F30A-F40A Service Manual

Worldwide:
(6BT)
(6BG)
USA, CAN, AUS, and NZL:

(6BT)
(6BG)
6BG-28197-ZX-11
LIT-18616-03-84
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 YMBS (Yamaha Marine Business System,
USA only) or YPEC-web (except USA). Additional information and up-to-date information on
Yamaha products and services are available on YMBS, YMPE (Yamaha Multimedia Product Ency-
clopedia, Canada only), or Yamaha Service Portal (except USA and Canada).
Important information
Particularly important information is distinguished in this manual by the following notations:
 : This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to the outboard
motor or other property.
TIP:
A TIP provides key information to make procedures easier or clearer.
F30B, F40F
F30A, F40A
SERVICE MANUAL
©2018 by Yamaha Motor Co., Ltd.
1st Edition, July 2018
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
6BG-28197-ZX-11
LIT-18616-03-84
Contents
General information 0
Specification 1
Technical feature and description 2
Rigging information 3
Troubleshooting 4
Electrical system 5
Fuel system 6
Power unit 7
Lower unit 8
Bracket unit 9
Maintenance 10
Appendix A
General information
Model information .............................................................. 0-1

Applicable model ........................................................................ 0-1
0
Model name designation ............................................................ 0-1
General feature .......................................................................... 0-3
Important safety and service information........................ 0-4

Rotating parts ............................................................................. 0-4
Hot parts..................................................................................... 0-4
Electric shock ............................................................................. 0-4
Propeller ..................................................................................... 0-4
Handling of gasoline................................................................... 0-4
Ventilation................................................................................... 0-4
Self-protection ............................................................................ 0-4
Lifting outboard motors............................................................... 0-5
Handling of gas torch ................................................................. 0-5
Parts, lubricants, and sealants ................................................... 0-5
Handling of lubricants and sealants ........................................... 0-5
Special service tools................................................................... 0-6
Tightening torque ....................................................................... 0-6
Non-reusable parts..................................................................... 0-6
Disassembly and assembly........................................................ 0-6
Disposal of used components and chemicals ............................ 0-6
How to use this manual ..................................................... 0-7

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

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

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

Model information
Model information
Applicable model
This manual applies to the following models.
Worldwide
Model name Approved model code Starting serial No.
F30BEHD
6BTK 1000001–
F30BET
F40FEHD
F40FED 6BGK 1000001–
F40FET
USA, CAN, AUS, and NZL

Model name Approved model code Starting serial No.
F30EHA
F30HA 6BTK 1000001–
F30A
F40EHA
F40HA 6BGK 1000001–
F40A
Model name designation

Worldwide
F 40 F E H D L
1 2 3 4 5
1 Model category F: 4-stroke

2 Output horsepower 30/40
3 Model generation B/F
Level 1: Starting method
E: Electric start
Level 2: Control method

None: Remote control without tiller handle
4 Model variation
H: Tiller handle
Level 3: Trim and tilt method

D: Hydraulic tilt
T: PT/T (Power trim and tilt)
S: 15 in
5 Motor transom height
L: 20 in
0-1
Model information
USA, CAN, AUS, and NZL
F 40 L E H A
1 2 3 4 5 6
1 Model category F: 4-stroke

2 Horsepower 30/40
S: 15 in
3 Motor transom height
L: 20 in
Blank: PTT and E-start
4 Starting method/PTT
E: Electric start
Blank: Remote control
5 Control method
H: Tiller handle
6 Generation A: 1st change on motor
0-2
Model information
General feature
• Electronic fuel injected, 4-stroke, L3, SOHC, 6-valve, 747 cm³ (45.6 cu. in) engine
• Low exhaust emissions conform to EU1, US EPA, CARB 3-STAR, and JBIA regulations.
• Low fuel evaporative/permeation emissions conform to US EPA regulation.
a. Power unit c. Bracket unit

• Multipoint electronic fuel injection • Long span mounts
• Single throttle body • Small and compact PTT (PTT model)
• Long intake manifold • High-pressure gas-assisted hydro tilt (hydro
• Blowby gas reburning system tilt model)
• Fuel cooler • Multifunction tiller handle (tiller handle mod-
• Closed fuel vapor gas system el)
• One piece top cowling with water draining air
intake duct d. Upper case
• Labyrinth idle exhaust system
b. Electrical
• Electronic fuel injection control e. Lower unit
• ISC (Idle Speed Control) • Lower unit equivalent to that of a one-class-
• Over-revolution control higher mode
• Fail-safe
• Self-diagnosis system with YDIS (1.33 and a
later versions) b
• Alert systems including low oil pressure,
overheat, and water detection
• High generator output (maximum 17 A)
• Y-COP acceptable (optional)
• Variable troll speed control (650–900 r/min) c
• Conventional gauge (6Y5/6Y7) or 6Y8/6YC
Multifunction Meters acceptable
d
• Speed sensor (optional)
• Water pressure sensor (optional)
0-3
Important safety and service information
Important safety and service in- Handling of gasoline

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

During and after operation, engine parts are • Gasoline vapor and exhaust gases are
hot enough to cause burns. Do not touch any heavier than air and extremely poisonous. If
parts under the top cowling until the engine has gasoline vapor or exhaust gases are inhaled
cooled. in large quantities, it may cause loss of con-
sciousness and death within a short time.
Electric shock • When test running an engine indoors (for ex-
Do not touch any electrical parts while starting ample, in a water tank) make sure to do so
or operating the engine. Otherwise, shock or where adequate ventilation can be main-
electrocution could result. tained.
Propeller
Do not hold the propeller with your hands when
loosening or tightening the propeller nut. Sharp
propeller edges can cause injury. Place a
wood block between gear case and propeller
to hold the propeller for removal and installa-
tion.
Self-protection
• Protect your eyes by wearing safety glasses
or safety goggles during all operations involv-
ing drilling and grinding, or when using an air
compressor.
0-4
• Protect your hands and feet by wearing pro-
tective gloves and safety shoes when neces-
sary.
Parts, lubricants, and sealants

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

• Follow all instructions and safety precautions
provided on the product label and the materi-
al safety data sheet (MSDS/SDS) for lubri-
cants, sealants, and other shop chemicals.
• Wear impervious gloves, eye protection, or
other protective apparel when required.
• Wash skin thoroughly after contact with lubri-
cants, sealants, and other shop chemicals,
Handling of gas torch and change clothing if contaminated with
• Improper handling of a gas torch may result them.
in burns. For information on the proper han-
dling of the gas torch, see the operation man-
ual issued by the manufacturer.
• When using a gas torch, keep it away from
gasoline and oil to prevent a fire.
• Components become hot enough to cause
burns. Do not touch any hot components di-
rectly.
0-5
Special service tools
For safety and to help protect parts from dam-
age, use the recommended special service
tools.
• During disassembly, cover all openings,

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

chemicals
Obey all federal, state and local regulations
when disposing of used components and/or
Disassembly and assembly chemicals such as crate frames, replaced
• Use compressed air to remove dust and dirt parts, gaskets, oil, and so on.
during disassembly.
• Apply engine oil to the contact surfaces of
moving parts before assembly.
0-6
How to use this manual

Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the following information as a guide for effective and quality service.
• Parts are shown and detailed in an exploded diagram and are listed in the component list (see “1” in
the following figure for an example page).
• The component list consists of the basic removal or disassembly order (“ ”), part names, quantities,
and remarks, which indicate the bolt and screw dimensions and other information (see “2” in the fol-
lowing figure). For the installation or assembly procedure, reverse the order.
• Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
the lubrication points (see “3” in the following figure).
• Tightening torque specifications are provided in the exploded diagrams (see “4” in the following fig-
ure), and in the related detailed instructions. Some torque specifications are listed in stages as torque
figures or angles in degrees.
• Separate procedures and illustrations are used to explain the details of removal, checking, and instal-
lation where necessary (see “5” in the following figure for an example page). Detailed explanations of
the procedures are enclosed in (see “6” in the following figure for an example page).
• Numbers enclosed in brackets are used to indicate the removal or tightening order of bolts, screws,
and other parts (see “7” in the following figure).
TIP:
For troubleshooting procedures, see Chapter 4, “Troubleshooting”.
3 4 1
Cylinder head
5 7
Cylinder head
6 N·m (0.6 kgf·m, 4.4 lb·ft)
15 New 12 N·m (1.2 kgf·m, 8.9 lb·ft)
Cylinder head
12 17 N·m (1.7 kgf·m, 13 lb·ft)
16 3. Tighten:
34 N·m (3.4 kgf·m, 25 lb·ft)
• Cylinder head bolt (M9)
90°
• Cylinder head bolt (M6)
b a
13 7 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Tighten the cylinder head bolts (M9) “1” to
16 the specified torques in 3 stages and in the
8 d c
7 order [1], [2], and so on.
9 TIP:
In the third tightening stage for the cylinder
head bolts (M9) “1”, mark the bolts and cylinder
4 Cylinder head bolt (M9) diameter head with identification marks “a”, and then
difference limit tighten the bolts 90 from the marks on the cyl-
14 “a” – “b” = Less than 0.13 mm inder head.
9 (0.01 in)
Measuring point “c”: 10.0 mm
11 10 b. Tighten the cylinder head bolts (M6) “2” to
(0.39 in)
New 3 the specified torques in 2 stages and in the
Measuring point “d”: 62.5 mm
order [9], [10], and so on.
(2.46 in)
[8] 1
6 New ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ [12]
2
Installing the cylinder head a 90 [7]
9 5 Before installing the cylinder head, check the
1 [10]
1 cylinder head bolts. See “Checking the cylinder
1 head bolt” (7-26). [4] [3]
Part name Q’ty Remarks [9]
1 Bolt M6 45 mm 4 1. Check that the hole “a” on the retaining
plate is aligned with the “△” mark “b” on 2 [2]
2 Oil pump assembly 1
3 Gasket 1
the cylinder block. [1]
4 Bolt M6 20 mm 7 [11]
[6]
5 Cylinder head cover 1 b [5]
6 Gasket 1
7 Screw M4 10 mm 4 a Cylinder head bolt (M9) “1” [1]–[8]
8 Plate 1
1st: 17 N·m (1.7 kgf·m, 13 lb·ft)
T.
9 Grommet 5
R.
2nd: 34 N·m (3.4 kgf·m, 25 lb·ft)

10 Oil filler cap 1
3rd: 90
11 O-ring 1
Cylinder head bolt (M6) “2” [9]–
12 Bolt M6 25 mm 4
[12]
13 Bolt M9 93 mm 8
2. Install: 1st: 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Cylinder head assem-
14 1 • Dowel pin 2nd: 12 N·m (1.2 kgf·m, 8.9 lb·ft)
bly
15 Gasket 1 • Cylinder head gasket New ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
16 Dowel pin 2 • Cylinder head
7-25
7-27
2 6
0-7
Conditions when testing and adjusting
Conditions can affect specifications when checking, measuring and making certain adjustments. Ser-
vice data in this manual was determined under the following conditions:
• Electrical resistance for components such as ignition coils and sensors was measured at 20 C
(68 F).
• Engine compression was measured at:
• Sea level
• 20 C (68 F)
• All spark plugs removed
• Throttle valve at WOT (depending on model specification)
• Trim/tilt angles shown are when the transom angle is 12 degrees.
Abbreviation
The following abbreviations are used in this service manual.
Abbreviation Description
ECM Electronic Control Module
ISC Idle Speed Control
PTT Power Trim and Tilt
TPS Throttle Position Sensor
VST Vapor Separator Tank
Y-COP Yamaha Customer Outboard Protection
YDIS Yamaha Diagnostic System
Color code
B Black Lg Light green Sb Sky blue
Br Brown Or Orange W White
G Green P Pink Y Yellow
Gy Gray Pu Purple
L Blue R Red
TIP:
For example, “R/Y” stands for a Red with Yellow tracer stripe wire.
0-8
Specified tightening torque
Specified tightening torque

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

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

New
Lubricant, sealant, and thread locking agent

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

Lubricant
rine Gearcase Lube
Water resistant grease
Lubricant
(Yamaha grease A or Yamalube Marine Grease)
Low temperature resistant grease
(Yamaha grease C or Yamalube Molybdenum Lubricant
Disulfide grease)
Corrosion resistant grease
Lubricant
(Yamaha grease D or Yamalube Marine Grease)
Molybdenum disulfide grease
Lubricant
(Yamalube Molybdenum Disulfide grease)
Symbols in an exploded diagram or illustration indicate the type of sealant or thread locking agent and
the application points.
Gasket Maker Sealant
ThreeBond 1104J Sealant
ThreeBond 1322D Thread locking agent
ThreeBond 1342J Thread locking agent
0-10
Symbol
ThreeBond 1377B Thread locking agent
ThreeBond 1901 Lubricant
LOCTITE 242 (blue) Thread locking agent
LOCTITE 271 (red) Thread locking agent
LOCTITE 572 (white) Sealant
0-11
Special service tool

Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division.
Special service tools with USA and Canada tool numbers (YB/YM/YS/YU–*****) are distributed by K&L
Supply Co.
Some of the special service tools are only available from the Marine Service Division.
WW SST No.
YDIS2 Hardware Kit Digital circuit tester Peak voltage adapter B Test harness FWY–6
90890-06884 90890-03243 90890-03172 90890-06872
Vacuum/pressure Test harness (3 pins) Test harness Ignition checker (Spark

pump gauge set 90890-06870 FW13613–2 gap tester)
90890-06945 90890-06887 90890-06754
Test harness Test harness (3 pins) Test harness (2 pins) Fuel pressure gauge
SM6195043 90890-06869 90890-06867 adapter
90890-06861 90890-06946
Fuel pressure gauge Leakage tester Fuel injection meter Compression gauge
90890-06753 90890-06840 FIM20000ME 90890-03160
Flywheel holder Flywheel puller Crankshaft holder 16 Valve spring compres-

90890-06522 90890-06521 90890-06355 sor
90890-04019
0-12
Valve spring compres- Valve guide remover/ Valve guide installer Valve guide reamer
sor attachment installer 90890-06810 90890-06804
90890-06320 90890-06801
Valve lapper Valve seat cutter hold- Valve seat cutter 30 Valve seat cutter 45
90890-04101 er 90890-06326 90890-06312
90890-06316
Valve seat cutter 60 Valve seat cutter 30 Valve seat cutter 45 Valve seat cutter 60
90890-06323 90890-06328 90890-06325 90890-06315
Driver rod LS Bearing outer race at- Oil filter wrench Piston slider
90890-06606 tachment 90890-01426 90890-06529
90890-06626
Stopper guide plate Bearing separator Bearing puller assem- Stopper guide stand
90890-06501 90890-06534 bly 90890-06538
90890-06535
Driver rod L3 Needle bearing attach- Bearing inner race at- Needle bearing attach-
90890-06652 ment tachment ment
90890-06614 90890-06639 90890-06608
0-13
Drive shaft holder 3 Pinion nut holder Bearing inner race at- Driver rod LL
90890-06517 90890-06715 tachment 90890-06605
90890-06641
Bearing outer race at- Driver rod SL Bearing depth plate Bearing outer race at-
tachment 90890-06602 90890-06603 tachment
90890-06622 90890-06627
Bearing inner race at- Ball bearing attach- Shift rod socket Bearing housing puller
tachment ment 90890-06681 claw L
90890-06644 90890-06634 90890-06502
Center bolt Backlash indicator Magnet base plate Dial gauge set
90890-06504 90890-06706 90890-07003 90890-03238
Magnet base B Pinion height gauge Pinion Gear Bushing Needle bearing attach-
90890-06844 90890-06668 Installer ment
90890-06601 90890-06611
Cylinder end screw

wrench
90890-06591
0-14
US SST No.
YDIS2 Hardware Kit Digital multimeter Peak volt adapter Test harness FWY–6
LIT-YDIS2-01-KT YU-34899-A YU-39991 YB-06872
Pressure/vacuum tes- Test harness (3 pins) Test harness Spark checker

ter YB-06870 FW13613–2 YM-34487
YB-35956-B YB-06887
Test harness Test harness (3 pins) Test harness (2 pins) Fuel pressure gauge
SM6195043 YB-06869 YB-06867 adapter
YB-06861 YB-06946
Fuel pressure gauge Combination compres- Flywheel magneto Universal Puller

YU-03153M sion gauge and cylin- holder YB-06117
der leakdown test kit YB-06139
YB-45544-A
Crankshaft holder Valve spring compres- Valve spring compres- Valve guide remover
YW-06355 sor sor adaptor YB-06801
YM-04019 YB-06320
Valve guide installer Valve guide reamer Valve lapping tool Neway valve seat kit
YB-06810 YB-06804 YM-A8998 YB-91044
0-15
Driver handle (large) Driveshaft bearing in- Oil filter wrench Piston ring compressor
YB-06071 staller YB-01426 YM-08037
YB-06110
Slide hammer Bearing puller legs Needle bearing attach- Bearing housing bear-
YB-06096 YB-06523 ment ing/oil seal installer
YB-06112 YB-06111
Oil seal installer Bearing inner race at- Bearing cup installer Driveshaft holder
YB-06168 tachment YB-06167 YB-06079
YB-06639
Pinion nut holder Bearing splitter plate Roller bearing installer/ Driveshaft needle
YB-06715 YB-06219 remover bearing remover and
YB-06432 installer
YB-06063
Forward gear bearing Forward gear outer Bearing inner race at- Bearing installer-Re-
installer race installer tachment verse gear bearing
YB-06270-A YB-41446 YB-06644 YB-06016
0-16
Shift rod socket Bearing housing puller Backlash indicator rod Backlash adjustment
YB-06681 YB-06207 YB-06265 plate
YB-07003
Dial indicator gauge Magnetic base stand Pinion height gauge Reverse gear bearing
YU-03097 YU-A8438 YB-06668 remover
YB-41707
Pinion gear bushing in- Driveshaft needle Trim cylinder wrench

staller bearing installer and YB-06175-2B
YB-06029-4 remover
YB-06196
0-17
Specification
Specification data .............................................................. 1-1
External dimensions .......................................................... 1-1

1
Clamp bracket dimensions ............................................... 1-9
Specification data
Specification data
For specification data, see Appendix, “Specification” (A-1).
External dimensions
TIP:
The dimension values may include reference values.
1-1
External dimensions
F30BEHD, F30EHA
mm (in)
364 (14.3)
40°
128 (5.0)
654 (25.7)
192 (7.6)
779 (30.7)
342 (13.5) 923 (36.3)
235 (9.3) 583 (23.0)
178 (7.0)
65 (2.6)
770 (30.3)
695 (27.4)
471 (18.5)
304 (12.0)
43 (1.7)
43 (1.7)
536 (21.1)
H*1
879 (34.6)
66 (2.
6) 2
660 (26.0)
°*
65
175 (6.9)
12°
19 (0.7)
–3°
29 (1.1) 522 (20.6)
*1. Motor transom height

*2. Fully tilt-up angle (Not tilt support angle)
1-2
External dimensions
F30HA
mm (in)
364 (14.3)
40°
128 (5.0)
654 (25.7)
192 (7.6)
779 (30.7)
345 (13.6) 925 (36.4)
235 (9.3) 583 (23.0)
177 (7.0)
65 (2.6)
770 (30.3)
695 (27.4)
471 (18.5)
306 (12.0)
43 (1.7)
44 (1.7)
536 (21.1)
H*1
879 (34.6)
66 (2.
6)
667 (26.3)
2
°*
66
175 (6.9)
12°
19 (0.7)
–3°
29 (1.1) 522 (20.6)

1-3
External dimensions
F30BET, F30A
192 (7.6) 364 (14.3)
40°
S: 817 (32.2)
345 (13.6) L: 924 (36.4)
134 (5.3) 583 (23.0)
65 (2.6)
695 (27.4)
471 (18.5)
306 (12.0)
43 (1.7)
14 (0.6)
S: 414 (16.3)
L: 536 (21.1)
158 (6.2)
H*1
S: 757 (29.8)
L: 879 (34.6)
S: 77
(
L: 66 3.0)
(2.6)
S: 606 (23.9)
L: 667 (26.3)
° *2
66
175 (6.9)
12°
19 (0.7)
–3°
S: 0 (0)
L: 29 (1.1) 522 (20.6)

1-4
External dimensions
F40FEHD, F40EHA
mm (in)
364 (14.3)
40°
128 (5.0)
654 (25.7)
192 (7.6)
779 (30.7) S: 816 (32.1)
342 (13.5) L: 923 (36.3)
235 (9.3) 583 (23.0)
178 (7.0)
65 (2.6)
770 (30.3)
695 (27.4)
471 (18.5)
304 (12.0)
43 (1.7)
43 (1.7)
S: 414 (16.3)
175 (6.9) L: 536 (21.1)
H*1
S: 757 (29.8)
L: 879 (34.6)
S: 77
(
L: 66 3.0)
S: 594 (23.4)
L: 660 (26.0)
(2.6) 2
°*
65
12°
19 (0.7)
–3°
S: 0 (0)
L: 29 (1.1) 522 (20.6)

1-5
External dimensions
F40HA
mm (in)
364 (14.3)
40°
128 (5.0)
654 (25.7)
192 (7.6)
779 (30.7)
345 (13.6) 925 (36.4)
235 (9.3) 583 (23.0)
177 (7.0)
65 (2.6)
770 (30.3)
695 (27.4)
471 (18.5)
306 (12.0)
43 (1.7)
44 (1.7)
536 (21.1)
H*1
879 (34.6)
66 (2.
6)
667 (26.3)
2
°*
66
175 (6.9)
12°
19 (0.7)
–3°
29 (1.1) 522 (20.6)

1-6
External dimensions
F40FED
mm (in)
192 (7.6) 364 (14.3)
40°
S: 816 (32.1)
342 (13.5) L: 923 (36.3)
134 (5.3) 583 (23.0)
65 (2.6)
695 (27.4)
471 (18.5)
304 (12.0)
43 (1.7)
15 (0.6)
S: 414 (16.3)
L: 536 (21.1)
158 (6.2)
H*1
S: 757 (29.8)
L: 879 (34.6)
S: 77
(
S: 594 (23.4)
L: 660 (26.0)
L: 66 3.0) ° *2
(2.6)
65
175 (6.9)
12°
19 (0.7)
–3°
S: 0 (0)
L: 29 (1.1) 522 (20.6)

1-7
External dimensions
F40FET, F40A
mm (in)
192 (7.6) 364 (14.3)
40°
S: 817 (32.2)
345 (13.6) L: 924 (36.4)
134 (5.3) 583 (23.0)
65 (2.6)
695 (27.4)
471 (18.5)
306 (12.0)
43 (1.7)
14 (0.6)
S: 414 (16.3)
L: 536 (21.1)
158 (6.2)
H*1
S: 757 (29.8)
L: 879 (34.6)
S: 77
(
L: 66 3.0)
(2.6)
S: 606 (23.9)
L: 667 (26.3)
° *2
66
175 (6.9)
12°
19 (0.7)
–3°
S: 0 (0)
L: 29 (1.1) 522 (20.6)

1-8
Clamp bracket dimensions
Clamp bracket dimensions

TIP:
The dimension values may include reference values.
mm (in)
180 (7.1) 180 (7.1)
163.5 (6.4) 163.5 (6.4) 69 (2.7)
50.8 (2.0)
254 (10.0)
18.5 (0.7)
13 (0.5)
338 (13.3)
55.5 (2.2)
13 (0.5)
125.9 (5.0) 125.9 (5.0)
1-9
Technical feature and description
Electronic control system ................................................. 2-1

Electrical components ................................................................ 2-3
Fail-safe...................................................................................... 2-5
Engine ECM ........................................................................ 2-7
Intake silencer .................................................................... 2-7 2

Fuel system ........................................................................ 2-8
Fuel diagram .............................................................................. 2-8
Lubrication system .......................................................... 2-10

Lubrication diagram.................................................................. 2-10
Cooling system ................................................................ 2-12

Cooling diagram ....................................................................... 2-12
Intake and exhaust system ............................................. 2-14

Intake and exhaust diagram ..................................................... 2-14
Hose routing ..................................................................... 2-15

Fuel hose.................................................................................. 2-15
Vapor gas hose and blowby hose ............................................ 2-16
Cooling water hose................................................................... 2-17
Electronic control system

This model uses an electronic fuel injection control, ignition timing control, engine speed control, ISC
valve control, and fail-safe control.
The engine ECM performs these controls based on signals received from each sensor and switch.
The engine ECM is equipped with a self-diagnosis function which can be used to check trouble codes
on the YDIS.
It is also equipped with Y-COP as an anti-theft measure (optional).
8. Ignition coil
10. Vapor shut-off valve

12. ISC valve
9. Fuel injector 11. High-pressure

fuel pump
13. TPS
24. ISC valve control
14. Intake air pressure

sensor
22. Fuel injection control
23. Ignition control 15. Intake air temperature sensor
17. YDIS 1. Pulser coil

