Serv. Manual f70

F70A
SERVICE MANUAL
6CJ-28197-3N-11
Preface
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have 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. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual. Also, up-to-date parts information is available on YPEC-web. Additional information and up-
to-date information on Yamaha products and services are available on Yamaha Service Portal.
Important information
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
A WARNING indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
A NOTICE indicates special precautions that must be taken to avoid damages to the out-
board motor or other property.
TIP:
A TIP provides key information to make procedures easier or clearer.
F70A
SERVICE MANUAL
©2010 by Yamaha Motor Co., Ltd.
1st Edition, May 2010
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Contents
GEN
General information INFO 0
Specification SPEC 1
TECH
Technical features and description FEA 2
RIG
Rigging information GING 3
TRBL
Troubleshooting SHTG 4
Electrical system ELEC 5
Fuel system FUEL 6
Power unit POWR 7
Lower unit LOWR 8
Bracket unit BRKT 9
Maintenance MNT 10
Index
Appendix A
GEN
INFO
General information 0
Safety while working .................................................... 0-1

Rotating part .............................................................................. 0-1
Hot part ...................................................................................... 0-1
0
Electric shock ............................................................................ 0-1
Propeller .................................................................................... 0-1
Handling of gasoline .................................................................. 0-1
Ventilation .................................................................................. 0-1
1
Self-protection ........................................................................... 0-2
Working with crane .................................................................... 0-2
Handling of gas torch ................................................................ 0-2
Part, lubricant, and sealant ........................................................ 0-2
2
Handling of sealant .................................................................... 0-3
Special service tool ................................................................... 0-3
Tightening torque ...................................................................... 0-3
Non-reusable part ...................................................................... 0-3
3
Disassembly and assembly ....................................................... 0-3
How to use this manual .................................................... 0-4 4

Manual format ........................................................................... 0-4
Abbreviation .............................................................................. 0-5
Lubricant, sealant, and thread locking agent ................. 0-6

5
Symbol ...................................................................................... 0-6
Special service tool ........................................................... 0-8

6
7
8
9
10
A
GEN
INFO General information
Safety while working Handling of gasoline
To prevent an accident or injury and to pro- • Gasoline is highly flammable. Keep gaso-
vide quality service, observe the following line and all flammable products away from
safety procedures. heat, sparks, and open flames.
• Gasoline is poisonous and can cause injury
Rotating part or death. Handle gasoline with care. Never
• Hands, feet, hair, jewelry, clothing, personal siphon gasoline by mouth. If you swallow
flotation device straps, and so on, can some gasoline, inhale a lot of gasoline
become entangled with internal rotating vapor, or get some gasoline in your eyes,
parts of the engine, resulting in serious see your doctor immediately. If gasoline
injury or death. spills on your skin, wash with soap and
• Keep the top cowling installed whenever water. If gasoline spills on your clothing,
possible. Do not remove or install the top change your clothes.
cowling when the engine is running.
• Only operate the engine with the top cowl-
ing removed according to the specific
instructions in the manual. Keep hands,
feet, hair, jewelry, clothing, personal flota-
tion device straps, and so on, away from
any exposed moving parts.
Hot part
During and after operation, engine parts are
hot enough to cause burns. Do not touch any Ventilation
parts under the top cowling until the engine • Gasoline vapor and exhaust gas are
has cooled. heavier than air and extremely poisonous. If
gasoline vapor or exhaust gas is inhaled in
Electric shock large quantities, it may cause loss of con-
Do not touch any electrical parts while start- sciousness and death within a short time.
ing or operating the engine. Otherwise, shock • When test running an engine indoors (for
or electrocution could result. example, in a water tank) make sure to do
so where adequate ventilation can be main-
Propeller tained.
Do not hold the propeller with your hands
when loosening or tightening the propeller
nut.
0-1
Safety while working
Self-protection Handling of gas torch
• Protect your eyes by wearing safety • Improper handling of a gas torch may result
glasses or safety goggles during all opera- in burns. For information on the proper han-
tions involving drilling and grinding, or when dling of the gas torch, see the operation
using an air compressor. manual issued by the manufacturer. 0
• Protect your hands and feet by wearing pro- • When using a gas torch, keep it away from
tective gloves and safety shoes when nec- the gasoline and oil, to prevent a fire.
essary. • Components become hot enough to cause
burns. Do not touch any hot components 1
directly.
2
3
Working with crane
• Outboard motors weighing 18.0 kg (39.7 lb)
4
and over must be carried by a crane. Part, lubricant, and sealant
• Use the wire ropes of adequate strength, Use only genuine Yamaha parts, lubricants,
and lift up the outboard motor using the
three-point suspension.
and sealants, or those recommended by
Yamaha, when servicing or repairing the out-
5
• If the outboard motor does not have three board motor.
or more points to be suspended, support it
using additional ropes, or the like, so that 6
the outboard motor can be lifted and carried
in a stable manner.
7
8
9
10
A
0-2
GEN
Handling of sealant Non-reusable part
• Wear protective gloves to protect your skin, Always use new gaskets, seals, O-rings, cot-
when using the sealants. ter pins, and so on, when installing or assem-
• See the material safety data sheet issued bling parts.
by the manufacturer. Some of the sealants
may be harmful to human health.
Disassembly and assembly

• Use compressed air to remove dust and dirt
Special service tool during disassembly.
Use the recommended special service tools • Apply engine oil to the contact surfaces of
to work safely, and to protect parts from dam- moving parts before assembly.
age.
• Install bearings so that the bearing identifi-

cation mark is facing in the direction indi-
Tightening torque
cated in the installation procedure. In
When tightening nuts, bolts, and screws, fol-
addition, make sure to lubricate the bear-
low the tightening instructions provided
ings liberally.
throughout the manual. If the tightening order
• Apply a thin coat of water resistant grease
is not specified, tighten the large sizes first,
to the lip and periphery of an oil seal before
and then tighten the small sizes, starting from
installation.
the center and moving outward.
• Check that moving parts operate normally
after assembly.
0-3
Safety while working / How to use this manual
How to use this manual
Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the following information as a guide for effective and quality service.
0
• Parts are shown and detailed in an exploded diagram and are listed in the component list (see a
in the following figure for an example page).
• The component list consists of part names and quantities, as well as bolt and screw dimensions
(see b in the following figure).
1
• Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
the lubrication points (see c in the following figure).
• Tightening torque specifications are provided in the exploded diagrams (see d in the following fig-
ure), and in the related detailed instructions. Some torque specifications are listed in stages as
2
torque figures or angles in degrees.
• Separate procedures and illustrations are used to explain the details of removal, checking, and
installation where necessary (see e in the following figure for an example page). 3
TIP:
For troubleshooting procedures, see Chapter 4, “Troubleshooting.”
4
c d
a
5
6
7
8
9
10
e A
0-4
GEN
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
API American Petroleum Institute
ATF Automatic Transmission Fluid
BTDC Before Top Dead Center
CCA Cold Cranking Ampere
C/E Check Engine
DN Down side
ECM Electronic Control Module
EN European Norm (European standard)
EX Exhaust
F Forward
ID Identification
IEC International Electrotechnical Commission
IN Intake
ISO International Organization for Standardization
ISC Idle Speed Control
N Neutral
PORT Port side
PTT Power Trim and Tilt
R Reverse
RON Research Octane Number
SAE Society of Automotive Engineers
SOHC Single Overhead Camshaft
STBD Starboard side
TCI Transistor-Controlled Ignition
TDC Top Dead Center
TPS Throttle Position Sensor
UP Up side
W/F Water in Fuel
Y-COP Yamaha Customer Outboard Protection
YDIS Yamaha Diagnostic System
0-5
How to use this manual / Lubricant, sealant, and thread locking agent
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
0
Yamaha 4-stroke motor oil Lubricant
1
Gear oil Lubricant
2
Water resistant grease Lubricant
(Yamaha grease A)
ThreeBond 1901 Lubricant

3
Corrosion resistant grease
(Yamaha grease D)
Lubricant
4
Low temperature resistant grease Lubricant
(Yamaha grease C)
5
Symbols in an exploded diagram or illustration indicate the type of sealant or thread locking agent
and the application points. 6
Gasket Maker Sealant
7
ThreeBond 1322 Thread locking agent
8
ThreeBond 1377B Thread locking agent
LOCTITE 271 (red) Thread locking agent 9

LOCTITE 242 (blue) Thread locking agent 10
LOCTITE 572 (white) Sealant
A
0-6
GEN

Silicone sealant Sealant
0-7
Lubricant, sealant, and thread locking agent / Special service tool
Special service tool
For all markets except U.S.A. and Canada
Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division.
Drilling plate Peak voltage adapter B 0

90890-06783 90890-03172
1
2
YDIS (CD-ROM, Ver. 1.33) Test harness (8 pins)
60V-WS853-06 90890-06879
3
4
YDIS USB adapter and cable
60V-WS850-00
Leakage tester
90890-06840 5
6
Diagnostic flash indicator B Vacuum/pressure pump gauge set

7
90890-06865 90890-06756
8
9
Digital circuit tester Test harness (6 pins)
90890-03174 90890-06848
10
A
0-8
GEN
Ignition tester (Spark gap tester) Compression gauge
90890-06754 90890-03160
Test harness (2 pins) Flywheel holder

90890-06867 90890-06522
Test harness (3 pins) Flywheel puller

90890-06869 90890-06521
Fuel pressure gauge adapter Crankshaft holder

90890-06942 90890-06562
Fuel pressure gauge Valve spring compressor

90890-06786 90890-04019
0-9
Valve spring compressor attachment Valve seat cutter 30°
90890-04108 90890-06328
0
1
Valve guide remover/installer Valve seat cutter 45°
90890-06801 90890-06312
2
3
Valve guide reamer Valve seat cutter 60°
90890-06804 90890-06315 4
5
Valve lapper Valve seat cutter 30°

6
90890-04101 90890-06329
7
8
Valve seat cutter holder Valve seat cutter 45°
90890-06316 90890-06330
9
10
A
0-10
GEN
Valve seat cutter 60° Shift rod socket
90890-06813 90890-06679
Driver rod LS Needle bearing attachment

90890-06606 90890-06610
Bearing outer race attachment Driver rod L3

90890-06626 90890-06652
Oil filter wrench Ring nut wrench extension

90890-01426 90890-06513
Piston slider Ring nut wrench 3

90890-06529 90890-06511
0-11
Bearing housing puller claw L Bearing puller assembly
90890-06502 90890-06535
0
1
Stopper guide plate Needle bearing attachment
90890-06501 90890-06612
2
3
Center bolt Ball bearing attachment
90890-06504 90890-06655 4
5
Bearing separator Needle bearing attachment

6
90890-06534 90890-06608
7
8
Stopper guide stand Needle bearing attachment
90890-06538 90890-06607
9
10
A
0-12
GEN
Drive shaft holder 4 Bearing inner race attachment
90890-06518 90890-06643
Pinion nut holder Driver rod LL

90890-06715 90890-06605
Bearing inner race attachment Bearing outer race attachment

90890-06639 90890-06621
Needle bearing attachment Driver rod SL

90890-06611 90890-06602
Needle bearing attachment Bearing depth plate

90890-06614 90890-06603
0-13
Backlash indicator Bushing installer center bolt
90890-06706 90890-06601
0
1
Magnet base plate Needle bearing attachment
90890-07003 90890-06653
2
3
Dial gauge set Needle bearing attachment
90890-01252 90890-06613 4
5
Magnet base B Needle bearing attachment

6
90890-06844 90890-06616
7
8
Pinion height gauge Cylinder-end screw wrench
90890-06669 90890-06588
9
10
A
0-14
GEN
Cylinder-end screw wrench
90890-06568
0-15
— MEMO —
0
1
2
3
4
5
6
7
8
9
10
A
0-16
SPEC
Specification 1
Model feature ..................................................................... 1-1

General feature ......................................................................... 1-1
Model designation ..................................................................... 1-2
Serial number ............................................................................ 1-2
Model data ......................................................................... 1-3

Dimension and weight ............................................................... 1-3
Performance .............................................................................. 1-3
Power unit ................................................................................. 1-3
Lower unit .................................................................................. 1-4
Bracket unit ............................................................................... 1-4
Fuel and oil requirement ............................................................ 1-4
Battery requirement ................................................................... 1-5
PTT fluid requirement ................................................................ 1-5
Electrical system technical data ...................................... 1-6

Ignition timing control system .................................................... 1-6
Fuel injection control system ..................................................... 1-7
Engine speed control system .................................................... 1-7
PTT system ............................................................................... 1-8
Charging system ....................................................................... 1-8
Starting system .......................................................................... 1-8
Gauge/sensor ............................................................................ 1-9
Fuel system technical data ............................................ 1-10

Fuel system ............................................................................. 1-10
Power unit technical data ............................................... 1-11

Power unit ............................................................................... 1-11
Cylinder head assembly .......................................................... 1-11
Crankcase assembly ............................................................... 1-12
Lower unit technical data ............................................... 1-14

Lower unit assembly ................................................................ 1-14
Bracket unit technical data ............................................ 1-14

PTT system ............................................................................. 1-14
Specified tightening torque ............................................ 1-15

Rigging information ................................................................. 1-15
Fuel system ............................................................................. 1-15
Power unit ............................................................................... 1-15
Lower unit ................................................................................ 1-16
Tiller handle model .................................................................. 1-17
Bracket unit ............................................................................. 1-17
PTT unit ................................................................................... 1-17
General tightening torque .............................................. 1-18

0
1
2
4
5
6
7
8
9
10
A
SPEC
Specification
Model feature
General feature
F70A overall feature
• Electronic fuel injected, 4-stroke, L4, SOHC, 16-valve, 996.0 cm3 (60.8 cu. in) engine
• Low exhaust emissions conform to EU regulations
• Y-COP (optional in non-European markets)
• 6Y8 Multifunction Meter (optional)
a Power unit d Upper case

• Multi-point electronic fuel injection • Labyrinth idle exhaust system
• Single throttle body • Two-piece upper case
• Long intake manifold
• Blowby gas reburning system e Lower unit
• Fuel cooler • Dual thrust propeller
• Closed fuel vapor gas system • 2.33 high gear ratio
• One-piece top cowling with water draining
air intake duct
• Speed sensor and water pressure sensor a
(optional) b
b Electrical
• Electronic fuel injection control
• Ignition timing control
• Knock control
• ISC control c
• Engine speed control
• Fail-safe control d
• Variable trolling speed control (6Y8 Multi-
function Meter-equipped model or tiller han-
dle model)
• Alert systems including low oil pressure,
overheat, and water detection
e
• New YDIS 1.33 version
c Bracket unit
• Long span mount
• Compact PTT
• Freshwater flushing devise
• Multifunction tiller handle (optional)
1-1
Model feature
Model designation
F 70 A E T L 0
a b c d e f
a
b
Model description
Model name
F: 4-stroke regular rotation
70: 70
1
c Product generation A: A and later
d
e
Functions
E: Electric starter
T: PTT 2
L: L (20 in)
f Transom height
X: UL (25 in)
3
Serial number
The outboard motor serial number is indi-
cated on a label affixed to the port clamp
4
bracket.
5
6
7
c a
8
b d
YAMAHA MOTOR CO., LTD. e
MADE IN JAPAN
PAYS D'ORIGINE JAPON 9
a Model name 10
b Approved model code
c Transom height
d Serial number
e Model year code
Approved Starting
Model name
model code serial No.
F70AET 6CJ 1000001– A
1-2
SPEC
Specification
Model data
Dimension and weight
Model
Item Unit
F70AET
Overall length mm (in) 713.0 (28.1)
Overall width mm (in) 386.0 (15.2)
Overall height
L mm (in) 1476.0 (58.1)
X mm (in) 1590.0 (62.6)
Boat transom height
L mm (in) 534.0 (21.0)
X mm (in) 648.0 (25.5)
Weight (without propeller)
L kg (lb) 119.0 (262.4)
X kg (lb) 121.0 (266.8)
Performance
Model
Item Unit
F70AET
Maximum output
At 5800 r/min kW (HP) 51.5 (70)
Full throttle operating range r/min 5300–6300
Maximum fuel consumption
L (US gal,
At 5800 r/min 22.7 (6.0, 5.0)
Imp gal)/hr
Engine idle speed r/min 700–800
Power unit
Model
Item Unit
F70AET
Type 4-stroke, SOHC L
Cylinder quantity 4
Total displacement cm³ (cu. in) 996.0 (60.8)
Bore stroke mm (in) 65.0 75.0 (2.56 2.95)
Compression ratio 9.40: 1
Control system Remote control
Starting system Electric
Fuel system Fuel injection
Ignition control system TCI
Advance type Microcomputer
Maximum generator output V, A 12.0, 16.0
Spark plug LKR7E (NGK)
Firing order 1–3–4–2
Cooling system Water
Exhaust system Propeller boss
Lubrication system Wet sump
1-3
Model data
Lower unit
Model
Item Unit
F70AET
Gear shift positions
Gear ratio
F-N-R
2.33 (28/13)
0
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type
Propeller direction (rear view)
Spline
Clockwise
1
Propeller mark K
Bracket unit 2
Model
Item Unit
F70AET
Trim angle
At 12º boat transom
degree –4 to 16 3
Tilt-up angle degree 65
Steering angle degree 40 + 40
Trim and tilt system PTT 4
Fuel and oil requirement
Item Unit
Model
F70AET 5
Fuel type Regular unleaded gasoline
Minimum fuel octane number RON 91
Engine oil
4-stroke motor oil with combination of the fol-
lowing SAE and API oil classifications
6
API SE, SF, SG, SH, SJ, SL
Engine oil grade (*1)
SAE 5W-30, 10W-30, 10W-40
Total engine oil quantity
L (US qt,
7
Without oil filter replacement 1.9 (2.01, 1.67)
Imp qt)
With oil filter replacement
L (US qt,
Imp qt)
2.1 (2.22, 1.85) 8
Gear oil type Hypoid gear oil
API GL-4
Gear oil grade (*2)
SAE
L (US qt,
90
9
Gear oil quantity 0.670 (0.708, 0.590)
Imp qt)
(*1) If the recommended engine oil grades are not available, use engine oil with an API classification
of SH, SJ, or SL and an SAE classification of 15W-40, 20W-40, or 20W-50. 10
(*2) Meeting both API and SAE requirements.
A
1-4
SPEC
Specification
Battery requirement
Model
Item Unit
F70AET
Minimum cold cranking amps
CCA/EN A 430.0
Minimum rated capacity
20HR/IEC Ah 70.0
PTT fluid requirement

Model
Item Unit
F70AET
Fluid type ATF DEXRON II
1-5
Model data / Electrical system technical data
Electrical system technical data
Ignition timing control system
Model
Spark plug
Item Unit
F70AET 0
Gap mm (in) 0.8–0.9 (0.032–0.035)
Spark plug wire
Resistance (*1)
At 20 °C (68 °F) kΩ 1.9–5.0
1
Ignition coil
Primary coil resistance (*1)
At 20 °C (68 °F) Ω 1.53–2.07 2
Secondary coil resistance
At 20 °C (68 °F) kΩ 12.495–16.905
Pulser coil
Air gap mm (in) 0.5–1.0 (0.020–0.039)
3
Output peak voltage
At cranking (unloaded) V 5.7
At cranking (loaded)
At 1500 r/min (loaded)
V
V
4.7
14.9
4
At 3500 r/min (loaded) V 24.6
Resistance
At 20 °C (68 °F) Ω 398.0–594.0 5
Sensor assembly
Input voltage V 4.75–5.25
Thermo sensor
6
Resistance (*1)
At 20 °C (68 °F) kΩ 2.439
At 60 °C (167 °F)
At 100 °C (194 °F)
kΩ
kΩ
0.589
0.193
7
Knock sensor
Resistance
At 20 °C (68 °F) kΩ 504.0–616.0 8
Neutral switch
Input voltage (*1) V 4.75–5.25
(*1) The figures are for reference only. 9
10
A
1-6
SPEC
Specification
Fuel injection control system
Model
Item Unit
F70AET
Water detection switch
Float height (*1) mm (in) 19.4 (0.76)
Fuel injector
Input voltage V 12.0
Resistance (*1)
At 20 °C (68 °F) Ω 12.0
High-pressure fuel pump
Resistance (*1)
At 20 °C (68 °F) Ω 0.2–0.3
Vapor shut-off valve
Resistance
At 20 °C (68 °F) Ω 30.0–34.0
(*1) The figures are for reference only.
Engine speed control system

Model
Item Unit
F70AET
TPS
Output voltage (*1)
With throttle valve fully
V 0.978
closed
V 4.213
open
Throttle valve opening angle
(*1)
degree 6.9
closed
degree 87.8
open
ISC valve
Resistance (*1)
At 20 °C (68 °F) Ω 27.0–33.0
Oil pressure switch
Input voltage (*1) V 11.7
kPa (kgf/
Working pressure 29.4–58.8 (0.294–0.588, 4.3–8.5)
cm2, psi)
1-7
Electrical system technical data
PTT system
Model
Item Unit
F70AET
Trim sensor
Free position resistance (*1) Ω 168.3–288.3
0
Setting resistance Ω 9.0–11.0
1
Charging system
Model
Lighting coil
Item Unit
F70AET 2
Output peak voltage
At cranking (unloaded) V 13.0
At 1500 r/min (unloaded) V 40.2 3
At 3500 r/min (unloaded) V 95.0
Resistance (*1)
Fuse
At 20 °C (68 °F) Ω
A
0.513–0.627
20
4
Rectifier Regulator
Output peak voltage
At 1500 r/min (unloaded)
At 3500 r/min (unloaded)
V
V
13.0
13.0
5
Starting system 6
Model
Item Unit
F70AET
Y-COP 7
Starter motor
Type
Output kW
Sliding gear
1.4
8
Cranking time limit second 30
Commutator
Standard diameter
Wear limit
mm (in)
mm (in)
29.0 (1.14)
28.0 (1.10)
9
Standard undercut mm (in) 0.8 (0.03)
Wear limit mm (in) 0.2 (0.01)
Brush 10
Standard length mm (in) 15.5 (0.61)
A
1-8
SPEC
Specification
Gauge/sensor
Model
Item Unit
F70AET
Water pressure sensor
Output voltage (*1)
At 392.0 kPa (3.92 kgf/cm2,
V 2.5
56.8 psi)
At 784.0 kPa (7.84 kgf/cm2,
V 4.5
113.7 psi)
Speed sensor
Output voltage (*1)
At 392.0 kPa (3.92 kgf/cm2,
V 2.5
56.8 psi)
At 784.0 kPa (7.84 kgf/cm2,
V 4.5
113.7 psi)
1-9
Electrical system technical data / Fuel system technical data
Fuel system technical data
Fuel system
Model
Item
Fuel pressure (*1)
Unit
F70AET 0
Within 3 seconds after
kPa (kgf/
engine start switch turned to 290.0 (2.90, 42.1)
ON
cm2, psi)
kPa (kgf/
1
At engine idle speed 230.0 (2.30, 33.4)
cm2, psi)
Fuel joint
Holding pressure 2
kPa (kgf/
Positive pressure 50.0 (0.50, 7.3)
cm2, psi)
Fuel filter assembly
Holding pressure
3
kPa (kgf/
cm2, psi)
Negative pressure
kPa (kgf/
cm2, psi)
80.0 (0.80, 11.6) 4
Primer pump
Holding pressure
Positive pressure
kPa (kgf/
135.0 (1.35, 19.6)
5
cm2, psi)
Fuel pump
Holding pressure
Inlet positive pressure
kPa (kgf/
50.0 (0.50, 7.3)
6
cm2, psi)
kPa (kgf/
Inlet negative pressure
cm2, psi)
kPa (kgf/
30.0 (0.30, 4.4)
7
Outlet positive pressure 50.0 (0.50, 7.3)
cm2, psi)
Fuel strainer
Holding pressure
kPa (kgf/
8
cm2, psi)
Vapor separator tank
Float height (*1) mm (in) 35.0 ± 1.0 (1.38 ± 0.04) 9
10
A
1-10
SPEC
Specification
Power unit technical data
Power unit
Model
Item Unit
F70AET
Compression pressure
kPa (kgf/
Minimum (*1) 800.0 (8.00, 116.0)
cm2, psi)
Engine oil
Oil pressure (*2)
At 60 °C (140 °F) with SL
kPa (kgf/
10W-30 engine oil and at 190.0 (1.90, 27.6)
cm2, psi)
750 r/min
At 61 °C (142 °F) with SL
kPa (kgf/
10W-30 engine oil and at 450.0 (4.50, 65.3)
cm2, psi)
3000 r/min
Thermostat
Valve opening temperature °C (°F) 58–62 (136–144)
Fully open temperature °C (°F) 70 (158)
Fully open stroke mm (in) 3.0 (0.12)
(*1) Measuring conditions: Ambient temperature 20 °C (68 °F), fully open throttle, with spark plugs
removed from all cylinders. The figures are for reference only.
(*2) For the checking method, see “Checking the oil pressure” (7-1). The figures are for reference
only.
Cylinder head assembly

Model
Item Unit
F70AET
Valve
Clearance
Intake mm (in) 0.20 ± 0.05 (0.008 ± 0.002)
Exhaust mm (in) 0.30 ± 0.05 (0.012 ± 0.002)
Seat contact width
Intake mm (in) 1.05–1.45 (0.041–0.057)
Exhaust mm (in) 0.90–1.30 (0.035–0.051)
Margin thickness
Intake mm (in) 0.800–1.200 (0.0315–0.0472)
Exhaust mm (in) 0.700–1.100 (0.0276–0.0433)
Cylinder head
Warpage limit mm (in) 0.10 (0.0039)
Valve spring
Free length mm (in) 39.74 (1.56)
Tilt limit mm (in) 1.7 (0.07)
Valve stem
Diameter
Intake mm (in) 5.475–5.490 (0.2156–0.2161)
Exhaust mm (in) 5.460–5.475 (0.2150–0.2156)
Runout
Intake and exhaust mm (in) 0.01 (0.0004)
1-11
Power unit technical data
Model
Item Unit
F70AET
Valve guide
Inside diameter
Intake and exhaust mm (in) 5.500–5.512 (0.2165–0.2170) 0
Valve guide clearance
Intake mm (in) 0.010–0.037 (0.0004–0.0015)
Exhaust
Installation height
mm (in)
mm (in)
0.025–0.052 (0.0010–0.0020)
11.8–12.2 (0.46–0.48)
1
Rocker arm
Inside diameter mm (in) 16.000–16.018 (0.6299–0.6306)
Rocker arm shaft
Outside diameter mm (in) 15.971–15.991 (0.6288–0.6296)
2
Camshaft
Cam lobe height
Intake mm (in) 30.538–30.638 (1.2023–1.2062) 3
Exhaust mm (in) 31.187–31.287 (1.2278–1.2318)
Cam lobe width mm (in) 25.950–26.050 (1.0217–1.0256)
Runout
Journal diameter #1
mm (in)
mm (in)
0.03 (0.0012)
36.925–36.945 (1.4537–1.4545)
4
Journal diameter #2, #3, #4 mm (in) 36.935–36.955 (1.4541–1.4549)
Cylinder head journal inside
diameter
mm (in) 37.000–37.025 (1.4567–1.4577)
5
Crankcase assembly
Item Unit
Model
F70AET 6
Piston
Diameter mm (in) 64.950–64.965 (2.5571–2.5577)
Measuring point
Oversize diameter
mm (in) 12.0 (0.47)
7
1st mm (in) 65.200–65.215 (2.5669–2.5675)
2nd mm (in) 65.450–65.465 (2.5768–2.5774)
Piston clearance
Ring groove (top)
mm (in)
mm (in)
0.035–0.065 (0.0014–0.0026)
1.21–1.23 (0.0476–0.0484)
8
Ring groove (2nd) mm (in) 1.51–1.53 (0.0594–0.0602)
Ring groove (oil)
Pin boss inside diameter
mm (in)
mm (in)
2.52–2.54 (0.0992–0.1000)
15.974–15.985 (0.6289–0.6293) 9
Pin outside diameter mm (in) 15.965–15.970 (0.6285–0.6287)
Cylinder
Bore mm (in) 65.000–65.015 (2.5591–2.5596)
10
A
1-12
SPEC
Specification
Model
Item Unit
F70AET
Piston ring
End gap measuring point mm (in) 10.0 (0.39)
Top ring
Type Barrel
Dimension height (B) mm (in) 1.17–1.19 (0.0461–0.0469)
Dimension width (T) mm (in) 2.30–2.50 (0.0906–0.0984)
End gap (*1) mm (in) 0.15–0.30 (0.0059–0.0118)
Side clearance mm (in) 0.02–0.06 (0.0008–0.0024)
2nd ring
Type Taper
Dimension width (T) mm (in) 2.60–2.80 (0.1024–0.1102)
End gap (*1) mm (in) 0.30–0.50 (0.0118–0.0197)
Oil ring
Dimension width (T) mm (in) 2.75 (0.1083)
End gap (*1) mm (in) 0.20–0.70 (0.0079–0.0276)
Connecting rod
Small end inside diameter mm (in) 15.985–15.998 (0.6293–0.6298)
Big end inside diameter mm (in) 36.000–36.024 (1.4173–1.4183)
Big end side clearance mm (in) 0.05–0.22 (0.0020–0.0087)
Crankpin oil clearance mm (in) 0.016–0.040 (0.0006–0.0016)
Crankshaft
Journal diameter mm (in) 42.984–43.000 (1.6923–1.6929)
Crankpin diameter mm (in) 32.984–33.000 (1.2986–1.2992)
Crankpin width mm (in) 21.000–21.070 (0.8268–0.8295)
Runout mm (in) 0.03 (0.0012)
Crankcase
Crankshaft journal oil clear-
mm (in) 0.012–0.036 (0.0005–0.0014)
ance
1-13
Lower unit technical data
Power unit technical data / Lower unit technical data / Bracket
Lower unit technical data
Lower unit assembly
Model
Lower unit
Item Unit
F70AET 0
kPa (kgf/
Holding pressure 68.6 (0.686, 9.9)
cm2, psi)
Forward gear
Backlash (*1) mm (in) 0.09–0.72 (0.0035–0.0283)
1
Pinion shim (T3) mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Forward gear shim (T1)
Propeller shaft
mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
2
Runout mm (in) 0.02 (0.0008)
Drive shaft
Runout mm (in) 0.5 (0.0197)
3
(*1) Figures obtained using the special service tools.
Bracket unit technical data

PTT system
4
Model
Item Unit
Motor commutator
F70AET
5
Standard diameter mm (in) 22.0 (0.87)
Standard undercut (*1)
Wear limit
mm (in)
mm (in)
1.5 (0.06)
1.0 (0.04)
6
Motor brush
Standard length mm (in) 10.0 (0.39)
Wear limit mm (in) 3.5 (0.14) 7
8
9
10
A
1-14
SPEC
Specification
Specified tightening torque
Specified tightening torques are provided for specific nuts, bolts, and screws. When tightening these
fasteners, follow the tightening torque specifications indicated throughout the manual to meet the
design aims of the outboard motor.
Rigging information
Tightening torques
Part to be tightened Screw size
N·m kgf·m ft·lb
Battery cable nut — 9 0.9 6.6
Shift cable locknut — 5 0.5 3.7
Throttle cable locknut — 5 0.5 3.7
Tiller handle nut — 37 3.7 27.3
Water pressure sensor nipple — 23 2.3 17.0
Water pressure sensor — 18 1.8 13.3
Speed sensor — 18 1.8 13.3
Receiver screw M4 4 0.4 3.0
Fuel system
Tightening torques
N·m kgf·m ft·lb
Fuel cup assembly — 5 0.5 3.7
Fuel pump screw M5 3 0.3 2.2
ISC valve screw M5 4 0.4 3.0
Cover screw M5 2 0.2 1.5
Sensor assembly screw M5 3.5 0.35 2.58
M8 21 2.1 15.5
Intake manifold bolt
M6 10 1.0 7.4
Link rod locknut — 5 0.5 3.7
Vapor separator drain screw — 1.5 0.15 1.11
Fuel cooler screw M6 3.5 0.35 2.58
Hose joint — 4 0.4 3.0
Float chamber plate screw M5 2 0.2 1.5
Lead holder screw M5 3 0.3 2.2
Vapor separator cover screw M5 3 0.3 2.2
Pressure regulator bolt M6 5 0.5 3.7
Power unit
Tightening torques
N·m kgf·m ft·lb
Valve adjusting locknut — 14 1.4 10.3
1st 21 2.1 15.5
Power unit mounting bolt M8
2nd 21 2.1 15.5
Oil pan bolt M8 21 2.1 15.5
Apron screw M6 3 0.3 2.2
PTT motor lead bolt M6 4 0.4 3.0
Driven sprocket bolt M10 38 3.8 28.0
Drive sprocket nut — 150 15.0 110.6
Flywheel magnet nut — 157 15.7 115.8
1-15
Specified tightening torque
Tightening torques
N·m kgf·m ft·lb
Starter relay mount screw ø6 3 0.3 2.2
Starter relay lead bolt
Starter relay lead screw
M6
M4
4
2
0.4
0.2
3.0
1.5 0
Starter motor bolt M8 30 3.0 22.1
Terminal nut — 9 0.9 6.6
Ignition coil bolt
YDIS coupler bracket screw
M6
ø6
7
3
0.7
0.3
5.2
2.2
1
Main relay screw ø6 3 0.3 2.2
PTT relay lead nut — 4 0.4 3.0
1st
2nd M9
23
37
2.3
3.7
17.0
27.3
2
Cylinder head bolt 3rd 180°
1st
2nd
M6
6
12
0.6
1.2
4.4
8.9 3
Oil pump bolt M6 10 1.0 7.4
Rocker arm shaft bolt M8 17 1.7 12.5
Cylinder head anode screw
Cylinder head anode plug
M5
— 18
2 0.2
1.8
1.5
13.3
4
Spark plug — 18 1.8 13.3
Oil filter union bolt — 40 4.0 29.5
Oil filter
Oil pressure switch
—
—
18
9
1.8
0.9
13.3
6.6
5
Oil pressure switch bolt M4 2 0.2 1.5
Thermo sensor — 23 2.3 17.0
Exhaust cover bolt
1st
M6
6 0.6 4.4 6
2nd 12 1.2 8.9
M14 38 3.8 28.0
Exhaust cover plug
Connecting rod bolt

1st
M18
M6
56
6
5.6
0.6
41.3
4.4
7
2nd 17 1.7 12.5
1st 15 1.5 11.1
Crankcase bolt
2nd
1st
M8
33
6
3.3
0.6
24.3
4.4
8
M6
2nd 12 1.2 8.9
Knock sensor — 32 3.2 23.6
Lower unit
9
Tightening torques
Drain screw —
N·m
9
kgf·m
0.9
ft·lb
6.6
10
Check screw — 9 0.9 6.6
Propeller nut — 35 3.5 25.8
Lower case mounting bolt (L-transom model) M10 40 4.0 29.5
Plate bolt M6 11 1.1 8.1
Lower case stud bolt (X-transom model) — 23 2.3 17.0
Lower case mounting nut (X-transom model) — 40 4.0 29.5
Ring nut — 103 10.3 76.0 A
1-16
SPEC
Specification
Tightening torques
N·m kgf·m ft·lb
Pinion nut — 94 9.4 69.3
Water inlet cover screw M5 1.0 0.1 0.7
Tiller handle model

Tightening torques
N·m kgf·m ft·lb
Friction plate nut — 7 0.7 5.2
Friction adjusting nut — 4 0.4 3.0
Throttle grip screw M5 2 0.2 1.5
Grease nipple — 3 0.3 2.2
Tiller handle bracket bolt M12 32 3.2 23.6
Tiller handle bracket nut — 32 3.2 23.6
Engine start switch nut — 4.5 0.45 3.32
Engine shut-off switch nut — 2.5 0.25 1.84
Alert indicator screw ø6 2 0.2 1.5
Bracket unit
Tightening torques
N·m kgf·m ft·lb
Bushing bolt M5 4 0.4 3.0
Shift rod detent bolt — 18 1.8 13.3
Flushing hose adapter screw ø6 5 0.5 3.7
Upper mounting nut — 24 2.4 17.7
Upper case bolt M10 36 3.6 26.6
Drain bolt — 27 2.7 19.9
1st 12 1.2 8.9
Cover bolt M6
2nd 12 1.2 8.9
Exhaust manifold bolt M6 11 1.1 8.1
Muffler bolt M6 11 1.1 8.1
Steering arm stud bolt — 20 2.0 14.8
Steering hook nut — 37 3.7 27.3
Self-locking nut — 23 2.3 17.0
Grease nipple — 3 0.3 2.2
Trim sensor screw M6 4 0.4 3.0
PTT unit
Tightening torques
N·m kgf·m ft·lb
PTT motor assembly bolt M6 4 0.4 3.0
Pump bracket bolt M5 5 0.5 3.7
Valve bracket bolt M5 5 0.5 3.7
Gear pump bolt M6 7 0.7 5.2
Manual valve — 2 0.2 1.5
Tilt piston bolt M10 61 6.1 45.0
Tilt cylinder end screw — 110 11.0 81.1
Trim cylinder end screw — 150 15.0 110.6
Reservoir cap — 7 0.7 5.2
1-17
Specified tightening torque / General tightening torque
General tightening torque
This chart indicates the tightening torques for
standard fasteners with a standard ISO
thread pitch.
Width General torque
0
Screw
across specifications
size (B)
flats (A) N·m kgf·m ft·lb
8 mm M5 5 0.5 3.7 1
10 mm M6 8 0.8 5.9
12 mm M8 18 1.8 13.3
14 mm
17 mm
M10
M12
36
43
3.6
4.3
26.6
31.7 2
3
4
5
6
7
8
9
10
A
1-18
SPEC
Specification
— MEMO —
1-19
TECH
FEA
Technical features and description 2
Electronic control system ................................................ 2-1

Engine ECM component ........................................................... 2-2
Electronic fuel injection control .................................................. 2-4
0
Ignition timing control ................................................................ 2-5
Engine speed control ................................................................. 2-6
Knock control ............................................................................. 2-8
ISC Control ................................................................................ 2-8
1
Alert indicator, alert buzzer control ............................................ 2-8
Fail-safe control ......................................................................... 2-9
2
Y-COP ............................................................................... 2-10
Power unit ........................................................................ 2-11 3

Fuel system ..................................................................... 2-12
Fuel diagram ........................................................................... 2-12 4
Lubrication system ......................................................... 2-14
Lubrication diagram ................................................................. 2-14 5
Cooling system ............................................................... 2-15
Cooling diagram ...................................................................... 2-15
6
Intake and exhaust system ............................................ 2-16
Intake and exhaust diagram .................................................... 2-16
7
PTT unit ............................................................................ 2-17
Trim-up and tilt-up function ...................................................... 2-17
Trim-down and tilt-down function ............................................ 2-18
Stationary condition ................................................................. 2-19
8
Shock-absorbing function ........................................................ 2-19
9
10
A
TECH
FEA Technical features and description
Electronic control system
This model uses an electronic fuel injection control, ignition timing control, engine speed control,
knock control, ISC 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 trou-
ble codes on the YDIS and flash indicator.
It is also equipped with Y-COP as an anti-theft measure (optional in non-European markets).
Ignition coil
High-pressure
Fuel injector fuel pump
ISC valve
Vapor gas control Fuel pump control
Fuel control ISC control
Ignition control TPS
Pulser coil
Sensor assembly (air pressure sensor, air
temperature sensor)
Engine
Oil pressure switch
ECM Knock sensor
Neutral switch
Battery Thermo sensor
Engine shut-off switch
Y-COP Hub Water pressure sensor (optional)
Speed sensor (optional)
Water detection switch
6Y8 Multifunction YDIS

Meter
2-1
Engine ECM component
b c
d 0
a
1
e
h
2
g
f 3
l
k 4
m 5
j
n
6
i
o
7
8
a Engine ECM m TPS
b Pulser coil n High-pressure fuel pump 9
c Thermo sensor o Knock sensor
d Oil pressure switch
e Ignition coil
f Neutral switch
10
g Main relay
h ISC valve
i Water detection switch
j Fuel injector
k Vapor shut-off valve
l Sensor assembly (air pressure sensor, air
temperature sensor) A
2-2
TECH
Sensor, switch, and actuator
Engine ECM Determines the engine operating conditions according to the
input signals from the sensors, and sends output signals to
operate the actuators to perform the various control functions.
Pulser coil Detects the engine speed.
Detects the crankshaft angle.
TPS Detects the throttle valve opening.
Air pressure sensor Detects the intake air pressure.
Air temperature sensor Detects the intake air temperature.
Oil pressure switch Detects oil pressure decrease.
Thermo sensor Detects cooling water temperature.
Neutral switch Detects when the gear shift is in the N position.
Engine shut-off switch Stops the engine forcibly.
Injector Injects fuel.
Ignition coil Activates the ignition.
High-pressure fuel pump Pressurizes the fuel and sends the fuel to the fuel rail.
ISC valve Adjusts the flow of air to the engine when idling.
Vapor shut-off valve Controls the amount of vapor gas to be sent from the vapor
separator to the intake system.
Knock sensor Detects engine knocking.
2-3
Electronic fuel injection control
The engine ECM switches the control mode between the start-up mode, normal operating mode,
and fuel injection cutoff mode according to the signals from the sensors. In addition, various com-
pensations are made to determine the actual fuel injection timing and fuel injection amount. Addi-
tionally, when the engine start switch is turned to ON, the engine ECM moves the injectors once 0
before activating the high-pressure pump relay to prevent them from sticking.
Pulser coil 1
TPS (*1)
Air pressure sensor (*1) High-pressure fuel pump 2

Air temperature sensor (*1)
Thermo sensor (*1) Engine

ECM
3
Oil pressure switch
Neutral switch
Fuel injector #1, #4
4
Engine start switch Fuel injector #2, #3
Engine shut-off switch 5

Battery
(*1) Sensors that perform compensations.

6
Synchronized injection when To improve engine startup, fuel is injected into all cylinders
cylinders are not identified simultaneously in synchrony with the signal from the pulser
coil until the cylinders have been identified. 7
Simultaneous injection into all When cylinders have been identified and the engine is
cylinders at startup running at less than 500 r/min, fuel is injected into all cylinders
Synchronized injection by group

simultaneously, based on BTDC 100°.
Fuel injection completion timing is set based on the exhaust
8
when running normally TDC for both #1, #4, and #2, #3 cylinder groups.
Asynchronous injection during
acceleration
During acceleration, when the TPS or the air pressure sensor
signal exceeds the set figure, fuel is injected into all cylinders 9
without being synchronized with the pulser coil signal.
Cutoff when engine shut-off Fuel flow is cut when the engine shut-off switch is on.
switch is on
Cutoff when over revving To protect the engine, fuel injection is skipped when engine
10
speed is more than a predetermined level.
Cutoff due to activation of Fuel is not injected when the engine is locked by Y-COP.
Y-COP When a communication error occurs, fuel flow is cut to control
engine speed.
A
2-4
TECH
Ignition timing control
This model uses simultaneous ignition in cylinders #1 and #4, and in cylinders #2 and #3.
The engine ECM switches the control mode between the start-up mode, normal operating mode,
and fuel injection cutoff mode according to the signals from the sensors.
In addition, various compensations are made to determine the actual ignition timing and the energi-
zation time of current to the ignition coil.
The ignition timing is also controlled by the knock control.
Pulser coil
TPS (*1)
Air pressure sensor (*1)

Ignition coil #1, #4
Air temperature sensor
Thermo sensor Engine

ECM
Oil pressure switch
Ignition coil #2, #3
Neutral switch
Knock sensor
Engine start switch
Battery
(*1) Sensors that perform compensations.

Ignition timing when starting Ignition is at BTDC 10° when the engine is running at less
than 500 r/min.
Normal ignition timing Ignition timing is set based on signals from the pulser coil and
the TPS, and all necessary compensations are made.
Cutoff when engine shut-off Ignition is cut when the engine shut-off switch is on.
switch is on
Cutoff when over revving To protect the engine, ignition is skipped when engine speed
is more than a predetermined level.
Cutoff due to activation of Ignition does not take place when the engine is locked by
Y-COP Y-COP.
When a communication error occurs, ignition is cut to control
engine speed.
2-5
Engine speed control
The engine ECM stops ignition and fuel injection as necessary to prevent damage to the engine
when engine speed is more than a predetermined level, when the engine overheats, or if oil pres-
sure decrease is detected. Fuel injection is cut together when ignition in the grouped cylinders has
been cut completely. 0
Pulser coil
TPS
Ignition coil #1, #4 1
Air pressure sensor Ignition coil #2, #3

2
Thermo sensor Engine
Oil pressure switch

ECM 3
Neutral switch
Engine start switch Alert buzzer

4
Battery
Alert indicator 5
6
7
8
9
10
A
2-6
TECH
Control
Criteria Description
name
Over- When engine speed 6449–6601 r/min Firing will be skipped for
revving is more than a cylinder #1 or #4.
control predetermined level 6602–6749 r/min Firing and fuel injection will
be skipped for cylinders #1
and #4.
6750–6800 r/min Firing and fuel injection for
cylinders #1 and #4, and
firing for cylinder #3 or #2 will
be skipped.
Over 6801 r/min Firing and fuel injection for all
cylinders will be skipped.
Over- Control starts when No determination on overheat Firing and fuel injection will
heat the cooling water will be made until the engine be skipped in stages to limit
control temperature is 79 °C speed is more than 2000 engine speed to
(174 °F) or more r/min for 24 seconds or more approximately 2600 r/min.
Control stops when after the engine has started, Stage 1: #1 or #4
the cooling water or until 79 seconds after the Stage 2: #1 and #4
temperature is 70 °C engine has started. Stage 3: #1, #4, and #3 or #2
(158 °F) or less The overheat alert indicator
comes on, and the alert
buzzer sounds.
Low oil When the oil A low oil pressure Firing and fuel injection will
pressure pressure switch is determination is made when be skipped in stages to limit
control on. the cooling water engine speed to
temperature is 40 °C (104 °F) approximately 2600 r/min,
or more, or the engine is Stage 1: #1 or #4
running at more than Stage 2: #1 and #4
1400–1500 r/min. Stage 3: #1, #4, and #3 or #2
The low oil pressure alert
comes on, and the alert
buzzer sounds.
2-7
Knock control
The engine ECM receives a knock signal from the knock sensor that is installed to the cylinder
block. To protect the engine from damage the engine ECM retards the ignition timing and decreases
the engine speed according to the amount of knocking.
If the knocking occurs frequently, the ignition timing is retarded until knocking is no longer detected, 0
and the retarded ignition timing is maintained, using the learning function.
Regardless of the preceding conditions the knock control also activates when the water temperature
sensor is malfunctioning.
Engine
1
temperature Less than 20 °C More than 25 °C
20–25 °C (68–77 °F)
(68 °F) (77 °F)
Engine speed 2
Less than 4500 r/min Knock control does Knock control Knock control
not activate activates if conditions activates
continue for 0.5
seconds
3
4500 r/min or more Knock control
activates
ISC Control
4
The engine ECM adjusts the ISC valve opening so that engine speed is maintained at a target level
when idling. Initialization control is performed when the engine shut-off switch is on. Fuel injection is
halted during initialization control. The ISC control is also fitted with a learning function and trolling 5
speed control function.
Trolling speed can be adjusted by opening and closing the ISC valve using 6Y8 Multifunction Meter
(tachometer) or the tiller handle when the gear shift is in the F or R position.
However, when the gear shift is set to the N position or when the throttle is opened and engine 6
speed is more than 3000 r/min, the trolling speed control function is deactivated.
Alert indicator, alert buzzer control

7
Alert indicator control Overheated
Low oil pressure
Alert buzzer control

Water in the fuel filter
Overheated
8
Low oil pressure
Water in the fuel filter when the gear shift is in the N position.
Engine cranked when the clip is removed from the engine 9
shut-off switch.
10
A
2-8
TECH
Fail-safe control
The engine ECM enters fail-safe mode when an electrical component malfunctions. The fail-safe
control system records the engine trouble codes.
Trou- LAN
ble Item gauge Trouble conditions to be detected
code display
15 Water temp sensor C/E Open or short circuit in the thermo sensor circuit
(thermo sensor) Output voltage is less than 0.1 V or more than 4.52 V
when the engine starts: Set to 5 °C (41 °F), 20 °C (68
°F), or 40 °C (104 °F) depending on the signal from the
air temperature sensor (*2).
After engine start: Maintained at 40 °C (104 °F) (*2).
17 Knock sensor C/E Open circuit in the knock sensor circuit
Output voltage is less than 0.9 V or more than 4.0 V.
18 Throttle position C/E Open or short circuit in the TPS circuit
sensor (TPS) Output voltage is less than 0.3 V or more than 4.7 V.
Determines the fully closed position of the throttle
based on the signal from the air pressure sensor (*2).
19 Battery voltage V (*1) Voltage is less than 12 V for 2 minutes, even when
engine speed is more than 2000 r/min.
23 Intake temp sensor C/E Open or short circuit in the air temperature sensor
(air temperature circuit
sensor) Output voltage is less than 0.1 V or more than 4.61 V.
Set to 40 °C (104 °F) (*2).
27 Water in fuel W/F The neutral switch is on and the water detection switch
is on.
28 Shift position switch C/E Cranking while in gear.
(neutral switch) Cranking while the neutral switch circuit is open-
circuited.
29 Intake press sensor C/E Open or short circuit in the air pressure sensor circuit
(air pressure sensor) Output voltage is less than 0.2 V or more than 4.5 V.
Temporarily sets air pressure levels based on the
engine speed and the TPS signal (*2).
37 Intake air passage C/E The neutral switch is off, the throttle is fully closed, the
ISC valve is fully closed, and the engine speed is more
than 1100 r/min.
44 Engine stop lanyard C/E Cranking when the clip is removed.
switch (engine
shut-off switch)
49 Over cooling C/E Cooling water temperature is less than 40 °C (104 °F),
and engine speed is more than 3000 r/min for more
than 2 minutes.
86 Immobilizer (Y-COP) C/E Open or short circuit in the Y-COP circuit.
Communication error continues for more than 3
seconds.
(*1) Battery voltage and battery alert are displayed.
(*2) Control mode when the part malfunctions.
2-9
Electronic control system / Y-COP
Y-COP
Y-COP consists of a transmitter and a receiver. The receiver transmits an authorization ID to the
engine ECM. If an authorization ID is not received or if the transmitted authorization ID does not
match the registered ID in the engine ECM, the receiver cannot perform data communication with
the engine ECM. Pushing the lock and unlock buttons on the transmitter causes the receiver to rec- 0
ognize the lock and unlock state, and to send data to the engine ECM. The locked or unlocked state
is maintained even when the battery switch is turned to OFF.
Y-COP 1
Transmitter Ignition coil #1, #4
Receiver Ignition coil #2, #3 2
Hub Engine
Fuel injector #1, #4 3
ECM
4
Alert indicator
Battery
5
State Operation
Unlocked Normal 6
Locked Stops fuel injection and ignition, and prevents
the engine from starting.
Communication error, improper wiring
connection.
The engine will start, but engine speed is
limited to 2600 r/min.
7
Outputs a trouble code
TIP: 8
• The receiver can register up to 5 transmitters.
• Additional transmitters cannot be registered if none of the transmitters is functioning properly.
•
•
The transmitter and receiver function within a distance of approximately 3 m (10 ft).
Installation location requires special attention to avoid electrical interference, obstructions, or
9
water exposure.
10
A
2-10
TECH
Power unit
This model uses the 16-valve for the first time in a 4-cylinder, in-line SOHC engine in order to
improve the efficiency of the intake and exhaust, boosting the power of the engine.
The single valve throttle body, plastic intake silencer, and long intake manifold ensure a quiet
engine.
Multi-point injectors with high atomization performance and a computer controlled fuel vapor reduc-
tion system have resulted in a configuration that is easy to start regardless of ambient conditions.
Intake manifold
Intake silencer
Throttle body
Fuel injector
2-11
Power unit / Fuel system
Fuel system
Fuel diagram
Pressure regulator
Vapor shut-off valve 0
Fuel filter (with water
separator and water
detection switch) Vapor separator 1
Strainer
2
Primer pump
3
4
High-pressure
fuel pump 5
Fuel cooler
6
Low-pressure
fuel pump Fuel injector
Fuel rail
7
8
9
10
A
2-12
TECH
Vapor separator
Pressure
regulator Vapor shut-off valve
Fuel rail
High-pressure
Fuel cooler fuel pump
Fuel injector Fuel injector Fuel injector Fuel injector
#1 #2 #3 #4
Filter
Combustion Combustion Combustion Combustion

Float chamber chamber #1 chamber #2 chamber #3 chamber #4
Strainer
Intake manifold
Low-pressure
fuel pump Intake silencer
Fuel filter (with water A

separator and water B
detection switch) Primer pump Fuel tank
A Fuel flow
B Vapor gas flow
2-13
Fuel system / Lubrication system
Lubrication system
Lubrication diagram
0
1
2
Oil pump
3
4
Oil filter
5
Oil strainer
Oil pan
6
Piston Sleeve 7
Crankpin Camshaft journal #1
Rocker arm shaft bolt

8
Crankshaft journal
Rocker arm shaft

Main gallery 9
Rocker arm shaft bolt
Oil filter
Rocker arm
Oil pump Relief valve Camshaft journal #2–#4

10
Intake and exhaust valves
Oil strainer
Oil pan A
A Engine oil flow A

2-14
TECH
Cooling system
Cooling diagram
Fuel cooler
Thermostat
Oil pan
Cooling water wall

Cooling water outlet
Fuel cooler
Thermostat Cylinder block
Cylinder head
Exhaust cover
Water pump
Cylinder block
Exhaust guide Exhaust guide
Upper case Oil pan
Water pump
Lower case
Trim tab water inlet Propeller boss Cooling water inlet
A Water
A Cooling water flow
2-15
Cooling system / Intake and exhaust system
Intake and exhaust system
Intake and exhaust diagram
0
Intake silencer
Throttle body
1
2
3
4
5
Labyrinth idle
exhaust system
6
7
Exhaust Intake manifold
manifold
8
9
10
A
B
A Intake air flow

B Exhaust gas flow A
2-16
TECH
PTT unit
Trim-up and tilt-up function
Pushing the UP button on the PTT switch causes the PTT motor a to activate the gear pump, gen-
erating the PTT fluid pressure. The PTT fluid pressure moves the up-main valve b and down-main
valve c.
The PTT fluid passes through the up passage and flows into the lower chamber of the trim cylinder
d. The PTT fluid pressure pushes up the trim cylinder d, and the PTT fluid in the upper chamber of
the trim cylinder passes through the down passage, returning to the gear pump.
The valve a opens when the trim cylinder is pushed up to its upper extreme.
The PTT fluid pressure pushes up the tilt piston e, and the PTT fluid in the upper chamber of the tilt
cylinder passes through the down passage, returning to the gear pump. When tilt-up operation is
complete, the PTT fluid pressure increases causing the up-relief valve f to open, and the PTT fluid
returns to the reservoir b.
B A
b
a b
f
a
c
b
d
e
C
D
A Trim range C Send circuit

B Tilt range D Return circuit
2-17
PTT unit
Trim-down and tilt-down function
Pushing the DN button on the PTT switch causes the PTT motor a to activate the gear pump, gen-
erating the PTT fluid pressure. The PTT fluid pressure moves the down-main valve b and up-main
valve c.
The PTT fluid passes through the down passage and flows into the tilt cylinder, pushing down the tilt 0
piston d. The PTT fluid in the lower chamber of the tilt cylinder passes through the up passage,
returning to the gear pump.
The trim cylinder e is pushed down when the tilt cylinder is filled with the PTT fluid.
The PTT fluid in the lower chamber of the trim cylinder passes through the up passage and returns 1
to the gear pump.
When tilt-down operation is complete, the PTT fluid pressure increases causing the down-relief
valve f to open. The PTT fluid returns to the reservoir a. 2
B A 3
a
a
a
f
4
5
a
b
c 6
7
d
e
8
9
10
a
C
D
A Trim range C Return

B Tilt range D Send A
2-18
TECH
Stationary condition
When the PTT switch is not pushed, the gear pump assembly will not pump the PTT fluid, the up-
main valve and down-main valve will remain closed, and the PTT fluid in the system will remain at a
constant pressure. As a result, the PTT ram stays in its current position.
Shock-absorbing function
If the lower case strikes an obstacle while the boat is moving, a force causing the PTT ram a to
extend will be applied suddenly.
Because this force will cause the PTT fluid pressure in the tilt cylinder upper chamber a to
increase, the tilt piston absorber valves b will open.
The PTT fluid enters the space between the tilt piston c and the free piston b extending the PTT
ram.
The damping effect of the absorber valve stops the tilt piston before it reaches the top of the tilt cyl-
inder.
After the collision, a force is generated as the outboard motor returns to its original position due to
the weight of the outboard motor and the thrust of the propeller. The PTT fluid enters the tilt cylinder
upper chamber a through the shock return valve d in the tilt piston c. The tilt rod a stops when it
contacts the free piston b.
a a
a a
d
c
b b
A B
A Fluid flow when the outboard motor strikes an obstacle.

