
Bleeding the PTT unit............................................................... 9-46
Installing the PTT unit............................................................... 9-47
PTT motor ......................................................................... 9-50

Removing the reservoir ............................................................ 9-51
Disassembling the PTT motor .................................................. 9-51
Checking the PTT motor .......................................................... 9-51
Checking the brush .................................................................. 9-52
Checking the reservoir ............................................................. 9-52
Checking the filter..................................................................... 9-52
Assembling the PTT motor....................................................... 9-52
Installing the reservoir .............................................................. 9-53
Installing the PTT motor ........................................................... 9-53
PTT gear pump ................................................................. 9-55

Disassembling the gear pump assembly.................................. 9-57
Checking the gear pump .......................................................... 9-57
Checking the gear pump housing............................................. 9-57
Bracket unit
Checking the filter..................................................................... 9-57

Assembling the gear pump assembly ...................................... 9-57
Installing the gear pump assembly........................................... 9-59
PTT cylinder...................................................................... 9-60

Removing the tilt ram ............................................................... 9-62
Removing the trim ram ............................................................. 9-62
Checking the tilt cylinder and trim cylinder ............................... 9-63
Checking the absorber valve.................................................... 9-63
Assembling the trim ram........................................................... 9-63
Assembling the tilt ram ............................................................. 9-63
Installing the tilt cylinder ........................................................... 9-64
Installing the trim ram ............................................................... 9-65
Installing the tilt ram ................................................................. 9-65
Bottom cowling cover and apron cover
4 1
3
3 5
4
2
1
3 4
3
4
8
1
6
LT
572
7

1 Bolt M6 × 25 mm 4
2 Cover 1
3 Collar 4
4 Grommet 4
5 Damper 2
6 Grommet 1
7 Bolt M6 × 14 mm 6
8 Cover 1
9-1
Installing the bottom cowling cover

1. Assemble:
• Grommet “1”
• Dampers “2”
• Grommets “3”
• Collars “4”
• Bolts “5”
2
5
3
4
2. Install:
• Apron cover
9-2
Bottom cowling (PORT and STBD)

3
1 2
36
LT 19 N·m (1.9 kgf·m, 14 lb·ft)
572 35 22
33 21
34
26 19 23
5
6 4 16 25
12 20 18
17
36 15
35 12
11 28
1342
27
34
33 13
31 14
1342
17 16 27
30
8 N·m (0.8 kgf·m, 5.9 lb·ft) 30 26
8 12 11 12 13
14 13
32
9
7 13
15 13
3.2 N·m (0.32 kgf·m, 2.4 lb·ft)
26
20
18 19 10
22 25
21 24 29

1 Bolt M6 × 12 mm 1 18 Shaft 2
2 Plate 1 19 Washer 2
3 Rubber seal 1 20 Wave washer 2
4 Bolt M6 × 25 mm 7 21 Retaining clip 2
5 Bolt M6 × 14 mm 1 22 Pin 2
Bottom cowling 23 Lock lever (STBD) 1
6 1 24 Lock lever (PORT) 1
(STBD)
8 Bolt M6 × 14 mm 1 26 Bushing 4
Bottom cowling 27 Bolt M6 × 12 mm 4
9 1
(PORT) 28 Clamp plate (STBD) 1
10 Rubber seal 1 29 Clamp plate (PORT) 1
11 Collar 12 30 Screw M5 × 16 mm 4
12 Grommet 14 31 Damper (STBD) 1
13 Grommet 4 32 Damper (PORT) 1
14 Bolt M6 × 12 mm 4 33 Damper 2
15 Bracket 2 34 Stay 2
16 Bolt M8 × 12 mm 2 35 Bolt M6 × 20 mm 4
17 Clamp lever 2 36 Bracket 2
9-3
Removing the bottom cowling 2. Remove:

1. Remove: • Plate
• Bolts (M6 × 14 mm) • Rubber seal
• Bottom cowlings • Bottom cowlings
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Dipstick guide
a. Remove the bolts (M6 × 14 mm) “1”, and See “Intake manifold” (6-25).
then loosen the bolts (M6 × 25 mm) “2”. • Cowling brackets
TIP: Assembling the bottom cowling

Although the bolts (M6 × 25 mm) “2” will remain
1. Install:
in the bottom cowlings when the bolts are loos-
• Dampers
ened, make sure that the bolts (M6 × 14 mm)
• Clamp plates
“1” do not fall from the bottom cowlings be-
cause those bolts are removed. Damper screw
3.2 N·m (0.32 kgf·m, 2.4 lb·ft)
T.
R.
b. Remove the bottom cowlings.
2. Assemble:
A • Washers “1”
2 • Lever shafts “2”
• Cowling lock levers “3”
• Pins “4”
• Retaining clips “5”
1 2
TIP:
Install the pins “4” in the direction shown.
2 A 4 B 3
4
3
B
5
2 5 1 1
2
2 2
1
A. PORT
2 B. STBD
3. Install:
• Bushings
2 • Wave washers
2 • Washers
• Cowling lock lever assemblies
• Clamp levers
2
• Bottom cowling cover brackets
A. PORT Clamp lever bolt

B. STBD 19 N·m (1.9 kgf·m, 14 lb·ft)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9-4
4. Install:
• Grommets “1”, “2” TIP:
• Collars “3” • Align the upper end of the rubber seal “1” with
• Bolts (M6 × 25 mm) “4” (to the collars “3”) the portion “a” of the bottom cowling (PORT)
“2”.
A • Make sure that the rubber seal “1” is not in-
3 2 stalled on the portion “b” of the bottom cowl-
1 ing (PORT) “2”.
• Install the rubber seal “1” so that the lip on the
seal is pointing in the direction shown.
4
a
1 2
1
1 1
b
Installing the bottom cowling

1. Install:
B • Cowling brackets
2 4 • Dipstick guide
• Cowling stays
• Dampers
1
3 Cowling stay
8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
1 2
2. Install:
• Bottom cowlings
• Bolts (M6 × 14 mm)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the grommet “1” onto the protrusion
1 “a” on the exhaust joint.
b. Install the grommet “2” onto the protrusion

“b” on the bottom cowling (front) “3”, and
then install the bolts (M6 × 14 mm) “4”.
A. PORT TIP:
B. STBD Install the bolts (M6 × 14 mm) “4”, and then in-
stall the bolts “5”.
5. Install:
9-5
2 b a 1
3
5
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Plate
TIP:
• Align the seam “a” of the rubber seal “1” with
the mating surface “b” of the bottom cowling.
• After installing the rubber seal “1”, make sure
that there are no wavy areas of the seal.
1 a
9-6
Apron
Apron
8 N·m (0.8 kgf·m, 5.9 lb·ft)

10
3
8 1
7
6 1
LT
12 572
1 1
2
9
7 7
8 6 11
6 1
8 N·m (0.8 kgf·m, 5.9 lb·ft) 7 6
1
7 6
4
6
7
1
5 6
1
6
1
1

1 Bolt M6 × 14 mm 15
2 Bolt M6 × 30 mm 1
3 Apron (STBD) 1
4 Apron (PORT) 1
5 Nut M6 2
6 Grommet 8
7 Stay 6
8 Bolt M6 × 20 mm 4
9 Bracket (PORT) 1
10 Bracket (STBD) 1
11 Nut M6 2
12 Bracket 1
9-7
Cooling water hose and gear oil changing hose

21 20
4
19 LT
5
572
7 New 22
23
27 9
3
28
6 29
4 8
30 16
LT New 7 New 7
572 4 5
13
6 12 New
33
4 34
22 23 New 7 New 12
1 New
LT
18
572
New 12
a b 15 2
a>b 17 14
32
c d 31 11
32 LT
31 572
13,14 16,17 26 10
25
LT
c>d 35
New 12 572
24 LT
20 N·m (2.0 kgf·m, 15 lb·ft) 572 24

1 Plastic tie 2 20 Cover (air) 1 “AIR”
2 Hose 1 21 Quick connector 2
3 Hose 1 22 Hose fitting (gear oil) 1
4 Bolt M6 × 20 mm 4 23 Hose fitting (air) 1
5 Joint 2 24 Bolt M8 × 25 mm 2
6 Joint 2 25 Joint (gear oil) 1
7 Rubber seal 4 26 Joint (air) 1
9 Band 2 28 Hose holder 1
10 Bolt M6 × 12 mm 1 29 Bolt M6 × 16 mm 2
11 Cover 1 30 Holder 2
13 Hose (gear oil) 1 32 Holder 2
14 Hose (gear oil) 1 33 Cap 1
15 Joint (gear oil) 1 34 Grommet 1
16 Hose (air) 1 35 Rubber seal 1
17 Hose (air) 1
18 Joint (air) 1
19 Cover (gear oil) 1 “OIL”
9-8
Removing the cooling water hose (oil 2. Assemble:

pan side) • Quick connectors “1”
1. Remove: • Hose fitting (air) “2”
• Cooling water hose (engine side) • Hose fitting (gear oil) “3”
See “Intake manifold” (6-25). • Cover (air) “4”
• Cover (gear oil) “5”
2. Remove:
• Plastic ties 1
LT
O
IL
• Cooling water hoses (oil pan side) 572
• Joints (exhaust guide side) 5
• Joints (oil pan side)
3
AI
• Rubber seals b
R
4
Installing the gear oil changing hose
LT
1. Install: a 2 572 a b
• Holders “1”, “2”
• Hose holder “3” 3. Install:
• Grommet “4” • Hoses (air)
• Cap “5” • Hoses (gear oil)
• Rubber seal “6” • Plastic ties New
• Joint (air) “7” • Joint (air)
• Joint (gear oil) “8” • Joint (gear oil)
• Hose fitting assembly (air)
• Hose fitting assembly (gear oil)
• Bands
• Plastic ties
3
• Cover
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 a. Install the hose (gear oil) “1” and hose (air)
“2” onto the hose fitting on the joint. Face
the paint mark “a” on the hoses downward.
5 b. Fasten the hose (gear oil) “1” and hose

4 (air) “2” using new plastic ties “3”.
1 2
3
2
2 LT a
7 572
8 a 3
LT
572
6
c. Fasten the hose (gear oil) “1” and hose
Joint bolt (air) “2” using the holders “3”.
20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
9-9
d. Install the joints “4” and “5” into the hose
(gear oil) “1” and hose (air) “2”, and then TIP:
fasten the hoses using new plastic ties “6”. • Install the hose fitting assemblies “a” and “b”
and hoses “1” and “2” so that the “AIR” and
5 “OIL” marks are facing outward.
• Make sure that the “AIR” and “OIL” marks on
4 the hose fitting assemblies “a” and “b” are po-
3 sitioned next to the corresponding “AIR” and
6
“OIL” marks on the hose holder “3”.
2 h. Install the bands “4”.

a b
i. Fasten the hoses “1” and “2” using the
1 1 2 plastic ties “5” as shown.
a>b TIP:
Do not cut off the excess end of the plastic ties.
e. Route the hose (gear oil) “1” and hose (air)
“2” through the grommet “3”, and then con- 3
a
nect the joints “4” and “5”. b
OIL OIL AIR AIR
4
TIP: 2
Route the hose (gear oil) “1” and hose (air) “2” 1
4
to the inside of the PTT motor lead “6” and PTT
sensor lead “7”. 5
5
1
2
f. Fasten the hose (gear oil) “1” and hose
(air) “2” using new plastic ties “8”. j. Align the white paint marks “a” on the hose
(gear oil) “1” and hose (air) “2” with the pro-
jections “b” on the oil pan (lower), and then
install the cover “3”.
k. Align the white paint marks “c” on the hose

3 (gear oil) “4” and hose (air) “5”, and then
7
fasten the grommet “6” using new plastic
6 ties “7”.
2 1
a b
5 8
1 2
4
a>b
g. Install the hose fitting assemblies “a” and

“b” into the hose (gear oil) “1” and hose
(air) “2”, and then install the hose fitting as-
semblies “a” and “b” onto the hose holder
“3”.
9-10
2. Install:
2 a • Cooling water hose (engine side)
5
b 1
4
3
6
c
c
7
LT
572
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Installing the cooling water hose

1. Install:
• Rubber seals New
• Joints (oil pan side)
• Joints (exhaust guide side)
• Cooling water hose (oil pan side) (STBD)
• Cooling water hose (oil pan side) (PORT)
“1”
• Plastic ties “2” New
TIP:
• Route the PTT motor lead “3” and PTT sen-
sor lead “4” through the grommet “a” on the
cooling water hose (oil pan side) (PORT) “1”.
• Route the hose (gear oil) “5” and hose (air)
“6” through the grommet “b” on the cooling
water hose (oil pan side) (PORT) “1”.
• Install new plastic ties “2” as shown.
4
2
3
1
a 2
b 5
6
9-11
Shift actuator and shift rod

8 11 8 41 N·m (4.1 kgf·m, 30 lb·ft)
19 N·m (1.9 kgf·m, 14 lb·ft)
14 New 20 A
11 23 21
11 15
24
16 22
9 12
12 11 12
A
11 11 17 A
A
10 25
10 10 13
4
5 A 19 N·m (1.9 kgf·m, 14 lb·ft)
5
4
6 5
18 19 7
3 New
2
A
1 26
27

1 Clip 1 20 Clip 1
2 Self-locking nut M6 1 21 Bolt M6 × 40 mm 2
3 Washer 1 22 SPS 1
5 Washer 3 24 Bushing 1
6 Bracket 1 25 Shift rod 1
7 Bushing 2 26 O-ring 1
8 Bolt M8 × 35 mm 3 27 Grommet 1
9 Shift actuator 1
10 Collar 3
11 Grommet 6
12 Washer 3
13 Bushing 1
14 Cotter pin 1
15 Nut M10 1
16 Washer 1
17 Joint pin 1
18 Clip 1
19 Shift lever 1
9-12
Installing the shift actuator and shift

c
rod
1. Assemble: d 2
• SPS a
• Bushing
• Washer 3 2
• Shift rod
• Clip
4 b
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1
a. Turn the protrusion “a” on the SPS “1” in
the direction of the arrow using a slotted
screwdriver, and then insert a suitable pin
“b” into the hole “c” to secure the protru- 4
sion.
5
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
c • Grommet “1”
b
1 b (into the shift rod)
• Shift rod assembly “a”
b. Install the bushing “1” into the SPS “2”.
TIP:
c. Install the washer “3” onto the SPS “2”. Install the shift rod assembly “a” so that it is
aligned with the mark “b” on the bottom cowling
d. Fit the protrusion “a” on the SPS “2” into
(front) as shown.
the slot “b” in the tip of the shift rod “4”, and
then install the clip “5” in the direction
shown. b
e. Remove the pin “c”.
TIP: a a
After removing the pin “c”, fill the hole “d” with A
a small amount of grease. 2
1
3. Assemble:
• Shift actuator “1”
• Joint pin “2”
• Washer “3”
• Joint pin nut (upper) “4”
9-13
• Cotter pin “5” New • Washers

• Joint pin nut (lower)
TIP: • Clip
• Install the joint pin “2” so that the flat sides “a” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
of the pin are parallel to the sides of the rod a. Install the bushing “1” and shift actuator “2”
of the shift actuator “1”. onto the shift bracket “3”.
• Install a new cotter pin “5” in the direction
shown and bend the ends 45° or more from
TIP:
Install the shift actuator “2” so that the center of
the centerline of the joint pin “2”.
the joint pin “4” is aligned with the protrusion “a”
on the shift bracket “3”.
45°
1 5
4 2 4 3
3 2
5 45° 4
a
a
2
a
3 1
Joint pin nut (upper) “4”
41 N·m (4.1 kgf·m, 30 lb·ft)
T.
Shift actuator bolt

R.
19 N·m (1.9 kgf·m, 14 lb·ft)

T.
4. Install:
R.
• Shift lever “1”

b. Install the bushings “1”, shift actuator as-
• Clip “2”
sembly “a”, washer “2”, and joint pin nut
TIP: (lower) “3”.
• Make sure that the “6GR” mark “a” on the
c. Install the clip “4” in the direction shown.
shift lever “1” is facing up.
• Install the clip “2” in the direction shown. 5
a
2
1 1
2
6G
R 3 1
a 4
5. Assemble:
• Bushing
• Washers Shift bracket bolt “5”
• Grommets 19 N·m (1.9 kgf·m, 14 lb·ft)
T.
R.
• Collars
• Shift actuator ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Shift bracket
• Bushings
9-14
Bottom cowling (front) and flushing hose
9 20
19 New 2
14 10 A
17
22 19 N·m (1.9 kgf·m, 14 lb·ft)
New 2 33 21
31 18
10
30 11
3
4 14 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
12 33 17 19 N·m (1.9 kgf·m, 14 lb·ft)
7
8 32
6 5
17 1
New 2 15
16
17
A
16
27 30
26 29 24
25
23
28 13

1 Lead 1 *1 20 Rubber seal 1
3 Hose 1 22 Clamp lever 1
4 Nipple 1 23 Shaft 1
5 Joint 1 24 Washer 1
6 Hose 1 25 Wave washer 1
7 Gasket 1 26 Retaining clip 1
8 Joint 1 27 Pin 1
9 Joint 1 28 Lock lever 1
10 Grommet 2 29 Washer 1
11 Screw M5 × 19 mm 1 30 Bushing 2
12 Adapter 1 31 Bolt M6 × 12 mm 2
13 Switch 1 PTT 32 Clamp plate 1
14 Bolt M8 × 35 mm 2 33 Grommet 3
15 Bottom cowling 1
*1. For the multiple engines.
16 Collar 2
17 Grommet 4
18 Rubber seal (PORT) 1
19 Rubber seal (STBD) 1
9-15
Assembling the bottom cowling A

(front) a
1. Install:
• Grommets 1
• Clamp plate
a
2. Assemble: 3
• Washer “1”
• Lever shaft “2”
• Cowling lock lever “3”
• Pin “4” B
• Retaining clip “5”
a
TIP:
Install the pin “4” in the direction shown.
2
4 a 3
3
1
A. PORT
2
B. STBD
5 Bottom cowling (front) bolt

19 N·m (1.9 kgf·m, 14 lb·ft)
T.
R.
3. Install:
• Bushings Installing the flashing hose and PTT
• Wave washer
switch
• Washer
1. Install:
• Cowling lock lever assembly
• PTT switch
• Clamp lever
Clamp lever bolt TIP:
19 N·m (1.9 kgf·m, 14 lb·ft) Install the PTT switch so that the side with the
T.
“UP” mark is facing up.