16. Engine 2. Oil pressure switch
ECM
18. 6Y8/6YC Multifunction 3. Thermo sensor
Meters 4. Shift position switch
5. Water detection switch
19. Y-COP *1 20. Multi-hub
6. Water pressure sensor *1
7. Speed sensor *1
21. Battery
2-1
1. Pulser coil
2. Oil pressure switch
3. Thermo sensor
4. Shift position switch
6. Water pressure sensor *1
7. Speed sensor *1
8. Ignition coil
9. Fuel injector
11. High-pressure fuel pump
12. ISC valve
13. TPS
14. Intake air pressure sensor
15. Intake air temperature sensor
16. Engine ECM
17. YDIS
18. 6Y8/6YC Multifunction Meters
19. Y-COP *1
20. Multi-hub
21. Battery
22. Fuel injection control
23. Ignition control
24. ISC valve control
*1. Optional
2-2
Electrical components
9
11 10
2-3
Part name Function

Detects the engine speed.
1 Pulser coil
Detects the crankshaft angle and piston positions.
2 Thermo sensor Detects water temperature.
3 Ignition coil Produces high voltage to ignite a spark plug.
4 Oil pressure switch Detects oil pressure decrease.
Determines the engine operating conditions based on the input
5 Engine ECM signals from the sensors which are installed at various locations
on the engine, and transmits control signals to each actuator.
Controls the amount of vapor gas that is sent from the VST to
6 Vapor shut-off valve
the intake system to be reburned.
TPS:
Detects the throttle valve opening angle.
Intake air pressure sensor:
Detects the intake air pressure.
7 Throttle body Intake air temperature sensor:
Detects the intake air temperature.
ISC valve:
Adjusts the intake air distribution to the engine when the throttle
valve is fully closed.
8 Shift position switch Detects the neutral position.
9 High-pressure fuel pump Pressurizes and feeds the fuel to the fuel rails for injection.
10 Fuel injector Injects fuel.
11 Water detection switch Detects water accumulated in the fuel filter.
2-4
Fail-safe
In the fail-safe control, the engine ECM enters the fail-safe control mode when an electrical component
malfunctions.
The fail-safe control system records the trouble codes according to the engine trouble conditions.
Trouble Trouble conditions to be detect-
Item Control and operation
code ed
Control is performed based on
Open or short circuit in the the intake air temperature
thermo sensor circuit. when starting.
15 Thermo sensor
Output voltage is 0.2 V or less Set to 40 C (104 F) when
or 4.9 V or more. running.
High engine idle speed.
Open or short circuit in the
Control is performed based on
TPS circuit.
18 TPS the intake air pressure.
Output voltage is 0.3 V or less
High engine idle speed.
or 4.7 V or more.
Voltage is 12 V or less for 2
19 Battery voltage minutes, even when engine High engine idle speed.
speed is 2000 r/min or more.
Open or short circuit in the in-
take air temperature sensor
Intake air tempera- Set to 40 C (104 F).
23 circuit.
ture sensor High engine idle speed.
Output voltage is 0.4 V or less
or 4.8 V or more.
The shift position switch is on
27 Water in fuel filter and the water detection switch The alert buzzer sounds.
is on.
Cranking while in gear.
Cranking while the shift posi-
28 Shift position switch ECM does not control.
tion switch circuit is open-cir-
cuited.
Open or short circuit in the in-
take air pressure sensor cir- Control is performed based on
Intake air pressure
29 cuit. the TPS.
sensor
Output voltage is 0.1 V or less High engine idle speed.
or 4.4 V or more.
Ignition timing is retarded to
The shift position switch is off, limit the engine speed to 900 r/
the throttle is fully closed, the min.
37 Intake air passage ISC valve is fully closed, and Ignition is skipped if the engine
the engine speed is more than speed does not decrease to
1100 r/min. 900 r/min even if ignition timing
is fully retarded.
Engine shut-off Cranking when the clip is re-
44 Fuel injection is cut.
switch moved.
2-5
Trouble Trouble conditions to be detect-

Item Control and operation
code ed
Cooling water temperature is
40 C (104 F) or less, and en-
49 Over cooling ECM does not control.
gine speed is 3000 r/min or
more for 2 minutes or more.
Open or short circuit in the Y-
The engine starts, but the en-
COP circuit.
86 Immobilizer gine speed is limited to less
Communication error contin-
than 2600 r/min.
ues for more than 3 seconds.
2-6
Engine ECM
Engine ECM
The F30B engine ECM has been newly developed based on the F40F engine.
The approved model codes “a” identify each engine ECM.
EC1302
6BT 8125
Model name Approved model code “a”

F30B 6BT
F40F 6BG
Intake silencer
The intake silencer comes in shapes suitable for the intake air volume of each model.
A B
A. F30B
B. F40F
2-7
Fuel system
Fuel system
Fuel diagram

10. Pressure regulator
5. Fuel strainer
4. Low-pressure
fuel pump
2. Primer pump
3. Fuel filter 6. Vapor separator
12. Fuel injector 15. Fuel cooler

11. Fuel rail
2-8
Fuel system
6. Vapor separator
10. Pressure 17. Intake silencer 18. Intake manifold
regulator
284kPa
(2.84kgf/cm2,
41.2 psi)
11. Fuel rail

15. Fuel
cooler 9. High-pressure 12. 12. 12.
fuel pump Fuel injector Fuel injector Fuel injector
#1 #2 #3
8. Filter 13. Intake port
14. 14. 14.

7. Float chamber Combustion Combustion Combustion
chamber #1 chamber #2 chamber #3
5. Fuel strainer
4. Low-pressure fuel pump 3. Fuel filter 2. Primer pump 1. Fuel tank

A
B
1. Fuel tank A. Fuel flow
2. Primer pump B. Vapor gas flow
3. Fuel filter (Water separator)
4. Low-pressure fuel pump
5. Fuel strainer
6. Vapor separator
7. Float chamber
8. Filter
10. Pressure regulator
11. Fuel rail
12. Fuel injector
13. Intake port
14. Combustion chamber
15. Fuel cooler
17. Intake silencer
18. Intake manifold
2-9
Lubrication system
Lubrication system
Lubrication diagram
3. Oil pump
4. Oil filter
1. Oil pan
2. Oil strainer
10. Sleeve 14. Intake and exhaust valves
9. Piston 13. Rocker arm
8. Crankshaft pin 12. Rocker arm shaft
7. Crankshaft
11. Camshaft journal
journal
6. Oil pressure 5. Main gallery

switch
4. Oil filter
15. Relief valve 3. Oil pump

441 kPa
(4.41 kgf/cm2,
63.9 psi) 2. Oil strainer
1. Oil pan
A
2-10
Lubrication system
1. Oil pan
2. Oil strainer
3. Oil pump
4. Oil filter
5. Main gallery
7. Crankshaft journal
8. Crankshaft pin
9. Piston
10. Sleeve
11. Camshaft journal
12. Rocker arm shaft
13. Rocker arm
14. Intake and exhaust valves
15. Relief valve
A. Engine oil flow
2-11
Cooling system
Cooling system
Cooling diagram
10. Thermostat
8. Fuel cooler
11. Exaust guide
15. Trim tab water inlet

3. Water pump
2. Water inlet
2-12
Cooling system
8. Fuel cooler
9. Cooling water
pilot hole
11. Exhaust guide 7. Exhaust cover 10. Thermostat
12. Upper case 4. Exhaust port 6. Cylinder head

5. Cylinder block
13. Lower case
3. Water pump
B
15. Trim tab

2. Water inlet
14. Propeller boss water inlet
1. Water
1. Water
2. Water inlet
3. Water pump
4. Exhaust port
5. Cylinder block
6. Cylinder head
7. Exhaust cover
8. Fuel cooler
9. Cooling water pilot hole
10. Thermostat
11. Exhaust guide
12. Upper case
13. Lower case
14. Propeller boss
15. Trim tab water inlet
A. Cooling water flow
B. Hydrodynamic water pressure for cool-
ing the propeller boss damper
2-13
Intake and exhaust system
Intake and exhaust system

Intake and exhaust diagram
1. Intake silencer
2. Throttle body
3. Intake manifold
8. Idle exhaust hole

4. Exhaust guide
5. Exhaust manifold
6. Muffler
7. Propeller boss
A
B
1. Intake silencer
2. Throttle body
3. Intake manifold
4. Exhaust guide
5. Exhaust manifold
6. Muffler
7. Propeller
8. Idle exhaust hole
A. Intake air flow
B. Exhaust gas flow
2-14
Hose routing
Hose routing
Fuel hose
9
6
8
3 1
1. Fuel joint to joint

2. Joint to fuel filter
3. Fuel filter to fuel pump
4. Fuel pump to strainer
5. Strainer to vapor separator
6. Pressure regulator to fuel cooler
7. Fuel cooler to vapor separator
8. Vapor separator to fuel rail
9. Pressure regulator to intake manifold
2-15
Hose routing
Vapor gas hose and blowby hose
1. Vapor separator to joint

2. Vapor separator to joint
3. Joint to vapor shut-off valve
4. Vapor shut-off valve to throttle body
5. Cylinder head cover to intake silencer
2-16
Hose routing
Cooling water hose
6
2
8
7 4
5
1. Exhaust cover to joint

2. Joint to fuel cooler
3. Fuel cooler to fuel cooler
4. Fuel cooler to joint
5. Joint to joint
6. Joint to exhaust guide
7. Joint to cooling water pilot hole
8. Flushing hose adapter to joint
2-17
Rigging information
Important reminder on rigging.......................................... 3-1

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

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

Uncrating procedure................................................................... 3-3
Rigging grommet mounting .............................................. 3-5 3

Rigging grommet description...................................................... 3-5
Installing the battery cable.......................................................... 3-5
Installing the shift cable and throttle cable ................................. 3-6
Installing the main wire harness ................................................. 3-8
Installing the 6Y8 multifunction meter harness
(pigtail bus wire) ......................................................................... 3-8
Installing the conventional gauge (6Y5/6Y7) harness ................ 3-9
Installing the rigging grommet .................................................... 3-9
Tiller handle ........................................................................ 3-9

Installing the tiller handle............................................................ 3-9
Battery installation ........................................................... 3-11
Rigging recommendation ................................................ 3-11

Battery cable length.................................................................. 3-11
Propeller selection ........................................................... 3-12

Important reminder on rigging
Important reminder on rigging

Outboard motor mounting instructions
• Overpowering a boat could cause severe instability. Do not install an outboard motor with
more horsepower than the maximum rating on the capacity plate of the boat. If the boat does
not have a capacity plate, consult the boat manufacturer.
• Improper mounting of the outboard motor could result in hazardous conditions, such as poor
handling, loss of control, or fire hazards.
Too much weight on the transom can change the center of gravity, buoyancy, operating bal-
ance, or performance of the boat, which could cause loss of control or swamping. Consult the
boat manufacturer for the maximum engine weight allowable on the transom, which is different
from the overall boat capacity. Overloading the transom with an outboard motor that is too
heavy could also damage the hull, transom, deck, or helm area, as well as the outboard motor
and other equipment.
Before mounting the outboard motor, consult the manufacturer of the engine jack plates or
brackets. Excessive loads could damage the engine jack plates, brackets, boat transom, steer-
ing system, or engine. These damages could cause loss of control.
3-1
Crate handling
Crate handling
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.
1
6 7
9 8
3 4
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.
1. WARNING 3. IMPORTANT
Wear suitable protective gear such as This unit delivered to carrier in a good
gloves and eye protection when han- condition.
dling and opening crate. For protection against loss due to dam-
2. NOTICE age, inspect thoroughly.
• Use forklifts with forks that are at least If damage is noted, make note on freight
1 m (40 in) in length. bill.
• Only stack with crate of the same size. Shipper assumes no further liability to
• Be sure unit is stacked securely (all the transportation company.
four corners fit securely on unit below Your claim should be filed against carri-
it). er for damage of any nature.
• Stack Limit - 2 units (at handling). 4. Lifting fork insert position
5. Crate barycentric position
6. Stack limit: Maximum 6 units for storage
7. Upward indication
8. Care handling indication
9. Water avoidance indication
3-2
Uncrating
Uncrating g. Install the shackles “1” to the engine hang-

Uncrating procedure ers “2”, and then install the lifting harness-
es “3” to the shackles “1”.
3 1 2
Wear gloves to avoid injury from sharp
steel edges while uncrating.
1. Uncrate:
• Outboard motor 3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the crate for shipping damage. If
any damage is found, consult your Yama-
ha agency.
1
b. Cut the strap, and then remove the top
cover. 2
c. Remove all of the bolts from the bottom h. Apply tension to the lifting harnesses “1”.
plate, and then remove the frame.
TIP:
Place a rag “2” between the flywheel magneto,
Be careful not to damage the outboard mo- lifting harness, and shackle.
tor.
d. Remove the wrapping, and then check the

outboard motor for concealed damage. If
any damage is found, consult your Yama-
ha agency.
e. Remove the top cowling. 1
f. Remove the bolt “1”, and then remove the

flywheel magneto cover “2”. 2
3-3
Uncrating
i. Lift up the outboard motor carefully along m. For the procedure of outboard motor
with the bottom frame “1”. mounting on boat, see “Rigging Guide”
(6YR-2819Y-**).
Make sure that the lifting harnesses do not n. Remove the lifting harness and shackles,
damage any parts of the outboard motor. and then install the fiywheel magneto cov-
er and top cowling.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
j. Remove the skeg holder “1”.
k. Remove the bolts “1”.
l. Remove the steering retainer, and then in-

stall a hydraulic steering cylinder or steer-
ing cable following the recommendation of
the manufacturer (remote control model).
3-4
Rigging grommet mounting
Rigging grommet mounting Installing the battery cable

Rigging grommet description 1. Install:
Pass all the rigging components through the • Battery cable
proper holes in the rigging grommet. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the plastic tie “1”, and then re-
6 1 move the main wire harness coupler “a”.
b. Remove the cover “2”.

2
5
a
3
1
4
2
1. Alert indicator harness
2. Trolling switch harness
3. Main wire harness
4. Speedometer hose
5. Battery cable c. Route the battery cable “1” through the
6. 6Y8 multifunction meter harness (pigtail bottom cowling.
bus wire)/gauge harness/Y-COP wire
harness d. Connect the positive and negative termi-
nals of the battery cable.
1. Remove:
• Nut “1” TIP:
The positive battery cable is marked with “+”
• Nut “2”
mark.
• Steering retainer “3”
• Bolt“4”
e. Install the rubber caps “2”.
f.
4
2
1 3 2
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-5
Installing the shift cable and throttle b. Move the remote control lever to the N po-
cable sition.
c. Align the pin “1” with the mark “a” on the

Always perform the cable adjustment in ad- shift bracket “2”.
vance, following the procedures in the in-
struction accompanied with remote control
1
box.
1. Route:
• Shift cable a
• Throttle cable
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the cable guide “1” to the grooves
“a” of the shift cable “2” and the throttle ca-
d. Make a mark “a” on the fully retracted inner
ble “3”, and then route the bottom cowling.
cable, and then make a mark “b” on the ful-
b. Tighten the cable guide bolt “4” to the ly extended inner cable.
specified torque.
e. Make a mark “c” in the middle point be-
tween marks “a” and “b”, and then align the
mark “c” with the outer cable edge “d”.
2 a
a
a c b
3
4
1 a c
Cable guide bolt “4” d

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
f. Adjust the shift cable joint “1”, and then in-

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
stall it to the pin “2”.
2. Install:
• Shift cable
• Throttle cable The shift cable joint must be screwed in 8.0
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ mm (0.31 in) or more.
a. Fully screw in the shift cable joint “1” to the
shift cable “2”.
g. Install the clip “3”, and then check that the
shift cable locknut “4” is fully seated on the
shift cable joint “1”.
2
1
3-6
h. Tighten the shift cable locknut “4” from its l. Pull the inner cable “3” using the force of
fully seated position to the specified angle. 15 N (1.5 kgf, 3.4 lbf) to remove any free
play in the cable.
2 3
1 m. Adjust the throttle cable joint “4”, and then
install it to the pin “5” of the throttle lever.
4 The throttle cable joint must be screwed in

8.0 mm (0.31 in) or more.
1 a
b
Dimension “a”
8.0 mm (0.31 in) or more 4 c
a
Shift cable locknut “4” 2 b
90
T.
R.
i. Fully screw in the throttle cable joint “1” to

the throttle cable “2”.
5
1 a 4 3
Dimension “c”
8.0 mm (0.31 in) or more
2
1 n. Install the clip “1”, and then check that the
throttle cable locknut “2” is fully seated on
the throttle cable joint “3”.
j. Check that the throttle control lever “1”
contacts the stopper “2”. o. Tighten the throttle cable locknut “2” from
its fully seated position to the specified an-
gle.
1
3
2 2
1
k. Align the protrusion “a” on the throttle lever
“1” with the protrusion “b” on the shift
bracket “2”. Throttle cable locknut “2”
90
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-7
3. Check:
1 a
• Shift cable operation
• Throttle cable operation 3 2
Improper  Repeat from step 2.
4
4. Install:
• Grommet “1” 5
1 6
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Installing the 6Y8 multifunction meter

harness (pigtail bus wire)
1. Remove the cap “1”.
2. Route the pigtail bus wire “2” through the

bottom cowling.
Installing the main wire harness
1. Install: 3. Connect the coupler “a” to the coupler “b”.
• Main wire harness
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the cover “1”.
b. Route the main wire harness “2” through 2

the bottom cowling. See “Bottom cowling b
(tiller handle model)” (5-8) or “Bottom a
cowling (remote control model)” (5-9).
c. Connect the main wire harness coupler 1

(10-pin) “a”, and then secure it using the
plastic tie “3”. 4. Remove the yellow tape “1” and caps “2”.
d. Install the main wire harness “2” to the 5. Connect the trim sensor coupler “a”.
clamp “4”, and then fasten the main wire
harness “2” to the bracket “5” with a plastic
2
tie “6”. a
TIP:
Before fastening the main wire harness “2” to 1
the clamp “4” and the bracket “5”, pull it to pre-
vent loosening.
2
3-8
Tiller handle
Installing the conventional gauge
(6Y5/6Y7) harness
1
1. Install:
• Gauge harness
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 5
a. Remove the cap “1”.
b. Route the gauge harness “2” through the 4 5

bottom cowling. See “Bottom cowling (re- 3 2
mote control model)” (5-9).
c. Connect the gauge harness coupler “a”. Grommet holder bolt “5”
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a
Tiller handle
Installing the tiller handle
1 1. Install:
• Tiller handle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the cable guide “1” into the grooves “a”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ in the shift cable “2” and the throttle cable
“3”.
Installing the rigging grommet
1. Install: TIP:
• Rigging grommet The shape “b” identifies the shift cable “2”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Route each cable, harness, and hose
through the proper holes in the rigging
grommet. See “Rigging grommet descrip- 2
tion” (3-5). a
b. Install the battery cable with the positive 3

battery cable “1” on top and align the white
tape “2” on the battery cable with the outer
end of the rigging grommet. 1
c. Install the rigging grommet “3” along with

b
the grommet holder “4”, and then tighten
the grommet holder bolts “5” to the speci-
fied torque.
b. Route the shift cable “1” and throttle cable

“2” through the bottom cowling.
3-9
Tiller handle
c. Install the tiller handle assembly “3” to the h. Remove the cap “1”.
steering arm “4”, and then tighten the tiller
handle nuts “5” to the specified torque. i. Route the trolling switch harness “2”
through the bottom cowling, and then con-
d. Install the cable guide “6” to the bottom nect the trolling switch harness coupler “a”.
cowling, and then tighten the cable guide
2
bolt “7” to the specified torque.
4 a
3
1
2
1
6
7 5 j. Install the shift cable and throttle cable.
5
See steps 2–4 in “Installing the shift cable
and throttle cable” (3-6).
Tiller handle nut “5”
40 N·m (4.0 kgf·m, 30 lb·ft)
T.
k. Install the rigging grommet and grommet

R.
Cable guide bolt “7” holder. See “Installing the rigging grom-
10 N·m (1.0 kgf·m, 7.4 lb·ft) met” (3-9).
e. Install the main wire harness and battery l. Fasten the main wire harness, battery ca-
cable. See “Installing the main wire har- ble, alert indicator harness, trolling switch
ness” (3-8) and “Installing the battery ca- harness, shift cable, and throttle cable us-
ble” (3-5). ing the plastic tie “1”.
f. Remove the cap “1”.
g. Route the alert indicator harness “2”

through the bottom cowling, and then con-
nect the alert indicator harness coupler “a”.
2
a 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-10
Battery installation
2. Check: Battery installation
• Steering friction
TIP: Make sure to connect the battery properly

Make sure that the hoses, harnesses, leads, and select the proper cable sizes. Other-
and cables do no interfere with the steering
wise, a fire could result.
friction plate assembly.
Do not reverse the battery connections.

Otherwise, the charging system could be
damaged.
Rigging recommendation
Battery cable length
b a The battery cable length from the negative ter-
minal of the battery cable to the rigging grom-
a. Increase the friction
met.
b. Decrease the friction
The positive battery cable is 100 mm (3.9 in)
3. Adjust: longer than the negative battery cable.
• Steering friction See “Specification” (A-1).
Do not overtighten the friction adjuster. If

there is too much resistance, it could be dif-
ficult to operate the throttle grip, which
could result in an accident.
TIP:
• Tighten or loosen the friction adjusting nut “1”
at the steering lock lever in the position “a”.
• To increase the friction, tighten the friction ad-
justing nut “1” in direction “b”.
• To decrease the friction, loosen the friction
adjusting nut “1” in direction “c”.
c b
1
1
A
A
a
3-11
Propeller selection
Propeller selection
With the engine speed at full throttle operating range and under a maximum boat load, the engine
speed should be within the upper half of the full throttle operating speed range.
Full throttle operating range

5000–6000 r/min
Blade Dia. (in) Pitch (in) Mark Material Part number Remarks
3 12 1/4 8 G Aluminum 63D-45941-00
3 12 1/4 9 G Aluminum 663-45956-01
3 11 3/4 10 G Aluminum 663-45954-01
3 11 3/8 12 G Aluminum 663-45952-02
3 11 1/4 14 G Aluminum 663-45958-01
3 10 3/4 16 G Aluminum 663-45949-01
3 10 3/4 17 G Aluminum 663-45941-01
3 10 5/8 12 G Aluminum 6H5-45952-00
3 10 3/8 13 G Aluminum 6H5-45945-00
3 10 1/4 14 G Aluminum 6H5-45958-00
3 10 15 G Aluminum 6H5-45943-00
3 11 5/8 11 G Aluminum 69W-45947-00
3 11 3/8 12 G Aluminum 69W-45952-00
3 11 1/8 13 G Aluminum 69W-45945-00
3 11 1/4 14 G Aluminum 69W-45958-00
3 11 15 G Aluminum 69W-45943-00
3 12 11 G Stainless steel 663-45972-60
3 11 3/4 12 G Stainless steel 663-45970-60
TIP:
The part numbers are subject to change without notice. Make sure to confirm the latest numbers.
3-12
Troubleshooting
YDIS ..................................................................................... 4-1

Connecting the communication cable ........................................ 4-1
Outboard motor troubleshooting...................................... 4-3

Troubleshooting procedure ........................................................ 4-3
Troubleshooting the power unit using the YDIS ......................... 4-3
Trouble code and checking step ................................................ 4-5
Troubleshooting procedure (trouble code not detected) ............ 4-7
Troubleshooting the power unit .................................................. 4-7
Troubleshooting the PTT unit ................................................... 4-12
Troubleshooting the lower unit ................................................. 4-13
4
YDIS
YDIS
The Yamaha Diagnostic System uses precision fault diagnosis to offer better serviceability at a time
when there is increasing demand for service tools for electronically controlled products. It provides
quick, reliable, safe, and reasonable service, and is intended to obtain customer satisfaction. The Ya-
maha Diagnostic System features updated software and expanded tool functions that allow it to re-
spond to new models and technologies, maintaining compatibility with regulations. See YDIS (Ver. 2.33
or later) instruction manual for detailed information.
YDIS2 Hardware Kit

90890-06884
YDIS2 Hardware Kit
LIT-YDIS2-01-KT
Connecting the communication cable

CAN-Line
2. Adapter cap 3. Adapter interface

4. USB cable
1. CAN-Line harness
5. Multi-hub 5. Multi-hub
1. CAN-Line harness
2. Adapter cap
3. Adapter interface
4. USB cable
5. Multi-hub
4-1
YDIS
K-Line
a. YDIS coupler
2. Adapter cap
4. K-Line harness
3. USB cable
2. Adapter cap
3. USB cable
4. K-Line harness
a. YDIS coupler (gray)
4-2
Outboard motor troubleshooting