B Fluid flow when the outboard motor returns to the original position.
2-19
RIG
GING
Rigging information 3
Outboard motor installation ............................................. 3-1

0
Dimension .......................................................................... 3-2
Exterior: F70AET ....................................................................... 3-2
Exterior: F70A (tiller handle model) ........................................... 3-3
Clamp bracket ........................................................................... 3-4
1
Crate top cover pictograph description .......................... 3-5
2
Uncrating procedure ......................................................... 3-6
Outboard motor mounting ................................................ 3-7 3

Rigging grommet mounting ............................................. 3-9
Rigging grommet description ..................................................... 3-9 4
Installing the shift cable and throttle cable ................................ 3-9
Installing the wiring harness .................................................... 3-11
Installing the 6Y8 Multifunction Meter harness ........................ 3-12
Installing the remote control box and tachometer ................... 3-13 5
Optional equipment ........................................................ 3-13
Installing the water pressure sensor ........................................ 3-13
Installing the speed sensor ...................................................... 3-14
6
Installing the tiller handle ......................................................... 3-15
Installing Y-COP (optional in non-European markets) 3-17 7

Registering the receiver ID to the ECM ................................... 3-17
Battery installation .......................................................... 3-18 8

System diagram .............................................................. 3-19
Single outboard motor application ........................................... 3-19 9
Rigging recommendation ............................................... 3-21
Battery requirement ................................................................. 3-21 10
Propeller selection .......................................................... 3-21
Propeller size ........................................................................... 3-21
Selection .................................................................................. 3-21
A
RIG
GING Rigging information
Outboard motor installation
• 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. Consult your dealer or have a Yamaha-
trained person experienced in proper rigging mount the outboard motor.
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 out-
board 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,
steering system, or engine. These damages could cause loss of control.
3-1
Outboard motor installation / Dimension
Dimension
Exterior: F70AET
mm (in)
0
193 (7.6) 363 (14.3)
40°
1
2
L: 1000 (39.4)
421 (16.6) X: 1103 (43.5)
152 (6.0) 3
122 (4.9) 591 (23.3)
62 (2.5)
4
5
741 (29.2)
561 (22.1)
6
371 (14.7)
7
49 (2.0)
26 (1.1)
X: 648 (25.6)
L: 534 (21.1)
8
H (*1)
X: 1029 (40.6)
L: 915 (36.1)
X: 815 (32.1)
L: 749 (29.5)
°
65
9
191 (7.6)
67 (2.
7)
12°
10
29 (1.2)
–4°
26 (1.1) 582 (23.0)
(*1) Transom height

A
3-2
RIG
Exterior: F70A (tiller handle model)

mm (in)
363 (14.3)
40°
137 (5.4)
676 (26.5)
193 (7.6)
788 (31.1) L: 1000 (39.4)
421 (16.6) X: 1103 (43.5)
225 (8.9) 591 (23.3)
182 (7.2)
62 (2.5)
790 (31.2)
741 (29.2)
561 (22.1)
371 (14.7)
49 (2.0)
29 (1.2)
191 (7.6) X: 648 (25.6)
L: 534 (21.1)
H (*1)
X: 1029 (40.6)
L: 915 (36.1)
X: 815 (32.1)
L: 749 (29.5)
°
65
67 (2.
7)
12°
29 (1.2)
–4°
26 (1.1) 582 (23.0)
(*1) Transom height
3-3
Dimension
Clamp bracket
mm (in)
0
1
2
180 (7.1) 180 (7.1) 3
163.5 (6.4) 163.5 (6.4)
50.8 (2.0)
4
5
18.5 (0.8)
69 (2.8)
254 (10.0)
6
350 (13.8)
13 (0.6)
7
55.5 (2.2)
13 (0.6) 8
126 (5.0) 126 (5.0)
9
10
A
3-4
RIG
Crate top cover pictograph description
The following pictographs are important when handling the crate.
Read the notice and understand what each pictograph means to prevent damage to the outboard
motor when handling, transporting, and storing the crate.
Lifting fork insert position

Stack limit: Maximum units for storage
Upward
Handle with care

Avoid water
Product barycentric position

IMPORTANT
This unit delivered to carrier in a good condition.
For protection against loss due to damage, inspect thoroughly.
If damage is noted, make note on freight bill.
Shipper assumes no further liability to the transportation company.
Your claim should be filed against carrier for damage of any nature.
3-5
Crate top cover pictograph description / Uncrating procedure
Uncrating procedure
1. Check the crate for shipping damage.
2. Remove the top cover.
3. Remove all of the bolts from the bottom

0
plate, and then remove the frame.
NOTICE: Be careful not to damage
the outboard motor. b 1
4. Remove the wrapping, and then check
the outboard motor for concealed dam-
age. a 2
5. Remove the top cowling, and then
remove the flywheel magnet cover a. TIP:
Place a rag a between the flywheel magnet 3
and the lifting harness.
a
8. Lift up the outboard motor carefully along
with the bottom frame d.
4
NOTICE: Make sure that the lifting
harnesses do not damage any parts of
the outboard motor. 5
6. Install the lifting harnesses b to the
engine hangers c.
6
d
c
b
7
b
8
c
7. Tension the lifting harnesses b. 9. Remove the skeg holder e.

9
10
A
3-6
RIG
10. Remove the bolts f. B C/L
a b
c d
A Hull without strakes

B Hull with strakes
11. Remove the steering retainer, and then
C/L: Centerline of the transom
install a hydraulic steering cylinder or
steering cable following the recommen-
dation of the manufacturer. TIP:
Make sure that distance a is equal to dis-
Outboard motor mounting tance b, and distance c is equal to distance
Proper mounting of the outboard motor pro- d.
vides better performance, maximum reliabil-
ity, and the highest customer satisfaction. 2. Adjust the position of the outboard motor
This chapter contains the specifications nec- so that the height of the anti-cavitation
essary to mount the outboard motor, and may plate e is equal to or slightly above the
vary slightly depending on the applications. bottom of the boat transom.
When mounting the outboard motor, make
sure that there is sufficient clearance for the
outboard motor to fully tilt up, and to fully
move to port and starboard. See “Dimension”
(3-2).
e
1. Place the outboard motor on the vertical
centerline of the boat transom.
A C/L
TIP:
This mounting height information is for refer-
a b ence only. It is impossible to provide com-
plete instructions for every possible boat and
outboard motor combination.
c d 3. Adjust the height of the scale f to the

transom height (H), and place it on the
special service tool a. Secure the spe-
cial service tool a to the boat transom
using screws or vises.
TIP:
For the transom height (H), see “Dimension”
(3-2).
3-7
Uncrating procedure / Outboard motor mounting
4. When the outboard motor mounting posi-
tion has been determined, mark the best b
suited 4 symmetrical mounting holes on c d
c
the boat transom g. Drill the mounting e
holes perpendicular to the surface of the
boat transom using a 13.0 mm (0.5 in) h
b
0
drill bit. c
d e
f
a
c 1
D 2
b c d
c
e
g
3
H Boat transom
thickness (D)
Mounting bolt 4
h 65–75 mm M12 105 mm
(2.56–2.95 in) (4.13 in)
f
5
C/L TIP:
C/L: Centerline of transom The second hole from the top of each clamp
Drilling plate a: 90890-06783
bracket is recommended for the upper
mounting bolt.
6
5. Apply sealant to the mounting holes, and
then secure the outboard motor using the 6. Install the mounting bolts, and then
included mounting bolts b, small wash-
ers c, large washers d, and nuts e.
tighten the nuts firmly. NOTICE: Make 7
sure that the clamp brackets do not
NOTICE: Make sure that there is no bite into the boat transom.
clearance between the surfaces of the
boat transom and the clamp brackets. 7. Tighten the locknuts firmly. 8
Otherwise, the clamp brackets or boat
transom may be damaged.
9
10
A
3-8
RIG
Rigging grommet mounting
Rigging grommet description
c
f a
a
b
d
e
c
b
d 3. Route the shift cable c and throttle cable

d through the bottom cowling.
a Alert indicator harness
b Trolling switch harness 4. Install the cable guide b and grommet e
c 10-pin wiring harness to the bottom cowling.
d Speedometer hose
e Battery cable
e
f 6Y8 Multifunction Meter harness
b
Installing the shift cable and throttle
cable
c
Before installing the shift cable and throt- d

tle cable, make sure to adjust the cables
according to the procedures in the remote 5. Fully screw in the shift cable joint f to
control operation manual. the shift cable c.
1. Remove the steering retainer plate a

and cable guide b.
c
f
6. Move the remote control lever to the N

position.
b 7. Align the pin b with the mark c on the

shift bracket g.
a
2. Fit the cable guide b into the groove a

in the shift cable c and the groove a in
the throttle cable d.
3-9
h
b
0
c
g i 1
8. Mark the fully retracted inner cable with Shift cable locknut i:
an identification mark d, and then mark
the fully extended inner cable with an
5 N·m (0.5 kgf·m, 3.7 ft·lb) 2
identification mark e. 12. Fully screw in the throttle cable joint j to
9. Mark the middle point between the marks
d and e with an identification mark f,
3
and then align the mark f with the outer
cable edge g.
d
4
d
j
d fe
5
d f 13. Check that the throttle control lever k
contacts the stopper m. 6
g
m k
10. Adjust the shift cable joint f, and then
install the shift cable joint f to the pin b. 7
WARNING! The shift cable joint must
be screwed in 8.0 mm (0.31 in) or
more.
8
f h
b
14. Align the protrusion n on the throttle
control lever k with the protrusion p on
9
the shift bracket g.
f
15. Pull the inner cable so that there is no
free play (backlash).
10
16. Adjust the throttle cable joint j, and then
Dimension h: 8.0 mm (0.31 in) or more
install the throttle cable joint j to the pin
11. Install the clip h, and then tighten the r of the throttle control lever k.
shift cable locknut i to the specified WARNING! The throttle cable joint
torque. must be screwed in 8.0 mm (0.31 in) or
more. A
3-10
RIG
2. Route the 10-pin wiring harness b
through the bottom cowling.
j s 3. Route the battery cable c through the

p bottom cowling.
g p
c
n
b
r
k n j
Dimension s: 8.0 mm (0.31 in) or more

4. Install the battery cable c, and then
17. Install the clip l, and then tighten the tighten the battery cable nut d to the
throttle cable locknut m to the specified specified torque.
torque.
5. Fasten the battery cable using the hold-
ers e and f.
m
d
c
e
l c f
Throttle cable locknut m:

5 N·m (0.5 kgf·m, 3.7 ft·lb)
Battery cable nut d:
18. Check the shift cable and throttle cable 9 N·m (0.9 kgf·m, 6.6 ft·lb)
for proper operation.
6. Connect the 10-pin harness coupler b,
Installing the wiring harness and then fasten it using the plastic ties a
1. Remove the plastic tie a, and then and g.
remove the main wiring harness coupler
a.
a g
a a
7. Remove the cap h.
3-11
Installing the 6Y8 Multifunction
h Meter harness
1. Remove the cap a and holder b.
a
0
b
1
8. Route the gauge harness through the
bottom cowling, and then connect the
gauge harness coupler c.
2
2. Route the 6Y8 Multifunction Meter har-
ness through the bottom cowling, and
then connect the 6Y8 Multifunction Meter 3
harness coupler a.
3. Install the holder b.

4
a
c
9. See “Installing the 6Y8 Multifunction b

5
Meter harness” (3-12).
10. Route the battery cable, 10-pin wiring

harness, alert indicator harness, and
6
speed sensor hose through the proper
hole in the rigging grommet. See “Rig-
ging grommet description” (3-9).
4. Remove the yellow tape b and caps c.
7
11. Install the battery cable with the positive
b
battery cable d on top, aligning the white
tape e on the battery cable with the 8
outer end of the rigging grommet.
12. Install the grommet holder i.

9
d c
e
5. Connect the trim sensor coupler d.
10
A
3-12
RIG
Optional equipment
Installing the water pressure sensor
See 6Y8 Multifunction Meter set up manual
for details of the components.
1. Remove the exhaust cover plug a.
d
a
Installing the remote control box and
tachometer
For the installation procedures, see Remote
control box operation manual or Rigging
guide.
2. Install a new gasket b and the water

pressure sensor nipple c, and then
tighten the water pressure sensor nipple
c to the specified torque. NOTICE: Do
not reuse a gasket, always replace it
with a new one.
Water pressure sensor nipple c:

23 N·m (2.3 kgf·m, 17.0 ft·lb)
3. Install the water pressure sensor d to

the water pressure sensor adapter e,
and then tighten the water pressure sen-
sor d to the specified torque.
3-13
Rigging grommet mounting / Optional equipment
Water pressure sensor d:

18 N·m (1.8 kgf·m, 13.3 ft·lb) c
e
g
4. Install the water pressure sensor adapter
e to the bottom cowling using a tapping h 0
bolt f.
1
Installing the speed sensor
See 6Y8 Multifunction Meter set up manual
for details of the components.
2
e
f 1. Install the speed sensor a to the speed
sensor adapter b, and then tighten the
speed sensor a to the specified torque.
3
5. Remove the cap a.
b 4
a
5
a
Speed sensor a:
6
6. Connect the water pressure sensor cou-
pler b. 18 N·m (1.8 kgf·m, 13.3 ft·lb)
2. Install the speed sensor adapter b to the

cylinder head cover.
7
b 8
b
9
7. Cut the extension hose and corrugated
tube to 320.0 mm.
3. Remove the speed meter hose c from
10
8. Install the extension hose g and corru-
gated tube h to the water pressure sen- the rigging grommet, and then remove
sor nipple c and water pressure sensor the nipple d.
adapter e.
A
3-14
RIG
d c c
4. Route the speed meter hose c from the Installing the tiller handle
PORT side, and then connect it to the 1. Remove the steering retainer plate a
speed sensor adapter b. and cable guide b.
b
c
c a
b
5. Remove the tape e and cap a.
a e 2. Fit the cable guide b into the groove a

in the shift cable c and the groove a in
c
a
6. Connect the speed sensor coupler b.
7. Cut the rubber seal c to 30.0 mm

(1.2 in), and then block the rigging grom-
met using a rubber seal c. c
3-15
Optional equipment
TIP:
The shape b identifies the shift cable c.
3. Route the shift cable c and throttle cable

d through the bottom cowling.
0
4. Install the tiller handle assembly e to the
steering arm f, and then tighten the tiller c 1
handle nuts g to the specified torque.
9. Install the shift cable and throttle cable.
5. Install the cable guide b and grommet h
to the bottom cowling.
See “Installing the shift cable and throttle
cable” (3-9).
2
f e
10. Install each harness and cable to the cor-
responding position on the rigging grom-
met. See “Rigging grommet description”
3
(3-9).
b
11. Install the battery cable with the positive
battery cable d on top, aligning the white
4
h
g g tape e on the battery cable with the
Tiller handle nut g:

outer end of the rigging grommet.
5
37 N·m (3.7 kgf·m, 27.3 ft·lb) 12. Install the grommet holder j into the
bottom cowling.
6. Install the extension wiring harness, bat-
tery cable, and alert indicator harness. d 6
See steps 1–7 in “Installing the wiring e
harness” (3-11).
7. Remove the cap i. 7

i
j 8
13. Fasten the extension wiring harness, bat-
tery cables, alert indicator harness, troll-
ing switch harness, shift cable, and 9
throttle cable using the plastic tie k.
8. Route the trolling switch harness through k 10

the bottom cowling, and then connect the
trolling switch harness coupler c.
A
3-16
RIG
14. Check the steering friction plate assem- Installing Y-COP (optional in
bly. non-European markets)
See Yamaha Security System Y-COP instal-
lation manual.
• Install the receiver so that the “UP”

mark is facing up.
• Do not install the receiver in a location
where it will be exposed to water.
g f
• Do not cover the receiver with metal
f Increase the friction objects. Otherwise, signals may not be
g Decrease the friction received.
TIP: 1. Install the receiver a, and then tighten

Make sure that the hoses, harness, lead, and the receiver screws b to the specified
cables do no interfere with the steering fric- torque.
tion plate assembly.
15. Adjust the friction adjusting nut l so that a

the steering operates properly.
WARNING! Do not overtighten the b
friction adjuster. If there is too much
a
resistance, it could be difficult to
steer, which could result in an acci-
dent. b
k h
l
Receiver screw b:
l
4 N·m (0.4 kgf·m, 3.0 ft·lb)
A
A
g f
TIP:
• Mount the receiver within 3 m (10 ft) from
the steering position.
TIP:
• Tighten or loosen the friction adjusting nut • For the installation position and drill holes,
at the steering lock lever in the position f. see Yamaha Security System Y-COP instal-
• To increase the friction, tighten the friction lation manual.
adjusting nut l in direction h.
• To decrease the friction, loosen the friction 2. Connect the Y-COP wires. See “System
adjusting nut l in direction k. diagram” (3-19).
Registering the receiver ID to the

ECM
1. Check that the engine start switch is
OFF.
3-17
Optional equipment /
Installing Y-COP (optional in non-European markets) / Battery installation
2. Push the unlock button a of the transmit-
ter. The buzzer of the receiver will sound TIP:
2 short beeps. If the outboard motor is equipped with the
6Y8 Multifunction Meter, c is displayed on
the tachometer when the engine start switch
is turned to ON.
0
7. Push the unlock button a of the transmit-
ter. Check that the buzzer of the receiver 1
will sound 2 short beeps.
a
a 2
3. Turn the engine start switch to ON. The
buzzer of the receiver will sound 1
medium beep. 3
4. Turn the engine start switch to OFF. Initial
registration is complete. Y-COP is
unlocked. 4
5. Push the lock button b of the transmitter.
Check that the buzzer of the receiver will
sound 1 short beep. 5
TIP:
b If the outboard motor is equipped with the
6Y8 Multifunction Meter, “0” is displayed on 6
the tachometer when the engine start switch
is turned to ON.
8. Turn the engine start switch to OFF.

7
6. Turn the engine start switch to ON.
Battery installation 8
c
Make sure to connect the battery properly
and select the proper cable sizes. Other- 9
wise, a fire could result.
10
Do not reverse the battery connections.
Otherwise, the charging system could be
damaged.
A
3-18
RIG
System diagram
Single outboard motor application
(*1) Install the waterproof cap to the open terminal.
(*2) Y-COP (optional in non-European markets)
a Engine ECM
b Remote control box
c Fuse (10 A)
d Power wire
e Pigtail bus wire
f Single hub
g Main bus wire
h Hub
i In-line resistor
j Tachometer unit
k Speedometer unit
l Receiver
a Power port
b Bus port
c Device port
Color code
B : Black
G : Green
R : Red
Y : Yellow
3-19
System diagram
0
1
j k l
(*2) 2
3
h e
b i
c
e
e
4
c
c
b
d
(*1)
R
G
b
5
a B B
Y Y Y
g
c 6
7
f
8
e
a
10
A
3-20
RIG
Rigging recommendation
Battery requirement
Select a battery stud that is best-suited to the a b c
terminal size.
Solder the cable and terminal connections to
prevent them from corroding.
Ambient temperature above 0 °C (32 °F)
Unit Minimum
capacity
CCA/EN 430.0 Amps a Propeller diameter (in inches)
20HR/IEC 70.0 Ah b Propeller pitch (in inches)
c Propeller type (propeller mark)
Propeller selection
The size and type of the propeller that is used Selection
will affect the performance of a boat and out- When the engine speed is at full throttle oper-
board motor critically. Propellers greatly ating range, the ideal propeller for the boat is
affect boat speed, acceleration, engine life, the one that provides maximum performance
fuel economy, and even boating and steering in relation to the boat speed and fuel con-
capabilities. An incorrect choice could sumption.
adversely affect performance and could also Full throttle operating range:
seriously damage the engine. 5300–6300 r/min
Use the following information as a guide for
selecting a propeller that meets the operating Propeller size (in) Material
conditions of the boat and outboard motor. 12 5/8 21 - K
13 19 - K
Propeller size
The size of the propeller is indicated on the 13 23 - K
propeller boss end, on the propeller blade, or 13 25 - K
on the side of the propeller boss. 13 1/4 17 - K
13 1/2 15 - K Aluminum
13 1/2 17 - K
13 1/2 19 - K
a b c
13 5/8 13 - K
13 5/8 14 - K
14 11 - K
13 17 - K
13 19 - K
13 21 - K
13 23 - K Stainless
13 25 - K
13 1/2 14 - K
a b c
13 1/2 16 - K
3-21
TRBL
SHTG
Troubleshooting 4
YDIS .................................................................................... 4-1

Feature ...................................................................................... 4-1
Hardware requirement ............................................................... 4-1
0
Function ..................................................................................... 4-2
Connecting the communication cable to the outboard motor .... 4-3
1
Outboard motor troubleshooting ..................................... 4-4
Troubleshooting procedure ....................................................... 4-4
Troubleshooting the power unit using the YDIS ........................ 4-4
Trouble code and checking step ............................................... 4-6
2
Troubleshooting the power unit using the diagnostic
flash indicator ............................................................................ 4-8
Troubleshooting the power unit (trouble code not detected) ..... 4-9
Troubleshooting the PTT unit .................................................. 4-13
3
Troubleshooting the lower unit ................................................ 4-14
4
5
6
7
8
9
10
A
TRBL
SHTG Troubleshooting
YDIS
This manual contains model-specific information. See the YDIS instruction manual for detailed infor-
mation.
Feature
The newly developed YDIS provides quicker detection and analysis of the engine malfunctions.
By connecting your computer to the engine ECM of an outboard motor using the communication
cable, this software can be used to display sensor data and data stored in the engine ECM on the
computer monitor.
If this software is run on Microsoft Windows 2000, Windows XP, or Windows Vista, the information
can be displayed in colorful graphics. Also, the software can be operated using either a mouse or a
keyboard.
In addition, the data for the main functions (Diagnosis, Diagnosis record, Engine monitor, Data log-
ger, and Record of engine oil exchange) can be saved on a disk or printed out.
Hardware requirement
Make sure that your computer meets the following requirements before using this software.
Computer: IBM PC/AT compatible computer
Operating system: Microsoft Windows 2000, Windows XP, or Windows Vista
CPU:
Windows 2000: Pentium, 166 MHz or higher (Pentium, 233 MHz or higher recommended)
Windows XP: Pentium, 300 MHz or higher (Pentium, 500 MHz or higher recommended)
Windows Vista: Core family, 1.6 GHz or higher (Core family, 2.0 GHz or higher
recommended)
Memory:
Windows 2000: 64 MB or more (128 MB or more recommended)
Windows XP: 128 MB or more (256 MB or more recommended)
Windows Vista: 1 GB or more
Hard disk free space: 20 MB or more (40 MB or more recommended)
Drive: CD-ROM drive
Display: VGA (640 480 pixels) 256 or more colors
SVGA (800 600 pixels or more recommended) 256 or more colors
Mouse: Compatible with the operating systems mentioned previously
Communication port: RS232C (D-sub-9 pin) port, USB port
Printer: Compatible with the operating systems mentioned previously
TIP:
• The amount of memory and the amount of free space on the hard disk differs depending on the
computer.
• Using this software while there is not enough free space on the hard disk could cause errors and
result in insufficient memory.
• This software will not run properly on some computers.
• When starting up this program, do not start other software programs.
• Do not use the screen saver function or the energy saving feature when using this program.
• If the engine ECM is changed, restart the program.
• Windows XP and Windows Vista are multiuser operating systems. Therefore, make sure to quit
this program if the login user is changed.
4-1
YDIS
Function
• Diagnosis
Displays each part name and the engine ECM trouble codes and status when the engine start
switch is turned to ON. This enables you to find the malfunctioning parts. The trouble codes dis-
played are the same as those described in this chapter. See “Trouble code and checking step” (4- 0
6).
• Diagnosis record
Displays each part name and the engine ECM trouble codes that have been recorded. This 1
enables you to check the records of malfunctions for the outboard motor. The trouble codes dis-
played are the same as those described in this chapter. See “Trouble code and checking step” (4-
6). 2
• Engine monitor
The status of each sensor and the engine ECM data are displayed when the engine start switch is
turned to ON. This enables you to find malfunctioning parts quickly. In addition, the data displayed
using the Engine monitor function can be displayed in a graph.
3
Engine speed TPS voltage Intake temperature
Intake pressure (*1) Throttle valve opening

Engine stop lanyard switch
(*2)
4
Atmospheric pressure ISC valve opening Shift position switch (*3)
Ignition timing Fuel injection duration Oil press switch
Battery voltage Water temperature — 5
(*1) Intake air pressure (*3) Neutral switch
(*2) Engine shut-off switch
• Stationary test
6
Operation tests can be performed while the engine is stopped.
Ignite ignition coil (#1–#4)
Operate electric fuel pump
Operate injector (#1–#4)
—
Operate ISC valve
—
7
• Active test
The test can be performed while the engine is running and the gear shift is set to the N position. It 8
is not possible to perform the test while the boat is moving.
Fully open ISC valve Angle of ISC valve opening
9
• Data logger
Displays 13 minutes of recorded data for 2 or more of the items stored in the engine ECM. In addi-
tion, the operating time as compared to the engine speed and the total operating time are dis-
played. This enables you to check the operating status of the engine. You can also save the engine
10
ECM record data to a file so that you can view and display the graph later.
Engine speed TPS voltage Intake pressure
Battery voltage Water temperature Oil press switch
• Record of engine oil exchange

Records the history of engine oil changes. A
4-2
TRBL
Connecting the communication cable to the outboard motor
b
a YDIS coupler (gray)
YDIS (CD-ROM, Ver. 1.33) a:
60V-WS853-06
YDIS USB adapter and cable b:
60V-WS850-00
4-3
YDIS / Outboard motor troubleshooting
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 0
fully charged.
3. Check the trouble code using the YDIS first, and then check the electronic control system follow-
ing the trouble code chart.
4. When a trouble code is detected, check the data logger of the engine ECM record data graph as
1
well.
5. If a trouble code is not detected, check the power unit according to “Troubleshooting the power
unit (trouble code not detected)” (4-9).
6. Before using the YDIS to check the power unit, check the engine ECM circuit. See “Checking
2
the engine ECM circuit” (5-14).
TIP: 3
• 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
result, the engine ECM determines that the part is disconnected and a trouble code is detected.
4
Therefore, make sure to delete the diagnosis record after checking the input voltage.
Troubleshooting the power unit using the YDIS 5

1. Use the trouble codes displayed by the YDIS to check each part according to the “Trouble code
and checking step” table.
2. Delete the trouble codes after checking, repairing, or replacing a part and check that the trouble
codes are not detected again. If the same trouble codes are detected, the engine ECM may be
6
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.
7
Trouble code table
: Indicated
—: Not indicated 8
Trouble Diagnostic YDIS diagno-
Item YDIS diagnosis
code flash indicator sis record
1
13
No trouble (functioning properly)
Pulser coil (pulser coil malfunction)
U
—
—
—
—
—
9
15 Water temp sensor malfunction U U U
(thermo sensor malfunction)
17 Knock sensor
(knock sensor malfunction)
U U U 10
18 Throttle position sensor malfunction U U U
19 Battery voltage malfunction U U U
(charging system malfunction)
23 Intake temp sensor malfunction U U U
(air temperature sensor malfunction)
28 Shift position switch malfunction U U U
(neutral switch OFF) A
4-4
TRBL
Trouble Diagnostic YDIS diagno-
Item YDIS diagnosis
code flash indicator sis record
29 Intake press sensor malfunction U U U
(air pressure sensor malfunction)
37 Intake air passage (air leakage) U U U
44 Engine stop lanyard switch ON U U —
(engine shut-off switch ON)
49 Over cooling U U U
86 Immobilizer malfunction (Y-COP mal- U — U
function)
4-5
Trouble code and checking step
—: Not applicable
Trouble LAN gauge
Item Condition Symptom Remarks Checking steps See page
code display
15 Water temp sen- Out of specifica- C/E High engine idle speed Measure the thermo sensor
5-29
sor malfunction tion Degraded acceleration performance input voltage.
Declining maximum engine speed Measure the thermo sensor
Overheat 5-29
— resistance.
Check for wiring continuity
5-29
between the thermo sensor and
A-3
the engine ECM.
17 Knock sensor Out of specifica- C/E High engine idle speed Measure the knock sensor resis-
5-30
malfunction tion Degraded acceleration performance tance.
— Check for wiring continuity
5-30
between the knock sensor and
A-3
the engine ECM.
18 Throttle position Out of specifica- C/E High engine idle speed Measure the TPS output voltage
sensor malfunction Degraded acceleration performance and opening angle using the 5-15
tion YDIS.
— Measure the TPS input voltage. 5-15
5-15
between the TPS and the
A-3
engine ECM.
19 Battery voltage Less than speci- C/E Engine does not restart (Depends Measure the lighting coil output
5-23
malfunction fied voltage on battery condition) peak voltage.
Engine operates normally Measure the Rectifier Regulator
— 5-24
output peak voltage.
Check the Rectifier Regulator for
5-24
continuity.
23 Intake temp sen- Out of specifica- C/E Engine operates normally Check the air temperature using
5-27
sor malfunction tion High engine idle speed the YDIS.
Measure the sensor assembly
5-27
— input voltage.
5-27
between the sensor assembly
A-3
and the engine ECM.
4-6
9
8
7
6
5
4
3
2
1
0
A
10
Trouble LAN gauge
4-7
Item Condition Symptom Remarks Checking steps See page
code display
28 Shift position Irregular signal C/E Engine operates normally Check the gear shift operation. 10-5
TRBL
SHTG
switch malfunc- Measure the neutral switch input

tion 5-30
voltage.
Check the neutral switch for con-
— 5-30
tinuity.
5-30
between the neutral switch and
A-3
the engine ECM.
29 Intake press sen- Out of specifica- C/E High engine idle speed Check the air pressure using the
5-28
sor malfunction tion YDIS.
Measure the sensor assembly
5-28
— input voltage.
Troubleshooting

5-28
between the sensor assembly
A-3
and the engine ECM.
37 Intake air pas- Air leak C/E High engine idle speed Check the gaskets of the intake
sage malfunction Engine operates normally except at manifold, throttle body, sensor 6-23
idle assembly, and fuel injector.
Check the air hose for damage. 6-19
— Check the intake manifold for
6-26
cracks.
Check the opening condition of
TPS and the ISC valve using the 5-16
YDIS.
49 Over cooling Irregular signal C/E Engine operates normally Check that the trouble code 15
4-6
— has not appeared.
Check the thermostat. 7-53
86 Immobilizer Communication C/E Declining maximum engine speed Check that the immobilizer is
3-19
error properly connected.
—
Measure the immobilizer input
5-32
voltage.
Troubleshooting the power unit
using the diagnostic flash indicator TIP:
When more than 1 trouble code is detected,
1. Connect the special service tool a.
the diagnostic flash indicator B flashes in the
pattern of the lowest trouble code. After that
trouble code is corrected, the indicator
0
flashes in the pattern of the next lowest trou-
ble code. This continues until all of the trou-
a
ble codes are detected and corrected. 1
a 2
3
a Diagnostic test lead (Blue/White)
Diagnostic flash indicator B a:
90890-06865
4
TIP:
When performing this diagnosis, make sure
to connect all of the electrical wires properly.
5
2. Start the engine and let it idle.
6
3. Check the flash patterns of the trouble
codes.
Example: The illustration indicates code
number 23.
7
2
d
3
8
9
b b e b b b c
b : Light on, 0.33 second 10

c : Light off, 4.95 seconds
d : Light off, 0.33 second
e : Light off, 1.65 seconds
4. If a trouble code is detected, see “Trouble

code and checking step” (4-6).
A
4-8
TRBL
Troubleshooting the power unit (trouble code not detected)
Troubleshooting consists of the following 3 items:
Symptom 1: Specific trouble conditions
Symptom 2: Trouble conditions of an area or individual part
Cause: Trouble causes of symptom 2
— : Not applicable
Symptom 1: Engine does not crank.
See
Symptom 2 Cause Checking steps
page
Starter motor does not Gear shift not in the N position Set the gear shift to the N position. 10-5
operate Blown fuse Check the fuse. 5-4
A-5
Starter relay malfunction Check the starter relay. 5-31
Engine start switch malfunction Check the engine start switch. 5-32
Neutral switch malfunction Check the neutral switch. 5-32
Short, open, or loose connec- Measure the starter relay input voltage. 5-31
tion in starter motor circuit A-5
Check the wiring harness for continuity. A-5
Starter motor malfunction Disassemble and check the starter 5-36
motor.
Starter motor operates, Starter motor malfunction Check the starter motor pinion. 5-36
but the engine does not Check the magnet switch. 5-36
crank Stuck piston or crankshaft Disassemble and check the power unit. 7-56
Stuck drive shaft Check the drive shaft bushing. 9-29
Disassemble and check the lower unit. 8-17
Symptom 1: Engine will not start (engine cranks).

See
page
Engine ECM does not Blown fuse Check the fuse. 5-4
operate Main relay malfunction Check the main relay. 5-13
Short, open, or loose connec- Check for continuity between the main 5-13
tion in the engine ECM circuit relay and the engine ECM. A-1
Check for continuity between the engine 5-14
ECM and ground. A-1
Spark plug does not Pulser coil malfunction Measure the pulser coil output peak volt- 5-26
produce a spark age.
(all cylinders) Check the pulser coil air gap. 7-2
Measure the pulser coil resistance. 5-26
Short, open, or loose connec- Check for continuity between the pulser 5-26
tion in the pulser coil circuit coil and the engine ECM.
Y-COP is locked Unlock Y-COP. 3-17
4-9
See
page
Fuel not supplied — Measure the fuel pressure. 6-4
(all cylinders) Clogged filter Check the fuel filter for dirt and obstruc- 6-10
Fuel leakage
tions.
Check the fuel line for leakage. 6-1
0
High-pressure fuel pump mal- Check the high-pressure fuel pump oper- 5-21
function ation using the YDIS.
Measure the high-pressure fuel pump
resistance.
5-21 1
Main relay malfunction Check the main relay. 5-13
Short, open, or loose connec- Measure the high-pressure fuel pump
tion in high-pressure fuel pump input voltage.
circuit Check for continuity between the high-
5-21
5-21
2
pressure fuel pump and the main relay. A-1
Fuel pump malfunction

Check for continuity between the high-
pressure fuel pump and ground.
Check the fuel pump for leakage.
5-21
A-1
6-15
3
Check the diaphragm for tears. 6-16
Y-COP is locked
Check the rocker arm.
Unlock Y-COP.
7-46
3-17 4
Compression pressure Improper valve timing Check the timing belt. 7-17
is low Compression leakage Measure the compression pressure. 7-1
Check the valve for bends or sticking.
Check the piston and piston rings for
7-38
7-56
5
damage.
Check the cylinder for scratches. 7-58
—
Intake air passage malfunction Check the ISC valve for sticking.
Check the intake manifold and throttle
5-16
6-23
6
body for air leakage.
Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited
engine speed. 7
See
page
Throttle valve does not
move properly
Throttle valve malfunction Check the throttle valve for proper move-
ment.
6-26
8
Throttle link and the throttle Adjust the throttle link and the throttle 3-9
cable are not installed properly cable. 6-32
Spark plug does not
produce a spark
Spark plug malfunction Check the ignition spark.
Check the spark plugs.
5-25
7-47
9
(some cylinders) Short, open, or loose connec- Measure the spark plug wire resistance. 5-25
tion in ignition coil circuit Check for wiring continuity between the 5-25
Ignition coil malfunction

ignition coil and the engine ECM.
Measure the ignition coil resistance.
A-3
5-25
10
Fuel pressure is low High-pressure fuel line mal- Measure the fuel pressure. 6-4
function Check the pressure regulator. 6-5
Check the fuel filter for dirt and obstruc- 6-44
tions.
Check the high-pressure fuel pump. 5-21
A
4-10
TRBL
See
page
Fuel not supplied Fuel injector malfunction Check the fuel injector operation using 5-20
(some cylinders) the YDIS.
Measure the fuel injector resistance. 5-20
Short, open, or loose connec- Measure the fuel injector input voltage. 5-20
tion in fuel injector circuit Check for continuity between the fuel 5-20
injector and the main relay. A-1
Check for continuity between the fuel 5-20
injector and the engine ECM. A-1
Clogged fuel injector filter Replace the fuel injector. 6-25
Engine ECM malfunction Replace the engine ECM. 7-21
Compression pressure Improper valve timing Check the timing belt. 7-17
is low Compression leakage Measure the compression pressure. 7-1
Measure the valve clearance. 7-2
Check the rocker arm for damage. 7-46
Check the camshaft for damage. 7-46
Check the valve and valve seat for wear. 7-38
Check the piston and piston ring for 7-56
damage.
Check the cylinder for scratches. 7-58
Symptom 1: High engine idle speed.
See
page
Air leakage (throttle valve–cyl- Check the gaskets of the intake mani- 6-23
inder head) folds and throttle body.
Check the intake manifold for cracks. 6-26
Throttle link and the throttle Adjust the throttle link and the throttle 3-9
—
cable are not installed properly cable. 6-32
ISC valve malfunction Check the ISC valve operation using the 5-16
YDIS.
Measure the ISC valve resistance. 5-16
Symptom 1: Limited engine speed.

See
page
Buzzer comes on, over- Clogged cooling water inlet Check the pilot hole for cooling water dis- 10-3
heat alert indicator charge.
comes on Check the cooling water inlet. 10-8
Water pump impeller malfunc- Check the impeller. 8-10
tion Check the Woodruff key. 8-10
Check the insert cartridge. 8-10
Water leakage from water Check the water pump housing. 8-10
pump housing Check the outer plate cartridge. 8-10
Clogged cooling water pas- Check the cooling water passages. 2-15
sages
Thermostat malfunction Check the thermostat. 7-53
4-11
See
page
Buzzer comes on, oil Insufficient engine oil Check the oil level. 10-9
pressure alert indicator Check for engine oil leakage. 2-14
comes on Check the valve seals and valves. 7-42 0
Check the piston rings. 7-58
Engine oil pressure decrease Measure the oil pressure. 7-1
Check the oil pressure switch.
Check the oil pump.
5-17
7-34 1
Check the oil strainer. 9-34
Check the oil passages (power unit and 2-14
the oil pump).
Replace the oil filter. 10-9
2
— Y-COP malfunction Check Y-COP for wiring continuity. 3-17
Symptom 1: Discharged battery.

See
3
page
Battery performance decrease Check the battery capacity and specific 10-3
gravity.
Short, open, or loose connec- Check the battery cable and terminals
—
4
tion in charging circuit for proper connections.
Check the charging circuit for wiring con- A-5
— Lighting coil malfunction

nection and damage.
Measure the lighting coil output peak 5-23
5
voltage.
Measure the lighting coil resistance. 5-23
Rectifier Regulator malfunction Measure the Rectifier Regulator output
peak voltage.
5-24
6
Check the Rectifier Regulator for conti- 5-24
nuity.
7
8
9
10
A
4-12
TRBL
Troubleshooting the PTT unit
Cause: Trouble causes of symptom 2
Symptom 1: PTT unit does not operate.
See
page
PTT relay does not Blown fuse Check the fuse. 5-4
operate PTT switch malfunction Check the PTT switch. 5-45
5-46
PTT relay malfunction Check the PTT relay. 5-44
Short, open, or loose connec- Measure the PTT switch input voltage. 5-45
tion of the wiring harness 5-46
Measure the PTT relay input voltage. 5-44
Check for continuity between the PTT 5-45
switch and the PTT relay. 5-46
A-5
PTT motor does not PTT motor malfunction Check the PTT motor. 9-49
operate Short, open, or loose connec- Check for continuity between the PTT A-5
tion in PTT motor circuit motor and the PTT relay terminal.
PTT fluid pressure does Manual valve open Check the manual valve. 9-65
not increase Insufficient PTT fluid Add sufficient PTT fluid. 10-12
PTT fluid leakage Check the PTT fluid leakage. 10-12
Clogged fluid passage Disassemble and check the PTT unit. 9-53
9-59
Check the filter for dirt and obstructions. 9-57
Check the valves for damage. 9-57
Check the fluid passage for obstructions. 2-17
PTT motor malfunction Check the PTT motor. 9-49
Gear pump malfunction Check the gear pump operation. 9-56
Symptom 1: PTT unit does not hold the outboard motor up.
See
page
PTT fluid pressure does Manual valve open Check the manual valve. 9-65
not increase Insufficient PTT fluid Add sufficient PTT fluid. 10-12
PTT fluid leakage Check the PTT fluid leakage. 10-12
Clogged fluid passages Disassemble and check the PTT unit. 9-53
9-59
Check the valves for damage. 9-57
Check the fluid passages for obstruc- 2-17
tions.
4-13
Troubleshooting the lower unit
Cause: Trouble causes of symptom 2 0
Symptom 1: Shift mechanism of the forward gear and reverse gear does not operate prop-
erly. 1
See
page
—
Shift cable is not adjusted
properly
Adjust the shift cable. 3-9
2
Shift rod does not operate Check the shift rod for wear. 8-10
properly Check the detent mechanism. 9-16
Shift mechanism malfunction
(in lower unit)
Check the shift rod connection.
Check the dog clutch.
8-23
8-14
3
Check the forward gear, reverse gear, 8-14
—
and pinion for damage and wear. 8-19
Adjust the shims.