R.
Installing the bottom cowling (front)

1. Install: 2. Install:
• Rubber seal (onto the exhaust guide) • Adapter
• Rubber seal (PORT) “1” • Grommets
• Rubber seal (STBD) “2” • Hoses
• Bottom cowling (front) “3” • Joint
TIP: • Gasket
When installing the rubber seal (PORT) “1” and
• Nipple
rubber seal (STBD) “2” to the bottom cowling
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
(front) “3”, install both ends “a” of the rubber a. Install the adapter “1” to the bottom cowl-
seals first, and then install the center portions ing (front) “2” so that the slot “a” in the
of the seals. adapter is aligned with the protrusion “b”
on the cowling.
9-16
a
2
1 5
2 1 4
a 3
b
1 3
Adapter screw f. Install the joint “1” onto the hose “2”, and
4.0 N·m (0.40 kgf·m, 3.0 lb·ft) then install the joint “3” into the hose “2”.
T.
R.
g. Fasten the hose “2” using a new plastic tie

b. Install the grommet “1” onto the hose “2”
“4”.
so that the grommet is aligned with the
edge of the white paint mark “a” toward the TIP:
white mark “b” as shown. Cut off the excess end of the new plastic tie to
1 mm (0.04 in) or less.
TIP:
Apply instant glue to the indicated points “c” to
affix the grommet “1” to the hose “2”. h. Install the gasket “5”, and then install the
joint “3” onto the adapter “6”.
i. Install the nipple “7” into the hose “8”, and

b then fasten the hose “8” using a new plas-
2 a 1
tic tie “9”.
TIP:
c Cut off the excess end of the new plastic tie to
3 mm (0.12 in) or less.
c. Install the grommet “1” into the bottom

cowling (front). 7 9 8
d. Install the hoses “2” and “3”, and then in-
2
stall the joint “4”.
TIP:
Align the paint mark “a” on the hose “3” with the
1 4 3 5 6
grommet “1”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
e. Fasten the hoses “2” and “3” to the joint “4” 3. Connect:
using new plastic ties “5” as shown. • SCU communication lead
(for the multiple engines)
TIP:
Cut off the excess end of each plastic tie to 3
mm (0.12 in) or less.
9-17
Upper case assembly and mount

54 N·m (5.4 kgf·m, 40 lb·ft) 200 N·m (20 kgf·m, 148 lb·ft) 12
15 54 N·m (5.4 kgf·m, 40 lb·ft) 36
22 23 29 9 New 20
16 A
31 17 27 6
22 26
LT
25 35
572
33 24 4 1 New
14
30 34
LT 4
572 A
28
8 27 29
10 26
13
7
24 25 LT
23 572
11 22
54 N·m (5.4 kgf·m, 40 lb·ft)
New 1
21 15
34 32 16
5 17 A
200 N·m (20 kgf·m, 148 lb·ft)

31
19 30 LT
New 3 4 572
2
18 72 N·m (7.2 kgf·m, 53 lb·ft) 1 New 54 N·m (5.4 kgf·m, 40 lb·ft)

1 Plastic tie 6 20 Upper case assembly 1
2 Protective tube 1 21 Damper 1
4 Bolt M6 × 12 mm 4 23 Bracket 2
5 Holder 2 24 Washer 2
6 Cap seal 1 25 Lower mount 2
7 Lead 1 26 Washer 2
8 Lead 1 27 Washer 2
9 Plastic tie 1 28 Ground lead 1
10 Protector cover 1 29 Bolt M14 × 227 mm 2
11 Holder 2 30 Bolt M10 × 40 mm 12
12 Cap seal 1 31 Bracket 2
13 Lead 1 Red paint
32 Upper mount (PORT) 1
14 Protector 1 marks
15 Cap 2 Green paint
33 Upper mount (STBD) 1
16 Bolt M16 × 202 mm 2 marks
17 Washer 2 34 Damper 2
18 Nut M14 2 35 Grommet 1
19 Washer 2 36 Grommet 1
9-18
Removing the upper case assembly A

1. Drain: 2
• Engine oil
See step 5 in “Changing the engine oil by re- 1
moving the drain bolt” (10-15). a a
2. Suspend:
• Upper case assembly
5 a 2
LT a
3. Remove: 4
572
• Caps
B
• Upper mount bolts
3
• Washers
4. Loosen:
1 b b
• Lower mount bracket bolts
LT
5. Remove: 572
• Lower mount nuts “1”
• Washers “2” 3 b 5
b 4
• Upper case assembly “a”
• Damper “3”
A. PORT
B. STBD
a. Red paint marks

b. Green paint marks
2. Install:
a • Ground lead (PORT only)
• Washers
3 • Lower mount bolts
• Lower mounts
• Lower mount brackets
2 • Lower mount bracket bolts (temporarily tight-
1 en)
2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the ground lead “1” and washers “2”
Installing the upper case assembly and “3” onto the lower mount bolt “4”.
1. Install:
• Grommets b. Install the lower mount bolt “4” into the lower
• Dampers “1” mount “5”.
(into the upper mount bracket)
• Upper mount (PORT) “2” c. Install the lower mount “5” and lower mount
• Upper mount (STBD) “3” bracket “6”, and then tighten the lower mount
• Upper mount brackets “4” bracket bolt “7” temporarily.
• Upper mount bracket bolts “5” (temporarily
tighten) TIP:
The ground lead “1” should be installed on the
same side as originally installed.
9-19
A B
A
[2] [1] 1 [1] [2]
[3] 1 [3]
1 4
2
3
[6] [6]
[5] [4] [4] [5]
2 5 LT
6 572
7
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ A. PORT
3. Install: B. STBD
• Washers “1”
• Damper “2” Upper mount bracket bolt “1”
• Upper case assembly “a” 54 N·m (5.4 kgf·m, 40 lb·ft)
T.
R.
• Washers “3”
• Lower mount nuts “4” b. Tighten the lower mount bracket bolts “1”.
• Washers “5” A B
• Upper mount bolts “6” 1 1
• Caps “7”
7
5
6
a 5 7 A. PORT
6
B. STBD
21
3 Lower mount bracket bolt “1”
54 N·m (5.4 kgf·m, 40 lb·ft)
T.
R.
4 1 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Lower mount nut “4” 5. Install:

72 N·m (7.2 kgf·m, 53 lb·ft) • Protector
T.
• SCU lead
R.
Upper mount bolt “6”

200 N·m (20 kgf·m, 148 lb·ft) • Holders
• Protector cover
• Grommet
4. Tighten:
• Upper mount bracket bolts • Plastic ties New
• Lower mount bracket bolts ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the protector “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Tighten the upper mount bracket bolts “1”
b. Install the SCU lead “2” to the protector “1”
to the specified torque in the order [1], [2],
so that the plastic ties “3” on the lead are
and so on.
positioned within the specified distances
“a” shown from the ends of the protector.
c. Install the protector cover “4”.
9-20
d. Fasten the grommet “5” and SCU lead “2”
using a new plastic tie “6” so that the lower TIP:
edge of the grommet overlaps the white • Position the plastic tie “6” the specified dis-
tape “b” on the lead. tance “c” from the end of the steering arm “5”.
• Route the PTT sensor lead “4” to the inside
e. Fasten the SCU lead “2” using the holders of the holders “2” and “3”.
“7”.
STBD c. Fasten the PTT motor lead “1” and PTT
sensor lead “4” using a new plastic tie “7”
4 between the holders “2” and “3” as shown.
1 a d. Fasten the PTT motor lead “1” and PTT

sensor lead “4” using a new plastic tie “8”
a at the white tape “d” on the corrugated
3 tube “e”.
3 2 PORT
4
b
6
5
2 c
5 6
b
7
e 7
2 1 3
Distance “a”
30–50 mm (1.18–1.97 in) 8 a 4
d
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install: Distance “c”

• PTT motor lead 40 mm (1.57 in)
• Holders
• PTT sensor lead e. Wrap the protective tube “1” around the
• Protective tube PTT motor lead “2” and PTT sensor lead
• Plastic ties New “3”, and then fasten the tube using new
• Cap seal plastic ties “4” so that the end of the tube is
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ aligned with the white tape “a” on the PTT
a. Fasten the PTT motor lead “1” using the sensor lead.
holders “2” and “3” so that the white tape
“a” on the lead is aligned with the holder
“2”.
b. Fasten the PTT sensor lead “4” at the

white tape “b” to the steering arm “5” using
a new plastic tie “6”.
9-21
f. Route the PTT motor lead “2” and PTT
sensor lead “3” through the grommet “5”,
and then fasten the leads and grommet us-
ing new plastic ties “6” so that the white
tape “b” on the leads is aligned with the
grommet.
3 a 4 PORT
1
2
5
6
6 b
b
3 4
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9-22
Exhaust guide
Exhaust guide
1 42 N·m (4.2 kgf·m, 31 lb·ft) 12 6
2 42 N·m (4.2 kgf·m, 31 lb·ft) 11 LT
18 18 13 572
New 10
12 16 14 LT
15 9 7
18 14 572 4
4
LT
8
572
1
5
2
WR-No.2 19
3 New 1.3 N·m (0.13 kgf·m, 0.95 lb·ft)
20 20
15
21 New
LT
572 17
LT
572
1 42 N·m (4.2 kgf·m, 31 lb·ft)
17 2 42 N·m (4.2 kgf·m, 31 lb·ft)

1 Bolt M6 × 12 mm 1 19 Exhaust guide 1
2 Plate 1 20 Dowel 2
3 Oil seal 1 21 Gasket 1
4 Clamp 2
5 Hose 1
6 Bolt M6 × 20 mm 2
7 Silencer 1
8 Bolt M6 × 16 mm 1
9 Nipple 1
10 Gasket 1
11 Holder 2
12 Bolt M6 × 12 mm 3
13 Bracket 1
14 Cap seal 4
15 Grommet 4
16 Bracket 1
17 Bolt M10 × 70 mm 16
18 Bolt M10 × 80 mm 4
9-23
Exhaust guide
Checking the exhaust guide A

1. Clean:
• Removed parts LT
572
2. Check:
• Exhaust guide
[4]
1 [3] [2] [16] [15] [14]
[6] [5]
Installing the exhaust guide
1. Install:
• Dowels B
• Gasket New
• Exhaust guide
LT
572
2. Tighten:
• Exhaust guide bolts (M10 × 80 mm) “1”
[9]
1
TIP: [13] [12] [11] [1] [10]
Tighten the bolts “1” to the specified torques in 2 [8] [7]
A. PORT
B. STBD
LT
572 [4]
[1] Exhaust guide bolt (M10 × 70
1 mm) “1”
T.
R.
1st: 42 N·m (4.2 kgf·m, 31 lb·ft)

[2] [3] 2nd: 42 N·m (4.2 kgf·m, 31 lb·ft)
4. Install:
• Bracket
Exhaust guide bolt (M10 × 80 • Grommets
mm) “1” • Cap seals
T.
R.
1st: 42 N·m (4.2 kgf·m, 31 lb·ft) • Bracket

2nd: 42 N·m (4.2 kgf·m, 31 lb·ft) • Holder
• Gasket New
3. Tighten: • Nipple
• Exhaust guide bolts (M10 × 70 mm) “1” • Silencer
• Clamps “1”
TIP:
• Hose “2”
Tighten the bolts “1” to the specified torques in 2
stages and in the order [1], [2], and so on. TIP:
• Face the mark “a” on the hose “2” to starboard.
• Install each clamp “1” in the direction shown.
9-24
Exhaust guide

1 0.45–0.75 mm (0.0177–0.0295
in)
2 6. Install:
1 • Plate “1”
TIP:
a Install the plate “1” so that the portion “a” of the
plate contacts the protrusion “b”.
Clamp screw
1.3 N·m (0.13 kgf·m, 0.95 lb·ft)
T.
R.
5. Install:
• Oil seal “1” New b 1
A
a
2
3
a
1
WR-No.2
4
5
a
1
WR-No.2
A. Worldwide
B. USA and Canada

90890-06605
Ball bearing attachment “3”
90890-06636
YB-06229
Driveshaft seal installer “5”
YB-06348
9-25
Upper case, muffler, and oil pan

1 42 N·m (4.2 kgf·m, 31 lb·ft)
12
2 42 N·m (4.2 kgf·m, 31 lb·ft)
1 42 N·m (4.2 kgf·m, 31 lb·ft) 12
2 42 N·m (4.2 kgf·m, 31 lb·ft)
4
11
26 25 A
LT
LT
8
572
572
LT
572
27 29 New
10
9
LT
16 LT
572 7 6 5 572
New 17 42 N·m (4.2 kgf·m, 31 lb·ft)
28
22 18 WR-No.2 3 3
42 N·m (4.2 kgf·m, 31 lb·ft)
28 19 New 14
21 20 New
23 LT
2
30 572
LT 15
1 572 1 LT
24
572
1 35 A
34 E
33
LT 25 25
31
572
LT
1 42 N·m (4.2 kgf·m, 31 lb·ft) 1
25 572 2 42 N·m (4.2 kgf·m, 31 lb·ft) LT
572
New 13 32 New 60 N·m (6.1 kgf·m, 44 lb·ft)
1 42 N·m (4.2 kgf·m, 31 lb·ft) 1 42 N·m (4.2 kgf·m, 31 lb·ft)
2 42 N·m (4.2 kgf·m, 31 lb·ft) 2 42 N·m (4.2 kgf·m, 31 lb·ft) 42 N·m (4.2 kgf·m, 31 lb·ft)

1 Bolt M10 × 70 mm 12 17 Gasket 2
2 Upper case 1 18 Bolt M6 × 25 mm 1
3 Dowel 2 19 Cover 1
4 Rubber seal 1 20 Gasket 1
For X-tran- 21 Spring 1
5 Pipe 151 mm (5.9 in) 1
som model 22 PCV 1
For U-tran- 23 Grommet 1
6 Pipe 278 mm (10.9 in) 1
som model 24 Bolt M10 × 35 mm 1
For E-tran- 25 Bolt M10 × 70 mm 18
7 Pipe 405 mm (15.9 in) 1
som model
26 Bolt M10 × 120 mm 3
8 Rubber seal 1
27 Oil pan (upper) 1
9 Bolt M6 × 30 mm 12
28 Dowel 2
10 Bolt M10 × 70 mm 4
29 Gasket 1
11 Muffler 1
30 Oil pan (lower) 1
12 Dowel 2
31 Drain bolt M38 1
13 Gasket 1
32 O-ring 1
14 Bushing 1
33 Circlip 1
15 Grommet 1
34 Strainer 1
16 Bolt M6 × 26 mm 2 35 Damper 1
9-26
Disassembling the upper case Checking the muffler

1. Remove: 1. Clean:
• Drive shaft bushing “1” • Removed parts
A
2. Check:
• Muffler
1
3
Checking the PCV
1. Check:
• PCV
2 Damaged → Replace.
4 • Grommet
B • Spring
Corroded/deformed/fatigued → Replace.
1 5
Checking the oil pan and oil strainer
1. Clean:
• Removed parts
2. Check:
• Oil strainer
Dirt/residue → Clean.
A. Worldwide
B. USA and Canada 3. Check:
• Oil pan (upper and lower)
Bearing puller assembly “2” Corroded/cracked → Replace.
90890-06535
Stopper guide plate “3” Assembling the oil pan
90890-06501 1. Install:
Stopper guide stand “4” • Damper
90890-06538 • Strainer
Slide hammer “5” • Circlip
YB-06096
• O-ring New
• Drain bolt
Checking the upper case • Dowels
1. Clean: • Gaskets New
• Removed parts • Oil pan (upper and lower)
• Grommet
2. Check:
• PCV
• Drive shaft bushing
• Spring
• Cover
3. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the bolts (M10 × 70 mm) “1” and bolts
• Upper case
(M10 × 120 mm) “2”, and then tighten the
bolts to the specified torques in 2 stages and
9-27
A
1 2
[13] [14] 1
2 [17] 1
[7]
[6] [8] LT 2
[16] 572 3
[5] [1]
[3] [2] [9] 2
[15]
[4] [10] 3
WR-No.2
2 [12] [11]
Drain bolt B
60 N·m (6.1 kgf·m, 44 lb·ft) 1
T.
R.
Oil pan bolt “1”, “2”

1st: 42 N·m (4.2 kgf·m, 31 lb·ft) 4
2nd: 42 N·m (4.2 kgf·m, 31 lb·ft) 5
4
b. Install the bolt (M10 × 35 mm) “1” and bolts
(M10 × 70 mm) “2”, and then tighten the 5
bolts “1” and “2” to the specified torques in WR-No.2
2 stages and in the order [1], [2], and so

on.
A. Worldwide
1 2 B. USA and Canada
2
LT
[4] 572
90890-06605
[5] Ball bearing attachment “3”
[3] 1
[1] 90890-06636
[2]
2 YB-06229
2 Driveshaft seal installer “5”
YB-06348
Oil pan bolt “1”, “2”
1st: 42 N·m (4.2 kgf·m, 31 lb·ft)
Installing the muffler and upper case
T.
R.
2nd: 42 N·m (4.2 kgf·m, 31 lb·ft)

1. Install:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Dowels
• Gasket New
Assembling the upper case • Muffler
1. Install: • Muffler bolts (M10 × 70 mm) “1”
• Grommet • Muffler bolts (M6 × 30 mm) “2”
• Drive shaft bushing “1” New • Rubber seals
• Water pipe
TIP:
• Check that the rubber seal where the water
pipe is inserted is installed properly, there is
no foreign material on the rubber seal, and so
on.
• Install the water pipe completely.
9-28
1 2
2 [12] [8] [5] [9] LT

1
[1] [13]
572
[16] [4]
[2]
[15] [3] [14]
[11] [10]
[7] [6] 1
Muffler bolt “1”

42 N·m (4.2 kgf·m, 31 lb·ft)
T.
R.
2. Install:
• Dowels
• Upper case
A
LT
1 572
[5]
[9] [1]
[4]
[8]
[12]
B
[10] 1
[2]
[3] [6]
[7]
LT
[11] 572
A. PORT
B. STBD
Upper case bolt “1”

42 N·m (4.2 kgf·m, 31 lb·ft)
T.
R.
9-29
Steering actuator and steering arm
27 N·m (2.7 kgf·m, 20 lb·ft)

21
12 8 22
21 30
19 8
16
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
13 N·m (1.3 kgf·m, 9.6 lb·ft) 15 A
17 27
9
1 11 31
18 14
2 New 2013
3
4
10
7
LT 6
242 60 N·m (6.0 kgf·m, 44 lb·ft)
3 31 5 New
9
A 2
29 New
28
24 27 1
26
23
25

1 Bolt M6 × 14 mm 6 Negative ter-
18 Bolt M6 × 8 mm 1
2 Cover 2 minal
3 Bolt M6 × 14 mm 4 19 Lead 1
4 Cover 1 20 Plastic tie 1
5 Cotter pin 1 21 Bolt M6 × 30 mm 2
6 Nut M14 1 22 Guide 1
7 Lever 1 23 Bolt M6 × 10mm 2
8 Bolt M8 × 35 mm 4 24 Ground lead 1
10 Bracket (PORT) 1 26 Steering yoke 1
11 Bracket (STBD) 1 27 Washer 2
12 Steering actuator 1 28 Washer 1
13 Bolt M6 × 18 mm 2 29 O-ring 1
14 Holder 1 30 Steering arm 1
31 Bushing 2
15 Bolt M4 × 10 mm 4
16 Cover 1
Positive ter-
17 Bolt M8 × 8 mm 1
minal
9-30
Removing the steering actuator (with the • Grommet holder

power unit installed) • Rigging grommet
The steering actuator can be removed even when See “Power unit assembly” (7-13).
the power unit is installed.
6. Disconnect:
1. Remove:
• PTT switch coupler “a”
• Top cowling
• Main wire harness coupler “b”
• Flushing hose joint “1”
• Apron cover
See “Bottom cowling cover and apron cover” a
(9-1).
• Bottom cowlings (PORT and STBD)
See “Bottom cowling (PORT and STBD)” b
(9-3).
• Apron (STBD)
1
2. Disconnect:
• Battery cables
7. Remove:
3. Remove: • Bottom cowling (front) “1”
• Cover “1”
• Low-pressure fuel pump bracket bolts “2”
1
1
8. Remove:
• Dipstick guide
• Shroud cover
See “Shroud cover and terminal cover” (7-5).
4. Remove: 9. Disconnect:
• Swivel bracket top cover “1” • SCU positive terminal “a”
• SCU couplers “b”, “c”
• SCU ground terminal “d”
1
5. Remove:
• Plastic tie
9-31
2. Remove:
a • Steering actuator
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the cotter pin “1”, nut “2”, and
manual steering lever “3”.
3
2
1
b. Remove the bolts “1”.

b c d
10. Remove:
1
• Protector cover 1
• SCU lead
(from the holders and exhaust guide)
See “Upper case assembly and mount”
(9-18).
11. Remove:
• Steering actuator c. Remove the steering actuator brackets “1”
See “Removing the power steering unit and “2”.
(with the power unit removed)” (9-32).
Removing the power steering unit

(with the power unit removed) 1
1. Remove: 2
• Clamp bracket side covers “1”
• Swivel bracket top cover “2”
2
1
d. Turn the shaft “a” of the steering actuator
“1” clockwise until the starboard end of the
shaft is the specified length “b”, and then
move the steering actuator to the star-
1 board side as shown.
9-32
1 b 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Length “b”
50 mm (1.97 in) Removing the steering arm
1. Remove:
e. Remove the protrusions “a” and “b” on the • Ground lead
steering arm joint “c” from the hole “d” and • Circlip
slots “e” in the steering actuator “1”, and • Steering yoke “1”
then move the steering arm “2” in the di- • Washers
rection of the arrow. • Steering arm
1 d • O-ring
2 • Steering arm bushings
a
A
c
1
e e
4
1 2
f. Turn the steering arm joint “a” as shown

and remove the joint from the steering arm 2
“1”.
4
a a
1 1
g. Remove the steering actuator “1”.
9-33
B
b
1
2
4
1 3
a
3
b. Hold the steering arm “1”, and then strike

A. Worldwide
the steering yoke “2” using a copper ham-
B. USA and Canada
mer until the groove “a” for installing the
Needle bearing attachment “2” circlip is visible.
90890-06608
c. Install the circlip “3”
Driveshaft needle bearing installer
“3”
YB-06231
Gear puller “4”
(commercially available) 1
Checking the steering arm and

steering arm joint
1. Check:
• Steering arm
Worn → Replace. a 2
• Steering arm joint
Cracked/worn → Replace the steering ac- 2
3 3
tuator.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Installing the steering arm 2. Inject:
1. Install: • Grease
• Steering arm bushings
(into the swivel bracket) TIP:
• Washers Inject grease into the grease nipple “1” until
• Steering arm grease “a” comes out from both the upper and
• O-ring New lower bushings.
• Steering yoke
• Circlip
• Ground lead
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the steering yoke “1” so that it faces
the same direction as the steering arm “2”
(aligning “a” with “b”).
9-34
a TIP:
a • Fit the grommets “a” on the SCU positive
lead “b” and SCU negative lead “c” into the
slots “d” in the steering actuator “5”, and then
install the terminal cover “3” to the steering
actuator.
1 • Position the SCU negative lead “c”, SCU
positive lead “b”, and SCU signal lead “e” in
the order listed from port to starboard so that
3. Install: the leads do not overlap, and then fasten the
• Guide “1” leads using the holder “4”.