Troubleshooting procedure
1. Before troubleshooting the outboard motor, check that fresh fuel of the specified type has been
used.
2. Check that all electrical connections are secure and free from corrosion, and that the battery is fully
charged.
3. Check the trouble code using the YDIS first, and then check the electronic control system following
the trouble code chart.
4. When a trouble code is detected, check the data logger of the engine ECM record graph as well.
5. If a trouble code is not detected, check the power unit according to “Troubleshooting the power unit”
(4-7).
6. Before using the YDIS to check the power unit, check the engine ECM circuit. See “Checking the
engine ECM circuit” (5-18).
TIP:
• When deleting the diagnosis record on the YDIS, make sure to check the time that the trouble codes
were detected.
• When checking the input voltage of a part, the coupler or connector must be disconnected. As a result,
the engine ECM determines that the part is disconnected and a trouble code is detected.
Therefore, make sure to delete the diagnosis record after checking the input voltage.
• Since the main relay comes on for approximately 10 seconds after the engine start switch is turned to
OFF, the power of the engine ECM cannot be turned off. Therefore, if the engine start switch is turned
to ON within 10 seconds after it was turned to OFF, the trouble codes cannot be deleted.
Troubleshooting the power unit using the YDIS

1. Use the trouble codes displayed by the YDIS to check each part according to the table of “Trouble
code and checking step” (4-5).
2. Delete the trouble codes after checking, repairing, or replacing a part and check that the trouble
codes are not detected again. If the same trouble codes are detected, the engine ECM may be
faulty.
3. Check the items listed in the table. If all of the items are in good condition, delete the trouble codes,
and then check the trouble codes again. If the same trouble codes are detected again, the engine
ECM is faulty.
4-3
Trouble code table
✔: Indicated
—: Not indicated
YDIS diagnosis
Code No. Item YDIS diagnosis
record
15 Thermo sensor ✔ ✔
18 TPS ✔ ✔
19 Battery voltage ✔ ✔
23 Air temperature sensor ✔ ✔
27 Water in fuel filter ✔ ✔
28 Shift position switch ✔ ✔
29 Air pressure sensor ✔ ✔
37 Intake air passage ✔ ✔
44 Engine shut-off switch ✔ —
49 Over cooling ✔ ✔
86 Immobilizer ✔ ✔
4-4
Trouble code and checking step
—: Not applicable
Trou-
See
ble Item (Condition) Symptom Checking steps
page
code
“Check Engine” is displayed. Measure the thermo sensor in-
5-32
High engine idle speed put voltage.
Thermo sensor Degraded acceleration perfor- Measure the thermo sensor re-
5-32
15 (Out of specifi- mance sistance.
cation) Declining maximum engine Check for wiring continuity be-
speed tween the thermo sensor and A-15
Overheat the engine ECM.
Measure the TPS output volt-
age and opening angle using 5-19
“Check Engine” is displayed. the YDIS.
TPS (Out of High engine idle speed Measure the TPS input volt-
18 5-19
specification) Degraded acceleration perfor- age.
mance Check for wiring continuity be-
tween the throttle body and the A-15
engine ECM.
Check the battery cable and
terminals for proper connec- 10-7
tion.
Battery voltage and battery Measure the lighting coil out-

5-26
Battery voltage alert are displayed. put peak voltage.
19 (Below speci- Engine operates normally. Measure the lighting coil resis-
5-26
fied voltage) Engine does not restart (de- tance.
pends on battery condition). Measure the rectifier/regulator
5-27
output peak voltage.
Check the rectifier/regulator
5-27
for continuity.
Check the intake air tempera-
Air tempera- 5-31
ture using the YDIS.
ture sensor “Check Engine” is displayed.
23 Check for wiring continuity be-
(Out of specifi- High engine idle speed
cation) tween the throttle body and the A-15
engine ECM.
Check the fuel filter for water. —
Measure the water detection
5-22
switch input voltage.
Water in fuel fil- “Water in fuel” is displayed.
27 ter (Water in Alert buzzer comes on while Check the water detection
5-22
fuel filter) the shift is in the N position. switch for continuity.
Check for wiring continuity be-
tween the water detection A-15
switch and the engine ECM.
4-5
Trou-
See
ble Item (Condition) Symptom Checking steps
page
code
Check the gear shift operation. 10-4
Measure the shift position
5-32
switch input voltage.
Shift position
“Check Engine” is displayed. Check the shift position switch
28 switch (Irregu- 5-32
Engine operates normally. for continuity.
lar signal)
Check for wiring continuity be-
tween the shift position switch A-15
and the engine ECM.
Measure the intake air pres-
“Check Engine” is displayed. 5-31
Air pressure sure sensor input voltage.
High engine idle speed
29 sensor (Out of Check for wiring continuity be-
Declining maximum engine
specification) tween the throttle body and the A-15
speed
engine ECM.
Check the gaskets of the in-
take manifold and the throttle 6-12
body.
“Check Engine” is displayed.
Intake air pas- Check the intake manifold for
37 Engine operates normally, ex- 6-13
sage (Air leak) cracks.
cept at idle.
Check the opening condition of
TPS and the ISC valve using 5-19
the YDIS.
Over cooling Check that the trouble code 15
4-5
49 (Irregular sig- Engine operates normally. has not appeared.
nal) Check the thermostat. 7-46
Check that Y-COP is connect-
—
Immobilizer ed properly.
86 (Communica- Engine operates normally. Measure the remote control re-
—
tion error) ceiver input voltage.
Check the Y-COP circuit. —
4-6
Troubleshooting procedure (trouble code not detected)
Troubleshooting consists of the following 5 items:
Symptom 1: Specific trouble conditions
Symptom 2: Trouble conditions of an area or individual part
Cause: Trouble causes of symptom 2
Checking steps: Method for checking
See page: Reference page
—: Not applicable
Troubleshooting the power unit
Symptom 1: Engine does not crank.

See
Symptom 2 Cause Checking steps
page
Gear shift not in the N posi-
Set the gear shift to the N position. 10-4
tion
Blown fuse Check the fuse. 5-1
Starter relay malfunction Check the starter relay. 5-34
Engine start switch mal-
Check the engine start switch. 5-35
Starter motor does function
not operate Neutral switch malfunction Check the neutral switch. —
Short, open, or loose con- Check the starter relay input voltage. 5-34
nection in starter motor cir- Check the wire harness for continui-
cuit A-16
ty.
Disassemble and check the starter
Starter motor malfunction 5-36
motor.
Disassemble and check the power
Stuck piston or crankshaft 7-49
Starter motor oper- unit.
ates, but the engine Check the drive shaft bushing. 9-16
does not crank Stuck drive shaft Disassemble and check the lower
8-11
unit.
Symptom 1: Engine will not start (engine cranks).

See
page
Main relay malfunction Check the main relay. 5-17
Engine ECM does not Check for wire harness continuity

operate Short, open, or loose con- between the main relay and the en- A-15
nection in the engine ECM gine ECM.
circuit Check for continuity between the en-
5-18
gine ECM and ground.
4-7
See
page
Measure the pulser coil output peak
5-30
voltage.
Pulser coil malfunction
Checking the pulser coil air gap. 7-2
Measure the pulser coil resistance. 5-30
Spark plug does not
produce a spark (all Check the engine ECM output peak
Engine ECM malfunction 5-29
cylinders) voltage.
Short, open, or loose con- Check for wire harness continuity
nection in the pulser coil cir- between the pulser coil and the en- A-15
cuit gine ECM.
Y-COP is locked. Unlock Y-COP. —
Pinched or kinked fuel hose Check the fuel hose. 2-15
Check the fuel filter element for dirt
Clogged fuel filter element 6-5
and obstructions.
Check the fuel strainer for dirt and
Clogged fuel strainer 6-22
obstructions.
Fuel leakage Check the fuel line for leakage. 2-15
Check the high-pressure fuel pump
5-24
High-pressure fuel pump operation using the YDIS.
malfunction Measure the high-pressure fuel
5-24
pump resistance.
Main relay malfunction Check the main relay. 5-17
Fuel not supplied (all
cylinders) Measure the high-pressure fuel
5-24
pump input voltage.
Check for continuity between the
Short, open, or loose con-
high-pressure fuel pump and the A-15
nection in high-pressure
main relay.
fuel pump circuit
high-pressure fuel pump and A-15
ground.
Check the fuel pump for leakage. 6-9
Fuel pump malfunction Check the diaphragm for tears. 6-10
Check the rocker arm. 7-40
Y-COP is locked. Unlock Y-COP. —
Check the valve timing. 7-16
Improper valve timing
Check the timing belt. 7-15
Check the valve for bends or stick-
Compression pres- 7-33
ing.
sure is low
Compression leakage Check the piston and piston rings for
7-49
damage.
Check the cylinder for scratches. 7-51
4-8
See
page
Check the ISC valve for sticking. 5-20
Intake air passage malfunc-
— Check the intake manifold and throt-
tion 6-12
tle body for air leakage.
Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, or limited en-
gine speed.
See
page
Check the throttle valve for proper
Throttle valve malfunction 6-13
movement.
Throttle valve does
not move properly Throttle link rod and the
Adjust the throttle link rod and the 3-6
throttle cable are not in-
throttle cable. 6-15
stalled properly
Spark plug malfunction Check the spark plugs. 7-40
Short, open, or loose con- Check for wiring continuity between
A-15
nection in ignition coil circuit the ignition coil and the engine ECM.
Spark plug does not
Ignition coil malfunction Measure the ignition coil resistance. 5-29
produce a spark
(some cylinders) Measure the spark plug cap resis-
Spark plug cap malfunction 5-30
tance.
Check the engine ECM output peak
Engine ECM malfunction 5-29
voltage.
Fuel leakage Check for fuel leakage. 2-15
Check the fuel filter element for dirt
Clogged fuel filter element 6-5
and obstructions.
Check the fuel strainer for dirt and
Clogged fuel strainer 6-22
Fuel pressure is low obstructions.
High-pressure fuel line mal-
Check the high-pressure fuel pump. 5-24
function
Pressure regulator mal-
Check the pressure regulator. 10-7
function
Check the fuel injector operation us-
5-23
Fuel injector malfunction ing the YDIS.
Measure the fuel injector resistance. 5-23
Measure the fuel injector input volt-
5-23
age.
Fuel not supplied Short, open, or loose con-
(some cylinders) nection in fuel injector cir- A-15
fuel injector and the main relay.
cuit
A-15
fuel injector and the engine ECM.
Clogged fuel injector filter Replace the fuel injector. 6-25
Engine ECM malfunction Replace the engine ECM. 7-19
4-9
See
page
Check the valve timing. 7-16
Improper valve timing
Check the timing belt. 7-15
Measure the valve clearance. 7-2
Check the rocker arm for damage. 7-39
Compression pres- Check the camshaft for damage. 7-40
sure is low
Compression leakage Check the valve and valve seat for 7-33
wear. 7-36
Check the piston and piston ring for
7-49
damage.
Check the cylinder for scratches. 7-51
Symptom 1: High engine idle speed.

See
page
Check the gaskets of the intake
6-12
Air leakage (throttle valve– manifolds and throttle body.
cylinder head) Check the intake manifold for
6-13
cracks.
— Throttle link rod and the
Adjust the throttle link rod and the 3-6
throttle cable are not in-
throttle cable. 6-15
stalled properly
Check the ISC valve operation using
ISC valve malfunction 5-20
the YDIS.
Symptom 1: Limited engine speed (below 2000–3000 r/min).

See
page
Check the pilot hole for cooling water
10-8
Clogged cooling water inlet discharge.
Check the cooling water inlet. 10-14
Check the impeller. 8-4
Buzzer comes on, Water pump malfunction Check the impeller key. 8-4
overheat alert indica- Check the insert cartridge. 8-4
tor comes on Check the water pump housing. 8-4
Water leakage from water
pump housing Check the outer plate cartridge. 8-4
Clogged cooling water pas-
Check the cooling water passages. 2-12
sages
Thermostat malfunction Check the thermostat. 7-46
4-10
See
page
Check the engine oil level. 10-15
Check for engine oil leakage. 2-10
Insufficient engine oil
Check the valve seals and valves. 7-30
Check the piston rings. 7-52
Buzzer comes on, oil
Check the oil pressure switch. 5-20
pressure alert indica-
tor comes on Check the oil pump. 7-46
Engine oil pressure de- Check the oil strainer. 9-19
crease Check the oil passages (power unit
2-10
and the oil pump).
Replace the oil filter. 10-17
Symptom 1: Discharged battery.

See
page
Battery performance de- Check the battery capacity and spe-
10-7
crease cific gravity.
Check the battery cable and termi-
3-5
Short, open, or loose con- nals for proper connections.
nection in charging circuit Check the charging circuit for wiring
A-16
Low voltage indicator connection and damage.
activates on the Measure the lighting coil output peak
5-26
gauge Lighting coil malfunction voltage.
Measure the lighting coil resistance. 5-26
Measure the rectifier/regulator out-
5-27
Rectifier/regulator malfunc- put peak voltage.
tion Check the rectifier/regulator for con-
5-27
tinuity.
Symptom 1: Y-COP lock and unlock do not function.

See
page
Check the button cell battery volt-
—
Y-COP remote control age.
There is an answer- transmitter malfunction Replace with a spare remote control
—
back (beep) transmitter.
Check the Y-COP circuit. —
nection of the wire harness
4-11
Symptom 1: Y-COP lock and unlock function, but there is no answer-back (beep).
See
page
Buzzer malfunction Check the buzzer. —
— Short, open, or loose con- Measure the buzzer input voltage. —
nection of the wire harness Check the Y-COP circuit. —
Troubleshooting the PTT unit
Symptom 1: PTT unit does not operate.

See
page
PTT switch malfunction Check the PTT switch. 5-45
PTT relay malfunction Check the PTT relay. 5-44
PTT relay does not Measure the PTT switch input volt-
5-45
operate age.
Short, open, or loose con- Measure the PTT relay input volt-
5-44
nection of the wire harness age.
Check for continuity between the A-16
PTT switch and the PTT relay. A-17
PTT motor malfunction Check the PTT motor. 9-33
Bent trim and tilt ram Check the trim and tilt ram. 9-41
PTT motor does not Disassemble and check the PTT

Stuck trim and tilt ram 9-41
operate unit.
PTT motor and the PTT relay termi- A-16
nection in PTT motor circuit
nal.
Manual valve open Check the manual valve. 9-27
Insufficient PTT fluid Add sufficient PTT fluid. 10-20
PTT fluid leakage Check for PTT fluid leakage. 10-20
Disassemble and check the PTT 9-38
unit. 9-41
PTT fluid pressure Check the filter for dirt and obstruc-
9-40
does not increase Clogged fluid passage tions.
Check the valves for damage. 9-40
Check the fluid passages for ob- 9-38
structions. 9-41
PTT motor malfunction Check the PTT motor. 9-33
Gear pump malfunction Check the gear pump operation. 9-27
4-12
Symptom 1: PTT unit does not hold the outboard motor up.
See
page
Manual valve open Check the manual valve. 9-27
Insufficient PTT fluid Add sufficient PTT fluid. 10-20
PTT fluid leakage Check for PTT fluid leakage. 10-20
PTT fluid pressure Disassemble and check the PTT 9-38
does not increase unit. 9-41
Clogged fluid passages Check the valves for damage. 9-40
Check the fluid passages for ob- 9-38
structions. 9-41
Troubleshooting the lower unit
Symptom 1: Shift mechanism of the forward gear and reverse gear does not operate properly.
See
page
Shift cable is not adjusted
Adjust the shift cable. 3-6
properly
—
Shift rod does not operate Check the shift rod for wear. 8-4
properly Check the detent mechanism. 9-10
Check the shift rod for proper posi-
8-11
tion.
Shift mechanism malfunc- Check the dog clutch. 8-8
—
tion (in lower unit) Check the forward gear, reverse 8-14
gear, and pinion for damage and 8-8
wear. 8-14
4-13
Electrical system
Electrical component and wire harness routing ............. 5-1

Port............................................................................................. 5-1
Starboard.................................................................................... 5-3
Front ........................................................................................... 5-5
Rear............................................................................................ 5-6
Top ............................................................................................. 5-7
Bottom cowling (tiller handle model) .......................................... 5-8
Bottom cowling (remote control model)...................................... 5-9
Tiller handle (tiller handle model) ............................................. 5-11
ECM circuit diagram ........................................................ 5-13
ECM coupler layout.......................................................... 5-15
Checking the electrical component................................ 5-16

Using the YDIS......................................................................... 5-16
Measuring the peak voltage ..................................................... 5-16
Using the digital tester.............................................................. 5-17
Engine control unit and component............................... 5-17

Checking the main relay........................................................... 5-17
Checking the engine ECM circuit ............................................. 5-18
Checking the TPS .................................................................... 5-19
Checking the ISC valve ............................................................ 5-20
Checking the oil pressure switch.............................................. 5-20
Checking the alert indicator (tiller handle model) ..................... 5-21
Checking the alert buzzer......................................................... 5-22
Checking the trolling switch (tiller handle model) ..................... 5-22
Fuel control unit and component ................................... 5-22

Checking the water detection switch ........................................ 5-22
Checking the fuel injector ......................................................... 5-23
Checking the high-pressure fuel pump..................................... 5-24
Checking the vapor shut-off valve ............................................ 5-25
Charging unit and component ........................................ 5-26

Checking the lighting coil (stator assembly) ............................. 5-26
Checking the rectifier/regulator ................................................ 5-27
Electrical system
Ignition unit and component ........................................... 5-28

Checking the ignition spark ...................................................... 5-28
Checking the engine ECM........................................................ 5-29
Checking the ignition coil.......................................................... 5-29
Checking the spark plug cap .................................................... 5-30
Checking the pulser coil ........................................................... 5-30
Checking the intake air temperature sensor............................. 5-31
Checking the intake air pressure sensor .................................. 5-31
Checking the thermo sensor .................................................... 5-32
Checking the shift position switch ............................................ 5-32
Checking the engine shut-off switch......................................... 5-33
Starting unit and component .......................................... 5-34

Checking the starter relay ........................................................ 5-34
Checking the engine start switch.............................................. 5-35
Starter motor .................................................................... 5-36

Removing the starter motor...................................................... 5-37
Disassembling the starter motor............................................... 5-37
5
Checking the starter motor pinion ............................................ 5-37
Checking the armature (starter motor) ..................................... 5-38
Checking the brush holder ....................................................... 5-38
Assembling the starter motor ................................................... 5-39
Installing the starter motor........................................................ 5-41
6Y8 Multifunction Meters sensor .................................... 5-42

Checking the water pressure sensor........................................ 5-42
Checking the speed sensor...................................................... 5-43
PTT system ....................................................................... 5-44

Checking the PTT relay............................................................ 5-44
Checking the PTT switch (on bottom cowling) ......................... 5-45
Checking the PTT switch (tiller handle model) ......................... 5-46
Checking the trim sensor.......................................................... 5-46
Electrical component and wire harness routing

Port
3 4 A
1 2 5
6
C
E
E
11
7
D D
10
9 8
13
12
18 15 19
6
17
21 20
16
14
D-D E-E
5-1
1. Engine ECM
2. Fuse (20 A) (engine start switch, PTT
switch)
3. Fuse (30 A) (main relay)
4. Fuse (20 A) (starter relay)
5. Lighting coil lead
6. Wire harness
7. Ignition coil
8. Water pressure sensor (optional)
9. Rectifier/regulator
11. YDIS coupler
12. Diode (connect to the PTT relay)
13. Joint connector 2
15. Trim sensor lead
16. PTT motor lead
17. Starter relay lead
18. Main wire harness
19. Rectifier/regulator lead
20. Thermo sensor lead
21. Oil pressure connector
A. Pass the lighting coil lead “5” through
the groove of the magnet base.
B. Pass the wire harness “6” between the
engine hanger and the cylinder head.
C. Connect the ignition coil coupler marked
with white tape to the #1 cylinder ignition
coil.
5-2
Starboard
2 3 C D
4
B H 5
G
1 G H
F F E
8
6
7
8
a 2 9
b
1
3
3
F-F G-G H-H
5-3
1. Fuel hose
2. Blowby hose
3. Wire harness
4. Vapor gas hose
5. Throttle body lead
6. Throttle body
8. Fuel injector
9. Vapor shut-off valve lead
A. Install the injector leads #1 and #2 into
the positions “a”, and then install the
wire harness into the positions “b”.
B. Clamp the fuel hose “8” and the wire
harness “3” at the position marked with
white tape.
C. Install the wire harness holders to the
holes of the intake manifold.
D. Clamp the holder to the wire harness “3”
at the position marked with white tape,
and then install the vapor gas hose “4”
and the blowby hose “2” to the holder.
E. Fasten the throttle body leads “5” to the
blowby hose “2” with a plastic tie.
5-4
Front
11
D
4
2
A
5
6 D
C C 7
10
9 8
1. Positive battery cable 10. Starter relay lead (brown)

2. Negative battery cable 11. 10-pin coupler
3. PTT relay
A. Install the negative battery cable “2” into
4. PTT motor lead (blue)
the slots of the bracket.
5. PTT motor lead (green)
B. After fastening the 10-pin coupler “11”,
6. Main relay
fold the end of plastic tie inward so that
7. Starter relay lead (red)
it does not come out.
8. Starter relay
C. The PTT motor leads “7” and “10” must
9. Shift position sensor
be installed within 30.
5-5
Rear
2
3 2
B-B

2. Water detection switch lead
3. Speed sensor (optional)
4. Fuel hose
A. Wind the water detection switch lead se-
curing it with a clamp.
5-6
Top
7
8 5
9
B B
10
B-B
1. Vapor shut-off valve 9. High-pressure fuel pump lead

2. Spark plug 10. Wire harness
3. Thermo sensor
4. Pulser coil
5. Lighting coil (stator assembly)
6. Starter motor
7. Blowby hose
8. Vapor gas hose
5-7
Bottom cowling (tiller handle model)
A
A
C C
1
B D
B D
7
3
4
6
5
11 14
8 10
9 13
11
10
16 16
16
10 12 15
A-A B-B C-C D-D
1. Shift position switch 9. Speedometer hose

2. Water pressure sensor coupler 10. PTT motor lead (PTT model)
3. Shift position switch coupler 11. Trolling switch lead
4. Trolling switch coupler 12. Shift position switch lead
5. Alert indicator coupler 13. Alert indicator harness
6. 6Y8 multifunction meter communication 14. Water pressure sensor lead
coupler 15. Main wire harness
7. Trim sensor coupler 16. Trim sensor lead
8. Fuel hose
5-8
Bottom cowling (remote control model)
A
A
C C
1
3
B D
B D
9
5
6
8
7
14
10 16
11 13
18
12
13
12 15 13
17
A-A B-B C-C D-D
5-9

2. PTT switch (PTT model)
3. PTT switch coupler (PTT model)
4. Water pressure sensor coupler
5. Shift position switch coupler
6. Trolling switch coupler
7. Alert indicator coupler
8. 6Y8 multifunction meter communication
coupler
9. Trim sensor coupler
10. Fuel hose
11. Speedometer hose
12. PTT motor lead (PTT model)
13. Trim sensor lead (PTT model)
15. Shift position switch lead
16. Water pressure sensor lead
17. PTT switch lead (PTT model)
18. Sub wire harness
5-10
Tiller handle (tiller handle model)
F
A
10
8
7 B
F
C
6
1
5
11 E 4
3
5-11
1. Engine start switch coupler

2. Extension wire harness
4. Grommet
5. Engine start switch
6. Engine shut-off switch
7. Alert buzzer
8. Neutral switch
9. PTT switch (F30HA, F40HA)
10. Trolling switch
11. Alert indicator
A. Run the leads (blue and black) under
the control link assembly.
B. Run the neutral switch leads (brown)
under the buzzer.
C. Bend the extension wire harness “2”,
and then connect the harness coupler.
This harness bending position must be
10.0 mm (0.39 in) or more away from
the engine start switch coupler “1”. The
bend radius should be 10.0 mm (0.39 in)
or more.
D. Align the tape ends of the extension
wire harness “2” and the alert indicator
harness “10” with the end of the grom-
met “9”.
E. Install the engine start switch “8” with
the hole of the switch facing upward.
5-12
ECM circuit diagram
ECM circuit diagram

, : Indicate a connection between the symbols.
The circled numbers in the illustration indicate the engine ECM terminal numbers.
< INPUT > < OUTPUT >
1. Pulser coil 21. Fuel injector #1

34 52
2. TPS 22. Fuel injector #2
24 51
23. Fuel injector #3
6 50
49
3. Intake air pressure sensor 23
8 18 25. YDIS
4. Speed sensor 7
26. Oil pressure alert indicator