8-19
8-33 4
5
6
7
8
9
10
A
4-14
ELEC
Electrical system 5
Electrical component and wiring harness routing ......... 5-1

Port ............................................................................................ 5-1
Starboard ................................................................................... 5-3
Front .......................................................................................... 5-4
Top ............................................................................................ 5-5
Bottom cowling .......................................................................... 5-6
Tiller handle (optional) ............................................................... 5-8
Circuit diagram ................................................................ 5-10
ECM coupler layout ......................................................... 5-11
Checking the electrical component ............................... 5-12

Using the YDIS ........................................................................ 5-12
Measuring the peak voltage .................................................... 5-12
Using the digital tester ............................................................. 5-13
Engine control unit and component .............................. 5-13

Checking the main relay .......................................................... 5-13
Checking the engine ECM circuit ............................................ 5-14
Checking the TPS ................................................................... 5-15
Checking the ISC .................................................................... 5-16
Checking the oil pressure switch ............................................. 5-17
Checking the alert indicator (tiller handle model) .................... 5-18
Checking the alert buzzer ........................................................ 5-18
Checking the trolling switch (tiller handle model) .................... 5-18
Fuel control unit and component .................................. 5-19

Checking the water detection switch ....................................... 5-19
Checking the fuel injector ........................................................ 5-20
Checking the high-pressure fuel pump .................................... 5-21
Checking the vapor shut-off valve ........................................... 5-22
Charging unit and component ....................................... 5-23

Checking the lighting coil (stator assembly) ............................ 5-23
Checking the Rectifier Regulator ............................................. 5-24
Ignition unit and component .......................................... 5-25

Checking the ignition spark ..................................................... 5-25
Checking the spark plug wire .................................................. 5-25
Checking the ignition coil ......................................................... 5-25
Checking the pulser coil .......................................................... 5-26
Checking the air temperature sensor ...................................... 5-27
Checking the air pressure sensor ............................................ 5-28
Checking the thermo sensor ................................................... 5-29
Checking the knock sensor ..................................................... 5-30
Checking the neutral switch .................................................... 5-30
Checking the engine shut-off switch ........................................ 5-31
Starting unit and component ......................................... 5-31 0

Checking the starter relay ....................................................... 5-31
Checking the engine start switch ............................................. 5-32
Checking the neutral switch (tiller handle model) .................... 5-32
Checking Y-COP ..................................................................... 5-32 1
Starter motor ................................................................... 5-34
Removing the starter motor ..................................................... 5-36 2
Checking the starter motor operation ...................................... 5-36
Checking the magnet switch ................................................... 5-36
Checking the starter motor pinion ........................................... 5-36
Disassembling the starter motor .............................................. 5-37 3
Checking the armature (starter motor) .................................... 5-38
Checking the brush holder ...................................................... 5-39
Assembling the starter motor .................................................. 5-39
Installing the starter motor ....................................................... 5-41 4
6Y8 Multifunction Meter sensor ..................................... 5-41
Checking the water pressure sensor (optional) ....................... 5-41
Checking the speed sensor (optional) ..................................... 5-42
5
PTT electrical system ..................................................... 5-44
Checking the PTT relay ........................................................... 5-44 6
Checking the PTT switch (bottom cowling) ............................. 5-45
Checking the PTT switch (tiller handle) ................................... 5-46
Checking the trim sensor ......................................................... 5-46
7
8
9
10
A
ELEC
Electrical system
Electrical component and wiring harness routing
Port
A B C b
a
A A
B B
C D
C
e c
E
i j
g h k
j
m i
j
i k
l
l
A-A B-B C-C
a Starter motor i Wiring harness

b Oil pressure switch j Lighting coil lead
c Spark plug wire k Starter motor lead
d Rectifier Regulator l Positive battery cable
e Ignition coil m Negative battery cable
f Starter relay
g Battery power source lead
h Oil pressure switch lead
5-1
A B C b
a
0
c 1
d
2
A A
3
B B
4
C D
C
5
6
f
c
e E
7
i j
g h
j
k
8
m i
j
i k
l
l 9
A-A B-B C-C
A Route the lighting coil harness under the D Fasten the spark plug wire at the white
10
magnet base. tape using the clamp.
B Route the thermo sensor lead and lighting E Fasten the spark plug wire at the white
coil lead through the clamp in this order, tape to the exhaust guide using the clamp.
and then fasten them using the clamp.
C Install the oil pressure lead to the upper
side of the oil pressure switch.
A
5-2
ELEC
Electrical system
Starboard
A B C
A
a b
D
A A
a
B B
f
c
d
a
h g h
g
A-A B-B
a Fuel injector A Fasten the main wiring harness, vapor gas

b Main wiring harness coupler hose, and blowby hose using the holder.
c TPS B Install the clamp at the paint mark on the
d High-pressure fuel pump blowby hose.
e Knock sensor C Fasten the knock sensor lead using the
f Water detection switch holder.
g Speed sensor lead D Fasten the main wiring harness coupler
h Fuel injector lead using the plastic tie.
5-3
Front
A
0
A
A
i
1
a b c d
B B
C C
2
3
d
e
4
f
A-A 5
A
6
g
i
7
B-B
8
h
j
k 9
C-C
a Engine ECM h YDIS coupler

10
b Fuse (20 A) (main relay) i Diode (connect to the PTT relay)
c Fuse (15 A) (engine start switch, PTT j Wiring harness
switch) k Diode lead
d Fuse (30 A) (starter relay)
e Main relay A Install the plastic tie so that the end is not
f Diagnostic flash indicator connector
g PTT relay
pointing down. Be careful not to cut the
end of the plastic tie. A
5-4
ELEC
Electrical system
Top
f g
B
a A-A
A A
A
B
a Vapor shut-off valve A Fasten the pulser coil lead to the magnet
b Thermo sensor base using the plastic tie.
c Pulser coil B Install the wiring harness holders to the
d Sensor assembly holes in the intake manifold.
e Lighting coil (stator assembly)
f High-pressure fuel pump lead
g Vapor shut-off valve lead
h Fuel hose
5-5
Bottom cowling
0
D
D
1
C i
2
C
3
4
a B h
A
A
B
5
g 6
f
b c d e
7
j l
m
o p
q 8
o r
l k n m
s 9
A-A B-B C-C D-D
a Neutral switch h Trim sensor coupler

10
b 6Y8 Multifunction Meter communication i PTT switch
coupler j Alert indicator harness
c PTT switch coupler k Neutral switch lead
d Alert indicator coupler l PTT switch lead
e Trim sensor connector m Trim sensor lead
f Neutral switch coupler
g Trolling switch coupler
n Sub wiring harness
o PTT motor lead A
5-6
ELEC
Electrical system
D
D
C i
a B h
A
A
B
g
f
b c d e
j l p
o
q
m
o r
l k s
n m
A-A B-B C-C D-D
p Speedometer hose
q Lighting coil harness
r Water pressure sensor harness
s Water detection switch lead
5-7
Tiller handle (optional)
0
a
1
2
A
3
b
A
c
d
4
A
B
C
5
g
e
6
f
D 7
h
8
k i
E
j 9
a PTT switch i Grommet

10
b Trolling switch j Alert indicator harness
c Neutral switch k Alert indicator
d Alert buzzer
e Engine start switch coupler A Route the neutral switch leads (blue and
f Extension wiring harness black) under the control link assembly.
B Route the neutral switch leads (brown)
g Engine shut-off switch
h Engine start switch under the buzzer. A
5-8
ELEC
Electrical system
b
A
c
A d
B
C
g
e
h
k i
E
j
C Bend the extension wiring harness f, and D Align the tape ends of the extension wiring
then connect the harness coupler. This harness f and alert indicator harness j
harness bending position must be with the end of the grommet i.
10.0 mm (0.39 in) or more away from the E Install the engine start switch h so that
engine start switch coupler e. The bend the hole in the switch is facing up.
radius should be 10.0 mm (0.39 in) or
more.
5-9
Electrical component and wiring harness routing / Circuit diagram
Circuit diagram
TIP:
The circled numbers in the illustration indicate the engine ECM terminal numbers.
0
Pulser coil Fuel injector #4
TPS
40
16
3
Fuel injector #1 1
Fuel injector #3
36 Fuel injector #2
Air pressure sensor 17

4
11
Vapor shut-off valve 2
Water pressure sensor 18
46 Ignition coil #1, #4
3
Speed sensor 37
1
Ground Ignition coil #2, #3
31
38
23
4
Thermo sensor
6 ISC
48 valve
20
Trim sensor
Knock sensor
45 21 5
44 13 YDIS
Water detection switch Engine
Neutral switch
33 ECM
26
Oil pressure alert indicator
6
34 Overheat alert indicator
Engine shut-off switch 8
Oil pressure switch

27
25
Diagnostic flash indicator 7
10
Trolling switch (UP) Alert buzzer
Trolling switch (DN)

28 9
Tachometer
BZ
8
29 7 T
P
24 43
6Y8 Multifunction Meter
9
High-pressure 52
fuel pump
15
14
10
Engine start
switch Main relay
5
Battery
Indicates a connection between the symbols.

A
5-10
ELEC
Electrical system
ECM coupler layout
434241403938373635 1716 15141312 1110 9 8 7 6 5 4 3 2 1

525150494847464544 3433323130292827262524232221201918
No. Connecting part Color No. Connecting part Color

1 Ignition coil #2, #3 Black/White 27 Engine shut-off White
2 switch
3 Fuel injector #1, #4 Purple/Red 28 Trolling switch (UP) Orange/
White
4 Fuel injector #2, #3 Purple/Black
29 Trolling switch (DN) White/Blue
5 Ground Black
30
6 ISC Green/Black
31 Sensor ground Black
7 Main relay, Green
tachometer 32
8 Overheat alert Pink/Black 33 Water detection Blue/White
indicator switch
9 Alert buzzer Pink 34 Neutral switch Blue/Green
10 Oil pressure switch Pink/White 35
11 Vapor shut-off valve Green/Black 36 TPS Pink
12 37 Speed sensor Blue
13 YDIS White/Black 38 Air temperature Black/Yellow
sensor
14 Ground Black
39
15 Main relay Red/Yellow
40 Pulser coil White/Red
16 Sensor power Orange
source 41
17 Air pressure sensor Pink/Green 42
18 Ignition coil #1, #4 Black/Red 43 6Y8 Multifunction White
Meter
19
44 Knock sensor Green
20 ISC Green/Yellow
45 Trim sensor Pink
21 ISC Green
46 Water pressure Blue/Black
22
sensor
23 ISC Green/Red
47
24 Main relay (high- Blue
48 Thermo sensor Black/Yellow
pressure fuel pump
49
25 Diagnostic flash Blue/White
indicator 50
26 Oil pressure alert Pink/White 51
indicator
5-11
ECM coupler layout / Checking the electrical component
No. Connecting part Color

52 6Y8 Multifunction Blue When measuring the peak voltage
Meter between the terminals of an electrical
Checking the electrical

component using the digital tester, make
sure that the leads do not contact any
0
component metal parts. Otherwise, the electrical com-
Using the YDIS ponent may short-circuit and be dam-
When checking the TPS, ISC, high-pressure aged. 1
fuel pump, fuel injector, or each sensor, use
the YDIS. To check the electrical components or mea-
When deleting the diagnosis record in the
YDIS, make sure to check the time that the
sure the peak voltage, use the special ser-
vice tools. A malfunctioning electrical
2
trouble codes were detected. component can be checked easily by mea-
When checking the input voltage of a compo- suring the peak voltage. The specified engine
nent, the coupler or connector must be dis-
connected. As a result, the engine ECM
speed when measuring the peak voltage is
affected by many factors such as fouled
3
determines that the component is discon- spark plugs or a weak battery. If one of these
nected and a trouble code is detected. There- factors is present, the peak voltage cannot be
fore, make sure to delete the diagnosis
record after checking the input voltage.
measured properly. 4
YDIS (CD-ROM, Ver. 1.33):
60V-WS853-06
YDIS USB adapter and cable: DC V
5
60V-WS850-00
TIP: 6
• Before checking the electrical components,
make sure that the battery is fully charged.
• Install the proprietary YDIS software on the
CD-ROM onto the computer. Always use Digital circuit tester: 90890-03174 7
the exclusive communication cable to con- Peak voltage adapter B: 90890-03172
nect the engine ECM to the computer. For a
description of the communication cable and
CD-ROM to be used, see “YDIS” (4-1).
TIP:
• Before measuring the peak voltage, check
8
Also, make sure to check the CD-ROM ver- all of the wiring harnesses for corrosion.
sion before using it. Also, make sure that the wiring harnesses
• To connect and operate the YDIS, see the
YDIS (Ver. 1.33 or later) instruction manual.
are connected properly and that the battery
is fully charged.
9
• Use the peak voltage adapter B with the
recommended digital circuit tester.
Measuring the peak voltage
• Connect the positive pin of the peak voltage 10
adapter B to the positive terminal of the dig-
ital tester, and connect the negative pin to
When measuring the peak voltage, do not
the negative terminal.
touch any of the connections of the digital
• When measuring the peak voltage, set the
tester probes.
digital circuit tester to the DC voltage
mode.
A
5-12
ELEC
Electrical system
Using the digital tester
The electrical technical data apply to the
measurements taken using the Yamaha rec- 1
ommended tester.
The resistance values shown are the values
taken before the engine is started. The actual
resistance may vary depending on the envi-
ronmental conditions and ambient tempera- a
ture.
The input voltage changes depending on the
battery voltage. Wiring harness continuity:
If the tester probe cannot be inserted into the Terminal 1–Ground
coupler, prepare a test lead suitable for the
measurement. 3. Measure the input voltage between the
terminal and ground.
5
a b
Digital circuit tester: 90890-03174

Test lead: Main relay input voltage:
Terminal, male a: (commercially avail- Terminal 5–Ground
able) 12.0 V (battery voltage)
Terminal, female b: (commercially avail-
able) 4. Turn the engine start switch to ON, and
then measure the input voltage between
the terminal and ground.
TIP:
Use a terminal a of the appropriate size for
the coupler terminal to be measured. If a ter-
minal of the appropriate size is not available, a
adjust the width of the terminal a using a
grinder. 2
Engine control unit and

component
Checking the main relay
1. Disconnect the main relay coupler a. Main relay input voltage:
Terminal 2–Ground
2. Check the wiring harness for continuity. 12.0 V (battery voltage)
6. Remove the main relay a, and then con-

nect the special service tool b.
5-13
Checking the electrical component / Engine control unit and component
7. Connect the positive battery lead to the
Connector
connector b, connect the negative bat- Battery lead
d h
tery lead to the connector c, and then
check for continuity between the connec- Connect C C
tors d and e. Replace the relay if out of
specification. NOTICE: Do not reverse
Disconnect 0
9. Disconnect the special service tool b.
the battery leads.
a 10. Install the main relay a, and then con-

nect the main relay coupler a.
1
Checking the engine ECM circuit
b
1. Disconnect the engine ECM couplers a. 2
12345678
b B
R
Y L d 3
P Br
W O
c e 4
a
Test harness (8 pins) b: 90890-06879
Connector
2. Check for continuity between the engine
ECM coupler terminals and ground.
5
Battery lead
d e
Connect C C a
Disconnect
5 14
6
connector f, connect the negative bat-
tery lead to the connector g, and then 7
check for continuity between the connec-
tors h and d. Replace the relay if out of
specification. NOTICE: Do not reverse
the battery leads. 8
a
9
Wiring harness continuity:
Terminal 5–Ground
b
g 12345678
h
Terminal 14–Ground
10
R B 3. Turn the engine start switch to ON, and
f
Y L then measure the input voltage between
P Br the engine ECM coupler terminals and
W O d ground.
A
5-14
ELEC
Electrical system
Checking the TPS
a
1. Connect the YDIS to display “TPS volt-
15
age” and “Throttle valve opening.”
24
2. Start the engine, warm it up for 5–10 min-
utes, and then stop it.
3. Turn the engine start switch to ON, and

then measure the TPS output voltage
and throttle valve opening angles when
the remote control lever is at the fully
closed position a and fully open position
b.
A N
F R
Engine ECM input voltage: a
12.0 V (battery voltage)

b
5. Disconnect the main relay coupler b.
B b
6. Check the wiring harness for continuity. A Remote control model

a B Tiller handle model
TPS output voltage and throttle valve
15
opening angle (reference data):
24
Item Fully closed a Fully open b
Output
b 0.978 V 4.213 V
voltage
4 Opening
6 6.9° 87.8°
angle
Wiring harness continuity: 4. Disconnect the TPS coupler c.

Terminal 15–Terminal 6
7. Connect the main relay coupler b and

engine ECM couplers a.
5-15
Engine control unit and component
Checking the ISC
O B 1. Check the operation of the ISC using the
YDIS “Stationary test” and check the
operating sound.
2. Start the engine, and then check the

0
engine speed increases using the YDIS
c “Active test.”
1
3. Disconnect the ISC valve coupler a.
5. Turn the starter switch to ON, and then
measure the throttle body input voltage. 2
TPS input voltage:
Orange (O)–Black (B)
4.75 V–5.25 V
3
a
7. Disconnect the engine ECM couplers d
and e. 4
4. Measure the ISC valve resistance.
d
5
6
e
8. Check the wiring harness for continuity. 7

ISC valve resistance (reference data):
c d 27.0–33.0 Ω at 20 °C (68 °F)
3 2 1
36 5. Disconnect the engine ECM coupler b. 8
e
16
9
31
Wiring harness continuity: 10

Terminal 1–Terminal 36 b
6. Check the wiring harness for continuity.
9. Connect the engine ECM couplers d
and e and TPS coupler c.
A
5-16
ELEC
Electrical system
6. Apply positive pressure to the oil pres-
a sure switch a slowly, and then check
2 1 that continuity is lost in the range of the
4 3
working pressure. Replace the oil pres-
sure switch if the continuity is not lost in
b the working pressure range.
6
20 21 23
a
Terminal 1–Terminal 21 b
7. Connect the engine ECM coupler b and Leakage tester b: 90890-06840

ISC valve coupler a.
Working pressure:
Checking the oil pressure switch 29.4–58.8 kPa
1. Disconnect the oil pressure switch con- (0.294–0.588 kgf/cm2, 4.3–8.5 psi)
nector a.
7. Disconnect the special service tool b.
then measure the oil pressure switch 8. Disconnect the engine ECM coupler b.
input voltage.
a
b
P/W
Oil pressure switch input voltage
(reference data): a
Pink/White (P/W)–Ground
11.7 V P/W
b
10
4. Remove the oil pressure switch a.
5. Connect the special service tool b to the

oil pressure switch a.
Pink/White (P/W)–Terminal 10
10. Connect the engine ECM coupler b.
5-17
Engine control unit and component
11. Install the oil pressure switch a and oil Checking the alert buzzer
pressure switch lead. See “Installing the 1. Remove the alert buzzer.
oil pressure switch” (7-53).
2. Connect the battery leads to the alert
Checking the alert indicator (tiller buzzer connectors, and check that the 0
handle model) alert buzzer comes on. Replace the alert
1. Remove the tiller handle cover, and then buzzer if it does not come on.
disconnect the alert indicator couplers a
and b. 1
2. Connect the battery (1.5 V) to the alert
indicator couplers a and b. Check that
the overheat alert indicator c or the oil
2
pressure alert indicator d comes on.
Replace the alert indicator if it does not
come on. NOTICE: Do not apply a volt-
age higher than 1.7 V when checking
3
the LED. 3. Install the alert buzzer.
a Checking the trolling switch (tiller 4

handle model)
d c 1. Disconnect the trolling switch coupler a.
d
P/W
b Y
5
P/B
c
P/B
P/W 6
a
a
7
2. Check the trolling switch a for continuity.
b Replace the trolling switch if out of speci-
fication.
8
Lighting-up Terminal Battery
Overheat alert
indicator c
Yellow (Y)
b c d
a 9
Pink/Black
(P/B)
Oil pressure
alert indicator d
Yellow (Y)
Pink/White

10
(P/W)
3. Connect the alert indicator couplers a

and b, and then install the tiller handle
cover.
A
5-18
ELEC
Electrical system
Switch Terminal
position b c d a
UP L/W B
Free
DN
3. Disconnect the engine ECM coupler e.
Water detection switch input voltage:

Blue/White (L/W)–Black (B)
4.75–5.25 V
3. Turn the engine start switch to OFF, and

then remove the filter cup assembly.
e
4. Check that the float a moves smoothly.
5. Check the water detection switch for con-
tinuity when the float is in positions A
a
and B . NOTICE: Do not remove the
3 2 1
clip and float.
A
e
28 29 31
b c a

B
5. Connect the engine ECM coupler e and
trolling switch coupler a.
d
b c a
Fuel control unit and component
Checking the water detection switch
1. Disconnect the water detection switch
coupler a.
2. Turn the engine start switch to ON, and Float Terminal

then measure the input voltage at the position b c
water detection switch coupler.
A
B
Float height d (reference data):

19.4 mm (0.76 in)
5-19
Engine control unit and component / Fuel control unit and component
6. Disconnect the engine ECM coupler e.
R/Y
a 0
1
e
Fuel injector input voltage:
7. Check the wiring harness for continuity. Red/Yellow (R/Y)–Ground
2
a
2 1
5. Measure the fuel injector resistance.
3
e
31 33
4
5
8. Connect the engine ECM coupler e.

Fuel injector resistance (reference data):
6
9. Install the filter cup assembly. See “Fuel 12.0 Ω at 20 °C (68 °F)
filter assembly” (6-7).
10. Connect the water detection switch cou-

6. Disconnect the engine ECM coupler b
and main relay coupler c.
7
pler a.
Checking the fuel injector 8

1. Check the operation of the fuel injectors
using the YDIS “Stationary test” and
check the operating sound.
9
2. Disconnect the fuel injector couplers a.
b
then measure the input voltage between 10
the fuel injector coupler terminal and
ground.
A
5-20
ELEC
Electrical system
B L
a
c
7. Check the wiring harness for continuity. High-pressure fuel pump input voltage:
Blue (L)–Black (B)
a c 12.0 V (battery voltage)
1
2 4. Turn the engine start switch to OFF.
7
5. Measure the resistance of the high-pres-

b
sure fuel pump motor.
3 4

High-pressure fuel pump resistance
8. Connect the engine ECM coupler b and (reference data):
main relay coupler c. 0.2–3.0 Ω at 20 °C (68 °F)
9. Connect the fuel injector couplers a. 6. Disconnect the engine ECM coupler b
Checking the high-pressure fuel
pump
1. Check the operation of the high-pressure
fuel pump using the YDIS “Stationary
test” and check the operating sound.
2. Disconnect the high-pressure fuel pump

coupler a.
b
3. Connect the tester probes to the termi-
nals of the high-pressure fuel pump cou-
pler, and then measure the input voltage
within 3 seconds after turning the engine
start switch to ON.
5-21
Fuel control unit and component
Vapor shut-off valve input voltage:

Red/Yellow (R/Y)–Ground
3. Remove the vapor shut-off valve, and 0

then connect the special service tool a
to the vapor shut-off valve.
c
4. Apply the specified negative pressure to 1
the vapor shut-off valve.
a c
5. Check that the vapor shut-off valve
opens and that the negative pressure is
2
1 released when the battery voltage is
4
2 applied to the vapor shut-off valve termi-
8
nals. NOTICE: Connect the battery
lead to the vapor shut-off valve termi-
3
b
nals for only a few seconds.
24
a 4
Terminal 2–Ground
5
8. Connect the engine ECM coupler b and

main relay coupler c.
6
Vacuum/pressure pump gauge set a:
9. Connect the high-pressure fuel pump 90890-06756
coupler a.
Specified negative pressure:
7
Checking the vapor shut-off valve 67.0 kPa (0.67 kgf/cm2, 9.7 psi)
1. Disconnect the vapor shut-off valve cou-
pler a. 6. Remove the special service tool a. 8
2. Turn the engine start switch to ON, and 7. Measure the vapor shut-off valve resis-
tance.
then measure the input voltage between
the vapor shut-off valve coupler terminal Vapor shut-off valve resistance:
9
and ground. 30.0–34.0 Ω at 20 °C (68 °F)
a 8. Disconnect the engine ECM coupler b

10
R/Y
A
5-22
ELEC
Electrical system
3. Measure the lighting coil output peak

voltage between all combinations of the
connectors. Replace the stator assembly
if below specification.
c
R
B
R
9. Check the wiring harness for continuity. G G G
a
a c
2 1
7
11
a
Test harness (6 pins) a: 90890-06848
10. Install the vapor shut-off valve, and then
connect the vapor shut-off valve coupler Lighting coil output peak voltage:
a. Green (G)–Green (G)
Unloaded
11. Connect the engine ECM coupler b and r/min
Cranking 1500 3500
main relay coupler c.
DC V 13.0 40.2 95.0
Charging unit and component
Checking the lighting coil (stator TIP:
assembly) When measuring the lighting coil output peak
1. Disconnect the Rectifier Regulator cou- voltage under the cranking (unloaded) condi-
pler a. tion, remove the clip from the engine shut-off
switch to prevent the engine from starting.
4. Measure the lighting coil resistance.
5-23
Fuel control unit and component / Charging unit and component
Lighting coil resistance Rectifier Regulator output peak voltage:

(reference data): Red (R)–Ground
0.513–0.627 Ω at 20 °C (68 °F) Unloaded
r/min
5. Disconnect the special service tool a,
DC V
1500
13.0
3500
13.0
0
and then connect the Rectifier Regulator
coupler a.
Checking the Rectifier Regulator

TIP:
Do not use the peak voltage adapter B when 1
measuring the Rectifier Regulator output
peak voltage.
Do not connect the battery cables in
reverse. Otherwise, the Rectifier Regula- 4. Disconnect the special service tool a.
2
tor could be damaged.
5. Set the digital circuit tester to the diode,
1. Disconnect the Rectifier Regulator cou-
and then check the Rectifier Regulator
for continuity.
3
pler a.
c d
4
e
a
5
f
b
6
2. Connect the special service tool a. b
d
3. Measure the Rectifier Regulator output
peak voltage. e
7
f
G R c 8
G B
G R
R
a
9
10
a
A
5-24
ELEC
Electrical system
Rectifier Regulator continuity

(testing diode mode): OK
Tester probe Display value
(reference data)
b c OL
d
e
f a
c b 0.763
d 0.438 Ignition tester (spark gap tester) a:
e 0.437 90890-06754
f 0.437
4. Remove the special service tool a, and
d b 0.440 then connect the spark plug wire.
c OL
e Checking the spark plug wire
f 1. Remove the spark plug wire.
e b 0.437
c OL 2. Measure the spark plug wire resistance.
d
f
f b 0.442
c OL
d
e
OL: Indicates overload
6. Connect the Rectifier Regulator couplers

a. Spark plug wire resistance
(reference data):
Ignition unit and component 1.9–5.0 kΩ at 20 °C (68 °F)
Checking the ignition spark
1. Disconnect the spark plug wire from the 3. Install the spark plug wire.
spark plug.
Checking the ignition coil
2. Connect the spark plug wire to the spe- 1. Disconnect the ignition coil couplers a
cial service tool a. and b.
a R/Y
3. Check the ignition spark using the YDIS
“Stationary test.” WARNING! Do not
touch any of the connections of the
special service tool.
b
5-25
Charging unit and component / Ignition unit and component
2. Remove the spark plug wire.
a b d
3. Measure the ignition coil resistance.
2 1 2 1
B A 7
0
c
1
18 1
aTerminal 1–cTerminal 1
aTerminal 2–dTerminal 7
2
Ignition coil resistance: bTerminal 1–cTerminal 18
A Primary coil (reference data): bTerminal 2–dTerminal 7
1.53–2.07 Ω at 20 °C (68 °F)
B Secondary coil: 7. Connect the engine ECM coupler c and
3
12.495–16.905 kΩ at 20 °C (68 °F) main relay coupler d.
4. Disconnect the engine ECM coupler c. 8. Connect the ignition coil couplers a and
b.
4
9. Install the spark plug wires.
5
Checking the pulser coil
1. Disconnect the pulser coil coupler a.
6
c
a
5. Disconnect the main relay coupler d. 7
8
2. Connect the special service tool a, and
d
then measure the pulser coil output peak
voltage. 9
6. Check the wiring harness for continuity. 10
A
5-26
ELEC
Electrical system
W/B W/R b
B B
G G/W
c
a
a b
40
1 2
Pulser coil output peak voltage:
White/Red (W/R)–Black (B)
Unload c
Loaded
r/min ed
Cranking 1500 3500 31
DC V 5.7 4.7 14.9 24.6
Test harness (2 pins) a: 90890-06867 Wiring harness continuity:

TIP: Terminal 2–Terminal 40
• When measuring the pulser coil output
peak voltage under the cranking (unloaded)
c.
condition, disconnect the coupler a to pre-
vent the engine from starting.
7. Connect the pulser coil coupler a.
• When measuring the pulser coil output
peak voltage under the cranking (loaded) Checking the air temperature sensor
condition, remove the clip from the engine
The air temperature sensor is a component
shut-off switch to prevent the engine from
of the sensor assembly.
starting.
1. Measure the ambient temperature.
3. Disconnect the special service tool a,
and then measure the pulser coil resis- 2. Connect the YDIS to display “Intake tem-
tance. perature” (air temperature).
Pulser coil resistance: 3. Check that the difference between the
398.0–594.0 Ω at 20 °C (68 °F) ambient temperature and the displayed
intake temperature is within ± 5 °C
4. Disconnect the engine ECM coupler b
(± 9 °F).
and c.
5-27
Ignition unit and component
TIP: a b
• Check the air temperature sensor when the 38
engine is cold. 3 2 1
• When checking the air temperature sensor,
remove the top cowling and do not start the c
0
engine.
16
4. Disconnect the sensor assembly coupler

31
1
a.
then measure the input voltage at the
2
sensor assembly coupler.
B O 8. Connect the engine ECM couplers b

and c.
3
9. Connect the sensor assembly coupler a.
a
Checking the air pressure sensor
4
The air pressure sensor is a component of
the sensor assembly.
5
Sensor assembly input voltage: 1. Disconnect the sensor assembly coupler
Orange (O)–Black (B) a.
4.75–5.25 V
2. Turn the engine start switch to ON, and 6
6. Disconnect the engine ECM couplers b then measure the input voltage at the
and c. sensor assembly coupler.
b B O
7
a
8
c
9
7. Check the wiring harness for continuity. Sensor assembly input voltage:
4.75–5.25 V
10
3. Disconnect the engine ECM coupler b.
A
5-28
ELEC
Electrical system
4. Remove the thermo sensor.
5. Place the thermo sensor in a container of

water and heat the water slowly.
4 3 2
b 6. Measure the thermo sensor resistance.
16 17 Thermo sensor resistance

31 (reference data):
at 20 °C (68 °F): 2.439 kΩ
at 60 °C (167 °F): 0.589 kΩ
Wiring harness continuity: at 100 °C (194 °F): 0.193 kΩ
7. Install the thermo sensor. See “Installing
the thermo sensor” (7-54).
5. Connect the engine ECM coupler b. 8. Disconnect the engine ECM coupler b,
and c.
6. Connect the sensor assembly coupler a.
b
Checking the thermo sensor
1. Disconnect the thermo sensor coupler
a.

then measure the input voltage at the
thermo sensor coupler. c

B B/Y
a b
1 2
48
c
a
31
Thermo sensor input voltage:
Black/Yellow (B/Y)–Black (B)
4.75–5.25 V
5-29
Ignition unit and component
Wiring harness continuity: Wiring harness continuity:

Terminal 1–Terminal 31 Terminal 1–Terminal 44
10. Connect the engine ECM couplers b

5. Connect the engine ECM coupler b
and knock sensor coupler a. 0
and c.
Checking the neutral switch
11. Connect the thermo sensor coupler a. 1. Disconnect the neutral switch coupler a.
1
Checking the knock sensor 2. Turn the engine start switch to ON, and
1. Disconnect the knock sensor coupler a. then measure the input voltage.
2. Measure the knock sensor resistance. B L/G

2
3
a 4
a Neutral switch input voltage
Knock sensor resistance

(reference data):
Blue/Green (L/G)–Black (B) 5
504.0–616.0 kΩ at 20 °C (68 °F): 4.75–5.25 V
3. Disconnect the engine ECM coupler b. 3. Turn the engine start switch to OFF.
6
4. Remove the neutral switch.
5. Check the neutral switch for continuity.

b
7
c
8
b d e

9
a
b
1 Neutral switch continuity:
Position
Terminal 10
d e
b
44 c
6. Disconnect the engine ECM coupler f.
A
5-30
ELEC
Electrical system
Terminal
Switch position
a b
Clip removed C C
Clip installed
Button pushed (*1) C C
(*1) Tiller handle model
f 3. Turn the engine start switch to OFF.
7. Check the wiring harness for continuity. 4. Connect the 10-pin coupler.
a Starting unit and component

Checking the starter relay
2 1
1. Disconnect the starter relay connector
a.
f
2. Turn the engine start switch to START,
and then measure the starter relay input
31 34
voltage.

Terminal 2–Terminal 31 Br
8. Connect the engine ECM coupler f. a
9. Install the neutral switch, and then con-

nect the neutral switch coupler a.
Checking the engine shut-off switch Starter relay input voltage:

1. Disconnect the 10-pin coupler. Brown (Br)–Ground
then check the engine shut-off switch for 3. Turn the engine start switch to OFF.
continuity.
4. Disconnect the starter relay leads, and
ON (*1)
OFF START then remove the starter relay.
NOTICE: Before disconnecting the
starter relay terminals, make sure to
disconnect the negative battery termi-
nal.

relay connector a, and the negative bat-
tery lead to the relay lead b, and then
a check for continuity between terminals c
and d. Replace the starter relay if out of
b specification.
5-31
Ignition unit and component / Starting unit and component
2. Turn the engine start switch to START,
c d and then check the neutral switch for
continuity at the shift lever positions F, N,
and R.
N
0
a
Br a R
1
F
b
B
b 2
Terminal Lever Terminal
Battery lead
c d position a b 3
Connect C C F
Disconnect N C C
6. Install the starter relay, and then connect

R 4
the starter relay leads. 3. Remove the neutral switch.
Checking the engine start switch

1. Disconnect the 10-pin coupler.
4. Check the neutral switch for continuity.
c d
5
2. Check the engine start switch for continu-
ity. 6
ON c L Br e
OFF START
d
a
7
e B Br f
b
Switch
position e
Terminal
f
8
c
d C C
Switch
position a b
Terminal
c d e 5. Install the neutral switch. See “Assem-
9
OFF C C bling the tiller handle” (9-9).
ON
START
C
C
C
C C
6. Connect the 10-pin coupler. 10
3. Connect the 10-pin coupler. Checking Y-COP
1. Disconnect the Y-COP coupler a, and
Checking the neutral switch (tiller then measure the Y-COP input voltage.
handle model)
1. Disconnect the 10-pin coupler.
A
5-32
ELEC
Electrical system
Y-COP input voltage:

Red (R)–Black (B)
2. Connect the Y-COP coupler a.
5-33
Starting unit and component / Starter motor
Starter motor
19 20 0
1 1 13
9 21
1
1
9 14
21
22
1
2
3 15
10
2
14
16
5
3
6
11 23 4
17 14
4 24
12
18 5
8
25
7 26 6
27
No. Part name Q’ty Remarks 7

1 Brush spring 4
2 Brush assembly 1
3
4
Brush holder assembly
Starting motor gear assembly
1
1
8
5 Washer set 1
6 Bracket 1
7
8
Bolt
Screw
2
2
M6 117 mm
M4 16 mm
9
9 Planetary gear 3
10 Plate 1
11
12
Stator
Armature
1
1
10
13 Clutch assembly 1
14 Washer set 1
15 Bracket 1
16 Bracket 1
17 Outer gear 1
A
5-34
ELEC
Electrical system
19 20
1 1 13
9 21
1
1 22
21
9 14
2
3 15
10
14
16
6
11 23
17 14
4 24
18
12
8
25
7 26
27
No. Part name Q’ty Remarks

18 Pinion shaft 1
19 Pinion 1
20 Pinion stopper set 1
21 Bolt 2 M6 37 mm
22 Cover 1
23 Lever assembly 1
24 Seal set 1 39
25 Magnet switch 1
26 Washer 1
27 Nut 1
5-35
Starter motor
Removing the starter motor Checking the magnet switch
1. Connect the tester probes to the magnet
switch terminals a and b.
Before removing the starter motor, make
sure to disconnect the negative battery 2. Connect the negative battery cable a to
the starter motor body.
0
terminal.
3. Connect the starter motor relay lead b to
1. Remove the starter motor from the power
unit. See “Removing the starter motor”
the positive battery cable c, and then 1
check the magnet switch for continuity.
(7-22). NOTICE: Do not connect the starter
Checking the starter motor operation

1. Connect the positive battery cable a to
motor relay lead to the battery for
more than 1 second. 2
the magnet switch terminal a, and then 4. Check that there is continuity between
connect the negative battery cable b to
the starter motor body.
the magnet switch terminals a and b.
Replace the magnet switch if out of spec-
3
ification.
2. Connect the starter relay lead c to the
b
magnet switch terminal b.
c
a
4
3. Connect the starter motor relay lead c to
the positive battery terminal, and then
check the starter motor operation.
WARNING! Do not touch the starter b
a
5
motor pinion.
a
a
a
6
c c
b b
7
b Magnet switch
terminal
Battery lead
a b 8
b Connect C C
c
a Disconnect
TIP:
9
TIP: The starter motor pinion should be pushed
• Check the starter motor operation for a few
seconds.
out while the magnet switch is on.
10
• If the starter motor is disassembled for Checking the starter motor pinion
maintenance, make sure to check the oper-
ation after assembling it.
Before checking the starter motor pinion,
4. Disconnect the negative and positive bat- make sure to disconnect the battery
tery cables from the battery terminals. cables.
A
5-36
ELEC
Electrical system
1. Check the pinion teeth. Replace the pin-
ion if cracked or worn.
2. Turn the pinion counterclockwise to

check that it operates smoothly and turn
it clockwise to check that it locks in place.
Disassembling the starter motor

1. Remove the magnet switch a and spring
a. e
5. Remove the plate c, outer gear f and

planetary gears d.
a c
2. Push the pinion stopper b down, and d

then remove the clip c.
c b
c
6. Remove the rubber seal g, lever h, and

pinion shaft assembly k.
b
3. Remove the pinion stopper b, pinion b,

and spring d.
h
b g
k
b
7. Remove the E-clip m, and then remove

the clutch assembly e.
4. Remove the stator assembly e.
5-37
Starter motor
h
i
r e
e
r j 0
m n p
f 1
f n p k
2
11. Remove the plate v, and then remove
TIP:
Push the clutch assembly e down com- the armature i from the brush holder 3
pletely onto the pinion shaft f in direction n, assembly j.
turn it one spline in direction p, and then
remove it in direction r.
i 4
i
8. Remove the shim s, brackets g, gasket
t, and shim u.
j
5
v
v 6
s t
u
j 7
Checking the armature (starter
motor)
1. Check the commutator. Clean using
600-grit sandpaper and compressed air if
8
g
dirty.
9. Remove the stator h.
9
10. Remove the armature i, along with the
brush holder assembly j, from the
bracket k.
10
2. Measure the commutator diameter a.

Replace the armature if below specifica-
tion. A
5-38
ELEC
Electrical system
e
a
c b
d
a c a
Commutator standard diameter a: e

29.0 mm (1.14 in)
Wear limit: 28.0 mm (1.10 in) d b
3. Measure the commutator undercut b. Brush holder assembly continuity:
a b c d e
b C C
C C
C C
C C
2. Measure the length f of each brush.

Replace the brush assembly if below
specification.
Commutator standard undercut b:

0.8 mm (0.03 in)
Wear limit: 0.2 mm (0.01 in)
4. Check the armature for continuity.

g f
Replace if out of specification.
c Brush standard length f:

15.5 mm (0.61 in)
d e f Wear limit g: 9.5 mm (0.37 in)
Assembling the starter motor
Armature continuity:
• Do not apply grease or oil to the commu-
c d e f
tator of the armature.
C C
• Do not reuse a gasket or seal set, always
Checking the brush holder replace it with a new one.
1. Check the brush holder assembly for
continuity. Replace if out of specification. 1. Push the brushes a into the holders,
and then install the armature a to the
brush holder assembly b.
5-39
Starter motor
2. Install the plate b.
a
a
k
0
h
g
a
b
b
1
b
e
2
b a
5. Push the clutch assembly f down com-
3. Install the armature a armature along pletely onto the pinion shaft g in direc- 3
with the brush holder assembly b to the tion m, turn it one spline in direction n,
bracket c, and then install the stator d. and then slide it in direction p.
d 6. Install the E-clip r. 4
f
c
f
5
p
a
d
b
b
r n m
p
6
g
e g
n m
7
c f
c
8
TIP:
Make sure that the clutch assembly f does
TIP:
Align the holes c and d in the plate b with
not come out from the pinion shaft g. 9
the holes e and f in the bracket c. 7. Install the pinion shaft assembly s, the
lever t, a new rubber seal u, the plane-
4. Install the shim g, a new gasket h, the tary gears h, the outer gear v, and the 10
brackets e, and the shim k. plate i.
A
5-40
ELEC
Electrical system
i A B A
k
k
v
y
h
u
s t
C 10. Install a new gasket D, the spring E,

and the magnet switch l.
t
s l
8. Align the protrusion w on the stator d

E
with the slot x in the cover assembly j,
and then assemble the starter motor.
j D
d
l
j d TIP:
Before installing the starter motor to the
x w power unit, make sure to check the starter
motor operation. See “Checking the starter
motor operation” (5-36).
Installing the starter motor

1. Install the starter motor to the power unit.
See “Installing the starter motor” (7-23).
9. Install the spring y, pinion k, pinion
stopper A, and clip B.
6Y8 Multifunction Meter sensor
Checking the water pressure sensor
(optional)
1. Disconnect the water pressure sensor
coupler a.
5-41
Starter motor / 6Y8 Multifunction Meter sensor
2. Turn the engine start switch to ON, and 5. Turn the engine start switch to OFF, and
then measure the input voltage at the then disconnect the special service tool
water pressure sensor coupler. b and pressure pump a.
B O 6. Disconnect the engine ECM couplers b

and c.
0
a
b
1
2
Water pressure sensor input voltage:
Orange (O)–Black (B) c
4.75–5.25 V
3
3. Remove the water pressure sensor, and
then connect the pressure pump a and a b
special service tool b.
3 2 1
4
46
4. Apply positive pressure to the water pres-
sure sensor slowly, and then measure
the output voltage.
c
16
5
L/B 31
B
O
G/W B G
6
b Terminal 1–Terminal 16
Terminal 3–Terminal 46 7
8. Install the water pressure sensor, and
then connect the water pressure sensor
coupler a. See “Installing the water 8
a pressure sensor” (3-13).
b
Pressure pump a:
c. 9
(commercially available)
Test harness (3 pins) b: 90890-06869 Checking the speed sensor
Water pressure sensor output voltage

(optional)
1. Disconnect the speed sensor coupler a.
10
(reference data):
Blue/Black (L/B)–Black (B) 2. Turn the engine start switch to ON, and
2.5 V at 392.0 kPa then measure the input voltage at the
(3.92 kgf/cm2, 56.8 psi) speed sensor coupler.
4.5 V at 784.0 kPa
(7.84 kgf/cm2, 113.7 psi)
A
5-42
ELEC
Electrical system
6. Disconnect the engine ECM couplers b
B O and c.
Speed sensor input voltage: c

4.75–5.25 V 7. Check the wiring harness for continuity.
3. Remove the speed sensor, and then con- a b

nect the pressure pump a and special 37
service tool b. 3 2 1
4. Apply positive pressure to the speed sen- c

sor slowly, and then measure the output
voltage. 16
31
L
B
O
G/W B G Wiring harness continuity:
b Terminal 2–Terminal 31
8. Install the speed sensor, and then con-

b nect the speed sensor coupler a. See
“Installing the speed sensor” (3-14).
a 9. Connect the engine ECM couplers b

and c.
Pressure pump a:
Test harness (3 pins) b: 90890-06869
Speed sensor output voltage

(reference data):
Blue (L)–Black (B)
2.5 V at 392.0 kPa
(3.92 kgf/cm2, 56.8 psi)
4.5 V at 784.0 kPa
(7.84 kgf/cm2, 113.7 psi)
5. Turn the engine start switch to OFF, and

then disconnect the special service tool
b and pressure pump a.
5-43
6Y8 Multifunction Meter sensor / PTT electrical system
PTT electrical system PTT relay continuity:
Checking the PTT relay a b c d e f
1. Measure the input voltage between the C C
PTT relay terminals a and b.
C
C
C
C
0
C C
b a
connector e, connect the negative bat-
1
tery lead to the terminal b, and then
check the PTT relay for continuity.
Replace if out of specification. 2
Lg
PTT relay input voltage:
Terminal a–Terminal b G/W G a
Sb
3
12.0 V (battery voltage) e f c
b
2. Disconnect the battery power source,
ground lead, PTT motor leads, and PTT
a
4
relay coupler. NOTICE: Before discon-
necting the PTT relay terminals, make
sure to disconnect the battery nega-
tive terminal.
d 5
4. Check the PTT relay for continuity. PTT relay continuity:

6
Replace if out of specification. a b c d
C C
C C 7
Lg
Sb 6. Connect the positive battery lead to the
G/W G a connector f, connect the negative bat-
e f b
c tery lead to the terminal b, and then 8
check the PTT relay for continuity.
a Replace if out of specification.
9
d
10
A
5-44
ELEC
Electrical system
Lg
Sb
G/W G a
c b d
e f b c
a Sb d
R c
Lg b
d Switch Terminal
position b c d
UP C C
Free
PTT relay continuity: DN C C
a b c d
C C 4. Disconnect the PTT relay coupler e.
C C
7. Disconnect the special service tool a.
8. Connect the PTT relay coupler, battery

power source, ground lead, and PTT
motor leads.
e
Checking the PTT switch (bottom
cowling)
1. Disconnect the PTT switch coupler a. 5. Remove the fuse a.
2. Measure the input voltage between the a
PTT switch coupler terminal and ground.
a 6. Check the wiring harness for continuity.
PTT switch input voltage:

Red (R)–Ground f
a e
2 1
3. Check the PTT switch for continuity. 2 1 15A
3
5-45
PTT electrical system
4. Disconnect the 10-pin coupler e and
PTT relay coupler f.
a Terminal 1–e Terminal 1
a Terminal 2–e Terminal 2
a Terminal 3–Terminal f
0
7. Connect the PTT relay coupler e and e
PTT switch coupler a.
8. Install the fuse a.

1
f
Checking the PTT switch (tiller
handle)
1. Disconnect the PTT switch connectors 5. Remove the fuse a.
2
a.
a
2. Measure the input voltage between the
PTT switch connector and ground.
3
a
4

5
R
PTT switch input voltage:

e
f
g 6
Red (R)–Ground 1
3. Check the PTT switch for continuity.

7 5 2 1 15A
7
b
Sb
8
R UP
c DN
e Terminal 1–Terminal g
e Terminal 5–f Terminal 1
d
Lg e Terminal 7–f Terminal 2 9
b Sb 7. Connect the PTT relay coupler f, 10-pin
c R coupler e, and PTT switch connectors
d Lg a. 10
Switch Terminal 8. Install the fuse a.
position b c d
UP C C Checking the trim sensor
Free 1. Disconnect the trim sensor coupler a,
DN C C and then remove the trim sensor.
A
5-46
ELEC
Electrical system
d
a
2
2 1
2. Measure the trim sensor resistance. Wiring harness continuity:

a Terminal 1–Ground
3. Turn the trim sensor lever a from the a Terminal 2–d Terminal 2
position b to the position c, and then
measure the resistance as it gradually 6. Install the trim sensor.
changes.
7. Connect the gauge harness coupler d
c and trim sensor coupler a. See “Adjust-
ing the trim sensor” (9-43).
b
a
Trim sensor resistance (reference data):

168.3–288.3 Ω at b
9.0–11.0 Ω at c (setting resistance)
4. Disconnect the alert indicator harness

coupler d.
5-47
PTT electrical system
— MEMO —
0
1
2
3
4
5
6
7
8
9
10
A
5-48
FUEL
Fuel system 6
Hose routing ...................................................................... 6-1

Fuel hose ................................................................................... 6-1
Blowby hose, vapor gas hose, and air hose .............................. 6-2
Cooling water hose .................................................................... 6-3
Fuel system ....................................................................... 6-4

Reducing the fuel pressure ....................................................... 6-4
Disconnecting the quick connector ............................................ 6-4
Measuring the fuel pressure ...................................................... 6-4
Checking the pressure regulator ............................................... 6-5
Fuel filter assembly ........................................................... 6-7

Removing the fuel filter assembly ............................................. 6-9
Checking the fuel joint ............................................................... 6-9
Checking the fuel filter assembly ............................................. 6-10
Disassembling the fuel filter assembly .................................... 6-10
Checking the fuel filter element ............................................... 6-10
Checking the fuel cup assembly .............................................. 6-11
Checking the primer pump ...................................................... 6-11
Assembling the fuel filter assembly ......................................... 6-11
Installing the fuel filter assembly ............................................. 6-11
Fuel pump assembly ....................................................... 6-13

Removing the fuel pump assembly ......................................... 6-15
Checking the fuel pump assembly .......................................... 6-15
Disassembling the fuel pump assembly .................................. 6-16
Checking the diaphragm and valve ......................................... 6-16
Checking the fuel strainer ........................................................ 6-16
Assembling the fuel pump assembly ....................................... 6-17
Installing the fuel pump assembly ........................................... 6-18
Intake silencer ................................................................. 6-19

Removing the intake silencer .................................................. 6-21
Checking the ISC valve ........................................................... 6-21
Installing the intake silencer .................................................... 6-21
Intake manifold ................................................................ 6-23

Removing the fuel injector ....................................................... 6-25
Checking the fuel rail and fuel injectors ................................... 6-25
Removing the intake manifold ................................................. 6-25
Checking the intake manifold .................................................. 6-26
Checking the throttle body ....................................................... 6-26
Checking the TPS ................................................................... 6-26
Installing the intake manifold ................................................... 6-26
Installing the fuel injector ......................................................... 6-28
Throttle link rod ............................................................... 6-30
Removing the throttle link ........................................................ 6-31
Installing the throttle link .......................................................... 6-31
Adjusting the throttle link rod ................................................... 6-32
0
Vapor separator ............................................................... 6-34
Draining the fuel ...................................................................... 6-36
Removing the vapor separator ................................................ 6-36
Checking the vapor shut-off valve ........................................... 6-38
1
Installing the vapor separator .................................................. 6-38
Vapor separator and high-pressure fuel pump ............ 6-41 2

Disassembling the vapor separator ......................................... 6-43
Checking the high-pressure fuel pump .................................... 6-44
Checking the vapor separator ................................................. 6-44
Adjusting the float height ......................................................... 6-44 3
Assembling the vapor separator .............................................. 6-44
4
5
6
7
8
9
10
A
FUEL
Fuel system
Hose routing
Fuel hose
g
g
e f
e
a
d
a h h
k
a Fuel hose (fuel joint to joint) a Fuel joint

b Fuel hose (joint to fuel filter assembly) b Joint
c Fuel hose (fuel filter assembly to fuel c Fuel filter assembly
pump) d Fuel pump
d Fuel hose (fuel pump to fuel strainer) e Fuel strainer
e Fuel hose (fuel strainer to vapor separa- f Vapor separator
tor) g Pressure regulator
f Fuel hose (vapor separator to fuel rail) h Fuel cooler
g Fuel hose (pressure regulator to fuel k Fuel rail
cooler)
h Fuel hose (fuel cooler to vapor separator)
6-1
Hose routing
Blowby hose, vapor gas hose, and air hose
0
g
d d
c
g
a
1
g e
b
3
c
f
4
5
f
a 6
b 7
8
e
a Blowby hose (cylinder head cover to a Intake silencer

9
intake silencer) b Vapor separator
b Vapor gas hose (vapor separator to joint) c Joint
c Vapor gas hose (vapor separator to joint)
d Vapor gas hose (joint to vapor shut-off
d Vapor shut-off valve
e Throttle body
10
valve) f ISC valve
e Vapor gas hose (vapor shut-off valve to g Pressure regulator
throttle body)
f Air hose (throttle body to ISC valve)
g Pressure regulator hose (pressure regula-
tor to intake manifold)
A
6-2
FUEL
Fuel system
Cooling water hose
a h
a e g b fc f
a Cooling water hose (exhaust cover to joint) a Joint

b Cooling water hose (joint to joint) b Joint
c Cooling water hose (joint to fuel cooler) c Fuel cooler
d Cooling water hose (fuel cooler to fuel d Joint
cooler) e Cooling water outlet (on the bottom cowl-
e Cooling water hose (fuel cooler to joint) ing)
f Cooling water hose (joint to exhaust f Flushing hose adapter
guide)
g Cooling water hose (joint to cooling water
outlet)
h Flushing hose (flushing hose adapter to
joint)
6-3
Hose routing / Fuel system
Fuel system 2. Wrap a rag around the quick connector
Reducing the fuel pressure a, and then push the quick connector
tab b toward the stopper c. NOTICE:
Do not push the quick connector tab
Before servicing the high-pressure fuel
past the stopper. Otherwise, the quick
connector could be damaged.
0
line or vapor separator, make sure to
reduce the fuel pressure in the fuel line. a
Otherwise, pressurized fuel could spray
out.
1
c
b
1. Disconnect the high-pressure fuel pump
coupler a. 2
a
3. Disconnect the quick connector a from

3
the fuel rail.
a
4
a
2. Start the engine. 5

d
TIP:
After disconnecting the high-pressure fuel
pump coupler, wait until the engine stalls.
6
TIP:
3. After the engine stalls, crank the engine 2
or 3 times.
• After disconnecting the quick connector a,
be careful not to lose the retainer d.
7
• Cover the quick connector and fuel rail with
a plastic bag to prevent damage and to pro-
5. Connect the high-pressure fuel pump tect them from dirt. 8
coupler a.
Measuring the fuel pressure
Disconnecting the quick connector 1. Reduce the fuel pressure.
9
2. Disconnect the quick connector from the
Before disconnecting the quick connec- fuel rail.
tor, reduce the fuel pressure. Otherwise,
pressurized fuel could spray out.
3. Connect the special service tool a to the
10
quick connector and fuel rail.
1. Reduce the fuel pressure.
A
6-4
FUEL
Fuel system
7. Measure the fuel pressure.
Fuel pressure (reference data):
a 230.0 kPa (2.30 kgf/cm2, 33.4 psi)
at engine idle speed
9. Reduce the fuel pressure. See “Reducing

the fuel pressure” (6-4).
Fuel pressure gauge adapter a: 10. Disconnect the special service tools a
90890-06942 and b. WARNING! Before disconnect-
ing the special service tools, cover the
4. Connect the special service tool b. end of the hose using a clean and dry
WARNING! To prevent fuel from leak- rag.
ing out, screw in the gauge gently
until it is connected firmly. Also, make 11. Connect the quick connector to the fuel
sure that the drain screw c is tight- rail.
ened securely, before measuring the
fuel pressure. 12. After measuring the fuel pressure, cover
the end of the hose with a clean and dry
rag so that the hose end is pointing
down. Loosen the drain screw c to drain
the remaining fuel from the hose and the
gauge. WARNING! When storing the
a fuel pressure gauge, make sure that
the drain screw is tightened securely.
b
Checking the pressure regulator
2. Disconnect the quick connector from the

c
fuel rail. See “Disconnecting the quick
connector” (6-4).
Fuel pressure gauge b: 90890-06786
3. Connect the special service tools. See
5. Turn the engine start switch to ON, and steps 3 and 4 in “Measuring the fuel
then measure the fuel pressure within 3 pressure” (6-4).
seconds.
Fuel pressure (reference data): 4. Disconnect the pressure regulator hose
290.0 kPa (2.90 kgf/cm2, 42.1 psi) a, and then connect the special service
tool b to the pressure regulator c.
TIP:
The fuel pressure will decrease 3 seconds
after the engine start switch is turned to ON.
6. Start the engine and warm it up until the

engine idle speed stabilizes at
700–800 r/min.
6-5
Fuel system
a 0
c
b
1
b
2
Vacuum/pressure pump gauge set b:
90890-06756 3
5. Block the end of the pressure regulator
hose a using a rubber plug.
6. Start the engine and let it idle.