4
TIP: b
Route the PTT sensor lead “3” under the guide
“1”, and then fasten the PTT sensor lead “3” at c
the white tape “a” using a new plastic tie “2”. a
a
e
2
2 1
1 5
6 3 d
a SCU positive terminal bolt “1”

13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
Installing the steering actuator (with Terminal cover bolt “6”

the power unit removed) 2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
If the steering actuator is removed, the calibra-
tion is required after installation. See “Calibra- 2. Install:
tion (6X6 Digital Electronic Control)” (3-58). • Steering actuator
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1. Install: a. Turn the shaft “a” of the steering actuator
• SCU lead “1” until the starboard end of the shaft is
(to the steering actuator) the specified length “b”.
• SCU positive terminal bolt “1”
• SCU negative terminal bolt “2” TIP:
• Terminal cover “3” To decrease the shaft length “b”, turn the shaft
• Holder “4” “a” clockwise.
To increase the shaft length “b”, turn the shaft
“a” counterclockwise.
9-35
1 d. Move the steering arm “1” in the direction

b of the arrow, fit the protrusions “a” and “b”
on the steering arm joint “c” into the hole
“d” and slots “e” in the steering actuator
“2”, and install the steering arm joint to the
a steering actuator.
e. Install the steering arm joint bolts tempo-

rarily.
2 d
Length “b” 1
a
50 mm (1.97 in) c
b. Install the steering actuator “1” to the swiv-

el bracket “2”. e e
1
b
2 f. Turn the shaft “a” of the steering actuator

“1” counterclockwise to position the shaft
in the center steering position.
1
c. Install the steering arm joint “a” onto the
steering arm “1”, and then turn the steering
arm joint “a” as shown. a
TIP:
Move the steering actuator “2” to the starboard
side as shown to create space for installing the
steering arm joint “a”. g. Install the steering actuator brackets “1”
and “2”.
a a TIP:
Install the steering actuator bracket “1” with the
smaller center hole on the port side, and install
1 1 the steering actuator bracket “2” with the larger
center hole on the starboard side.
2 2
9-36
b
1
4
a
1 5
2 c
LT
3
242
1
2
3
h. Tighten the steering arm joint bolts “1”. 5
1 Steering shaft end nut

1
60 N·m (6.0 kgf·m, 44 lb·ft)
T.
R.
Installing the steering actuator (with
the power unit installed)
If the steering actuator is removed, the calibra-
tion is required after installation. See “Calibra-
Steering arm joint bolt “1”
tion (6X6 Digital Electronic Control)” (3-58).
27 N·m (2.7 kgf·m, 20 lb·ft)
1. Install:
T.
R.
• SCU lead
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Steering actuator
3. Install: See “Installing the steering actuator (with
• Manual steering lever “1” the power unit removed)” (9-35).
• Steering shaft end nut “2”
• Cotter pin “3” New 2. Connect:
• Swivel bracket top cover “4” • SCU positive terminal “a”
• Clamp bracket side covers “5” • SCU couplers “b”, “c”
• SCU ground terminal “d”
TIP:
• Align the hole “a” in the manual steering lever
“1” with the flat sides “b” of the steering shaft. When tightening the electrical management
• Bend the ends of the cotter pin “3” along the box terminal nuts, do not exceed the spec-
shaft “c” as shown. ified torque. Otherwise, the base of the
electrical management box could be dam-
aged.
9-37
• Flushing hose joint “1”
a
a
6. Install:
• Rigging grommet
• Grommet holder
• Plastic tie
See “Rigging grommet mounting” (3-14).
b c d
7. Install:
• Swivel bracket top cover “1”
nal nut
T.
R.
7.6 N·m (0.76 kgf·m, 5.6 lb·ft) 1
3. Install:
• Protector cover
• SCU lead
(to the holders)
See step 5 in “Installing the upper case as- LT
sembly” (9-19). 242

• Dipstick guide
See “Intake manifold” (6-25). 8. Install:
• Low-pressure fuel pump bracket bolts “1”
4. Install: • Cover “2”
• Bottom cowling (front) “1”
1
Bottom cowling (front) bolt

19 N·m (1.9 kgf·m, 14 lb·ft)
T.
R.
5. Connect: 9. Connect:
• PTT switch coupler “a” • Battery cables
• Main wire harness coupler “b”
9-38
10. Install:
• Apron (STBD)
• Bottom cowlings (PORT and STBD)
(9-3).
• Apron cover
• Top cowling
er” (9-1).
9-39
Clamp bracket and swivel bracket

6 18 A
A 21
LT
271
8
12
18 N·m (1.8 kgf·m, 13 lb·ft)
10
9
21 A
25
22 17
6
22 18 N·m (1.8 kgf·m, 13 lb·ft)

20 10
19 19
16 21 11
LT
16 271
13 15 10
1 1 7
9
2
14 6
3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 24 6
23
3.0 N·m (0.30 kgf·m, 2.2 lb·ft) 9
D 24
D
20 21 20
17 17
4 5
3 4
LT
3
242 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)

1 Bolt M6 × 10 mm 2 Tilt support lever
18 1
2 Ground lead 1 (STBD)
3 Bolt M6 × 30 mm 4 19 Distance collar 2
4 Plate 2 20 Pin 1
5 Anode 1 21 Bushing 3
6 Bushing 4 22 Nut M10 2
7 Clamp bracket (PORT) 1 23 Trim stopper 2
8 Clamp bracket (STBD) 1 24 Grommet 2
9 Grease nipple M6 5 25 Swivel bracket 1
10 Bolt M10 × 20 mm 4
11 Bracket (PORT) 1
12 Bracket (STBD) 1
13 Spring 1
14 Bolt M6 × 12 mm 1
15 Hook 1
16 Pin 2
Tilt support lever
17 1
(PORT)
9-40
Removing the clamp bracket

Distance “a”
1. Remove: 30.3–30.6 mm (1.19–1.20 in)
• PTT unit
See “Removing the PTT unit” (9-44).
3. Install:
• Bushings
Checking the clamp bracket anode
• Tilt support levers
1. Check:
• Distance collar assembly
• Anode
• Pins “1”
• Hook
Adhered is grease, oil, paint, or scales →
• Spring
Clean.
1 1 b
Do not apply grease, oil, or paint to the anode.

a c
Assembling the swivel bracket b>c
1. Install: 1
• Grommets
• Grease nipples
• Trim stoppers “1”
TIP:
Install the trim stoppers “1” in the direction shown.
Distance “a”
1 2.5–3.5 mm (0.10–0.14 in)
Installing the clamp bracket

1. Install:
• Brackets
• Grease nipples
1
D • Clamp brackets
1
• Bushings
Grease nipple • Clamp bracket anode
3.0 N·m (0.30 kgf·m, 2.2 lb·ft) • Plates
T.
R.
• Ground lead
2. Assemble: Bracket bolt
• Pin 18 N·m (1.8 kgf·m, 13 lb·ft)
T.
R.
• Distance collars Grease nipple

3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
2. Inject:
a
• Grease
9-41
TIP:
Inject grease into the grease nipples “1” until
grease comes out from both the port and star-
board bushings “2”.
2 2
1 1
3. Install:
• PTT unit
See “Installing the PTT unit” (9-47).
9-42
PTT unit
PTT unit
4 55 N·m (5.5 kgf·m, 41 lb·ft)
2 LT
572
A
14
11
LT
10 New 15 271
8 9 A 55 N·m (5.5 kgf·m, 41 lb·ft)
7 New 15
13 17
6 12 1 New
5 A
A
LT LT
572 271
14
3.6 N·m (0.36 kgf·m, 2.7 lb·ft)
55 N·m (5.5 kgf·m, 41 lb·ft)
17
15
LT
271 D
15 55 N·m (5.5 kgf·m, 41 lb·ft) 16

1 Pin 1
2 Bolt M6 × 12 mm 1
3 Plate 1
4 Lead 1
5 Bolt M5 × 16 mm 2
6 Sensor 1 PTT
7 O-ring 1
8 Bolt M5 × 16 mm 2
9 Adapter 1
10 O-ring 1
11 Shaft 1
12 Bolt M6 × 12 mm 1
13 Holder 1
14 Bolt M10 × 75 mm 2
15 Bolt M10 × 35 mm 6
16 PTT unit 1
17 Bushing 2
9-43
PTT unit
Removing the PTT unit a

G L
When removing or installing the PTT unit with
the power unit or upper case assembly in-
stalled, make sure to suspend the outboard
motor.
1. Remove:
• PTT unit
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the battery jumper leads to the PTT Ram PTT motor lead Battery
motor lead “a” to fully tilt the swivel bracket up, Green (G) (+)
and then support it using the tilt support lever Retract
Blue (L) (–)
“1”.
d. Remove the holder, and then pull the PTT
1
motor lead inward to remove it from the hole
in the clamp bracket.
a e. Remove the PTT unit.
L G
When removing or installing the PTT unit, do
not hold the PTT unit using the tilt cylinder.
Otherwise, the pipe could break, causing PTT
fluid to leak.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the PTT motor electric current

Ram PTT motor lead Battery when the relief valve operates
Blue (L) (+) 1. Check:
Extend • PTT fluid level
Green (G) (–)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the PTT unit in an upright position.
b. Push in the pin “1” past the upper mount shaft
“2”, and then remove the shaft. b. Connect the battery jumper leads to the PTT
motor lead “a” to fully extend the PTT rams.
1 2 a
L G
c. Connect the battery jumper leads to the PTT

motor lead “a” to fully retract the PTT rams. Ram PTT motor lead Battery
Blue (L) (+)
Extend
Green (G) (–)
9-44
PTT unit
c. Remove the reservoir cap “1”, and then
check the fluid level in the reservoir. TIP:
Use a clamp meter “1” that can measure DC
100 A or more.
Before removing the reservoir cap “1”,
make sure that the PTT rams are fully ex-
tended. Otherwise, fluid could be expelled
forcefully from the PTT unit due to internal
pressure.
DC
A
TIP:
If the fluid is at the proper level, a small amount 1
of fluid should flow out of the filler hole. G L
a b
b. Electric current direction
Ram PTT motor lead Battery

Blue (L) (+)
Extend
Green (G) (–)
Clamp meter “1”

1
d. If the fluid is below the proper level, add Electric current

the recommended fluid. Up
69-93 A
e. Install the reservoir cap.
Reservoir cap b. Connect the battery jumper leads to the
7 N·m (0.7 kgf·m, 5.2 lb·ft) PTT motor lead “a” to fully retract the PTT
T.
R.
rams, and then measure the PTT motor

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ electric current using the clamp meter “1”.
2. Measure:
TIP:
• PTT motor electric current when the up-re-
Use a clamp meter “1” that can measure DC
lief valve operates
100 A or more.
• PTT motor electric current when the down-
relief valve operates
Out of specification → Check the PTT mo-
tor or PTT gear pump. DC
A
1
See “Checking the PTT motor” (9-51) or
“Checking the gear pump” (9-57).
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the battery jumper leads to the
PTT motor lead “a” to fully extend the PTT
rams, and then measure the PTT motor L G
electric current using a clamp meter “1”. a b
b. Electric current direction
9-45
PTT unit
Ram PTT motor lead Battery a

Green (G) (+) G L
Retract
Blue (L) (–)
Clamp meter “1”

Electric current
Down
43-59 A Ram PTT motor lead Battery
Green (G) (+)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Retract
Blue (L) (–)
Bleeding the PTT unit
e. Reverse the connection between battery
1. Bleed:
jumper leads and the PTT motor lead “a” to
• PTT unit
fully extend the PTT rams.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the PTT unit in an upright position.
TIP:
b. Turn the manual valve “1” clockwise to If the PTT rams do not move up easily, pull on
close it. the PTT rams to assist operation.
a
1
L G
Manual valve “1”

Ram PTT motor lead Battery
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
T.
R.
Blue (L) (+)

Extend
c. Check the fluid level. Green (G) (–)
See step 1 in “Checking the PTT motor
electric current when the relief valve oper- f. Repeat steps (d) and (e) to fully extend
ates” (9-44). and retract the PTT rams 4 or 5 times.
d. Connect the battery jumper leads to the g. Fully extend the PTT ram.
PTT motor lead “a” to fully retract the PTT
rams.
TIP:
If the PTT rams do not move down easily, push
on the PTT rams to assist operation.
9-46
PTT unit
h. Remove the reservoir cap, and then check b. Install the bushings “1” and PTT unit “2”.
the fluid level in the reservoir.
When removing or installing the PTT unit,

Before removing the reservoir cap, make do not hold the PTT unit using the tilt cylin-
sure that the PTT rams are fully extended. der. Otherwise, the pipe could break, caus-
Otherwise, fluid could be expelled forceful- ing PTT fluid to leak.
ly from the PTT unit due to internal pres-
sure.
TIP:
If the fluid is below the proper level, add the
recommended PTT fluid. Repeat steps (c)–(g) LT
until the fluid remains at the proper level. 271
1
A
i. Install a new O-ring and the reservoir cap. LT
271
Reservoir cap 1
LT
7 N·m (0.7 kgf·m, 5.2 lb·ft)
2
T.
271
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Installing the PTT unit PTT unit mounting bolt

55 N·m (5.5 kgf·m, 41 lb·ft)
T.
R.
When removing or installing the PTT unit c. Route the PTT motor lead “a” through the
with the power unit or upper case assembly hole “b” in the clamp bracket (PORT), and
installed, make sure to suspend the out- then install the holder “1” to fasten the PTT
board motor. motor lead at the white tape “c”.
1. Install:
• Bushings
b 1
(into the swivel bracket) c
• PTT unit
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fully tilt the swivel bracket up, and then
support it using the tilt support lever “1”. d
a
1
Distance “d”
0–20 mm (0–0.79 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
• O-rings New
• Adapter
• Upper mounting shaft
• PTT sensor
• Pin
9-47
PTT unit
• PTT sensor lead
• Plate TIP:
Install the upper mount shaft “3” into the swivel
bracket so that the groove “d” in the shaft is
Do not install the PTT sensor to the upper facing in the direction shown.
mounting shaft while the sensor is installed
to the adapter. Otherwise, the PTT sensor b c d
could be damaged. 1 3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2
a. Connect the battery jumper leads to the a 3
PTT motor lead “a” to extend the PTT rams
until the end of the tilt ram is aligned with
the mounting position hole. a
a a 2 1 3
L G
e. Install a new O-ring “1” and the PTT sen-

sor “2”.
Ram PTT motor lead Battery 3 2 1

Blue (L) (+)
Extend
Green (G) (–)
b. Install a new O-ring “1” into the adapter “2”.

LT
572
c. Install the upper mounting shaft “3” com-
pletely into the adapter “2”, and then install
the magnet “a” to the shaft.
PTT sensor bolt “3”
TIP: 3.6 N·m (0.36 kgf·m, 2.7 lb·ft)
T.
R.
Align the flat portion “b” of the magnet “a” with

the flat portion “c” of the upper mounting shaft f. Align the hole in the upper mounting shaft
“3”. and hole in the tilt rod, and then install a
new pin “1”.
d. Install the upper mounting shaft assembly

into the swivel bracket.
1
Do not strike or tap the upper mounting

shaft to install it. Otherwise, the bushing
1
could be damaged.
g. Install the PTT sensor lead “1” and plate

“2”.
9-48
PTT unit
TIP:
• Route the PTT sensor lead along the swivel
bracket.
• Align the white tape “a” on the PTT sensor
lead “1” with the plate “2”.
1
2
h. Fully tilt the swivel bracket down.
TIP:
Make sure that the PTT motor lead “a” is routed
between the tilt cylinder “1” and the protrusions
“b” on the PTT body.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9-49
PTT motor
PTT motor
15 N·m (1.5 kgf·m, 11 lb·ft) 15 N·m (1.5 kgf·m, 11 lb·ft) 10
4
18
3
11 23
22 14
New 2 21
18 18
1
5 New 21 15
9 New 19
6
New 16
7
17
New 20
13
New 12
7 N·m (0.7 kgf·m, 5.2 lb·ft)

Reservoir cap M12 × 19 Brush holder 1
1 1
10 mm 20 Oil seal 1
2 O-ring 1 21 Spring 2
3 Bolt M8 × 20 mm 3 22 Brush 1
4 Reservoir 1 23 Circuit breaker 1
5 O-ring 1
6 Sheet 1
7 Filter 1
8 Spacer 1
9 Plastic tie 1
10 Bolt M8 × 35 mm 3
11 PTT motor assembly 1
12 O-ring 1
13 Joint 1
14 Screw M4 × 17 mm 2
15 Stator 1
16 O-ring 1
17 Armature assembly 1
18 Screw M4 × 10 mm 4
9-50
PTT motor
Removing the reservoir 2. Measure:

• Commutator diameter “a”
Out of specification → Replace the armature.
Before removing the reservoir, make sure that
the PTT rams are fully extended. Otherwise,
fluid could be expelled forcefully from the PTT
unit due to internal pressure.
Disassembling the PTT motor

1. Remove:
• Stator “1” a
When removing or installing the armature Standard commutator diameter

along with the motor base assembly, secure 28.00 mm (1.1024 in)
the end of the armature shaft using a pair of Wear limit
pliers. Otherwise, the armature could separate 27.00 mm (1.0630 in)
from the motor base assembly due to the mag-
netic force of the stator and damage the 3. Measure:
brushes. • Commutator undercut “a”
Out of specification → Replace the armature.
1
a
Checking the PTT motor Standard commutator undercut

1. Check: 2.00 mm (0.0787 in)
• Commutator Wear limit
Dirty → Clean using 600-grit sandpaper and 1.50 mm (0.0591 in)
compressed air.
4. Check:
• Armature for continuity
Out of specification → Replace the armature
assembly.
a
b
c d
9-51
PTT motor

Checking the reservoir
1. Check:
“a” “b” “c” “d” • Reservoir
Checking the brush Checking the filter

1. Measure: 1. Check:
• Brush length • Filter
Clogged/damaged → Replace.
Assembling the PTT motor
b
a Do not apply grease or oil to the commuta-
tor of the armature.
1. Assemble:
a. Standard brush length • Brush holder
b. Wear limit • Oil seal New
• Brush “1”
Standard brush length • Circuit breaker “2”
12.00 mm (0.4724 in) • Springs “3”
Wear limit 2
4.3 mm (0.17 in)
2. Check:
• Circuit breaker for continuity 3
No continuity → Replace.
Do not touch the bimetal “1”. Otherwise,