5. Water pressure sensor 25 38
6. Trim sensor 27. Overheat alert indicator

27
47
7. Thermo sensor
10 28. Alert buzzer
40 BZ
9
9. Oil pressure switch 29. Tachometer
28 20. Engine 31 T
ECM
13
11. Trolling switch (UP) 33
29 32
30. ISC
12. Trolling switch (DN) 16
12
15
30
14. Water detection switch 43
31. Ignition coil #1
14
15. Ground
42
26
16. Main relay 41
45
46
3
34. 6Y8 network
4
44 48
17. Battery 18. High-pressure
P fuel pump 39
36 17
5-13
ECM circuit diagram
1. Pulser coil
2. TPS
3. Intake air pressure sensor
4. Speed sensor
5. Water pressure sensor
6. Trim sensor
7. Thermo sensor
11. Trolling switch (UP)
12. Trolling switch (DN)
15. Ground
16. Main relay
17. Battery
20. Engine ECM
21. Fuel injection #1
25. YDIS
26. Oil pressure alert indicator
27. Overheat alert indicator
28. Alert buzzer
29. Tachometer
30. ISC
34. 6Y8 network
5-14
ECM coupler layout
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 — — 27 Trim sensor Pink
2 — — 28 Oil pressure switch Pink/White
3 6Y8 network White 29 Trolling switch (UP) Orange/White
4 6Y8 network White 30 Shift position switch Blue/Green
5 — — Tachometer (remote
31 Green
control)
6 TPS Pink
32 ISC Green/Black
7 Sensor power source Orange
33 ISC Green/Red
8 Speed sensor Blue
34 Pulser coil White/Red
Intake air tempera-
9 Black/Yellow 35 — —
ture sensor
10 Thermo sensor Black/Yellow 36 Engine start switch Yellow
11 — — 37 — —
12 Trolling switch (DN) White/Blue Oil pressure alert indi-
38 Pink/White
cator
Engine shut-off
13 White 39 Ground Black
switch
Water detection 40 Alert buzzer Pink
14 Blue/White
switch 41 Ignition coil #3 Black/Yellow
15 ISC Green 42 Ignition coil #2 Black/White
16 ISC Green/Yellow 43 Ignition coil #1 Black/Orange
17 Ground Black Main relay (high-pres-
44 Blue
18 YDIS White/Black sure fuel pump)
19 — — 45 Main relay Yellow/Green
20 — — 46 Main relay Red/Yellow
21 — — Overheat alert indica-
47 Pink/Black
tor
22 — —
48 Ground Black
Intake air pressure
23 Pink/Green 49 Vapor shut-off valve Green/Black
sensor
24 Sensor power source Orange 50 Fuel injector #3 Purple/Yellow
25 Water pressure sensor Blue/Black 51 Fuel injector #2 Purple/Black
26 Sensor ground Black 52 Fuel injector #1 Purple/Red
5-15
Checking the electrical component
Checking the electrical compo- To check the electrical components or mea-

nent sure the peak voltage, use the special service
tools. A malfunctioning electrical component
Using the YDIS
can be checked easily by measuring the peak
When checking the TPS, ISC valve, high-pres-
voltage. The specified engine speed when
sure fuel pump, fuel injector, and related sen-
measuring the peak voltage is affected by
sors, use the YDIS.
many factors, such as fouled spark plugs or a
TIP: weak battery. If one of these factors is present,
• When deleting the diagnosis record in the the peak voltage cannot be measured proper-
YDIS, make sure to check the time that the ly.
trouble codes were detected.
TIP:
• When checking the input voltage of a part, the
• Before measuring the peak voltage, check all
coupler or connector must be disconnected.
of the wire harnesses for corrosion. Also,
As a result, the engine ECM determines that
make sure that the wire harnesses are con-
the part is disconnected and a trouble code is
nected properly and that the battery is fully
detected. Therefore, make sure to delete the
charged.
diagnosis record after checking the input volt-
• Use peak voltage adapter with the recom-
age.
mended digital circuit tester.
• To connect and operate the YDIS, see the
• Connect the positive pin of peak voltage
YDIS (Ver. 2.33 or later) instruction manual.
adapter to the positive terminal of the digital
• The software is available through YMAN (Ya-
tester, and the negative pin to the negative
maha Marine Associate Network).
terminal.
• When measuring the peak voltage, set the
YDIS2 Hardware Kit digital circuit tester to the DC voltage mode.
90890-06884
YDIS2 Hardware Kit A
LIT-YDIS2-01-KT
Measuring the peak voltage DC V
When measuring the peak voltage, do not

touch any of the connections of the digital
tester probes.
B
When measuring the peak voltage between

the terminals of an electrical component V
using the digital tester, make sure that the
leads do not contact any metal parts. Other-
wise, the electrical component may short-
circuit and be damaged.
A. Worldwide
B. USA and Canada
5-16
Engine control unit and component
Engine control unit and compo-

Digital circuit tester
nent
90890-03243
Checking the main relay
Digital multimeter
1. Check:
YU-34899-A
• Main relay
Peak voltage adapter B
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
90890-03172
a. Disconnect the main relay coupler “a”.
Peak volt adapter
YU-39991 b. Measure the input voltage between the ter-
minal and ground.
Using the digital tester
The electrical technical data applies to the R
measurements taken using the Yamaha rec-
ommended tester.
The resistance values shown are the values
taken before the engine is started. The actual
resistance may vary depending on the environ-
mental conditions and ambient temperature.
The input voltage changes depending on the a
battery voltage.
If the tester probe cannot be inserted into the
coupler, prepare a test lead suitable for the Input voltage
measurement. 12 V (battery voltage)
Red (R)–Ground
Red (R)–Ground
c. Turn the engine start switch to ON, and

then measure the input voltage between
the terminal and ground.
1 2
1
Digital circuit tester
90890-03243
Digital multimeter
YU-34899-A
Test lead
Terminal, male “1”
(commercially available) Input voltage
Terminal, female “2” 12 V (battery voltage)
(commercially available) Terminal 1–Ground
d. Turn the engine start switch to OFF.
e. Connect the special service tool “2” to the

main relay “1”.
5-17
f. Connect the positive battery lead to the
connector “a”, and the negative battery
lead to the connector “b”, and then check
for continuity between the connectors “c”
and “d”. Replace the relay if out of specifi-
cation.
b 12345678 d
R B a
Do not reverse the battery leads. Y L
P Br
1 W O c
2 Relay terminals continuity

12345678 “c” “d”
a
R B
Y L d
P Br i. Disconnect the special service tool.
W O
j. Connect the main relay coupler.
c
b ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the engine ECM circuit

Test harness FWY–6 “2” 1. Disconnect:
90890-06872 • Engine ECM coupler “a” and “b”
Test harness FWY–6 “2”
YB-06872
Relay terminals continuity

“c” “d”
a
b
g. Turn the engine start switch to OFF.
h. Connect the positive battery lead to the

connector “a”, and the negative battery
lead to the connector “b”, and then check
for continuity between the connectors “c”
and “d”. Replace the relay if out of specifi-
cation.
Do not reverse the battery leads.
5-18
2. Check: 4. Measure:
• Engine ECM ground circuit continuity • Engine ECM input voltage
Out of specification  Replace the wire Out of specification  Check the wire har-
harness. ness for continuity.
a Engine ECM input voltage

39
12 V
48 Terminal 36–Ground
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the engine start switch to ON, and
then measure the input voltage at the en-
gine ECM coupler terminal and ground.
b a
17 36
Engine ECM ground circuit continu-

ity
Terminal 39–Ground
Terminal 48–Ground
Terminal 17–Ground b. Turn the engine start switch to OFF.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Measure: 5. Connect:
• Engine ECM input voltage • Engine ECM couplers
Out of specification  Check the wire har-
ness for continuity. Checking the TPS
a 1. Measure:
• TPS output voltage
Out of specification  Check the TPS in-
45
put voltage.
Output voltage at throttle valve ful-

ly closed
0.67 V
Throttle valve opening angle at
throttle valve fully closed (refer-
ence data)
Engine ECM input voltage
0.1 
12 V
Terminal 45–Ground ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the YDIS to display “TPS volt-
age”.
b. Start the engine and warm it up for 5–10

minutes, and then stop it.
5-19
c. Turn the engine start switch to ON, and ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
then measure the TPS output voltage a. Start the engine, and then check that the
when the remote control lever is at the fully engine speed increases using the YDIS
closed position. “Active test”.
d. Turn the engine start switch to OFF. b. Stop the engine.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Measure: Checking the oil pressure switch

• TPS input voltage 1. Measure:
Out of specification  Check the wire har- • Oil pressure switch input voltage
ness for continuity. Out of specification  Check the wire har-
ness for continuity.
Input voltage
5V Oil pressure switch input voltage
Orange (Or)–Black (B) 12 V
Pink/White (P/W)–Ground
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the throttle body coupler “a”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the oil pressure switch lead
b. Turn the engine start switch to ON, and “a”.
then measure the TPS input voltage at the
TPS coupler. b. Turn the engine start switch to ON, and
then measure the oil pressure switch input
Or B voltage.
a a a
c. Turn the engine start switch to OFF.
d. Connect the throttle body coupler. c. Turn the engine start switch to OFF.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
d. Connect the oil pressure lead. See “Wire
Checking the ISC valve harness” (7-20).
1. Check: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• ISC valve operation (using the YDIS “Sta-
tionary test”) 2. Check:
No operating sound  Check the wire har- • Oil pressure switch continuity
ness for continuity. Out of specification  Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2. Check: a. Remove the oil pressure switch “1”.
• ISC valve operation (using the YDIS “Ac-
tive test”) b. Connect the special service tool “2” to the
No change in engine speed  Replace oil pressure switch “1”.
the throttle body.
5-20
c. Apply positive pressure to the oil pressure
switch “1” slowly, and then check that con-
Do not apply a voltage higher than 1.7 V
tinuity is lost in the range of the working
when checking the LED.
pressure.
1 2 a
d c
b Y
d
P/W P/B
c
P/B
P/W
Vacuum/pressure pump gauge a

set “2”
90890-06945
Pressure/vacuum tester “2”
YB-35956-B
b
Oil pressure switch

Working pressure Lighting-up Terminal Battery
29.40–58.80 kPa (0.294–0.588
Yellow (Y) (+)
kgf/cm², 4.26–8.53 psi) Overheat alert
indicator “c” Pink/Black
(–)
d. Disconnect the special service tool. (P/B)
Oil pressure Yellow (Y) (+)
e. Install the oil pressure switch. See “Ex- alert indicator Pink/White
haust cover” (7-44). “d” (–)
(P/W)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Connect the alert indicator couplers and,

Checking the alert indicator (tiller han-
and then install the tiller handle cover.
dle model)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1. Check:
• Alert indicator continuity
Out of specification  Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the tiller handle cover, and then
disconnect the alert indicator couplers “a”
and “b”.
b. Connect the battery (1.5 V) to the alert in-

dicator couplers “a” and “b”. Check that the
overheat alert indicator “c” or the oil pres-
sure alert indicator “d” comes on. Replace
the alert indicator if it does not come on.
5-21
Fuel control unit and component
Checking the alert buzzer 2. Check:
1. Check: • Trolling switch continuity
• Alert buzzer continuity Out of specification  Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the alert buzzer. a b c
b. Connect the battery leads to the alert

buzzer connectors, and check that the
alert buzzer comes on. Replace the alert
buzzer if it does not come on.
Trolling switch conti- Terminal

nuity “a” “c” “b”
Switch position UP
Switch position DN

Checking the water detection switch
c. Install the alert buzzer.
1. Measure:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Water detection switch input voltage
Checking the trolling switch (tiller Out of specification  Check the wire har-
handle model) ness for continuity.
1. Disconnect:
Input voltage
• Trolling switch coupler “a”
5V
a Blue/White (L/W)–Black (B)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the water detection switch
coupler “a”.
b. Turn the engine start switch to ON, and

then measure the input voltage at the wa-
ter detection switch coupler.
B L/W
a
5-22
d. Connect the water detection switch cou- Checking the fuel injector
pler. 1. Check:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Fuel injector operation (using the YDIS
“Stationary test”)
2. Check: No operating sound  Check the fuel in-
• Water detection switch continuity jector input voltage.
Out of specification  Replace the fuel
cup assembly. 2. Measure:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Fuel injector input voltage
a. Remove the fuel cup assembly. See “Fuel Out of specification  Check the wire har-
filter” (6-4). ness for continuity.
b. Check that the float “1” moves smoothly. Input voltage
12 V
c. Check the water detection switch for conti-
Red/Yellow (R/Y)–Ground
nuity when the float “1” is in positions “A”
and “B”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the fuel injector couplers “a”.
Do not remove the clip and float. b. Turn the engine start switch to ON, and
A the fuel injector coupler terminal and
ground.
1
R/Y
a

1
d. Connect the fuel injector couplers.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Water detection switch continuity

No continuity
Float position “A”
Continuity
Float position “B”
d. Install the fuel cup assembly. See “Install-

ing the fuel filter assembly” (6-7).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-23
3. Measure:
• Fuel injector resistance
Out of specification  Replace. a
Resistance (reference data) L B

12.00 
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the fuel injector couplers.
b. Measure the fuel injector resistance.

d. Connect the high-pressure fuel pump cou-

pler.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Measure:
• High-pressure fuel pump resistance
Resistance (reference data)

c. Connect the fuel injector couplers. 1.4–1.7 
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Checking the high-pressure fuel a. Disconnect the high-pressure fuel pump
pump coupler.
1. Check:
b. Measure the high-pressure fuel pump mo-
• High-pressure fuel pump operation (using
tor resistance.
the YDIS “Stationary test”)
No operating sound  Check the high-
pressure fuel pump input voltage.
2. Measure:
• High-pressure fuel pump input voltage
Input voltage
12 V
Blue (L)–Black (B) c. Connect the high-pressure fuel pump cou-
pler.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. Disconnect the high-pressure fuel pump
coupler “a”.
b. Connect the tester probes to the terminals

of the high-pressure fuel pump coupler,
and then measure the input voltage within
3 seconds after turning the engine start
switch to ON.
5-24
Checking the vapor shut-off valve
1. Measure: Connect the battery leads to the vapor
• Vapor shut-off valve input voltage shut-off valve terminals for only a few sec-
Out of specification  Check the wire har- onds.
Input voltage 1
12 V
Red/Yellow (R/Y)–Ground
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the vapor shut-off valve cou-
pler “a”.

the vapor shut-off valve coupler terminal
Vacuum/pressure pump gauge
and ground.
set “1”
90890-06945
a
YB-35956-B
R/Y
Specified negative pressure
67.0 kPa (0.67 kgf/cm², 9.7 psi)
d. Disconnect the special service tool.
c. Turn the engine start switch to OFF. e. Install the vapor shut-off valve.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
d. Connect the vapor shut-off valve coupler.
3. Measure:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Vapor shut-off valve resistance
2. Check: Out of specification  Replace.
• Vapor shut-off valve operation
Not operating  Replace. Resistance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 30.0–34.0 
a. Remove the vapor shut-off valve, and then ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
connect the special service tool “1” to the a. Disconnect the vapor shut-off valve cou-
vapor shut-off valve. pler.
b. Apply the specified negative pressure to b. Measure the resistance between the vapor
the vapor shut-off valve. shut-off valve terminals.
c. Check that the vapor shut-off valve opens c. Connect the vapor shut-off valve coupler.
and the negative pressure is released ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
when the battery leads are connected to
the vapor shut-off valve terminals.
5-25
Charging unit and component
Charging unit and component a

Checking the lighting coil (stator as-
sembly)
1. Measure:
• Lighting coil output peak voltage GGG 1
Out of specification  Measure the light-
ing coil resistance.
Lighting coil output peak voltage 1 G
G GG
(reference data)
Green (G)–Green (G)
Unloaded
r/min
Cranking 1500 3500
DC V 14.0 45.0 102.0
Test harness (3 pins) “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
90890-06870
a. Disconnect the lighting coil coupler “a”.
a YB-06870
h. Stop the engine, and then disconnect the

special service tool.
i. Connect the lighting coil coupler.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Measure:
• Lighting coil resistance
b. Connect the special service tool “1”. Out of specification  Replace.
c. Remove the clip from the engine shut-off Resistance (reference data)
switch. 0.5610–0.7590 
Green (G)–Green (G)
d. While cranking the engine, measure the
peak voltage. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the lighting coil coupler “a”.
e. Insert the clip into the engine shut-off
switch. b. Measure the lighting coil resistance.
a
f. Start the engine, and then measure the
peak voltage at the specified engine
G G G
speed.
g. Measure the lighting coil output peak volt-

age between all combinations of the con-
nectors.
c. Connect the lighting coil coupler.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-26
Charging unit and component
Checking the rectifier/regulator
Test harness FW13613–2 “1”
90890-06887
Do not connect the battery cables in re- Test harness FW13613–2 “1”
verse. Otherwise, the rectifier/regulator YB-06887
could be damaged.
c. Disconnect the special service tool.
1. Measure:
d. Connect the rectifier/regulator coupler.
• Rectifier/regulator output voltage
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Out of specification  Check the rectifier/
regulator for continuity. 2. Check:
Rectifier/regulator output voltage • Rectifier/regulator continuity
(reference data) Out of specification  Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Red (R)–Ground
a. Disconnect the rectifier/regulator coupler.
Unloaded
r/min
1500 3500 b. Set the digital circuit tester to the diode
mode, and then check the rectifier/regula-
DC V 13 13
tor for continuity.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the rectifier/regulator coupler c
“a”.
a d
e
b
c
b. Connect the special service tool “1”, and
then measure the rectifier/regulator output d
voltage at the specified engine speed. e
R b
B
R B
1
1 a
5-27
Ignition unit and component
Rectifier/regulator continuity Ignition unit and component

(testing diode mode) Checking the ignition spark
1. Check:
Tester probe Display value
• Ignition spark
(+) (–) (reference data)
No spark  Check ignition system circuit.
b ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
c a. Disconnect the spark plug cap from the

a OL spark plug.
d
e b. Connect the spark plug cap to the special
a 0.7–0.8 V service tool “1”.
c c. Check the ignition spark using the YDIS

b
d 0.4–0.5 V “Stationary test”.
e
a 0.4–0.5 V Do not touch any of the connections of the
b special service tool.
c
d OL
e OK
a 0.4–0.5 V
b
d
c OL
e
a 0.4–0.5 V
1
b
e
c OL
Ignition checker (Spark gap tes-
d
ter) “1”
OL: Indicates an overload 90890-06754
Spark checker “1”
c. Connect the rectifier/regulator coupler. YM-34487
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
d. Remove the special service tool, and then
connect the spark plug cap.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-28
Checking the engine ECM
1. Measure: Test harness SM6195043
• Engine ECM output peak voltage 90890-06861
Out of specification  Checking the pulser Test harness SM6195043
coil. YB-06861
Engine ECM output peak voltage

d. Disconnect the special service tool.
(reference data)
#1: Black/Orange (B/Or)–Black (B) e. Connect the ignition coil coupler.
#2: Black/White (B/W)–Black (B)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
#3: Black/Yellow (B/Y)–Black (B)
Unloaded Checking the ignition coil
r/min 1. Measure:
Cranking
• Ignition coil resistance
DC V 100.0 Out of specification  Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ignition coil coupler “a”. Primary coil resistance
0.180–0.240 
Secondary coil resistance
3.26–4.88 k
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a a. Disconnect the ignition coil couplers.
b. Disconnect the spark plug caps from the

spark plugs.
c. Remove the spark plug caps from the igni-

b. Connect the special service tool “1”. tion coil.
c. While cranking the engine, measure the d. Measure the ignition coil resistance.
peak voltage. B A
R/Y
B/Or
B/W R/Y Or B/Or
B/Y B/W
a B B/Y
1
A. Primary coil
B. Secondary coil
e. Install the spark plug caps to the ignition

coil.
f. Connect the spark plug caps and ignition

1 coil couplers.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-29
Checking the spark plug cap Checking the pulser coil
1. Measure: 1. Measure:
• Spark plug cap resistance • Pulser coil output peak voltage
Out of specification  Replace. Out of specification  Measure the pulser
coil resistance.
Spark plug cap resistance (refer-
Pulser coil output peak voltage
ence data)
(reference data)
5.0 k
White/Red (W/R)–Black (B)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Un-
a. Remove the spark plug cap from the spark Loaded
r/min loaded
plug wire by turning the spark plug cap
counterclockwise. Cranking 1500 3500
DC V 5.0 2.7 6.5 9.8
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the pulser coil connectors “a”.
b. While cranking the engine, measure the

peak voltage under unloaded condition.
a
b. Measure the spark plug cap resistance.
a
W/R W/R
B B
c. Install the spark plug cap to the spark plug

wire by turning the spark plug cap clock-
wise.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ c. Connect the pulser coil connectors “a”.
d. Remove the clip from the engine shut-off

switch.
e. While cranking the engine, measure the

peak voltage under loaded condition.
f. Insert the clip into the engine shut-off

switch.
5-30
g. Start the engine, and then measure the b. Connect the YDIS to display “Intake air
peak voltage at the specified engine temperature”.
speed.
c. Check that the difference between the am-
bient temperature and the displayed intake
air temperature is within  5 C ( 9 F).
a
TIP:
• Check the intake air temperature sensor
when the engine is cold.
• When checking the intake air temperature
sensor, remove the top cowling and do not
start the engine.
a ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
W/R W/R Checking the intake air pressure sen-

B B sor
The intake air pressure sensor is a component
of the throttle body which cannot be disassem-
bled.
h. Stop the engine. 1. Measure:

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Intake air pressure sensor input voltage
2. Measure: ness for continuity.
• Pulser coil resistance
Out of specification  Replace. Input voltage
5V
Resistance Orange (Or)–Black (B)
152.0–228.0 
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the throttle body coupler “a”.
a. Disconnect the pulser coil connectors.
b. Measure the pulser coil resistance. then measure the input voltage at the
throttle body coupler.
c. Connect the pulser coil connectors.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Or B
Checking the intake air temperature
a
sensor
The intake air temperature sensor is a compo-
nent of the throttle body which cannot be disas-
sembled.
1. Check:
• Intake air temperature sensor operation
Not operating  Check the wire harness c. Turn the engine start switch to OFF.
for continuity.
d. Connect the throttle body coupler.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. Measure the ambient temperature.
5-31
Checking the thermo sensor
1. Measure:
• Thermo sensor input voltage
Input voltage
5V
Black/Yellow (B/Y)–Black (B)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the thermo sensor coupler “a”. d. Install the thermo sensor. See “Installing
the thermo sensor” (7-47).
b. Turn the engine start switch to ON, and ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
then measure the input voltage at the ther-
mo sensor coupler. Checking the shift position switch
1. Measure:
• Shift position switch input voltage
B B/Y Out of specification  Check the wire har-
Input voltage
12 V
a Blue/Green (L/G)–Black (B)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the shift position switch cou-
c. Turn the engine start switch to OFF. pler “a”.
d. Connect the thermo sensor coupler. b. Turn the engine start switch to ON, and
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ then measure the input voltage at the shift
position switch coupler.
2. Measure:
• Thermo sensor resistance
B L/G a
Resistance at 20 C (68 F)

2.49 k
0.589 k
0.193 k
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ c. Turn the engine start switch to OFF.
a. Remove the thermo sensor.
d. Connect the shift position switch coupler.
b. Place the thermo sensor in a container of ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
water and heat the water slowly.
c. Measure the thermo sensor resistance.
5-32
2. Check:
2. ON
• Shift position switch continuity A
1. OFF 3. START b
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a
a. Remove the shift position switch.
b. Check the shift position switch for continu-

ity.
B
a
b
a
b
1. OFF
2. ON
3. START
A. Switch panel (704 binnacle mount re-

Shift position switch continuity mote control)
No continuity B. Tiller handle model and 703 side mount
Switch position “a” remote control
Continuity
Switch position “b” Engine shut-off switch continuity
Terminal
c. Install the shift position switch. See “Shift Clip
“a” “b”
rod and shift bracket” (9-10).
Removed
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Installed
Checking the engine shut-off switch Button
1. Check: pushed in *1
• Engine shut-off switch continuity
Out of specification  Replace. *1 Tiller handle model only
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the main wire harness coupler
or switch panel coupler. d. Connect the main wire harness coupler or
switch panel coupler.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
then check the engine shut-off switch for
continuity.
5-33
Starting unit and component
Starting unit and component 3. Check:

Checking the starter relay • Starter relay operation
1. Check: Out of specification  Replace.
• Starter relay input voltage ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Out of specification  Check the pulser a. Connect the positive battery lead to the re-
coil or replace the engine ECM. lay connector “a”, and the negative battery
lead to the relay connector “b”, and then
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the starter relay connector “a”. check for continuity between terminals “c”
and “d”.
b. Connect the digital circuit tester lead to the
starter relay connector. c d
c. Turn the engine start switch to START.
d. Measure the input voltage between the ter-

minal and ground.
Br a
B
a b
Br Starter relay terminals continuity

Battery lead connected
Terminal “c”–Terminal “d”
Input voltage
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
12 V (battery voltage)
Brown (Br)–Ground 4. Install:
• Starter relay
e. Disconnect the digital circuit tester. • Positive battery lead
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Negative battery lead
See “Wire harness” (7-20).
2. Remove:
• Negative battery lead
• Positive battery lead
• Starter relay
See “Wire harness” (7-20).
Before disconnecting the starter relay ter-

minals, make sure to disconnect the nega-
tive battery terminal.
5-34
Starting unit and component
Checking the engine start switch
1. Check:
• Engine start switch continuity
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the main wire harness coupler
or switch panel coupler.
b. Check the engine start switch for continui-

ty.
A
d b
a
2. ON e
1. OFF 3. START c
B
c
d
a
b e
1. OFF
2. ON
3. START
A. Switch panel (704 binnacle mount re-

mote control)
B. Tiller handle model and 703 side mount
remote control
Engine start switch continuity