4
7. Check that the fuel pressure is reduced
when negative pressure is applied to the 5
pressure regulator.

6
9. Disconnect the special service tool b,
and then connect the pressure regulator
hose a.
7
11. Disconnect the special service tools. See 8

steps 10–12 in “Measuring the fuel pres-
sure” (6-4).
9
10
A
6-6
FUEL
Fuel system
10
9
11
8
1
2
1
12
3
1 13
14
15
4 17 22
1
21
5 N·m (0.5 kgf·m, 3.7 ft·lb)
20
6 16
19
7 7
5
18

1 Clamp 4
2 Hose 1
3 Cover 1
4 Hose 1
5 Joint 1
6 Holder 1
7 Plastic tie 2
8 Holder 1
9 Bolt 1 M8 16 mm
10 Nut 1
11 Bracket 1
12 Fuel filter element 1
13 O-ring 1 39
14 Clip 1
15 Float 1
16 Fuel cup assembly 1
17 Fuel filter assembly 1
6-7
10
9
11 0
8
1
1
2
1
12
3 2
1 13
14
15
3
4 17 22
1 4
21
5 N·m (0.5 kgf·m, 3.7 ft·lb)
16
20 5
6
19
7
5
7
18
6

18 Hose 1
19 Clamp 1
20
21
Cover
Bolt
1
1 M6 25 mm
8
22 Fuel joint 1
9
10
A
6-8
FUEL
Fuel system
Removing the fuel filter assembly
Cover the fuel components using a rag to
prevent fuel from spilling out.
1. Disconnect the water detection switch

coupler a.
2. Remove the holders a and b.
h
b
8. Remove the fuel joint i, and then dis-
connect the fuel hose j.
a
i
j
3. Remove the bracket c.
4. Disconnect the fuel hoses d and e.
5. Remove the fuel filter assembly f.

9. Remove the fuel hose j from the hold-
ers k and l.
k
c j
l
e Checking the fuel joint

1. Check the fuel joint. Replace if cracked or
damaged.
6. Remove the fuel hose e and holder g.
fuel joint outlet a.
e
3. Apply the specified positive pressure.
Replace the fuel joint if the specified
g pressure cannot be maintained for 10
seconds or more.
7. Remove the clamp h.
6-9
4. Block the fuel inlet a using a rubber plug
a b, and then apply the specified negative
pressure. Replace the O-ring, fuel cup
assembly, or fuel filter assembly if the
specified pressure cannot be maintained 0
a for 15 seconds or more.
b 1
a
90890-06756 a
2
b
Specified positive pressure: c
50.0 kPa (0.50 kgf/cm2, 7.3 psi)
b 3
Checking the fuel filter assembly
fuel inlet a. 4
2. Block the fuel outlet b using a rubber Vacuum/pressure pump gauge set c:
plug b, and then apply the specified pos-
itive pressure. Replace the O-ring, fuel
cup assembly, or fuel filter assembly if
90890-06756
5
the specified pressure cannot be main- 80.0 kPa (0.80 kgf/cm2, 11.6 psi)
tained for 15 seconds or more.
Disassembling the fuel filter 6
assembly
1. Remove the fuel cup assembly a, O-ring
a
b, fuel filter element c, and clamp d. 7
b
a
c 8
b b
b 9
a
a
Leakage tester a: 90890-06840 d
10
Specified positive pressure:
200.0 kPa (2.00 kgf/cm2, 29.0 psi)
3. Connect the special service tool c to the Checking the fuel filter element
fuel outlet b. 1. Check the fuel filter element. Replace the
fuel filter element if there is dirt or resi-
due.
A
6-10
FUEL
Fuel system
Checking the fuel cup assembly
1. Check the fuel cup assembly. Clean
using straight gasoline if there is foreign
material or replace if cracked. NOTICE: a
When cleaning the fuel cup assembly,
do not remove the clip and float. b
2. Check the water detection switch. See
“Checking the water detection switch” (5-
19). c
Checking the primer pump

primer pump inlet a.
Fuel cup assembly c:
2. Block the fuel outlet b using a rubber
5 N·m (0.5 kgf·m, 3.7 ft·lb)
plug b.
2. Install the clamp d.
3. Apply the specified positive pressure.
Replace the primer pump if the specified
d
pressure cannot be maintained for 30
seconds or more.
b
a
b b a
a: 115–125 mm(4.53–4.92 in)

b: 20–30 mm(0.79–1.18 in)
a
Installing the fuel filter assembly
Leakage tester a: 1. Pass the fuel hose a through the bottom
90890-06840 cowling b.
Specified positive pressure: 2. Install the clamp c temporarily onto the

135.0 kPa (1.35 kgf/cm2, 19.6 psi) fuel hose a, and then connect the fuel
hose to the fuel joint d.
Assembling the fuel filter assembly
1. Install the fuel element a, a new O-ring 3. Fasten the fuel hose a using the clamp
b, and the fuel cup assembly c, and c.
then tighten the fuel cup assembly c to
the specified torque. NOTICE: Do not 4. Install the fuel joint d.
reuse an O-ring, always replace it with
a new one.
6-11
10. Install the clamps k temporarily onto the
c fuel hoses j and l.
a
11. Connect the fuel hoses j and l, and
d
then fasten them using the clamp k. 0
12. Install the fuel filter assembly m to the
bracket n.
b 13. Install the bracket n to the cylinder head

1
cover.
5. Install the clamp e.
2
n
3
k
m
e l
4
6. Install the fuel hose a to the holders f
and g. j
5
14. Install the holders o and p.
f
g
a
15. Connect the water detection switch cou- 6
pler a.
p 7
7. Install the clamp h.
a
8
8. Install the clamp i temporarily onto the
fuel hose j. o
9. Connect the fuel hose j, and then fas-
9
ten it using the clamp i.
10
j i
A
6-12
FUEL
Fuel system
Fuel pump assembly
17
18
19
16
3 N·m (0.3 kgf·m, 2.2 ft·lb) 6

20
4 21
3
2
3
2 5 14
3
11 13
1 3 12
2 2
11
11
10
9
11
15 7 8
15

1 Fuel pump assembly 1
2 Fuel pump screw 4 M5 43 mm
3 Washer 4
4 Cover 1
5 Diaphragm 1
6 Fuel pump body 2 1
7 Diaphragm 1
8 Pin 1
9 Spring 1
10 Fuel pump body 1 1
11 Nut 4
12 Spring 1
13 Plunger 1
14 O-ring 1 39
15 Bolt 2 M6 30 mm
16 Clamp 1
17 Clamp 1
6-13
Fuel pump assembly
17
18
19
0
16
3 N·m (0.3 kgf·m, 2.2 ft·lb) 6

20
1
4 21
3
2 2
3
2 5
3
11 13
14
3
1 3 12
2 2
11 4
11 5
10
9
11
15 7 8
6
15

18 Hose 1
19 Fuel strainer 1
20
21
Holder
Bolt
1
1 M6 16 mm
8
9
10
A
6-14
FUEL
Fuel system
Removing the fuel pump assembly Checking the fuel pump assembly
Cover the fuel components using a rag to 1. Connect the special service tool a to the
prevent fuel from spilling out. fuel pump inlet a.
1. Remove the bracket a. 2. Block the fuel pump outlet b using a rub-
ber plug b, and then apply the specified
2. Disconnect the fuel hoses b and c. positive pressure. Check that there is no
air leakage.
c
a
a
b
b
b a

90890-06756
3. Disconnect the fuel hose b from the fuel
strainer d. Specified positive pressure:
50.0 kPa (0.50 kgf/cm2, 7.3 psi)
d 3. Apply the specified negative pressure,
and then check that there is no air leak-
age.
4. Remove the fuel pump assembly e. b a

30.0 kPa (0.30 kgf/cm2, 4.4 psi)
e
fuel pump outlet b.
5. Block the fuel pump inlet a using a rub-

ber plug b.
6. Apply the specified positive pressure,

and then check that there is no air leak-
age.
6-15
Fuel pump assembly
b a 0
a
f 1
4. Remove the diaphragm g, spring h,
Specified positive pressure:
50.0 kPa (0.50 kgf/cm2, 7.3 psi)
plunger e, and spring i. 2
e
Disassembling the fuel pump i
assembly
1. Remove the cover a, diaphragm b, and
3
fuel pump body 2 c.
a 4
h
b 5
g
Checking the diaphragm and valve 6

1. Check the diaphragm a. Replace if torn.
c
2. Check the valves a. Replace the fuel
pump body 2 b if deformed or worn. 7
2. Align the groove a in the fuel pump body
1 d with the hole b in the plunger e by
turning them.
a
8
e
b
9
a d b a
Checking the fuel strainer 10

fuel inlet a.
3. Remove the pin f by pressing the

plunger and diaphragm.
A
6-16
FUEL
Fuel system
2. Block the fuel outlet b using a rubber 3. Install the pin e.
plug b, and then apply the specified pos-
itive pressure. Replace the fuel strainer if c a
the specified pressure cannot be main-
tained for 15 seconds or more.
d b
b
a
e
b a
Leakage tester a: 90890-06840 4. Turn the plunger c so that both the dia-
phragm tab c and the groove d face in
Specified positive pressure: the same direction.
200.0 kPa (2.00 kgf/cm2, 29.0 psi)
c
Assembling the fuel pump assembly
Before assembling the fuel pump assembly,
clean the parts and soak the valves and dia-
phragm in gasoline to obtain prompt opera-
tion of the fuel pump assembly.
Do not reuse an O-ring, always replace it

with a new one.
d
1. Install the springs a and b, plunger c, c
and diaphragm d.
5. Install the fuel pump body 2 f, dia-
c
b phragm g, and cover h, and then
tighten the fuel pump screws i to the
specified torque.
h
i
g
a
2. Align the hole a in the plunger c with

the hole b in the diaphragm d by push-
ing the plunger and diaphragm. f
6-17
Fuel pump assembly
Fuel pump screw i:

3 N·m (0.3 kgf·m, 2.2 ft·lb) f g
i
Installing the fuel pump assembly
1. Install a new O-ring a and the fuel pump e
h
0
assembly b. NOTICE: Do not reuse an
O-ring, always replace it with a new
one.
1
b d
a
2
3
2. Install the clamps c and d temporarily
onto the fuel hose e.
4
3. Connect the fuel hose e to the fuel
strainer f, and then fasten it using the
clamp c.
5
4. Install the clamp g temporarily onto the
fuel hose h. 6
f
g h
c
7
e
d
8
9
5. Install the fuel strainer f. 10
6. Connect the fuel hoses e and h, and
then fasten the fuel hoses using the
clamps d and g.
7. Install the holder i.

A
6-18
FUEL
Fuel system
Intake silencer
5
2 N·m (0.2 kgf·m, 1.5 ft·lb)
6
1 7
2 3
3 3 8
4
9
4 N·m (0.4 kgf·m, 3.0 ft·lb)

10
11
12 10
19
13
20
15
16
17
18
16
14 17 18
12

1 Blowby hose 1
2 Holder 1
3 Holder 3
4 Holder 1
5 Fuse puller 1
6 Cover 1
7 Cover screw 2 ø5 10 mm
8 Cover 1
9 Cover 1
10 ISC valve screw 2 M5 13 mm
11 ISC valve 1
12 Plastic tie 2
13 Hose 1
14 Clamp 1
15 Intake silencer 1
16 Grommet 2
17 Collar 2
6-19
Intake silencer
5
2 N·m (0.2 kgf·m, 1.5 ft·lb) 0
6
1 7 1
2 3
3 3 8
2
4
9
4 N·m (0.4 kgf·m, 3.0 ft·lb)

3
10
11
19
12 10 4
13
20
15
16
5
17
18
14
16
17 18 6
12

18 Bolt 2 M6 35 mm
19 Hose 1
20 Holder 1 8
9
10
A
6-20
FUEL
Fuel system
Removing the intake silencer
1. Remove the cover, and then remove the
e f h i
g
cover a.
d e
5. Remove the intake silencer j.
2. Remove the air hose b, and then discon-

nect the ISC valve coupler a.
Checking the ISC valve

a 1. Check the ISC valve exterior. Replace if
cracked.
2. Check the ISC valve electrical perfor-

b mance. See “Checking the vapor shut-off
valve” (5-22).
3. Remove the ISC valve c. Installing the intake silencer

1. Install the intake silencer a, and then
c fasten it using the clamp b.
b a
4. Remove the holders d, e, f, and g,
blowby hose h, and vapor gas hose i.
2. Install the vapor gas hose c and blowby
hose d, and then install the holders e,
f, g, and h.
6-21
Intake silencer
e h d c
f
g e
m 0
n
1
3. Install the ISC valve i, and then tighten Cover screw n:
the ISC valve screws j to the specified
torque.
2 N·m (0.2 kgf·m, 1.5 ft·lb) 2
j i
j
3
4
ISC valve screw j:

5
4 N·m (0.4 kgf·m, 3.0 ft·lb)
4. Connect the ISC valve coupler a. 6

5. Install the air hose k, and then fasten it
using the plastic ties l.
7
l
8
a 9
k
10
l
6. Install the cover m, and then tighten the

cover screws n to the specified torque.
A
6-22
FUEL
Fuel system
Intake manifold
3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 8 8
7 10 11 9
10
6 12
5
13
4 10
15 12
14
17 16
15
15
17 16
1
18
4
2
17
16
3 4 20 18
17
21 N·m (2.1 kgf·m, 15.5 ft·lb) 4 16
19
10 N·m (1.0 kgf·m, 7.4 ft·lb) 20

1 Dowel 2
2 Gasket 1 39
3 Intake manifold 1
4 Intake manifold bolt 5 M8 40 mm
5 O-ring 1 39
6 Sensor assembly 1
7 Sensor assembly screw 2 M5 13 mm
8 Screw 2 M5 13 mm
9 TPS 1
10 Bolt 3 M6 16 mm
11 O-ring 1 39
12 Bolt 2 M6 35 mm
13 Throttle body 1
14 Gasket 1 39
15 Intake manifold bolt 3 M6 45 mm
16 O-ring set 4 39
17 Fuel injector 4
6-23
Intake manifold
3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 8 8

7 10 11 9
6
10
12
0
5
13
1
4 10
15 12
14 2
17 16
15
3
15
17 16
1
18
4
4
2
17
16
5
3 4 20 18
17
21 N·m (2.1 kgf·m, 15.5 ft·lb) 4
19
16 6
10 N·m (1.0 kgf·m, 7.4 ft·lb) 20

18 Holder 2
19 Fuel rail 1
20 Bolt 2 M6 38 mm 8
9
10
A
6-24
FUEL
Fuel system
Removing the fuel injector
Cover the fuel components using a rag to b
b
1. Disconnect the quick connector a and
fuel injector couplers b.
c
2. Remove the wiring harness from the
holder. b
a c
b
Checking the fuel rail and fuel

injectors
b 1. Check the fuel rail. Replace if cracked or
deformed.
2. Check the fuel injectors. See “Checking

the fuel injector” (5-20).
Removing the intake manifold

3. Remove the fuel rail a. 1. Disconnect the TPS coupler a.
2. Remove the throttle link rod a from the

throttle body side.
4. Remove the fuel injectors b and holders

c.
3. Remove the throttle body b and gasket

c.
6-25
Intake manifold
b
h 0
1
4. Disconnect the sensor assembly coupler Checking the intake manifold
b. 1. Check the intake manifold. Replace if
cracked or deformed.
2
5. Remove the holders c from the intake
manifold. Checking the throttle body
6. Disconnect the pressure regulator hose
1. Turn the throttle valve manually and 3
check that it moves smoothly.
d.
d b
Checking the TPS
1. Check the TPS exterior. Replace if 4
cracked.
2. Check the electrical performance of the

TPS. See “Checking the TPS” (5-15).
5
c
Installing the intake manifold
6
7. Remove the grommet e, and then Do not reuse an O-ring or gasket, always
remove the intake manifold f and dow- replace it with a new one.
els g. 7
1. Install a new O-ring a and the sensor
assembly b, and then tighten the sensor
assembly screws c to the specified
torque.
8
c
9
b
f a 10
g
e
8. Remove the sensor assembly h. Sensor assembly screw c:

3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
A
6-26
FUEL
Fuel system
2. Install a new gasket d onto the intake 7. Connect the sensor assembly coupler c.
manifold. Check that the tab on the gas-
j c
ket is properly and firmly fitted into the
groove a in the intake manifold.
b
d
f
8. Install the drain hose k to the intake

manifold f.
a
k
f
3. Install the dowels e and intake manifold
f, and then tighten the intake manifold
bolts g and h to the specified torque. 9. Install a new gasket l onto the intake
manifold. Check that the tab on the gas-
4. Install the grommet i. ket is properly and firmly fitted into the
groove d in the intake manifold.
h
10. Install the throttle body m.
e g
i
Intake manifold bolt g: d

21 N·m (2.1 kgf·m, 15.5 ft·lb)
Intake manifold bolt h:
10 N·m (1.0 kgf·m, 7.4 ft·lb) 11. Connect the throttle link rod n to the
throttle body.
5. Connect the pressure regulator hose j.
6. Install the holders b to the intake mani-

fold f.
6-27
Intake manifold
a
0
n
c
b
a 1
c
12. Connect the TPS coupler e. a
2
3. Install the fuel rail b onto the intake
manifold. 3
e 4. Tighten the bolts d equally.
4
Installing the fuel injector b
1. Install new O-rings a and b to fuel
injector a. NOTICE: Do not reuse an d
5
O-ring, always replace it with a new
one.
6
a
d
a
7
5. Install the wiring harness to the holders,
b
and then connect the fuel injector cou-
plers c.
8
6. Connect the quick connector d.
2. Install the fuel injectors a onto the fuel
rail b, and then install the holders c. 9
10
A
6-28
FUEL
Fuel system
6-29
Intake manifold / Throttle link rod
Throttle link rod
1
0
1
5 N·m (0.5 kgf·m, 3.7 ft·lb)
2
5
2
3
3
4 6 4
7
10
9
5
11 8

1 Throttle link rod 1
2 Collar 1
3
4
Spring
Throttle control lever
1
1
8
5 Throttle cam roller 1
39
6
7
Cotter pin
Bolt
1
1 M6 35 mm 9
8 Bolt 1 M6 45 mm
9 Collar 1
10
11
Wave washer
Throttle cam
1
1
10
A
6-30
FUEL
Fuel system
Removing the throttle link
1. Remove the clip a and throttle cable b.
2. Remove the throttle link rod c.
c
a
b
b
3. Remove the throttle cam assembly a. 6. Remove the bolt g, collar h, spring i,
cotter pin j, and roller k.
a k
h
j
g
Installing the throttle link

1. Install the roller a, a new cotter pin b,
the spring c, the collar d, and the bolt
4. Remove the bolt d, collar e, and wave e. NOTICE: Do not reuse a cotter pin,
washer f. always replace it with a new one.
e d
d c
a
f b
e
5. Remove the throttle lever assembly b. 2. Install the throttle lever assembly a to
the crankcase. Fit the end b of the
spring c into the hole c in the crank-
case.
6-31
Throttle link rod
c
i
b
0
1
c
6. Install the throttle cable and clip. See
a “Installing the shift cable and throttle
cable” (3-9).
2
3. Install the wave washer f, collar g, and 7. Adjust the throttle link rod.
bolt h.
Adjusting the throttle link rod
3
1. Loosen the locknut a, and then remove
the throttle link rod a from the throttle
cam b. 4
g
h
5
f a
4. Install the throttle cam assembly d.

b a 6
d
2. Check that the protrusion b on the throt- 7
tle lever c and the protrusion c on the
shift bracket d are aligned.
3. Turn the throttle cam until it contacts the 8

roller e slightly.
5. Install the throttle link rod i. 10
A
6-32
FUEL
Fuel system
Link rod locknut a:

d c c 5 N·m (0.5 kgf·m, 3.7 ft·lb)
b
c b
4. Adjust the throttle link rod length so that

its end d fits onto the protrusion e on
the throttle cam, and then install the
throttle link rod to the throttle cam.
TIP:
To adjust the throttle link rod length, make
sure to align the protrusions b and c.
5. Tighten the link rod locknut a to the

specified torque.
6-33
Throttle link rod / Vapor separator
Vapor separator
2
1 3
4
5
6
7
6
6
3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 0
10
9 14
6
13 11
13 1
8
12
6
15
16 2
11
17
11 25
15
16 3
6 13
24 18
15
19
4
16
6
26
6
20 5
6 21
6
23 22
6

1 Nut 1
2 Bolt 1 M6 16 mm
3
4
Grommet
1
1
8
5 Bracket 1
6
7
Plastic tie
Hose
10
1 9
8 Hose 1
9 Joint 1
10
11
Hose
Clamp
1
3
10
12 Hose 1
13 Collar 3
14 Hose 1
15 Grommet 3
16 Bolt 3 M6 30 mm
17 Hose 1
A
6-34
FUEL
Fuel system
2
1 3
4 6
6 3.5 N·m (0.35 kgf·m, 2.58 ft·lb)
7 6
5 10
9 14
6 13
13 11
8
15
6 16
12
11
17
15
25 16
11
6 13
24 18
19
15
16
6 6
20
26
6 21
6
23 22

18 Fuel cooler 1
19 Holder 1
20 Fuel cooler screw 2 M6 14 mm
21 Hose 1
22 Hose 1
23 Hose 1
24 Hose 1
25 Hose 1
26 Vapor separator assembly 1
6-35
Vapor separator
Draining the fuel
a
1. Loosen the drain screw a, and then
remove the cap b.
2. Push the air valve a inward using a 0

screwdriver to drain the fuel into a drain b
pan.
a
1
3. Disconnect the vapor shut-off valve cou-
pler c and high-pressure fuel pump cou-
pler d.
2
a c
3
d
4
b
4. Disconnect the vapor gas hoses b from

5
the vapor shut-off valve c.
a
6
b
3. Tighten the drain screw a to the speci-

7
fied torque, and then install the cap b. c
Vapor separator drain screw a:
1.5 N·m (0.15 kgf·m, 1.11 ft·lb)
8
I
5. Remove the vapor shut-off valve c.
Removing the vapor separator
1. Disconnect the knock sensor coupler a.
c
9
2. Remove the knock sensor lead b from
the holder a. 10
A
6-36
FUEL
Fuel system
6. Disconnect the cooling water hoses d
and e.
g
e
10. Remove the vapor gas hoses h, i, and
j and pressure regulator hose k.
7. Remove the vapor separator assembly
f. j
i
k
h
f
11. Remove the fuel hose l.
12. Remove the cooling water hose m.
l
8. Remove the cooling water hoses d and
e.
m
d
13. Remove the fuel hoses n and o.
e n
9. Remove the fuel hose g. o
14. Remove the fuel cooler p.
6-37
Vapor separator
c
f
e
c 0
d
p 1
4. Install the cooling water hose g.
5. Install the fuel hose h, and then fasten it

2
using the plastic ties i.
Checking the vapor shut-off valve
1. Check the vapor shut-off valve exterior.
i 3
Replace if cracked. h

vapor shut-off valve. See “Checking the g
4
vapor shut-off valve” (5-22).
Installing the vapor separator

1. Install the fuel cooler a, and then tighten
i
5
the fuel cooler screws b to the specified 6. Connect the vapor gas hoses j, k, and
torque. l to the joint m, and then fasten them
using the plastic ties n. 6
l n
n j
7
m
a
k
8
b
7. Connect the vapor gas hoses j and k,
and then fasten them using the plastic
9
b
ties o.
Fuel cooler screw b:
3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 8. Connect the pressure regulator hose p. 10
2. Install the clamps c and d temporarily
onto the fuel hoses e and f.
3. Connect the fuel hoses e and f, and

then fasten them using the clamps c.
A
6-38
FUEL
Fuel system
12. Connect the cooling water hoses s and
t.
k p
o j
t
s
9. Install the fuel hose q, and then fasten it
using the plastic ties r.
13. Install the vapor shut-off valve v.
r
10. Install the cooling water hoses s and t.
t 14. Connect the vapor gas hose l, and then

fasten it using the plastic tie w.
s
w
l
11. Install the vapor separator assembly u.
15. Connect the high-pressure fuel pump

coupler a and vapor shut-off valve cou-
u pler b.
6-39
Vapor separator
a
0
1
16. Install the knock sensor lead c to the
holder x, and then route the knock sen-
sor lead inside the vapor gas hose k.
2
17. Connect the knock sensor coupler d.
d
3
k
4
c
x 5
6
7
8
9
10
A
6-40
FUEL
Fuel system
Vapor separator and high-pressure fuel pump
5 N·m (0.5 kgf·m, 3.7 ft·lb)
11 11
3 N·m (0.3 kgf·m, 2.2 ft·lb) 10
1
2 9
12
4 N·m (0.4 kgf·m, 3.0 ft·lb) 13

4
14
15
5 19 16
3 17
18 2 N·m (0.2 kgf·m, 1.5 ft·lb)
20
25 2 N·m (0.2 kgf·m, 1.5 ft·lb)
4 15 21
4 N·m (0.4 kgf·m, 3.0 ft·lb)
7 5
8
26 22
2 N·m (0.2 kgf·m, 1.5 ft·lb)
6
24
23
1.5 N·m (0.15 kgf·m, 1.11 ft·lb)

1 Gasket 1 39
2 Holder 1
3 Float chamber 1
4 O-ring 2 39
5 Hose joint 2
6 Hose 1
7 O-ring 1 39
8 Vapor separator drain screw 1
9 Vapor separator cover screw 6 M5 14 mm
10 Cap 1
11 Pressure regulator bolt 2 M6 12 mm
12 Pressure regulator 1
13 Cover 1
14 Plate 1
15 Float chamber plate screw 2 M4 6 mm
16 Lead 1
17 Lead holder screw 1 M4 6 mm
6-41
5 N·m (0.5 kgf·m, 3.7 ft·lb)

11 11
1
2
3 N·m (0.3 kgf·m, 2.2 ft·lb) 10
0
9
12
1
4 N·m (0.4 kgf·m, 3.0 ft·lb) 13
4
14 2
15
5 19 16
3 17
20
18 2 N·m (0.2 kgf·m, 1.5 ft·lb) 3
25 2 N·m (0.2 kgf·m, 1.5 ft·lb)
4 15 21
7 5
4 N·m (0.4 kgf·m, 3.0 ft·lb)
4
8
26 22
6
2 N·m (0.2 kgf·m, 1.5 ft·lb) 5
24
23 6
1.5 N·m (0.15 kgf·m, 1.11 ft·lb)

18 Plate 1
19 Pin 1 39
20
21
Grommet
Collar
1
1
8
22 High-pressure fuel pump 1
23
24
Clip
Filter
1
1 9
25 Needle valve 1
26 Float 1
10
A
6-42
FUEL
Fuel system
Disassembling the vapor separator 5. Remove the pin j in the direction of the
1. Remove the pressure regulator a. arrow.
2. Remove the cap b, hose joint c, and O-

ring d.
b
a j
d j
3. Remove the cover e, gasket f, and

holder g. 6. Remove the float k and needle valve l.
e
f
k
l
7. Remove the holder b, and then discon-

nect the lead connectors c and d.
d
4. Remove the high-pressure fuel pump h
and grommet i, and then disconnect the
high-pressure fuel pump coupler a.
b c
h
8. Remove the plates m and n.
n
m
i
a
6-43
9. Remove the filter o. 3. Check the filter. Clean if there is dirt or
residue.
Adjusting the float height

1. Bend a of the float to adjust the float
height to specification b.
0
1
o
c a
b 2
10. Remove the hose joint p, drain screw q,
Float height b:
3
O-rings r and s, and drain hose t.
35.0 ± 1.0 mm (1.38 ± 0.04 in)
TIP:
4
• Do not bend the lever c.
r • Bend both portions of a equally.
q s p 5
Assembling the vapor separator
t
Do not reuse a float pin, gasket, or O-ring,
6
Checking the high-pressure fuel always replace it with a new one.
pump
high-pressure fuel pump. See “Checking
1. Install a new O-ring a and the hose joint 7
b, and then tighten the hose joint b to
the high-pressure fuel pump” (5-21).
the specified torque.
Checking the vapor separator
1. Check the needle valve. Replace the
2. Install a new O-ring c, the drain screw 8
d, and the drain hose e, and then
needle valve if bent or worn. tighten the vapor separator drain screw
d to the specified torque.
9
a
10
d c b
2. Check the float. Replace if deteriorated. e
A
6-44
FUEL
Fuel system
Hose joint b: 4 N·m (0.4 kgf·m, 3.0 ft·lb) c k

Vapor separator drain screw d:
1.5 N·m (0.15 kgf·m, 1.11 ft·lb)
3. Install the plates f and g, and then

tighten the float chamber plate screws h
to the specified torque.
h h
g l
l
f
TIP:
Install the float pin so that the tapered end is
pointing toward the mark c on the cover.
Float chamber plate screw h:
2 N·m (0.2 kgf·m, 1.5 ft·lb) 7. Measure the float heights d. Adjust if out
of specification.
4. Connect the connectors a and b, and
then tighten the lead holder screws i to
i
b d
a
Float height d (reference data):
35.0 ± 1.0 mm (1.38 ± 0.04 in)
Lead holder screw i:
2 N·m (0.2 kgf·m, 1.5 ft·lb) TIP:
The float should be resting on the needle
5. Install the needle valve j to the float k. valve. Do not press the float.
8. Install the filter m.

k
6. Install the float k and a new float pin l.
6-45
s
r
q
m
p 1
2
9. Connect the high-pressure fuel pump Vapor separator cover screw s:
coupler e, and then install the grommet 3 N·m (0.3 kgf·m, 2.2 ft·lb) 3
n and high-pressure fuel pump o.
12. Install the pressure regulator t, and
then tighten the pressure regulator bolts
u to the specified torque. 4
13. Install a new O-ring v and the hose joint
o w, and then tighten the hose joint w to
the specified torque. 5
u u
t 6
n
e
w
v 7
10. Install the holder p and a new gasket q.
11. Install the cover r, and then tighten the Pressure regulator bolt u: 8
vapor separator cover screws s to the 5 N·m (0.5 kgf·m, 3.7 ft·lb)
specified torque. Hose joint w: 4 N·m (0.4 kgf·m, 3.0 ft·lb)
9
10
A
6-46
POWR
Power unit 7
Power unit (check and adjustment) ................................. 7-1

Checking the compression pressure ......................................... 7-1
Checking the oil pressure .......................................................... 7-1
Checking the pulser coil air gap ................................................ 7-2
Adjusting the pulser coil air gap ................................................ 7-2
Checking the valve clearance ................................................... 7-2
Adjusting the valve clearance .................................................... 7-4
Power unit assembly ........................................................ 7-5

Removing the power unit ........................................................... 7-7
Installing the power unit ............................................................. 7-9
Flywheel magnet and timing belt ................................... 7-13

Removing the flywheel magnet ............................................... 7-15
Removing the stator assembly ................................................ 7-15
Removing the timing belt and sprocket ................................... 7-16
Checking the timing belt and sprocket .................................... 7-17
Installing the sprocket and timing belt ..................................... 7-17
Installing the stator assembly .................................................. 7-18
Installing the flywheel magnet ................................................. 7-19
Engine ECM and starter motor ...................................... 7-21

Removing the starter motor ..................................................... 7-22
Remove the starter relay ......................................................... 7-22
Installing the starter relay ........................................................ 7-22
Installing the starter motor ....................................................... 7-23
Rectifier Regulator and ignition coil .............................. 7-24

Removing the Rectifier Regulator and ignition coil .................. 7-25
Installing the ignition coil and Rectifier Regulator .................... 7-25
Wiring harness ................................................................ 7-27

Removing the wiring harness .................................................. 7-30
Installing the wiring harness .................................................... 7-31
Shift bracket .................................................................... 7-33
Cylinder head .................................................................. 7-34

Removing the cylinder head .................................................... 7-35
Checking the cylinder head bolt .............................................. 7-35
Installing the cylinder head ...................................................... 7-35
Camshaft and valve ........................................................ 7-38

Disassembling the cylinder head ............................................. 7-40
Checking the cylinder head ..................................................... 7-41
Checking the valve spring ....................................................... 7-41
Checking the valve .................................................................. 7-42
Checking the valve guide ........................................................ 7-42
Replacing the valve guide ....................................................... 7-42
Checking the valve seat .......................................................... 7-43
Refacing the valve seat ........................................................... 7-44
0
Checking the rocker arm and rocker arm shaft ....................... 7-46
Checking the camshaft ............................................................ 7-46
Checking the spark plug .......................................................... 7-47
Checking the cylinder head anode .......................................... 7-47
1
Assembling the cylinder head ................................................. 7-47
Exhaust cover .................................................................. 7-50 2

Removing the exhaust cover ................................................... 7-52
Removing the thermo sensor .................................................. 7-52
Removing the oil pressure switch ............................................ 7-52
Removing the oil filter .............................................................. 7-52 3
Checking the exhaust cover anode ......................................... 7-53
Checking the thermostat ......................................................... 7-53
Installing the oil filter ................................................................ 7-53
Installing the oil pressure switch .............................................. 7-53 4
Installing the thermo sensor .................................................... 7-54
Installing the exhaust cover ..................................................... 7-54
Cylinder block ................................................................. 7-56

5
Disassembling the cylinder block ............................................ 7-57
Checking the piston diameter .................................................. 7-58
Checking the cylinder bore ...................................................... 7-58
Checking the piston ring .......................................................... 7-58
6
Checking the piston ring end gap ............................................ 7-58
Checking the piston ring groove .............................................. 7-59
Checking the piston ring side clearance .................................. 7-59
Checking the piston pin boss .................................................. 7-59
7
Checking the piston pin ........................................................... 7-59
Checking the connecting rod small end inside diameter and
big end inside diameter ........................................................... 7-59
Checking the connecting rod big end side clearance .............. 7-60
8
Checking the crankshaft .......................................................... 7-60
Checking the crankpin oil clearance ........................................ 7-60
Selecting the crankpin bearing ................................................ 7-62
Checking the crankshaft journal oil clearance ......................... 7-62
9
Selecting the crankshaft journal bearing ................................. 7-63
Assembling the cylinder block ................................................. 7-64
10
A
POWR
Power unit
Power unit (check and Checking the oil pressure
adjustment) 1. Disconnect the oil pressure switch lead
from the oil pressure switch end.
Checking the compression pressure
1. Start the engine, warm it up for 5 min-
2. Remove the oil pressure switch, and then
utes, and then stop it.
install an oil pressure gauge a to the oil
pressure switch installation hole.
2. Remove the clip from the engine shut-off
switch.
3. Start the engine and warm it up until the
engine idle speed stabilizes at 700–800
3. Disconnect the spark plug wires.
r/min.
4. Remove all of the spark plugs, and then
4. Measure the oil pressure.
install the special service tool a into the
spark plug hole. NOTICE: Before
removing the spark plugs, remove any
dirt or dust in the spark plug wells
that could fall into the cylinders.
a
Oil pressure gauge a:

Oil pressure (reference data):

at 60 °C (140 °F) with SL 10W-30 engine
Compression gauge a: 90890-03160
oil and at 750 r/min:
5. Fully open the throttle. 190.0 kPa (1.90 kgf/cm2, 27.6 psi)
at 61 °C (142 °F) with SL 10W-30 engine
6. Crank the engine until the reading on the oil and at 3000 r/min:
compression gauge stabilizes, and then 450.0 kPa (4.50 kgf/cm2, 65.3 psi)
measure the compression pressure.
Minimum compression pressure TIP:
(reference data): • Use a pressure gauge with an adapter that
800.0 kPa (8.00 kgf/cm2, 116.0 psi) has a 1/8 pitch thread.
at 20 °C (68 °F) • The actual oil pressure may vary depending
on the temperature and viscosity of the
7. Remove the special service tool a. engine oil.
8. Install all of the spark plugs, and then 5. Remove the oil pressure gauge a.
tighten the spark plugs to the specified
torque. 6. Install the oil pressure switch. See
Spark plug: 18 N·m (1.8 kgf·m, 13.3 ft·lb) “Installing the oil pressure switch” (7-53).
9. Connect the spark plug wires.
7-1
Power unit (check and adjustment)
Checking the pulser coil air gap
Do not turn the flywheel magnet counter-
clockwise. Otherwise, the water pump
impeller could be damaged. 0
impeller could be damaged.
1. Remove all of the spark plugs, blowby
hose a, fuel hoses b, c, and d, fuel fil-
1. Turn the flywheel magnet clockwise to
align the protrusions on the flywheel
ter assembly e, and Rectifier Regulator 1
f, and then remove the cylinder head
magnet and pulser coil.
cover g.
2. Measure the pulser coil air gap a. Adjust
if out of specification. g
2
a
b
3
a
Pulser coil air gap a:

e
5
0.5–1.0 mm (0.020–0.039 in) c
Adjusting the pulser coil air gap
f
d 6
1. Loosen the pulser coil bolts a, and then
adjust the pulser coil air gap.
TIP:
Cover the fuel components using a rag to
7
2. Turn the flywheel magnet clockwise to

align the “1” mark a on the driven
8
a sprocket h with the “P” mark b on the
cylinder head.
9
Pulser coil air gap a:
0.5–1.0 mm (0.020–0.039 in)
10
2. Tighten the pulser coil bolts a, and then
h
recheck the pulser coil air gap.
a
Checking the valve clearance
Measure the valve clearances when the b
engine is cold.
A
7-2
POWR
Power unit
3. Measure the valve clearances c and d 5. Turn the flywheel magnet clockwise 360°
according to steps 4–6. to align the “4” mark e on the driven
sprocket h with the “P” mark b on the
EX IN
cylinder head.
#1
#2
h
#3
e
#4 b
6. Measure the intake and exhaust valve

clearances of the applicable cylinders.
Adjust if out of specification.
#1 #2 #3 #4
c d IN — — ✓ ✓
EX — ✓ — ✓
—: Not applicable
✓ : Specified cylinder
7. Install a new gasket i and the cylinder

head cover g. NOTICE: Do not reuse a
gasket, always replace it with a new
one.
Valve clearance:
Intake c:
0.20 ± 0.05 mm (0.008 ± 0.002 in)
Exhaust d:
0.30 ± 0.05 mm (0.012 ± 0.002 in)
TIP:
Write down the measurement data.
4. Measure the intake and exhaust valve

clearances of the specified cylinders. i
g
Adjust if out of specification.
#1 #2 #3 #4 8. Install the fuel filter assembly e, connect
the fuel hoses b, c, and d, and then
IN ✓ ✓ — —
fasten the fuel hoses using the clamps i
EX ✓ — ✓ —
and j.
—: Not applicable
✓ : Specified cylinder 9. Install the Rectifier Regulator f and
blowby hose a.
7-3
Power unit (check and adjustment)
2. Tighten the valve adjusting locknut a to
the specified torque, and then recheck
the valve clearances.
a Valve adjusting locknut a:
14 N·m (1.4 kgf·m, 10.3 ft·lb)
0
b
i
1
e
j
2
c
f
d
3
j
Adjusting the valve clearance

Adjust the valve clearances when the engine
4
is cold.

5
impeller could be damaged.
6
1. Loosen the valve adjusting locknut a,
and then turn the adjusting screw b until
the valve clearance is within specifica-
tion.
7
b
a 8
b
9
a
10
TIP:
• To decrease the valve clearance, turn the
adjusting screw b in direction a.
• To increase the valve clearance, turn the
adjusting screw b in direction b.
A
7-4
POWR
Power unit
Power unit assembly
6
14
7
4 5
1 8
3
2 9
13
10
11 15
1
12
16
18
17
a 21 N·m (2.1 kgf·m, 15.5 ft·lb)
b 21 N·m (2.1 kgf·m, 15.5 ft·lb) 12 3 N·m (0.3 kgf·m, 2.2 ft·lb)

1 Bolt 3 M6 20 mm
2 Grommet holder 1
3 Grommet 1
4 Cable guide 1
5 Bolt 2 M6 20 mm
6 Bracket 1
7 Collar 1
8 Neutral switch 1
9 Plate 1
10 Screw 2 M4 16 mm
11 Rigging grommet 1
12 Power unit mounting bolt 8 M8 80 mm
13 Gasket 1 39
14 Dipstick 1
15 Bolt 2 M6 16 mm
16 Apron screw 2 M6 25 mm
17 Nut 2
7-5
Power unit assembly
6
14 0
1
4 5
7
8
1
3
2 9
13
10 2
11 15
1
12 3
4
16 5
18
a 21 N·m (2.1 kgf·m, 15.5 ft·lb)

17 6
b 21 N·m (2.1 kgf·m, 15.5 ft·lb) 12 3 N·m (0.3 kgf·m, 2.2 ft·lb)

18 Apron 1
8
9
10
A
7-6
POWR
Power unit
Removing the power unit
1. Remove the grommet holder a, grom-
met b, and rigging grommet c.
j
k
m
a c
l j n
2. Remove the clips d, and then discon-
nect the shift cable e and throttle cable 6. Remove the caps o, and then remove
f. the PTT motor leads p from the PTT
relay q.
e
q
o
f
d
o
p
3. Remove the plastic tie g, and then dis-
p
connect the 10-pin coupler a.
4. Remove the 10-pin wiring harness h

from the plastic tie i.
7. Disconnect the neutral switch coupler b
a h and 6Y8 Multifunction Meter harness
coupler c.
8. Disconnect the gauge harness coupler

d, and PTT switch coupler e.
g
9. Remove each harness from the clamps
r.
r
c d
i
r
5. Remove the battery cables j from the
starter motor k, bracket l, and holders
m and n.
b e
7-7
Power unit assembly
10. Disconnect the trim sensor coupler f. 14. Disconnect the cooling water hoses y.
0
1
f
11. Remove the stator assembly harness g,

water pressure sensor harness h, and
15. Remove the dipstick z. 2
water detection switch harness k from
the holder s.
s
3
z
g
4
k h
16. Remove the clip A, and then remove the
shift rod lever B from the shift rod
5
bracket C.
12. Disconnect the cooling water hose t.
17. Remove the bracket D. 6
C 7
t A 8
B
13. Remove the fuel hose u from the hold-

ers v and w, and then disconnect the
fuel hose u from the filter assembly x.
9
x
D 10
u
18. Remove the apron E.

v
w
A
7-8
POWR
Power unit
19. Install the shackles F to the engine

hangers G, and then install the lifting
harnesses to the shackles F.
b
20. Suspend the power unit. 3. Tighten the power unit mounting bolts b
and oil pan bolts c to the specified
21. Remove the power unit mounting bolts torque in the order a, b, and so on.
H, and then remove the power unit.
4. Tighten the oil pan bolts d to the speci-
F F fied torque.
G
5. Tighten the power unit mounting bolts b
G
STBD
Front
d c b
H
d g a f
e h
b
Front c d
b
H k j i
b c
Installing the power unit PORT
1. Clean the power unit mating surface, and
Front
then install a new gasket a. NOTICE:
Do not reuse a gasket, always replace b c d
it with a new one.
2. Install the power unit using the power unit

mounting bolts b.
7-9
Power unit assembly
9. Install the dipstick l.
Power unit mounting bolt b:
1st: 21 N·m (2.1 kgf·m, 15.5 ft·lb)
2nd: 21 N·m (2.1 kgf·m, 15.5 ft·lb)
Oil pan bolt c:
21 N·m (2.1 kgf·m, 15.5 ft·lb)
0
Oil pan bolt d:
21 N·m (2.1 kgf·m, 15.5 ft·lb) l
6. Install the apron e and apron bolts f,
1
and then tighten the apron screws g to
f
10. Connect the cooling water hoses m. 2
m
3
4
g e
11. Connect the fuel hose n to the fuel filter
assembly o, and then fasten the fuel
5
hose n using the clamp p.
Apron screw g: 3 N·m (0.3 kgf·m, 2.2 ft·lb)
7. Install the bracket h.