1
the operation of the circuit breaker can be
affected. 2. Install:
• Armature “1”
TIP:
Push the brushes “2” into the holders, and then
install the armature “1”.
1
1 2
3. Check:
• PTT motor base assembly
Cracked/damaged → Replace the PTT
motor assembly.
9-52
PTT motor
3. Install: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the gear pump housing with the recom-
• O-ring New
mended fluid up to the proper level “a”.
• Stator “1”
b. Turn the joint “1” using a screwdriver to re-
move any air between the pump gear
When removing or installing the armature
teeth.
along with the motor base assembly, se-
cure the end of the armature shaft using a 1
pair of pliers. Otherwise, the armature a
could separate from the motor base assem-
bly due to the magnetic force of the stator
and damage the brushes.
c. Remove all of the air bubbles using a sy-

ringe or suitable tool.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• O-ring New
• PTT motor assembly “1”
Installing the reservoir
1. Install: TIP:
• Spacer Align the protrusion “a” on the armature shaft
• Filter with the slot “b” in the joint.
• Sheet
• O-rings New
• Reservoir 1
• Reservoir cap
b
Reservoir mounting bolt
15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.
Reservoir cap
7 N·m (0.7 kgf·m, 5.2 lb·ft) a
Installing the PTT motor

PTT motor mounting bolt
15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.
When assembling the PTT unit, do not use

a rag. Otherwise, dust and particles could 4. Fasten:
get on the PTT unit components, causing • PTT motor lead
poor performance.
1. Install:
• Joint
2. Fill:
• PTT fluid
9-53
PTT motor
TIP:
• Route the PTT motor lead “a” to the inside of
the protrusions “b” on the PTT body.
• Place the slack in the PTT motor lead be-
tween the PTT body and the tilt cylinder “1”.
• Route the PTT motor lead “a” under the pro-
trusion “c” on the PTT body.
• Fasten the PTT motor lead “a” using a new
plastic tie “d” at the white tape “e”.
d a
e 1
b
c
9-54
PTT gear pump
PTT gear pump

32 33 4 13,16,32 33
5
34
36 38
35 New a b
New 37 38 a>b
1.8 N·m (0.18 kgf·m, 1.3 lb·ft) 17

18
18
32 21
19
12 23
16 13 20 22
16
11
15
15 10
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
14 New
8 6 New
9 7 30
7 31
30
27 31
New 29
26 28
3 New 24
26
2
1 25 New
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)

1 Circlip 1 3.92 mm
2 Manual valve 1 16 Ball 2 (0.15 in) (ref-
3 O-ring 1 erence data)
4 Bolt M5 × 45 mm 4 17 Bolt M3 × 25 mm 2
5 Gear pump assembly 1 18 Bolt M5 × 30 mm 2
6 O-ring 2 19 Cap 1
7 Filter 2 20 Spring 1
8 Filter 1 21 Valve lock screw 1
9 Plate 1 22 Spring 1
10 Bolt M3 × 5 mm 1 23 Pin 1
11 Relief valve seat 1 24 Valve support pin 1
12 Manual release plate 1 25 O-ring 1
3.92 mm 26 Spring 2
13 Ball 2 (0.15 in) (ref- 27 Down-main valve 1
erence data) 28 Up-main valve 1
14 O-ring 2 29 O-ring 1
15 Spring 2 30 E-clip 2
31 Main valve seal 2
9-55
PTT gear pump
32 33 4 13,16,32 33
5
34
36 38
35 New a b
New 37 38 a>b
1.8 N·m (0.18 kgf·m, 1.3 lb·ft) 17

18
18
32 21
19
12 23
16 13 20 22
16
11
15
15 10
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
14 New
8 6 New
9 7 30
7 31
30
27 31
New 29
26 28
3 New 24
26
2
1 25 New
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)

3.92 mm
32 Ball 2 (0.15 in) (ref-
erence data)
3.13 mm
33 Ball 1 (0.12 in) (ref-
erence data)
34 Relief valve seat 1
35 O-ring 1
36 Valve pin 1
37 Valve seal 1
38 Pin 2
9-56
PTT gear pump
Disassembling the gear pump assembly Checking the gear pump housing
1. Remove: 1. Check:
• Valve lock screw “1” • Gear pump housing
Corroded/cracked → Replace the PTT unit.
TIP:
Before removing the valve lock screw “1”, mea- Checking the filter
sure and write down the screw depth “a”. 1. Check:
• Filters
1
Assembling the gear pump assembly
Lubricate the parts using recommended fluid
during assembly.
a
When assembling the PTT unit, do not use a
1 rag. Otherwise, dust and particles could get
on the PTT unit components, causing poor
performance.
1. Install:
• Drive gear “a”
Checking the gear pump • Driven gear “b”
1. Check: • O-rings “1”, “2” New
• Drive gear “a” • Main valve seals “3”
• Driven gear “b” • E-clips “4”
Damaged/worn → Replace the gear pump • Down-main valve “5”
assembly. • Up-main valve “6”
• Up-relief valve “c” • Springs “7”
• Down-relief valve “d” • Pins “8”
• Main valves “e”, “f”, “g” • Valve support pin “9”
7
8
d b 1
c a
b
2
a 5
9
3
7
4
6 8
3
g 4
f
e 2. Install:
e • Balls “1”, “2”
• Relief valve seat “4”
9-57
PTT gear pump
• Valve seal “5” New

• Valve pin “6”
TIP:
• Install the valve lock screw “5” to the depth
TIP: “a” that was measured before removing it.
To prevent the balls “1” and “2” from falling out • When installing a new part, install it accord-
of the gear housing assembly, apply a small ing to the preceding reference data.
amount of grease to the balls.
6
5
6
4
2
4 5 3
1 1 2
3 1 a
5
1 2
a b
a>b
Installation depth “a” (reference
3. Assemble: data)
• Gear housing assemblies “a”, “b” 1.35 mm (0.053 in)
Gear pump bolt “6”

Make sure that there is no gap between the
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
gear housings. If there is a gap, parts be-

R.
tween them may not be installed properly.

5. Install:
• Balls “1”, “2”
a b • Adapters “a”
• Springs “3”
• O-rings “4” New
• Manual release plate “5”
• Relief valve seat “6”
7
6 4
3
4. Install: 4
a
• Spring “1” 3 1
• Plate “2” a
• Pin “3” 1
• Spring “4”
• Valve lock screw “5” 2
5
2
9-58
PTT gear pump
Relief valve seat bolt “7”

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
Installing the gear pump assembly

1. Install:
• Plate
• Filters
• O-rings New
• Gear pump assembly
• Manual valve
• Circlip
Manual valve
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
T.
R.
9-59
PTT cylinder
PTT cylinder
18 8 23
19 New
160 N·m (16 kgf·m, 118 lb·ft)
14 16 New 22 22 34
15 25 New
65 N·m (6.5 kgf·m, 48 lb·ft) 24
26 New
10
17 37 New 21
20
38
12
15 N·m (1.5 kgf·m, 11 lb·ft) 36
New 30 29
65 N·m (6.5 kgf·m, 48 lb·ft) 35 13 New
New 31
32
2 New 33
4 New
3
9 28
5
11 27
150 N·m (15 kgf·m, 111 lb·ft)

1
New 7 9
7 New
6 4 New 3
65 N·m (6.5 kgf·m, 48 lb·ft)
15 N·m (1.5 kgf·m, 11 lb·ft) 2

1 Pipe 1 19 Dust seal 2
2 Circlip 2 20 Nut 1
3 Cap 2 21 Washer 1
4 O-ring 2 3.92 mm
5 Spring 1 22 Ball 4 (0.15 in) (ref-
6 Shaft 1 erence data)
7 O-ring 4 23 Tilt piston 1
8 Tilt cylinder assembly 1 24 Backup ring 1
9 Spacer 2 25 O-ring 1
10 Tilt cylinder end screw 1 26 O-ring 1
11 Tilt ram assembly 1 27 Adapter 1
12 Free piston 1 28 Spring 1
13 O-ring 1 29 Tilt cylinder end 1
14 Circlip 1 30 Dust seal 1
Trim cylinder end 31 O-ring 1
15 2 32 Backup ring 1
screw
16 O-ring 2 33 O-ring 1
17 Trim ram assembly 2 34 Tilt rod 1
18 Circlip 2 35 Circlip 2
9-60
PTT cylinder
18 8 23
19 New
160 N·m (16 kgf·m, 118 lb·ft)
14 16 New 22 22 34
15 25 New
65 N·m (6.5 kgf·m, 48 lb·ft) 24
26 New
10
17 37 New 21
20
38
12
15 N·m (1.5 kgf·m, 11 lb·ft) 36
New 30 29
65 N·m (6.5 kgf·m, 48 lb·ft) 35 13 New
New 31
32
2 New 33
4 New
3
9 28
5
11 27
150 N·m (15 kgf·m, 111 lb·ft)

1
New 7 9
7 New
6 4 New 3
65 N·m (6.5 kgf·m, 48 lb·ft)
15 N·m (1.5 kgf·m, 11 lb·ft) 2

36 Spring 2
37 O-ring 2
38 Backup ring 2
9-61
PTT cylinder
Removing the tilt ram
Before removing the tilt cylinder end screw, 2

make sure that the PTT rams are fully ex-
tended. Otherwise, fluid could be expelled
forcefully from the PTT unit due to internal 1
pressure.
1. Remove:
• Pipe “1”
5. Remove:
• Circlips “2”
• Free piston “1”
• Lower mounting shaft caps “3”
• O-rings “4”
• Spring “5” When removing the free piston, never look
into the tilt cylinder opening because the
2 free piston and PTT fluid could be expelled
3
4 forcefully.
TIP:
5 1 Cover the tilt cylinder using a rag “2”, and then
4
3 blow compressed air through the hole “a” to re-
2
move the free piston “1”.
2. Remove:
2
• Lower mounting shaft “1”
• O-rings “2”
1
• Tilt cylinder assembly “3”
• Spacers “4” a
3
4
4 Removing the trim ram
1. Loosen:
• Trim cylinder end screws “1”
2
2
1
2 1
3. Drain:
• Fluid 1
4. Loosen:
• Tilt cylinder end screw “1”
Cylinder end screw wrench “2”
90890-06958
90890-06959
9-62
PTT cylinder
2. Drain: • O-ring “2” New
• Fluid • Spring “3”
• Adapter “a”
Checking the tilt cylinder and trim • Circlip “4”
cylinder
1. Check:
• PTT body
• Tilt cylinder 1
Corroded/cracked → Replace. 3 1 2
2. Check: a
• Inner surface of the PTT body
• Inner surface of the tilt cylinder 4 2
Scratched → Replace.
3. Check: 2. Install:
• Outer surfaces of the tilt piston • Dust seal “1” New
• Outer surfaces of the trim piston • Circlip “2”
• Outer surfaces of the free piston • O-ring “3” New
Scratched → Replace. • Trim cylinder end screw “4”
(onto the trim ram “5”)
4. Check:
• Backup rings 2
Damaged/worn → Replace. 1 2
1
5. Check: 4 3
5
• Trim rams
• Tilt ram
3
Rust → Clean using 400–600-grit sandpa-
per.
Bent/corroded → Replace.
6. Check: Assembling the tilt ram

• Pipe
Checking the absorber valve a rag. Otherwise, dust and particles could
1. Check: get on the PTT unit components, causing
• Tilt piston absorber valves poor performance.
1. Install:
Assembling the trim ram • Dust seal “1”
• Backup ring “2”
• O-rings “3”, “4” New
a rag. Otherwise, dust and particles could
get on the PTT unit components, causing
poor performance.
1. Install:
9-63
PTT cylinder
1
1 5
2 4
4 b
3 4 a
4 2 2
3
2 1
b 1 b
3
a 3 a
2. Install: 3
• Tilt ram “a”
b
• Tilt cylinder end screw “1”
• Tilt cylinder end “2” a b
• Spring “3” 3 a
• Adapter “4” 3
• Tilt piston “6”
Tilt piston nut “5”
65 N·m (6.5 kgf·m, 48 lb·ft)
T.
6
R.
a
6 Installing the tilt cylinder
1
5
2 5 When assembling the PTT unit, do not use
3 a rag. Otherwise, dust and particles could
4 get on the PTT unit components, causing
poor performance.
3. Install:
1. Install:
• Spacers “1”
• Tilt cylinder “a”
• Balls “3”
• Absorber valve pins “a” • O-rings “2”, “3” New
• Springs “b” • Lower mounting shaft “4”
• Washer “4” • Spring “5”
• Tilt piston nut “5” • Lower mounting shaft caps “6”
• Circlips “7”
a
6
1
7
1 3
2 5
3
76 2
Lower mounting shaft cap “6”

65 N·m (6.5 kgf·m, 48 lb·ft)
T.
R.
9-64
PTT cylinder
Installing the trim ram Installing the tilt ram
When assembling the PTT unit, do not use When assembling the PTT unit, do not use
a rag. Otherwise, dust and particles could a rag. Otherwise, dust and particles could
get on the PTT unit components, causing get on the PTT unit components, causing
poor performance. poor performance.
1. Fill: 1. Install:
• PTT fluid • Gear pump assembly
See “Installing the gear pump assembly”
TIP: (9-59).
Fill the trim cylinders with the recommended
fluid up to the proper level “a”. 2. Install:
• Reservoir
See “Installing the reservoir” (9-53).
a 3. Install:
• O-ring New
• Free piston
4. Fill:
• PTT fluid
TIP:
2. Install: • Fill the tilt cylinder and PTT body with the rec-
• Trim ram assemblies “1” ommended fluid up to the proper level “a”.
• Place the tilt cylinder end “1” at the bottom of
the tilt ram assembly.
1 a
2
1
Cylinder end screw wrench “2” 1

90890-06959
Trim cylinder end screw

160 N·m (16 kgf·m, 118 lb·ft)
a
T.
R.
9-65
PTT cylinder
5. Install:
Torque wrench setting value = 150
• Tilt ram assembly “1”
N·m ÷ (A + 0.031) × A
T.
R.
TIP: 150 N·m (15 kgf·m, 111 lb·ft)
Place the tilt cylinder end “2” at the bottom of Specified tightening torque for
the tilt ram assembly “1”. the tilt cylinder end screw
0.031 m
Cylinder end screw wrench
1 length
Am
Torque wrench length
2 7. Install:
• Pipe
Pipe joint
15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.
6. Tighten:
• Tilt cylinder end screw “1” 8. Install:
• PTT motor
TIP: See “Installing the PTT motor” (9-53).
Place a block of wood “a” between the tilt cylin-
der and the PTT body to secure the tilt cylinder
when tightening the tilt cylinder end screw “1”.
1
a
0.031 m Am

90890-06958
9-66
Maintenance
Outline ............................................................................... 10-1

Maintenance interval chart 1 .................................................... 10-1
Maintenance interval chart 2 .................................................... 10-3
Predelivery check............................................................. 10-4

Checking the engine oil level.................................................... 10-7
Checking the battery ................................................................ 10-7
Checking the cooling water pilot hole....................................... 10-8
Checking the gear oil level ....................................................... 10-8
Checking the outboard motor mounting height ........................ 10-8
General periodic maintenance ...................................... 10-10

Checking the engine idle speed ............................................. 10-14
Changing the engine oil using an oil changer ........................ 10-14
Changing the engine oil by removing the drain bolt ............... 10-15
Replacing the oil filter ............................................................. 10-17
Changing the gear oil using an oil changer ............................ 10-18
Changing the gear oil by removing the drain screw ............... 10-21
Greasing points ...................................................................... 10-23
Checking the PTT fluid level................................................... 10-24
Checking the PTT unit operation............................................ 10-24
Checking the top cowling fitting.............................................. 10-25
10
Outline
Outline
• To obtain long product life, Yamaha strongly recommends that the specified periodic checks and
maintenance be performed according to the maintenance interval charts.
• If replacement parts are necessary, use only genuine Yamaha parts of equivalent design and quality.
Any parts of inferior quality may cause a malfunction, and the resulting loss of control could endanger
the operator and passengers. Yamaha genuine parts and accessories are available from Yamaha
dealers.
• The service intervals provided in the maintenance interval charts are based upon “typical” operating
conditions that include speed variations, sufficient time for engine warm up and cool-down, medium
to light load, and an average cruising speed in the 3000–4000 r/min range. If your normal operating
conditions are more intensive, more frequent servicing will be required, especially the engine oil and
gear oil changes. Examples of the intensive operation will be: wide-open-throttle, trolling, or idling op-
eration for extended periods of time, carrying heavy loads, and frequent starting and stopping or shift-
ing. In most cases, the frequent maintenance pays off in increased engine life and greater owner
satisfaction.
• The maintenance cycle on these charts is based on usage of 100 hours per year and regular flushing
of the cooling water passages. Adjust the maintenance frequency when operating the engine under
adverse conditions, such as extended trolling.
• Disassembly or repairs may be necessary depending on the outcome of maintenance checks.
• Expendable or consumable parts and lubricants will lose their effectiveness over time and through
normal usage regardless of the warranty period.
• When operating the outboard motor in salt water, or in muddy, turbid (cloudy), or acidic water, flush
the engine using clean water after each use.
Maintenance interval chart 1

The “” symbol indicates the check-ups which the owners or operators may carry out themselves.
The “” symbol indicates work to be carried out by a Yamaha dealer.
Initial Every
Item Actions 20 hours 100 hours 300 hours 500 hours
(3 months) (1 year) (3 years) (5 years)
Inspection or replace-
Anode(s) (external) /
ment as necessary
Battery (electrolyte lev-
Inspection / /
el, terminal)
Battery (electrolyte lev- Fill, charging or replac-

el, terminal) ing as necessary
Cooling water leakage  
ment as necessary
Cowling lock lever Inspection /
Engine starting condi-
tion/noise
Engine idle speed/noise Inspection / /
Engine oil Replacement  
Engine oil filter (car-
Replacement 
tridge)
10-1
Outline
Initial Every
Fuel filter (can be disas- Inspection or replace-
/ /
sembled) ment as necessary
Fuel line (Direct injec-
Inspection 
tion pressure)
Fuel line (Direct injec- Inspection or replace-

tion pressure) ment as necessary
Fuel line (High pres-
Inspection  
sure)
Fuel line (High pres- Inspection or replace-
 
sure) ment as necessary
Fuel line (Low pres-
Inspection  
sure)
Fuel line (Low pres- Inspection or replace-
 
sure) ment as necessary
Fuel pump 
ment as necessary
Fuel/engine oil leakage Inspection  
Gear oil Replacement / /
Greasing points Greasing / /
Impeller/water pump Inspection or replace-

housing ment as necessary
Impeller/water pump
Replacement 
housing
OCV (Oil Control Valve)
Replacement 
filter
Power trim and tilt unit Inspection / /
Propeller/propeller nut/ Inspection or replace-
/ /
cotter pin ment as necessary
PCV (Pressure Control Inspection or replace-

Valve) ment as necessary
Spark plug(s) 
ment as necessary
Water from the cooling
water pilot hole
Thermostat 
ment as necessary
Timing belt 
ment as necessary
Cooling water inlet Inspection / /
10-2
Outline
Initial Every
Main switch/stop switch  
ment as necessary
Wire harness connec-
tions/wire coupler con-  
ment as necessary
nections
(Yamaha) Meter/gauge Inspection  
SBW    
ment as necessary
Maintenance interval chart 2