Switch posi- Terminal
tion “a” “b” “c” “d” “e”
OFF
ON
START
c. Connect the main wire harness coupler or

switch panel coupler.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-35
Starter motor
Starter motor
15 4
14
10
17
18
20
11 16 5
19
12
2
8 13
8 4 1
9
7 3
6 6 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
Part name Q’ty Remarks Part name Q’ty Remarks

1 Nut 1 16 Planetary gear 3
2 Screw M5  7 mm 1 17 Pinion stopper set 1
3 Lead 1 18 Pinion shaft 1
Screw set 19 Outer gear 1
Cover screw: M6  25 20 Clutch assembly 1
4 mm 1
Bracket screw: M5  8
mm
5 Magnet switch 1
6 Bolt M5  25 mm 2
7 Bracket 1
8 Bolt M5  105 mm 2
9 Stator 1
10 Armature 1
11 Brush holder assembly 1
12 Bracket 1
13 Lever assembly 1
Starting motor gear as-
14 1
sembly
15 Cover 1
5-36
Starter motor
Removing the starter motor 2. Remove:
• Cap
• Pinion stopper
Before removing the starter motor, make • Clip
sure to disconnect the negative battery ter- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
minal. a. Push the pinion stopper “1” down, and
then remove the clip “2”.
1. Remove:
• Starter motor
See “Starter motor” (7-24). a
3
b
Disassembling the starter motor
3
1. Remove: 1
• Stator
• Bracket screw
• Bracket
1
• Armature
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2
a. Remove the stator “1”.
b. Remove the armature “2” along with the

brush holder assembly “3” from the brack- Pipe “3”
et “4”. (commercially available)
“a”: 15.5 mm (0.61 in)
2 “b”: 11.0 mm (0.43 in)
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3
Checking the starter motor pinion
1. Check:
• Pinion teeth
Cracked/worn  Replace the pinion.
2. Check:
• Pinion movement
4
Not smooth  Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the pinion counterclockwise to check
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
that it operates smoothly and turn it clock-
wise to check that it locks in place.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-37
Starter motor
Checking the armature (starter motor)
1. Check: Standard commutator undercut
• Commutator 0.5 mm (0.02 in)
Dirty  Clean using 600-grit sandpaper Wear limit
and compressed air. 0.2 mm (0.01 in)
4. Check:
• Armature continuity
Out of specification  Replace the arma-
ture.
a
d
2. Measure: b c
• Commutator diameter “a”
Below specification  Replace the arma-
ture.
Armature continuity
“a” “b” “c” “d”
Checking the brush holder

1. Check:
• Brush holder assembly continuity
a Out of specification  Replace.
c a e
Standard commutator diameter
29.4 mm (1.16 in)
Wear limit
28.8 mm (1.13 in)
d
3. Measure: b
• Commutator undercut “a”
c a
Below specification  Replace the arma-
ture.
e
a d b
Brush holder assembly continuity

“a” “b” “c” “d” “e”
5-38
Starter motor
2. Measure:
b.
• Brush length
Below specification  Replace the brush.
2
a
b
3
a. Standard brush length
b. Wear limit ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
Standard brush length • Brush holder assembly
12.3 mm (0.48 in) • Bracket
Wear limit • Bracket screw
5.5 mm (0.22 in) • Stator
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Assembling the starter motor a. Install the armature “1” along with the
brush holder assembly “2” to the bracket
“3”, and then install the stator “4”.
Do not apply grease or oil to the commuta-
tor of the armature.
4 1
1. Install:
• Brush spring (to the brush holder) 2
• Brush assembly (to the brush holder)
2. Install:
• Armature
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Push the brushes “1” into the holders, and
3
then install the armature “2” to the brush
holder assembly “3”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-39
Starter motor
4. Assemble: 6. Install:
• Clutch assembly “1” • Pinion shaft assembly “1”
• Outer gear “2” • Lever “2”
• Pinion shaft “3” • Planetary gear “3”
• Rubber seal “4” New
4
3
3
2
1
5. Install:
• Pinion stopper “1” 7. Install:
• Clip “2” • Stator “1”
• Bracket “2”
5-40
Starter motor
8. Install:
• Cap “1”
• Magnet switch “2”
• Starter motor lead “3”
• Starter motor lead screw “4”
2
4
Stator motor lead screw

3.0N·m (0.30 kgf·m, 2.2 lb·ft)
T.
R.
Installing the starter motor

1. Install:
• Starter motor
See “Installing the starter motor” (7-25).
5-41
6Y8 Multifunction Meters sensor
6Y8 Multifunction Meters sensor ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Checking the water pressure sensor a. Remove the water pressure sensor, and
1. Measure: then connect the pressure pump “1” and
• Water pressure sensor input voltage special service tool “2”.
b. Turn the engine start switch to ON.
c. Apply positive pressure to the water pres-
Input voltage
sure sensor slowly, and then measure the
5V
output voltage.
Orange (Or)–Black (B)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ B Or
a. Disconnect the water pressure sensor
coupler “a”.
a
then measure the input voltage at the wa-
ter pressure sensor coupler.
B Or
Pressure pump “1”
a (commercially available)
90890-06869
YB-06869
c. Connect the water pressure sensor cou- d. Turn the engine start switch to OFF, and
pler. then disconnect the special service tool
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ and pressure pump.
2. Measure: e. Install the water pressure sensor.

• Water pressure sensor output voltage ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Out of specification  Replace the water
pressure sensor.
Output voltage at 392 kPa (3.92

kgf/cm², 56.8 psi) (reference data)
2.5 V
kgf/cm², 113.7 psi) (reference da-
ta)
4.5 V
Blue/Black (L/B)–Black (B)
5-42
6Y8 Multifunction Meters sensor
Checking the speed sensor c. Apply positive pressure to the speed sen-
1. Measure: sor slowly, and then measure the output
• Speed sensor input voltage voltage.
ness for continuity. L
B O
Input voltage G B G/W 2
5V
Orange (Or)–Black (B)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the speed sensor coupler “a”.

then measure the input voltage at the
speed sensor coupler.
B Or 1
a
2
Pressure pump “1”

(commercially available)
90890-06869
c. Connect the speed sensor coupler. Test harness (3 pins) “2”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ YB-06869
2. Measure:
• Speed sensor output voltage d. Turn the engine start switch to OFF, and
Out of specification  Replace the speed then disconnect the special service tool
sensor. and pressure pump.
Output voltage at 392 kPa (3.9 e. Install the speed sensor.

kgf/cm², 57 psi) (reference data) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2.5 V
kgf/cm², 114 psi) (reference data)
4.5 V
Blue/Red (L/R)–Black (B)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the speed sensor, and then con-
nect the pressure pump “1” and special
service tool “2”.
b. Turn the engine start switch to ON.
5-43
PTT system
PTT system
Checking the PTT relay
1. Measure: Lg
• PTT relay input voltage Sb
G/W G
Out of specification  Check the wire har- 1
c
ness for continuity. e f b
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a
a. Remove the caps.
b. Measure the input voltage between the

PTT relay terminal “a” and terminal “b”.
d
b

90890-06867
YB-06867
a
PTT relay continuity
“a” “b” “c” “d” “e” “f”
Input voltage
12 V
Terminal “a”–Terminal “b” e. Connect the positive battery lead to the
terminal “a”, and the negative battery lead
c. Install the caps. to the terminal “b”, and then check the PTT
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ relay for continuity.
2. Check:
• PTT relay continuity Lg
Sb
Out of specification  Replace. G/W G
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ d
a b
a. Disconnect the battery power source,
ground lead, PTT motor leads, and PTT c
relay coupler.
Before disconnecting the PTT relay termi-

nals, make sure to disconnect the battery e
negative terminal.
b. Remove the PTT relay.

PTT relay continuity
c. Connect the special service tool “1”. “b” “c” “d” “e”
d. Check the PTT relay for continuity.
5-44
PTT system
f. Connect the positive battery lead to the
terminal “a”, and the negative battery lead
to the terminal “b”, and then check the PTT
relay for continuity. a
R
Lg
Sb
G/W G
a d
b
c c. Connect the PTT switch coupler.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
e • PTT switch continuity
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the PTT switch coupler.
PTT relay continuity b. Check the PTT switch for continuity.
“b” “c” “d” “e”
c a
g. Disconnect the special service tool. b
Sb
h. Install the PTT relay. R
Lg
i. Connect the PTT relay coupler, battery
power source, ground lead, and PTT mo-
tor leads. PTT switch continuity
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Switch po- Terminal
Checking the PTT switch (on bottom sition “a” “b” “c”
cowling) UP
1. Measure:
DN
• PTT switch input voltage
Out of specification  Check the wire har- c. Connect the PTT switch coupler.
ness for continuity. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Input voltage
12 V
Red (R)–Ground
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the PTT switch coupler “a”.
b. Measure the input voltage between the

PTT switch coupler terminal and ground.
5-45
PTT system
Checking the PTT switch (tiller handle PTT switch continuity
model)
Switch po- Terminal
1. Measure:
• PTT switch input voltage sition “a” “b” “c”
Out of specification  Check the wire har- UP
Free
Input voltage DN
12 V
c. Connect the PTT switch connector.
Red (R)–Ground
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the PTT switch connectors “a”. Checking the trim sensor
1. Measure:
b. Measure the input voltage between the • Trim sensor resistance
PTT switch connector and ground. Out of specification  Replace.
a
Free position resistance
239–379  (F30A, F30BET,
F30HA, F40A, F40FET, F40HA)
Setting resistance
9–11  (F30A, F30BET, F30HA,
F40A, F40FET, F40HA)
R ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the trim sensor coupler “a”,
and then remove the trim sensor.
c. Connect the PTT switch connectors.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• PTT switch continuity a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the PTT switch connector.
b. Check the PTT switch for continuity.

Sb
b. Measure the trim sensor resistance.
a
R UP
b DN
c
Lg
a Sb
b R
c Lg
5-46
PTT system
c. Turn the trim sensor lever “1” from the free
position “a” to the setting position “b”, and
then measure the resistance as it gradual-
ly changes.
a
1
d. Install the trim sensor, and then connect

the trim sensor coupler.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-47
Fuel system
Fuel system ........................................................................ 6-1

Reducing the fuel pressure ........................................................ 6-1
Disconnecting the quick connector............................................. 6-1
Measuring the fuel pressure....................................................... 6-1
Checking the pressure regulator ................................................ 6-3
Fuel filter ............................................................................. 6-4

Removing the fuel filter assembly .............................................. 6-5
Checking the fuel filter assembly................................................ 6-5
Checking the fuel filter element .................................................. 6-5
Checking the fuel cup assembly................................................. 6-5
Checking the primer pump ......................................................... 6-6
Checking the fuel joint ................................................................ 6-6
Assembling the fuel filter assembly ............................................ 6-6
Installing the fuel filter assembly ................................................ 6-7
Fuel pump assembly.......................................................... 6-8

Checking the fuel pump assembly ............................................. 6-9
Disassembling the fuel pump ..................................................... 6-9
Checking the diaphragm and valve .......................................... 6-10
Assembling the fuel pump ........................................................ 6-10
Installing the fuel pump assembly ............................................ 6-11
Intake silencer, intake manifold and throttle body........ 6-12

Checking the throttle body........................................................ 6-13
Checking the intake manifold ................................................... 6-13
Checking the vapor shut-off valve ............................................ 6-13
Installing the intake manifold .................................................... 6-13
Throttle link rod ................................................................ 6-14

Installing the throttle link........................................................... 6-15
Adjusting the throttle link rod .................................................... 6-15
Vapor separator................................................................ 6-17

Draining the fuel ....................................................................... 6-18
Removing the vapor separator ................................................. 6-18
Installing the vapor separator ................................................... 6-18
Fuel system
Fuel cooler ........................................................................ 6-20
Vapor separator and high-pressure fuel pump ............. 6-21

Checking the fuel strainer......................................................... 6-22
Checking the vapor separator .................................................. 6-22
Adjusting the float height .......................................................... 6-22
Assembling the vapor separator............................................... 6-23
Fuel injector ...................................................................... 6-25

Removing the fuel injector........................................................ 6-26
Checking the fuel rail and fuel injector ..................................... 6-26
Installing the fuel injector.......................................................... 6-26
6
Fuel system
Fuel system Disconnecting the quick connector

Reducing the fuel pressure
Before disconnecting the quick connector,
Before servicing the high-pressure fuel line reduce the fuel pressure. Otherwise, pres-
or vapor separator, make sure to reduce surized fuel could spray out.
the fuel pressure in the fuel line. Otherwise,
Cover the fuel components using a rag to pre-
pressurized fuel could spray out.
vent fuel from spilling out.
1. Reduce: 1. Disconnect:
• Fuel pressure • Quick connector
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the fuse holder cover “1”, and a. Reduce the fuel pressure. See “Reducing
then remove the main fuse (30 A) “2”. the fuel pressure” (6-1).
1 b. Wrap a rag around the quick connector “1”.
c. Disconnect the quick connector “1”.
TIP:
Cover the quick connector and fuel rail with a
plastic bag to prevent damage and dirt from
entering them.
2
1
b. Start the engine.
TIP:
After removing the main fuse, wait until the en-
gine stalls.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. After the engine stalls, crank the engine 2 Measuring the fuel pressure
or 3 times. Cover the fuel components using a rag to pre-
d. Turn the engine start switch to OFF.
1. Measure:
e. Install the main fuse (30 A), and then install • Fuel pressure
the fuse holder cover. Out of specification  Check the fuel line.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Fuel pressure at engine start
switch to “ON” within 3 seconds
280 kPa (2.8 kgf/cm², 40.6 psi)
Fuel pressure at idle speed
230 kPa (2.3 kgf/cm², 33.4 psi)
6-1
Fuel system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ B
a. Reduce the fuel pressure. See “Reducing
the fuel pressure” (6-1).
b. Disconnect the quick connector from the

fuel rail. See “Disconnecting the quick con-
nector” (6-1).
c. Connect the special service tool “1” to the

1
quick connector and the fuel rail.
A. Worldwide
B. USA and Canada
Fuel pressure gauge “1”

90890-06753
Fuel pressure gauge “1”
Fuel pressure gauge adapter “1” YU-03153M
90890-06946
Fuel pressure gauge adapter “1” e. Install the flywheel magneto cover.
YB-06946
f. Turn the engine start switch to ON, and
d. Connect the special service tool “1”. then measure the fuel pressure within 3
seconds.
To prevent fuel from leaking out, screw in TIP:

the gauge gently until it is connected firmly. • The fuel pressure will decrease 3 seconds af-
ter the engine start switch is turned to ON.
• The high-pressure fuel pump does not oper-
A
ate when the engine start switch is turned to
ON again within 10 seconds after turning the
1 engine start switch to OFF.
g. Start the engine and warm it up until the

engine idle speed stabilizes at the speci-
fied engine idle speed range.
Idle speed (in neutral)

750–850 r/min
h. Measure the fuel pressure.
i. Turn the engine start switch to OFF.
j. Reduce the fuel pressure. See “Reducing

6-2
Fuel system
k. Disconnect the special service tool.
B
5 3
Before disconnecting the special service 1 4

tools, cover the end of the hose using a
clean and dry rag. 6
4
l. Connect the quick connector to the fuel
rail.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the pressure regulator 2

1. Reduce the fuel pressure. See “Reducing
A. Worldwide
2. Disconnect the quick connector from the B. USA and Canada
delivery pipe. See “Disconnecting the
quick connector” (6-1). d. Start the engine and let it idle.
3. Check: e. Check that the fuel pressure is reduced

• Pressure regulator when negative pressure is applied to the
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
pressure regulator.
a. Connect the special service tools “1” and
“2”. See “Measuring the fuel pressure” (6- f. Stop the engine.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1).
4. Reduce the fuel pressure. See “Reducing
b. Disconnect the pressure regulator hose
“3”, and then connect the special service
tool “4” to the pressure regulator “5”. 5. Disconnect the special service tools, and
then connect the pressure regulator hose
c. Block the end of the pressure regulator
and quick connector.
hose “3” using a rubber plug “6”.
A
5 3
1 4
6-3
Fuel filter
Fuel filter
20 6
19
1 2 10
3
9 New
11
2
12
7 17
5 8
2
18
13
14 16
4 New
5 N·m (0.5 kgf·m, 3.7 lb·ft)

15
4 New

1 Cover 1 20 Bracket 1
2 Clip 4
3 Hose 1
4 Plastic tie 2
5 Hose 1
6 Nut 1
7 Fuel filter assembly 1
8 Fuel cup assembly 1
9 O-ring 1
10 Fuel filter element 1
11 Clip 1
12 Float 1
13 Clamp 1
14 Joint 1
15 Hose 1
16 Bolt M6  25 mm 1
17 Fuel joint 1
18 Grommet 1
19 Bolt M8  20 mm 1
6-4
Fuel filter
Removing the fuel filter assembly d. Block the fuel inlet “b” using a rubber plug
Cover the fuel components using a rag to pre- “2”, and then apply the specified negative
vent fuel from spilling out. pressure. Replace the O-ring, fuel cup as-
sembly, or fuel filter assembly if the speci-
Checking the fuel filter assembly fied pressure cannot be maintained for 15
1. Check: seconds or more.
• No air leakage
Air leakage  Replace the O-ring, fuel cup
assembly, or fuel filter assembly.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the special service tool “1” to the 1
fuel inlet “a”.
a
b
b. Block the fuel outlet “b” using a rubber plug
“2”, and then apply the specified positive
pressure. Replace the O-ring, fuel cup as-
sembly, or fuel filter assembly if the speci- a
fied pressure cannot be maintained for 15 2
seconds or more. b

set “1”
1 90890-06945
b
a YB-35956-B
Fuel outlet holding pressure (neg-

b ative pressure)
80.0 kPa (0.80 kgf/cm2, 11.6 psi)
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a
Checking the fuel filter element
Vacuum/pressure pump gauge 1. Check:
set “1” • Fuel filter element
90890-06945 Dirt/residue  Replace.
YB-35956-B Checking the fuel cup assembly
1. Check:
• Fuel cup assembly
Fuel inlet holding pressure (posi- Foreign material  Clean.
tive pressure) Cracked  Replace.
200.0 kPa (2.00 kgf/cm2, 29.0
psi)
When cleaning the fuel cup assembly, do
c. Connect the special service tool “1” to the not remove the clip and float.
fuel outlet “a”.
6-5
Fuel filter
Checking the primer pump ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1. Check: a. Connect the special service tool “1” to the
• No air leakage fuel joint outlet “a”.
Air leakage  Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b. Apply the specified positive pressure. Re-
a. Connect the special service tool “1” to the place the fuel joint if the specified pressure
primer pump inlet “a”. cannot be maintained for at least 10 sec-
onds.
b. Block the fuel outlet “b” using a rubber plug
1
“2”, and then apply the specified positive
pressure. Replace the primer pump if the
specified pressure cannot be maintained
for 30 seconds or more. a
2 b a

set “1”
90890-06945
YB-35956-B
1 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Assembling the fuel filter assembly

1. Install:
Vacuum/pressure pump gauge • Fuel filter element
set “1” • O-ring New
90890-06945 • Fuel cup assembly
Pressure/vacuum tester “1” • Clamp
YB-35956-B
Positive pressure
170.0 kPa (1.70 kgf/cm², 24.7
psi) a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b
Checking the fuel joint
1. Check:
• Fuel joint
Cracked/damaged  Replace. a: 115–125 mm (4.53–4.92 in)
• Holding pressure
b: 20–30 mm (0.79–1.18 in)
Holding pressure (positive pres- Fuel cup assembly

sure) 5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
R.
49.0 kPa (0.5 kgf/cm², 7.11 psi)
6-6
Fuel filter
Installing the fuel filter assembly
1. Install:
• Fuel joint
• Fuel filter assembly
• Clamp
• Hose
• Plastic tie New
6-7
Fuel pump assembly
Fuel pump assembly

3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
7
5
4
4 5 8 New
5 3 New
2 5
4 4
6 11
12
6
15
1 14
6
13 10
1
Part name Q’ty Remarks
1 Bolt M6  30 mm 2
2 Fuel pump assembly 1
3 O-ring 1
4 Screw M5  43 mm 4
5 Washer 4
6 Nut 4
7 Cover 1
8 Diaphragm 1
9 Fuel pump body 1
10 Pin 1
11 Plunger 1
12 Spring 1
13 Diaphragm 1
14 Spring 1
15 Fuel pump body 1
6-8
Fuel pump assembly
Checking the fuel pump assembly
1. Check: Fuel inlet holding pressure (nega-
• No air leakage tive pressure)
Air leakage  Disassemble and check the 30.0 kPa (0.30 kgf/cm², 4.4 psi)
fuel pump. See “Disassembling the fuel
pump” (6-9). d. Connect the special service tool “1” to the
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ fuel pump outlet “a”.
a. Connect the special service tool “1” to the
fuel pump inlet “a”. e. Block the fuel pump inlet “b” using a rubber
plug “2”.
b. Block the fuel pump outlet “b” using a rub-
ber plug “2”, and then apply the specified f. Apply the specified positive pressure, and
positive pressure. Check that there is no then check that there is no air leakage.
air leakage.
2 a
2 a
b
1
b
1
Fuel outlet holding pressure (pos-

Vacuum/pressure pump gauge itive pressure)
set “1” 50.0 kPa (0.50 kgf/cm², 7.3 psi)
90890-06945 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
YB-35956-B Disassembling the fuel pump
1. Disassemble:
• Fuel pump body
Fuel inlet holding pressure (posi-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
tive pressure)
a. Align the groove “a” in the fuel pump body
50.0 kPa (0.50 kgf/cm², 7.3 psi)
“1” with the hole “b” in the plunger “2” by
turning them.
c. Apply the specified negative pressure, and
then check that there is no air leakage.
2
b
a
1
6-9
Fuel pump assembly
b. Remove the pin “1” by pressing the plung- Assembling the fuel pump
er and diaphragm. Before assembling the fuel pump, clean the
parts and soak the valves and diaphragm in
gasoline to obtain prompt operation of the fuel
pump.
1. Assemble:
• Fuel pump body
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 a. Install the springs “1” and “2”, plunger “3”,
and diaphragm “4”.
c. Remove the diaphragm, plunger, and 3

2
springs.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the diaphragm and valve

1. Check:
• Diaphragm “1”
Torn/deformed/worn  Replace.
• Valve “2” 1
Deformed/worn  Replace the fuel pump
body “3”.
4
b. Align the hole “a” in the plunger “1” with the

2 hole “b” in the diaphragm “2” by pushing
the plunger and diaphragm.
c. Install the pin “3”.
3 1
1 a
b
2
6-10
Fuel pump assembly
d. Turn the plunger “1” so that both the dia-
phragm tab “a” and the groove “b” face to-
ward the same direction.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
• Fuel pump body “1”
• Diaphragm “2” New
• Fuel pump cover “3”
• Nut “4”
• Fuel pump screw “5”
3
2
4
5
4
Fuel pump screw

3.0 N·m (3.0 kgf·m, 2.2 lb·ft)
T.
R.
Installing the fuel pump assembly

1. Install:
• O-ring (to the fuel pump assembly) New
• Fuel pump assembly
• Fuel pump assembly bolt
• Hose
• Clip (to the hose)
6-11
Intake silencer, intake manifold and throttle body
6 New 9
6
6 12 New
10 10
5 New 1
6 8 7
7 2
11
10 3
4

1 Plastic tie 1
2 Cover 1
3 Bolt M6  12 mm 2
4 Intake silencer 1
5 O-ring 1
6 Bolt M8  40 mm 4
7 Bolt M6  35 mm 2
8 Intake manifold 1
9 Gasket 1
10 Bolt M6  16 mm 3
11 Throttle body 1
12 Gasket 1
6-12
Checking the throttle body
1. Check:
• Throttle body exterior
Cracked  Replace.
2. Check:
• Throttle valve movement
Not smooth  Clean.
Checking the intake manifold

1. Check:
• Intake manifold
Cracked/deformed  Replace.
Checking the vapor shut-off valve

1. Check:
• Vapor shut-off valve exterior
Installing the intake manifold

1. Install:
• Gasket (to the intake manifold) New
• O-ring (to the intake manifold) New
• Throttle body (to the intake manifold)
• Intake manifold
• Intake manifold bolt
6-13
Throttle link rod
Throttle link rod
4
3
8
5
6
9
7
New 10 11
1 Throttle link rod 1
2 Bolt M6  45 mm 1
3 Collar 1
4 Wave washer 1
5 Throttle cam 1
6 Bolt M6  35 mm 1
7 Throttle control lever 1
8 Collar 1
9 Spring 1
10 Cotter pin 1
11 Throttle cam roller 1
6-14
Throttle link rod
Installing the throttle link d. Install the throttle cam assembly “1”.
1. Install:
• Throttle link rod
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the roller “1”, a new cotter pin “2”,
the spring “3”, the collar “4”, and the bolt 1
“5”.
e. Install the throttle link rod.