12. Install the fuel hose n to the holders q
and r.
6
8. Install the shift rod lever i to the shift rod p
bracket j, and then install the clip k.
o
7
n
j
8
q
r
k
13. Connect the cooling water hose s.
9
i
10
h
s
A
7-10
POWR
Power unit
14. Install the water detection switch harness
a, water pressure sensor harness b, w
and stator assembly harness c to the
holder t.
y
t x
c
c y
b v
a
v
t
a b
15. Connect the trim sensor coupler d. PTT motor lead bolt x:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
21. Install the battery cables z to the hold-

ers A and B, starter motor C, and
bracket D, and then tighten the battery
cable nut E to the specified torque.
16. Connect the gauge harness coupler e

E
and PTT switch coupler f.
17. Connect the neutral switch coupler g C

and 6Y8 Multifunction Meter harness
A
coupler h. z
18. Install each harness to the clamps u.
See “Bottom cowling” (5-6). D z B
u
Battery cable nut E:
h e 9 N·m (0.9 kgf·m, 6.6 ft·lb)
22. Connect the 10-pin coupler k, and then

u
fasten it to the cover F using the plastic
tie G.
23. Fasten the 10-pin wiring harness H to

g f
the bracket I using the plastic tie J.
19. Install the PTT motor leads v to the PTT
relay w, and then tighten the PTT motor
lead bolts x to the specified torque.
20. Install the caps y.
7-11
Power unit assembly
I
0
k
G
1
J
H
2
24. Install the shift cable and throttle cable.
See “Installing the shift cable and throttle 3
cable” (3-9).
4
5
6
7
8
9
10
A
7-12
POWR
Power unit
Flywheel magnet and timing belt
1 157 N·m (15.7 kgf·m, 115.8 ft·lb)
38 N·m (3.8 kgf·m, 28.0 ft·lb)
2
11
150 N·m (15.0 kgf·m, 110.6 ft·lb)
3
4
17
6 6 10
18
6 12
7
5 13 19
14 20
6
6 15
6
16
9 9

1 Flywheel magnet nut 1 Width across flats: 30 mm
2 Washer 1
3 Flywheel magnet 1
4 Bolt 2 M5 12 mm
5 Pulser coil 1
6 Bolt 7 M6 30 mm
7 Stator assembly 1
8 Base 1
9 Dowel 2
10 Plastic tie 1
11 Timing belt 1
12 Drive sprocket nut 1 Width across flats: 41 mm
13 Retaining plate 1
14 Drive sprocket 1
15 Woodruff key 1
16 Woodruff key 1
17 Driven sprocket bolt 1 M10 35 mm
7-13
1 157 N·m (15.7 kgf·m, 115.8 ft·lb)

38 N·m (3.8 kgf·m, 28.0 ft·lb)
2
11
0
150 N·m (15.0 kgf·m, 110.6 ft·lb)
3 1
4
17
6 6 10
18
2
6 12
7
5 13 19 3
14 20
6
6 6 15 4
16
8 5
9 9
6

18 Washer 1
19 Driven sprocket 1
20 Dowel 1 8
9
10
A
7-14
POWR
Power unit
Removing the flywheel magnet Removing the stator assembly
1. Turn the flywheel magnet clockwise to 1. Disconnect the pulser coil coupler a,
align the “1” mark a on the driven and then remove the pulser coil a.
sprocket a with the “P” mark b on the
cylinder head. a
a a
a
b 2. Disconnect the positive lead coupler b,

and then remove the ground lead c.
2. Loosen the flywheel magnet nut.
NOTICE: Apply force in the direction
of the arrow to prevent the flywheel
holder from slipping off easily. b
c
3. Disconnect the Rectifier Regulator cou-

pler d.
Flywheel holder b: 90890-06522
3. Remove the flywheel magnet and Woo-

druff key. NOTICE: To prevent damage
to the engine or tools, screw in the fly-
wheel puller set bolts evenly and com-
pletely so that the flywheel puller is d
parallel to the flywheel magnet.
4. Remove the stator assembly harness e
from the holders b, c, d, and e.
Flywheel puller c: 90890-06521
7-15
b a
0
e
c
1
2. Loosen the drive sprocket nut b.
e
d
2
5. Remove the stator assembly f and base
g. 3
c
f 4
c
5
g
b
6
Crankshaft holder c: 90890-06562
7
TIP:
Use the air tool to loosen the drive sprocket
Removing the timing belt and

nut easily. 8
sprocket 3. Remove the drive sprocket nut b, retain-
ing plate d, drive sprocket e, and Woo-
druff key f. 9
When the timing belt is not installed, do
not turn the crankshaft or driven sprocket.
Otherwise, the pistons and valves could
collide with each other and be damaged.
10
1. Remove the timing belt a from the
driven sprocket side.
A
7-16
POWR
Power unit
Installing the sprocket and timing
b belt
d
When the timing belt is not installed, do
not turn the crankshaft or driven sprocket.
e
Otherwise, the pistons and valves could
collide with each other and be damaged.
f
1. Install the dowel a and driven sprocket
b, and then tighten the driven sprocket
bolt c to the specified torque.
4. Loosen the driven sprocket bolt g, and b

then remove the driven sprocket h.
NOTICE: When loosening the driven
sprocket bolt, do not turn the cam- a
shaft.
g
h i
Flywheel holder i: 90890-06522 d

b
Checking the timing belt and
sprocket Flywheel holder d: 90890-06522
1. Check the interior and exterior of the tim-
ing belt. Replace if cracked, damaged, or Driven sprocket bolt c:
worn. 38 N·m (3.8 kgf·m, 28.0 ft·lb)
2. Check the drive sprocket and driven 2. Install the Woodruff key e, drive
sprocket. Replace if cracked, damaged, sprocket f, retaining plate g, and drive
or worn. sprocket nut h.
7-17
g
a
0
f b
e
1
d
2
c
3
3. Tighten the drive sprocket nut h to the
specified torque.
5. Install the timing belt j from the drive
sprocket side. 4
j
5
i
6
h
TIP:
7
Be careful not to install the timing belt with
i
the part number upside down.
8
Installing the stator assembly
1. Install the dowels a, base b, and stator
assembly c.
9
Crankshaft holder i: 90890-06562
Drive sprocket nut h:

150 N·m (15.0 kgf·m, 110.6 ft·lb) 10
4. Check that the “1” mark a on the driven
sprocket is aligned with the “P” mark b
on the cylinder head, and that the hole c
on the retaining plate is aligned with the
“P” mark d on the cylinder block.
A
7-18
POWR
Power unit
d
c
b
f
a a
g
5. Install the pulser coil h, and then con-

nect the pulser coil coupler e.
h
2. Connect the positive lead coupler a, and
then install the ground lead b.
a
b
Installing the flywheel magnet

1. Install the Woodruff key a, and then
install the flywheel magnet b and fly-
wheel magnet nut c.
3. Connect the Rectifier Regulator coupler
c
c.
a
b b a
c
4. Install the stator assembly harness d to

the holders d, e, f, and g.
7-19
TIP:
Make sure to remove any oil from the tapered
portions of the crankshaft a and flywheel
magnet b. 0
2. Tighten the flywheel magnet nut c to the
specified torque. NOTICE: Apply force
in the direction of the arrow to prevent 1
the flywheel holder from slipping off
easily.
2
d
3
c 4
Flywheel holder d: 90890-06522
Flywheel magnet nut c:

5
157 N·m (15.7 kgf·m, 115.8 ft·lb)
6
7
8
9
10
A
7-20
POWR
Power unit
Engine ECM and starter motor
30 N·m (3.0 kgf·m, 22.1 ft·lb)
4
3
5
1 5
1 2 N·m (0.2 kgf·m, 1.5 ft·lb)

1 5
13 9 6
17 12 7
14 11
16 15 8
12
3 N·m (0.3 kgf·m, 2.2 ft·lb) 10
11
4 N·m (0.4 kgf·m, 3.0 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb)

1 Bolt 3 M6 16 mm
2 Bracket 1
3 Engine ECM 1
4 Starter motor 1
5 Starter motor bolt 3 M8 45 mm
6 Terminal 1
7 Terminal nut 1
8 Cap 1
9 Starter relay lead screw 1 M4 6 mm
10 Starter relay lead 1
11 Cap 2
12 Starter relay lead bolt 2 M6 10 mm
13 Bolt 1 M6 16 mm
14 Starter relay 1
15 Holder 1
16 Starter relay mount screw 1 ø6 20 mm
17 Holder 1
7-21
Engine ECM and starter motor
Removing the starter motor Remove the starter relay
1. Remove the cap a, terminal b, and pos- 1. Remove the starter relay lead a and
itive lead a. ground lead b.
2. Disconnect the starter relay connector

c.
0
a
c 1
a
2
b
b
a
3. Remove the holder a and starter relay
3
2. Remove the starter relay lead c. b.
b 4
a
5
c
6
3. Remove the starter motor d. Installing the starter relay
1. Install the starter relay a and holder b,
and then tighten the starter relay mount 7
screw c to the specified torque.
d b
a 8
c
9
4. Remove the starter relay lead c.
10
Starter relay mount screw c:
3 N·m (0.3 kgf·m, 2.2 ft·lb)
2. Connect the starter relay connector a.

c
A
7-22
POWR
Power unit
3. Install the starter relay lead b and 3. Install the starter relay lead a, and then
ground lead c, and then tighten the tighten the starter relay lead bolt e to the
starter relay lead bolt d to the specified specified torque.
torque.
e
a
d
a
b
Starter relay lead bolt e:

Starter relay lead bolt d: 4 N·m (0.4 kgf·m, 3.0 ft·lb)
4 N·m (0.4 kgf·m, 3.0 ft·lb)
4. Install the positive lead a and terminal
Installing the starter motor f, and then tighten the terminal nut g to
1. Install the starter relay lead a, and then the specified torque.
tighten the starter relay lead screw b to
the specified torque. 5. Install the cap h.
b
a
Starter relay lead screw b: f

2 N·m (0.2 kgf·m, 1.5 ft·lb) g
h
2. Install the starter motor c, and then
tighten the starter motor bolts d to the Terminal nut g:
specified torque. 9 N·m (0.9 kgf·m, 6.6 ft·lb)
d
d c
Starter motor bolt d:

30 N·m (3.0 kgf·m, 22.1 ft·lb)
7-23
Engine ECM and starter motor / Rectifier Regulator and ignition coil
Rectifier Regulator and ignition coil
7 N·m (0.7 kgf·m, 5.2 ft·lb)

0
14
2
3 1
14 2
6
1 4 1
6 14 3
4
3
6
14 4
9
5
13
10
5
1
1 7
8
6 12
11
6
11

1 Ignition coil bolt 4 M6 25 mm
2 Bracket 1
3
4
Ignition coil
Holder
2
2
8
5 Bracket 1
6
7
Spark plug wire
Holder
4
1 9
8 Holder 1
9 Holder 1
10
11
Rectifier Regulator
Bolt
1
2 M6 25 mm
10
12 Bolt 2 M6 20 mm
13 Engine hanger 1
14 Grommet 5
A
7-24
POWR
Power unit
Removing the Rectifier Regulator Installing the ignition coil and
and ignition coil Rectifier Regulator
1. Remove the Rectifier Regulator a. 1. Install the ignition coils a, and then
tighten the ignition coil bolts b to the
specified torque.
a b
a
2. Remove the spark plug wires b. b
b Ignition coil bolt b:

7 N·m (0.7 kgf·m, 5.2 ft·lb)
2. Install the spark plug wires c.
b b
c
3. Remove the ignition coils c.
c c
c
7-25
Rectifier Regulator and ignition coil
3. Install the Rectifier Regulator d.
0
1
d
2
3
4
5
6
7
8
9
10
A
7-26
POWR
Power unit
Wiring harness
4 N·m (0.4 kgf·m, 3.0 ft·lb) 16
18
4 N·m (0.4 kgf·m, 3.0 ft·lb) 15 17
2 14
1 10 11
13
9
41 8 12
5 7
40 4 6
41 27
1 26
30
29
3
31 39 38
32
31
32
26
31 19
32
30 22 13
29
30 28
29 33 32 21
25 18 20
31
34 23
37
36 35 30
29 15 24
29 30 32

1 Bolt 2 M6 20 mm
2 PTT relay 1
3 Engine hanger 1
4 Bolt 2 M6 20 mm
5 Bolt 1 M6 14 mm
6 Holder 1
7 Cap 1 Green
8 Cap 1 Black
9 Cap 1 Yellow
10 Fuse 1 20 A
11 Fuse 1 15 A
12 Fuse 1 30 A
13 Bolt 2 M6 16 mm
14 Plastic tie 1
15 Bolt 2 M6 16 mm
16 Holder 1
17 Plastic tie 1
7-27
Wiring harness
4 N·m (0.4 kgf·m, 3.0 ft·lb) 16

18
4 N·m (0.4 kgf·m, 3.0 ft·lb) 15 17
1
2
10 11
14
0
13
41
9
8 12
1
5 7
40 4 6
41 27
29
30
1 26
2
3
31 39 38
32
31 3
32
26
31
32
19
4
30 22 13
29
30
29 33 32
28
25 18
21
20
5
31
34 23
37
36 35 30
29 30 32 29 15 24 6

18 Bolt 2 M8 25 mm
19 Holder 1
20
21
Bolt
Bracket
1
1
M6 14 mm 8
22 Wiring harness 1
23
24
Plastic tie
Holder
1
1 9
25 Bracket 1
26 Dowel 2
27
28
Stud bolt
Bracket
1
1
10
29 Bolt 6 M6 28 mm
30 Grommet 6
31 Grommet 4
32 Collar 6
33 Bolt 2 M8 35 mm
34 Bracket 1
A
7-28
POWR
Power unit
4 N·m (0.4 kgf·m, 3.0 ft·lb) 16

18
4 N·m (0.4 kgf·m, 3.0 ft·lb) 15 17
2 14
1 10 11
13
9
41 8 12
5 7
40 4 6
41 27
1 26
30
29
3
31 39 38
32
31
32
26
31 19
32
30 22 13
29
30 28
29 33 32 21
25 18 20
31
34 23
37
36 35 30
29 15 24
29 30 32

35 YDIS coupler bracket screw 1 ø6 20 mm
36 Main relay 1
37 Main relay screw 1 ø6 20 mm
38 Nut 1
39 Bracket 1
40 Cap 2
41 PTT motor lead bolt 2 M6 10 mm
7-29
Wiring harness
Removing the wiring harness 5. Disconnect the main relay coupler h,
1. Disconnect the oil pressure switch con- and then remove the main relay c.
nector a and thermo sensor coupler b,
and then remove the ground leads c
and d. 0
h 1
c
d
a 6. Remove the ground lead k.
2
b
3
k
c
2. Remove the bracket a.

4
7. Remove the bracket d along with the

5
wiring harness.
d
6
a
3. Remove the caps e, and then remove

7
the PTT relay leads f.
4. Disconnect the PTT relay coupler g, and

then remove the PTT relay b.
d 8
8. Remove the YDIS coupler bracket e.
b
9. Remove the plastic ties f, g, and h,
holders m, and fuse holders n.
9
e e
10
f g
A
7-30
POWR
Power unit
f
n n
n m
g
m f
f
e 4. Install the ground lead c.
Installing the wiring harness c

To install all the wiring harnesses, see “Elec-
trical component and wiring harness routing”
(5-1).
1. Install the fuse holders a, holders b,

and plastic ties a, b, and c.
5. Install the main relay g, and then tighten
2. Install the YDIS coupler bracket d, and the main relay screw h to the specified
then tighten the YDIS coupler bracket torque.
screw e to the specified torque.
6. Connect the main relay coupler d.
a a
a b h
b
c
d
b
a
g
d
Main relay screw h:
b
e 3 N·m (0.3 kgf·m, 2.2 ft·lb)
YDIS coupler bracket screw e: 7. Install the PTT relay i, and then connect
3 N·m (0.3 kgf·m, 2.2 ft·lb) the PTT relay coupler e.
3. Install the bracket f along with the wir- 8. Install the PTT relay leads f, and then
ing harness. tighten the PTT relay lead nuts g to the
specified torque.
9. Install the caps h.
7-31
Wiring harness
h h
0
g
g 1
f e 2
PTT relay lead nut g:
4 N·m (0.4 kgf·m, 3.0 ft·lb) 3
10. Install the bracket j.
4
5
j 6
11. Connect the oil pressure switch connec-
tor k, thermo sensor coupler m, and
ground leads n and p. 7
8
p
k 9
m
10
n
A
7-32
POWR
Power unit
Shift bracket
2
1
5
7

1 Bolt 1 M6 25 mm
2 Bushing 1
3 Bracket 1
4 Washer 1
5 Clip 1
6 Shift rod lever 1
7 Bolt 1 M6 20 mm
7-33
Shift bracket / Cylinder head
Cylinder head
1 a 6 N·m (0.6 kgf·m, 4.4 ft·lb)
a 23 N·m (2.3 kgf·m, 17.0 ft·lb)
b 12 N·m (1.2 kgf·m, 8.9 ft·lb)
2 b 37 N·m (3.7 kgf·m, 27.3 ft·lb)
c 180° 0
3
11
4
12
1
11
5 2
1
13
3
8
15
14 4
5
6
10 16
10 N·m (1.0 kgf·m, 7.4 ft·lb)
7
6
9 10 N·m (1.0 kgf·m, 7.4 ft·lb)
9

1 Dowel 2
2 Gasket 1 39
3
4
Cylinder head bolt
Cylinder head bolt
5
10
M6 25 mm
M9 93 mm
8
5 Cylinder head assembly 1
39
6
7
Gasket
Oil pump assembly
1
1 9
8 Gasket 1 39
9 Oil pump bolt 4 M6 45 mm
10
11
Gasket
Screw
1
6
39
M4 10 mm
10
12 Plate 1
13 Bolt 6 M6 20 mm
14 Oil filler cap 1
15 O-ring 1 39
16 Cylinder head cover 1
A
7-34
POWR
Power unit
Removing the cylinder head
e
Do not disassemble the oil pump.
d
1. Remove the oil pump assembly a.
Checking the cylinder head bolt

1. Measure the diameters a and b of the
2. Remove the cylinder head cover b. cylinder head bolt (M9) at the specified
measuring points c and d. Replace the
cylinder head bolt if the difference
between the diameters is above specifi-
b cation.
b a
d c
Cylinder head bolt diameter difference

3. Remove the cylinder head bolts c and
limit:
d, and then remove the cylinder head
a – b = Less than 0.13 mm (0.0051 in)
e. NOTICE: Be careful not to scratch
Measuring point c: 10.0 mm (0.39 in)
or damage the mating surfaces of the
Measuring point d: 62.5 mm (2.46 in)
cylinder head and cylinder block.
Installing the cylinder head
Do not reuse a gasket, always replace it

with a new one.
7-35
Cylinder head
1. Install the dowels a, a new gasket b,
the cylinder head c, and the cylinder TIP:
head bolts d and e. • Tighten the M9 bolts d a–j to the speci-
fied torques in 3 stages.
• In the third stage, mark the M9 bolts and
cylinder head with paint marks a, tighten
0
c the M9 bolts 90° from the marks, and then
tighten them another 90°.
d • After tightening the M9 bolts d a–j,
tighten the M6 bolts e k–o to the speci-
1
fied torques in 2 stages.
e
b 3. Install the plate f, a new gasket g, and
2
a the cylinder head cover h.
a
3
h
f
4
g
2. Tighten the cylinder head bolts d and e
to the specified torques in the order a,
b, and so on.
5
h
d
n
e
g
6
a 90q 4. Fill the oil pump assembly i with engine
l c
oil through the oil passage b.
90q k
d
7
a b
i
m
e f 8
o
i j
Cylinder head bolt d a–j (M9):

b
9
1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb)
5. Install a new gasket j, the oil pump
2nd: 37 N·m (3.7 kgf·m, 27.3 ft·lb)
3rd: 180° assembly i, and the oil pump bolts k, 10
Cylinder head bolt e k–o (M6): aligning the slot in the oil pump drive
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb) shaft c with the camshaft pin d.
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
A
7-36
POWR
Power unit
d
c
i k
k
6. Tighten the oil pump bolts k to the spec-

ified torque in the order a, b, and so on.
k
a
d
c
b
Oil pump bolt k:

10 N·m (1.0 kgf·m, 7.4 ft·lb)
7-37
Cylinder head / Camshaft and valve
Camshaft and valve
4
3
5
6 17 N·m (1.7 kgf·m, 12.5 ft·lb)
0
2
14 N·m (1.4 kgf·m, 10.3 ft·lb)
1
7
8 9
13 15
1
10
11 12 16
7
13
2
30 8
17 14
14
9
10
3
18
13 17
30 28 11 19
29
27
12
14 17
14 20
21
19
4
24 14
23
26 18
13 20
19
5
21
18 N·m (1.8 kgf·m, 13.3 ft·lb) 19
14
2 N·m (0.2 kgf·m, 1.5 ft·lb)
18 N·m (1.8 kgf·m, 13.3 ft·lb) 25 22 18

19
6
14 N·m (1.4 kgf·m, 10.3 ft·lb)

1 Cylinder head 1
2 Intake valve 8
3
4
Exhaust valve
Oil seal
8
1 39
8
5 Gasket 1 39
6
7
Retaining bolt
Valve guide
1
16 39 9
8 Valve spring seat 16
9 Valve seal 16 39
10
11
Valve spring
Valve spring retainer
16
16
10
12 Valve cotter 32
13 Rocker arm 4 IN
14 Rocker arm 8 EX
15 Adjusting screw 8 IN
16 Valve adjusting locknut 8 IN
17 Washer 4
A
7-38
POWR
Power unit
3 4
5
6 17 N·m (1.7 kgf·m, 12.5 ft·lb)
2
14 N·m (1.4 kgf·m, 10.3 ft·lb)
1
7 13 15
8 9
10
11 12 16
13
7
30 8
17 14
14
9
10 18
13 17
30 28 11 19
29 12 14 20
14 17 21
27 14 19
24
23
26 18
19
13 20
21
18 N·m (1.8 kgf·m, 13.3 ft·lb) 19
14
2 N·m (0.2 kgf·m, 1.5 ft·lb)
22 18
18 N·m (1.8 kgf·m, 13.3 ft·lb) 25 19
14 N·m (1.4 kgf·m, 10.3 ft·lb)

18 Washer 3
19 Rocker arm shaft bolt 5 M8 22 mm
20 Tensioner 2
21 Stopper 2
22 Rocker arm shaft 1
23 Valve adjusting locknut 8 EX
24 Adjusting screw 8 EX
25 Camshaft 1
26 Cylinder head anode plug 3
27 O-ring 3 39
28 Anode 3
29 Cylinder head anode screw 3 M5 24 mm
30 Spark plug 4
7-39
Camshaft and valve
Disassembling the cylinder head e e
g
1. Remove the cylinder head anodes a, e f
h
spark plugs b. e
f
g
a
e 0
f h
j i
k
j
k
j 1
i j
k j k
b 2
j
2. Loosen the valve adjusting locknuts c
and adjusting screws d on cylinders #2
(EX), #3 (IN), and #4 (IN and EX). i
j
3
EX IN
c
#1 TIP:
Make sure to keep the parts in the order of
4
d removal.
#2 c
d
c
d
c
4. Remove the retaining bolt l, and then 5
#3 remove the camshaft m and oil seal n.
d
c
d
#4
c
d l 6
d d
c c
3. Remove the rocker arm shaft bolts e,

7
washers f, stoppers g, and tensioners
h, and then remove the washers i and
rocker arms j and k. 8
n
m
9
10
A
7-40
POWR
Power unit
5. Remove the intake and exhaust valves.
a b
o
Cylinder head warpage limit:
Valve spring compressor o: 90890-04019 0.10 mm (0.0039 in)
Valve spring compressor attachment p:
90890-04108 Checking the valve spring
1. Measure the valve spring free length a.
TIP:
removal.
6. Remove the valve seals q.
Valve spring free length a:

39.74 mm (1.56 in)
2. Measure the valve spring tilt b. Replace

if above specification.
Checking the cylinder head b

1. Remove carbon deposits from the com-
bustion chambers and check the cylinder
head for damage and scratches.
2. Check the cylinder head warpage using a

straightedge a and a thickness gauge b
in 7 directions. Replace the cylinder head
if above specification.
Valve spring tilt limit b: 1.7 mm (0.07 in)
7-41
Camshaft and valve
Checking the valve
1. Check the valve face. Replace if pitted or
worn.
2. Measure the valve margin thickness a.

0
a
1
Valve stem runout:
Intake and exhaust:
0.01 mm (0.0004 in)
2
Checking the valve guide
Valve margin thickness a:

Before checking the valve guides, make sure
that the valve stem diameter is within specifi-
3
Intake: cation.
0.800–1.200 mm (0.0315–0.0472 in)
Exhaust: 1. Measure the valve guide inside diameter 4
0.700–1.100 mm (0.0276–0.0433 in) a.
3. Measure the valve stem diameter b.

Replace if out of specification. 5
b
a 6
7
Valve guide inside diameter a:
Intake and exhaust:
Valve stem diameter b:

5.500–5.512 mm (0.2165–0.2170 in)
8
Intake: 2. Calculate the valve guide clearance.
5.475–5.490 mm (0.2156–0.2161 in) Replace if out of specification.
Exhaust:
5.460–5.475 mm (0.2150–0.2156 in)
Valve guide clearance:
Intake:
9
0.010–0.037 mm (0.0004–0.0015 in)
4. Measure the valve stem runout.
Exhaust:
0.025–0.052 mm (0.0010–0.0020 in) 10
Replacing the valve guide
After replacing a valve guide, check the valve
seat contact area.
1. Remove the valve guide a from the com-

bustion chamber side.
A
7-42
POWR
Power unit
TIP:
b • To ream the valve guide, turn the valve
guide reamer clockwise.
• When removing the valve guide reamer, do
not turn counterclockwise.
• After reaming the valve guide, make sure to
a
clean it.
4. Measure the valve guide inside diameter.

Valve guide remover/installer b: Valve guide inside diameter:
90890-06801 Intake and exhaust:
5.500–5.512 mm (0.2165–0.2170 in)
2. Install a new valve guide c from the
camshaft side to the specified installation Checking the valve seat
height a. NOTICE: Do not reuse a 1. Remove carbon deposits from the valve.
valve guide, always replace it with a
new one. 2. Apply a thin, even layer of Mechanic's
blueing dye (Dykem) onto the valve seat.
b 3. Push the valve lightly against the valve

seat using the special service tool a.
a
a
c
Installation height a:
11.8–12.2 mm (0.46–0.48 in)
3. Insert the special service tool d into the

valve guide c, and then ream the valve Valve lapper a: 90890-04101
guide.
4. Measure the valve seat contact width a
where the blueing dye is adhered to the
c valve face. Reface the valve seat if the
valve is not seated properly or if the valve
d seat contact width is out of specification.
Check the valve guide if the valve seat
contact width is uneven.
Valve guide reamer d: 90890-06804
7-43
Camshaft and valve
Valve seat cutter holder: 90890-06316

Intake:
Valve seat cutter 30°: 90890-06328
0
a Exhaust:
1
2. Cut the surface of the valve seat using a
45° cutter by turning the cutter clockwise
until the valve seat face has become
2
smooth. NOTICE: Do not over cut the
valve seat. To prevent chatter marks,
make sure to turn the cutter evenly 3
using a downward force of 40–50 N
(4.0–5.0 kgf, 8.8–11.0 lbf).
4
5
Valve seat contact width a:
Intake:
1.05–1.45 mm (0.041–0.057 in)
Exhaust:
6
0.90–1.30 mm (0.035–0.051 in)
45
Refacing the valve seat a 7
After every lapping procedure, make sure
to clean off any remaining lapping com- 8
pound from the cylinder head and valves.
1. Reface the valve seat using the valve

seat cutters.
a Slag or rough surface 9
3. Adjust the top edge of the valve seat con-
tact width using a 30° cutter.
10
30 45 60
A
7-44
POWR
Power unit
• If the valve seat contact area is too wide
30 and situated in the center of the valve face,
b cut the top edge of the valve seat using a
30° cutter. Cut the bottom edge using a 60°
cutter to center the area and set its width.
30
b
b Previous contact width
4. Adjust the bottom edge of the valve seat

contact width using a 60° cutter. 60

b
• 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 to center the area. Set its
width using a 45° cutter.
60
30
b Previous contact width b
5. Adjust the valve seat contact width to

specification using a 45° cutter.
b
c
• If the valve seat contact area is too narrow

45 and situated near the bottom edge of the
valve face, cut the bottom edge of the valve
seat using a 60° cutter. Set its width using a
b Previous contact width 45° cutter.
c Specified contact width
6. Check the valve seat contact area of the

b
valve. See “Checking the valve seat” (7-
43).
Example:
60
7-45
Camshaft and valve
7. After refacing the valve seat to the speci- Checking the camshaft
fied contact width, apply a thin, even 1. Measure the cam lobe height a and
layer of lapping compound onto the valve width b.
seat, and then lap the valve using the
special service tool a. NOTICE: Do not
get the lapping compound on the
0
valve stem and valve guide.
a
a
1
b
2
Cam lobe height a:
Intake:
30.538–30.638 mm 3
(1.2023–1.2062 in)
Valve lapper a: 90890-04101 Exhaust:
8. Recheck the valve seat contact area of

31.187–31.287 mm
(1.2278–1.2318 in) 4
the valve. See “Checking the valve seat” Cam lobe width b:
(7-43). 25.950–26.050 mm
Checking the rocker arm and rocker

(1.0217–1.0256 in) 5
arm shaft 2. Measure the camshaft runout.
1. Check the rocker arms, rocker arm shaft,
and contact surface a of each rocker
arm. Replace if worn.
6
2. Measure the rocker arm inside diameter
b and rocker arm shaft outside diameter
c.
7
a
8
Camshaft runout: 0.03 mm (0.0012 in)
b c 3. Measure the camshaft journal diameters

c, d, e and f, and cylinder head jour-
9
nal inside diameter g.
Rocker arm inside diameter b:

10
Intake and exhaust:
16.000–16.018 mm
(0.6299–0.6306 in)
Rocker arm shaft outside diameter c:
15.971–15.991 mm
(0.6288–0.6296 in)
A
7-46
POWR
Power unit
g
g
g
g
f
e Specified spark plug: LKR7E (NGK)
d Spark plug gap b:
c 0.8–0.9 mm (0.032–0.035 in)
Camshaft journal diameter #1 c: Checking the cylinder head anode

36.925–36.945 mm 1. Check the anodes. Replace if eroded.
(1.4537–1.4545 in) Clean if there is grease, oil, or scales.
Camshaft journal diameter #2 d, #3 e, #4 NOTICE: Do not apply grease, oil, or
f: paint to the anodes.
36.935–36.955 mm
(1.4541–1.4549 in) Assembling the cylinder head
Cylinder head journal inside diameter g:
37.000–37.025 mm
(1.4567–1.4577 in) Do not reuse a gasket, oil seal, or valve
seal, always replace it with a new one.
Checking the spark plug
1. Clean the electrodes a using a spark 1. Install a new valve seal a onto the valve
plug cleaner. guide b.
a a b
2. Check the spark plug. Replace if the 2. Install the valve c, valve spring seat d,
electrodes are eroded, or there is carbon valve spring e, and valve spring retainer
or other deposits. f in this order, and then install the spe-
cial service tools g and h.
3. Check the spark plug gap b. Replace if
out of specification.
7-47
Camshaft and valve
f
e
h
d 0
1
i
g
i
2
c 3
Valve spring compressor g: 90890-04019
Valve spring compressor attachment h:
5. Install a new oil seal j.
4
90890-04108 j
k
3. Compress the valve spring, and then
install the valve cotters i. l
5
6
i
Driver rod LS k: 90890-06606
Bearing outer race attachment l: 7
90890-06626
4. Tap the valve spring retainer lightly using

6. Install the camshaft m in the direction of
the arrow, and then install a new gasket
8
a plastic hammer to seat the valve cot- n and the retaining bolt o.
ters i securely.
o
9
n
10
m
A
7-48
POWR
Power unit
7. Align the dowel hole a in the camshaft
with the “P” mark b on the cylinder w
head. b
d
a
b
c
8. Install the rocker arms p and q and
washers r onto the rocker arm shaft s, Rocker arm shaft bolt w:
and then install the tensioners t, stop- 17 N·m (1.7 kgf·m, 12.5 ft·lb)
pers u, washers v, and rocker arm
shaft bolts w. 10. Install new O-rings x and the cylinder
head anodes y to the cylinder head
u w anode plugs z, and then tighten the cyl-
d w u
inder head anode screws A to the speci-
w t v
w fied torque.
v c
t u 11. Tighten the cylinder head anode plugs z
v w s to the specified torque.
qp r
12. Install the spark plugs B, and then
p p tighten them to the specified torque.
q
r p
q p q y x
p
A z
p
r
B
TIP:
• Make sure that the mark c on the rocker Cylinder head anode screw A:
arm shaft s is facing up. 2 N·m (0.2 kgf·m, 1.5 ft·lb)
• Make sure that the marks d on the stop- Cylinder head anode plug z:
pers u are facing up. 18 N·m (1.8 kgf·m, 13.3 ft·lb)
Spark plug B:
9. Tighten the rocker arm shaft bolts w 18 N·m (1.8 kgf·m, 13.3 ft·lb)
gradually to the specified torque and in
the order a, b, and so on. 13. Install the cylinder head. See “Installing
the cylinder head” (7-35).
14. Adjust the valve clearance. See “Check-

ing the valve clearance” (7-2).
7-49
Camshaft and valve / Exhaust cover
Exhaust cover
23 N·m (2.3 kgf·m, 17.0 ft·lb)
7 a 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2 8 b 12 N·m (1.2 kgf·m, 8.9 ft·lb)
1 0
3
4 9
10
11 12
13
1
15
2
14 9
5
16
6 3
9 N·m (0.9 kgf·m, 6.6 ft·lb) 18 17
2 N·m (0.2 kgf·m, 1.5 ft·lb)
18 56 N·m (5.6 kgf·m, 41.3 ft·lb)
38 N·m (3.8 kgf·m, 28.0 ft·lb)
4
17
5 26
19
20
23
24 5
21
22
25
40 N·m (4.0 kgf·m, 29.5 ft·lb)
27
6
18 N·m (1.8 kgf·m, 13.3 ft·lb)

1 Thermo sensor 1
2 Gasket 1 39
3
4
Bracket
Bolt
1
1 M6 14 mm
8
5 Dowel 2
6
7
Oil pressure switch
Gasket
1
1 39 9
8 Exhaust cover 1
9 Exhaust cover bolt 12 M6 35 mm
10
11
Thermostat
Gasket
1
1 39
10
12 Gasket 1 39
13 Thermostat cover 1
14 Exhaust cover plug 1 M18 17 mm
15 Gasket 1 39
16 Hose joint 1
17 Exhaust cover plug 2 M14 12 mm
A
7-50
POWR
Power unit
23 N·m (2.3 kgf·m, 17.0 ft·lb)

7 a 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2 8 b 12 N·m (1.2 kgf·m, 8.9 ft·lb)
1
3
4 9
10
11 12
13
15
14 9
5
16
6
9 N·m (0.9 kgf·m, 6.6 ft·lb) 18 17

18
38 N·m (3.8 kgf·m, 28.0 ft·lb)
17
19 23
24
5 26 20
21
22
25 27
40 N·m (4.0 kgf·m, 29.5 ft·lb)
18 N·m (1.8 kgf·m, 13.3 ft·lb)

18 Gasket 2 39
19 Grommet 1
20 Anode 1
21 Cover 1
22 Bolt 1 M5 12 mm
23 Plate 1
24 Bolt 1 M6 20 mm
25 Union bolt 1
26 Oil filter 1
27 Oil pressure switch lead 1
7-51
Exhaust cover
Removing the exhaust cover
1. Remove the exhaust cover plugs a and
b, exhaust cover anode c, and hose
joint d.
0
b a 1
b
d
a 2
c
Removing the oil pressure switch
1. Remove the oil pressure switch a. 3
a
2. Remove the exhaust cover bolts e, ther-

mostat cover f, thermostat g, and
4
exhaust cover h.
a
g
f
5
Removing the oil filter 6
1. Remove the oil filter a.
e
e
7
b
h
a 8
9
Oil filter wrench b: 90890-01426
Removing the thermo sensor
1. Remove the thermo sensor a and
bracket b.
2. Remove the oil filter union bolt c.
10
A
7-52
POWR
Power unit
Water tem-
Valve opening a
perature
58–62 °C
Starts opening
(136–144 °F)
c above 70 °C
3.0 mm (0.12 in) or above
(158 °F)
Installing the oil filter

1. Install the oil filter union bolt a, and then
tighten it to the specified torque.
Checking the exhaust cover anode
1. Check the anodes. Clean if there is
grease, oil, or scales. NOTICE: Do not
apply grease, oil, or paint to the
anodes.
a
Checking the thermostat
1. Suspend the thermostat in a container of
water.
2. Place a thermometer in the water, and

Oil filter union bolt a:
then heat the water slowly.
40 N·m (4.0 kgf·m, 29.5 ft·lb)
2. Install the oil filter b, and then tighten it

b
3. Measure the thermostat valve opening a

at the specified water temperatures.
Oil filter wrench c: 90890-01426
a
Oil filter b: 18 N·m (1.8 kgf·m, 13.3 ft·lb)
Installing the oil pressure switch

1. Install the oil pressure switch a, and
then tighten it to the specified torque.
2. Install the oil pressure switch lead a,

and then tighten the oil pressure switch
bolt b to the specified torque.
7-53
Exhaust cover
2. Install a new gasket d to the thermostat
a e.
b 3. Install the thermostat e, a new gasket

a f, and thermostat cover g, and the
exhaust cover bolts h.
0
e
d f
a b
g 1
c
Oil pressure switch a:
9 N·m (0.9 kgf·m, 6.6 ft·lb)
Oil pressure switch bolt b:
2
2 N·m (0.2 kgf·m, 1.5 ft·lb) h
Installing the thermo sensor

1. Install a new gasket a and the thermo
h 3
sensor b, and then tighten the thermo
sensor b to the specified torque.
NOTICE: Do not reuse a gasket,
a
4
always replace it with a new one.
2. Install the thermo sensor coupler a to

the bracket c. 5
4. Tighten the exhaust cover bolts h to the
specified torques in 2 stages, and in the
order a, b, and so on. 6
h k
h
g
d 7
a c
b
c a
b 8
e
a f
Thermo sensor b: i 9
23 N·m (2.3 kgf·m, 17.0 ft·lb) j l
Installing the exhaust cover Exhaust cover bolt h: 10

1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
Do not reuse a gasket, always replace it
with a new one. 5. Install the exhaust cover anode i.
1. Install the dowels a, a new gasket b,

and the exhaust cover c. A
7-54
POWR
Power unit
6. Install a new gaskets j and the exhaust
cover plugs k, and then tighten the
exhaust cover plugs k to the specified
torque.
7. Install a new gasket l and the exhaust

cover plug m, and then tighten the
exhaust cover plug m to the specified
torque.
m
l
j
k
j
k
Exhaust cover plug k (M14):

38 N·m (3.8 kgf·m, 28.0 ft·lb)
Exhaust cover plug m (M18):
56 N·m (5.6 kgf·m, 41.3 ft·lb)
8. Install the hose joint n to the specified

installation height a.
Installation height a:
18.0–20.0 mm (0.71–0.79 in)
7-55
Exhaust cover / Cylinder block
Cylinder block
2 a 6 N·m (0.6 kgf·m, 4.4 ft·lb)
32 N·m (3.2 kgf·m, 23.6 ft·lb) b 12 N·m (1.2 kgf·m, 8.9 ft·lb)
a 15 N·m (1.5 kgf·m, 11.1 ft·lb)
b 33 N·m (3.3 kgf·m, 24.3 ft·lb)
0
3
1 4
9
5
1
10
3 9
2
16
6
9
9 3
3 3
14 9
17
13
4
12 9
15
9
9
5
14
a 6 N·m (0.6 kgf·m, 4.4 ft·lb)
11 8
6
b 17 N·m (1.7 kgf·m, 12.5 ft·lb) 7

1 Knock sensor 1
2 Cylinder block 1
3
4
Dowel
Oil seal
4
1 39
8
5 Crankcase bolt 10 M8 84 mm
M6 35 mm
6
7
Crankcase bolt
Crankcase
10
1 9
8 Oil seal 1 39
9 Crankshaft journal bearing 10
10
11
Crankshaft
Connecting rod bolt
1
8 M6 30 mm
10
12 Connecting rod assembly 4
13 Piston 4
14 Clip 8 39
15 Piston pin 4
16 Piston ring set 4
17 Crankpin bearing 8
A
7-56
POWR
Power unit
Disassembling the cylinder block
1. Remove the knock sensor a. TIP:
• To prevent mixing the pistons, connecting
rods, and connecting rod caps, mark each
with an identification number c of the cor-
responding cylinder.
• Make sure to keep the parts in the order of
removal.
4. Remove the crankshaft f, crankshaft

a journal bearings g, and oil seals h and
i.
2. Remove the crankcase bolts b and c, g
and then remove the crankcase d.
i g
c c b b g
c
c
c c
c
b g f
g
g
b h
b
b g
d
5. Remove the piston pin clips j and piston
pin k, and then remove the connecting
3. Remove the connecting rod bolts e and rod d.
connecting rod caps a, and then remove
j
the connecting rod and piston assem-
blies b.
e e
a
d
TIP:
removal.
b 6. Remove the piston rings.

c
7-57
Cylinder block
Checking the piston diameter Cylinder bore (D1–D6):
1. Measure the piston outside diameter a 65.000–65.015 mm
at the specified measuring point b. (2.5591–2.5596 in)
Checking the piston ring 0

1. Measure piston ring dimensions B and T.
b
a
a
B
b
B 1
T T
c
2
B
Piston diameter a:
64.950–64.965 mm
(2.5571–2.5577 in)
T
3
Measuring point b: Piston ring dimensions:
12.0 mm (0.47 in) above the bottom Top ring a:
of the piston skirt
Oversize piston diameter:
B: 1.17–1.19 mm (0.0461–0.0469 in)
T: 2.30–2.50 mm (0.0906–0.0984 in)
4
Oversize 1st: 2nd ring b:
65.200–65.215 mm B: 1.47–1.49 mm (0.0579–0.0587 in)
(2.5669–2.5675 in)
Oversize 2nd:
T: 2.60–2.80 mm (0.1024–0.1102 in)
Oil ring c:
5
65.450–65.465 mm B: 2.36–2.48 mm (0.0929–0.0976 in)
(2.5768–2.5774 in)
Checking the cylinder bore

T: 2.75 mm (0.1083 in)
Checking the piston ring end gap

6
1. Measure the cylinder bore (D1–D6) at 1. Level the piston ring a in the cylinder
measuring points a, b, and c, and in
direction d (D1, D3, D5), which is parallel
using a piston crown at the specified
measuring point a. 7
to the crankshaft, and direction e (D2,
D4, D6), which is at a right angle to the 2. Measure the piston ring end gap b.
crankshaft.
8
a
b D2 D1
c
D4 D3
d
e
9
D6 D5
a
a
10
b
a 10.0 mm (0.39 in)

b 48.0 mm (1.89 in)
c 85.0 mm (3.35 in)
A
7-58
POWR
Power unit
Measuring point a: 10.0 mm (0.39 in) Checking the piston pin boss
Piston ring end gap b (reference data): 1. Measure the piston pin boss inside diam-
Top ring: eter a.
0.15–0.30 mm (0.0059–0.0118 in)
a
2nd ring:
0.30–0.50 mm (0.0118–0.0197 in)
Oil ring:
0.20–0.70 mm (0.0079–0.0276 in)
Checking the piston ring groove

1. Measure the piston ring grooves.
a Piston pin boss inside diameter a:

15.974–15.985 mm
b (0.6289–0.6293 in)
c Checking the piston pin

1. Measure the piston pin outside diameter
a.
a
Piston ring groove:
Top ring a:
1.21–1.23 mm (0.0476–0.0484 in)
2nd ring b:
1.51–1.53 mm (0.0594–0.0602 in)
Oil ring c:
2.52–2.54 mm (0.0992–0.1000 in)
Checking the piston ring side

clearance Piston pin outside diameter a:
1. Measure the piston ring side clearance. 15.965–15.970 mm
(0.6285–0.6287 in)
a Checking the connecting rod small

end inside diameter and big end
b inside diameter
1. Tighten the connecting rod bolts a to the
c specified torques in 2 stages.
2. Measure the connecting rod small end

inside diameter a and big end inside
Piston ring side clearance: diameter b.
Top ring a:
0.02–0.06 mm (0.0008–0.0024 in)
2nd ring b:
0.02–0.06 mm (0.0008–0.0024 in)
Oil ring c:
0.04–0.18 mm (0.0016–0.0071 in)
7-59
Cylinder block
a a
a b
1
Connecting rod bolt a:
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 17 N·m (1.7 kgf·m, 12.5 ft·lb)
2
Connecting rod small end inside c
diameter a:
15.985–15.998 mm
3
(0.6293–0.6298 in)
Connecting rod big end inside diameter b:
36.000–36.024 mm
Crankshaft journal diameter a:
42.984–43.000 mm 4
(1.4173–1.4183 in) (1.6923–1.6929 in)
Crankpin diameter b:
Checking the connecting rod big end
side clearance
32.984–33.000 mm
(1.2986–1.2992 in)
5
1. Measure the connecting rod big end side Crankpin width c:
clearance a. 21.000–21.070 mm
(0.8268–0.8295 in) 6
2. Measure the crankshaft runout.
a 7
a 8
Connecting rod big end side clearance a:
0.05–0.22 mm (0.0020–0.0087 in) 9
Checking the crankshaft Crankshaft runout: 0.03 mm (0.0012 in)
1. Measure the crankshaft journal diame-
ters a, crankpin diameters b, and
crankpin widths c.
Checking the crankpin oil clearance
1. Clean the crankpin bearings, connecting
10
rod, connecting rod cap, and crankpin.
2. Install the crankpin bearings a into the

connecting rod a and connecting rod
cap b.
A
7-60
POWR
Power unit
a b
a
b d a
c
d f
c
b
e
TIP:
• Install the crankpin bearings in the original
positions.
• Install the protrusions c on the crankpin
bearing into the grooves d in the connect-
ing rod a and connecting rod cap b.
3. Place a piece of Plastigauge (PG-1) on

Connecting rod bolt b:
the crankpin, parallel to the crankshaft.
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 17 N·m (1.7 kgf·m, 12.5 ft·lb)
TIP:
• Make sure that the protrusions f on the
connecting rod a and connecting rod cap
b face toward the flywheel magnet end of
the crankshaft.
• Do not turn the connecting rod a until the
crankpin oil clearance measurement has
been completed.
TIP:
Do not place the Plastigauge (PG-1) over the
6. Remove the connecting rod cap, and
oil hole in the crankpin of the crankshaft.
then measure the width of the com-
pressed Plastigauge (PG-1) on the
4. Install the connecting rod a and con- crankpin.
necting rod cap b onto the crankpin e.
5. Tighten the connecting rod bolts b to the

specified torques in 2 stages.
Crankpin oil clearance:

0.016–0.040 mm (0.0006–0.0016 in)
7-61
Cylinder block
Selecting the crankpin bearing Crankpin bearing selection table at 20 °C
When replacing the crankpin bearing, select (68 °F)
the suitable bearing as follows:
Connecting rod Crankpin Bearing
1. Check the connecting rod mark a or
painted color b.
mark a/color b mark c
A
color d
Yellow
0
|/Red
B
Red
A
||/Blue
B
Pink
1
A
b |||/Yellow
B Green
a Checking the crankshaft journal oil

2
clearance
1. Clean the crankshaft journal bearings,
2. Check the crankpin mark c.

crankshaft journals, and bearing portions
of the crankcase and cylinder block.
3
2. Place the cylinder block upside down.
c P1 c P2 c P3 c P4
3. Install the crankshaft journal bearings a
4
and crankshaft b into the cylinder block
c.
b
5
a
c
3. Select the suitable colors d for the

6
crankpin bearings from the table.
7
d
TIP:
Install the crankshaft journal bearings in the
8
original positions.
d
4. Place a piece of Plastigauge (PG-1) on 9
the crankshaft journals, parallel to the
crankshaft.
10
A
7-62
POWR
Power unit
TIP: Crankcase bolt f a–j (M8):

Do not place the Plastigauge (PG-1) over the 1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb)
oil hole in the crankshaft journal. 2nd: 33 N·m (3.3 kgf·m, 24.3 ft·lb)
Crankcase bolt g k–t (M6):
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
5. Install the crankshaft journal bearings
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
into the crankcase.
TIP:
TIP:
Do not turn the crankshaft until the crankshaft
Install the crankshaft journal bearings in the
journal oil clearance measurement has been
original positions.
completed.
6. Install the dowels d and crankcase e

8. Remove the crankcase.
onto the cylinder block, and then install
the crankcase bolts f and g.
9. Measure the width of the compressed
f f g g Plastigauge (PG-1) on the crankshaft
f
f journal.
f g
f
g
g
g
g
e
d
Crankshaft journal oil clearance:
0.012–0.036 mm (0.0005–0.0014 in)
7. Tighten the crankcase bolts (M8) f
a–j to the specified torques in 2 Selecting the crankshaft journal
stages, and then tighten the crankcase bearing
bolts (M6) g k–t to the specified When replacing the crankshaft journal bear-
torques in 2 stages. ing, select the bearing as follows:
1. Check the crankshaft journal mark a.

f
i j
s t
a J1 a J2 a J3 a J4 a J5
g
o p
e f
k l
a b
n m
d c
r q
h g 2. Check the cylinder block mark b.
7-63
Cylinder block
c c
c
J1 d 0
J2
b
J3
J4
a 1
J5
2
a
3. Select the suitable colors c for the
crankshaft journal bearings from the b c
b 3
table.
c
TIP:
• Face the protrusions b on the connecting
4
rod a in the same direction as the “UP”
mark c on the piston a.
• Do not align the piston pin clip end with the
groove d in the piston pin boss.
5
c 2. Install the oil rings e, 2nd ring f, and
top ring g.
6
Crankshaft journal bearing selection table
at 20 °C (68 °F) 3. Offset the piston ring end gaps.
Crankshaft jour-
nal mark a
Cylinder
block
Bearing
color c
NOTICE: Be careful not to scratch the
pistons or break the piston rings.
7
mark b
A Yellow e
B
A
Red
#5
h
8
A
B #4
B f
Pink #3
A
B
C
Green #2
g 9
#1
45 45
Assembling the cylinder block #5 #2
10
h
Do not reuse an oil seal or piston pin clip, #1
always replace it with a new one. #4 #3
1. Assemble the piston a, the connecting

rod a, the piston pin b, and new piston
pin clips c. A
7-64
POWR
Power unit
TIP:
• Make sure that the “T” marks h on the 2nd
ring f and top ring g are facing up.
• Make sure that the piston rings move
p
smoothly.
4. Install the crankpin bearings d into the

connecting rod a and connecting rod r
cap k.
f
f
f
g
d a
k n
m
n
d
m
TIP: TIP:
• Install the crankpin bearings d in the origi- Install the crankshaft journal bearings f in
nal positions. the original positions.
• Fit the protrusions m on the crankpin bear-
ing into the grooves n in the connecting 7. Install new oil seals h and i onto the
rod a and connecting rod cap k. crankshaft j, and then install the crank-
shaft onto the cylinder block g.
5. Apply engine oil to the side of the piston, g
piston rings, and cylinder wall, and then
install the piston so that the “UP” mark on h
the piston crown is facing toward the fly- j
wheel magnet.
i g
e h
j
i
Piston slider e: 90890-06529
g
6. Install the crankshaft journal bearings f
so that the holes p in the crankshaft 8. Install the connecting rod caps s to the
journal bearings f and the holes r in connecting rods, and then tighten the
the cylinder block g are aligned. connecting rod bolts k to the specified
torques in 2 stages.
7-65
Cylinder block
11. Install the dowels m and crankcase n
k onto the cylinder block, and then install
the crankcase bolts o and p.
s
t s o o
o
p
o
p
0
o p
o
p 1
m
p
p
2
p
Connecting rod bolt k: n
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb) m 3
2nd: 17 N·m (1.7 kgf·m, 12.5 ft·lb)
12. Tighten the crankcase bolts (M8) o
TIP:
• Make sure that the protrusions t on the
a–j to the specified torques in 2
stages, and then tighten the crankcase 4
connecting rod and connecting rod caps s bolts (M6) p k–t to the specified
are facing toward the flywheel magnet end torques in 2 stages.
of the crankshaft.
• After tightening the connecting rod cap
5
bolts k, make sure that the crankshaft o
i j
turns smoothly. s t
p 6
9. Install the crankshaft journal bearings l o p
in the original positions. e f
10. Apply a thin, even layer of sealant onto

k
a b
l 7
the mating surface of the crankcase.
n m
r
d
h
c
g
q 8
l l l l l
Crankcase bolt o a–j (M8):
1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb)
2nd: 33 N·m (3.3 kgf·m, 24.3 ft·lb)
9
Crankcase bolt p k–t (M6):
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb) 10
TIP:
• Install the crankshaft journal bearings l in TIP:
their original positions. Make sure that the crankshaft turns smoothly.
• Do not apply any sealant to the crankshaft
journal bearings l. 13. Install the knock sensor q, and then
A
7-66
POWR
Power unit
Knock sensor q:
32 N·m (3.2 kgf·m, 23.6 ft·lb)
7-67
Cylinder block
— MEMO —
0
1
2
3
4
5
6
7
8
9
10
A
7-68
LOWR
Lower unit 8
Lower unit (L-transom model) .......................................... 8-1

Removing the lower unit ............................................................ 8-3
Checking the propeller .............................................................. 8-3
Checking the lower unit anode .................................................. 8-3
Lower unit (X-transom model) ......................................... 8-4

Removing the lower unit ............................................................ 8-6
Checking the propeller .............................................................. 8-6
Checking the lower unit anode .................................................. 8-6
Water pump and shift rod ................................................. 8-7

Removing the water pump and shift rod .................................... 8-9
Disassembling the oil seal housing ........................................... 8-9
Checking the water pump and shift rod ................................... 8-10
Assembling the oil seal housing .............................................. 8-10
Propeller shaft housing .................................................. 8-11

Removing the propeller shaft housing assembly ..................... 8-13
Disassembling the propeller shaft assembly ........................... 8-13
Disassembling the propeller shaft housing assembly ............. 8-14
Checking the propeller shaft .................................................... 8-14
Checking the dog clutch .......................................................... 8-14
Checking the propeller shaft housing ...................................... 8-14
Checking the reverse gear ...................................................... 8-14
Assembling the propeller shaft assembly ................................ 8-14
Assembling the propeller shaft housing assembly .................. 8-15
Drive shaft and lower case ............................................. 8-17

Removing the drive shaft ......................................................... 8-18
Disassembling the drive shaft ................................................. 8-18
Disassembling the forward gear .............................................. 8-18
Disassembling the lower case ................................................. 8-18
Checking the pinion ................................................................. 8-19
Checking the forward gear ...................................................... 8-19
Checking the drive shaft .......................................................... 8-19
Assembling the forward gear ................................................... 8-19
Assembling the drive shaft ...................................................... 8-20
Assembling the lower case ...................................................... 8-20
Installing the drive shaft ........................................................... 8-22
Installing the propeller shaft housing assembly ....................... 8-22
Installing the shift rod .............................................................. 8-23
Installing the water pump ........................................................ 8-24
Checking the lower unit for air leakage ................................... 8-25
Installing the lower unit (L-transom model) ............................. 8-25
Installing the lower unit (X-transom model) ............................. 8-26
Shimming ......................................................................... 8-28
Shimming workflow ................................................................. 8-28
Shimming check sheet ............................................................ 8-29
Measuring the forward gear backlash before disassembly ..... 8-30
Shimming ................................................................................ 8-33
Shim location ........................................................................... 8-33
0
Selecting the pinion shim (T3) ................................................. 8-34
Pinion shim (T3) selection table .............................................. 8-37
Measuring the forward gear backlash ..................................... 8-39
Adjusting the forward gear shim thickness (T1) ...................... 8-39
1
Forward gear shim (T1) selection chart ................................... 8-41
2
3
4
5
6
7
8
9
10
A
LOWR
Lower unit
Lower unit (L-transom model)
9 35 N·m (3.5 kgf·m, 25.8 ft·lb)
6
10
7
6
5 8
11
13
14 12
4 16
3 15
17
18
9 N·m (0.9 kgf·m, 6.6 ft·lb)
3
2
19
9 N·m (0.9 kgf·m, 6.6 ft·lb)
1 40 N·m (4.0 kgf·m, 29.5 ft·lb)

1 Lower unit 1
2 Drain screw 1
3 Gasket 2 39
4 Check screw 1
5 Hose nipple 1
6 Plastic tie 2
7 Speedometer hose 1
8 Dowel 2
9 Grommet 1
10 Bolt 1 M10 45 mm
11 Propeller nut 1
12 Cotter pin 1 39
13 Washer 1
14 Washer 1
15 Propeller 1
16 Spacer 1
17 Trim tab 1
8-1
Lower unit (L-transom model)
9 35 N·m (3.5 kgf·m, 25.8 ft·lb)

6
10
7
0
6
5 8
11
1
8
2
13
14 12
4 16 3
3 15
9 N·m (0.9 kgf·m, 6.6 ft·lb)

18
17
5
3
2
19 6
9 N·m (0.9 kgf·m, 6.6 ft·lb)
1 40 N·m (4.0 kgf·m, 29.5 ft·lb)