Every
Item Actions
1000 hours
Exhaust guide/exhaust Inspection or replace-

manifold ment as necessary
Timing belt Replacement 
Cam chain 
ment as necessary
Cam chain tensioner 
ment as necessary
Inspection and adjust-
Valve clearance 
ment
Fuel strainer 
ment as necessary
Fuel line (Direct injection
Inspection 
pressure)
Fuel line (Direct injection Inspection or replace-

pressure) ment as necessary
Anode(s) (internal) *1 
ment as necessary
Anode(s) (Under the Inspection or replace-

timing belt) ment as necessary
SBW 
ment as necessary
*1 cylinder head, cylinder block, oil cooler, water jacket cover (lower), exhaust joint, rectifier/regulator
10-3
Predelivery check
Predelivery check
To make the delivery process smooth and efficient, complete the predelivery checks as explained in
the following procedures.
Item Procedures See
Check the oil level using the dipstick.
Engine oil level 10-7
Oil is not at the proper level → Add or extract engine oil.
Check the battery electrolyte level.
Below the minimum level mark → Add distilled water.
Battery 10-7
Check the specific gravity of the electrolyte.
Below specification → Fully charge the battery.
Start the engine. —
Cooling water pilot Check that the cooling water is discharged from the cooling water
hole 10-8
pilot hole.
2-45
Not discharged → Check the cooling passage for clog.
Check that the digital electronic control-active indicator light
Communication be-
comes on in blue.
tween the engine and 3-30
Light does not come on in blue → Check the wire harness for
the Digital Electronic 5-48
proper connections, the main wire harness (16 pins) for continuity,
Control
and the Digital Electronic Control circuit.
Check that the engine starts when the engine start switch is
turned to START. 5-40
Engine start switch Out of specification → Check the engine start switch.
(Single application) Check that the engine stops when the engine start switch is
turned to OFF. 5-40
Out of specification → Check the engine start switch.
Turn the main switch to ON, and then push the engine start/stop
button. Check that the engine starts.
5-40
Out of specification → Check the main switch or engine start/stop
button.
Main switch
Start the engine. Check that the engine stops when the main
Engine start/stop but-
switch is turned to OFF. 5-40
ton
Out of specification → Check the main switch.
Start the engine. Check that the engine stops when the engine
start/stop button is pushed. 5-40
Out of specification → Check the engine start/stop button.
Check that the engine stops when the clip is removed from the
Engine shut-off
engine shut-off switch. 5-39
switch
Out of specification → Check the engine shut-off switch.
Check the fuel line connection.
Disconnect → Connect.
Fuel line 2-34
Check all the fuel lines for leakage.
Leaking → Check the related parts.
Check the gear oil level.
Gear oil 10-8
Below the proper level → Add the recommended gear oil.
10-4
Predelivery check
Item Procedures See

8-11
Check that the gear shift operates properly when the remote con-
8-18
trol lever is moved from the N position to the F or R position.
8-52
Shift and throttle op- Not properly → Check the shift actuator and related parts.
9-12
eration
Check that the throttle operates properly when the remote control
lever is moved from the F or R position to the fully open position. 6-29
Not properly → Check the ETV and/or LPS.
Outboard motor Check the outboard motor mounting height.
10-8
mounting height Improper → Adjust.
Check the PTT unit operation.
Not smooth → Check the PTT fluid level and PTT motor electric 10-24
current when the relief valve operate.
9-43
Check that there is no abnormal noise produced when the out-
9-50
PTT unit board motor is tilted up or down.
9-55
Abnormal noise → Overhaul PTT unit.
9-60
Steer the tilted-up outboard motor. 3-14
Interference → Check the hose and wire harness routing, or 5-1
mounting of the outboard motor. 1-2
Check that the steering operates smoothly.
9-30
Not smooth → Check the steering arm, swivel bracket, steering
9-40
actuator, helm unit or related parts.
Steering system
Check that the there is no interference with hose or leads when
3-14
the outboard motor is steered.
5-1
Interference → Check the hose and wire harness routing.
Start the engine, and then check that the gear shift operates prop-
—
erly.
Warm up the engine, and then check the engine idle speed. 10-14
Out of specification → Perform the troubleshooting procedures. 4-37
Operate the boat at trolling speed. —
Test run Operate the outboard motor according to the break-in procedure. —
Check that the outboard motor does not tilt up when reverse oper-
ation. 9-43
Tilt up → Check the PTT unit.
Check that the power trim operates smoothly while cruising.
9-43
Not smooth → Check the PTT unit.
10-5
Predelivery check
Item Procedures See

Operate the engine under load (in gear with a propeller installed)
—
for 10 hours.
For the first hour of operation:
Operate the engine at varying speeds up to 2000 r/min or approx- —
imately 1/2 throttle.
For the second hour of operation:
Increase the engine speed until the boat is on plane (but do not
Break-in —
fully open the throttle), and then back off on the throttle while
keeping the boat at a planing speed.
For the remaining 8 hours of operation:
Operate the engine at any engine speed. However, do not operate —
the engine at full throttle for more than 5 minutes at a time.
After the first 10 hours of operation:
—
Operate the engine normally.
Check for water in the gear oil.
8-7
Oil is milky → Check the lower case for airtightness and oil seal.
Check all the fuel lines for leakage.
2-34
After test run Leaking → Check the connection or replace affected parts.
Flush the cooling water passages using fresh water.
When using the equipped flashing device, flush the cooling water —
passages without starting the engine.
10-6
Predelivery check
Checking the engine oil level Checking the battery
Make sure that the engine is filled with en- Battery electrolyte is dangerous; it con-
gine oil before operating the outboard mo- tains sulfuric acid, which is poisonous and
tor for the first time. Otherwise, the engine highly caustic. Always follow these preven-
could be damaged severely. tive measures:
• Avoid bodily contact with electrolyte as it
1. Check: can cause severe burns or permanent eye
• Engine oil level injury.
Not at the proper level → Add or extract • Wear protective eye gear when handling
the engine oil. or working near batteries.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Antidote (EXTERNAL):
a. Place the outboard motor in an upright po-
• SKIN - Wash with water.
sition.
• EYES - Flush with water for 15 minutes
and get immediate medical attention.
If the outboard motor is not level, the oil lev- Antidote (INTERNAL):
el indicated on the dipstick may not be cor- • Drink large quantities of water or milk fol-
rect. lowed with milk of magnesia, beaten egg,
or vegetable oil. Get immediate medical
attention.
b. Start the engine and warm it up for 5–10 Batteries generate explosive, hydrogen
minutes. gas. Always follow these preventive mea-
sures:
c. Stop the engine and leave it off for 5–10
• Charge batteries in a well-ventilated area.
minutes.
• Keep batteries away from fire, sparks, or
d. Remove the top cowling. open flames (for example, welding equip-
ment and lighted cigarettes).
e. Remove the dipstick “1” and wipe it clean. • DO NOT SMOKE when charging or han-
dling batteries.
f. Insert the dipstick “1” completely for a cor- KEEP BATTERIES AND ELECTROLYTE
rect measurement and remove it again. OUT OF REACH OF CHILDREN.
g. Check that the oil level indicated on the 1. Check:

dipstick “1” is between the upper mark “a” • Battery electrolyte level
and the lower mark “b”. If the engine oil is Below the minimum level mark “a” → Add
not at the proper level, add or extract en- distilled water until the level is between the
gine oil. maximum and minimum level marks.
a
a
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
10-7
Predelivery check
2. Check: b. Remove the upper water inlet covers “1”,
• Specific gravity of the electrolyte oil level plug “2”, and O-ring “3”, and then
Below specification → Fully charge the check the gear oil level.
battery.
TIP:
TIP: If the oil is at the proper level, a small amount
• Batteries vary depending on the manufactur- of oil should flow out of the check hole.
er. The procedures mentioned in this manual
may not always apply. Therefore, see the in-
struction manual of the battery. 1
• Disconnect the negative battery cable first,
and then disconnect the positive battery ca-
ble.
Recommended battery capacity

Battery rating 3
700 A (CCA/SAE) 1 2
900 A (MCA/ABYC)
c. Install a new O-ring “1” and the oil level
170 minutes (RC/SAE)
plug “2”.
670 A (CCA/EN)
110 Ah (20 HR/IEC) d. Install the upper water inlet covers “3”.
Checking the cooling water pilot hole 3

1. Place the lower unit in water, and then start
the engine.
2. Check:
• Cooling water is discharged from the cool-
ing water pilot hole.
Not discharged → Check the cooling pas- 1 New
sages for clog. 3 2
Oil level plug

3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
T.
R.
Upper water inlet cover bolt

3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the outboard motor

mounting height
Checking the gear oil level 1. Check:
1. Check: • Outboard motor mounting height
• Gear oil level Improper → Adjust.
Below the proper level → Add the recom- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check that the anti-cavitation plate “1” is
mended gear oil.
aligned with the bottom of the boat “2”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the outboard motor in an upright po-
sition.
10-8
Predelivery check
TIP:
• If the mounting height is too high, cavitation
will occur and propulsion will decrease.
Besides, the engine speed will increase ab-
normally and cause the engine to overheat.
• If the mounting height is too low, water resis-
tance will increase, which will decrease en-
gine efficiency and performance.
• The appropriate mounting height depends on
the combination of the boat and outboard
motor. To determine the appropriate mount-
ing height, test run the outboard motor at dif-
ferent heights.
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Mount bolts
Loosen → Tighten.
10-9
General periodic maintenance

Item Procedures See
7-9
7-38
Check the anodes. 7-67
Anodes Eroded (1/2 or more worn out) → Replace. 7-74
Adhered grease, oil, paint, or scales → Clean. 7-77
8-6
9-41
Check the battery electrolyte level.
Below the minimum level mark → Add distilled water.
Battery 10-7
Check the specific gravity of the electrolyte.
Below specification → Fully charge the battery.
Check the cooling water inlets.
Cooling water inlets 2-45
Clogged → Clean.
Start the engine. —
Cooling water pilot Check that the cooling water is discharged from the cooling water
hole pilot hole. 2-45
Not discharged → Check the cooling system.
Engine idle speed Check the engine idle speed. 10-14
Check the oil level using the dipstick.
10-7
Not at the proper level → Add or extract the engine oil.
Engine oil Check the engine oil.

Replacement interval has been exceeded/deterioration → 10-14
Change. 10-15
Milky → Overhaul the outboard motor.
Oil filter Replace the oil filter. 10-17
Check that the engine starts when the engine start switch is
turned to START. 5-40
Engine start switch Out of specification → Check the engine start switch.
(Single application) Check that the engine stops when the engine start switch is
turned to OFF. 5-40
Out of specification → Check the engine start switch.
Turn the main switch to ON, and then push the engine start/stop
button. Check that the engine starts.
5-40
Out of specification → Check the main switch or engine start/stop
button.
Main switch
Start the engine. Check that the engine stops when the main
Engine start/stop but-
switch is turned to OFF. 5-40
ton
Out of specification → Check the main switch.
Start the engine. Check that the engine stops when the engine
start/stop button is pushed. 5-40
Out of specification → Check the engine start/stop button.
10-10
Item Procedures See

Check that the engine stops when the clip is removed from the
Engine shut-off
engine shutoff switch. 5-39
switch
Out of specification → Check the engine shut-off switch.
Exhaust joint Check the exhaust joint and exhaust guide. 7-9
Exhaust guide Corroded/cracked/damaged → Replace. 9-24
Check the fuel filter element.
Dirt/residue → Replace.
Water accumulated → Drain.
Checking the fuel cup assembly.
Fuel filter Foreign material → Clean. 6-4
Checking the fuel inlet or fuel outlet holding pressure.
Out of specification → Replace the O-ring, fuel cup assembly, or
fuel filter assembly.
Check the fuel strainer
Cracked/damage → Replace.
Check the fuel strainer element.
Fuel strainer Dirt/residue → Clean. 6-14
Check the fuel strainer holding pressure.

Check the operation of the fuel pump using the YDIS “Stationary
5-29
Fuel pump test” and check the operating sound.
5-30
Abnormal sound → Check the fuel pump internal parts.
Check the fuel line.
Fuel leakage 2-34
Check the engine oil line.
Engine oil leakage 2-41
Check the gear oil level.
10-8
Below the proper level → Add the recommended gear oil.
Gear oil Check the gear oil.

Replacement interval has been exceeded/deterioration → 10-18
Change. 10-21
Milky → Overhaul the lower unit.
OCV filter Replace the OCV gasket. 7-59
Greasing Apply lubricants. 10-23
Check the propeller blade and damper rubber spline.
Propeller 8-2
Propeller nut
Cotter pin Check the installed condition of propeller nut and cotter pin.
8-1
Improperly installed → Reinstall.
Check the PCV.
PCV (Pressure Con-
Corroded/damaged/deformed/fatigued → Replace the PCV, 9-27
trol Valve)
grommet, or spring.
10-11
Item Procedures See

Check that a small amount of fluid flows out of the filler hole.
PTT fluid level 10-24
Below the proper level → Add the recommended fluid.
Check the PTT unit operation.
10-24
PTT operation is not smoothly → Check the PTT fluid level.
Check the tilt support lever.
10-24
Tilt support lever locks in place not properly → Check the related
PTT unit operation 9-40
parts.
10-24
Check the PTT fluid leakage.
9-50
9-60
Clean the electrodes using a spark plug cleaner. —
Check the spark plug.
Electrodes are damaged/worn or insulator is abnormal color →
Spark plug
Replace. 7-41
Check the spark plug gap.
Check the ignition spark.
Ignition coil 5-35
Check the timing belt.
Timing belt 7-43
Check the cam chain.
Cam chain Damaged/stiffness → Replace the cam chain, camshaft (EX), and 7-49
VCT assembly as a set.
Check the cam chain tensioner.
Cam chain tensioner 7-50
Cracked/damaged/rough movement/worn → Replace.
Measure the thermostat valve opening.
Thermostat 7-74
Check the fitting by pushing the top cowling.
Cowling lock lever 10-25
Looseness/rattling → Adjust or replace the top cowling stopper.
Check the valve clearance.
Valve clearance 7-2
Out of specification → Adjust.
Check the upper water pump housing.
Check the upper impeller, insert cartridge, and outer plate car-
tridge.
Water pump Cracked/worn → Replace. 8-13
Check the lower impeller and lower water pump housing.
Check the impeller key and keyway in the drive shaft.
Deformed/worn → Replace.
Wire harness Check the wire harness coupler and lead coupler connections. —
Yamaha
Check the gauge display. —
Gauge
10-12
Item Procedures See

Check that the steering operates smoothly.
9-30
Not smooth → Check the steering arm, swivel bracket, steering
9-40
actuator, helm unit, or related parts.
Check whether the steering responds immediately when the
steering wheel is turned. 9-30
Slow response → Check the steering control system components 9-40
for tightness, looseness, and wear.
SBW
Check the steering control system components.
9-30
Looseness → Tighten.
9-40
Worn/corroded → Replace.
Check the trouble code using the YDIS.
Trouble code is detected → Perform the troubleshooting proce- 4-15
dures.
Check the wire harness coupler and lead coupler. —
10-13
Checking the engine idle speed

1. Check:
• Engine idling speed
1
Out of specification → Perform the trouble-
shooting procedures. See “Troubleshoot-
ing procedure” (4-11).
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the engine idle speed using the
YDIS. See the YDIS (Ver. 2.33 or later) in-
struction manual.
Idle speed (in neutral) b. Remove the dipstick “1” and extract the
650–750 r/min engine oil using the oil changer “2”.
1
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2
Changing the engine oil using an oil
changer
Change the engine oil after the first 20

hours of operation or 3 months, and every
100 hours or at 1-year intervals thereafter.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1. Warm up:
• Engine 4. Fill:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Engine oil
a. Place the outboard motor in an upright po- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
sition. a. Fill the engine with the specified amount of
the recommended engine oil through the
oil filler hole. Install the oil filler cap and dip-
If the outboard motor is not level, the oil lev- stick.
el indicated on the dipstick may not be cor-
rect.
Do not overfill the engine with engine oil.
Otherwise, the engine could be damaged or
b. Start the engine and warm it up for 5–10 oil could leak. If the engine oil is above the
minutes. upper level, extract the excess engine oil
until the oil is at the proper level.
c. Stop the engine and leave it off for 5–10
minutes.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Engine oil quantity (without oil fil-
ter replacement)
2. Remove: 7.5 L (7.93 US qt, 6.60 Imp.qt)
• Top cowling
b. Leave the outboard motor off for 5–10 min-
3. Drain:
utes.
• Engine oil
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the oil filler cap “1”. c. Remove the dipstick “1” and wipe it clean.
d. Insert the dipstick “1” completely for a cor-

rect measurement and remove it again.
10-14
e. Check that the oil level indicated on the
dipstick “1” is between the upper mark “a”
and the lower mark “b”.
b
1
f. Start the engine and check that the oil

pressure alert indicator does not come on.
Also, check that there is no oil leakage.
2
If the oil pressure alert indicator comes on 3. Remove:
or if there is oil leakage, stop the engine • Rubber seal “1”
and find the cause. Continued operation • Bottom cowlings “2”, “3”
with a problem could cause severe engine
damage. TIP:
Although the bolts (M6 × 25 mm) “4” will remain
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ in the bottom cowlings when the bolts are loos-
Changing the engine oil by removing ened, make sure that the bolts (M6 × 14 mm)
“5” do not fall from the bottom cowlings be-
the drain bolt
cause those bolts are removed.
Change the engine oil after the first 20 5 3

hours of operation or 3 months, and every
100 hours or at 1-year intervals thereafter.
1. Warm up:
• Engine
See step 1 in “Changing the engine oil us- 5
1
ing an oil changer” (10-14).
2. Remove:
• Top cowling
• Bottom cowling cover “1” 4
• Apron cover “2”
2
4. Remove:
• Apron (PORT) “1”
10-15
7. Install:
• Oil strainer “1”
• Circlip “2”
• Drain bolt “4”
1
2
4
1 3
E
5. Drain:
• Engine oil Drain bolt
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
60 N·m (6.1 kgf·m, 44 lb·ft)
a. Remove the oil filler cap “1”.
T.
R.
8. Fill:
• Recommended engine oil
1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the engine with the specified amount of
oil filler hole. Install the oil filler cap.

b. Place a drain pan “1” under the engine oil oil could leak. If the engine oil is above the
drain hole. upper level, extract the excess engine oil
c. Remove the drain bolt “2”, O-ring “3”, cir-
clip “4”, and oil strainer “5” and let the oil
Engine oil quantity (without oil fil-
drain completely.
ter replacement)
7.5 L (7.93 US qt, 6.60 Imp.qt)
b. Leave the outboard motor off for 5–10 min-

5
3 4 utes.
2
c. Remove the dipstick “1” and wipe it clean.
1
d. Insert the dipstick “1” completely for a cor-
rect measurement and remove it again.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ e. Check that the oil level indicated on the

6. Check: dipstick “1” is between the upper mark “a”
• Oil strainer and the lower mark “b”.
See “Checking the oil pan and oil strainer”
(9-27).
10-16
1 3 a 2 2
a
1 b
3
b
f. Start the engine and check that the oil

pressure alert indicator does not come on.
Also, check that there is no oil leakage.
1
Replacing the oil filter

If the oil pressure alert indicator comes on
1. Warm up:
or if there is oil leakage, stop the engine
• Engine
and find the cause. Continued operation
See step 1 in “Changing the engine oil us-
with a problem could cause severe engine
ing an oil changer” (10-14).
damage.
2. Remove:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Top cowling
9. Install: • Bottom cowling cover
• Apron (PORT) “1” • Apron cover
• Rubber seal
• Bottom cowlings
• Apron (PORT)
See steps 2–4 in “Changing the engine oil
by removing the drain bolt” (10-15).
3. Drain:
• Engine oil
See step 3 in “Changing the engine oil us-
ing an oil changer” (10-14) or step 5 in
“Changing the engine oil by removing the
1 drain bolt” (10-15).
TIP:
If the engine oil was changed by removing the
10. Install:
drain bolt, install the drain bolt. See step 7 in
• Bottom cowlings “1”, “2”
“Changing the engine oil by removing the drain
bolt” (10-15).
• Top cowling
TIP: 4. Replace:
Align the seam “a” of the rubber seal “3” with • Oil filter
the mating surface “b” of the bottom cowling. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a rag under the oil filter, and then re-
move the oil filter.
10-17
TIP: Engine oil quantity (with oil filter

Make sure to clean up any oil spills. replacement)
7.8 L (8.24 US qt, 6.86 Imp.qt)
b. Install the oil filler cap and dipstick, and

1 then start the engine and warm it up for 5–
10 minutes.
c. Stop the engine, and then leave it off for 5–

10 minutes.
d. Check the oil level.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Oil filter wrench “1” 6. Install:

90890-06874 • Apron (PORT)
Oil filter wrench “1” • Bottom cowlings
YB-06874 • Rubber seal
• Apron cover
b. Install a new oil filter “1”. • Bottom cowling cover
• Top cowling
See steps 9–10 in “Changing the engine
oil by removing the drain bolt” (10-15).
Changing the gear oil using an oil

changer
1
E If the outboard motor cannot be tilted up 60° or
more due to the boat on which the outboard
motor is mounted, this method cannot be used
to change the gear oil. Use the usual method
Oil filter “1” for changing the gear oil, or place the outboard
18 N·m (1.8 kgf·m, 13 lb·ft) motor in an upright position and fill the lower
T.
R.
unit with the specified gear oil quantity.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1. Remove:
• Top cowling
5. Fill:
• Recommended engine oil 2. Drain:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Gear oil
a. Fill the engine with the specified amount of
2,3 1
oil filler hole. Install the oil filler cap.