5
3 f. Adjust the throttle link rod. See “Adjusting
the throttle link rod” (6-15).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Adjusting the throttle link rod

1 1. Adjust:
• Throttle link rod
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the link rod locknut “1”, and then
b. Install the throttle lever assembly “1” to the
remove the throttle link rod “2” from the
crankcase. Fit the end “a” of the spring “2”
throttle cam “3”.
into the hole “b” in the crankcase.
a 1
2
b
2
1
3
c. Install the wave washer “1”, collar “2”, and

bolt “3”.
1
2
6-15
Throttle link rod
b. Check that the protrusion “a” on the throttle
lever “1” and the protrusion “b” on the shift
bracket “2” are aligned.
c. Turn the throttle cam until it contacts the

roller “3” slightly.
2 b
b
a
1 a
d. Adjust the throttle link rod length so that its

end “a” fits onto the protrusion “b” on the
throttle cam, and then install the throttle
link rod to the throttle cam.
e. Check that the link rod locknut “1” is fully

seated on the throttle link rod joint “2”.
f. Tighten the link rod locknut “1” from its fully

seated position to the specified angle.
a 2 1
Link rod locknut “1”

90
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-16
Vapor separator
Vapor separator
1
3
4 5
6
7
2
7
13
9 11
12
16
14
18
19 15
17
10
18
19
17
18
19
17
1 Bolt M6  20 mm 1 17 Bolt M6  30 mm 3
2 Cover 1 18 Collar 3
3 Collar 1 19 Grommet 3
4 Grommet 1
5 Fuse puller 1
6 Hose 1
7 Holder 2
8 Holder 1
9 Holder 1
10 Hose 1
11 Nut 1
12 Vapor shut-off valve 1
13 Bolt M6  16 mm 1
14 Bracket 1
15 Bolt M6  20 mm 1
16 Bracket 1
6-17
Vapor separator
Draining the fuel 2. Disconnect:
1. Drain: • Quick connector
• Fuel • Blowby hose
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Vapor gas hose
a. Loosen the drain screw “1”. • High-pressure fuel pump coupler
• Cooling water hoses
3. Remove:
• Vapor separator assembly
Installing the vapor separator

1. Install:
Vapor separator assembly
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 a. Install the vapor separator assembly “1”.
b. Remove the cap “1”.
c. Push in the air valve “2”. with a screw- 1

driver.
1
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Connect:
• High-pressure fuel pump coupler
• Cooling water hose
• Quick connector
• Vapor gas hose
d. Tighten the drain screw to the specified
• Blowby hose
torque, and then install the cap.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the high-pressure fuel pump coupler
Drain screw
“a”, and then connect the fuel pump cou-
1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
T.
pler “b”.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Removing the vapor separator

b
a
1. Drain:
• Fuel
See “Draining the fuel” (6-18).
6-18
Vapor separator
b. Connect the cooling water hoses “1” and
“2”.
c. Connect the vapor gas hoses “1” and “2”,

and then install the holder “3”.
1
2
d. Connect the quick connector “1”, and then

install the holder “2” aligning it with the
white tape “3” of the wire harness.
2 3
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-19
Fuel cooler
Fuel cooler
8 New
3
10 9 4 1
2
1
19 5 1
25 New 11 7 6
11 New
15
23
12
11 New 24 11 New
New 11 16
22
17
18
3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
New 11
3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
17
New 11 11 New
20 14
21 20 11 New
New 11
13

1 Clamp 3 20 Hose 2
2 Hose 1 21 Joint 1
3 Clip 1 22 Hose 1
4 Hose 1 23 Hose 1
5 Strainer 1 24 Joint 1
6 Holder 1 25 Holder 1
7 Clamp 1
8 Clamp 1
9 Hose 1
10 Quick connector 1
11 Plastic tie 13
12 Hose 1
13 Hose 1
14 Drain hose 1
15 Hose 1
16 Holder 1
17 Screw M6  14 mm 2
18 Fuel cooler 1
19 Hose 1
6-20
Vapor separator and high-pressure fuel pump

5 N·m (0.5 kgf·m, 3.7 lb·ft)
4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

2
22 2
3
New 23 24
3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
1
New 16 7
25
4 New
18
20
17 19 21
New 27
19
23 New New 10
26
22
9
New 8 5
14
4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
13
2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 15
1.5 N·m (0.15 kgf·m, 1.1 lb·ft) 11
12

1 Hose 1 19 Screw M4  7 mm 2
2 Bolt M6  12 mm 2 20 Plate 1
3 Pressure regulator 1 21 Plate 1
4 Plastic tie 1 22 Nipple 2
5 Lead 1 23 O-ring 2
6 Screw M5  14 mm 6 24 Cap 1
7 Cover 1 25 Float chamber 1
8 Gasket 1 26 Drain screw 1
High-pressure fuel 27 O-ring 1
9 1
pump
10 O-ring 1
11 Holder 1
12 Clip 1
13 Joint 1
14 Clip 1
15 Filter 1
16 Pin 1
17 Float 1
18 Needle valve 1
6-21
Checking the fuel strainer 2. Check:
1. Check: • Float
• No air leakage Deteriorated  Replace.
Air leakage  Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3. Check:
a. Connect the leakage tester “1” to the fuel • Filter
inlet “a”. Dirt or residue  Clean.
b. Block the fuel outlet “b” using a rubber plug Adjusting the float height
“2”, and then apply the specified positive 1. Measure:
pressure. Replace the fuel strainer if the • Float height “a”
specified pressure cannot be maintained • Float height “b”
for 15 seconds or more. Out of specification  Adjust the float
height.
b
1
2 a a
Leakage tester “1”

90890-06840
Leakage tester “1” b
Holding pressure (positive pres-

sure)
200.0 kPa (2.00 kgf/cm2, 29.0
psi)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the vapor separator

1. Check:
• Needle valve
Bent/worn  Replace the float.
6-22
2. Adjust: Assembling the vapor separator
• Float height “a” 1. Assemble:
• Float height “b” • Vapor separator
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Bend portions “1” of the float to adjust the a. Install the plates “1” and “2”, and then tight-
float height to specification “a”. en the float chamber plate screws “3” to
the specified torque.
3 3
2 1
Float height
40.7–42.7 mm (1.60–1.68 in) Float chamber plate screw “3”
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
T.
R.
b. Bend portions “1” of the float to adjust the

float height to specification “b”. b. Install the needle valve “1”, float “2”, and
float pin “3”.
TIP:
• Do not bend the lever “2”. TIP:
• Bend both portions of “1” equally. • Do not reuse the float pin. Always replace it
with a new one.
2 • Install the float pin with its tapered end facing
towards the mark “a” on the float chamber
cover.
b
1
1 2
Float height (reference data)

30.7 mm (1.21 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-23
a 4
4
2
1
3 3
c. Install the filter “1”.
Float chamber cover screw “4”

3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
T.
R.
1 f. Connect the lead “a”.
g. Install the pressure regulator “1”, the pres-

sure regulator bolts “2”, new O-rings “3”,
d. Connect the high-pressure fuel pump con- and the nipples “4”, and then tighten the
nectors “a”, and then install a new O–ring pressure regulator bolts “2” and the nipple
“1” and the high-pressure fuel pump “2”. “4” to the specified torque.
4 1
3
2
a
a
a
3
4
e. Install the filter holder “1”, a new gasket

“2”, and the cover assembly “3”, and then Pressure regulator bolt“2”
tighten the float chamber cover screws “4” 5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
R.
to the specified torque. Nipple “4”

3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-24
Fuel injector
Fuel injector
4
5 New
4
5 New
4 1 3
New 5
1

1 Bolt M6  40 mm 2
2 Fuel rail 1
3 Holder 3
4 Fuel injector 3
5 O-ring set 3 2 pcs/set
6-25
Fuel injector
Removing the fuel injector
Cover the fuel components using a rag to pre- Fuel injection volume
vent fuel from spilling out. 71–83 cm³ (90 cc)/30 sec
Test fuel
1. Reduce: Dry sorbent (viscosity: 1.2  0.03
• Fuel pressure mm²/s, specific gravity: 0.774 [15
See “Reducing the fuel pressure” (6-1). C])
Test fuel temperature
2. Disconnect: 22–24 C (room temperature and
• Quick connector test fuel temperature should be
See “Disconnecting the quick connector” the same)
(6-1). Test fuel pressure
300  1.5 kPa
Checking the fuel rail and fuel injector
Measuring cylinder internal pres-
1. Check:
sure (standard atmosphere pres-
• Fuel rail
sure)
Cracked/deformed  Replace.
960–1060 hPa
2. Measure:
• Fuel volume injected by the injector Installing the fuel injector
See the “Fuel Injection Meter Operation 1. Install:
Manual” (90894-62982-85). • O-ring New
• Fuel injector
• Holder
Do not use gasoline when measuring the • Fuel rail
fuel injection volume. Otherwise, the cylin- • Fuel rail bolt
der could be damaged, which can cause a
gasoline leakage. Make sure to follow the
instructions for operation of the fuel injec-
tion meter.
TIP:
• When measuring, obtain a result from the av-
erage of 4 measurements.
• It is not possible to obtain correct measure-
ments under disparate test conditions.
• Make sure to fully charge the battery.
• The cylinder is graduated in increments of 2.5
cm³ (2.5 cc).
• Make sure to comply with the laws and regu-
lations of the region when disposing of the
used test fuel.
Fuel injection meter

FIM20000ME
6-26
Power unit
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..................................................... 7-5
Power unit assembly ......................................................... 7-6

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

Removing the flywheel magneto .............................................. 7-14
Removing the timing belt and sprocket .................................... 7-15
Checking the timing belt and sprocket ..................................... 7-15
Installing the sprocket and timing belt ...................................... 7-16
Installing the stator assembly ................................................... 7-17
Installing the flywheel magneto ................................................ 7-18
Engine ECM, rectifier/regulator, and ignition coil ......... 7-19
Wire harness..................................................................... 7-20

Installing the wire harness........................................................ 7-21
Starter motor .................................................................... 7-24

Installing the starter motor........................................................ 7-25
Cylinder head ................................................................... 7-26

Removing the cylinder head..................................................... 7-27
Checking the cylinder head bolt ............................................... 7-28
Installing the cylinder head....................................................... 7-28
Camshaft and valve ......................................................... 7-30

Disassembling the cylinder head.............................................. 7-31
Checking the cylinder head ...................................................... 7-32
Checking the valve spring ........................................................ 7-33
Checking the valve ................................................................... 7-33
Checking the valve guide ......................................................... 7-34
Power unit
Replacing the valve guide ........................................................ 7-34

Checking the valve seat ........................................................... 7-36
Refacing the valve seat ............................................................ 7-36
Checking the rocker arm and rocker arm shaft ........................ 7-39
Checking the camshaft............................................................. 7-40
Checking the spark plug........................................................... 7-40
Checking the cylinder head anode ........................................... 7-41
Assembling the cylinder head .................................................. 7-41
Exhaust cover................................................................... 7-44

Removing the exhaust cover.................................................... 7-45
Removing the oil filter............................................................... 7-45
Checking the exhaust cover anode .......................................... 7-46
Checking the thermostat .......................................................... 7-46
Installing the oil filter................................................................. 7-46
Installing the thermo sensor ..................................................... 7-47
Installing the exhaust cover...................................................... 7-47
Cylinder block .................................................................. 7-49

Disassembling the cylinder block ............................................. 7-50
Checking the piston diameter................................................... 7-51
Checking the cylinder bore....................................................... 7-51
Checking the piston clearance ................................................. 7-52
Checking the piston ring........................................................... 7-52
Checking the piston ring end gap............................................. 7-52
Checking the piston ring groove............................................... 7-53
Checking the piston ring side clearance................................... 7-53 7
Checking the piston pin boss inside diameter .......................... 7-54
Checking the piston pin diameter ............................................. 7-54
Checking the connecting rod small end inside diameter and
big end inside diameter ............................................................ 7-54
Checking the connecting rod big end side clearance............... 7-55
Checking the crankshaft........................................................... 7-55
Checking the big end oil clearance .......................................... 7-56
Selecting the crankshaft pin bearing ........................................ 7-57
Checking the journal oil clearance ........................................... 7-58
Selecting the crankshaft journal bearing .................................. 7-59
Assembling the cylinder block .................................................. 7-60
Power unit (check and adjustment)
Power unit (check and adjust- g. Crank the engine until the reading on the
ment) compression gauge stabilizes, and then
measure the compression pressure.
Checking the compression pressure
1. Check: h. Remove the special service tools.
• Compression pressure
Below specification  Check the engine i. Install all of the spark plugs, and then tight-
internal parts. en the spark plugs to the specified torque.
Compression pressure Spark plug

Minimum (reference data) 18 N·m (1.8 kgf·m, 13 lb·ft)
T.
R.
840.0 kPa (8.40 kgf/cm², 121.8
psi) j. Connect the spark plug caps and fuel in-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
jector couplers.
a. Start the engine, warm it up for 5 minutes, ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
and then stop it.
Checking the oil pressure
b. Remove the clip from the engine shut-off 1. Check:
switch. • Oil pressure
Below specification  Check the engine
c. Disconnect the fuel injector couplers and internal parts.
spark plug caps.
Engine oil pressure at idle speed
d. Remove all of the spark plugs. (reference data)
230.0 kPa (2.30 kgf/cm², 33.4
e. Install the special service tools into the psi)
spark plug hole. / SL 10W-30 engine oil
Engine oil pressure at 3000 r/min
(reference data)
Before removing the spark plugs, remove 480.0 kPa (4.80 kgf/cm², 69.6
any dirt or dust in the spark plug wells that psi)
could fall into the cylinders.
/ SL 10W-30 engine oil
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
a. Disconnect the oil pressure switch lead
from the oil pressure switch end.
b. Remove the oil pressure switch, and then

install an oil pressure gauge “1” to the oil
pressure switch installation hole.
c. Start the engine and warm it up until the

engine idle speed stabilizes at the speci-
fied engine idle speed range.
Compression gauge “1”
90890-03160 Idle speed (in neutral)
Combination compression gauge 750–850 r/min
and cylinder leakdown test kit “1”
YB-45544-A
f. Fully open the throttle.
7-1
d. Measure the oil pressure.
b
TIP:
a
• Use a pressure gauge with an adapter that c
has a 1/8 pitch thread.
• The actual oil pressure may vary depending
on the temperature and engine oil viscosity.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Adjusting the pulser coil air gap

1
1. Loosen:
• Pulser coil bolt “1”
2. Adjust:
• Pulser coil air gap “a”
Oil pressure gauge “1”

e. Remove the oil pressure gauge.
f. Install the oil pressure switch. See “Cylin-

der block” (7-49).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1 a
Checking the pulser coil air gap

Pulser coil
Air gap
Do not turn the flywheel magneto counter- 0.35–1.35 mm (0.014–0.053 in)
clockwise. Otherwise, the water pump im-
peller could be damaged.
3. Tighten:
• Pulser coil bolt
1. Check:
• Pulser coil air gap 4. Recheck:
Out of specification  Adjust the air gap. • Pulser coil air gap
“Checking the pulser coil air gap” (7-2)
Pulser coil
Air gap Checking the valve clearance
0.35–1.35 mm (0.014–0.053 in) • Measure the valve clearances when the en-
gine is cold.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Cover the fuel components using a rag to
a. Turn the flywheel magneto clockwise to prevent fuel from spilling out.
align the protrusion “a” on the pulser coil
with the protrusion “b” on the pulser coil.
Do not turn the flywheel magneto counter-
b. Measure the pulser coil air gap “c”. clockwise. Otherwise, the water pump im-
peller could be damaged.
7-2
1. Check: e. Turn the flywheel magneto clockwise and
• Valve clearance align the “1△” mark “a” on the driven
Out of specification  Adjust. See “Adjust- sprocket “1” with the “△” mark “b” on the
ing the valve clearance” (7-5). cylinder head.
Valve clearance IN (cold engine) 1

0.15–0.25 mm (0.0059–0.0098
in)
Valve clearance EX (cold engine)
0.25–0.35 mm (0.0098–0.0138
in) a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the blowby hose “1”, the fuel hos- b
es “2”, and the fuel filter assembly “3”.
f. Measure each valve clearance “a” and “b”
b. Remove all the spark plug caps “4” from following the step g–k.
the spark plugs.
TIP:
c. Disconnect the ignition coil couplers “a”, Write down the measurement data.
and then remove the ignition coils “5”.
EX IN
d. Remove the clamps “b” from the cylinder
head cover “6”, and then remove the cylin-
der head cover “6”. #1
#2
1
6
#3
4 a 5
2
b
a 3
4 5 a
b
a 2
a. Intake
b. Exhaust
7-3
g. Measure the intake and exhaust valve k. Measure the intake and exhaust valve
clearances of the specified cylinder. clearances of the applicable cylinder.
#1 #2 #3 #1 #2 #3
IN ✔ — — IN — — ✔
EX ✔ — — EX — — ✔
—: Not applicable —: Not applicable

✔: Specified cylinder ✔: Specified cylinder
h. Turn the flywheel magneto clockwise 240 l. Install a new gasket “1” and the cylinder
to align the alignment mark “a” on the driv- head cover “2”.
en sprocket “1” with the “△” mark “b” on
the cylinder head.
2
b
1
i. Measure the intake and exhaust valve
clearances of the applicable cylinder.
m. Install the clamps “1” to the cylinder head
#1 #2 #3
cover “2”.
IN — ✔ —
EX — ✔ — n. Install the ignition coils “3”, and then con-
nect the ignition coil couplers “a”.
—: Not applicable
✔: Specified cylinder o. Install all the spark plug caps “4”.
j. Turn the flywheel magneto an additional

240 clockwise and align the alignment
mark “a” on the driven sprocket “1” with the
“△” mark “b” on the cylinder head.
7-4
p. Install the fuel filter assembly “5”, the fuel Adjusting the valve clearance
hoses “6”, and the blowby hose “7”. Adjust the valve clearances when the engine is
cold.
7
Do not turn the flywheel magneto counter-
2 clockwise. Otherwise, the water pump im-
a 3 peller could be damaged.
4 6
7
1. Adjust:
5 • Valve clearance
a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the valve adjusting locknut “1”, and
3
4 then turn the adjusting screw “2” until the
valve clearance is within specification.
TIP:
6
a • To decrease the valve clearance, turn the ad-
justing screw “2” in direction “a”.
• To increase the valve clearance, turn the ad-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
justing screw “2” in direction “b”.
2 1
a
b. Tighten the valve adjusting locknut to the

specified torque, and then recheck the
valve clearances.
Valve adjusting locknut

14 N·m (1.4 kgf·m, 10 lb·ft)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-5
Power unit assembly
Power unit assembly
14 6
18
4 13 12 New
1 17
3
2 16
15
7
5
1
11
10
9
21 N·m (2.1 kgf·m, 15 lb·ft)
21 N·m (2.1 kgf·m, 15 lb·ft) 11 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)

1 Bolt M6  20 mm 3
2 Grommet holder 1
3 Grommet 1
4 Cable guide 1
5 Rigging grommet 1
6 Dipstick 1
7 Bolt M6  16 mm 2
9 Nut 2
10 Apron 1
11 Bolt M8  80 mm 8
12 Gasket 1
13 Bolt M6  25 mm 2
14 Bracket 1
15 Screw M4  16 mm 2
16 Plate 1
17 Shift position switch 1
18 Collar 1
7-6
Power unit assembly
Removing the power unit e. Remove the cover “4”.
4
a
1. Remove:
• Power unit assembly 1 b
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the grommet holder “1”, grommet 2
“2”, and rigging grommet “3”.
f. Remove the battery cables “1”.

1 3
g. Remove the caps “2”, and then remove the
PTT motor leads “3” from the PTT relay
b. Remove the clips “1”, and then disconnect “4”, clamp “5”, and plastic tie “6” (PTT mod-
the shift cable “2” and the throttle cable “3”. el).
4
2
3
1 5
1
6
c. Remove the plastic tie “1”, and then dis-
connect the 10-pin coupler “a”. 3
d. Remove the main wire harness “b” from

the clamp “2” and the plastic tie “3”. h. Disconnect the shift position switch cou-
pler “a” and the 6Y8 multifunction meter
harness coupler “b”.
i. Disconnect the trolling switch coupler “c”

and the alert indicator coupler “d” (tiller
handle model).
7-7
Power unit assembly
j. Remove the each harness from the n. Disconnect the cooling water hoses “1”.
clamps “1”.
1
1
b
d
c
a
o. Remove the dipstick “1”.
k. Remove the water pressure sensor har-
ness “a” from the clamp “1”.
a
1
p. Remove the clip “1”, and then remove the
shift rod lever “2” from the shift rod bracket
l. Disconnect the cooling water hose “1”. “3”.
q. Remove the bracket “4”.
1
1
2
m. Disconnect the fuel hose “1”.
4
1
7-8
Power unit assembly
r. Remove the apron “1”. b. Install the power unit with the power unit
mounting bolts “2”.
c. Tighten the power unit mounting bolts “2”

to the specified torques in 2 stages and in
the order [1],[2], and so on.
1
1
2
s. Install the shackles “1” to the engine hang-
ers “2”, and then install the lifting harness-
es to the shackles “1”.
t. Suspend the power unit.
u. Remove the power unit mounting bolts “3”,

and then remove the power unit.
2
1 1 STBD
2
Front
2
2
[2] [10] [3] [8]
[9]
3 Front
[5]
[4] [1] [7] [6]
PORT
Front
3
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Installing the power unit Power unit mounting bolt “2”

1. Install: 1st: 21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.
• Power unit assembly 2nd: 21 N·m (2.1 kgf·m, 15 lb·ft)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the power unit mating surface, and
then install a new gasket “1”.
7-9
Power unit assembly
d. Install the apron “1” and apron bolts “2”, g. Install the dipstick “1”.
and then tighten the apron screws “3” to
2
h. Connect the cooling water hoses “1”.

1
3 1
Apron screw “3”

3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
T.
R.
e. Install the bracket “1”.

i. Connect the fuel hose “1”.
f. Install the shift rod lever “2” to the shift rod
bracket “3”, and then install the clip “4”.
3
1
4
2
j. Connect the cooling water hose “1”, and
then fasten it using a new plastic tie “2”.
1
2
7-10
Power unit assembly
k. Install the water pressure sensor harness
“a” to the clamp “1”.
4
6
3
7
a 5
1
2
1
l. Connect the trolling switch coupler “a” and
alert indicator coupler “b” (tiller handle
model).
PTT motor lead bolt “5”
m. Connect the shift position switch coupler 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.
“c” and 6Y8 multifunction meter harness

coupler “d”. s. Install the cover “1”.
n. Install the each harness to the clamps “1”. t. Connect the 10-pin coupler “a”, and then
fasten it to the cover “1” with a plastic tie
1 “2”.
u. Install the main wire harness “3” to the

1
clamp “4”, and then fasten the main wire
harness “3” to the bracket “5” with a plastic
tie “6”.
d b
a TIP:
c Before fastening the main wire harness “3” to
the clamp “4” and the bracket “5”, pull it to pre-
o. Install the PTT motor leads “1” to the plas- vent loosening.
tic ties “2”, clamp “3”, and PTT relay “4”
(PTT model).
1
p. Tighten the PTT motor lead bolts “5” to the a
specified torque (PTT model).
2 4
q. Install the caps “6” (PTT model).
r. Install the battery cables “7”.