18 Bolt 1 M8 60 mm
19 Lower case mounting bolt 4 M10 40 mm
8
9
10
A
8-2
LOWR
Lower unit
Removing the lower unit
f a
• Make sure to disconnect the battery

cables from the battery, and remove the e
clip from the engine shut-off switch.
• When removing the lower unit with the
b
power unit installed, make sure to sus-
c
pend the outboard motor. Otherwise, the
outboard motor could fall suddenly and
result in severe injuries.
• When loosening or tightening the pro- a
peller nut, do not hold the propeller
using your hands
c d
1. Drain the gear oil.
c
2. Remove the cotter pin.
TIP:
3. Set the gear shift to the N position. When disassembling the lower unit, measure
the backlash before disassembly. See “Mea-
4. Place a block of wood between the anti-
suring the forward gear backlash before dis-
cavitation plate and the propeller to pre-
assembly” (8-30).
vent the propeller from turning, and then
remove the propeller nut and propeller.
Checking the propeller
1. Check the propeller blades and splines.
Replace the propeller if cracked, dam-
aged, or worn.
Checking the lower unit anode

1. Check the trim tab. Clean if there is
grease, oil, or scales. NOTICE: Do not
apply grease, oil, or paint to the trim
tab.
5. Remove the grommet a.
6. Mark the trim tab b and lower case with

an identification mark a, and then
remove the trim tab b.
7. Remove the lower case mounting bolts

c and d, and then remove the lower
unit e.
8. Remove the speedometer hose f.
8-3
Lower unit (L-transom model) / Lower unit (X-transom model)
Lower unit (X-transom model)
13
23 N·m (2.3 kgf·m, 17.0 ft·lb)
14
35 N·m (3.5 kgf·m, 25.8 ft·lb)
0
12
8
10
11
1
11 11
15
2
11
5 18
17
16
3
4 20
9 3 19
5
4
6 6
11 N·m (1.1 kgf·m, 8.1 ft·lb)
8
7
9 N·m (0.9 kgf·m, 6.6 ft·lb)
21 5
2 3
22
1
25
24
6
9 N·m (0.9 kgf·m, 6.6 ft·lb) 23 40 N·m (4.0 kgf·m, 29.5 ft·lb)

1 Lower unit 1
2 Drain screw 1
3
4
Gasket
Check screw
2
1
39 8
5 Plate 2
M6 20 mm
6
7
Plate bolt
Hose nipple
4
1 9
8 Plastic tie 2
9 Extension 1
10
11
Speedometer hose
Dowel
1
4
10
12 Lower case stud bolt 4
13 Grommet 1
14 Bolt 1 M10 45 mm
15 Propeller nut 1
16 Cotter pin 1 39
17 Washer 1
A
8-4
LOWR
Lower unit
13
23 N·m (2.3 kgf·m, 17.0 ft·lb)
14
35 N·m (3.5 kgf·m, 25.8 ft·lb)
12
8 11
10
11 11
15
11
17
5 18 16
4 20
9 3 19
5
6 6
11 N·m (1.1 kgf·m, 8.1 ft·lb)
8 9 N·m (0.9 kgf·m, 6.6 ft·lb)
7 21
2 3
22
25
1 24
9 N·m (0.9 kgf·m, 6.6 ft·lb) 23 40 N·m (4.0 kgf·m, 29.5 ft·lb)

18 Washer 1
19 Propeller 1
20 Spacer 1
21 Trim tab 1
22 Bolt 1 M8 185 mm
23 Lower case mounting nut 4
24 Spring washer 4
25 Washer 4
8-5
Lower unit (X-transom model)
Removing the lower unit
TIP:
When disassembling the lower unit, measure
the backlash before disassembly. See “Mea-
• Make sure to disconnect the battery
cables from the battery, and remove the
suring the forward gear backlash before dis-
assembly” (8-30).
0
clip from the engine shut-off switch.
• When removing the lower unit with the
pend the outboard motor. Otherwise, the
See “Checking the propeller” (8-3). 1
outboard motor could fall suddenly and
result in severe injuries. Checking the lower unit anode
• When loosening or tightening the pro-
peller nut, do not hold the propeller
See “Checking the lower unit anode” (8-3).
2
using your hands.
1. Drain the gear oil. 3

2. Remove the propeller and trim tab. See
steps 2–6 in “Removing the lower unit”
(8-3).
4
3. Remove the lower case mounting nuts a
and lower case mounting bolt b, and
then remove the lower unit c and exten-
5
sion d.
4. Remove the speedometer hose e. 6

d
7
c 8
e 9
10
a b
A
8-6
LOWR
Lower unit
Water pump and shift rod
24 23
5 23 24
16
4 6
4
25
9
17
10
3 15 22 26
15
2
8 21
11 14 18
20
19
12 13
1 7

1 Shift rod 1
2 O-ring 1 39
3 Plate 1
4 Bolt 2 M6 16 mm
5 O-ring 1 39
6 Oil seal 1 39
7 E-clip 1
8 Gasket 1 39
9 Oil seal 2 39
10 Circlip 1
11 Rubber seal 1
12 Plate 1
13 Woodruff key 1
14 Oil seal housing 1
15 Dowel 2
16 Outer plate cartridge 1
17 Gasket 1 39
8-7
24 23
5 23 24
4 6
4
16
0
25
9
17
3
10 1
15 15 22 26
2
8 21
2
11 14 18
20
3
19
12 13
1 7
4
1
5
6

18 O-ring 1 39
19 Impeller 1
20
21
Insert cartridge
Gasket
1
1 39
8
22 Water pump housing 1
M8 55 mm
23
24
Bolt
Bolt
2
2 M8 45 mm 9
25 Cover 1
26 Seal 1
10
A
8-8
LOWR
Lower unit
Removing the water pump and shift
rod
1. Remove the water pump housing a,
gasket b, insert cartridge c, and impel- l
ler d.
R
2. Remove the Woodruff key e, outer plate N
cartridge f, gasket g, and dowels h. F
Shift rod socket l: 90890-06679

e 6. Remove the shift rod m.
f
a h
g
b
c h
m
d
90°
3. Remove the oil seal housing i.
TIP:
To remove the shift rod m, lift it up slightly,
and then turn the shift rod m 90° counter-
clockwise to pull it up.
Disassembling the oil seal housing

4. Remove the rubber seal j and plate k. 1. Remove the O-ring a.
j
k a
5. Set the gear shift to the N position. 2. Remove the circlip b and oil seals c.
8-9
b
b c
a
c
0
a 1
Checking the water pump and shift Needle bearing attachment b:
rod
1. Check the water pump housing. Replace
90890-06610
Driver rod L3 c: 90890-06652
2
if deformed.
Installation depth a:
TIP:
3.5–4.5 mm (0.138–0.177 in) 3
If the engine overheated, the inside of the
water pump housing may be deformed. TIP:
Therefore, make sure to remove the insert
cartridge when checking the water pump
Install an oil seal halfway into the oil seal
housing, and then install the other oil seal.
4
housing.
2. Install the circlip d and a new O-ring e.
2. Check the impeller, insert cartridge, and
e
5
outer plate cartridge. Replace if cracked
or worn.
3. Check the Woodruff key and the keyway d

6
in the drive shaft. Replace the drive shaft
if deformed or worn.
4. Check the shift rod. Replace if bent or

7
worn.
Assembling the oil seal housing 8

Do not reuse an O-ring or oil seal, always
replace it with a new one. 9
1. Install new oil seals a to the specified
installation depth a.
10
A
8-10
LOWR
Lower unit
Propeller shaft housing
2 3 1 5 4 7 6
4 5
1
3
2
1
7 18
13
16 17
12
15
11
10
14
8
103 N·m (10.3 kgf·m, 76.0 ft·lb)

1 Ball 2
2 Slider 1
3 Shift plunger 1
4 Cross pin 1
5 Spring 1
6 Propeller shaft 1
7 Dog clutch 1
8 Washer 1
9 Reverse gear 1
10 Thrust washer 1
11 Ball bearing 1 39
12 O-ring 1 39
13 Propeller shaft housing 1
14 Straight key 1
15 Needle bearing 1 39
16 Oil seal 2 39
17 Claw washer 1
8-11
2 3 1 5 4 7 6
6 0
4 5
1
1
3
2
1
7 18 2
1 3
13
17
12
15
16
4
11
10
14 5
8
103 N·m (10.3 kgf·m, 76.0 ft·lb)
6
9

18 Ring nut 1
8
9
10
A
8-12
LOWR
Lower unit
Removing the propeller shaft
housing assembly
1. Straighten the tab a on the claw washer g f
that is bent outward.
e
e
a
Bearing housing puller claw L e:

90890-06502
Stopper guide plate f: 90890-06501
Center bolt g: 90890-06504
2. Loosen the ring nut.
5. Remove the propeller shaft assembly b.
a
b
Ring nut wrench extension a:

90890-06513 Disassembling the propeller shaft
Ring nut wrench 3 b: 90890-06511 assembly
1. Remove the spring a, and then remove
3. Remove the ring nut c and claw washer the cross pin b, dog clutch c, slider d,
d. balls e, and shift plunger f.
c a
e
f
d
d
e
4. Remove the propeller shaft housing
assembly and key. c
TIP:
When removing the slider d, make sure that
the balls e do not fall out of position.
8-13
Disassembling the propeller shaft Driver rod L3 j: 90890-06652
housing assembly Needle bearing attachment k:
1. Remove the reverse gear a and thrust 90890-06612
washer b.
Checking the propeller shaft 0
1. Check the propeller shaft. Replace if
d
a damaged or worn.
e 2. Measure the propeller shaft runout.

1
f
b
c 2
Bearing separator c: 90890-06534
Stopper guide plate d: 90890-06501 3
Stopper guide stand e: 90890-06538
Bearing puller assembly f: 90890-06535
2. Remove the ball bearing g. Propeller shaft runout:

4
0.02 mm (0.0008 in)
d Checking the dog clutch

1. Check the dog clutch, shift plunger, cross
5
g pin, spring, balls, and slider. Replace if
e
cracked or worn.
f
g
Checking the propeller shaft housing
6
1. Check the propeller shaft housing.
Replace if cracked or damaged.
Stopper guide plate d: 90890-06501 7
Stopper guide stand e: 90890-06538 Checking the reverse gear
Bearing puller assembly f: 90890-06535 1. Check the teeth and dogs of the reverse
3. Remove the oil seals h along with the

gear. Replace if cracked or worn.
8
needle bearing i. Assembling the propeller shaft
assembly
1. Install the shift plunger a, balls b, and
slider c.
9
j
k j
10
k
i
h
A
8-14
LOWR
Lower unit
c b a e
b f
b a
f e
c
TIP: Assembling the propeller shaft

When installing the slider c, make sure that housing assembly
the balls b do not fall out of position.
2. Install the dog clutch d so that the hole Do not reuse a bearing, oil seal, or O-ring,
a in the dog clutch d and the hole b in always replace it with a new one.
the propeller shaft are aligned with the
hole c in the slider c. 1. Install a new needle bearing a into the
propeller shaft housing to the specified
a installation depth a.
b
d b
d a c b
d
a
c a
b c Driver rod L3 b: 90890-06652

Needle bearing attachment c:
TIP: 90890-06612
Make sure to face the “F” mark d on the dog
clutch d toward the slider c. Installation depth a:
25.0–25.5 mm (0.984–1.003 in)
3. Install the cross pin e, and then install

the spring f. TIP:
Face the bearing identification mark b on the
needle bearing toward the propeller side.
2. Install new oil seals d into the propeller

shaft housing to the specified installation
depth c.
8-15
Needle bearing attachment k:

e 90890-06607
c
f
5. Check that the reverse gear turns
smoothly. 0
6. Install a new O-ring l.
d
l
1
Driver rod LS e: 90890-06606
Ball bearing attachment f:
90890-06655
2
Installation depth c:
4.5–5.5 mm (0.177–0.217 in) 3
TIP:
Install an oil seal halfway into the propeller
shaft housing, and then install the other oil
4
seal.
3. Install the thrust washer g and a new

ball bearing h onto the reverse gear i.
5
j
j 6
h
h
g
i 7
g
i
Needle bearing attachment j:

8
90890-06608
4. Install the reverse gear assembly d. 9

d k
d k
10
A
8-16
LOWR
Lower unit
Drive shaft and lower case
7
4
6
10
7 9
8
3
2
11
12
13
1
14
94 N·m (9.4 kgf·m, 69.3 ft·lb)
16
15 1 N·m (0.1 kgf·m, 0.7 ft·lb)

1 Lower case 1
2 Water inlet cover (STBD) 1
3 Self-locking nut 1
4 Drive shaft 1
5 Taper roller bearing 1 39
6 Pinion shim (T3) —
7 Sleeve 1
8 Taper roller bearing 1 39
10 Forward gear 1
11 Forward gear shim (T1) —
13 Pinion 1
14 Pinion nut 1
15 Water inlet cover screw 1 M5 25 mm
16 Water inlet cover (PORT) 1
8-17
Removing the drive shaft Bearing inner race attachment a:
1. Loosen the pinion nut, and then remove 90890-06639
the pinion a and drive shaft b.
a
Disassembling the forward gear
1. Remove the taper roller bearing a. 0
b
c
a b c a
1
d
c
2
b
Ball bearing attachment b: 90890-06655 3

Bearing separator c: 90890-06534
Drive shaft holder 4 c: 90890-06518
Pinion nut holder d: 90890-06715 2. Remove the needle bearing from the
reverse gear. 4
2. Remove the forward gear assembly a.
Disassembling the lower case
a
5
• Use heat-resistant gloves. Otherwise,
burns could result.
• To prevent fires, remove any flammable 6
substances, such as gasoline and oil,
around the working area.
• Keep good ventilation while working.
7
Disassembling the drive shaft 1. Heat the installation area of the taper
1. Remove the taper roller bearing a. roller bearing outer race in the lower case
NOTICE: Do not press the threads b
of the drive shaft directly.
using a gas torch, and then remove the
taper roller bearing outer race a and for-
8
ward gear shims b. NOTICE: When
heating the lower case, heat the entire
b installation area evenly. Otherwise, 9
the paint on the lower case could be
burned.
a
a
a
10
a
A
8-18
LOWR
Lower unit
Needle bearing attachment g:

90890-06611
Driver rod L3 h: 90890-06652
Checking the pinion

1. Check the teeth of the pinion. Replace if
cracked or worn.
Checking the forward gear

1. Check the teeth and dogs of the forward
b gear. Replace if cracked or worn.
a
Checking the drive shaft
1. Check the drive shaft. Replace if dam-
2. Heat the installation area of the taper aged or worn.
roller bearing outer race in the lower case
using a gas torch, and then remove the 2. Measure the drive shaft runout.
taper roller bearing outer race c, pinion
shims d, and sleeve e. NOTICE: When
heating the lower case, heat the entire
installation area evenly. Otherwise,
the paint on the lower case could be
burned.
Drive shaft runout: 0.5 mm (0.0197 in)
Assembling the forward gear
e
Do not reuse a bearing, always replace it
with a new one.
d
c 1. Install a new taper roller bearing a.
3. Remove the needle bearing f.

b
h b
h a a
f
g
Needle bearing attachment b:

90890-06607
8-19
2. Install a new needle bearing c to the
specified installation depth a.
Do not reuse a bearing, always replace it
with a new one.
d
e
1. Install the original forward gear shims a.
0
a
c 2. Heat the installation area of the taper
roller bearing outer race in the lower case 1
using a gas torch, and then install a new
taper roller bearing outer race a.
Driver rod L3 d: 90890-06652

NOTICE: When heating the lower
case, heat the entire installation area 2
Needle bearing attachment e: evenly. Otherwise, the paint on the
90890-06614 lower case could be burned.
Installation depth a:
a 3
a
0.95–1.45 mm (0.037–0.057 in)
Assembling the drive shaft 4

1. Install a new taper roller bearing a.
NOTICE: Do not reuse a bearing,
5
6
a a
a
a
TIP:
Do not reuse a shim if deformed or 7
scratched.
Bearing inner race attachment a:

90890-06643
3. While holding the special service tool b,
strike the tool to check that the taper
8
roller bearing outer race is installed prop-
Assembling the lower case
erly.
9
• Use heat-resistant gloves. Otherwise,
burns could result.
• To prevent fires, remove any flammable
substances, such as gasoline and oil,
10
around the working area.
• Keep good ventilation while working.
A
8-20
LOWR
Lower unit
TIP:
• Face the bearing identification mark c on
b the needle bearing up.
• When using the driver rod, do not strike the
special service tool in a manner that forces
the stopper d out of place.
b
c 5. Heat the installation area of the taper
roller bearing outer race in the lower case
with a gas torch, and then install the drive
shaft sleeve h, the original pinion shims
c i, and a new taper roller bearing outer
race e. NOTICE: When heating the
Driver rod LL b: 90890-06605 lower case, heat the entire installation
Bearing outer race attachment c: area evenly. Otherwise, the paint on
90890-06621 the lower case could be burned.
e
TIP:
If a high-pitched metallic sound is produced i
f
when the special service tool is struck, the
outer race is installed properly.
h
4. Install a new needle bearing d into the

lower case to the specified installation
depth b.
c
g d
b e e TIP:
f • Face the protrusion f on the drive shaft
sleeve forward.
f d • Do not reuse a shim if deformed or
scratched.
Driver rod SL e: 90890-06602
Needle bearing attachment f: 6. While holding the special service tool b,
90890-06611 strike the tool to check that the taper
Bearing depth plate g: 90890-06603 roller bearing outer race is installed prop-
erly.
Installation depth b:
187.6–188.6 mm (7.386–7.425 in)
8-21
b
a
b j
0
j 1
Driver rod LL b: 90890-06605 3. Install the pinion b and pinion nut c,
Bearing outer race attachment j:
90890-06626
and then tighten the pinion nut c to the
specified torque.
2
b c
TIP:
If a high-pitched metallic sound is produced 3
when the special service tool is struck, the
outer race is installed properly.
7. Install the water inlet covers k and l,

e
4
nut m, and water inlet cover screw n,
and then tighten the water inlet cover
screw n to the specified torque.
a
d 5
k 6
Drive shaft holder 4 d: 90890-06518
Pinion nut holder e: 90890-06715
l
m Pinion nut c: 7
94 N·m (9.4 kgf·m, 69.3 ft·lb)
n
Water inlet cover screw n: TIP:

When installing the pinion b, lift up the drive
8
1 N·m (0.1 kgf·m, 0.7 ft·lb)
shaft a slightly and align the splines on the
drive shaft with the splines on the pinion.
TIP:
After installing the water inlet covers, make
9
sure that there is no rattling. 4. Check that the drive shaft turns smoothly.
Installing the drive shaft

Installing the propeller shaft housing
assembly
10
1. Install the forward gear assembly.
1. Install the washer a and propeller shaft
2. Install the drive shaft a. housing assembly a.
A
8-22
LOWR
Lower unit
e
a
f
d
2. Install the propeller shaft housing assem- Ring nut wrench extension e:
bly a along with the propeller shaft 90890-06513
assembly b, and then install the key b. Ring nut wrench 6 f: 90890-06677
b Ring nut d:
103 N·m (10.3 kgf·m, 76.0 ft·lb)
b
a 5. Bend one of the 4 tabs on the claw
washer outward, and then bend the other
3 tabs inward.
3. Install the claw washer c.
d
c Installing the shift rod
c
Do not reuse an oil seal or O-ring, always
replace it with a new one.
1. Install a new O-ring a and a new oil seal

b to the plate c.
TIP:
Make sure to fit the protrusion c on the pro- b
peller shaft housing into the slot d in the
claw washer c. c
4. Install the ring nut d, and then tighten it

a
8-23
2. Install the plate c, and then install a new
O-ring d to the shift rod e. g
b f
d e
a
c h
e
d
0
e c
1
4. Align the slot a in the impeller i with
3. Install the shift rod e.

the Woodruff key h, and then install the
impeller i.
2
a
3
e
i h
4
a
a
90°
5. Install the insert cartridge j.
5
b j
b c k 6
TIP:
Turn the shift rod e clockwise 90°, and then
push it down so that the tip a of the shift rod
e fits into the groove b in the shift slider.
7
4. Check that
smoothly.
the shift rod operates
8
TIP:
Installing the water pump Fit the protrusion b on the insert cartridge j
into the slot c in the water pump housing k.
9
Do not reuse a gasket, always replace it 6. Install the seal l and cover m.
with a new one.
10
1. Install the plate a and rubber seal b. m
2. Install a new gasket c, the oil seal hous-

ing d, the dowels e, a new gasket f, l
and the outer plate cartridge g.
3. Install the Woodruff key h.

A
8-24
LOWR
Lower unit
7. Install a new gasket n and water pump Installing the lower unit (L-transom
housing assembly d into the lower unit, model)
and then tighten the bolts o and p.
NOTICE: Do not turn the drive shaft
counterclockwise. Otherwise, the • Make sure to disconnect the battery
water pump impeller could be dam- cables from the battery, and remove the
aged. clip from the engine shut-off switch.
p p • When installing the lower unit with the
n power unit installed, make sure to sus-
o pend the outboard motor. Otherwise, the
o outboard motor could fall suddenly and
d peller nut, do not hold the propeller
using your hands.
1. Check that the pin a is aligned with the

TIP: mark b on the shift bracket a.
While turning the drive shaft clockwise, push
the water pump housing down to install it. a
a
Checking the lower unit for air
leakage
1. Remove the gear oil check screw a, and
then install the special service tool b. b
2. Set the gear shift to the N position.
a b
R
Leakage tester b: 90890-06840
N
2. Apply the specified pressure. Check that F
the pressure is maintained in the lower
unit for 10 seconds or more. Shift rod socket b: 90890-06679
NOTICE: Do not overpressurize the
lower unit. Otherwise, the oil seals 3. Install the dowels c, hose nipple d, and
could be damaged. speedometer hose e.
Lower unit holding pressure: 4. Install the lower unit f, and then tighten
68.6 kPa (0.686 kgf/cm2, 9.9 psi) the lower case mounting bolts g to the
specified torque.
8-25
5. Install the trim tab h to its original posi-
Propeller nut m:
tion a.
35 N·m (3.5 kgf·m, 25.8 ft·lb)
8. Install a new cotter pin n. NOTICE: Do

e
c not reuse a cotter pin, always replace 0
it with a new one.
d
c
f
h
1
g n
2
a
m
g 3
TIP:
If the slots in the propeller nut m are not
g
aligned with the cotter pin hole, tighten the
propeller nut until they are aligned.
4
Lower case mounting bolt g:
40 N·m (4.0 kgf·m, 29.5 ft·lb)
6. Install the spacer i, propeller j, wash-

9. Fill the lower unit with gear oil up to the
proper level. See steps 5–9 in “Changing 5
ers k and l, and propeller nut m. the gear oil” (10-10).
k l Installing the lower unit (X-transom

model)
6
m
• Make sure to disconnect the battery 7

j cables from the battery, and remove the
i clip from the engine shut-off switch.
• When installing the lower unit with the
power unit installed, make sure to sus- 8
7. Place a block of wood between the anti- pend the outboard motor. Otherwise, the
cavitation plate and the propeller to pre- outboard motor could fall suddenly and
vent the propeller from turning, and then
tighten the propeller nut m to the speci-
9
fied torque. peller nut, do not hold the propeller
using your hands.
10
1. Check that the shift rod is in the N posi-
tion. See steps 1 and 2 in “Installing the
lower unit (L-transom model)” (8-25).
2. Install the lower case stud bolts a, and

then tighten it to the specified torque.
A
8-26
LOWR
Lower unit
7. Fill the lower unit with gear oil up to the
proper level. See steps 5–9 in “Changing
the gear oil” (10-10).
a
a
Lower case stud bolt a:

23 N·m (2.3 kgf·m, 17.0 ft·lb)
3. Install the plates b, and then tighten the

plate bolts c to the specified torque.
4. Install the dowels d, hose nipple e, and

extension f.
5. Install the speedometer hose g, dowels

h, and lower unit i, and then tighten
the lower case mounting nuts j to the
specified torque.
f
d
d
h
i
h
b
b
g c
c
Plate bolt c:
11 N·m (1.1 kgf·m, 8.1 ft·lb)
Lower case mounting nut j:
40 N·m (4.0 kgf·m, 29.5 ft·lb)
6. Install the trim tab and propeller. See

steps 5–8 in “Installing the lower unit (L-
transom model)” (8-25).
8-27
Drive shaft and lower case / Shimming
Shimming
Shimming workflow
0
Remove the water pump
assembly and oil seal housing.
Measure the backlash before

1
disassembly.
YES
2
Within specification? Shimming is not required.
NO
Disassemble the lower unit.
3
Select the pinion shims (T3).
4
Assemble the lower unit.
Measure the backlash.

5
Within specification?
NO Adjust the forward gear shim
thickness (T1).
6
YES
Install the water pump
assembly and oil seal housing.
7
8
TIP:
• 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
9
housing, shimming is required.
10
A
8-28
LOWR
Lower unit
Shimming check sheet
Lower case deviation
Serial number P F R Remarks
Pinion height (mm)

Measurements
Measuring point #1
Measuring point #2
Measuring point #3
Measuring point #4
Average
Round-down average
(M)
Forward gear backlash (mm)

Measurements
Before disassembly After disassembly
Measuring point #1
Measuring point #2
Measuring point #3
Measuring point #4
Average
Round-down average
Forward gear shim (T1) thickness measurement in 2 places (mm)

Number of shim(s) Subtotal
0.10
0.12
0.15
0.18
0.30
0.40
0.50
Total
8-29
Shimming
Measuring the forward gear backlash
before disassembly
1. Install the lower unit onto a repair stand.
d
2. Remove the water pump assembly. See 0
“Removing the water pump and shift rod”
(8-9).
3. Set the gear shift to the N position. 1

Center bolt d (shimming):
a
5 N·m (0.5 kgf·m, 3.7 ft·lb) 2
8. Turn the lower unit to its upright position.
R
N
9. Install the special service tool e onto the
drive shaft at the lowest possible position
3
F where the shaft diameter is 18.0 mm
(0.71 in).
Shift rod socket a: 90890-06679
10. Install the handle stopper f so that it
4
4. Set up the special service tools b, c, rests on the step at the position a on the
drive shaft, and then tighten the nuts b
and d, and then tighten the center bolt
d temporarily. temporarily. 5
f
b c
e
6
a
b
b
7
d
Bearing housing puller claw L b: Backlash indicator e: 90890-06706 8

90890-06502 Handle stopper f: EU0-23814-30
Stopper guide plate c: 90890-06501
Center bolt d: 90890-06504
9
5. Turn the lower unit so that the propeller
shaft is pointing down.
6. Turn the drive shaft 10 times or more to

10
seat the taper roller bearing.
7. While holding the drive shaft to prevent it

from turning, tighten the center bolt d to
A
8-30
LOWR
Lower unit
11. Set up the special service tools g, h,
and i, and then install another special TIP:
service tool j on the handle stopper f • Do not turn the drive shaft using too much
to apply a load. force. Otherwise, the forward gear will turn,
leading to incorrect measurements.
• When turning the drive shaft, hold it using a
little force. A knocking sound may be heard
j when the drive shaft is turned, but this is
the sound of the pinion contacting the
i reverse gear and does not affect the back-
lash measurement.
f
g h 13. Turn the drive shaft 180° clockwise and
measure the backlash again.
c
Magnet base plate g: 90890-07003
Dial gauge set h: 90890-01252
Magnet base B i: 90890-06844 d
Pinion height gauge j: 90890-06669 f
12. Turn the drive shaft slowly clockwise and

counterclockwise, and then measure the
backlash between where the drive shaft
stops in each direction. e
TIP:
• Measure the backlash at 4 points: c, d,
e, and f, turning the drive shaft 180°
clockwise after each measurement.
• Write down the measurement data in the
shimming check sheet.
14. Determine the backlash average, and

then round down the average to the
1/100 place.
Example:
(mm)
Measurement point c 0.30
Measurement point d 0.36
Measurement point e 0.34
Measurement point f 0.33
Average 0.3325
Round-down average 0.33
8-31
Shimming
15. Check that the forward gear backlash
average is within specification.
Forward gear backlash:
0.09–0.72 mm (0.0035–0.0283 in)
0
TIP:
Adjust the shim thicknesses if the forward
gear backlash is out of specification. 1
16. Remove the special service tools, and
then install the oil seal housing and water
pump assembly. See “Installing the water
2
pump” (8-24).
3
4
5
6
7
8
9
10
A
8-32
LOWR
Lower unit
Shimming
• Before selecting the forward gear shim (T1), make sure to select the pinion shims (T3).
• When assembling the lower unit to measure the backlash after selecting the pinion shims (T3), do
not apply gear oil, grease, or sealant to the parts.
• 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
8-33
Shimming
Selecting the pinion shim (T3)
• Spray anti-rust lubricant on the bearing c
before installation. Do not apply gear oil to b
the parts. Otherwise, correct measure-
ments cannot be obtained.
d d
0
• Keep the parts free of foreign material,
such as dirt and lint.
a 1
Be careful not to damage the measure-
ment plane surface of the special service TIP:
tool. Otherwise, correct measurements
cannot be obtained.
If there is no gap, the pinion shim (T3) may 2
not have been removed.
1. Install the taper roller bearing and drive

shaft between a and b of the special
4. Install the special service tool d to the
drive shaft spline, and hold the special
3
service tool a, and then tighten the pin- service tool d.
ion height gauge bolts c temporarily.
5. Tighten the pinion nut c to the specified
torque.
4
a
a d
5
6
b
c c c 7
Pinion height gauge set a: 90890-06669
Drive shaft holder 4 d: 90890-06518

8
TIP:
Do not install the pinion shim (T3).
Pinion nut c: 94 N·m (9.4 kgf·m, 69.3 ft·lb)
2. Install the pinion b and pinion nut c, 6. Place the pinion so that it is facing up,
9
and then tighten the pinion nut c tempo- and hold it in the upright position.
rarily. NOTICE: When tightening the
pinion nut, make sure that the drive
shaft turns smoothly.
7. Turn the drive shaft 10 turns or more to 10
seat the taper roller bearing.
3. Check that there is a gap d between the 8. Tighten the pinion height gauge bolts c
pinion b and the special service tool a. to the specified torques in 4 stages so
NOTICE: If there is no gap and the that the distance e between the upper
drive shaft does not rotate, the special part and the lower part of the special ser-
service tool could be damaged. vice tools a become equal.
A
8-34
LOWR
Lower unit
TIP:
• When measuring the distance, insert the
end of the thickness gauge straight into the
a gap at the measurement point. Do not
insert the thickness gauge at an angle.
• Measure the distance at 4 points: f, g, h,
and k.
• Write down the measurement data in the
e e shimming check sheet.
c 11. Determine the distance average, and

then round down the average to the
1/100 place.
Pinion height gauge bolt c: Example:
1st: 1 N·m (0.1 kgf·m, 0.7 ft·lb) (mm)
2nd: 2 N·m (0.2 kgf·m, 1.5 ft·lb) Measurement point f 0.20
3rd: 3 N·m (0.3 kgf·m, 2.2 ft·lb) Measurement point g 0.20
4th: 4 N·m (0.4 kgf·m, 3.0 ft·lb)
Measurement point h 0.19
9. Recheck the gap d between the pinion Measurement point k 0.18
b and the special service tool a. Average 0.1925
Round-down average (M) 0.19
b 12. Determine the pinion shim (T3) thickness

adjustment using the “Pinion shim (T3)
selection table” according to the rounded
d d average (M) and the deviation (P)
stamped on the lower case. See “Pinion
shim (T3) selection table” (8-37).
a
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40,
TIP: 0.50 mm
If there is no gap, the shim(s) (T3) may not
have been removed.
10. Measure the distance between the pinion

b and the special service tool a.
b h
8-35
Shimming
Example:
(M) = 0.19
(P) = –3
F +2
0
1
R +4
m
P –3
2
(T3) = 0.60 mm from the “pinion shim (T3)
selection table.”
Pinion height
measurement (M)
3
0.18 0.19 0.20
Stamped
value on the
–2
–3 G
Y
0.60
4
lower case (P) –4
TIP: 5
The (P) mark m is stamped on the trim tab
mounting surface of the lower case in
0.01 mm units. If the (P) mark is unreadable,
replace the lower case.
6
13. Remove the special service tools, and
then install the determined pinion shims
(T3).
7
8
9
10
A
8-36
LOWR
Lower unit
Pinion shim (T3) selection table
(mm)
A
0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16
13 0.30 0.32 0.32 0.35 0.35 0.35 0.38 0.38 0.38 0.40 0.40 0.42
12 0.32 0.32 0.35 0.35 0.35 0.38 0.38 0.38 0.40 0.40 0.42 0.42
11 0.32 0.35 0.35 0.35 0.38 0.38 0.38 0.40 0.40 0.42 0.42 0.45
10 0.35 0.35 0.35 0.38 0.38 0.38 0.40 0.40 0.42 0.42 0.45 0.45
9 0.35 0.35 0.38 0.38 0.38 0.40 0.40 0.42 0.42 0.45 0.45 0.45
8 0.35 0.38 0.38 0.38 0.40 0.40 0.42 0.42 0.45 0.45 0.45 0.48
7 0.38 0.38 0.38 0.40 0.40 0.42 0.42 0.45 0.45 0.45 0.48 0.48
6 0.38 0.38 0.40 0.40 0.42 0.42 0.45 0.45 0.45 0.48 0.48 0.48
5 0.38 0.40 0.40 0.42 0.42 0.45 0.45 0.45 0.48 0.48 0.48 0.50
4 0.40 0.40 0.42 0.42 0.45 0.45 0.45 0.48 0.48 0.48 0.50 0.50
3 0.40 0.42 0.42 0.45 0.45 0.45 0.48 0.48 0.48 0.50 0.50 0.52
2 0.42 0.42 0.45 0.45 0.45 0.48 0.48 0.48 0.50 0.50 0.52 0.52
1 0.42 0.45 0.45 0.45 0.48 0.48 0.48 0.50 0.50 0.52 0.52 0.55
B 0 0.45 0.45 0.45 0.48 0.48 0.48 0.50 0.50 0.52 0.52 0.55 0.55
–1 0.45 0.45 0.48 0.48 0.48 0.50 0.50 0.52 0.52 0.55 0.55 0.55
–2 0.45 0.48 0.48 0.48 0.50 0.50 0.52 0.52 0.55 0.55 0.55 0.58
–3 0.48 0.48 0.48 0.50 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58
–4 0.48 0.48 0.50 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58
–5 0.48 0.50 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60
–6 0.50 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60
–7 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62
–8 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62
–9 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65
–10 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65
–11 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65
–12 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68
–13 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68
A
0.17 0.18 0.19 0.20 0.21 0.22 0.23 0.24 0.25 0.26 0.27 0.28
13 0.42 0.45 0.45 0.45 0.48 0.48 0.48 0.50 0.50 0.52 0.52 0.55
12 0.45 0.45 0.45 0.48 0.48 0.48 0.50 0.50 0.52 0.52 0.55 0.55
11 0.45 0.45 0.48 0.48 0.48 0.50 0.50 0.52 0.52 0.55 0.55 0.55
10 0.45 0.48 0.48 0.48 0.50 0.50 0.52 0.52 0.55 0.55 0.55 0.58
9 0.48 0.48 0.48 0.50 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58
8 0.48 0.48 0.50 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58
7 0.48 0.50 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60
6 0.50 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60
5 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62
4 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62
3 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65
2 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65
1 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65
B 0 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68
–1 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68
–2 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68
–3 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70
–4 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70
–5 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72
–6 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72
–7 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75
–8 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75
–9 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75
–10 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78
–11 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78
–12 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78
–13 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80
A Pinion height measurement (M)
B Stamped value on the lower case (P)
8-37
Shimming
(mm)
A
13
12
0.29
0.55
0.55
0.30
0.55
0.58
0.31
0.58
0.58
0.32
0.58
0.58
0.33
0.58
0.60
0.34
0.60
0.60
0.35
0.60
0.62
0.36
0.62
0.62
0.37
0.62
0.65
0.38
0.65
0.65
0.39
0.65
0.65
0.40
0.65
0.68
0
11 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68
10 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68
9
8
7
0.58
0.60
0.60
0.60
0.60
0.62
0.60
0.62
0.62
0.62
0.62
0.65
0.62
0.65
0.65
0.65
0.65
0.65
0.65
0.65
0.68
0.65
0.68
0.68
0.68
0.68
0.68
0.68
0.68
0.70
0.68
0.70
0.70
0.70
0.70
0.72
1
6 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72
5 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75
4
3
2
0.65
0.65
0.65
0.65
0.65
0.68
0.65
0.68
0.68
0.68
0.68
0.68
0.68
0.68
0.70
0.68
0.70
0.70
0.70
0.70
0.72
0.70
0.72
0.72
0.72
0.72
0.75
0.72
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.78
2
1 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78
B 0 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78
–1
–2
0.68
0.70
0.70
0.70
0.70
0.72
0.72
0.72
0.72
0.75
0.75
0.75
0.75
0.75
0.75
0.78
0.78
0.78
0.78
0.78
0.78
0.80
0.80
0.80 3
–3 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82
–4 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82
–5 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85
–6
–7
0.75
0.75
0.75
0.75
0.75
0.78
0.78
0.78
0.78
0.78
0.78
0.80
0.80
0.80
0.80
0.82
0.82
0.82
0.82
0.85
0.85
0.85
0.85
0.85
4
–8 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85 0.85 0.88
–9 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85 0.85 0.88 0.88
–10 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85 0.85 0.88 0.88 0.88
–11
–12
0.78
0.80
0.80
0.80
0.80
0.82
0.82
0.82
0.82
0.85
0.85
0.85
0.85
0.85
0.85
0.88
0.88
0.88
0.88
0.88
0.88
0.90
0.90
0.90
5
–13 0.80 0.82 0.82 0.85 0.85 0.85 0.88 0.88 0.88 0.90 0.90 0.92
13
0.41
0.68
0.42
0.68
0.43
0.68
0.44
0.70
0.45
0.70
0.46
0.72
0.47
0.72
0.48
0.75
6
12 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75
11 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75
10 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78
9
8
0.70
0.72
0.72
0.72
0.72
0.75
0.75
0.75
0.75
0.75
0.75
0.78
0.78
0.78
0.78
0.78
7
7 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80
6 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80
5
4
3
0.75
0.75
0.78
0.75
0.78
0.78
0.78
0.78
0.78
0.78
0.78
0.80
0.78
0.80
0.80
0.80
0.80
0.82
0.80
0.82
0.82
0.82
0.82
0.85
8
2 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85
1 0.78 0.80 0.80 0.82 0.82 0.85 0.85 0.85
B 0
–1
–2
0.80
0.80
0.82
0.80
0.82
0.82
0.82
0.82
0.85
0.82
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.88
0.85
0.88
0.88
0.88
0.88
0.88
9
–3 0.82 0.85 0.85 0.85 0.88 0.88 0.88 0.90
–4 0.85 0.85 0.85 0.88 0.88 0.88 0.90 0.90
–5
–6
–7
0.85
0.85
0.88
0.85
0.88
0.88
0.88
0.88
0.88
0.88
0.88
0.90
0.88
0.90
0.90
0.90
0.90
0.92
0.90
0.92
0.92
0.92
0.92
0.95
10
–8 0.88 0.88 0.90 0.90 0.92 0.92 0.95 0.95
–9 0.88 0.90 0.90 0.92 0.92 0.95 0.95 0.95
–10 0.90 0.90 0.92 0.92 0.95 0.95 0.95 0.98
–11 0.90 0.92 0.92 0.95 0.95 0.95 0.98 0.98
–12 0.92 0.92 0.95 0.95 0.95 0.98 0.98 0.98
–13 0.92 0.95 0.95 0.95 0.98 0.98 0.98 1.00
A Pinion height measurement (M)
B Stamped value on the lower case (P) A
8-38
LOWR
Lower unit
Measuring the forward gear backlash 2. Measure the thickness of original forward
• Spray anti-rust lubricant on the gears and gear shim (T1) in 2 places.
bearings before installation. Do not apply
gear oil to the parts. Otherwise, correct TIP:
measurements cannot be obtained. Do not reuse a shim if deformed or
• Keep the parts free of foreign material, scratched.
such as dirt and lint.
• When measuring the forward gear back- 3. Determine the forward gear shim (T1)
lash, use the original bearings and shims. thickness adjustment using the “Forward
gear shim (T1) selection chart” according
1. Install the original forward gear shims
to the backlash measurement (BL1) from
(T1).
“Measuring the forward gear backlash.”
See “Forward gear shim (T1) selection
TIP: chart” (8-41).
• If the original forward gear shims (T1) are Example:
missing, install new shims with a combined Backlash measurement (BL1) = 0.05 mm a
thickness of 0.50 mm. Forward gear shim (T1) thickness adjustment
• Do not reuse a shim if deformed or = –0.19 mm b
scratched. The current shim thickness must be
decreased by 0.19 mm.
2. Install the taper roller bearing outer race.
See “Assembling the lower case” (8-20) 0
step 2 and step 3. b
B (mm)
3. Install the forward gear assembly, drive –0.20

shaft, pinion, and pinion nut. See steps
1–3 in “Installing the drive shaft” (8-22). –0.40
0 5 10 15 20 25
4. Check that the drive shaft turns smoothly.
a A (1/100 mm)
5. Install the propeller shaft housing assem-
A 0 5 10 15 20 25
bly. See “Installing the propeller shaft
housing assembly” (8-22). B –0.22 –0.19
6. Check that the drive shaft turns smoothly.
A Backlash measurement (BL1)
B Shim thickness adjustment
7. Measure the forward gear backlash. See
steps 3–15 in “Measuring the forward
gear backlash before disassembly” (8-
30).
Forward gear backlash:
0.09–0.72 mm (0.0035–0.0283 in)
Adjusting the forward gear shim

thickness (T1)
1. Remove the taper roller bearing outer
race. See step 1 in “Disassembling the
lower case” (8-18).
8-39
Shimming
TIP: TIP:
• If the shim thickness adjustment value is • Use the lowest number of shims to obtain
positive, increase the current shim thick- the required shim thickness.
ness by that amount and, if the value is
negative, decrease the current shim thick-
• If the calculated shim thickness cannot be
obtained with a combination of the available
0
ness by that amount. shims, decrease the shim thickness by
• The gray-colored area on the selection 0.01 mm.
chart indicates the range of the specified
backlash. Shimming is not required if the
1
5. Install the determined forward gear shims
measured backlash is within the gray-col- (T1) and taper roller bearing outer race.
ored area.
• The values for the shim thickness adjust- 2
ments specified in the selection chart are
intended to obtain the median value within
the range for the specified forward gear
backlash.
3
• The table that follows the selection chart
shows the shim thickness adjustments for
the points marked on the chart. 4
4. Calculate the new forward gear shim (T1)
thickness.
Calculation formula: 5
New forward gear shim (T1) thickness = Cur-
rent forward gear shim thickness + shim
thickness adjustment
Example:
6
Use the following formula when the shim
thickness adjustment value is positive.
Current forward gear shim thickness =
0.50 mm
7
Shim thickness adjustment = 0.21 mm
New forward gear shim (T1) thickness =
0.50 mm + 0.21 mm 8
= 0.71 mm
Use the following formula when the shim
thickness adjustment value is negative.
Current forward gear shim thickness =
9
0.50 mm
Shim thickness adjustment = –0.19 mm
New forward gear shim (T1) thickness =
0.50 mm + (–0.19 mm)
10
= 0.31 mm
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40,
0.50 mm
A
8-40
Forward gear shim (T1) selection chart
8-41
1.00
LOWR
0.80
0.60
0.40
Lower unit
B (mm)
0.20
Continue next page
–0.20
–0.40
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
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
B –0.22 –0.19 0.18 0.21 0.24 0.26 0.29 0.32

1.00
0.80
0.60
0.40
B (mm)
0.20
–0.20
–0.40
100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
A (1/100 mm)
A 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
B 0.32 0.34 0.37 0.40 0.42 0.45 0.48 0.50 0.53 0.56 0.59 0.61 0.64 0.66 0.69 0.72 0.74 0.77 0.80 0.82 0.85

8-42
Shimming
9
8
7
6
5
4
3
2
1
0
A
10
BRKT
Bracket unit 9
Friction plate ...................................................................... 9-1

Removing the friction plate ........................................................ 9-3
Disassembling the friction plate ................................................. 9-3
Assembling the friction plate ..................................................... 9-3
Installing the friction plate assembly .......................................... 9-4
Tiller handle ....................................................................... 9-5

Disassembling the tiller handle .................................................. 9-8
Assembling the tiller handle ...................................................... 9-9
Electrical component (multifunction) ............................ 9-13

Disassembling the electrical component (multifunction) ......... 9-14
Assembling the electrical component (multifunction) .............. 9-14
Shift rod and shift bracket .............................................. 9-16

Disassembling the shift rod ..................................................... 9-17
Assembling the shift rod .......................................................... 9-17
Bottom cowling ............................................................... 9-18

Disassembling the bottom cowling .......................................... 9-21
Assembling the bottom cowling ............................................... 9-21
Upper case and mount ................................................... 9-24

Removing the upper case ....................................................... 9-26
Installing the upper case ......................................................... 9-26
Upper case ....................................................................... 9-28

Disassembling the upper case ................................................ 9-29
Checking the drive shaft bushing ............................................ 9-29
Assembling the upper case ..................................................... 9-29
Oil pan and exhaust manifold ........................................ 9-31

Disassembling the oil pan and exhaust manifold .................... 9-33
Checking the oil pan and exhaust manifold ............................. 9-34
Checking the oil strainer .......................................................... 9-34
Assembling the oil pan and exhaust manifold ......................... 9-34
Steering arm .................................................................... 9-36

Removing the steering arm ..................................................... 9-37
Installing the steering arm ....................................................... 9-37
Clamp bracket and swivel bracket ................................ 9-39

Removing the clamp bracket ................................................... 9-41
Checking the clamp bracket anode ......................................... 9-41
Installing the clamp bracket ..................................................... 9-41
Adjusting the trim sensor ......................................................... 9-43
PTT unit ............................................................................ 9-44

Removing the PTT unit ............................................................ 9-45 0
Checking the PTT unit anode .................................................. 9-45
Installing the PTT unit .............................................................. 9-45
PTT motor ........................................................................ 9-47

1
Removing the PTT motor ........................................................ 9-49
Disassembling the PTT motor ................................................. 9-49
Checking the armature (PTT motor) ........................................ 9-49 2
Checking the brush ................................................................. 9-50
Assembling the PTT motor ...................................................... 9-51
Installing the PTT motor .......................................................... 9-51
3
PTT gear pump ................................................................ 9-53
Disassembling the gear pump assembly ................................. 9-56
Checking the gear pump ......................................................... 9-56
Checking the filter .................................................................... 9-57
4
Assembling the gear pump housing ........................................ 9-57
PTT cylinder ..................................................................... 9-59 5

Disassembling the trim cylinder ............................................... 9-61
Disassembling the tilt cylinder ................................................. 9-61
Disassembling the PTT ram assembly .................................... 9-61
Checking the PTT cylinder and piston ..................................... 9-62 6
Assembling the PTT ram assembly ......................................... 9-62
Assembling the tilt cylinder ...................................................... 9-63
Assembling the trim cylinder ................................................... 9-64
Bleeding the PTT unit .............................................................. 9-65 7
8
9
10
A
BRKT
Bracket unit
Friction plate
4
5
1 11
5
4
12
13
15
14
6 16
2 18
3 17
7 15
10 19
8
9
10 20
21
22
7 N·m (0.7 kgf·m, 5.2 ft·lb)
32 N·m (3.2 kgf·m, 23.6 ft·lb) 21 18
37 N·m (3.7 kgf·m, 27.3 ft·lb) 22
4 N·m (0.4 kgf·m, 3.0 ft·lb)
32 N·m (3.2 kgf·m, 23.6 ft·lb) 23
24
25

1 Tiller handle assembly 1
2 Tiller handle bracket nut 1
3 Washer 1
4 Washer 2
5 Bushing 2
6 Tiller handle bracket 1
7 Collar 1
8 Washer 2
9 Tiller handle bracket bolt 1 M12 80 mm
10 Tiller handle nut 2
11 Bolt 1 M5 20 mm
12 Steering lock shaft 1
13 Bracket 1
14 Collar 1
15 Washer 2
16 Steering lock lever 1
17 Cap 1
9-1
Friction plate
4
5
1
5
11
0
4
12
1
13
15
2
14
6 16
2
3 17 15
18
3
7
10
8
19 4
9
10 20
21
22
7 N·m (0.7 kgf·m, 5.2 ft·lb)
5
32 N·m (3.2 kgf·m, 23.6 ft·lb) 21 18
37 N·m (3.7 kgf·m, 27.3 ft·lb) 22
32 N·m (3.2 kgf·m, 23.6 ft·lb)
24 23
4 N·m (0.4 kgf·m, 3.0 ft·lb)
6
25

18 Friction piece 2
19 Collar 1
20
21
Friction plate
Spring washer
1
2
8
22 Bolt 2 M6 12 mm
23
24
Friction plate nut
Steering lock washer
1
1 9
25 Friction adjusting nut 1
10
A
9-2
BRKT
Bracket unit
Removing the friction plate
1. Remove the friction plate bolts a, and
a
then remove the friction plate assembly
b. a a
a
2. Turn the steering lock shaft a so that the
thread side b faces toward the face c of
the bracket b.
a
Disassembling the friction plate

1. Remove the friction plate nut a and fric- b
a
tion adjusting nut b.
2. Remove the steering lock washer c, fric-

tion pieces d, collar e, washers f,
steering lock lever g, collar h, bracket b
i, steering lock shaft j, and bolt k. c
k
g TIP:
Do not turn the steering lock shaft a more
j
than 90°.
f d
i h 3. Install the bolt c, bracket b, collar d,
e steering lock lever e, washers f, collar
f
g, friction pieces h, and steering lock
washer i.
4. Install the friction adjusting nut j and

friction plate nut k temporarily.
d
5. Tighten the friction plate nut k to the
a
specified torque.
c
b
Assembling the friction plate

1. Screw in the steering lock shaft a so that
the top surface is level with the top sur-
face of the nut a.
9-3
Friction plate
c
h b
e
d
f
h
b
0
f g
d d
e a 1
h g f
i k
j g 2
Friction plate nut k:
7 N·m (0.7 kgf·m, 5.2 ft·lb) 3
Collar d and g dimensions:
c
d: 9.0 mm (0.35 in)
e: 3.8 mm (0.15 in) 4
f: 8.0 mm (0.31 in) Friction adjusting nut c:
g: 5.4 mm (0.21 in) 4 N·m (0.4 kgf·m, 3.0 ft·lb)
TIP:
5
• Make sure that the “TOP” mark h on the
steering lock lever e is facing up.
• Make sure to install the collars d and g in
the proper positions. The dimensions of the
6
collars are different.
Installing the friction plate assembly

7
1. Install the friction plate assembly a.
a 8
9
10
2. Install the tiller handle. See “Installing the
tiller handle” (3-15).
3. Move the steering lock lever b to the

position a, and then tighten the friction
adjusting nut c to the specified torque.
A
9-4
BRKT
Bracket unit
Tiller handle
5 6
3 N·m (0.3 kgf·m, 2.2 ft·lb)
2
3
24 25 23
22 23
7
8
10 9
11 8 21 34
12 20 26 39
35 37
11 4
13 27
19 36
18 33
29 38
17 28
42 40 41 40
32
28 31
14
15 16 28
28
2 N·m (0.2 kgf·m, 1.5 ft·lb)
30
43