oil could leak. If the engine oil is above the
upper level, extract the excess engine oil
4
10-18
d. Connect the oil socket “1” that is connect-
Gear oil attachment kit “1”
ed to the oil changer to the quick connector
90890-06963
“2” with the “OIL” mark and connect the air
Oil socket “2”
socket “3” to the quick connector “4” with
90890-06964
the “AIR” mark.
Air socket “3”
90890-06965 e. Extract the gear oil using the oil changer.
Joint “4”
90890-06966
After the gear oil has been drained, check
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
the used oil. If the oil is milky, water is get-
a. Fully tilt the outboard motor up, and then
ting into the lower case, which can cause
gear damage.
1 1
3 4
AIR
L
OI
b. Remove the bands “1”. 1 2
1 f. Disconnect oil socket and air socket by

wrapping a rag around the socket, and
then sliding the portion “a” of the socket in
the direction of the arrow.
TIP:
Make sure to clean up any oil spills.
c. Connect the oil socket “1”, hose “2”, and oil

changer “3”.
AIR
TIP:
A hose with an inner diameter of 6 mm (0.24 in)
L
OI
or more is recommended.
2 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Fill:
• Gear oil
3 2 1
10-19
2,3 1 TIP:
Place a container under the end of the hose “5”
that is connected to the air socket “3” to catch
the oil.
5 3 4
AIR
Gear oil attachment kit “1”
90890-06963
OIL
Oil socket “2”
90890-06964
Air socket “3” 1 2
90890-06965
d. Fill the lower unit slowly with gear oil until
Joint “4”
oil “a” flows out of the air socket “1”.
90890-06966
a 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the oil socket “1”, hose “2”, joint
“3”, and gear oil pump “4”.
AIR
TIP:
A hose with an inner diameter of 6 mm (0.24 in)
OIL
or more is recommended.
b. Connect the air socket “5” to a clear hose

“6”. Gear oil quantity (regular rotation
model)
5 1.950 L (2.061 US qt, 1.716
6 3 2 1 Imp.qt)
Gear oil quantity (counter rotation
model)
1.830 L (1.934 US qt, 1.610
Imp.qt)
6 5
e. Release the tilt support lever, and then tilt
the outboard motor down 10° to release
the pressure in the lower case.
TIP:
4 3 2 1 Leave the outboard motor in this position until
gear oil “a” stops flowing out of the oil socket
c. Connect the oil socket “1” that is connect-
“1”.
ed to the gear oil pump to the quick con-
nector “2” with the “OIL” mark and connect
the air socket “3” to the quick connector “4”
with the “AIR” mark.
10-20
1 1
AIR
a
OIL
2
1 2
10
2. Drain:
• Gear oil
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Tilt the outboard motor so that the drain
f. Disconnect oil socket and air socket by screw is at the lowest point.
wrapping a rag around the socket, and
b. Place a drain pan “1” under the gear oil
then sliding the portion “a” of the socket in
drain hole.
the direction of the arrow.
c. Remove the drain screw “2” and O-ring “3”.
TIP:
Make sure to clean up any oil spills.
If there is a significant amount of metal par-
a ticles on the magnetic drain screw, the low-
er unit may have a problem.
AIR
d. Remove the oil level plug “4” and O-ring

“5” and let the oil drain completely.
OIL
After the gear oil has been drained, check

the used oil. If the oil is milky, water is get-
g. Install the hose fitting assemblies onto the ting into the lower case, which can cause
hose holder, and then install the bands. gear damage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install: e. After the gear oil has been drained, check

• Top cowling the used oil. Pressure test the lower case
and inspect the oil seal for damage if the oil
Changing the gear oil by removing the is milky. See “Checking the lower unit for
drain screw leakage” (8-7).
Never get under the lower unit while it is tilt-

ed.
1. Remove:
• Upper water inlet covers “1”
• Lower water inlet covers “2”
10-21
4 5
1
2 3 1 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Drain screw “2”
Oil level plug “2”
TIP: 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
T.
R.
Before installing the magnetic drain screw,
make sure to remove all metal particles.
Gear oil quantity (regular rotation
model)
4. Remove: 1.950 L (2.061 US qt, 1.716
• Oil filler plug “3” Imp.qt)
• O-ring “4” Gear oil quantity (counter rotation
model)
1.830 L (1.934 US qt, 1.610
Imp.qt)
3 4 d. Remove the gear oil pump, and then install

a new O-ring “1” and the oil filler plug “2”.
1
2
Drain screw “2”

3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
T.
R.
1
5. Fill:
• Gear oil 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the outboard motor in an upright po- Oil filler plug “2”
sition. 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
T.
R.
b. Insert the gear oil pump into the filler hole, ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
and then fill the lower unit slowly with gear
6. Install:
oil until oil flows out of the check hole and
• Upper water inlet covers “1”
no air bubbles are visible.
• Lower water inlet covers “2”
c. Install a new O-ring “1” and the oil level
plug “2”.
10-22
1 2
Upper water inlet cover bolt

3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
T.
R.
Lower water inlet cover bolt

3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
Greasing points
1. Apply:
• Specified lubrication points
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply water resistant grease to the speci-
fied lubrication points.
b. Apply corrosion resistant grease to the

specified lubrication point.
10-23
TIP:
• If the fluid is at the proper level, a small
amount of fluid should flow out of the filler
hole when the reservoir cap is removed.
• If the fluid is below the proper level, add the
recommended fluid.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the PTT fluid level
2
Never get under the outboard motor while it 1
is tilted.
1. Check:
c. Install a new O-ring and the reservoir cap.
• PTT fluid level
Below the proper level → Add the recom- Reservoir cap
mended fluid. 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fully tilt the outboard motor up, and then ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the PTT unit operation
1 1 1. Check:
• PTT unit operation
PTT operation is not smooth → Check the
PTT fluid level.
See “Checking the PTT fluid level” (10-24).
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fully tilt the outboard motor up and down a
few times and check that it tilts up and
down smoothly.
b. Remove the reservoir cap “1” and O-ring b. Check the PTT motor makes a winding
“2”, and then check the fluid level in the sound when it is operating smoothly.
reservoir. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
Before removing the reservoir cap, make • Tilt support lever
sure that the PTT ram is fully extended. Tilt support lever does not lock in place
Otherwise, fluid could be expelled forceful- properly → Check the related parts.
ly from the unit due to internal pressure. See “Clamp bracket and swivel bracket”
(9-40).
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fully tilt the outboard motor up, and then
10-24
1 A B
1
a a
2
1
2
b
b
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ A. Front
3. Check: B. PORT and STBD
• Fluid leakage
c. Tighten the cowling stopper nut.
See “PTT motor” (9-50), “PTT gear pump” Cowling stopper nut
(9-55), or “PTT cylinder” (9-60). 19 N·m (1.9 kgf·m, 14 lb·ft)
T.
R.
Checking the top cowling fitting d. Recheck the fitting. Replace the rubber
1. Check: seal if looseness or rattling cannot be ad-
• Top cowling fitting justed.
Looseness or rattling → Adjust or replace ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
the top cowling stopper.
TIP:
Check the fitting by pushing the top cowling.
Adjust if there is looseness or rattling.
2. Adjust:
• Top cowling fitting
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the cowling stopper nut “1”.
b. Move the stopper “2” up or down slightly to

adjust its position.
TIP:
• To loosen the fitting, move the stopper in di-
rection “a”.
• To tighten the fitting, move the stopper in di-
rection “b”.
10-25
Appendix
Specification .......................................................................A-1
Model data.................................................................................. A-1
Electrical system technical data ................................................. A-2
Fuel system technical data......................................................... A-4
Power unit technical data ........................................................... A-5
Lower unit technical data............................................................ A-7
Bracket unit technical data ......................................................... A-8
Wiring diagram ...................................................................A-9

How to use the wiring diagram ................................................... A-9
Engine control unit.................................................................... A-10
Fuel unit.................................................................................... A-12
Ignition unit ............................................................................... A-14
Charging unit and starting unit ................................................. A-16
PTT unit and steering unit ........................................................ A-18
Rectifier/regulator continuity table.................................A-20
Shim selection table and chart

(regular rotation model)...................................................A-22
Pinion shim (T3) selection table ............................................... A-22
Forward gear shim (T1) selection table.................................... A-22
Reverse gear shim (T2) selection chart ................................... A-23
Propeller shaft shim (T4) selection chart.................................. A-24
Shim selection table and chart

(counter rotation model)..................................................A-25
Pinion shim (T3) selection table ............................................... A-25
Propeller shaft shim (T4) selection table .................................. A-25
Forward gear shim (T2) selection chart.................................... A-25
Reverse gear shim (T1) selection table.................................... A-26
A
Model XF425/F425A XF425/FL425A XF375/F375A XF375/FL375A
Specification Maximum generator out-
90 A
put
Model data
Maximum charging
Dimension and weight 72 A
capacity
Spark plug (NGK) ILMAR7E-9
Overall length 1217 mm (47.9 in)
Firing order 1-2-7-3-4-5-6-8
Overall width 652 mm (25.7 in)
Steering system Remote steering
Overall height X 2059 mm (81.1 in)
Cooling system Water
Overall height U 2186 mm (86.1 in)
Exhaust system Through propeller boss
Overall height E 2313 mm (91.1 in)
Lubrication system Wet sump
Motor transom height X 640 mm (25.2 in)
Motor transom height U 767 mm (30.2 in)
Motor transom height E 894 mm (35.2 in) Lower unit
Dry weight (SUS) X 442 kg (974 lb) Gear shift positions Forward-neutral-reverse
Dry weight (SUS) U 453 kg (999 lb) Gear ratio 1.79 (25/14)
Dry weight (SUS) E 463 kg (1021 lb) Gear type Spiral bevel gear
* Dry weight: With SUS (stainless steel) propeller Clutch type Dog clutch
Propeller fitting mecha-
Spline
Performance nism
Rated power 316.9 kW (425 HP) 279.6 kW (375 HP) Propeller direction (rear Counterclock- Counterclock-
Clockwise Clockwise
view) wise wise
Full throttle operating
5000–6000 r/min Propeller mark Y YL Y YL
range
142.0 L/h at 6000 r/min (37.5 US 121.0 L/h at 6000 r/min (31.9 US
Maximum fuel consump-
gal/h at 6000 r/min, 31.2 Imp.gal/h gal/h at 6000 r/min, 26.6 Imp.gal/h Bracket unit
tion (reference data)
at 6000 r/min) at 6000 r/min) Trim angle -4 ~ +16 °
Idle speed (in neutral) 650–750 r/min Full Tilt-up angle 77 °
Tilt support angle 68 °, 55 °
Power unit Steering angle 31 °
Type 4-stroke DOHC V8 32 valves Trim and tilt system Power trim and tilt
Total displacement 5559 cm³ (339.2 c.i.)
Bore × stroke 96.0 × 96.0 mm (3.78 × 3.78 in) Fuel and oil
Compression ratio 12.2 : 1 Recommended fuel Premium unleaded gasoline
Throttle & shift control Min. research octane
Remote control 94
system number (RON)
Starting system Electric starter Min. pump octane num-
89
Fuel system Fuel injection ber (PON)
Starting carburetion sys- YAMALUBE 4 or 4-stroke outboard motor oil
Fuel injection
tem Recommended engine (except for USA and CAN)
Ignition system TCI oil YAMALUBE 4M FC-W or 4-stroke outboard motor oil
(for USA and CAN)
Advance type Microcomputer
A-1
Model XF425/F425A XF425/FL425A XF375/F375A XF375/FL375A Electrical system technical data
Recommended engine SAE 10W-30/10W-40/5W-30 Ignition timing control system
oil grade 1 API SG/SH/SJ/SL
Recommended engine SAE 15W-40/20W-40/20W-50
Spark plug
oil grade 2 API SH/SJ/SL
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)
Engine oil quantity (with-
7.5 L (7.93 US qt, 6.60 Imp.qt) Ignition coil
out oil filter replacement)
Engine oil quantity (with Input voltage 12 V
7.8 L (8.24 US qt, 6.86 Imp.qt)
oil filter replacement) Cam position sensor
YAMALUBE outboard gear oil or Hypoid gear oil Input voltage 5V
(except for USA and CAN)
Recommended gear oil Crankshaft position sensor
Yamalube Marine Gearcase Lube HD or Hypoid gear oil
(for USA and CAN) Input voltage 5V
Recommended gear oil Intake air pressure/temperature sensor