3
7-11
Power unit assembly
v. Install the shift cable and throttle cable.
See “Installing the shift cable and throttle
cable (remote control model)” (3-14).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-12
Flywheel magneto and timing belt

1 160 N·m (16 kgf·m, 118 lb·ft) 38 N·m (3.8 kgf·m, 28 lb·ft)
11
2
150 N·m (15 kgf·m, 111 lb·ft)
5
16
7 6 17
7
12
8
7 18
13
14 19
7 7
4
7
15
9
10
10

Nut Width across flats: 16 Bolt M10  35 mm 1
1 1
30 mm 17 Washer 1
2 Washer 1 18 Driven sprocket 1
3 Flywheel magneto 1 19 Dowel pin 1
Flywheel
4 Woodruff key 1
magneto
5 Bolt M5  16 mm 2
6 Pulser coil 1
7 Bolt M6  30 mm 7
8 Stator assembly 1
9 Base assembly 1
10 Dowel pin 2
11 Timing belt 1
Nut Width across flats:
12 1
41 mm
13 Retaining plate 1
14 Drive sprocket 1
Drive sprock-
15 Woodruff key 1
et
7-13
Removing the flywheel magneto
1. Turn the flywheel magneto clockwise to Flywheel holder “2”
align the “1△” mark “a” on the driven 90890-06522
sprocket “1” with the “△” mark “b” on the Flywheel magneto holder “2”
cylinder head. YB-06139
3. Remove:
1 • Flywheel magneto
• Woodruff key
a To prevent damage to the engine or tools,

screw in the flywheel puller set bolts evenly
and completely so that the flywheel puller
b
is parallel to the flywheel magneto.
2. Loosen:
• Flywheel magneto nut “1” A
1
Apply force in the direction of the arrow to
prevent the special service tool “2” from
slipping off easily.
A
2
1 1
B 2
1 A. Worldwide
B. USA and Canada
A. Worldwide Flywheel puller “1”

B. USA and Canada 90890-06521
Universal Puller “1”
YB-06117
7-14
Removing the timing belt and sprock-
et Crankshaft holder 16 “2”
90890-06355
Crankshaft holder “2”
When the timing belt is not installed, do not YW-06355
turn the crankshaft or driven sprocket. Oth-
erwise, the pistons and valves could collide 3. Loosen:
with each other and be damaged. • Driven sprocket bolt “1”
1. Remove: When loosening the driven sprocket bolt,

• Timing belt “1” do not turn the camshaft.
1
A
2
2. Loosen:
• Drive sprocket nut “1” B 3
1
TIP:
Use the air tool to loosen the drive sprocket nut
easily.
A. Worldwide
B. USA and Canada
2
Flywheel holder “2”

90890-06522
Flywheel magneto holder “3”
YB-06139
2
Checking the timing belt and sprocket
1 1. Check:
• Interior and exterior of the timing belt
• Drive sprocket
• Driven sprocket
Cracked/damaged/worn  Replace.
7-15
Installing the sprocket and timing belt 3. Install:
• Woodruff key “1”
• Drive sprocket “2”
When the timing belt is not installed, do not • Retaining plate “3”
turn the crankshaft or driven sprocket. Oth- • Drive sprocket nut “4”
erwise, the pistons and valves could collide
with each other and be damaged.
4
1. Install:
• Dowel pin (to the camshaft) 3
• Driven sprocket
• Washer 2
2. Tighten: 1
• Driven sprocket bolt “1”
A
1
4. Tighten:
• Drive sprocket nut “1”
B
1
3
2
1
A. Worldwide
B. USA and Canada
2
90890-06522
YB-06139
Driven sprocket bolt “1” Crankshaft holder 16 “2”

38 N·m (3.8 kgf·m, 28 lb·ft) 90890-06355
T.
R.
Crankshaft holder “2”

YW-06355
7-16
Installing the stator assembly
Drive sprocket nut “1” 1. Install:
150 N·m (15 kgf·m, 111 lb·ft) • Base assembly “1”
T.
R.
• Stator assembly “2”

5. Install: • Stator assembly bolt “3”
• Timing belt • Stator assembly coupler “4”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Pulser coil “5”
a. Check that the “1△” mark “a” on the driven • Pulser coil bolt “6”
sprocket is aligned with the “△” mark “b” • Pulser coil connector “7”
on the cylinder head, and that the hole “c”
on the crankshaft is aligned with the 3
“△”mark “d” on the cylinder block.
2
4
a
b
1
c
5
6
6
7
b. Install the timing belt “1”.
TIP:
Be careful not to install the timing belt with the
part number upside down.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-17
Installing the flywheel magneto B
1. Install: 1
• Woodruff key “1” (to the crankshaft)
• Flywheel magneto “2”
TIP:
Make sure to remove any grease from the ta-
pered portion of the crankshaft “a” and the fly- 2
wheel magneto “b”.
A. Worldwide
B. USA and Canada
2
90890-06522
YB-06139
a
2 b 1 Flywheel magneto nut “1”
160 N·m (16 kgf·m, 118 lb·ft)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Tighten:
• Flywheel magneto nut “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Tighten the flywheel magneto nut to the
specified torque.
Apply force in the direction of the arrow to

prevent the special service tool “2” from
slipping off easily.
7-18
Engine ECM, rectifier/regulator, and ignition coil
Engine ECM, rectifier/regulator, and ignition coil
1 2
4
1 6 5
1 4
3
9
4
1 5
5
6
7 6
1 8 7
1 8

1 Bolt M6  25 mm 9
2 Engine ECM 1
3 Rectifier/regulator 1
4 Spark plug cap 3
5 Ignition coil 3
6 Grommet 6
7 Plate 2
8 Clamp 2
9 Plate 1
7-19
Wire harness
Wire harness
4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 14
15
13 14 15
1 13
5 16
4
21
A
33 23
3 6
2 22 1
3 12
A2 1
4 10
3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
9 6
8
9
8 11 19
7 25
26 9 19 20 17
27 18
17
27
29 26
28 24
B
32 1
30 6 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 31
1 Bolt M6  16 mm 6 20 A, spare is
19 Fuse 4
2 Cap 2 included.
3 Bolt M6  10 mm 2 20 Fuse 2
30 A, spare is
4 Bolt M6  20 mm 2 included.
21 Plastic tie 1
5 PTT relay 1
6 Screw M6  20 mm 3 22 Plastic tie 1
7 Plate 1 23 Holder 1
24 Plastic tie 2
8 Cap 2
9 Bolt M6  10 mm 3 25 Holder 1
10 Starter relay 1 26 Bolt 2
27 Grommet 2
11 Cap 1
12 Main relay 1 28 Bolt M6  16 mm 2
13 Bolt M6  28 mm 6 29 Bracket 1
30 Clamp 1
14 Collar 6
15 Grommet 6 31 Clamp 1
16 Bracket 1 32 Clamp 1
17 Cap Yellow 2 33 Wire harness 1
18 Cap Green 1 A: PTT model
B: Hydro tilt model
7-20
Wire harness
Installing the wire harness
1. Install: YDIS coupler screw “6”
• Clamp “1” 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
T.
R.
• PTT relay coupler “a”
• Fuse holder “2” 2. Install:
• Clamp “3” • Bracket “1”
• Diode “4” • Terminal “2”
• Plastic tie “5” • Terminal lead “3”
• YDIS coupler “b” • Terminal bolt “4”
• YDIS coupler screw “6”
1
a 1 1
4 3
3
2 Terminal bolt “4”

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.
4
5
7-21
Wire harness
3. Install:
• Main relay “1” Starter relay lead bolt “2”
• Main relay screw “2” 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.
• Main relay coupler “a”
6. Install:
• PTT relay “1”
2 • PTT relay coupler “a”
• PTT relay lead “2”
• PTT relay lead nut “3”
1 • Cap “4”
a
1
Main relay screw “2”

3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
T.
3 4
R.
2
4. Install:
• Starter relay “1”
• Plate “2”
• Starter relay screw “3”
• Starter relay connector “a” a
PTT relay lead nut “3”

1 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.
7. Install:
3 a • Ground lead “1”
2
• Ground lead “2”
• Clamp “3”
• Rectifier/regulator coupler “a”
• Thermo sensor coupler “b”
Starter relay screw “3”
• Oil pressure switch connector “c”
3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
T.

R.
• Clamp “5”
5. Install:
• Starter relay lead “1”
• Starter relay lead bolt “2”
1
• Cap “3”
3
3
7-22
Wire harness
3
1
a
b
7-23
Starter motor
Starter motor
18 16
30 N·m (3.0 kgf·m, 22 lb·ft)
17
15
16
14
5 18
1
19
14
3 16
6 9 10
11
2 12 13
2
8
4 9 N·m (0.9 kgf·m, 6.6 lb·ft)
7
4 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

1 Bolt M6  25 mm 1
2 Bolt M6  20 mm 3
3 Bracket 1
4 Clip 2
5 Bushing 1
6 Washer 1
7 Shift rod lever 1
8 Nut 1
9 Spring washer 1
10 Cap 1
11 Bolt M6  10 mm 1
12 Starter motor lead 1
13 Terminal 1
14 Bolt M8  45 mm 3
15 Starter motor 1
16 Bolt M8  45 mm 4
17 Bracket 1
18 Dowel pin 2
19 Engine hanger 1
7-24
Starter motor
Installing the starter motor
1. Install:
• Starter motor lead “1”
• Starter motor lead nut “2”
• Starter motor lead bolt “3”
• Starter motor “4”
• Starter motor bolt “5”
3
2
1
Starter motor lead nut “2”

9 N·m (0.9 kgf·m, 6.6 lb·ft)
T.
R.
Starter motor lead bolt “3”

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
Starter motor bolt “5”
30 N·m (3.0 kgf·m, 22 lb·ft)
7-25
Cylinder head
Cylinder head
6 N·m (0.6 kgf·m, 4.4 lb·ft)
15 New 12 N·m (1.2 kgf·m, 8.9 lb·ft)
12 17 N·m (1.7 kgf·m, 13 lb·ft)

16 34 N·m (3.4 kgf·m, 25 lb·ft)
90°
13 7
16
8
7
14
9
11 10
New 3
6 New
2
9 5
1 1
1
1 Bolt M6  45 mm 4
2 Oil pump assembly 1
3 Gasket 1
4 Bolt M6  20 mm 7
5 Cylinder head cover 1
6 Gasket 1
8 Plate 1
9 Grommet 5
10 Oil filler cap 1
11 O-ring 1
12 Bolt M6  25 mm 4
13 Bolt M9  93 mm 8
Cylinder head assem-
14 1
bly
15 Gasket 1
16 Dowel pin 2
7-26
Cylinder head
Removing the cylinder head 1
1. Remove: 2
• Oil pump assembly “1” [2]
[5] [6]
[4]
[10]
[9]
[3]
[11]
[12]
1
[1]
[8] [7]
4. Remove:
• Cylinder head bolt “1”
• Cylinder head bolt “2”
2. Remove: • Cylinder head “3”
• Cylinder head cover “1”
1 Do not scratch or damage the mating sur-

faces of the cylinder head and cylinder
block.
3
2
3. Loosen:
• Cylinder head bolt (M6) “1”
• Cylinder head bolt (M9) “2”
TIP:
Loosen the cylinder head bolts in the order [1],
[2], and so on.
7-27
Cylinder head
Checking the cylinder head bolt 2. Install:
1. Measure: • Dowel pin
• Cylinder head bolt (M9) diameter • Cylinder head gasket New
Out of specification  Replace. • Cylinder head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the diameters “a” and “b” of the 3. Tighten:
cylinder head bolt (M9) at the specified • Cylinder head bolt (M9)
measuring points “c” and “d”. • Cylinder head bolt (M6)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Tighten the cylinder head bolts (M9) “1” to
the specified torques in 3 stages and in the
b a
TIP:
d c In the third tightening stage for the cylinder
head bolts (M9) “1”, mark the bolts and cylinder
head with identification marks “a”, and then
tighten the bolts 90 from the marks on the cyl-
inder head.
Cylinder head bolt (M9) diameter
difference limit
b. Tighten the cylinder head bolts (M6) “2” to
“a” – “b” = Less than 0.13 mm
the specified torques in 2 stages and in the
(0.01 in)
Measuring point “c”: 10.0 mm
(0.39 in) [8] 1
[12]
Measuring point “d”: 62.5 mm
(2.46 in) a 90° [7]
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ [10]
Installing the cylinder head [4] [3]

Before installing the cylinder head, check the [9]
cylinder head bolts. See “Checking the cylinder
head bolt” (7-28). 2 [2]
[1]
1. Check that the hole “a” on the retaining
[11]
plate is aligned with the “△” mark “b” on [6]
the cylinder block. [5]
Cylinder head bolt (M9) “1” [1]–[8]

b
1st: 17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.
2nd: 34 N·m (3.4 kgf·m, 25 lb·ft)

a
3rd: 90
Cylinder head bolt (M6) “2” [9]–
[12]
1st: 6 N·m (0.6 kgf·m, 4.4 lb·ft)
2nd: 12 N·m (1.2 kgf·m, 8.9 lb·ft)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-28
Cylinder head
4. Install: 6. Install:
• Gasket “1” New • Gasket “1” New
• Plate “2” • Oil pump assembly “2”
• Cylinder head cover “3” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a new gasket “1”, the oil pump as-
3 sembly “2”, and the oil pump bolts, aligning
the slot in the oil pump drive shaft “a” with
2 the camshaft pin “b”.
2
b
5. Fill: a
• Engine oil
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the oil pump assembly “1” with engine
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
oil through the oil passages “a”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-29
Camshaft and valve
Camshaft and valve
29
23 New
21 New
7 28
20 30 New
18 N·m (1.8 kgf·m, 13 lb·ft)
24
31 15
14 13
32 27
26 25
31 New
17 16
6
27
5 19 19
4 15
3 New 30
9
New 2 26
5 22
25 8
1 18
24
18 N·m (1.8 kgf·m, 13 lb·ft)
15 11 10
19
2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 8
14
18 N·m (1.8 kgf·m, 13 lb·ft) 13 15
9
8
14 N·m (1.4 kgf·m, 10 lb·ft)
15 11 10
19 8
12
1 Anode plug 3 20 Retaining bolt 1
2 O-ring 3 21 Gasket 1
3 Anode 3 22 Camshaft 1
4 Screw M5  24 mm 3 23 Oil seal 1
5 Spark plug 3 24 Valve cotter 12
6 Bolt M6  20 mm 2 25 Valve spring retainer 6
7 Engine hanger 1 26 Valve spring 6
8 Bolt M8  22 mm 4 27 Valve spring seat 6
9 Washer 2 28 Intake valve 3
10 Stopper 2 29 Exhaust valve 3
11 Tensioner 2 30 Valve seal 6
12 Rocker arm shaft 1 31 Valve guide 6
13 Nut 5 32 Cylinder head 1
14 Adjusting screw 5
15 Rocker arm 5
16 Nut 1
17 Adjusting screw 1
18 Rocker arm 1
19 Washer 6
7-30
Camshaft and valve
Disassembling the cylinder head 3. Remove:
1. Remove: • Rocker arm shaft bolt “1”
• Cylinder head anode “1” • Washer “2”
• Spark plug “2” • Stopper “3”
• Engine hanger “3” • Tensioner “4”
• Washer “5”
• Rocker arm “6”
1 • Rocker arm “7”
TIP:
Make sure to keep the parts in the order of re-
3 moval.
2
3 1
1 1 4
2. Loosen: 3
• Rocker arm shaft bolt “1” 4 2
1
TIP: 2
Gradually loosen the rocker arm shaft bolts in 5 5
several stages and in the order [1], [2], and so
on. 6 6
7
6
[3] 1
5
5
[2]
[4] 4. Remove:
• Retaining bolt “1”
• Camshaft “2”
• Oil seal “3”
[1]
1
3
2
7-31
Camshaft and valve
5. Remove: Checking the cylinder head
• Valve cotter 1. Check:
• Retainer • Cylinder head
• Valve spring Damage/scratches  Replace.
• Valve spring seat • Cylinder head warpage
• Intake valve Out of specification  Replace.
• Exhaust valve
Warpage limit
TIP: 0.10 mm (0.0039 in)
Make sure to keep the parts in the order of re-
moval. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove carbon deposits from the com-
bustion chambers, and then check the cyl-
inder head for damage and scratches.
2 b. Check the cylinder head warpage using a

straightedge “1” and a thickness gauge “2”
in 7 directions.
1 2
Valve spring compressor “1”

90890-04019
YM-04019
Valve spring compressor attach-
ment “2” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
90890-06320
Valve spring compressor adaptor
“2”
YB-06320
7-32
Camshaft and valve
Checking the valve spring Checking the valve
1. Measure: 1. Check:
• Free length “a” • Valve face
Below specification  Replace. Pitted/worn  Replace.
2. Measure:
• Margin thickness “a”
a
Free length IN
39.85 mm (1.57 in)
Limit
37.86 mm (1.49 in)
Free length EX Margin thickness IN
39.85 mm (1.57 in) 0.80–1.20 mm (0.0315–0.0472
Limit in)
37.86 mm (1.49 in) Margin thickness EX
1.00–1.40 mm (0.0394–0.0551
in)
2. Measure:
• Tilt “a”
Above specification  Replace. 3. Measure:
• Stem diameter “a”
a Below specification  Replace.
Tilt limit IN
1.7 mm (0.07 in)
Tilt limit EX Diameter IN
1.7 mm (0.07 in) 5.475–5.490 mm (0.2156–
0.2161 in)
Limit
5.445 mm (0.2144 in)
Diameter EX
5.460–5.475 mm (0.2150–
0.2156 in)
Limit
5.430 mm (0.2138 in)
7-33
Camshaft and valve
4. Measure: 2. Calculate:
• Stem runout • Valve stem to valve guide clearance
Above specification  Replace. Out of specification  Replace the valve
and valve guide.
Valve stem to valve guide clear-

ance = valve guide inside diameter
– valve stem diameter
Clearance IN
0.010–0.037 mm (0.0004–
0.0015 in)
Limit
0.070 mm (0.0028 in)
Clearance EX
Runout limit EX
0.025–0.052 mm (0.0010–
0.01 mm (0.0004 in)
0.0020 in)
Runout limit IN
Limit
0.01 mm (0.0004 in)
0.070 mm (0.0028 in)
Checking the valve guide

Replacing the valve guide
Before checking the valve guides, make sure
After replacing a valve guide, check the valve
that the valve stem diameter is within specifica-
seat contact area.
tion.
1. Remove:
1. Measure:
• Valve guide “1” (from the combustion
• Inside diameter “a”
chamber side)
Above specification  Replace.
a
1
Valve guide remover/installer “2”

Inside diameter IN
90890-06801
5.500–5.512 mm (0.2165–
Valve guide remover “2”
0.2170 in)
YB-06801
Inside diameter EX
5.500–5.512 mm (0.2165–
0.2170 in)
7-34
Camshaft and valve
2. Install: 3. Ream:
• Valve guide New • Valve guide “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a new valve guide “1” to the speci-
TIP:
• To ream the valve guide, turn the valve guide
fied installation height “a” from the cam-
reamer clockwise.
shaft side.
• When removing the valve guide reamer, do
not turn it counterclockwise.
• After reaming the valve guide, make sure to
2 clean it.
a
3
1
1
2
Valve guide remover/installer “2”

90890-06801
Valve guide remover “2”
YB-06801
Valve guide installer “3” Valve guide reamer “2”
90890-06810 90890-06804
Valve guide installer “3” Valve guide reamer “2”
YB-06810 YB-06804
Installation height 4. Measure:

16.30–16.70 mm (0.6417– • Inside diameter
0.6575 in)
Inside diameter IN
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5.500–5.512 mm (0.2165–
0.2170 in)
Inside diameter EX
5.500–5.512 mm (0.2165–
0.2170 in)
7-35
Camshaft and valve
Checking the valve seat
1. Measure: 1
• Contact width “a”
Not seated properly/out of specification 
Reface.
Uneven  Check the valve guide.
Valve lapper “1”

a
90890-04101
Valve lapping tool “1”
YM-A8998
d. Measure the valve seat contact width “a”

where the blue layout fluid is adhered to
the valve face.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Refacing the valve seat
After every lapping procedure, make sure

to clean off any remaining lapping com-
pound from the cylinder head and valves.
1. Reface:
• Valve seat
Seat contact width IN A
1.20–1.60 mm (0.0472–0.0630
in)
Limit
2.050 mm (0.0807 in) 30 45 60
Seat contact width EX
1.20–1.60 mm (0.0472–0.0630
in)
Limit
2.050 mm (0.0807 in) B
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove carbon deposits from the valve.
30 45 60
b. Apply a thin, even layer of blue layout fluid
(Dykem) onto the valve seat.
30
c. Push the valve lightly against the valve 45
seat using the special service tool “1”.
7-36
Camshaft and valve
A. Worldwide B
B. USA and Canada
Valve seat cutter holder

90890-06316
Intake:
Valve seat cutter 30
90890-06326
90890-06312 A. Worldwide
Valve seat cutter 60 B. USA and Canada
90890-06323
Exhaust:
45°
90890-06328 a
90890-06325
90890-06315
Neway valve seat kit
YB-91044
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slag or rough surface
a. Cut the surface of the valve seat using a
45 cutter by turning the cutter clockwise b. Adjust the top edge of the valve seat con-
until the valve seat face has become tact width using a 30 cutter.
smooth.
30°
a
Do not overcut the valve seat. To prevent
chatter marks, make sure to turn the cutter
evenly using a downward force of 40–50 N
(4.0–5.0 kgf, 8.8–11.0 lbf).
a. Previous contact width
c. Adjust the bottom edge of the valve seat

contact width using a 60 cutter.
60°
7-37
Camshaft and valve
a. Previous contact width • If the valve seat contact area is too nar-
row and situated near the top edge of the
d. Adjust the valve seat contact width to valve face, cut the top edge of the valve
specification using a 45 cutter. seat using a 30 cutter to center the area.
Set its width using a 45 cutter.
a 30°
b a
45°

b. Specified contact width a. Previous contact width
e. Check the valve seat contact area of the • If the valve seat contact area is too nar-
valve. See “Checking the valve seat” (7- row and situated near the bottom edge of
36). the valve face, cut the bottom edge of the
valve seat using a 60 cutter. Set its
Example: width using a 45 cutter.
• If the valve seat contact area is too wide
and situated in the center of the valve
face, cut the top edge of the valve seat a
using a 30 cutter. Cut the bottom edge
using a 60 cutter to center the area and
set its width.
30° 60°
a
60°
7-38
Camshaft and valve
f. After refacing the valve seat to the speci- Checking the rocker arm and rocker
fied contact width, apply a thin, even layer arm shaft
of lapping compound onto the valve seat, 1. Check:
and then lap the valve using the special • Rocker arms, rocker arm shaft, and con-
service tool “1”. tact surface “a” of each rocker arm
Worn  Replace.
Do not get the lapping compound on the 2. Measure:

valve stem and valve guide. • Rocker arm inside diameter “b” and rocker
arm shaft outside diameter “c”
1
a
b
c
Valve lapper “1”

90890-04101
Rocker arm
Valve lapping tool “1”
Inside diameter IN
YM-A8998
16.000–16.018 mm (0.6299–
0.6306 in)
g. Recheck the valve seat contact area of the
Inside diameter EX
valve. See “Checking the valve seat” (7-
16.000–16.018 mm (0.6299–
36).
0.6306 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Rocker arm shaft
Outside diameter IN
15.971–15.991 mm (0.6288–
0.6296 in)
Outside diameter EX
15.971–15.991 mm (0.6288–
0.6296 in)
7-39
Camshaft and valve
Checking the camshaft 3. Measure:
1. Measure: • Camshaft journal diameters “a”, “b”, and
• Lobe height “a” “c” and cylinder head journal inside diame-
Below specification  Replace. ters “d”
a
d
d
Cam lobe height IN c

30.737–30.837 mm (1.2101– b
1.2141 in) a
Limit
30.587 mm (1.2042 in)
Cam lobe height EX Camshaft
30.933–31.033 mm (1.2178– Journal diameter
1.2218 in) 36.925–36.945 mm (1.4537–
Limit 1.4545 in)
30.783 mm (1.2119 in) Cylinder head
Journal inside diameter
2. Measure: 37.000–37.025 mm (1.4567–
• Runout 1.4577 in)
Checking the spark plug
1. Clean the electrodes “a” using a spark plug
cleaner.
Runout
0.030 mm (0.0012 in)
7-40
Camshaft and valve
2. Check: 2. Install:
• Spark plug • Intake valve
Electrodes are eroded, edges of elec- • Exhaust valve
trodes are rounded, insulator is damaged, • Valve spring seat
or there is carbon or other deposits.  Re- • Valve spring
place. • Retainer
• Valve cotter
3. Measure: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Spark plug gap “a” a. Install the valve “1”, valve spring seat “2”,
Out of specification  Adjust or replace. valve spring “3”, and valve spring retainer
“4” in this order, and then install the valve
spring compressor “5” and valve spring
a compressor attachment “6”.
4
3
2
6
Spark plug (NGK)

DPR6EB-9
Spark plug gap
0.8–0.9 mm (0.031–0.035 in)
Checking the cylinder head anode

1. Check: 5
• Anode
Eroded (1/2 or more)  Replace.
1
There is grease, oil, or scales.  Clean.

Do not apply grease, oil, or paint to the an- 90890-04019
odes. Valve spring compressor “5”
YM-04019
Valve spring compressor attach-
Assembling the cylinder head
ment “6”
1. Install:
90890-06320
• Valve stem seal “1” New Valve spring compressor adaptor
“6”
YB-06320
1
7-41
Camshaft and valve
b. Compress the valve spring, and then in- 3. Install:
stall the valve cotters “1”. • Oil seal “1” New
A 2
2
3 3
1
1
c. Tap the valve spring retainer lightly using a

plastic hammer to seat the valve cotters
“1” securely.
TIP: B
Make sure that both valve cotters “1” are seat- 4
ed securely and evenly.
4
5 5
1 1 A. Worldwide
B. USA and Canada
Driver rod LS “2”

90890-06606
Bearing outer race attachment “3”
90890-06626
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Driver handle (large) “4”
YB-06071
Driveshaft bearing installer “5”
YB-06110
7-42
Camshaft and valve
4. Install:
a 6 8
• Camshaft “1”
8
• Gasket “2” New 5
8 4
• Camshaft retaining bolt “3” 6
7
3 8 3
5
2 7
3
1 1
2
1
1
3
5. Install: c. Tighten the rocker arm shaft bolts “1” grad-

• Rocker arm ually to the specified torque and in the or-
• Washer der [1], [2], and so on.
• Rocker arm shaft
• Tensioner [2] 1
• Stopper
• Washer
• Rocker arm shaft bolt
[3]
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Align the dowel hole “a” in the camshaft
with the “△” mark “b” on the cylinder head.
[1]
a
[4]
Rocker arm shaft bolt “1”

b 18 N·m (1.8 kgf·m, 13 lb·ft)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Assemble the rocker arms “1”, “2”, and