1 Shift lever 1
2 Bolt 1 M8 40 mm
3 Screw 2 ø6 20 mm
4 Bushing 2
5 Nut 1
6 Friction piece 1
7 Bushing 1
8 Retainer 2
9 Spring 1
10 Collar 1
11 Washer 2
12 Plate 1
13 Cotter pin 1 39
14 PTT switch 1
15 Cap 1
16 Screw 1 M6 15 mm
17 Throttle grip 1
9-5
Tiller handle
1 0
5 6
3 N·m (0.3 kgf·m, 2.2 ft·lb)
2
3 1
24 25 23
4 2
22 23
7
11
10 9
8
34
3
8 20 21
12 26 35 39
11 4 37
13
19
18
27
36 4
33
29 38
17 28
42 40 41 40
28
32
31
5
14
15 16 28
28
2 N·m (0.2 kgf·m, 1.5 ft·lb)
30
6
43

18 Throttle grip screw 1 M5 22 mm
19 Bushing 1
20
21
Cotter pin
Throttle friction adjuster
1
1
39 8
22 Holder 1
23
24
Clamp
Grease nipple
2
1 9
25 Holder 1
26 Bracket 1
27
28
Bolt
Screw
2
6
M6 14 mm
M6 16 mm
10
29 Cap 1
30 Control link assembly 1
31 Throttle rod 1
32 Plastic tie 3
33 Neutral switch 1
34 Shift link 1
A
9-6
BRKT
Bracket unit
5 6
3 N·m (0.3 kgf·m, 2.2 ft·lb)
2
3
24 25 23
22 23
7
8
10 9
11 8 21 34
12 20 26 39
35 37
11 4
13 27
19 36
18 33
29 38
17 28
42 40 41 40
32
28 31
14
15 16 28
28
2 N·m (0.2 kgf·m, 1.5 ft·lb)
30
43

35 Throttle lever 1
36 Screw 2 M3 15 mm
37 E-clip 1
38 Drive gear 1
39 Holder 1
40 Clip 2
41 Throttle cable 1
42 Shift cable 1
43 Bolt 2 M6 30 mm
9-7
Tiller handle
Disassembling the tiller handle 5. Disconnect the connectors d of the PTT
1. Remove the bracket a. switch Red (R) lead, Sky blue (Sb) lead,
and Light green (Lg) lead.
2. Remove the cover b, and then discon-
nect the alert indicator couplers a and
b.
d
Lg 0
a Sb
1
R
2
6. Remove the PTT switch i, throttle grip
a b j, bushing k, and shift lever l.
3
l
b
4
j
5
3. Remove the clips c, and then remove i
the cable clamps d, shift cable e, and
throttle cable f.
k 6
d f c
e c
7. Remove the cotter pin m, throttle friction
adjuster n, and bolts o. 7
m
d f
8
d e
4. Remove the bracket g and holders h,

and then disconnect the connectors c of o
9
n
the neutral switch Brown (Br) leads.
g
8. Pull out the control link assembly p, and 10
then lift it up.
h
Br
h c
A
9-8
BRKT
Bracket unit
p p z
x
y
x
p
A
Assembling the tiller handle

1. Pass the throttle shaft a through the fric-
tion piece b and the tiller handle c.
2. Install the bushing d, retainers e, and

spring f.
9. Remove the neutral switch q, throttle
arm r, and bushing s. a b
d fe
r c
e
q 3. Install the collar g, the washers h, the

plate i, and a new cotter pin j.
10. Remove the cotter pin t, washers u,
plate v, and collar w.
h
g h i h
w uvu
u g
t j
w
v i h i
11. Remove the retainers x, spring y, and j
bushing z.
4. Install the neutral switch k, throttle arm
12. Remove the friction piece A and throttle
l, and bushing m.
shaft B.
9-9
Tiller handle
l 7. Face the section e of the plate i toward

m the throttle friction adjuster p.
8. Align the slot f in the bushing r with

the protrusion g on the tiller handle, and
then install the bushing r.
0
g
1
k
i p 2
f
e
5. Align the marks a and b, and align the
cutouts c and d, and then install the
r
i 3
control link assembly n.
c
d a
4
b 9. Align the mark h on the throttle grip s
with the protrusion g on the tiller handle,
and then install the throttle grip s.
5
n 10. Tighten the throttle grip screw t to the
specified torque.
11. Install the PTT switch u and shift lever

6
v.
h
v
7
TIP:
Route the neutral switch lead under the con-
trol link assembly n. See “Tiller handle
(optional)” (5-8).
g
8
s
6. Install the nut o, the throttle friction
adjuster p, and a new cotter pin q. u
9
q o
t
10
Throttle grip screw t:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
12. Check that the throttle grip operates

p smoothly. Also, check that the marks a
and b are aligned, and that the cutouts
c and d are aligned. A
9-10
BRKT
Bracket unit
c k
Lg
d a
b
Sb
16. Connect the connectors m of the neutral

switch Brown (Br) leads, and then install
the holders w and x and bracket y.
13. Check that the shift link lever operates y

smoothly when the shift lever is moved
from the N position to the F or R position. w Br
14. Check that the neutral switch k operates

x
properly.
x m
w
k
17. Install the shift cable z, throttle cable A,
clips B, and cable clamps C.
C A B B
B
N
z
R F
C A
C z
15. Connect the connectors k of the PTT
switch Red (R) lead, Sky blue (Sb) lead, 18. Connect the alert indicator couplers n
and Light green (Lg) lead. and p, and then install the cover D.
19. Install the grease nipple E, and then

20. Install the bushings F and washers G,

and then install the bracket H.
9-11
Tiller handle
21. Install the collar I, washer J, and tiller
handle bracket bolt K, and then tighten
the tiller handle bracket bolt K to the
specified torque.
22. Install the washer L and tiller handle

0
bracket nut M, and then tighten the tiller
handle bracket nut M to the specified
torque. 1
M H
L
G
F IJ
2
K
F
G 3
n E
p
4
D
Grease nipple E:
6
3 N·m (0.3 kgf·m, 2.2 ft·lb)
Tiller handle bracket bolt K:
32 N·m (3.2 kgf·m, 23.6 ft·lb) 7
Tiller handle bracket nut M:
32 N·m (3.2 kgf·m, 23.6 ft·lb)
8
9
10
A
9-12
BRKT
Bracket unit
Electrical component (multifunction)
8
1
2.5 N·m (0.25 kgf·m, 1.84 ft·lb)
4.5 N·m (0.45 kgf·m, 3.32 ft·lb)

7 2 N·m (0.2 kgf·m, 1.5 ft·lb)
9
3
15
1
2 15
14
14
3 16
13
2
4
5 17
11 12
10

1 Trolling switch 1
2 Engine shut-off switch 1
3 Engine start switch 1
4 Tiller handle 1
5 Bracket 1
6 Bolt 1 M6 15 mm
7 Alert indicator harness 1
8 Extension wiring harness 1
9 Grommet 1
10 Buzzer 1
11 Grommet 1
12 Gasket 1
13 Plate 1
14 Alert indicator screw 2 ø6 20 mm
15 Clamp 2
16 Alert indicator 1
17 Cover 1
9-13
Electrical component (multifunction)
Disassembling the electrical Assembling the electrical
component (multifunction) component (multifunction)
1. Remove the alert indicator a. 1. Install the engine start switch a so that
the hole a is facing up, and then tighten
the start switch nut b to the specified 0
torque.
a
2. Pass the extension wiring harness b,
alert indicator harness c, and trolling 1
switch lead c through the grommet d,
and then install them.
3. Install the engine shut-off switch e, and

2
then tighten the engine shut-off switch
nut d to the specified torque.
4. Install the buzzer f, and then connect

3
the engine shut-off switch connectors e
2. Remove the buzzer b, and then discon- and buzzer connectors f.
nect the buzzer connectors a and
engine shut-off switch connectors b. 5. Connect the engine start switch coupler
4
g.
3. Remove the engine shut-off switch c.
4. Disconnect the engine start switch cou-

c
5
c c
pler c.
b
5. Remove the extension wiring harness d,
alert indicator harness e, trolling switch d
b c 6
f, and grommet g. g
6. Remove the engine start switch h.

f
f
e a 7
e
e
d 8
g a
c
d b
9
b h
a Engine start switch nut b:
b
c 4.5 N·m (0.45 kgf·m, 3.32 ft·lb)
Engine shut-off switch nut d:
10
2.5 N·m (0.25 kgf·m, 1.84 ft·lb)
6. Align the blue tape h on the extension

wiring harness b and the green tape k
on the alert indicator harness c with the
f
inner end of the grommet d.
A
9-14
BRKT
Bracket unit
c
k
h
d
7. Install the alert indicator g, and then

tighten the alert indicator screws h to
h
h
g
Alert indicator screw h:

2 N·m (0.2 kgf·m, 1.5 ft·lb)
9-15
Electrical component (multifunction) / Shift rod and shift bracket
Shift rod and shift bracket
1
2
3 4 0
8
9
3
5
18 N·m (1.8 kgf·m, 13.3 ft·lb) 1
6
7
2
4 N·m (0.4 kgf·m, 3.0 ft·lb)
10
3
4
5
11

1 Cotter pin 1 39
2 Washer 1
3
4
Bushing
Bracket
2
1
8
5 Ball 1
6
7
Spring
Shift rod detent bolt
1
1 9
8 Bushing 1
9 Bushing bolt 1 M5 14 mm
10
11
Shift rod
Grommet
1
1
10
A
9-16
BRKT
Bracket unit
Disassembling the shift rod 3. Install the ball j, and then tighten the
1. Remove the shift rod detent bolt a, shift rod detent bolt i to the specified
spring b, and ball c. torque.
2. Remove the cotter pin d, and then

remove the washer e, bushings f,
bracket g, and bushing h.
i
h d
e
g
f
j
Shift rod detent bolt i:

c 18 N·m (1.8 kgf·m, 13.3 ft·lb)
f b
Assembling the shift rod

1. Install the bushing a, the bracket b, the
bushing c, the washer d, a new cotter
pin e, and the bushing f, and then
tighten the bushing bolt g to the speci-
fied torque.
2. Install the spring h into the shift rod

detent bolt i and tighten the shift rod
detent bolt i temporarily.
g f e
d
b
c
h
a
Bushing bolt g:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
9-17
Shift rod and shift bracket / Bottom cowling
Bottom cowling
5 N·m (0.5 kgf·m, 3.7 ft·lb) 18 30 31

16
10
18
19
22
23 24 1 32 37 0
9 1 28
8 33 36 38
20 1 27 35
7 17 29
21
5 6
5
25
26 34
1
14 28 27
13 16
1
15 26 2
11 12 39
17
43
44
45
16
1
40
3
43 14 16
1
44
4
1
15
43
44 1
41 4
3
1
11
48 43 42
5
44
3 46
2 1
6
49 47
5

1 Bolt 10 M6 20 mm
2 Bracket 1
3
4
Holder
Bracket
2
1
8
5 Plastic tie 5
6
7
Hose
Hose joint
1
1 9
8 Hose joint 1
9 Gasket 1
10
11
Adapter
Grommet
1
3
10
12 Plate 1
13 Grommet 1
14 Grommet 2
15 Grommet 2
16 Bolt 4 M6 30 mm
17 Guide 2
A
9-18
BRKT
Bracket unit
5 N·m (0.5 kgf·m, 3.7 ft·lb) 18 30 31

16
23 24 1 32
18 22 37
10 19
9 1 28
8 33 36 38
20 1 27 35
7 17 29
5 21 26 34
5 6
25
14 28 27
13 16
15 26
1
11 12 39
1
43 45
17 44 16 40
43 14 16
1
44
1 43
15 41
4 44 1
3 11
1 48 43 42
44
3 46
2 1
49 47
5

18 Hose joint 2
19 Grommet 1
20 Bracket 1
21 Holder 1
22 Flushing hose adapter screw 2 ø6 19 mm
23 Hose 1
24 Hose 1
25 Holder 1
26 Grommet 2
27 Grommet 2
28 Collar 2
29 Hook 1
30 Spring 1
31 Lever 1
32 Bushing 1
33 Bolt 1 M6 14 mm
34 Bushing 1
9-19
Bottom cowling
5 N·m (0.5 kgf·m, 3.7 ft·lb) 18 30 31

16
10
18
19
22
23 24 1 32 37 0
9 1 28
8 33 36 38
20 1 27 35
7 17 29
21
5 6
5
25
26 34
1
14 28 27
13 16
1
15 26 2
11 12 39
17
43
44
45
16
1
40
3
43 14 16
1
44
4
1
15
43
44 1
41 4
3
1
11
48 43 42
5
44
3 46
2 1
6
49 47
5

35 Wave washer 1
36 Washer 1
37
38
Hose
Cowling lock lever
1
1
8
39 Bottom cowling 1
40
41
Holder
Holder
1
1 9
42 Holder 1
43 Grommet 4
44
45
Collar
Water outlet
4
1
10
46 Holder 1
47 Rubber seal 1 39
48 PTT switch 1
49 Gasket 1 39
A
9-20
BRKT
Bracket unit
Disassembling the bottom cowling 5. Remove the flushing hose adapter i
1. Remove the plastic ties a, and then and hose joints j and k.
remove the trim sensor lead a, PTT
motor lead b, and speedometer hose b. 6. Remove the guide l, flushing hose m,
and grommet n.
a nl
b i
b j
k
m
a a a
2. Remove the holders c and d, and then

remove the PTT switch e. Assembling the bottom cowling
1. Route the flushing hose a through the
d e grommet b, and then fasten the grom-
met b using the plastic tie c.
c
b
c
a
3. Remove the spring f.
a
f
TIP:
Align the white paint mark a on the flushing
hose a with the outer end of the grommet b.
2. Install the guide d.
4. Remove the lever g and cowling lock

lever h.
h
3. Install the flushing hose adapter e, and
then tighten the flushing hose adapter
screws f to the specified torque.
9-21
Bottom cowling
4. Route the flushing hose through the hose
joint g, install it to the hose joint h, and
then fasten the flushing hose a using the
plastic tie i.
5. Install the hose joint to the adapter e

0
along with the gasket j. b
j
e 1
h f
g
i 9. Install a new gasket n and the PTT
a switch o along with the holders p and
q onto the bottom cowling.
2
NOTICE: Do not reuse a gasket,
p o
3
Flushing hose adapter screw f:
5 N·m (0.5 kgf·m, 3.7 ft·lb)
6. Install the cowling lock lever k and lever

n
4
l. q
l 5
10. Route the trim sensor lead c, PTT motor
k lead d, and speedometer hose r
through the grommet s, and then install
6
the grommet s and guide t to the bot-
tom cowling.
t
7
7. Install the spring m. s
m 8
d
r c 9
m
11. Align the gray tape e on the PTT motor
lead d with the outer end of the grommet 10
s and the end f of the clamp u. Install
8. Apply grease into the housing b until
the trim sensor lead c and PTT motor
grease comes out from the housing. lead d to the holder u.
A
9-22
BRKT
Bracket unit
f
c
s
u d s
e
x
12. Fasten the trim sensor lead c and PTT

motor lead d using the plastic tie v.
v d
13. Fasten the speedometer hose r and

holder u using the plastic tie w.
u w
TIP:
Fasten the speedometer hose r at the mid-
dle of the white tape g using the plastic tie
w.
14. Fasten the grommet s using the plastic

tie x.
9-23
Bottom cowling / Upper case and mount
Upper case and mount
12 13 16
13
0
24 N·m (2.4 kgf·m, 17.7 ft·lb) 14 15
3 9
11
1
7
10
2
6
8 2
4 5 6 7 8 9
5
4
10
3
1
6
8
11
4
10
9
7
18
4
5 2
5
17 3
19
19
17
6
18

1 Upper mounting nut 2
2 Cover 2
3
4
Bolt
Washer
4
2
M8 30 mm 8
5 Grommet 2
6
7
Lower mount
Washer
2
2 9
8 Rubber washer 2
9 Washer 2
10
11
Nut
Damper
2
2
10
12 Upper mount bolt 3 M8 30 mm
13 Bolt 2 M8 175 mm
14 Upper mount 1
15 Plate 1
16 Damper 1
17 Screw 1 M6 7 mm
A
9-24
BRKT
Bracket unit
12 13 16
13
24 N·m (2.4 kgf·m, 17.7 ft·lb) 14 15

11
3 9
7
10
8
6
2 4 5 6 7 8 9
5
4
10
1 8
6
11
10
9
7
5 2
4
18
17 3
19
19
17
18

18 Washer 2
19 Bolt 2 M12 170 mm
9-25
Upper case and mount
Removing the upper case 6. Remove the upper mounting nuts f, and
1. Drain the remaining engine oil. then remove the upper case assembly
a.
2. Remove the ground lead a.
0
a
f
1
a
a
2
3. Loosen the upper mount bolts b.
3
b
4
7. Remove the upper mount g.
5
4. Remove the lower mount covers c, and
then remove the lower mounts d. 6
g
7
d
c 8
5. Remove the damper e. 9
e
Installing the upper case
1. Install the plate a and upper mounting
10
bolts b to the upper mount c, and then
install the upper mount assembly.
2. Tighten the upper mount bolts d tempo-

rarily.
A
9-26
BRKT
Bracket unit
d k
b j
i
l
b
h
a g
f
c o
m
n
8. Tighten the upper mounting nuts e to

Upper mounting nut e:
24 N·m (2.4 kgf·m, 17.7 ft·lb)
9. Tighten the upper mount bolts d.
10. Install the damper p.

3. Install the upper mounting bolts to the
bracket assembly a. p
4. Install the upper mounting nuts e, and
then tighten the upper mounting nuts e
temporarily. d
e
11. Install the ground lead q.
a
q
q
5. Install the washers f, grommets g,
lower mounts h, washers i, rubber
washers j, and washers k to the upper
case assembly.
6. Install the lower mount nuts l, washers

m, and lower mount bolts n, and then
tighten the lower mount bolts n.
7. Install the lower mount covers o.
9-27
Upper case and mount / Upper case
Upper case
6 27 N·m (2.7 kgf·m, 19.9 ft·lb)
5
4
8
7
9 8
0
9
1
4
8
3 2
10
11
8 12 8 3
13
8 4
2
5
1
36 N·m (3.6 kgf·m, 26.6 ft·lb)
14
6

1 Circlip 1
2 Drive shaft bushing 1
3
4
Upper case
Dowel
1
2
8
5 Rubber seal 1
6
7
Hose joint
Hose
1
1 9
8 Upper case bolt 6 M10 45 mm
9 Dowel 2
10
11
Drain bolt
Gasket
1
1 39
10
12 Damper 1
13 Plastic tie 1
14 Rubber seal 1 39
A
9-28
BRKT
Bracket unit
Disassembling the upper case Stopper guide plate d: 90890-06501
1. Remove the drain bolt a. Bushing installer center bolt e:
90890-06601
Checking the drive shaft bushing

a 1. Check the bushing. Replace if cracked or
worn.
Assembling the upper case
Do not reuse a gasket or rubber seal,

2. Remove the oil pan assembly a. always replace it with a new one.
a
1. Install the drive shaft bushing a.
c b
Driver rod L3 b: 90890-06652

3. Remove the circlip b. 90890-06653
b 2. Install the circlip d.
4. Remove the drive shaft bushing c.
3. Install a new rubber seal e.
d
c
9-29
Upper case
0
1
4. Install a new rubber seal f to the upper
case assembly a. 2
5. Insert the tip of the water pipe g into the
rubber seal e, install the upper case
assembly a, and then tighten the upper
case bolts h to the specified torque.
3
h a h
4
h
h 5
e
h
g h
6
f
7
Upper case bolt h:
36 N·m (3.6 kgf·m, 26.6 ft·lb)
6. Install a new gasket i and the drain bolt 8

j, and then tighten the drain bolt j to
9
i
j
10
Drain bolt j:
27 N·m (2.7 kgf·m, 19.9 ft·lb)
A
9-30
BRKT
Bracket unit
Oil pan and exhaust manifold
1 2
9
5 8
3 7
6 8
4
13
24 10 10
11
21 19 10
21 4
23
14
18
21
17
21
10
21 10
19
21 15
20
12
22
10
16 11 N·m (1.1 kgf·m, 8.1 ft·lb)

a 12 N·m (1.2 kgf·m, 8.9 ft·lb)
b 12 N·m (1.2 kgf·m, 8.9 ft·lb) 21 N·m (2.1 kgf·m, 15.5 ft·lb) 15 11 N·m (1.1 kgf·m, 8.1 ft·lb)

1 Oil seal 1 39
2 Exhaust guide 1
3 Gasket 1 39
4 Dowel 2
5 Pipe 1
6 Pipe 1
7 Plate 1
8 Dowel 2
9 Gasket 1 39
10 Muffler bolt 6 M6 24 mm
11 Gasket 1 39
12 Muffler 1
13 Rubber seal 1
14 Water pipe 1
15 Exhaust manifold bolt 3 M6 60 mm
16 Rubber seal 1 39
17 Exhaust manifold 1
9-31
1 2
0
9
5 8
3 7 1
6 8
4
13 2
24 10 10
11
21
21 4
19 10
3
23
14
18
21
21
17 4
10
21 10
21
20
19
15
5
12
22
10
a 12 N·m (1.2 kgf·m, 8.9 ft·lb) 16 11 N·m (1.1 kgf·m, 8.1 ft·lb) 6
b 12 N·m (1.2 kgf·m, 8.9 ft·lb) 21 N·m (2.1 kgf·m, 15.5 ft·lb) 15 11 N·m (1.1 kgf·m, 8.1 ft·lb)

18 Gasket 1 39
19 Oil pan bolt 4 M8 30 mm
20
21
Oil pan
Cover bolt
1
6 M6 30 mm
8
22 Oil strainer 1
39
23
24
Gasket
Cover
1
1 9
10
A
9-32
BRKT
Bracket unit
Disassembling the oil pan and
exhaust manifold
1. Remove the water pipe a and rubber
seal b.
2. Remove the muffler c, gasket d, plate

e, and gasket f.
c
5. Remove the oil strainer k, gasket l,
cover m, and gasket n.
e
k
f
n
d l
3. Remove the rubber seal g, exhaust m

manifold h, and gasket i.
6. Remove the pipes o and p.
i
o
p
4. Remove the oil pan j.
9-33
7. Remove the oil seal q.
e
q d
0
1
3. Install a new gasket f, the cover g, a
Checking the oil pan and exhaust
manifold
new gasket h, and the oil strainer i. 2
i
1. Clean the removed parts.
2. Check the exhaust guide, exhaust mani- 3

fold, and muffler. Replace if corroded or f
cracked.
3. Check the oil pan. Replace if corroded or h 4

cracked.
Checking the oil strainer

1. Check the oil strainer. Clean if there is
g
5
dirt or residue.
Assembling the oil pan and exhaust

manifold
6
Do not reuse a gasket or oil seal, always 4. Tighten the cover bolts j to the specified 7
replace it with a new one. torque in 2 stages and in the order a, b,
and so on.
1. Install a new oil seal a.
e 8
a b
d j a
9
f
c c b
10
Cover bolt j:
Driver rod L3 b: 90890-06652 1st: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
Needle bearing attachment c: 2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
90890-06613
2. Install the pipes d and e. A

9-34
BRKT
Bracket unit
5. Install the dowels k and oil pan l, and 7. Install the dowels r, a new gasket s,
then tighten the oil pan bolts m tempo- the plate t, a new gasket u, and the
rarily. muffler v, and then tighten the muffler
m bolts w to the specified torque.
m
w
m v
w
w
t w
l
w
r
s
r
k
k Muffler bolt w:
11 N·m (1.1 kgf·m, 8.1 ft·lb)
8. Install the rubber seal x and water pipe

TIP: y.
When tightening the oil pan bolts m, tighten
the power unit mounting bolts at the same
time to the specified torque. See steps 3 and
4 in “Installing the power unit” (7-9).
y
6. Install a new gasket n, the exhaust man-
ifold o, and a new rubber seal p, and
then tighten the exhaust manifold bolts q
x
q o
q
Exhaust manifold bolt q:

11 N·m (1.1 kgf·m, 8.1 ft·lb)
9-35
Oil pan and exhaust manifold / Steering arm
Steering arm
8 9 37 N·m (3.7 kgf·m, 27.3 ft·lb)
7
20 N·m (2.0 kgf·m, 14.8 ft·lb)
6
8
0
6
1
2
6
3
5
1 4
2
4 10
5
3
2 11
1 6
12

1 Bushing 2
2 O-ring 2 39
3
4
Bushing
Washer
1
1
8
5 Steering arm 1
6
7
Steering arm stud bolt
Steering hook
2
1 9
8 Washer 2
9 Steering hook nut 2
10
11
Bushing
Steering yoke
1
1
10
12 Circlip 1
A
9-36
BRKT
Bracket unit
Removing the steering arm 2. Install the bushing g, a new O-ring h,
1. Remove the circlip a, and then strike the and the bushing i.
steering yoke b using a copper hammer
to remove the steering yoke b.
e
b
a a
f
2. Remove the steering hook c. a

b g
3. Remove the bushing d, O-ring e, and c
bushing f. h
d
i
4. Remove the steering arm g, washer h,
bushing i, O-ring j, and bushing k. 3. Install the steering yoke j so that the
steering arm e and the steering yoke j
c are facing in the same direction (a and
b are aligned).
b
h f
j i e e a
d
k
Installing the steering arm j
Do not reuse an O-ring, always replace it 4. Hold the steering arm e, and then strike
with a new one. the steering yoke j using a copper ham-
mer until the groove c for installing the
1. Install the washer a, the bushing b, a circlip is visible.
new O-ring c, and the bushing d onto
the steering arm e, and then install the 5. Install the circlip k.
steering arm to the swivel bracket f.
9-37
Steering arm
6. Install the steering arm stud bolts l, and
then tighten them to the specified torque.
7. Install the steering hook m, and then

tighten the steering hook nuts n to the
specified torque.
0
n
e l
m
1
l
2
3
j
4
k c
k
5
Steering arm stud bolt l:
20 N·m (2.0 kgf·m, 14.8 ft·lb)
Steering hook nuts n:
37 N·m (3.7 kgf·m, 27.3 ft·lb)
6
8. Inject grease into the grease nipple o
until it comes out from both the upper
and lower bushings d.
7
8
d
9
10
o
d
A
9-38
BRKT
Bracket unit
Clamp bracket and swivel bracket
2 3
1 4
5 6 23 N·m (2.3 kgf·m, 17.0 ft·lb)
4
4 N·m (0.4 kgf·m, 3.0 ft·lb)
15 7 8
27 14 26
15
10
14
9
11
3 N·m (0.3 kgf·m, 2.2 ft·lb) 1
14
21
22
4 21
20
19 25
20 13
20 22 20 24 11
21 21 23 10
18 12
17 16

1 Self-locking nut 2
2 Clamp bracket (STBD) 1
3 Tilt stop lever 1
4 Bushing 3
5 Swivel bracket 1
6 Tilt stop lever 1
7 Screw 2 M6 15 mm
8 Trim sensor 1
9 Through tube 1
10 Bolt 4 M6 25 mm
11 Clamp bracket anode 2
12 Clamp bracket (PORT) 1
13 Ground lead 1
14 Grease nipple 3
15 Bushing 2
16 Hook 1
17 Bolt 1 M6 10 mm
9-39
2 3
0
1 4
4
5 6 23 N·m (2.3 kgf·m, 17.0 ft·lb)
4 N·m (0.4 kgf·m, 3.0 ft·lb)

1
27 14
15
26
7 8 2
15
10
14
9
3
11
3 N·m (0.3 kgf·m, 2.2 ft·lb) 1
21
14 4
22
4 21
20 22 20
20
20
19 25
24
13
11
5
21 21 23 10
18
17 16
12
6

18 Spring 1
19 Bushing 1
20
21
Distance collar
Pin
2
2
8
22 Pin 1
23
24
Hose nipple
Plastic tie
1
1 9
25 Hose 1
26 Ground lead 1
27 Screw 1 M6 8 mm
10
A
9-40
BRKT
Bracket unit
Removing the clamp bracket
1. Remove the PTT unit. See “Removing
the PTT unit” (9-45). k m
m
2. Remove the speedometer hose a.
3. Remove the self-locking nuts b and

through tube c, and then remove the
clamp brackets d and e and bushings l
f.
8. Remove the tilt stop levers n and o, dis-
4. Remove the clamp bracket anodes g.
tance collar assembly a, and bushings
5. Remove the ground leads h and i. p and q.
p
f o
f p
b n
h p
a
i q
e
g
a Checking the clamp bracket anode
b 1. Check the anodes. Replace if eroded.
c g Clean if there is grease, oil, or scales.
NOTICE: Do not apply grease, oil, or
6. Remove the trim sensor j. paint to the anodes.
Installing the clamp bracket

j 1. Assemble the distance collar assembly.
7. Remove the spring k, hook l, and pins

m.
Distance a:
30.3–30.4 mm (1.19–1.20 in)
9-41
2. Install the bushings a and b, distance 5. Install the bushings i to the swivel
collar assembly b, and tilt stop levers c bracket j.
and d.
6. Install the through tube k, and then
a
tighten the self-locking nuts l to the
specified torque.
0
c
a 7. Install the clamp bracket anodes m.

d
8. Install the ground leads n and o and
1
grease nipples p, and then tighten the
grease nipples p to the specified torque.
a
i
2
j
b
b
p
i
3
p
3. Install the pins e, hook f, and spring
l
g. p
4
e e n
c o
5
e
m
g 6
k
l m
f
Self-locking nut l: 7
23 N·m (2.3 kgf·m, 17.0 ft·lb)
Grease nipple p:
Distance c: 3.0 mm (0.12 in)

3 N·m (0.3 kgf·m, 2.2 ft·lb)
8
9. Route the speedometer hose q.
4. Route the trim sensor lead d through the
clamp bracket (PORT), and then install q
the trim sensor h. 9
Front f
h c
10
d c
f d
q
e A
9-42
BRKT
Bracket unit
TIP: TIP:
• Overlap the white tape d on the speedom- • To decrease the resistance, turn the trim
eter hose q with the end e of the clamp sensor cam in direction a.
bracket (PORT). • To increase the resistance, turn the trim
• Make sure that the corrugated tube f on sensor cam in direction b.
the speedometer hose q is routed from the
tilt stop lever c toward the front of the out- 4. Fully tilt the swivel bracket down.
board motor.
5. Measure the trim sensor setting resis-
Adjusting the trim sensor tance. Check that the resistance is within
specification.
After tilting the swivel bracket up, make

sure to support it using the tilt stop lever.
Otherwise, the swivel bracket could sud- c d
denly lower. d
c
1. Fully tilt the swivel bracket up, and then
support it using the tilt stop lever a.
Digital circuit tester: 90890-03174

a
Trim sensor setting resistance:
Terminal c–Terminal d
9.0–11.0 Ω
6. Fully tilt the swivel bracket up, and then

support it using the tilt stop lever.
2. Loosen the trim sensor screws b.
7. Tighten the trim sensor screws b to the
3. Adjust the position of trim sensor, and specified torque. Check that the trim sen-
then tighten the trim sensor screws b sor resistance is within specification.
temporarily. Trim sensor screw b:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
b a
9-43
Clamp bracket and swivel bracket / PTT unit
PTT unit
2
0
1
3 1
4
14
3 2
5 7
3
13
6
4
6
12
8 5
5
9
11
10 6

1 Circlip 1
2 Shaft 1
3
4
Bushing
Collar
2
1
8
5 Bolt 2 M8 20 mm
6
7
Washer
PTT unit
2
1 9
8 Collar 1
9 Collar 1
10
11
Shaft
Bolt
1
2 M6 25 mm
10
12 PTT unit anode 1
13 Corrugated tube 1
14 Plastic tie 1
A
9-44
BRKT
Bracket unit
Removing the PTT unit
e
When removing the PTT unit with the

pend the outboard motor.
f
g
d
1. Fully tilt the swivel bracket up, and then f
h
l
m
a
j
h
k
i
Checking the PTT unit anode

2. Remove the plastic tie b, and then 1. Check the anode. Replace if eroded.
remove the corrugated tube c. Clean if there is grease, oil, or scales.
NOTICE: Do not apply grease, oil, or
paint to the anode.
Installing the PTT unit

1. Install the PTT unit anode a.
2. Install the bushings b and collar c.
c 3. Route the PTT motor lead a through the

b
hole b in the clamp bracket (PORT), and
then install the PTT unit d, upper mount
3. Remove the circlip d, upper mount shaft shaft e, and circlip f.
e, bushings f, and collar g.
4. Install the collars g and h and lower
4. Remove the bolts h, lower mount shaft mount shaft i.
i, collars j and k, and PTT unit l.
5. Remove the PTT unit anode m.
9-45
PTT unit
0
b
b c
f
b
1
d
a a
2
h
i
g 3
5. Install the corrugated tube j, and then
fasten it using the plastic tie k. 4
c
k
5
j
6
k
TIP:
7
Fasten the corrugated tube j along with the
trim sensor lead c using the plastic tie k.
8
9
10
A
9-46
BRKT
Bracket unit
PTT motor
13
2
13
1
6 12
11 14
6
10
5 15
9
4
8
7
16
3
7
17
1
18
21
20 19 4 N·m (0.4 kgf·m, 3.0 ft·lb)
7 N·m (0.7 kgf·m, 5.2 ft·lb)

1 PTT motor assembly bolt 3 M6 20 mm
2 PTT motor assembly 1
3 PTT motor base 1
4 Brush holder 1
5 Brush 1
6 Screw 2 M4 12 mm
7 Spring 2
8 Circuit breaker 1
9 Brush 1
10 Bushing 1
11 Washer 1
12 Lead 1
13 Screw 3 M5 20 mm
14 Stator 1
15 O-ring 1 39
16 Armature 1
17 Oil seal 1 39
9-47
PTT motor
13
2
13 0
1
6 12
6
11 14 1
10
5 15
4
9
2
8
7
16
3
7
3
4
17
1
5
18
21
20 19 4 N·m (0.4 kgf·m, 3.0 ft·lb)
6
7 N·m (0.7 kgf·m, 5.2 ft·lb)

18 O-ring 1 39
19 Joint 1
20
21
Reservoir cap
O-ring
1
1 39
8
9
10
A
9-48
BRKT
Bracket unit
Removing the PTT motor a
Before removing the reservoir, make sure

that the PTT rams are fully extended. Oth-
erwise, fluid could be expelled forcefully b
from the PTT unit due to internal pres-
sure.
1. Fully extend the tilt ram.

2. Remove the armature assembly c and
2. Remove the reservoir cap a, and then washer d.
drain the PTT fluid.
c
a
d
3. Remove the brushes e and f, lead g,

3. Remove the PTT motor assembly b, O- brush holder h, circuit breaker i, and
ring c, and joint d. springs j.
4. Remove the oil seal k and bushing l.

b
l g
h
c j i
d
j
Disassembling the PTT motor

1. Remove the stator a and O-ring b.
Checking the armature (PTT motor)

1. Check the commutator. Clean using 600–
grit sandpaper and compressed air if
dirty.
9-49
PTT motor
c
d f 0
e
1
2. Measure the commutator diameter a. Digital circuit tester: 90890-03174
Replace the armature if below specifica-
tion. Armature continuity:
2
c d e f
C C
Checking the brush

3
1. Measure the length of each brush.
Replace if below specification.
4
a
Motor commutator standard diameter a:

5
22.0 mm (0.87 in) b
a
Wear limit: 21.0 mm (0.83 in)
3. Measure the commutator undercut b.

6
Brush standard length a:
b 10.0 mm (0.39 in) 7
Wear limit b: 3.5 mm (0.14 in)
2. Check the circuit breaker for continuity.

Replace if there is no continuity. 8
Motor commutator standard undercut b

9
(reference data):
1.5 mm (0.06 in)
Wear limit: 1.0 mm (0.04 in) 10
4. Check the armature for continuity.
A
9-50
BRKT
Bracket unit
Assembling the PTT motor
l
k
• Do not reuse an oil seal or O-ring,
• Do not apply grease or oil to the commu- j
tator of the armature.
1. Install a new oil seal a.
a 4. Install a new O-ring m and the stator n.

n
b
c
Driver rod L3 b: 90890-06652

90890-06616 Installing the PTT motor
2. Install the bushing d, washer e, springs

f, circuit breaker g, brush holder h, Do not reuse an O-ring, always replace it
lead i, and brushes j and k. with a new one.
1. Install the joint a, a new O-ring b, and

i the PTT motor assembly c, and then
e
tighten the PTT motor assembly bolts d
d to the specified torque.
k
d
j c
d
f g
h
f
b
3. Push the brushes j and k into the

brush holder, and then install the arma- PTT motor assembly bolt d:
ture l. 4 N·m (0.4 kgf·m, 3.0 ft·lb)
9-51
PTT motor
2. Install a new O-ring e and the reservoir
cap f, and then tighten the reservoir cap
f to the specified torque.
0
e
f
1
2
Reservoir cap f:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
3
4
5
6
7
8
9
10
A
9-52
BRKT
Bracket unit
PTT gear pump
5 N·m (0.5 kgf·m, 3.7 ft·lb)

7 N·m (0.7 kgf·m, 5.2 ft·lb)
9
8
7
6 33
5 5
10
4 12 12 11
4 5 N·m (0.5 kgf·m, 3.7 ft·lb)
13 13
3 3 14 29
2 2 28 29
1 1 27 15
30
15 31
26 16
32
18
26 17
18
34
37 19 19
36 25
35 25
24 24 20
23 23
22 22
2 N·m (0.2 kgf·m, 1.5 ft·lb) 21 21

1 Filter 2
2 Spacer 2
3 O-ring 2 39
4 Pump bracket bolt 2 M5 20 mm
5 Washer 2
6 Bracket 1
7 Valve seal 1 39
8 Valve pin 1
9 Spring 1
10 Plate valve 1
11 Stopper 1
12 E-clip 2
13 Main valve seal 2
14 Up-main valve 1
15 Spring 2
16 Relief valve seat 1
17 O-ring 1 39
9-53
PTT gear pump
5 N·m (0.5 kgf·m, 3.7 ft·lb)

9 7 N·m (0.7 kgf·m, 5.2 ft·lb)
0
8
7
6 33 1
5 5
10
4
4 12
13
12
13
11
5 N·m (0.5 kgf·m, 3.7 ft·lb)
2
3 3 14 29
2 2 28 29
1 1 27 15
30 3
15 31
26 16
32
18
26 17 4
18
37 19 19
34 5
36 25
35 25
24 24 20
23
22
23
22
6
2 N·m (0.2 kgf·m, 1.5 ft·lb) 21 21

18 Pin 2
19 Ball 2
20
21
Manual release plate
O-ring
1
2 39
8
22 Spacer 2
23
24
Spring
Valve pin
2
2 9
25 Ball 2
26 Ball 2
27
28
O-ring
Down-main valve
1
1
39
10
29 Valve bracket bolt 2 M5 8 mm
30 Relief valve bracket 1
31 Filter 1
32 Backup ring 1
33 Gear pump bolt 3 M6 40 mm
34 Gear pump assembly 1
A
9-54
BRKT
Bracket unit
5 N·m (0.5 kgf·m, 3.7 ft·lb)

7 N·m (0.7 kgf·m, 5.2 ft·lb)
9
8
7
6 33
5 5
10
4 12 12 11
4 5 N·m (0.5 kgf·m, 3.7 ft·lb)
13 13
3 3 14 29
2 2 28 29
1 1 27 15
30
15 31
26 16
32
18
26 17
18
34
37 19 19
36 25
35 25
24 24 20
23 23
22 22
2 N·m (0.2 kgf·m, 1.5 ft·lb) 21 21

35 Circlip 1
36 Manual valve 1
37 O-ring 1 39
9-55
PTT gear pump
Disassembling the gear pump
assembly k
l
j
Do not remove the valve lock screw of the

k
m
n
0
up-relief valve.
l
1. Remove the manual valve a, and then

remove the gear pump assembly b.
m
n
1
o
2. Remove the filters c.
o
2
c
c 5. Remove the gear housing a, and then
remove the springs p, down-main valve 3
q, and up-main valve r.
b
6. Remove the drive gear b, driven gear
c, balls s, and pins t. 4
a
5
a
c b p
t s q
3. Remove the relief valve bracket d, and
then remove the spring e, valve pin f, s
6
valve seal g, filter h, and backup ring
i. p t
e
r 7
f
d
g
7. Remove the valve seat u.
8
h
i u
9
4. Remove the bracket j, and then remove
the spacers k, springs l, valve pins m,
and balls n and o.
10
Checking the gear pump

1. Check the drive gear a and driven gear
b. Replace the gear pump assembly if
damaged or worn. A
9-56
BRKT
Bracket unit
2. Check the down-relief valve c. Clean if
there is dirt or residue. b
a
3. Check the absorber valves d. Clean if
there is dirt or residue.
4. Check the main valves e and f. Clean if

there is dirt or residue.
a c
2. Install a new O-ring c to the down-main
b valve d.
3. Install the drive gear a, driven gear b,

down-main valve d, up-main valve e,
springs f, pins g, and plate valve h.
4. Install the stopper i to the specified

installation depth c.
e 5. Install the balls j and gear housing d.

f
d d
d
i
f c
b a
g d
Checking the filter j
1. Check the filters. Clean if there is dirt or c h
j
residue.
g
Assembling the gear pump housing f
Lubricate the parts using ATF DEXRON II i
e h
during assembly.
• When assembling the PTT unit, do not Installation depth c: 2.0 mm (0.078 in)
use a rag. Otherwise, dust and particles
6. Install the balls k, the valve pins l, the
could get on the PTT unit components,
springs m, the spacers n, a new O-ring
causing poor performance.
o.
• Do not reuse an O-ring, always replace it
with a new one. 7. Install the balls p and the manual
release plate q.
1. Install a new O-ring a and the relief
valve seat b. 8. Install the bracket r, and then tighten
the pump bracket bolts s temporarily.
9. Check that the gear pump turns

smoothly. Tighten the pump bracket bolts
s to the specified torque.
9-57
PTT gear pump
o
s s C E
n C
B
r m B
o A A
l 0
n k D
m
k
l 1
p F
q
p G H 2
Pump bracket bolt s: Gear pump bolt E:
5 N·m (0.5 kgf·m, 3.7 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 3
Manual valve G:
10. Install a new valve seal t, the valve pin 2 N·m (0.2 kgf·m, 1.5 ft·lb)
u, the spring v, the backup ring w, and
the filter x. 4
11. Install the relief valve bracket y, and
then tighten the valve bracket bolts z to
z
v
u
z
6
t y
x
w
7
Valve bracket bolt x: 8
5 N·m (0.5 kgf·m, 3.7 ft·lb)
12. Install the filters A, the spacers B, new

O-rings C, and the gear pump assembly 9
D, and then tighten the gear pump bolts
E to the specified torque.
13. Install a new O-ring F, the manual valve 10

G, and the circlip H, and then tighten the
manual valve G to the specified torque.
A
9-58
BRKT
Bracket unit
PTT cylinder
150 N·m (15.0 kgf·m, 110.6 ft·lb)
4
13
5 15
12 16
3
14
2
11
17
1 3 18
10
19
20
9
9
21
9 22
9
8
23
61 N·m (6.1 kgf·m, 66.4 ft·lb)
7
110 N·m (11.0 kgf·m, 81.1 ft·lb)
6
24

1 Circlip 1
2 Plate 1
3 Spring 2
4 Circlip 1
5 Cylinder base 1
6 Trim cylinder 1
7 Free piston 1
8 O-ring 1 39
9 Ball 6
10 Tilt cylinder 1
11 O-ring 1 39
12 Trim piston 1
13 O-ring 1 39
14 Backup ring 1
15 O-ring 1 39
16 Dust seal 1 39
17 Trim cylinder screw 1
9-59
PTT cylinder
150 N·m (15.0 kgf·m, 110.6 ft·lb)
4
13
0
5 15
3
12
14
16 1
2
11
17 2
1 3 18
10
19
20
3
9
9
4
21
9 22
9
8
23
5
61 N·m (6.1 kgf·m, 66.4 ft·lb)
7
6
110 N·m (11.0 kgf·m, 81.1 ft·lb) 6
24

18 Backup ring 1
19 O-ring 1 39
20
21
O-ring
Backup ring
1
1
39 8
22 O-ring 1 39
39
23
24
O-ring
Tilt piston assembly
1
1 9
10
A
9-60
BRKT
Bracket unit
Disassembling the trim cylinder
1. Loosen the trim cylinder end screw a.
b 3. Remove the circlip c, plate d, springs

e, and trim cylinder base f.
Cylinder-end screw wrench b:
90890-06588 c
e
2. Remove the trim cylinder c and balls d. d
c
f
d
d 4. Remove the circlip g, and then remove
d
d the free piston h.
d d
g
3. Drain the PTT fluid.
Disassembling the tilt cylinder

h
1. Loosen the tilt cylinder end screw a.
NOTICE: When loosening the end
screw, be careful not to damage the
check valve.
a Disassembling the PTT ram

assembly
a
1. Remove the washer a, plates b, pins
c, and absorber valves d.
d a
d c
c
Cylinder-end screw wrench a: d

90890-06568 b
2. Remove the tilt piston assembly b.
2. Remove the tilt piston e and ball f.
9-61
PTT cylinder
Checking the PTT cylinder and
piston
1. Check the trim cylinder and tilt cylinder.
f
Replace if scratched.
0
2. Check the outer surface of the tilt piston
e and free piston. Replace the PTT ram
assembly or free piston if scratched.
1
3. Check the PTT ram. Clean using
3. Remove the tilt cylinder end screw g 400–600 grit sandpaper if there is rust, or
and trim cylinder end screw a. replace the PTT ram assembly if bent or
corroded.
2
4. Check the check valve of the trim cylinder
a end screw. Clean if there is dirt or resi-
due.
3
5. Check the absorber valves. Clean if there
g
is dirt or residue. 4
Assembling the PTT ram assembly
4. Remove the O-rings b and c, backup

ring d, and dust seal e.
5
• When assembling the PTT unit, do not
e use a rag. Otherwise, dust and particles
d
6
• Do not reuse a dust seal or O-ring,
c always replace it with a new one.
b
1. Install a new dust seal a, the backup

7
ring b, and new O-rings c and d to the
trim cylinder end screw e.
5. Remove the O-rings f and g and a
8
backup ring h.
e
b
a e d
9
c
h
g d c b
10
f
2. Install the backup ring f and new O-
rings g and h to the tilt cylinder end
screw a.
A
9-62
BRKT
Bracket unit
a Tilt piston bolt k:

61 N·m (6.1 kgf·m, 45.0 ft·lb)
f Assembling the tilt cylinder

f
g
g h • When assembling the PTT unit, do not
h use a rag. Otherwise, dust and particles
a
3. Install the trim cylinder end screw e and • Do not reuse an O-ring, always replace it
tilt cylinder end screw a to the PTT ram with a new one.
b.
1. Install new O-rings a and b to the trim
piston c, and then install the trim piston
e c to the tilt cylinder d.
b
b a
a
4. Install the ball c and PTT ram b to the d

tilt piston d.
a
b
c
c
2. Install a new O-ring e and the backup
d
ring f to the tilt piston a.
b
3. Slide the tilt cylinder end screw b to the
bottom of the PTT ram c.
5. Install the absorber valves e, pins f,
plates g, and washer h, and then a fe
tighten the tilt piston bolt k to the speci- b
fied torque.
k f
e
e f
f
h
c
e e a
g
4. Install the tilt piston assembly g into the
tilt cylinder.
9-63
PTT cylinder
o
m
n
g
m
0
l
1
5. Tighten the tilt cylinder end screw b to Assembling the trim cylinder
b h
When assembling the PTT unit, do not use
a rag. Otherwise, dust and particles could
get on the PTT unit components, causing 3
poor performance.
1. Slide the trim cylinder end screw a to

the bottom of the PTT ram a.
4
Cylinder-end screw wrench h:
90890-06568
5
Tilt cylinder end screw b:
110 N·m (11.0 kgf·m, 81.1 ft·lb)
a
6
6. Install a new O-ring i to the free piston
j. a
7. Install the free piston j, and then install 2. Fill the trim cylinder with the recom-
7
the circlip k. mended PTT fluid to about 30% of the
cylinder capacity.
k 8
j 9
i
10
8. Install the trim cylinder base l, springs
m, and plate n, and then install the cir-
clip o.
A
9-64
BRKT
Bracket unit
Bleeding the PTT unit
1. Check that the PTT ram is fully extended.
2. Place the PTT unit in an upright position.
3. Turn the manual valve a clockwise to

close it.
4. Remove the reservoir cap b, and then

3. Install the balls b into the tilt cylinder c, check the fluid level.
and then install the tilt cylinder c into the
trim cylinder d.
c
d b b
b
b b
b b
TIP:
• If the fluid is at the proper level, a small
4. Tighten the trim cylinder end screw e. amount of fluid should flow out of the filler
hole.
• If fluid is below the proper level, add the
recommended PTT fluid.
5. Install the reservoir cap, and then tighten

it to the specified torque.
f
Reservoir cap:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
e
6. Connect the PTT motor leads to the bat-
Cylinder-end screw wrench f: tery terminals to fully retract the PTT
90890-06588 ram.
Trim cylinder end screw e:

150 N·m (15.0 kgf·m, 110.6 ft·lb)
9-65
PTT cylinder
9. Remove the reservoir cap, and then
check the fluid level. WARNING! Before
removing the reservoir cap, make sure
that the PTT ram is fully extended.
Otherwise, fluid could be expelled
forcefully from the PTT unit due to
0
G internal pressure.
10. Install the reservoir cap, and then tighten 1

L the reservoir cap to the specified torque.
Reservoir cap:
7 N·m (0.7 kgf·m, 5.2 ft·lb) 2
Battery
Ram PTT motor lead
terminal 3
Green (G)
Down
Blue (L)
7. Reverse the PTT motor lead connections 4

between the battery terminals to fully
extend the PTT ram.
5
6
L
7
G
8
Battery
Ram PTT motor lead
Blue (L)
terminal

9
Up
Green (G)
TIP:
10
• Repeat steps 6 and 7 to fully extend and
retract the PTT ram 4 or 5 times.
• If the PTT ram does not move up and down
easily, push and pull on the ram to assist
operation.
8. Fully extend the PTT ram. A

9-66
MNT
Maintenance 10
Outline .............................................................................. 10-1

Maintenance interval chart 1 ................................................... 10-1
Maintenance interval chart 2 ................................................... 10-2
Predelivery check ............................................................ 10-3

Checking the battery ............................................................... 10-3
Checking the cooling water pilot hole ...................................... 10-3
Checking the engine oil level ................................................... 10-4
Checking the engine start switch and engine
shut-off switch ......................................................................... 10-4
Checking the fuel system ........................................................ 10-5
Checking the gear oil level ...................................................... 10-5
Checking the gear shift and throttle operation
(remote control) ....................................................................... 10-5
(tiller handle) ............................................................................ 10-5
Checking the outboard motor mounting height ....................... 10-5
Checking the PTT system ....................................................... 10-6
Checking the steering system ................................................. 10-6
Checking the throttle cable and shift cable
(remote control) ....................................................................... 10-6
(tiller handle) ............................................................................ 10-6
Test run ................................................................................... 10-7
Break-in ................................................................................... 10-7
After test run ............................................................................ 10-7
General periodic maintenance ....................................... 10-7

Checking the anode ................................................................ 10-7
Checking the battery ............................................................... 10-8
Checking the cooling water passage ....................................... 10-8
Checking the engine idle speed .............................................. 10-8
Changing the engine oil ........................................................... 10-8
Checking the engine oil level ................................................... 10-9
Replacing the oil filter .............................................................. 10-9
shut-off switch ....................................................................... 10-10
Checking the fuel filter ........................................................... 10-10
Checking the fuel joint and fuel hoses ................................... 10-10
Changing the gear oil ............................................................ 10-10
Checking the gear oil level .................................................... 10-11
Lubricating the outboard motor ............................................. 10-11
Checking the propeller .......................................................... 10-12
Checking the PTT fluid level .................................................. 10-12
Checking the PTT operation .................................................. 10-13
Adjusting the shift cable ........................................................ 10-13
Checking the spark plug ........................................................ 10-13
Checking the timing belt ........................................................ 10-13
Replacing the timing belt ....................................................... 10-13
Checking the thermostat ....................................................... 10-13
Adjusting the throttle link rod and throttle cable .................... 10-13
Checking the top cowling ...................................................... 10-13
Checking the valve clearance ............................................... 10-14
Checking the water pump ...................................................... 10-14 0
1
2
3
4
6
6
7
8
9
10
A
MNT
Maintenance
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 qual-
ity. 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” operat-
ing 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 operation for extended periods of time, carrying heavy loads, and frequent start-
ing and stopping or shifting. 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

Initial Every See
Item Actions 20 hours 100 hours 300 hours 500 hours
page
(3 months) (1 year) (3 years) (5 years)
Anodes (external) Check/Replace 8-3
U 9-41
9-45
Anodes (cylinder head) Check/Replace U 7-47
Anodes Replace 7-53
U
(exhaust cover)
Battery Check/Charge/Replace 10-3
U U
(electrolyte level, terminal)
Cooling water leakage Check/Replace U U 10-8
Cowling clamp Check U 10-13
Engine starting condition/ Check 10-4
U U
Noise
Engine idle speed/Noise Check U U 10-8
Engine oil Replace U U 10-8
Engine oil filter Replace U 10-9
Engine start switch/ Check/Replace 10-4
U U
Fuel filter Check/Replace 6-10
U U
(can be disassembled)
10-1
Outline
Initial Every See

Item Actions 20 hours 100 hours 300 hours 500 hours
page
(3 months) (1 year) (3 years) (5 years)
Fuel strainer Replace 6-16
(disposal type)
U
0
Fuel hose (high pressure) Check/Replace U U 6-1
Fuel hose (low pressure) Check/Replace U U 6-1
Fuel pump
Fuel/Oil leakage
Check/Replace
Check U U
U 6-15
6-1
1
Gear oil Replace U U 10-10
Greasing points
Impeller/Water pump
Lubricate
Check/Replace
U U
U
10-11
8-10 2
housing
Impeller/Water pump Replace 8-7
U
housing
Pilot water Check U U 10-3
3
Propeller/Propeller nut/ Check/Replace 8-3
U U
Cotter pin
PTT unit Check/Replace U U 10-13 4
Shift link/Shift cable Check/Adjust/Replace 3-9
U U
10-5
Spark plugs Check/Replace
Throttle link/Throttle cable Check/Adjust/Replace
U 7-47
3-9
5
U U 6-32
Thermostat Check/Replace U
10-5
7-53 6
Timing belt Check/Replace U 7-17
Valve clearance Check/Adjust 7-2
Water inlet Check U U

U
7-4
10-8
7
Wiring harness Check/Replace
connections/Wiring
coupler connections
U U —
8
Yamaha meter/Gauge Check U U —
— :Not applicable
9
TIP:
When using lead high-sulfur gasoline, checking the valve clearance may be required more fre-
quently than every 500 hours.
10
Maintenance interval chart 2
Every See
Item Actions
1000 hours page
Exhaust guide/Exhaust Check/Replace 9-34
U
manifold
Timing belt Replace U 7-13 A
10-2
MNT
Maintenance
Predelivery check
To make the delivery process smooth and
efficient, complete the predelivery checks as
a
explained in the following procedures.
Checking the battery
Battery electrolyte is dangerous; it con-

tains sulfuric acid, which is poisonous
and highly caustic. Always follow these 2. Check the specific gravity of the
preventive measures: electrolyte. Fully charge the battery if
• Avoid bodily contact with electrolyte as below specification.
it can cause severe burns or permanent Representative examples:
eye injury. Recommended battery capacity:
• Wear protective eye gear when handling CCA/EN: 430.0 Amps
or working near batteries. 20HR/IEC: 70.0 Ah
Antidote (EXTERNAL): Electrolyte specific gravity:
• SKIN - Wash with water. 1.280 at 20 °C (68 °F)
• EYES - Flush with water for 15 minutes
and get immediate medical attention.
TIP:
Antidote (INTERNAL):
• Batteries vary depending on the manufac-
• Drink large quantities of water or milk
turer. The procedures mentioned in this
followed with milk of magnesia, beaten
manual may not always apply. Therefore,
egg, or vegetable oil. Get immediate
see the instruction manual of the battery.
medical attention.
• Disconnect the negative battery cable first,
Batteries generate explosive, hydrogen
and then disconnect the positive battery
gas. Always follow these preventive mea-
cable.
sures:
• Charge batteries in a well-ventilated
area. Checking the cooling water pilot hole
• Keep batteries away from fire, sparks, or 1. Start the engine, and then check that
open flames (for example, welding cooling water is discharged from the
equipment and lighted cigarettes). cooling water pilot hole.
• DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
1. Check the battery electrolyte level. If the

level is at or below the minimum level
mark a, add distilled water until the level
is between the maximum and minimum
level marks.
10-3
Predelivery check
Checking the engine oil level A ON
1. Place the outboard motor in an upright OFF START
position. NOTICE: If the outboard
motor is not level, the oil level indi-
cated on the dipstick may not be cor- 0
rect.
2. Start the engine and warm it up for 5–10

minutes. 1
3. Stop the engine and leave it off for 5–10
B ON
minutes. OFF START
2
4. Remove the top cowling.
5. Remove the dipstick a and wipe it clean.