SAE 80W API GL-5 / SAE 90 API GL-5
grade Input voltage 5V
1.950 L (2.061 1.830 L (1.934 1.950 L (2.061 1.830 L (1.934 Output voltage at -20.0
Gear oil quantity US qt, 1.716 US qt, 1.610 US qt, 1.716 US qt, 1.610 kPa (-0.20 kgf/cm², -2.9 0.79 V
Imp.qt) Imp.qt) Imp.qt) Imp.qt) psi)
* Recommended engine oil and gear oil grade: Meeting both API and SAE requirements. Output voltage at -46.7
kPa (-0.47 kgf/cm², -6.8 1.84 V
psi)
Battery requirement
Resistance at 0 °C
Battery rating 5.4–6.6 kΩ
700 A (32 °F)
(CCA/SAE)
Resistance at 80 °C
900 A (176 °F)
(MCA/ABYC)
Engine temperature sensor
Battery rating (RC/SAE) 170 minutes
Input voltage 5V
Battery rating (CCA/EN) 670 A
110 Ah (68 °F) (reference data)
(20HR/IEC)
Battery cable length 3.55 m (11.6 ft) 0.21–0.22 kΩ
(212 °F) (reference data)
Battery cable conductor Thermo sensor
60 mm² (AWG 2/0)
cross sectional area
Input voltage 5V
PTT system 2.25–2.65 kΩ
(68 °F)
ATF Dexron II (except for USA and CAN) Resistance at 80 °C
Recommended fluid Yamalube Marine Power Trim and Tilt fluid or ATF Dexron II (for USA 0.31–0.33 kΩ
(176 °F)
and CAN)
Knock sensor
Resistance 504–616 kΩ
A-2
Fuel injection control system Model XF425/F425A XF425/FL425A XF375/F375A XF375/FL375A
Model XF425/F425A XF425/FL425A XF375/F375A XF375/FL375A Throttle valve opening
Water detection switch angle at throttle valve
80.7 °
fully open (reference
Input voltage 5V
data)
Fuel injector
Input voltage 5V
Resistance (reference
1.74–2.04 Ω SPS
data)
Output voltage at gear
shift in the F position 1.170 V
Resistance (reference (reference data)
0.6 Ω
data)
Output voltage at gear
High-pressure fuel pump shift in the N position 2.540 V
Input voltage 12 V (reference data)
Resistance (reference Output voltage at gear
0.3 Ω shift in the R position 3.780 V
data)
(reference data)
Input voltage 5V
Resistance (reference
0.45–0.55 Ω Oil pressure sensor
data)
Fuel pressure sensor (high-pressure fuel pump) Input voltage 5V
Input voltage 5V Output voltage at 392
kPa (3.92 kgf/cm², 56.8 2.5 V
Fuel pressure sensor (direct injection pump)
psi)
Input voltage 5V
Output voltage at 784
kPa (7.84 kgf/cm², 113.7 4.5 V
Engine speed control system psi)
TPS
TPS 1 output voltage at VCT system
throttle valve fully closed 0.850 V OCV
(reference data)
Input voltage 12 V
TPS 2 output voltage at
Resistance 6.7–7.7 Ω
throttle valve fully closed 2.840 V
(reference data)
throttle valve fully open 4.340 V
(reference data)
throttle valve fully open 4.640 V
(reference data)
Throttle valve opening
angle at throttle valve
7.5 °
fully closed (reference
data)
A-3
Shift system Y-COP
Model XF425/F425A XF425/FL425A XF375/F375A XF375/FL375A Model XF425/F425A XF425/FL425A XF375/F375A XF375/FL375A
Shift actuator Receiver
Rod stroke at gear shift Input voltage 12 V
in the F position 62.0 mm (2.44 in) Buzzer
(reference data)
Input voltage 12 V
Rod stroke at gear shift
Button cell battery - CR2016
in the N position 82.0 mm (3.23 in)
(reference data) Battery voltage
3V
(reference data)
Rod stroke at gear shift
in the R position 41.0 mm (1.61 in)
(reference data) Gauge/sensor
Motor resistance Water pressure sensor
1.2 Ω
(reference data)
Input voltage 5V
Output voltage at 392
PTT system kPa (3.92 kgf/cm², 56.8 2.5 V
PTT sensor psi) (reference data)
Input voltage 5V Output voltage at 784
Output voltage at tilt sup- kPa (7.84 kgf/cm², 113.7 4.5 V
port lever upper position 4.07 V psi) (reference data)
(reference data)
Output voltage at tilt sup- Fuel system technical data
port lever lower position 3.57 V
Fuel system
(reference data)
Fuel line
Output voltage at full
0.93 V Fuel pressure at engine
trim-down position
idle speed
330–400 kPa (3.3–4.0 kgf/cm², 47.9–58.0 psi)
(high-pressure fuel
Charging system
pump)
Lighting coil Fuel pressure at engine
Resistance (reference idle speed 8.00 Mpa (80.0 kgf/cm², 1160.0 psi)
0.0904–0.1356 Ω
data) (direct injection pump)
Primer pump
Starting system Positive pressure 166.7 kPa (1.67 kgf/cm², 24.2 psi)
Starter motor Feed valve (low-pressure fuel pump)
Type Sliding gear Holding pressure
200.0 kPa (2.00 kgf/cm², 29.0 psi)
Output 2.00 kW (positive pressure)
Cranking time limit 30 sec Relief valve (low-pressure fuel pump)
Standard brush length 18.0 mm (0.71 in) Opening pressure
72.5–93.5 kPa (0.73–0.94 kgf/cm², 10.5–13.6 psi)
(positive pressure)
Wear limit 11.0 mm (0.43 in)
Holding pressure
Standard commutator 200.0 kPa (2.00 kgf/cm², 29.0 psi)
32.0 mm (1.26 in) (positive pressure)
diameter
A-4
Fuel strainer Timing belt
Holding pressure Installation height (bot-
300.0 kPa (3.00 kgf/cm², 43.5 psi)
(positive pressure) tom of drive sprocket
3.25 mm (0.1280 in)
Relief valve (high-pressure fuel pump) [crankshaft] to bottom of
timing belt)
Holding pressure
490.0 kPa (4.90 kgf/cm², 71.1 psi) Installation height (top of
(positive pressure)
driven sprocket to top of 0.75 mm (0.0295 in)
Opening pressure
445.0–455.0 kPa (4.45–4.55 kgf/cm², 64.5–66.0 psi) timing belt)
(positive pressure)
Installation height (top of
Feed valve (high-pressure fuel pump)
belt tensioner to top of 6.75 mm (0.2657 in)
Holding pressure timing belt)
490.0 kPa (4.90 kgf/cm², 71.1 psi)
(positive pressure)
Opening pressure Cylinder head assembly
9.3–12.6 kPa (0.09–0.13 kgf/cm², 1.3–1.8 psi)
(positive pressure)
Cylinder head
Warpage limit 0.10 mm (0.0039 in)
Fuel inlet holding pres-
200.0 kPa (2.00 kgf/cm², 29.0 psi) Journal inside diameter 25.000–25.021 mm (0.9843–0.9851 in)
sure (positive pressure)
Fuel outlet holding pres- Camshaft journal oil
-80.0 kPa (-0.80 kgf/cm², -11.6 psi) 0.020–0.061 mm (0.0008–0.0024 in)
sure (negative pressure) clearance
Limit 0.080 mm (0.0032 in)
Cam chain
Power unit technical data
Chain length 114.33–114.58 mm (4.5012–4.5110 in)
Power unit
Limit 114.85 mm (4.5216 in)
Compression pressure
Cam chain tensioner
Minimum (reference
947.9 kPa (9.48 kgf/cm², 137.4 psi) Maximum wear depth 1.00 mm (0.0394 in)
data)
Camshaft
* For the checking method, see “Checking the oil pressure” (7-1). The figures are for reference
only. Cam lobe height IN 47.011–47.111 mm (1.8508–1.8548 in)
Engine oil Limit 46.961 mm (1.8489 in)
Engine oil pressure at Cam lobe height EX 46.600–46.700 mm (1.8346–1.8386 in)
idle speed (reference 　 492.0 kPa (4.92 kgf/cm², 71.3 psi) Limit 46.550 mm (1.8327 in)
data)
Journal diameter 24.960–24.980 mm (0.9827–0.9835 in)
Engine oil pressure at
Runout 0.030 mm (0.0012 in)
3000 r/min (reference 676.0 kPa (6.76 kgf/cm², 98.0 psi)
data) Fuel pump cam width
across corner (direct 49.350–49.450 mm (1.9429–1.9468 in)
Thermostat
injection pump)
Valve opening tempera-
58–62 ° C (136–144 ° F) Valve clearance
ture
Valve clearance IN
Fully open temperature 70 ° C (158 ° F) 0.17–0.24 mm (0.0067–0.0094 in)
(cold engine)
Fully open stroke 3.0 mm (0.12 in) (oil cooler and water jacket)
Valve clearance EX
Fully open stroke 5.0 mm (0.20 in) (cylinder block) 0.37–0.44 mm (0.0146–0.0173 in)
(cold engine)
A-5
Model XF425/F425A XF425/FL425A XF375/F375A XF375/FL375A Crankcase assembly
Valve Model XF425/F425A XF425/FL425A XF375/F375A XF375/FL375A
Margin thickness IN 0.50–0.90 mm (0.0197–0.0354 in) Cylinder
Margin thickness EX 0.90–1.30 mm (0.0354–0.0512 in) Bore 96.000–96.012 mm (3.7795–3.7800 in)
Seat contact width IN 1.10–1.40 mm (0.0433–0.0551 in) Limit 96.072 mm (3.7824 in)
Limit 1.850 mm (0.0728 in) Piston
Seat contact width EX 1.40–1.70 mm (0.0551–0.0669 in) Diameter 95.945–95.960 mm (3.7774–3.7779 in)
Limit 2.150 mm (0.0846 in) Limit 95.905 mm (3.7758 in)
Valve lifter Measuring point 14.5 mm (0.57 in)
Outside diameter 30.964–30.980 mm (1.2191–1.2197 in) Piston clearance 0.040–0.067 mm (0.0016–0.0026 in)
Clearance IN (reference Limit 0.167 mm (0.0066 in)
0.020–0.061 mm (0.0008–0.0024 in)
data) Ring groove (Top) 1.22–1.25 mm (0.0480–0.0492 in)
Clearance EX (reference Ring groove (2nd) 1.22–1.24 mm (0.0480–0.0488 in)
0.020–0.061 mm (0.0008–0.0024 in)
data)
Ring groove (Oil) 2.51–2.53 mm (0.0988–0.0996 in)
Valve stem
Pin boss inside diameter 22.011–22.018 mm (0.8666–0.8668 in)
Diameter IN 5.477–5.492 mm (0.2156–0.2162 in)
Limit 22.038 mm (0.8676 in)
Limit 5.447 mm (0.2144 in)
Pin outside diameter 21.996–22.005 mm (0.8660–0.8663 in)
Diameter EX 5.464–5.479 mm (0.2151–0.2157 in)
Limit 21.986 mm (0.8656 in)
Limit 5.434 mm (0.2139 in)
Piston ring (Top)
Runout limit IN 0.01 mm (0.0004 in)
Type Barrel
Runout limit EX 0.01 mm (0.0004 in)
Height (B) 1.170–1.185 mm (0.0461–0.0467 in)
Valve guide
Width (T) 2.800–3.000 mm (0.1102–0.1181 in)
Inside diameter IN 5.504–5.522 mm (0.2167–0.2174 in)
End gap 0.20–0.30 mm (0.0079–0.0118 in)
Clearance IN 0.012–0.045 mm (0.0005–0.0018 in)
Limit 0.470 mm (0.0185 in)
Limit 0.070 mm (0.0028 in)
Side clearance 0.03–0.08 mm (0.0014–0.0032 in)
Inside diameter EX 5.504–5.522 mm (0.2167–0.2174 in)
Limit 0.130 mm (0.0051 in)
Clearance EX 0.025–0.058 mm (0.0010–0.0023 in)
Piston ring (2nd)
Limit 0.080 mm (0.0032 in)
Type Taper
Installation height 11.30–11.70 mm (0.4449–0.4606 in)
Height (B) 1.170–1.190 mm (0.0461–0.0469 in)
Valve spring
Width (T) 3.800–4.000 mm (0.1496–0.1575 in)
Free length IN 48.08 mm (1.89 in)
End gap 0.60–0.75 mm (0.0236–0.0295 in)
Limit 45.68 mm (1.80 in)
Limit 0.900 mm (0.0354 in)
Tilt limit IN 1.7 mm (0.07 in)
Free length EX 48.08 mm (1.89 in)
Limit 0.110 mm (0.0043 in)
Limit 45.68 mm (1.80 in)
Tilt limit EX 1.7 mm (0.07 in)
A-6
Piston ring (Oil) Available shim thicknesses
Height (B) 2.410–2.470 mm (0.0949–0.0972 in) 0.10/0.12/0.15/ 0.10/0.12/0.15/
Width (T) 2.350–2.750 mm (0.0925–0.1083 in) Pinion shims 0.18/0.30/0.40/ — 0.18/0.30/0.40/ —
0.50 mm 0.50 mm
End gap 0.15–0.60 mm (0.0059–0.0236 in)
2.00/2.03/2.06/ 2.00/2.03/2.06/
Forward shims 2.09/2.12/2.15/ — 2.09/2.12/2.15/ —
Connecting rod 2.18/2.21 mm 2.18/2.21 mm
Small end inside diame- 0.10/0.12/0.15/ 0.10/0.12/0.15/
22.008–22.025 mm (0.8665–0.8671 in)
ter Reverse shims 0.18/0.30/0.40/ — 0.18/0.30/0.40/ —
Big end inside diameter 65.990–66.010 mm (2.5980–2.5988 in) 0.50 mm 0.50 mm
Big end side clearance 0.140–0.310 mm (0.0055–0.0122 in) 0.10/0.12/0.15/ 0.10/0.12/0.15/
Limit 0.36 mm (0.0142 in) Propeller shaft shims 0.18/0.30/0.40/ — 0.18/0.30/0.40/ —
0.50/1.00 mm 0.50/1.00 mm
Big end oil clearance 0.026–0.049 mm (0.0010–0.0019 in)
Propeller shaft
Limit 0.079 mm (0.0031 in)
0.4–1.0 N·m 0.4–1.0 N·m
Crankshaft
(0.04–0.10 (0.04–0.10
Journal diameter 72.976–72.996 mm (2.8731–2.8739 in) Motive torque — —
kgf·m, 0.30– kgf·m, 0.30–
Crankshaft pin diameter 62.980–63.000 mm (2.4795–2.4803 in) 0.73 lb·ft) 0.73 lb·ft)
Runout 0.03 mm (0.0012 in) 0.02 mm 0.02 mm
Runout — —
Limit 0.04 mm (0.0016 in) (0.0008 in) (0.0008 in)
Crankshaft pin width 21.00–21.10 mm (0.8268–0.8307 in) Drive shaft
Journal oil clearance 0.029–0.053 mm (0.0011–0.0021 in) 0.3–3.0 N·m 0.3–3.0 N·m
(0.03–0.30 (0.03–0.30
Limit 0.073 mm (0.0029 in) Motive torque — —
kgf·m, 0.22–2.2 kgf·m, 0.22–2.2
lb·ft) lb·ft)
Lower unit technical data Runout
1.0 mm (0.039
—
1.0 mm (0.039
—
Lower unit assembly (regular rotation model) in) in)
Lower unit
68.6 kPa (0.69 68.6 kPa (0.69 Lower unit assembly (counter rotation model)
Holding pressure — —
kgf/cm², 9.9 psi) kgf/cm², 9.9 psi) Lower unit
Gear backlash 68.6 kPa (0.69 68.6 kPa (0.69
Holding pressure — —
0.13–0.50 mm 0.13–0.50 mm kgf/cm², 9.9 psi) kgf/cm², 9.9 psi)
Forward gear backlash (0.0051–0.0197 — (0.0051–0.0197 — Gear backlash
in) in) 0.20–0.61 mm 0.20–0.61 mm
0.39–0.83 mm 0.39–0.83 mm Forward gear backlash — (0.0079–0.0240 — (0.0079–0.0240
Reverse gear backlash (0.0154–0.0327 — (0.0154–0.0327 — in) in)
in) in) 0.40–0.81 mm 0.40–0.81 mm
* Figures obtained using the special service tools. Reverse gear backlash — (0.0157–0.0319 — (0.0157–0.0319
in) in)
* Figures obtained using the special service tools.
A-7
Available shim thicknesses Motor
0.10/0.12/0.15/ 0.10/0.12/0.15/ Standard commutator
28.00 mm (1.1024 in)
Pinion shims — 0.18/0.30/0.40/ — 0.18/0.30/0.40/ diameter
0.50 mm 0.50 mm Wear limit 27.00 mm (1.0630 in)
0.10/0.12/0.15/ 0.10/0.12/0.15/ Standard commutator
Forward shims — 0.18/0.30/0.40/ — 0.18/0.30/0.40/ 2.00 mm (0.0787 in)
undercut
0.50 mm 0.50 mm
2.00/2.03/2.06/ 2.00/2.03/2.06/
Standard brush length 12.00 mm (0.4724 in)
Reverse shims — 2.09/2.12/2.15/ — 2.09/2.12/2.15/
2.18/2.21 mm 2.18/2.21 mm Wear limit 4.3 mm (0.17 in)
0.10/0.12/0.15/ 0.10/0.12/0.15/
Propeller shaft shims — 0.18/0.30/0.40/ — 0.18/0.30/0.40/
0.50 mm 0.50 mm
Propeller shaft
0.42–0.52 mm 0.42–0.52 mm
Free play — (0.0165–0.0205 — (0.0165–0.0205
in) in)
0.02 mm 0.02 mm
Runout — —
(0.0008 in) (0.0008 in)
Drive shaft
0.3–3.0 N·m 0.3–3.0 N·m
(0.03–0.30 (0.03–0.30
Motive torque — —
kgf·m, 0.22–2.2 kgf·m, 0.22–2.2
lb·ft) lb·ft)
1.0 mm (0.039 1.0 mm (0.039
Runout — —
in) in)
Bracket unit technical data

PTT system
Hydraulic pressure
Up 15.00 Mpa (150.0 kgf/cm², 2175.0 psi)
Down 7.70 Mpa (77.0 kgf/cm², 1116.5 psi)
Electric current
Up 69–93 A
Down 43–59 A
A-8
Wiring diagram
Wiring diagram
How to use the wiring diagram
Composition of the wiring diagrams
The wiring diagram consists of five categories: “Engine control unit”, “Fuel unit”, “Ignition unit”,
“Charging unit and starting unit”, and “PTT unit and steering unit”.
Legend symbols in the wiring diagrams

1 2 3
4 5 6
BZ
1. Double-colored wire
2. Not used (vacant)
3. A wire is not included in the selected wiring unit
4. Alert buzzer
5. Optional parts
6. Continuity
Terminal numbers
• Terminal numbers are indicated for cases where terminal locations of wires are unclear.
• In the coupler illustrations, only the rightmost and leftmost terminal numbers are indicated, and termi-
nal numbers between them are omitted.
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
4 1
8 5
12 9
16 13
A-9
2.Electrical management box (fuse box) 851
Engine control unit
L 2
L 3
a b c d e f g h i
w j k l m W 6
W 7
10 7 4
r 4.Joint connector 2
y 12
124 132 80 88 36 44
s t u v x L 11
L 10
115 123 71 79 27 35 W 9
106 114 62 70 18 26 q
97 105 53 61 9 17 W 7
89 96 45 52 1 8 A n o L 5
p L 4
R
4 1
B
B
8 5 W 2
12 9 W 1
16 13
1.Engine ECM
3.Engine battery
1
132
131
127
126
124
122
120
117
116
115
114
111
110
109
108
107
106
105
103
102
101
100
15
14
12
11
10
26
21
18
17
99
97
96
95
90
89
88
82
81
79
74
63
62
59
53
49
48
47
46
45
9
8
7
6
4
3
2
9
8
6
4
3
2
1
5.Joint connector 1
W
L
R
R
W
W
L
Y/G 23
Y/G 22
Y/G 21
R/Y 19
R/Y 18
R/Y 17
R/G 15
R/L 13
Br/W 12
R/Y 10
Y
B
B
Y
B
W/G
B
B
B
B
R/G
W/L
Y/G
Pu
Br/W
G/Y
G/B
B
B
R/L
R/L
W
P/L
L/B
W/B
Or
B
B
B
B
Pu
Or
B
P
W
Y/G
P
R/G
R/Y
R/Y
G/B
G/R
P/L
P/L
W/B
L
W
B
B
B
3
Y/G
G/Or
R/Y 9
7
6
Or
Or
Or
Or
R
R/G
R/L
R
8 1 3 1 6.Bonder 7
16 9 6 4 Or 6
24 17 9 7
Or 1
B 10
7.Bonder 2
B 7
B 15
8.Bonder 1
B 7
B 3
B 2
B 1
B 11
B 10
B 8 9.Bonder 5
B 7
B 6
B 5
B 4
B 3
Or
B 2
B
B Or Or B 1
R/Y
Or
B
G/R
G/B
P/L
R/Y
Or
P/L
B
B
B
Or
Or
P
B
G/Or
W/G
W/B
R/Y 13
W/L
G/B
G/Y
W/B
B
P
B
R/Y
R/Y
P/L
R/Y
L/B
B
B
Or
Or
Pu
Pu
Or
Or
Or
R/Y 12
B
B
B
B
B
B
3 1
6 4 14.ETV
(PORT) (STBD) 10.Bonder 6
17.SPS 13.Oil pressure 12.Water pressure
16.Shift actuator B 15.OCV
sensor sensor
(PORT EX) (PORT IN) (STBD IN)
11.Cam position sensor
R/Y 1
A-10
Wiring diagram
1. Engine ECM
2. Electrical management box (fuse box)
3. Engine battery
4. Joint connector 2
6. BONDER 7
7. BONDER 2
8. BONDER 1
9. BONDER 5
10. BONDER 6
14. ETV
15. OCV
16. Shift actuator
17. SPS
a. Fuse (30A) (high-pressure fuel pump

system)
b. Fuse (10A) (ETV)
c. Fuse (15A) (shift actuator)
d. Fuse (20A) (injector driver)
e. Fuse (20A) (injector driver)
f. Fuse (30A) (main)
g. Fuse (30A) (starter motor)
h. Fuse (20A) (Digital Electronic Control)
i. Fuse (10A) (Digital Electronic Control
ECM)
j. Fuse (70A) (engine battery)
k. Fuse (70A) (engine battery)
l. Fuse (70A) (house battery)
m. Fuse (70A) (house battery)
n. Fuse (15A) (high-pressure fuel pump
[main])
o. Fuse (15A) (high-pressure fuel pump
[sub])
p. Fuse (10A) (low-pressure fuel pump)
q. Fuse (100A) (SCU)
r. High-pressure fuel pump relay
s. ETV motor relay
t. Shift actuator relay
u. Injector driver relay
v. Injector driver relay
w. Main relay
x. Starter relay
y. PTT relay
A. To Digital Electronic Control

B. To YDIS
A-11
851
Fuel unit 2.Electrical management box 2
L
124 132 80 88 36 44 (fuse box) a b c d e f g h i L 3
115 123 71 79 27 35
106 114 62 70 18 26 w j k l m
97 105 W 6
53 61 9 17 W 7
89 96 45 52 1 8 A 10 7 4
r y 4.Joint connector 2
4 1 12
8 5
12 9 s t u v x L 11
1.Engine ECM 16 13 L 10
q W 9
127
124
121
117
115
114
105
100
15
14
12
11
10
W
44
43
35
34
25
24
22
20
19
18
16
15
14
13
12
11
10
7
96
95
93
91
88
79
73
72
62
57
56
55
54
53
49
48
47
46
45
n o
9
8
7
6
4
3
2
9
4
3
2
1
L 5
W
L
R
R
W
W
L
L/W
B
B
B
B
B
p
Br/W
R/L
Y/G
B
W
R
R
G
G
R
B
B
R/L
W
G
B
W
Y
Y
B
B
B
B
B
W
B
G
W
Y/G
W
W
W
R/Y
R/Y
L/R
L/R
B
L/Y
L
Y/R
W
W
B
B
L
Or
L 4
B
W 2
18.Injector driver W 1
9 G/B
8 G/Y
7 G/R
5 1 6 G/W 3.Engine battery 1 5.Joint connector 1
10 6
4 R/L
8 1
Y/G 21
Y/R 20
R/Y 18
Y/G 16
R/L 13
Br/W 12
Y/R 11
9
7
6
3
9
8
6
4
2
1
3 R/Y
2 R/B 16 9
R
R/Y
Y/R
R/L
R/B
Y/R
R/B
Y/R
R
R
1 R/W 24 17
3 1 6.Bonder 7
4 B/W 6 4
3 B 9 7
2 W/L Or 4
1 R/B Or 3
Y/R Or 2
8 G Y/R Y/R Or 1
7 R
6 G
4 1 5 R
4 W
8 5 3 B B 12
2 W
1 B B 10
S B
8 G B 8 7.Bonder 2
7 R
4 1 6 G
5 R
8 5 4 W
3 B
2 W
1 B
B 15
4 B/W
3 B
2 W/L
1 R/B
9 G/B B 8 8.Bonder 1
8 G/R
7 G/W B 6
5 1 6 G/Y
10 6
4 R/L
3 R/B
2 R/W
1 R/Y
18.Injector driver
B 11
B 10
G/W
G/W
R/W
R/W
G/R
G/R
G/B
G/Y
G/B
G/Y
R/Y
R/B
R/Y
R/B
R/L
R/L
B 8 9.Bonder 5
B 7
1 4 B 6
4 1 B 5
5 8 B 4
8 5 B 3
5 8
8 5 B 2
Y/R
1 4 B 1
B
B
B
4 1
R/L
R/Y
R/W
R/B
G/B
G/Y
G/W
G/R
R/L
R/Y
R/W
R/B
G/B
G/Y
G/W
G/R
B/W
B/W
W/L
W/L
L/W
Y/R
Y/R
L/R
L/R
R/Y
B
B
B
B
B
B
B
Or
Or
Or
W
W
17.Fuel injector
B
R/Y
Y/R
Y/R
B
B
L/Y
B
15.Water detection 13.Low-pressure (PORT) (STBD)
(PORT) (STBD) switch (sub) (main) fuel pump 11.Direct injection pump 10.Fuel pressure sensor
G/W
G/W
16.Fuel pressure sensor

R/W
R/W
(high-pressure fuel pump)

G/R
14.High-pressure fuel pump 12.Low-pressure

G/B
G/B
G/Y
G/R
G/Y
R/B
R/Y
R/Y
R/B
R/L
R/L
(direct injection pump) fuel pump relay
#7 #5 #3 #1 #8 #6 #4 #2
A-12
Wiring diagram
1. Engine ECM A. To Digital Electronic Control

3. Engine battery
6. BONDER 7
7. BONDER 2
8. BONDER 1
9. BONDER 5
10. Fuel pressure sensor (high-pressure fuel
pump)
12. Low-pressure fuel pump relay
14. High-pressure fuel pump (main), (sub)
16. Fuel pressure sensor (direct injection
pump)
17. Fuel injector
18. Injector driver

system)
b. Fuse (10A) (ETV)
ECM)
[main])
[sub])
s. ETV motor relay
w. Main relay
x. Starter relay
y. PTT relay
A-13
2.Electrical management box (fuse box) 851
Ignition unit 2
L
L 3
a b c d e f g h i
w j k l m W 6
W 7
10 7 4
r 4.Joint connector 2
y 12
124 132 80 88 36 44 s t u v x L 11
115 123 71 79 L 10
B
B
27 35 9
106 114 62 70 18 26 q W
97 105 53 61 9 17
89 96 W 7
45 52 1 8 A n o 5
L
L 4
4 1 p 3.Engine battery
8 5 W 2
12 9 W 1
1.Engine ECM 16 13
1 5.Joint connector 1
128
127
125
124
117
115
114
105
100
15
14
12
11
10
41
40
39
38
37
30
29
28
18
98
96
95
88
87
80
79
77
71
68
67
66
62
53
49
48
47
46
45
9
8
7
6
4
3
2
9
4
3
2
1
W
L
R
R
W
W
L
G/W
Y/G
Br/W
B
B
R/L
R/L
W
B/L
B/L
B/Y
B/Or
B/W
W/B
B
B
B
B
B
B
B
B
B
B
B/W
B/Or
B/R
Y/G
W
Y
B
B
Y
B
R/Y
R/Y
B/Y
B/Y
B/Y
G
L
W
L
B/Y
Or
Or
Y/G 21
R/Y 19
R/Y 18
R/Y 17
R/L 13
Br/W 12
3
9
6
8 1
R
16 9
R/Y
R/L
3 1
R
24 17 6.Bonder 7
6 4
9 7 Or 5
Or 1
B 15
B 14
B 10
7.Bonder 2
B 15
8.Bonder 1
B 5
B 4
B 11
B 8 9.Bonder 4
B 7
B 6
B 5
B 4
G/W
Y/G
W/B
B/Y
B/Y
B/Y
B/Y
B 3
Or
Or
B
B
B
G
B
B
B 2
B/Or
B/Or
B/W
B/W
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
B/Y
R/Y
R/Y
R/Y
B/R
R/Y
R/Y
1
B/L
B
B/L
B
B
B
B
B
B
B
B
(PORT) (STBD)
13
(upper) (lower) 16.Engine 15.Crankshaft
1
2
3
4
5
6
7
8
9
14.Intake air pressure/ 13.Thermo sensor
17.Knock sensor temperature sensor position sensor
temperature sensor
#8 #7 #6 #5 #4 #3 #2 #1 B 11
B 10
12.Ignition coil
11.Bonder 6 B 8 10.Bonder 5
B 7
B 6
B
B
B
B
B 5
B 4
B 3
B 2
B 1
A-14
Wiring diagram
1. Engine ECM
3. Engine battery
6. BONDER 7
7. BONDER 2
8. BONDER 1
9. BONDER 4
10. BONDER 5
11. BONDER 6
12. Ignition coil
13. Thermo sensor
17. Knock sensor

system)
b. Fuse (10A) (ETV)
ECM)
[main])
[sub])
s. ETV motor relay
w. Main relay
x. Starter relay
y. PTT relay
A-15
Charging unit and starting unit
6.Stator assembly
7.Rectifier / regulator 851
R
R
R
R
R
R
2.Electrical management box (fuse box)
G 3 3 B
G 2 2 R
a b c d e f g h i G 1 1 R 10 7 4
W/G
w j k l m G 3 3 B 8.Joint connector 2
R
124 132 80 88 36 44 3.Starter motor G 2 2 R
115 123 71 79 27 35 G 1 1 R
L 2
106 114 62 70 18 26 r L 3
97 105 53 61 9 17 y G 3 3 B
89 96 45 52 1 8 G 2 2 R
A G 1 1 R
s t u v x W 6
W/G
R
W 7
4 1 q
Br/W
B
8 5
12 9
16 13 n o
1.Engine ECM
L 11
p L 10
W 9
124
115
114
105
15
14
12
11
10
B
18
B
B
96
95
88
79
62
60
58
53
49
48
47
46
45
9
8
7
6
4
3
2
9
4
3
2
1
W W 7
L
R
B
R
B
Y
R
B
W
W
L
B
B
W/G
Y/G
Br/W
B
B
R/L
R/L
W
R
B
B
B
B
B
W
R/Y
R/Y
L
W
Br
B
L 5
B
B
B
L 4
W 2
W 1
Y/G 21
R/Y 18
R/L 13
Br/W 12
3
9
3
8 1 9.Joint connector 1
R
R
R/Y
R/L
Br
R
16 9 3 1 4.Engine battery 5.House battery
24 17 12
B
6 4
9 7
R
1
B 11
B 10
B 8
B 7
B 6
B 5
B 4
B 3
B 2
B 1
10.Bonder 5
B
B
B
B
B
B
A-16
Wiring diagram
1. Engine ECM
3. Starter motor
4. Engine battery
5. House battery
6. Stator assembly
10. BONDER 5

system)
b. Fuse (10A) (ETV)
ECM)
[main])
[sub])
s. ETV motor relay
w. Main relay
x. Starter relay
y. PTT relay
A-17
PTT unit and steering unit 851
2.Electrical management box (fuse box)
a b c d e f g h i
w j k l m 10 7 4
4.Joint connector 2
r L 1
y L 2
124 132 80 88 36 44 L 3
115 123 71 79 27 35 s t u v x W 5
106 114 62 70 18 26
B
B
W 6
97 105 53 61 9 17 q W 7
89 96 45 52 1 8
A
n o
4 1 p 3.Engine battery L 12
8 5 L 11
12 9 L 10
1.Engine ECM 16 13 W 9
W 8
W 7
127
124
123
117
115
114
112
105
104
15
14
12
11
10
36
27
18
6
96
95
88
79
62
59
53
49
48
47
46
45
9
8
7
6
4
3
2
9
4
3
2
1
L 5
L 4
B
B
Sb
W
L
R
R
Y
R
W
W
L
Y/G
Br/W
B
B
R/L
R/L
B
B
P
Lg
B
B
B
B
B
Sb
W
R/Y
R/Y
Lg
B
B
B
Or
L
W
L
Y
W 3
Y/G 21
R/Y 18
R/L 13
Br/W 12
9
8
6
5
4
3
2
1
9
6
8 1 3 1 W 2
W 1
R
B
B
L
16 9 6 4
R/Y
R/L
W
Sb
R
R
R
R
Lg
L
24 17 9 7 5.Joint connector 1
12
6.Bonder 2
B 15
B 10
B 9
Y
Y Y
7.Bonder 5
W
W
Y
Y
L
Or
B 11
B 10
Or
P
B
B 8
G
7
L
B
Sb
B 6
Lg
R
B 5
W
W
Y
Y
L
B 4
B
B
B
B
B 3
B
B 2
4 1 4 1 9.PTT switch B 1
Or
P
B
B
B
10.PTT motor
4
3
2
1
4
3
2
1
11.Steering actuator
8.PTT sensor
A-18
Wiring diagram
1. Engine ECM
3. Engine battery
6. BONDER 2
7. BONDER 5
8. PTT sensor
9. PTT switch
10. PTT motor

system)
b. Fuse (10A) (ETV)
ECM)
[main])
[sub])
s. ETV motor relay
w. Main relay
x. Starter relay
y. PTT relay
A-19
Rectifier/regulator continuity table
b a
R W/G
d e
c f
h g
j k
i l
n m
p q
o r
t s
OL: Indicates an overload

Rectifier/regulator for continuity
Tester probe
Display value (reference data)
(+) (–)
“a” All terminals OL
“c” 0
“b”
Except for “c” OL
“b” 0
“c”
Except for “b” OL
“d” All terminals OL
“d” 0.22–0.43
“e”
Except for “d” OL
“d” 0.48–0.69
“f”
“d” 0.22–0.43
“g”
“d” 0.48–0.69
“h” “e”, “f”, and “g” 0.22–0.43
Except for “d”, “e”, “f”, and “g” OL
“i” All terminals OL
A-20
Rectifier/regulator for continuity

Tester probe
Display value (reference data)
(+) (–)
“j” All terminals OL
“j” 0.22–0.43
“k”
Except for “j” OL
“j” 0.22–0.43
“l”
“j” 0.22–0.43
“m”
j 0.48–0.69
“n” “k”, “l”, “m” 0.22–0.43
Except for “j”, “k”, “l”, and “m” OL
“o” All terminals OL
“p” All terminals OL
“p” 0.22–0.43
“q”
Except for “p” OL
“p” 0.22–0.43
“r”
“p” 0.22–0.43
“s”
“p” 0.48–0.69
“t” “q”, “r”, and “s” 0.22–0.43
Except for “p”, “q”, “r”, and “s” OL
A-21
Shim selection table and chart (regular rotation model)
Pinion shim (T3) selection table
The shim thickness does not have to be adjusted for the blue-colored cells.
(mm)
A 0.38 0.39 0.40 0.41 0.42 0.43 0.44 0.45 0.46 0.47 0.48 0.49 0.50 0.51 0.52 0.53 0.54 0.55 0.56 0.57 0.58 0.59 0.60
B +0.37 +0.36 +0.35 +0.34 +0.33 +0.32 +0.31 +0.30 +0.29 +0.28 +0.27 +0.26 +0.25 +0.24 +0.23 +0.22 +0.21 +0.20 +0.19 +0.18 +0.17 +0.16 +0.15
A 0.61 0.62 0.63 0.64 0.65 0.66 0.67 0.68 0.69 0.70 0.71 0.72 0.73 0.74 0.75 0.76 0.77 0.78 0.79 0.80 0.81 0.82 0.83
B +0.14 +0.13 +0.12 +0.11 +0.10 +0.09 +0.08 +0.07 +0.06 +0.05 +0.04 +0.03 +0.02 +0.01 -0.01 -0.02 -0.03 -0.04 -0.05 -0.06 -0.07 -0.08
A 0.84 0.85 0.86 0.87 0.88 0.89 0.90 0.91 0.92 0.93 0.94 0.95 0.96 0.97 0.98 0.99 1.00 1.01 1.02 1.03 1.04 1.05 1.06
B -0.09 -0.10 -0.11 -0.12 -0.13 -0.14 -0.15 -0.16 -0.17 -0.18 -0.19 -0.20 -0.21 -0.22 -0.23 -0.24 -0.25 -0.26 -0.27 -0.28 -0.29 -0.30 -0.31
A 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 1.21 1.22 1.23 1.24 1.25 1.26 1.27 1.28 1.29
B -0.32 -0.33 -0.34 -0.35 -0.36 -0.37 -0.38 -0.39 -0.40 -0.41 -0.42 -0.43 -0.44 -0.45 -0.46 -0.47 -0.48 -0.49 -0.50 -0.51 -0.52 -0.53 -0.54
A 1.30 1.31 1.32 1.33 1.34 1.35 1.36 1.37 1.38 1.39 1.40 1.41 1.42
B -0.55 -0.56 -0.57 -0.58 -0.59 -0.60 -0.61 -0.62 -0.63 -0.64 -0.65 -0.66 -0.67
A. Pinion distance measurement

Forward gear shim (T1) selection table

(mm)
A
0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.20 0.21 0.22 0.23 0.24 0.25 0.26 0.27 0.28 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 0.39 0.40 0.41 0.42 0.43 0.44 0.45 0.46 0.47 0.48 0.49 0.50 0.51
2.00 2.03 2.03 2.03 2.06 2.06 2.06 2.09 2.09 2.09 2.12 2.12 2.12 2.15 2.15 2.15 2.18 2.18 2.18
2.03 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.06 2.06 2.06 2.09 2.09 2.09 2.12 2.12 2.12 2.15 2.15 2.15 2.18 2.18 2.18 2.21 2.21 2.21
2.06 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.03 2.03 2.03 2.09 2.09 2.09 2.12 2.12 2.12 2.15 2.15 2.15 2.18 2.18 2.18 2.21 2.21 2.21 2.21 2.21 2.21
B 2.09 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.03 2.03 2.03 2.06 2.06 2.06 2.12 2.12 2.12 2.15 2.15 2.15 2.18 2.18 2.18 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21
2.12 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.03 2.03 2.03 2.06 2.06 2.06 2.09 2.09 2.09 2.15 2.15 2.15 2.18 2.18 2.18 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21
2.15 2.00 2.00 2.00 2.00 2.00 2.00 2.03 2.03 2.03 2.06 2.06 2.06 2.09 2.09 2.09 2.12 2.12 2.12 2.18 2.18 2.18 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21
2.18 2.00 2.00 2.00 2.03 2.03 2.03 2.06 2.06 2.06 2.09 2.09 2.09 2.12 2.12 2.12 2.15 2.15 2.15 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21
2.21 2.03 2.03 2.03 2.06 2.06 2.06 2.09 2.09 2.09 2.12 2.12 2.12 2.15 2.15 2.15 2.18 2.18 2.18

A-22
Reverse gear shim (T2) selection chart
0.80
0.60
0.40
0.20
–0.20
B (mm)
–0.40
–0.60
–0.80
–1.00
–1.20
–1.40
–1.60
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 182 190 195 200
A (1/100 mm)
A 0 5 10 15 20 25 30 35 40 45 50 55 60 61 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 200
B 0.67 0.62 0.56 0.51 0.45 0.40 0.34 0.29 –0.26 –0.32 –0.37 –0.43 –0.48 –0.54 –0.59 –0.65 –0.70 –0.76 –0.81 –0.87 –0.92 –0.98 –1.03 –1.09 –1.14 –1.20 –1.25 –1.31 –1.36 –1.42 –1.53

A-23
Propeller shaft shim (T4) selection chart
0.10
0.09
0.08
0.07
0.06
0.05
0.04
0.03
0.02
B (mm)
0.01
0
–0.01
–0.02
–0.03
–0.04
–0.05
–0.06
–0.07
–0.08
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6
A (N·m)
A 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6
B 0.07 0.06 0.05 0.04 0.03 0.02 –0.02 –0.03 –0.04 –0.05 –0.06 –0.07 –0.08 –0.09
A. Motive torque measurement

A-24
Shim selection table and chart (counter rotation model)
Pinion shim (T3) selection table

See “Pinion shim (T3) selection table” (A-22).
Propeller shaft shim (T4) selection table

The shim thickness does not have to be adjusted for the blue-colored cell.
(mm)
㻭㻜㻜㻚㻝㻜㻚㻞㻜㻚㻟㻜㻚㻠㻜㻚㻡㻜㻚㻢㻜㻚㻣㻜㻚㻤㻜㻚㻥㻝㻚㻜㻝㻚㻝㻝㻚㻞㻝㻚㻟㻝㻚㻠㻝㻚㻡
㻮㻙㻜㻚㻡㻙㻜㻚㻠㻙㻜㻚㻟㻙㻜㻚㻞㻙㻜㻚㻝㻗㻜㻚㻝㻗㻜㻚㻞㻗㻜㻚㻟㻗㻜㻚㻠㻗㻜㻚㻡㻗㻜㻚㻢㻗㻜㻚㻣㻗㻜㻚㻤㻗㻜㻚㻥㻗㻝㻚㻜
A. Free play measurement

Forward gear shim (T2) selection chart

0.60
0.40
0.20
–0.20
–0.40
B (mm)
–0.60
–0.80
–1.00
–1.20
–1.40
–1.60
–1.80
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 182 190 195 200
A (1/100 mm)
A 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
B 0.45 0.40 0.34 0.29 –0.26 –0.32 –0.37 –0.43 –0.48 –0.54 –0.59 –0.65 –0.70 –0.76 –0.81 –0.87 –0.92 –0.98 –1.03 –1.09 –1.14 –1.20 –1.25 –1.31 –1.36 –1.42 –1.47 –1.53 –1.58 –1.64 –1.69 –1.75

A-25
Reverse gear shim (T1) selection table
(mm)
A
0.42 0.43 0.44 0.45 0.46 0.47 0.48 0.49 0.50 0.51 0.52 0.53 0.54 0.55 0.56 0.57 0.58 0.59 0.60 0.61 0.62 0.63 0.64 0.65 0.66 0.67 0.68 0.69 0.70 0.71 0.72 0.73 0.74 0.75 0.76 0.77 0.78 0.79 0.80
2.00 2.03 2.03 2.03 2.06 2.06 2.06 2.09 2.09 2.09 2.12 2.12 2.12 2.15 2.15 2.15 2.18 2.18 2.18
2.03 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.06 2.06 2.06 2.09 2.09 2.09 2.12 2.12 2.12 2.15 2.15 2.15 2.18 2.18 2.18 2.21 2.21 2.21
2.06 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.03 2.03 2.03 2.09 2.09 2.09 2.12 2.12 2.12 2.15 2.15 2.15 2.18 2.18 2.18 2.21 2.21 2.21 2.21 2.21 2.21
B 2.09 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.03 2.03 2.03 2.06 2.06 2.06 2.12 2.12 2.12 2.15 2.15 2.15 2.18 2.18 2.18 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21
2.12 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.03 2.03 2.03 2.06 2.06 2.06 2.09 2.09 2.09 2.15 2.15 2.15 2.18 2.18 2.18 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21
2.15 2.00 2.00 2.00 2.00 2.00 2.00 2.03 2.03 2.03 2.06 2.06 2.06 2.09 2.09 2.09 2.12 2.12 2.12 2.18 2.18 2.18 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21
2.18 2.00 2.00 2.00 2.03 2.03 2.03 2.06 2.06 2.06 2.09 2.09 2.09 2.12 2.12 2.12 2.15 2.15 2.15 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21 2.21
2.21 2.03 2.03 2.03 2.06 2.06 2.06 2.09 2.09 2.09 2.12 2.12 2.12 2.15 2.15 2.15 2.18 2.18 2.18

A-26
Worldwide:
(6GT)
-
(6GU)
(6GR)
(6GS)

(6GT)
(6GR)
6GR-28197-ZX-11
LIT-18616-03-83
6GR-28197-ZX-11
LIT-18616-03-83
Worldwide:
(6GT)
-
(6GU)
(6GR)
(6GS)

(6GT)
(6GR)
6GR-28197-ZX-11
LIT-18616-03-83
6GR-28197-ZX-11
LIT-18616-03-83

F425 Service Manual Lit - 18616-03-83

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F425 Service Manual Lit - 18616-03-83

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Copyright:

Available Formats

Worldwide:

USA, CAN, EUR, AUS, and NZL:

Particularly important information is distinguished in this manual by the following notations:

F375A, FL375A, F425A, FL425A, XF375, XF425

Model information .............................................................. 0-1

Important safety and service information........................ 0-3

How to use this manual ..................................................... 0-6

Specified tightening torque............................................... 0-9

Symbol .............................................................................. 0-10

Special service tool.......................................................... 0-12

Model name Approved model code Starting serial No.

USA, CAN, EUR, AUS, and NZL

Model name designation

Level 2: Control method

Level 3: Trim and tilt method

X: XTO offshore series

Important safety and service Handling of gasoline

Hot parts Ventilation

Parts, lubricants, and sealants

Handling of lubricants and sealants

Special service tools

• During disassembly, cover all openings,

Disposal of used components and

How to use this manual

Part name Q’ty Remarks Part name Q’ty Remarks

5 Gasket 1 21 Thrust bearing 1 2nd: 90°

Conditions when testing and adjusting

Specified tightening torque

General tightening torque

Filling fluid Lubricant

Special tool Tightening torque

Electrical data New Replace the part with a new one.

Lubricant, sealant, and thread locking agent symbol

YAMALUBE 4 or YAMALUBE 4M FC-W Lubricant

YAMALUBE outboard gear oil or Yamalube Ma-

YAMAHA WR-No.2 grease Lubricant

ThreeBond 1901 Lubricant

Symbol Name Application

ThreeBond 1322 Thread locking agent

ThreeBond 1386B Sealant

ThreeBond 1377B Thread locking agent

LOCTITE 1342 Thread locking agent

ThreeBond 1530D Sealant

ThreeBond 1303 Thread locking agent

LOCTITE 271 (red) Thread locking agent

LOCTITE 242 (blue) Thread locking agent

LOCTITE 572 (white) Sealant

Special service tool

Liftting eye Bolt hexagon with Liftting hanger Drilling plate

Vacuum/pressure Injector remover Fuel injection meter Stopper

Seal fitter Nozzle cap Seal installer Compression gauge

Compression gauge Balance hanger Bolt set Rotor holder

Flywheel stopper Flywheel guide Shaft holder Valve spring compres-

Magnet base B Ring nut extension Pinion shimming Pinion shimming

Gear oil attachment kit Oil socket Air socket Joint

Test harness (3 pins) Spark checker Pressure/vacuum tes- Compression gauge

Specification data .............................................................. 1-1

External dimensions .......................................................... 1-2

66 (2.6) 861 (33.9)

Clamp bracket dimensions

222 (8.7) 222 (8.7)

163.5 (6.4) 163.5 (6.4)

Model feature ...................................................................... 2-1