3
6. Insert the dipstick a completely for a
correct measurement and remove it
again.
A 703 remote control
4
7. Check that the oil level indicated on the B Tiller handle (optional)
dipstick is between the upper mark a
and the lower mark b. If the engine oil is
not at the proper level, add or extract
3. Check that the engine stops when the
clip is removed from the engine shut-off
5
engine oil. switch, or when the engine shut-off
switch is pushed.
a
A 6
a
7
b
8
Checking the engine start switch and
engine shut-off switch B
1. Check that the engine starts when the 9
engine start switch is turned to START.
2. Check that the engine stops when the

engine start switch is turned to OFF. 10
A 703 remote control

B Tiller handle (optional)
A
10-4
MNT
Maintenance
Checking the fuel system 2. Check that the throttle operates smoothly
1. Check that the fuel hoses are connected when the remote control lever is moved
securely. To check the fuel hose connec- from the F or R position to the fully open
tions, see “Fuel hose” (6-1). position.
NOTICE: This outboard motor is
equipped with a 4-stroke engine. Checking the gear shift and throttle
Never use premixed fuel or 2-stroke operation (tiller handle)
outboard motor oil.
Checking the gear oil level Do not overtighten the friction adjuster. If
1. Place the outboard motor in an upright there is too much resistance, it could be
position. difficult to operate the throttle grip, which
could result in an accident.
2. Remove the check screw a, and then
check the gear oil level.
1. Check that the gear shift operates
smoothly when the shift lever is moved
from the N position to the F or R position.
TIP:
b a The shift lever can be operated only when the
throttle grip is in the fully closed position.
2. Check that the throttle operates smoothly

when the throttle grip is moved from the
fully closed position to the fully open
TIP: position.
If the oil is at the proper level, a small amount
of oil should flow out of the check hole. Checking the outboard motor
mounting height
3. Install a new gasket b and the check 1. Check that the anti-cavitation plate a is
screw a, and then tighten the check aligned with the bottom of the boat b. If
screw a to the specified torque. the mounting height is too high, cavita-
Check screw a: tion will occur and propulsion will
9 N·m (0.9 kgf·m, 6.6 ft·lb) decrease. Besides, the engine speed will
increase abnormally and cause the
Checking the gear shift and throttle engine to overheat. If the mounting
operation (remote control) height is too low, water resistance will
increase, which will decrease engine effi-
ciency and performance.
Do not overtighten the friction adjuster. If
there is too much resistance, it could be
difficult to operate the remote control
lever, which could result in an accident.
a
1. Check that the gear shift operates
smoothly when the remote control lever
is moved from the N position to the F or R b
position.
10-5
Predelivery check
TIP: b
b b
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-
0
ferent heights.
2. Check that the clamp brackets are a a a 1

secured using the clamp bolts.
3. Check that the pin c is aligned with the
Checking the PTT system
1. Check that the outboard motor tilts up
mark d on the shift bracket b. 2
and down smoothly when the PTT switch
c
is pushed.
2. Check that there is no abnormal noise

b 3
produced when the outboard motor is
tilted up or down.
3. Check that there is no interference with

d 4
cables, hoses, or leads when the tilted-up
outboard motor is steered.
4. Check that the trim meter points down

Checking the throttle cable and shift
cable (tiller handle)
5
when the outboard motor is fully tilted 1. Move the shift lever to the N position and
down. turn the throttle grip to the fully closed
position. 6
Checking the steering system
1. Check the steering friction for proper 2. Check that the protrusion a on the
adjustment. See steps 14 and 15 in
“Installing the tiller handle” (3-15).
throttle control lever a is aligned with the
protrusion b on the shift bracket b. 7
2. Check that the steering operates b
b b
smoothly.
8
3. Check that there is no interference with
cables, hoses, or lead when the outboard
motor is steered. 9
Checking the throttle cable and shift a a a
cable (remote control)
1. Move the remote control lever to the N
position and turn the throttle lever to the
3. Check that the pin c is aligned with the 10
mark d on the shift bracket b.
fully closed position.
2. Check that the protrusion a on the

throttle control lever a is aligned with the
protrusion b on the shift bracket b.
A
10-6
MNT
Maintenance
3. For the remaining 8 hours c of
c operation:
Operate the engine at any engine speed.
b However, do not operate the engine at
full throttle for more than 5 minutes at a
time.
d 4. After the first 10 hours of operation:

Operate the engine normally.
Test run
1. Start the engine, and then check that the
gear shift operates smoothly. a b c
2. Warm up the engine, and then check the

A 0 1 2 10
engine idle speed.
3. Operate the boat at trolling speed.
4. Operate the outboard motor according to A Hour

the break-in procedure.
After test run
5. Check that the outboard motor does not 1. Check for water in the gear oil.
tilt up when the remote control lever is
moved to the R position and that water 2. Check for fuel leakage in the cowling.
does not flow in over the transom.
3. Flush the cooling water passages using
6. Check that the PTT operates smoothly fresh water. NOTICE: When flushing
while the outboard motor is running. the cooling water passages, do not
start the engine. Otherwise, the water
pump could be damaged and the
TIP:
engine could be severely damaged
The test run is part of the break-in operation.
due to overheating.
Break-in
TIP:
Operate the engine under load (in gear with a When using the flushing device (flushing
propeller installed) for 10 hours as follows: hose joint adapter), flush the cooling water
passages without starting the engine.
1. For the first hour of operation a:
Operate the engine at varying speeds up
to 2000 r/min or approximately 1/2 throt- General periodic maintenance
tle. Checking the anode
2. For the second hour b of operation:

Increase the engine speed until the boat Do not apply grease, oil, or paint to the
is on plane (but do not fully open the anodes or the trim tab.
throttle), and then back off on the throttle
while keeping the boat at a planing
speed.
10-7
Predelivery check / General periodic maintenance
1. Check the anodes and trim tab. See
“Checking the cylinder head anode” (7- TIP:
47), “Checking the exhaust cover anode” After installing the water inlet covers, make
(7-53), “Checking the lower unit anode” sure that there is no rattling.
(8-3), “Checking the clamp bracket
anode” (9-41), and “Checking the PTT 5. Place the lower unit in water, and then
0
unit anode” (9-45). start the engine.
TIP: 6. Check that cooling water is discharged 1

Replace the anodes or trim tab if eroded. from the cooling water pilot hole. If there
Also, check the ground lead. is no water flow, check the cooling water
Checking the battery

passages inside the outboard motor.
2
1. Check the battery. See “Checking the
battery” (10-3).
3
Checking the cooling water passage
1. Remove the water inlet covers a.
2. Mark the trim tab b with an identification

4
mark a, and then remove it.
3. Check the water inlet covers a and

water inlets. Clean if clogged.
Checking the engine idle speed
5
minutes.
a
2. Check the engine idle speed using the
Yamaha genuine tachometer (on-board
6
meter) or the YDIS. To connect and
operate the YDIS, see the YDIS (Ver.
1.33 or later) instruction manual. 7
a Changing the engine oil
c
The engine oil should be extracted using an
oil changer. 8
b Change the engine oil after the first 20
hours of operation or 3 months, and every
9
a
100 hours or at 1-year intervals thereafter.
1. Place the outboard motor in an upright 10

position. NOTICE: If the outboard
motor is not level, the oil level indi-
4. Install the water inlet covers a and trim cated on the dipstick may not be cor-
tab b, and then tighten the water inlet rect.
cover screw c to the specified torque.
Water inlet cover screw c:
1 N·m (0.1 kgf·m, 0.7 ft·lb)
minutes.
A
10-8
MNT
Maintenance
3. Stop the engine and leave it off for 5–10 6. Leave the outboard motor off for 5–10
minutes. minutes.
4. Remove the oil filler cap a. Remove the 7. Remove the dipstick b and wipe it clean.
dipstick b and extract the engine oil
using the oil changer c. 8. Insert the dipstick b completely for a
correct measurement and remove it
again.
9. Check that the oil level indicated on the

dipstick b is between the upper mark a
and the lower mark b.
a
b
b
b
10. Start the engine and check that the oil

pressure alert indicator does not come
on. Also, check that there is no oil
c leakage. NOTICE: If the oil pressure
alert indicator comes on or if there is
oil leakage, stop the engine and find
the cause. Continued operation with a
problem could cause severe engine
5. Fill the engine with the specified amount damage.
of the recommended engine oil through
the oil filler hole. Install the oil filler cap a Checking the engine oil level
and dipstick b. NOTICE: Do not 1. Check the engine oil level. See “Check-
overfill the engine with engine oil. ing the engine oil level” (10-4).
Otherwise, the engine could be
damaged or oil could leak. If the Replacing the oil filter
engine oil is above the upper level, 1. Extract the engine oil using an oil
extract the excess engine oil until the changer. See steps 1–4 in “Changing the
oil is at the proper level. engine oil” (10-8).
Recommended engine oil: 2. Place a rag under the oil filter, and then
4-stroke motor oil with combination of the remove the oil filter.
following SAE and API oil classifications:
API: SE, SF, SG, SH, SJ, SL
SAE: 5W-30, 10W-30, 10W-40
Replacement engine oil quantity:
Without oil filter replacement:
1.9 L (2.01 US qt, 1.67 lmp qt)
10-9
General periodic maintenance
7. Check the oil level. If the oil level is low,
add engine oil up to the proper level.
Checking the engine start switch and

engine shut-off switch 0
1. Check the engine start switch and engine
shut-off switch. See “Checking the
a engine start switch and engine shut-off
switch” (10-4). 1
Oil filter wrench a: 90890-01426 Checking the fuel filter
TIP:
1. Check the fuel filter. See “Checking the
fuel filter assembly” (6-10), “Checking the
2
Make sure to clean up any oil spills. fuel filter element” (6-10), and “Checking
the fuel cup assembly” (6-11).
3. Install a new oil filter b, and then tighten Checking the fuel joint and fuel
3
it to the specified torque.
hoses
1. Check the fuel joint and fuel hose con-
nections. See “Fuel hose” (6-1). 4
Changing the gear oil
5
Never get under the lower unit while it is
a tilted.
b
6
Oil filter b:
18 N·m (1.8 kgf·m, 13.3 ft·lb) Do not reuse a gasket, always replace it
4. Fill the engine with the specified amount

with a new one. 7
of the recommended engine oil through 1. Tilt the outboard motor so that the drain
the oil filler hole.
Recommended engine oil:
screw is at the lowest point.
8
4-stroke motor oil with combination of the 2. Place a drain pan a under the gear oil
following SAE and API oil classifications: drain hole.
API: SE, SF, SG, SH, SJ, SL
SAE: 5W-30, 10W-30, 10W-40 3. Remove the drain screw b and gasket 9
Replacement engine oil quantity: c. NOTICE: If there is a significant
With oil filter replacement: amount of metal particles on the
2.1 L (2.22 US qt, 1.85 lmp qt) magnetic drain screw, the lower unit
may have a problem.
10
5. Install the oil filler cap and dipstick, and
then start the engine and warm it up for 4. Remove the check screw d and gasket
5–10 minutes. e and let the oil drain completely.
NOTICE: After the gear oil has been
6. Stop the engine, and then leave it off for drained, check the used oil. If the oil is
5–10 minutes. milky, water is getting into the lower
case, which can cause gear damage. A
10-10
MNT
Maintenance
8. Remove the gear oil pump, and then
install a new gasket g and the drain
screw b.
e
d 9. Tighten the check screw d and drain
screw b to the specified torque.
c
b
d
a
g b
TIP:
Before installing the magnetic drain screw,
Check screw d:
make sure to remove all metal particles.
9 N·m (0.9 kgf·m, 6.6 ft·lb)
Drain screw b:
5. Place the outboard motor in an upright 9 N·m (0.9 kgf·m, 6.6 ft·lb)
position.
Checking the gear oil level
6. Insert the gear oil pump into the drain 1. Check the gear oil level. See “Checking
hole, and then fill the lower unit slowly the gear oil level” (10-5).
with gear oil until oil flows out of the
check hole and no air bubbles are visible. Lubricating the outboard motor
1. Apply water resistant grease to the spec-
7. Install a new gasket f and the check
ified lubrication points.
screw d.
f
d
Recommended gear oil:

Hypoid gear oil
API: GL-4
SAE: 90
Oil quantity:
0.670 L (0.708 US qt, 0.590 lmp qt)
10-11
0
1
1. Check the propeller. See “Checking the
propeller” (8-3).
2
Checking the PTT fluid level
3
Never get under the outboard motor while
it is tilted.
4
1. Fully tilt the outboard motor up, and then
5
a 6
2. Apply low temperature resistant grease
to the specified lubrication point.
7
2. Remove the reservoir cap b and O-ring
c, and then check the fluid level in the 8
reservoir. WARNING! Before removing
the reservoir cap, make sure that the
PTT ram is fully extended. Otherwise,
fluid could be expelled forcefully from 9
the unit due to internal pressure.
3. Apply corrosion resistant grease to the

10
specified lubrication point.
c
A
10-12
MNT
Maintenance
Checking the spark plug
TIP: 1. Check the spark plugs. See “Checking
If the fluid is at the proper level, a small the spark plug” (7-47).
amount of fluid should flow out of the filler
hole when the reservoir cap is removed. Checking the timing belt
1. Check the timing belt. See “Checking the
3. If the fluid is below the proper level, add timing belt and sprocket” (7-17).
the recommended fluid.
Recommended PTT fluid: ATF DEXRON II
Replacing the timing belt
1. Replace the timing belt. See “Flywheel
4. Install a new O-ring and the reservoir cap magnet and timing belt” (7-13).
b, and then tighten the reservoir cap b
to the specified torque. NOTICE: Do not Checking the thermostat
reuse an O-ring, always replace it with 1. Check the thermostat. See “Checking the
a new one. thermostat” (7-53).
Reservoir cap b: Adjusting the throttle link rod and

7 N·m (0.7 kgf·m, 5.2 ft·lb)
throttle cable
1. Adjust the throttle link rod. See “Adjusting
Checking the PTT operation
the throttle link rod” (6-32).
1. Fully tilt the outboard motor up and down
a few times and check that the outboard
2. Install the throttle cable. See “Installing
motor tilts up and down smoothly. Check
the shift cable and throttle cable” (3-9).
the PTT fluid level if the tilt operation is
not smooth. Checking the top cowling
1. Check the fitting by pushing the top cowl-
TIP: ing. Adjust if there is free play.
Make sure that the PTT motor makes a wind-
ing sound when it is operating smoothly.
2. Fully tilt the outboard motor up, and then

Check that the tilt stop lever locks in
place properly.
2. Loosen the nuts a.

a
3. Move the hook b up or down slightly to
adjust its position.
3. Check the PTT unit for fluid leakage.
Adjusting the shift cable

1. Disconnect the shift cable, and then
adjust it. See “Installing the shift cable
and throttle cable” (3-9).
10-13
0
a
b
b
1
TIP:
• To loosen the fitting, move the hook in 2
direction a.
• To tighten the fitting, move the hook in
direction b.
3
4. Tighten the nuts a.
5. Recheck the fitting. Replace the cowling

seal if the free play cannot be adjusted.
4
Checking the valve clearance
1. Check the valve clearance. See “Check-
ing the valve clearance” (7-2).
5
Checking the water pump
1. Check the water pump housing and 6
impeller. See “Checking the water pump
and shift rod” (8-10).
7
8
9
10
A
10-14
Index i
Index
A. C.
Abbreviation ................................................0-5 Camshaft and valve.................................. 7-38
Adjusting the float height...........................6-44 Changing the engine oil............................ 10-8
Adjusting the forward gear shim Changing the gear oil ............................. 10-10
thickness (T1) .........................................8-39 Charging system......................................... 1-8
Adjusting the pulser coil air gap ..................7-2 Charging unit and starting unit....................A-5
Adjusting the shift cable ..........................10-13 Charging units and components............... 5-23
Adjusting the throttle link rod.....................6-32 Checking by use of YDIS.......................... 5-12
Adjusting the throttle link rod Checking by using the digital tester.......... 5-13
and throttle cable ..................................10-13 Checking the air pressure sensor............. 5-28
Adjusting the trim sensor ..........................9-43 Checking the air temperature sensor ....... 5-27
Adjusting the valve clearance .....................7-4 Checking the alert buzzer ......................... 5-18
After test run .............................................10-7 Checking the alert indicator (tiller handle
Alert indicator, alert buzzer control .............2-8 model)..................................................... 5-18
Assembling the bottom cowling ................9-21 Checking the anode.................................. 10-7
Assembling the cylinder block...................7-64 Checking the armature (PTT motor)......... 9-49
Assembling the cylinder head ...................7-47 Checking the armature (starter motor) ..... 5-38
Assembling the drive shaft...............6-17, 8-20 Checking the battery........................ 10-3, 10-8
Assembling the electrical component Checking the brush.......................... 5-39, 9-50
(multifunction) .........................................9-14 Checking the camshaft ............................. 7-46
Assembling the forward gear ....................8-19 Checking the clamp bracket anode .......... 9-41
Assembling the friction plate .......................9-3 Checking the compression pressure .......... 7-1
Assembling the fuel filter assembly...........6-11 Checking the connecting rod big end side
Assembling the fuel pump assembly ........6-17 clearance ................................................ 7-60
Assembling the gear pump housing..........9-57 Checking the connecting rod small end and big
Assembling the lower case .......................8-20 end inside diameter ................................ 7-59
Assembling the oil pan and exhaust Checking the cooling water passage ........ 10-8
manifold ..................................................9-34 Checking the cooling water pilot hole ....... 10-3
Assembling the oil seal housing................8-10 Checking the crankpin oil clearance......... 7-60
Assembling the propeller shaft Checking the crankshaft ........................... 7-60
assembly.................................................8-14 Checking the crankshaft journal oil
Assembling the propeller shaft housing clearance ................................................ 7-62
assembly.................................................8-15 Checking the cylinder bore ....................... 7-58
Assembling the PTT motor .......................9-51 Checking the cylinder head ...................... 7-41
Assembling the PTT ram assembly ..........9-62 Checking the cylinder head anode ........... 7-47
Assembling the shift rod............................9-17 Checking the cylinder head bolt ............... 7-35
Assembling the starter motor ....................5-39 Checking the diaphragm and valve .......... 6-16
Assembling the tiller handle ........................9-9 Checking the dog clutch ........................... 8-14
Assembling the tilt cylinder .......................9-63 Checking the drive shaft ........................... 8-19
Assembling the trim cylinder .....................9-64 Checking the drive shaft bushing ............. 9-29
Assembling the upper case.......................9-29 Checking the electrical component........... 5-12
Assembling the vapor separator ...............6-44 Checking the engine ECM circuit ............. 5-14
Checking the engine idle speed ............... 10-8
B. Checking the engine oil level........... 10-4, 10-9
Checking the engine shut-off switch......... 5-31
Battery requirement ...........................1-5, 3-21
Checking the engine start switch .............. 5-32
Bleeding the PTT unit ...............................9-65
Blowby hose, vapor gas hose,
shut-off switch.............................. 10-4, 10-10
and air hose ..............................................6-2
Checking the exhaust cover anode .......... 7-53
Bottom cowling...................................5-6, 9-18
Checking the filter..................................... 9-57
Bracket unit ........................................1-4, 1-17
Checking the forward gear ....................... 8-19
Bracket unit technical data........................1-14
Checking the fuel cup assembly............... 6-11
Break-in.....................................................10-7
Checking the fuel filter ............................ 10-10
i-1
Index
Checking the fuel filter assembly ..............6-10 Checking the PTT fluid level................... 10-12
Checking the fuel filter element.................6-10 Checking the PTT operation ................... 10-13
Checking the fuel injector..........................5-20 Checking the PTT relay ............................ 5-44
Checking the fuel joint.................................6-9 Checking the PTT switch
Checking the fuel joint and fuel hoses ....10-10
Checking the fuel pump assembly ............6-15
(bottom cowling) ..................................... 5-45
Checking the PTT switch
0
Checking the fuel rail and fuel injectors ....6-25 (tiller handle)........................................... 5-46
Checking the fuel system..........................10-5 Checking the PTT system ........................ 10-6
Checking the gear oil level.............10-5, 10-11
Checking the gear pump...........................9-56
Checking the PTT unit anode ................... 9-45
Checking the pulser coil ........................... 5-26
1
Checking the gear shift and throttle operation Checking the pulser coil air gap ................. 7-2
(remote control).......................................10-5 Checking the Rectifier Regulator .............. 5-24
(tiller handle) ...........................................10-5
Checking the reverse gear ....................... 8-14
Checking the rocker arm and rocker
2
Checking the high-pressure fuel pump .....6-44 arm shaft................................................. 7-46
Checking the high-pressure fuel Checking the spark plug ................ 7-47, 10-13
pump .......................................................5-21
Checking the ignition coil ..........................5-25
Checking the spark plug cap .................... 5-25
Checking the speed sensor (option)......... 5-42
3
Checking the ignition spark.......................5-25 Checking the starter motor operation ....... 5-36
Checking the intake manifold....................6-26 Checking the starter motor pinion............. 5-36
Checking the ISC ......................................5-16
Checking the ISC valve.............................6-21
Checking the starter relay......................... 5-31
Checking the steering system .................. 10-6
5
Checking the knock sensor.......................5-30 Checking the thermo sensor..................... 5-29
Checking the lighting coil Checking the thermostat................ 7-53, 10-13
(stator assembly) ....................................5-23
Checking the lower unit anode.............8-3, 8-6
Checking the throttle body........................ 6-26
6
Checking the lower unit for air (remote control) ...................................... 10-6
leakage ...................................................8-25 Checking the throttle cable and shift cable (tiller
Checking the magnet switch .....................5-36
Checking the main relay ...........................5-13
handle).................................................... 10-6
Checking the timing belt ......................... 10-13
7
Checking the neutral switch ......................5-30 Checking the timing belt and sprocket...... 7-17
Checking the neutral switch (tiller handle Checking the top cowling........................ 10-13
model) .....................................................5-32
Checking the oil pan and exhaust
Checking the TPS............................ 5-15, 6-26
Checking the trim sensor.......................... 5-46
8
manifold ..................................................9-34 Checking the trolling switch (tiller handle
Checking the oil pressure ...........................7-1 model)..................................................... 5-18
Checking the oil pressure switch ..............5-17
Checking the oil strainer ...........................9-34
Checking the valve ................................... 7-42
Checking the valve clearance.......... 7-2, 10-14
9
Checking the outboard motor mounting Checking the valve guide ......................... 7-42
height ......................................................10-5 Checking the valve seat ........................... 7-43
Checking the pinion ..................................8-19
Checking the piston diameter ...................7-58
Checking the valve spring ........................ 7-41
Checking the vapor separator .................. 6-44
10
Checking the piston pin.............................7-59 Checking the vapor
Checking the piston pin boss ....................7-59 shut-off valve ................................. 5-22, 6-38
Checking the piston ring ...........................7-58
Checking the piston ring end gap .............7-58
Checking the water detection switch ........ 5-19
Checking the water pressure sensor
10
Checking the piston ring groove ...............7-59 (option) ................................................... 5-41
Checking the piston ring side clearance ...7-59 Checking the water pump ....................... 10-14
Checking the pressure regulator.................6-5 Checking the water pump and shift rod .... 8-10
Checking the primer pump........................6-11 Checking Y-COP ...................................... 5-32
Checking the propeller ............. 8-3, 8-6, 10-12 Circuit diagram ......................................... 5-10
Checking the propeller shaft .....................8-14 Clamp bracket ............................................ 3-4
Checking the propeller shaft housing........8-14
Checking the PTT cylinder and piston ......9-62
Connecting the communication cable to the
outboard motor ......................................... 4-3
A
i-2
Index
Control unit................................................. A-7 Electrical component and wiring harness
Cooling diagram........................................2-15 routing....................................................... 5-1
Cooling system .........................................2-15 Electrical system technical data ................. 1-6
Cooling water hose .....................................6-3 Electronic fuel injection control ................... 2-4
Crankcase assembly.................................1-12 Engine control unit and fuel unit .................A-1
Crate top cover pictograph description .......3-5 Engine control units and components ...... 5-13
Cylinder block ...........................................7-56 Engine ECM and starter motor ................. 7-21
Cylinder head............................................7-34 Engine ECM Component............................ 2-2
Cylinder head assembly............................1-11 Engine speed control.................................. 2-6
Engine speed control system ..................... 1-7
D. Exhaust cover........................................... 7-50
Exterior: F70A (tiller handle model) ............ 3-3
Dimension and weight.................................1-3
Exterior: F70AET ........................................ 3-2
Dimensions .................................................3-2
Disassembling the bottom cowling............9-21
Disassembling the cylinder block..............7-57 F.
Disassembling the cylinder head ..............7-40 Fail-safe control .......................................... 2-9
Disassembling the drive shaft ...................8-18 Feature ....................................................... 4-1
Disassembling the electrical component Flywheel magnet and timing belt .............. 7-13
(multifunction) .........................................9-14 Forward gear shim (T1) selection chart .... 8-41
Disassembling the forward gear ...............8-18 Friction plate ............................................... 9-1
Disassembling the friction plate ..................9-3 Front ........................................................... 5-4
Disassembling the fuel filter assembly......6-10 Fuel and oil requirement............................. 1-4
Disassembling the fuel pump assembly....6-16 Fuel control units and components........... 5-19
Disassembling the gear pump Fuel diagram............................................. 2-12
assembly.................................................9-56 Fuel filter assembly..................................... 6-7
Disassembling the lower case ..................8-18 Fuel hose.................................................... 6-1
Disassembling the oil pan and exhaust Fuel injection control system ...................... 1-7
manifold ..................................................9-33 Fuel pump assembly ................................ 6-13
Disassembling the oil seal housing.............8-9 Fuel system .....................1-10, 1-15, 2-12, 6-4
Disassembling the propeller shaft Fuel system technical data ....................... 1-10
assembly.................................................8-13 Function...................................................... 4-2
Disassembling the propeller shaft housing
assembly.................................................8-14 G.
Disassembling the PTT motor...................9-49
Gauge/sensor ............................................. 1-9
Disassembling the PTT ram assembly .....9-61
General feature........................................... 1-1
Disassembling the shift rod.......................9-17
General periodic maintenance.................. 10-7
Disassembling the starter motor ...............5-37
General tightening torque ......................... 1-18
Disassembling the tiller handle ...................9-8
Disassembling the tilt cylinder...................9-61
Disassembling the upper case..................9-29 H.
Disassembling the vapor separator ..........6-43 Handling of gas torch.................................. 0-2
Disassembly and assembly ........................0-3 Handling of gasoline ................................... 0-1
Disconnecting the quick connector .............6-4 Handling of sealant..................................... 0-3
Draining the fuel........................................6-36 Hardware requirement................................ 4-1
Drive shaft and lower case........................8-17 Hose routing ............................................... 6-1
Hot part....................................................... 0-1
E. How to use this manual .............................. 0-4
ECM coupler layout...................................5-11
Electric control system ................................2-1 I.
Electric shock..............................................0-1 Ignition timing control.................................. 2-5
Electrical component Ignition timing control system ..................... 1-6
(multifunction) .........................................9-13 Ignition unit .................................................A-3
i-3
Index
Ignition units and components ..................5-25 K.
Installing the battery..................................3-18
Knock control.............................................. 2-8
Installing the clamp bracket ......................9-41
Installing the cylinder head .......................7-35
Installing the drive shaft ............................8-22
Installing the exhaust cover ......................7-54
L.
Lower unit ...................................1-4, 1-16, 8-1
0
Installing the flywheel magnet...................7-19 Lower unit (X-transom model) .................... 8-4
Installing the friction plate assembly ...........9-4 Lower unit assembly................................. 1-14
Installing the fuel injector ..........................6-28
Installing the ignition coil and Rectifier
Lower unit technical data.......................... 1-14
Lubricant, sealant, and thread locking
1
Regulator ................................................7-25 agent......................................................... 0-6
Installing the intake manifold.....................6-26 Lubricating the outboard motor............... 10-11
Installing the intake silencer......................6-21
Installing the lower unit .............................8-25
Lubrication diagram .................................. 2-14
Lubrication system.................................... 2-14
2
Installing the lower unit
(X-transom model) ..................................8-26
M.
Installing the oil filter .................................7-53
Installing the oil pressure switch ...............7-53 Maintenance interval chart 1 .................... 10-1 3
Installing the power unit ..............................7-9 Maintenance interval chart 2 .................... 10-2
Installing the propeller shaft housing Manual format............................................. 0-4
assembly.................................................8-22
Installing the PTT motor............................9-51
Measuring the forward gear
backlash ................................................. 8-39 5
Installing the PTT unit ...............................9-45 Measuring the forward gear backlash before
Installing the remote control box and disassembly............................................ 8-30
tachometer ..............................................3-13
Installing the shift cable and throttle
Measuring the fuel pressure ....................... 6-4
Measuring the peak voltage ..................... 5-12 6
cable .........................................................3-9 Model data.................................................. 1-3
Installing the shift rod ................................8-23 Model designation ...................................... 1-2
Installing the speed sensor .......................3-14
Installing the sprocket and timing belt.......7-17
Model features............................................ 1-1
7
Installing the starter motor ...............5-41, 7-23 N.
Installing the starter relay..........................7-22 Non-reusable part....................................... 0-3
Installing the stator assembly....................7-18
Installing the steering arm.........................9-37
O.
8
Installing the thermo sensor......................7-54
Installing the throttle body .........................6-44 Oil pan and exhaust manifold ................... 9-31
Installing the throttle link ...........................6-31
Installing the tiller handle ..........................3-15
Optional equipment .................................. 3-13
Outboard motor installation ........................ 3-1 9
Installing the upper case ...........................9-26 Outboard motor mounting........................... 3-7
Installing the vapor separator....................6-38 Outboard motor troubleshooting ................. 4-4
Installing the water pressure sensor .........3-13
Installing the water pump ..........................8-24
Outline ...................................................... 10-1
10
Installing the wiring harness......................7-31 P.
Installing the wiring harness (remote control Part, lubricant, and sealant......................... 0-2
model) .....................................................3-11
Installing the 6Y8 Multifunction Meter
Performance ............................................... 1-3
Pinion shim (T3) selection table ............... 8-37
10
harness ...................................................3-12 Port ............................................................. 5-1
Installing Y-COP (optional in non-European Power Unit ................................................ 2-11
markets) ..................................................3-17 Power unit.................................1-3, 1-11, 1-15
Intake and exhaust diagram......................2-16 Power unit (check and adjustment) ............ 7-1
Intake and exhaust system .......................2-16 Power unit assembly .................................. 7-5
Intake manifold..........................................6-23 Power unit technical data ......................... 1-11
Intake silencer...........................................6-19
ISC Control .................................................2-8
Predelivery check ..................................... 10-3 A
i-4
Index
Propeller......................................................0-1 Rigging grommet mounting ........................ 3-9
Propeller selection ....................................3-21 Rigging information................................... 1-15
Propeller shaft housing .............................8-11 Rigging recommendations........................ 3-21
Propeller size ............................................3-21 Rotating part ............................................... 0-1
PTT cylinder..............................................9-59
PTT electrical system................................5-44 S.
PTT fluid requirement .................................1-5
Safety while working................................... 0-1
PTT gear pump .........................................9-53
Selecting the crankpin bearing ................. 7-62
PTT motor .................................................9-47
Selecting the crankshaft journal
PTT system........................................1-8, 1-14
bearing.................................................... 7-63
PTT unit ...........................................2-17, 9-44
Selecting the pinion shim (T3) .................. 8-34
Selection................................................... 3-21
R. Self-protection ............................................ 0-2
Rectifier Regulator and ignition coil ..........7-24 Serial number ............................................. 1-2
Reducing the fuel pressure .........................6-4 Shift bracket.............................................. 7-33
Refacing the valve seat.............................7-44 Shift rod and shift bracket......................... 9-16
Registering the receiver ID to the ECM ....3-17 Shim location ............................................ 8-33
Remove the starter relay...........................7-22 Shimming......................................... 8-28, 8-33
Removing the clamp bracket ....................9-41 Shimming check sheet ............................. 8-29
Removing the cylinder head .....................7-35 Shimming workflow................................... 8-28
Removing the drive shaft ..........................8-18 Shock-absorbing function ......................... 2-19
Removing the exhaust cover ....................7-52 Special service tool.............................. 0-3, 0-8
Removing the flywheel magnet.................7-15 Specified tightening torque ....................... 1-15
Removing the friction plate .........................9-3 Starboard.................................................... 5-3
Removing the fuel injector ........................6-25 Starter motor............................................. 5-34
Removing the fuel pump assembly...........6-15 Starting system ........................................... 1-8
Removing the fuel tank ...............................6-9 Starting units and components ................. 5-31
Removing the intake manifold...................6-25 Stationary condition .................................. 2-19
Removing the intake silencer....................6-21 Steering arm ............................................. 9-36
Removing the lower unit ......................8-3, 8-6 Symbol........................................................ 0-6
Removing the oil filter ...............................7-52 System diagram........................................ 3-19
Removing the oil pressure switch .............7-52
Removing the power unit ............................7-7 T.
Removing the propeller shaft housing
Test run .................................................... 10-7
assembly.................................................8-13
Throttle link rod ......................................... 6-30
Removing the PTT motor..........................9-49
Tightening torque........................................ 0-3
Removing the PTT unit .............................9-45
Tiller handle ................................................ 9-5
Removing the Rectifier Regulator and ignition
Tiller handle (optional) ................................ 5-8
coil...........................................................7-25
Tiller handle (tiller handle model) ............... 5-8
Removing the starter motor .............5-36, 7-22
Tiller handle model ................................... 1-17
Removing the stator assembly..................7-15
Top ............................................................. 5-5
Removing the steering arm.......................9-37
Trim-down and tilt-down function.............. 2-18
Removing the thermo sensor....................7-52
Trim-up and tilt-up function....................... 2-17
Removing the throttle link .........................6-31
Trouble code and checking step................. 4-6
Removing the timing belt and sprocket.....7-16
Troubleshooting procedure......................... 4-4
Removing the upper case .........................9-26
Troubleshooting the power unit (trouble code
Removing the vapor separator..................6-36
not detected)............................................. 4-9
Removing the water pump and shift rod .....8-9
Troubleshooting the power unit using the
Removing the wiring harness....................7-30
diagnostic flash indicator .......................... 4-8
Replacing the oil filter................................10-9
Troubleshooting the power unit using
Replacing the timing belt.........................10-13
the YDIS ................................................... 4-4
Replacing the valve guide.........................7-42
Troubleshooting the PTT unit .......... 4-13, 4-14
Rigging grommet description ......................3-9
i-5
Index
U.
Uncrating procedure ...................................3-6
Upper case................................................9-28
Upper case and mount..............................9-24
0
V.
Vapor separator ........................................6-34
Vapor separator and high-pressure fuel
pump .......................................................6-41
1
Ventilation ...................................................0-1
W. 2
Water pump and shift rod............................8-7
Wiring harness ....................... 7-27, 7-28, 7-29
Working with crane .....................................0-2
3
Y.
Y-COP.......................................................2-10
YDIS............................................................4-1 5
6.
6Y8 Multifunction Meter sensor ................5-41
6
7
8
9
10
10
A
i-6
Index
— MEMO —
i-7
Appendix A
Wiring diagram ................................................................. A-1

How to use the wiring diagram .................................................
Engine control unit and fuel unit ...............................................
A-1
A-1
0
Ignition unit ............................................................................... A-3
Charging unit and starting unit ................................................. A-5
Control unit ............................................................................... A-7 1
2
3
5
6
7
8
9
10
10
10
A
Wiring diagram
How to use the wiring diagram
Composition of the wiring diagrams
The wiring diagram consists of four categories. The engine control unit and fuel unit, ignition unit,
charging unit and starting unit, and control unit.
Legend symbols in the wiring diagrams
a b c d e
BZ
a Double colors wire
b No wire connector
c A wire is not included in the selected wiring unit.
d Alert buzzer
e Optional parts
Color Code
O/W : Orange/White
B : Black
P : Pink
B/R : Black/Red
P/B : Pink/Black
B/W : Black/White
P/G : Pink/Green
B/Y : Black/Yellow
P/W : Pink/White
Br : Brown
Pu/B : Purple/Black
G : Green
Pu/R : Purple/Red
G/B : Green/Black
R : Red
Gy : Gray
R/B : Red/Black
G/R : Green/Red
R/Y : Red/Yellow
G/Y : Green/Yellow
Sb : Sky blue
L : Blue
W : White
L/B : Blue/Black
W/B : White/Black
L/G : Blue/Green
W/R : White/Red
L/W : Blue/White
W/L : White/Blue
Lg : Light green
Y : Yellow
O : Orange
Y/G : Yellow/Green
Engine control unit and fuel unit

a Fuse (15 A) (engine start switch, PTT switch)
b Fuse (20 A) (main relay)
c Fuse (30 A) (starter relay)
A To remote control/tiller handle

B To diagnostic flash indicator
C To trolling switch
D To YDIS
A-1
YAMAHA MOTOR CO., LTD.
May 2010 – ** × 1 ABE

(E_4)
Engine control unit and fuel unit
PTT relay
A
Main relay R R
R
G
Br
W
R
Y
Br
P
B
b c Battery
1
2
3
4
5
6
7
8
B
R/Y
R/Y
G
L
R
R
B
Y
L
Starter motor
1 R R R Br
Br Br
18 1 2 a B B
3 Pu/R
4 Pu/B Starter relay
5 B
6 G/B R/Y 1
7 G 2
8 B/R 3
9 P R/Y 4
10 P/W R/Y 5
11 G/B R/Y 6 1 13
12 R/Y 7
13 W/B 8
14 B R/Y 9
15 R/Y 10
16 O P/W 11
17 P/W 12
18 O 13
19 14
20 G/Y 15
21 G O 16
22 O 17
23 G/R 18
34 17 12 24
24 L 19
25 L/W 20 Joint connector 2
26 B 21
27 W B 22
28 O/W B 23
29 W/L B 24
30
31 B B 1
32 2
33 L/W 3
34 4
5
35 B 6 1 13
36 7
37 L 8
38 B 9
39 B 10
Engine ECM 40 11
B
44 35 41 12
42 13
43 14
44 15
45 16
46 L/B 17
47 18
Pu/R
Pu/R
Pu/B
Pu/B
O/W
12 24
W/B
P/W
W/L
G/R
G/Y
G/B
R/Y
G/B
R/Y
L/W
B/R
R/Y
R/Y
48 19
R/Y
L/B
O
G
O
B
B
B
L
49 20 Joint connector 1
50 21
B
B
51 22
B
B
52 #2 #3 #4 23
#1
52 43 24
Oil pressure
switch C D
L/W
Vapor
ISC valve shut-off
B Water pressure Water detection High-pressure valve
Fuel injector
sensor switch fuel pump
Speed sensor
A-2
Ignition unit
A-3
Ignition unit
PTT relay
A
Main relay R
R
G
Br
W
R
Y
Br
P
1
2
3
4
5
6
7
8
b c Battery
B
R/Y
R/Y
G
R
B
Y
R
1 B/W R R R Br Starter motor
2 Br Br
18 1 B B
3 a Starter relay
4
5 B
6 R/Y 1
7 G R/Y 2
8 3
9 P 4
10 5
11 6
1 13
12 7
13 R/Y 8
14 B 9
15 R/Y 10
16 O 11
17 P/G 12
18 B/R O 13
19 O 14
20 O 15
21 16
22 17
23 18
34 17 12 24
24 L 19
26 B 21
27 W 22
28 23
29 B 24
30
31 B B 1
32 W/B 2
33 B 3
34 L/G B 4
B 5
6 1 13
35 B 7
36 P 8
37 9
Engine ECM 38 B/Y 10
39 11
44 35 40 W/R 12
41 13
42 14
43 15
44 G 16
45 17
46 18
W/R
12 24
B/W
W/B
P/G
B/R
R/Y
R/Y
B/Y
L/G
47 19
B/Y
O
B
B
B
B
B
B
B
48 B/Y 20 Joint connector 1

49 21
50 22
51 23
52 43 52 #1, 4 #2, 3 24
Neutral
switch
Thermo sensor Pulser coil Ignition coil Ignition coil Knock sensor Sensor assembly TPS
A-4
Charging unit and starting unit
d Diode (connect to PTT relay)

B To 6Y8 Multifunction Meter
C To alert indicator (tiller handle/digital tachometer)
D Connect the couplers when displaying the 6Y8 Multifunction Meter
A-5
Charging unit and starting unit
A
Main relay Br
R Br Starter motor
Br Battery
W
R
Y
Br
Lg
L
P
B
B
1
2
3
4
5
6
7
8
1
Starter relay
2
G
B
R/Y
R
Y
L
1 3
18 1 2 4
3 R R 5
4 6
5 B a Stator assembly 7
1 13
6 8
7 G 9
8 P/B 10
9 P 11
10 12
11 R R 13
G
G
G
12 B 14
13 b c 15
14 B 16
15 R/Y 17
18
R
R
16
17 19 12 24
19 B 21
Sb
20 22
21 Lg PTT relay 23
22 B 24
23
34 17 Rectifier Regulator
24 L
25 B 1
26 P/W 2
L
Sb
Lg
27 W 3
B
B
28 4
29 B 5
30 6 1 13
31 B 7
32 B 8
33 9
34 10
11
35 12
36 Sb 13
37 Sb 14
38 Sb 15
Engine ECM 39 Sb 16
40 17
44 35 41 18
42 19 12 24
43 W 20 Joint connector 1
44 Lg 21
45 P Lg 22
46 Lg 23
47 Lg 24
48
G
Sb
Lg
L
Sb
Lg
R
49
P
B
50
d
P/W
P/B
P/B
51
B
B
P
52 L
B
52 43
W
L
B
B
C D
B
Trim sensor PTT switch PTT motor
A-6
Control unit A
A 703 remote control Engine alert switch Engine shut-off PTT switch
switch
B Tiller handle OFF
W B R Y Br
UP
Sb R Lg
W B
C To gauge ON Set Free
D To power unit START Pull DN
Lg
Sb
R
Br
W
Y
R
B
B
BZ
P Y
Lg
Sb
R
W
B
Y
R R R
C G
Y
G
W
B Sb
P D
Lg
L
B B
Br
Neutral switch
PTT switch Engine start switch Engine shut-off Trolling switch

switch
Sb R Lg W B R Y Br W/L B O/W
UP OFF W B UP
Free ON Set Free
DN START Pull DN
B
B
Sb
Lg
B
Br
W
R
R
Y
R
Y
O/W
W/L
B D
B
W
R
R Y
Y
Lg G
P W
Sb Sb
P D
B
P
Br Lg
W B
Br
P
L Br Br
B Br Br
Gy
P/W P
Neutral switch BZ P/B G/R D
G
Y Y Y
A-7

Serv. Manual f70

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Serv. Manual f70

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F70A

Safety while working .................................................... 0-1

How to use this manual .................................................... 0-4 4

Lubricant, sealant, and thread locking agent ................. 0-6

Special service tool ........................................................... 0-8

Disassembly and assembly

• Install bearings so that the bearing identifi-

ThreeBond 1901 Lubricant

LOCTITE 271 (red) Thread locking agent 9

Symbol Name Application

Drilling plate Peak voltage adapter B 0

Diagnostic flash indicator B Vacuum/pressure pump gauge set

Test harness (2 pins) Flywheel holder

Test harness (3 pins) Flywheel puller

Fuel pressure gauge adapter Crankshaft holder

Fuel pressure gauge Valve spring compressor

Valve lapper Valve seat cutter 30°

Driver rod LS Needle bearing attachment

Bearing outer race attachment Driver rod L3

Oil filter wrench Ring nut wrench extension

Piston slider Ring nut wrench 3

Bearing separator Needle bearing attachment

Pinion nut holder Driver rod LL

Bearing inner race attachment Bearing outer race attachment

Needle bearing attachment Driver rod SL

Needle bearing attachment Bearing depth plate

Magnet base B Needle bearing attachment

Model feature ..................................................................... 1-1

Model data ......................................................................... 1-3

Electrical system technical data ...................................... 1-6

Fuel system technical data ............................................ 1-10

Power unit technical data ............................................... 1-11

Lower unit technical data ............................................... 1-14

Bracket unit technical data ............................................ 1-14

Specified tightening torque ............................................ 1-15

General tightening torque .............................................. 1-18

a Power unit d Upper case

PTT fluid requirement

Engine speed control system

Cylinder head assembly

Bracket unit technical data

Connecting rod bolt

Tiller handle model

Electronic control system ................................................ 2-1

Power unit ........................................................................ 2-11 3

Vapor shut-off valve

6Y8 Multifunction YDIS

Air pressure sensor (*1) High-pressure fuel pump 2

Thermo sensor (*1) Engine

Engine shut-off switch 5

(*1) Sensors that perform compensations.

Synchronized injection by group

Air pressure sensor (*1)

Thermo sensor Engine

Engine start switch

Engine shut-off switch

(*1) Sensors that perform compensations.

Air temperature sensor

Oil pressure switch

Engine start switch Alert buzzer

Alert indicator, alert buzzer control

Alert buzzer control

Receiver Ignition coil #2, #3 2

Combustion Combustion Combustion Combustion