6. Install:
washers “3” onto the rocker arm shaft “4”,
• Cylinder head
and then install the tensioners “5”, stop-
See “Installing the cylinder head” (7-28).
pers “6”, washers “7”, and rocker arm shaft
bolts “8”. 7. Adjust:
• Valve clearance
TIP:
See “Adjusting the valve clearance” (7-5).
Make sure that the arrow marks “a” on the ten-
sioners “5” are facing towards the driven
sprocket.
7-43
Exhaust cover
Exhaust cover
New 22 2
23 N·m (2.3 kgf·m, 17 lb·ft) 3 3
21 28
1
29 4 1
1 3
9 N·m (0.9 kgf·m, 6.6 lb·ft) 6 N·m (0.6 kgf·m, 4.4 lb·ft)
12 N·m (1.2 kgf·m, 8.9 lb·ft)
19
18 17 New
New 20 16 New
14
15
27
14
24 23
14
5
56 N·m (5.6 kgf·m, 41 lb·ft)
6 New 8 New
2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 7
12
25 New 8
7 11 13
26
New 10
40 N·m (4.0 kgf·m, 30 lb·ft)
2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 9
18 N·m (1.8 kgf·m, 13 lb·ft)
23 N·m (2.3 kgf·m, 17 lb·ft)
18 N·m (1.8 kgf·m, 13 lb·ft) 23 N·m (2.3 kgf·m, 17 lb·ft)

1 Bolt M6  16 mm 3 20 Gasket 1
2 Bracket 1 21 Thermo sensor 1
3 Clamp 3 22 Gasket 1
4 Clamp 1 Oil pressure switch
23 1
5 Plug M18  17 mm 1 lead
6 Gasket 1 24 Oil pressure switch 1
7 Plug M14  12 mm 2 25 Oil filter 1
8 Gasket 2 26 Union bolt 1
9 Anode plug 1 27 Dowel pin 2
10 O-ring 1 28 Plate 1
11 Screw M5  24 mm 1 29 Clamp 1
12 Anode 1
13 Hose joint 1
14 Bolt M6  35 mm 10
15 Thermostat cover 1
16 Gasket 1
17 Gasket 1
18 Thermostat 1
19 Exhaust cover 1
7-44
Exhaust cover
Removing the exhaust cover 4. Remove:
1. Remove: • Exhaust cover bolt “1”
• Bracket “1” • Thermostat cover “2”
• Thermostat “3”
• Exhaust cover “4”
1
4 1
2. Remove:
• Exhaust cover plug “1” 3
• Exhaust cover plug “2” 2
• Exhaust cover anode “3”
• Hose joint “4”
1
1
Removing the oil filter

1. Remove:
2 • Oil filter “1”
4 1
2
2
3
3. Loosen:
• Exhaust cover bolt
Loosen the exhaust cover bolts “1” in the
1 [1] Oil filter wrench “2”
[3] [2] 90890-01426
Oil filter wrench “2”
[7] YB-01426
[8]
[10]
[9]
[5]
[6] [4]
7-45
Exhaust cover
2. Remove: c. Measure the thermostat valve opening “a”
• Oil filter union bolt “1” at the specified water temperatures.
Checking the exhaust cover anode Water tempera-

Valve opening “a”
1. Check: ture
• Anode 58–62 C
Eroded (1/2 or more)  Replace. Starts opening
(136–144 F)
above 70 C
3.0 mm (0.12 in) or above
(158 F)
Do not apply grease, oil, or paint to the an- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
odes.
Installing the oil filter
1. Install:
Checking the thermostat • Union bolt “1”
1. Check:
• Thermostat valve opening at the specified
water temperatures
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suspend the thermostat in a container of 1
water.
b. Place a thermo meter in the water, and

then heat the water slowly.
Union bolt “1”

40 N·m (4.0 kgf·m, 30 lb·ft)
T.
R.
7-46
Exhaust cover
2. Install: Installing the thermo sensor
• Oil filter “1” 1. Install:
1 • Gasket “1”
• Thermo sensor “2”
1
2

90890-01426
Oil filter wrench “2” Thermo sensor “2”
YB-01426 23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
Oil filter “1” Installing the exhaust cover

18 N·m (1.8 kgf·m, 13 lb·ft) 1. Install:
T.
R.
• Gasket “1” New

3. Install: • Exhaust cover “2”
• Oil pressure switch “1” • Gasket “3” New
• Oil pressure switch lead “2” • Thermostat “4”
• Oil pressure switch bolt “3”
• Thermostat cover “6”
• Exhaust cover bolt “7”
1 2
1
3 2
7
Oil pressure switch “1”
9 N·m (0.9 kgf·m, 6.6 lb·ft) 4 3
T.
R.
5
Oil pressure switch bolt “3” 6
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
7-47
Exhaust cover
2. Tighten:
• Exhaust cover bolt “1” Exhaust cover anode screw “3”
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
T.
R.
TIP: Exhaust cover anode plug “4”
Tighten the exhaust cover bolts “1” to the spec- 18 N·m (1.8 kgf·m, 13 lb·ft)
ified torques in 2 stages and in the order [1], [2], Exhaust cover plug (M14) “6”
and so on. 23 N·m (2.3 kgf·m, 17 lb·ft)
Exhaust cover plug (M18) “8”
[10]
56 N·m (5.6 kgf·m, 41 lb·ft)
[8] [9]
4. Install:
[9]
• Hose joint “1”
1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
[3]
a. Install the hose joint “1” to the specified in-
[1] stallation height “a”.
[2] a
[6]
[5] [7]
1
Exhaust cover bolt “1” 1

1st: 6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
2nd: 12 N·m (1.2 kgf·m, 8.9 lb·ft)
3. Install: Installation height

• O-ring “1” 18.0–20.0 mm (0.71–0.79 in)
• Exhaust cover anode “2” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Exhaust cover anode screw “3”
• Exhaust cover anode plug “4” 5. Install:
• Bracket “1”
• Exhaust cover plug “6”
• Gasket “7” New 1
• Exhaust cover plug “8”
7 5
5
6
3
2 4
1
7-48
Cylinder block
Cylinder block
16
4
14 New
15 N·m (1.5 kgf·m, 11 lb·ft)

30 N·m (3.0 kgf·m, 22 lb·ft) 13 4
6 N·m (0.6 kgf·m, 4.4 lb·ft)
12 N·m (1.2 kgf·m, 8.9 lb·ft)
12
13
3
13
2
4
13
4
13 New 8
7
1
10
13 11
New 15
9
8 New
6 6 N·m (0.6 kgf·m, 4.4 lb·ft)
5 New
17 N·m (1.7 kgf·m, 13 lb·ft)

1 Bolt M8  82 mm 8
2 Bolt M6  35 mm 8
3 Crankcase 1
4 Dowel pin 4
5 Bolt M6  30 mm 6
Connecting rod as-
6 3
sembly
7 Crankshaft pin bearing 6
8 Clip 6
9 Piston pin 3
10 Piston 3
11 Piston ring set 3
12 Crankshaft 1
Crankshaft journal
13 8
bearing
14 Oil seal 1
15 Oil seal 1
16 Cylinder block 1
7-49
Cylinder block
Disassembling the cylinder block 3. Remove:
1. Loosen: • Connecting rod bolt “1”
• Crankcase bolt “1” • Connecting rod cap “2”
• Crankcase bolt “2” • Piston assembly “3”
TIP: TIP:
Loosen the crankcase bolts in the order [1], [2], • Make sure to keep the crankshaft pin bear-
and so on. ings in their original groups.
• Mark each piston with an identification num-
ber “a” of the corresponding cylinder.
• Do not mix the connecting rods and caps.
2 Keep them organized in their proper groups.
[12] [11] 1
[4] 1 1
[3]
[16] [15]
[8] [7] 2
[13] [14]
[5] [6]
[1] [9] [10] [2]
2. Remove:
• Crankcase bolt “1”
• Crankcase bolt “2”
• Crankcase “3”
2 1
2 1 3
2 2 a
2
1 4. Remove:
• Crankshaft “1”
• Crankshaft journal bearing “2”
1 2
1 4
2
3
3
2
7-50
Cylinder block
5. Remove:
• Piston pin clip “1” Piston
• Piston pin “2” Diameter
• Connecting rod “3” 64.950–64.965 mm (2.5571–
2.5577 in)
1
Limit
64.910 mm (2.5555 in)
1st oversize diameter
65.200–65.215 mm (2.5669–
2.5675 in)
2nd oversize diameter
65.450–65.465 mm (2.5768–
2.5774 in)
2 Measuring point
5.0 mm (0.20 in)
1
above the bottom of the piston
3 skirt
Checking the piston diameter Checking the cylinder bore

1. Measure: 1. Measure:
• Piston outside diameter “a” (at the speci- • Cylinder bore (D1–D6) (at measuring
fied measuring point “b”) points “a”, “b”, and “c”, and in directions “d”
Below specification  Replace. (D1, D3, D5) and “e” (D2, D4, D6))
Above specification  Replace the cylin-
der block.
a
b D2 D1
a c d
b
D4 D3 e
D6 D5
a. 10.0 mm (0.39 in)

b. 48.0 mm (1.89 in)
c. 85.0 mm (3.35 in)
d. Parallel to the crankshaft
e. At a right angle to the crankshaft
Cylinder
Bore
65.000–65.015 mm (2.5591–
2.5596 in)
Limit
65.100 mm (2.5630 in)
7-51
Cylinder block
Checking the piston clearance
1. Measure: Piston ring dimensions
• Piston diameter Top ring
See “Checking the piston diameter” (7-51). Height (B)
• Cylinder bore 1.170–1.190 mm (0.0461–
See “Checking the cylinder bore” (7-51). 0.0469 in)
Width (T)
2. Calculate: 2.300–2.500 mm (0.0906–
• Piston clearance 0.0984 in)
Out of specification  Replace the piston 2nd ring
or cylinder block. Height (B)
1.470–1.490 mm (0.0579–
Piston clearance = maximum cylin- 0.0587 in)
der bore – piston outside diameter
Width (T)
Piston clearance
2.600–2.800 mm (0.1024–
0.035–0.065 mm (0.0014–
0.1102 in)
0.0026 in)
Oil ring
Limit
Height (B)
0.115 mm (0.0045 in)
2.360–2.480 mm (0.0929–
0.0976 in)
Checking the piston ring Width (T)
1. Measure: 2.750 mm (0.1083 in)
• Piston ring dimensions B and T
Below specification  Replace.
Checking the piston ring end gap
1. Measure:
a b
B B • Piston ring end gap
T T
Top ring
c End gap
B 0.15–0.30 mm (0.0059–0.0118
in)
T Limit
a. Top ring 0.500 mm (0.0197 in)
b. 2nd ring 2nd ring
c. Oil ring End gap
0.30–0.50 mm (0.0118–0.0197
in)
Limit
0.700 mm (0.0276 in)
Oil ring
End gap
0.20–0.70 mm (0.0079–0.0276
in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Level the piston ring “1” in the cylinder us-
ing a piston crown at the specified measur-
ing point “a”.
7-52
Cylinder block
b. Measure the piston ring end gap “b”. Checking the piston ring side clear-
ance
1. Measure:
• Piston ring side clearance
Above specification  Check the piston
ring grooves and piston ring.
See “Checking the piston ring groove” (7-
53) and “Checking the piston ring” (7-52).
aa
b 1 a
c
Measuring point
10.0 mm (0.39 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a. Top ring side clearance
b. 2nd ring side clearance
Checking the piston ring groove c. Oil ring side clearance
1. Measure:
• Piston ring groove
Piston ring side clearance
Top ring
Side clearance
a 0.02–0.06 mm (0.0008–0.0024
in)
b Limit
0.110 mm (0.0043 in)
c 2nd ring
Side clearance
0.02–0.06 mm (0.0008–0.0024
in)
a. Ring groove (Top) Limit
b. Ring groove (2nd) 0.110 mm (0.0043 in)
c. Ring groove (Oil) Oil ring
Side clearance
Piston ring groove 0.04–0.18 mm (0.0016–0.0071
Ring groove (Top) in)
1.21–1.23 mm (0.0476–0.0484
in)
Ring groove (2nd)
1.51–1.53 mm (0.0594–0.0602
in)
Ring groove (Oil)
2.52–2.54 mm (0.0992–0.1000
in)
7-53
Cylinder block
Checking the piston pin boss inside
diameter a
1. Measure:
• Piston pin boss inside diameter “a”
TIP:
When measuring the piston pin boss inside di-
ameter, do not measure it at the ring groove “b”
or oil groove “c”.
b
e
b c
f
a
d
c c
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the connecting rod small

end inside diameter and big end in-
side diameter
1. Measure:
• Connecting rod small end inside diameter
and big end inside diameter
Pin boss inside diameter
15.974–15.985 mm (0.6289–
0.6293 in) Small end inside diameter
Limit 15.985–15.998 mm (0.6293–
16.005 mm (0.6301 in) 0.6298 in)
Big end inside diameter
Checking the piston pin diameter 36.000–36.024 mm (1.4173–
1. Measure: 1.4183 in)
• Piston pin outside diameter
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Below specification  Replace.
a. Tighten the connecting rod bolts “1” to the
specified torques in 2 stages.
Pin outside diameter
15.965–15.970 mm (0.6285– TIP:
0.6287 in) When checking the big end inside diameter, re-
Limit use the removed connecting rod bolts.
15.955 mm (0.6281 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the piston pin outside diameter
“a” at measuring points “b”, “c”, and “d”,
and in directions “e” and “f”.
7-54
Cylinder block
b. Measure the connecting rod small end in-
side diameter “a” and big end inside diam- a
eter “b”.
Connecting rod bolt “1”

c
1st: 6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
2nd: 17 N·m (1.7 kgf·m, 13 lb·ft)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the connecting rod big end Journal diameter

side clearance 42.984–43.000 mm (1.6923–
1. Measure: 1.6929 in)
• Connecting rod big end side clearance “a” Crankshaft pin diameter
Above specification  Check the crank- 32.984–33.000 mm (1.2986–
shaft pin width. 1.2992 in)
See “Checking the crankshaft” (7-55). Crankshaft pin width
21.00–21.07 mm (0.8268–
0.8295 in)
2. Measure:
a • Runout
Big end side clearance

0.050–0.220 mm (0.0020–
0.0087 in)
Limit
0.27 mm (0.0106 in)
Checking the crankshaft Crankshaft

1. Measure: Runout
• Crankshaft journal diameters “a”, crank- 0.03 mm (0.0012 in)
shaft pin diameters “b”, and crankshaft pin Limit
widths “c” 0.04 mm (0.0016 in)
7-55
Cylinder block
Checking the big end oil clearance
1. Measure:
• Big end oil clearance
Out of specification  Replace crankshaft
pin bearing.
See “Selecting the crankshaft pin bearing”
(7-57).
Big end oil clearance

0.016–0.040 mm (0.0006–
0.0016 in) d. Install the connecting rod “1” and connect-
Limit ing rod cap “2” onto the crankshaft pin.
0.070 mm (0.0028 in)
TIP:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • When checking the oil clearance, reuse the
a. Clean the crankshaft pin bearings, con-
removed connecting rod bolts.
necting rod, connecting rod cap, and
• Make sure that the protrusions “a” on the con-
crankshaft.
necting rod “1” and connecting rod cap “2”
face toward the flywheel magneto end of the
b. Install the crankshaft pin bearings “1” into
crankshaft.
the connecting rod “2” and connecting rod
• Do not turn the connecting rod until the big
cap “3”.
end oil clearance measurement has been
TIP: completed.
• Install the crankshaft pin bearings in their
original positions. e. Tighten the connecting rod bolts “3” to the
• Install the protrusions “a” of the crankshaft pin specified torques in 2 stages.
bearing into the grooves “b” on the connect-
ing rod “2” and connecting rod cap “3”.
1 1
2
3 b a
a
3
b
a
c. Place a piece of Plastigauge (PG-1) on the

crankshaft pin, parallel to the crankshaft.
Do not place the Plastigauge (PG-1) over

the oil hole in the crankshaft pin of the
crankshaft. Connecting rod bolt “3”
1st: 6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
2nd: 17 N·m (1.7 kgf·m, 13 lb·ft)
7-56
Cylinder block
f. Remove the connecting rod cap, and then P1 P2 P3
measure the width of the compressed
Plastigauge (PG-1) on the crankshaft pin.
P1 P2
P3
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Selecting the crankshaft pin bearing

When replacing the crankshaft pin bearing, se-
lect the bearing as follows: d
1. Select:
• Crankshaft pin bearing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
d
a. Check the connecting rod mark “a” or
painted color “b”.
b. Check the crankshaft pin mark “c”. Crankshaft pin bearing selection table at 20
C (68 F)
c. Select the bearing color “d” for the crank-
Connecting rod Crankshaft Bearing
shaft pin bearing from the table.
mark “a”/color “b” pin mark “c” color “d”
A Yellow
|/Red
B
Red
b A
| |/Blue
B
Pink
A
a | | |/Yellow
B Green
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-57
Cylinder block
Checking the journal oil clearance
1. Measure:
• Journal oil clearance
Out of specification  Replace crankshaft
journal bearing.
See “Selecting the crankshaft journal bear-
ing” (7-59).
Journal oil clearance

0.012–0.036 mm (0.0005–
0.0014 in) e. Install the crankshaft journal bearings into
Limit the crankcase.
0.066 mm (0.0026 in)
TIP:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Install the crankshaft journal bearings in their
a. Clean the crankshaft journal bearings,
original positions.
crankshaft journals, and bearing portions
of the crankcase and cylinder block.
f. Install the crankcase “1”, and then tighten
b. Place the cylinder block with the crank- the crankcase bolts (M8) “2” to the speci-
case mating surface facing up. fied torques in 2 stages and in the order
[1], [2], and so on.
c. Install the crankshaft journal bearings “1”
and crankshaft “2” into the cylinder block g. Tighten the crankcase bolts (M6) “3” to the
“3”. specified torques in 2 stages and in the or-
der [9], [10], and so on.
TIP:
• Install the crankshaft journal bearings “1” in 2 3
2 3
their original positions. 2 2
• Do not turn the crankshaft “2” until the journal 2
oil clearance measurement has been com-
pleted.
3
2
1
3 3
3
1
d. Place a piece of Plastigauge (PG-1) on

each crankshaft journal, parallel to the
crankshaft.
Do not place the Plastigauge (PG-1) over

the oil hole in each crankshaft journal.
7-58
Cylinder block
b. Check the mark “a” on the crank web and
the mark “b” on the cylinder block.
2 c. Select the suitable colors “c” for the crank-
[5] [6] 3
shaft journal bearing.
[13] [14]
J1 J2 J3 J4
[1] [2]
[9] [10]
[4] [3]
[12] [11]
[8] [7] J1 J2 J3 J4
[16] [15]
a
Crankcase bolt (M8) “2” [1]–[8]
1st: 15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.
2nd: 30 N·m (3.0 kgf·m, 22 lb·ft)

1st: 6 N·m (0.6 kgf·m, 4.4 lb·ft)
2nd: 12 N·m (1.2 kgf·m, 8.9 lb·ft) b
h. Remove the crankcase, and then measure

the width of the compressed Plastigauge J1
(PG-1) on each crankshaft journal.
J2
TIP:
When loosening the crankcase bolts, loosen J3
them in the opposite order used for tightening. J4
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Selecting the crankshaft journal bear- c

ing
When replacing the crankshaft journal bearing,
select the bearing as follows:
1. Select:
• Crankshaft journal bearing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the crankshaft journal bearings.
7-59
Cylinder block
• Oil ring
Crankshaft journal bearing selection table at
• 2nd ring
20 C (68 F)
• Top ring
Cylinder ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Crankshaft journal Bearing col-
block mark a. Install the oil rings “1”, 2nd ring “2”, and top
mark “a” or “c”
“b” ring “3”.
A Yellow
A
B
Red Do not scratch the pistons or break the pis-
A ton rings.
B
B
Pink
A TIP:
C • Make sure that the “T” mark “a” on the top
B Green
ring “3” and 2nd ring “2” are facing up.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Make sure that the piston rings move
smoothly.
Assembling the cylinder block
1. Assemble:
• Piston “1” b. Offset the piston ring end gaps.
• Connecting rod “2”
• Piston pin “3” 1 a
• Clip “4” New
#5
TIP: #4
2
• Face the protrusions “a” on the connecting #3
3
rod “2” in the same direction as the “UP” mark
#2
“b” on the piston crown. #1
• Make sure that the clip “4” end is not aligned 45° 45°
#5 #2
with the groove “c” in the piston pin boss.
a
4 b #1
#4 #3
4 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c
2
3
a 4
2. Install:
7-60
Cylinder block
3. Install: A. Worldwide
• Crankshaft pin bearing “1” (into the con- B. USA and Canada
necting rod “2” and connecting rod cap “3”)
TIP: Piston slider “1”

• Install the crankshaft pin bearings in the orig- 90890-06529
inal positions. Piston ring compressor “2”
• Install the protrusions “a” of the crankshaft pin YM-08037
bearing into the grooves “b” on the connect- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ing rod “2” and connecting rod cap “3”.
5. Install:
• Crankshaft journal bearing “1” (into the cyl-
inder block “2”)
1 TIP:
2
3 b • Install the crankshaft journal bearings “1” in
a their original positions.
b • Align the oil holes “a” in the crankshaft journal
1 bearings “1” with the oil holes “b” in the cylin-
a
der block “2”, and then install the crankshaft
journal bearings “1” so that the specified dis-
4. Install: tances “c”, “d”, “e”, and “f” are obtained.
• Piston
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
1
a. Apply engine oil to the side of the piston,
piston rings, and cylinder wall, and then in-
stall the piston so that the “UP” mark on the
a b
piston crown is facing toward the flywheel 1
magneto end of the crankshaft. 2
A
1
e
d
c f
B 2
7-61
Cylinder block
Distance “c” TIP:

14.2–14.8 mm (0.56–0.58 in) • Make sure that the protrusions “a” on the con-
Distance “d” necting rod and connecting rod caps “1” are
95.4–96.0 mm (3.76–3.78 in) facing toward the flywheel magneto end of
Distance “e” the crankshaft.
167.4–168.0 mm (6.60–6.61 in) • After tightening the connecting rod bolts “2”,
make sure that the crankshaft turns smooth-
Distance “f” (reference data)
ly.
16.6 mm (0.65 in)
6. Install: 2
• Oil seal “1” New
• Oil seal “2” New 1
• Crankshaft “3” (into the cylinder block “4”) a 1
4 4
2 1
3
3
2
1
Connecting rod bolt “2”

3 1st: 6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
2nd: 17 N·m (1.7 kgf·m, 13 lb·ft)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Connecting rod cap • Dowel pin
• Connecting rod bolt New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 9. Install:
a. Install the connecting rod caps “1” to the • Crankshaft journal bearing
piston and connecting rod assemblies, • Crankcase
and then tighten new connecting rod bolts • Crankcase bolt (M8)
“2” to the specified torques in 2 stages. • Crankcase bolt (M6)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the crankshaft journal bearings “1”
onto the crankcase “2”.
7-62
Cylinder block
b. Apply a thin, even layer of sealant onto the
mating surface of the crankcase.
TIP: 2
[5] [6] 3
• Install the crankshaft journal bearings “1” into
the crankcase in the same positions as the [13] [14]
crankshaft journal bearings in the cylinder [1] [2]
block. [9] [10]
• Install the crankshaft journal bearings “1” in
their original positions. [4] [3]
• Do not apply any sealant to the crankshaft [12] [11]
journal bearings “1”.
[16] [8] [7] [15]
2
1 1 Crankcase bolt (M8) “2” [1]–[8]

1 1 1st: 15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.
2nd: 30 N·m (3.0 kgf·m, 22 lb·ft)

1st: 6 N·m (0.6 kgf·m, 4.4 lb·ft)
2nd: 12 N·m (1.2 kgf·m, 8.9 lb·ft)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Install the crankcase “1”, and then tighten

the crankcase bolts (M8) “2” to the speci-
fied torques in 2 stages and in the order
[1], [2], and so on.
d. Tighten the crankcase bolts (M6) “3” to the

specified torques in 2 stages and in the or-
der [9], [10], and so on.
TIP:
After tightening the crankcase bolts “2” and “3”,
make sure that the crankshaft turns smoothly.
2 3
2 3
2 2
2
3 1
3
7-63
Lower unit
Lower unit ........................................................................... 8-1

Removing the lower unit............................................................. 8-2
Checking the propeller ............................................................... 8-2
Checking the lower unit anode ................................................... 8-2
Water pump ........................................................................ 8-3

Checking the water pump........................................................... 8-4
Propeller shaft housing ..................................................... 8-5

Removing the propeller shaft housing assembly........................ 8-6
Disassembling the propeller shaft assembly .............................. 8-6
Disassembling the propeller shaft housing assembly ................ 8-6
Checking the propeller shaft....................................................... 8-8
Checking the dog clutch ............................................................. 8-8
Checking the propeller shaft housing ......................................... 8-8
Checking the reverse gear ......................................................... 8-8
Assembling the propeller shaft assembly................................... 8-8
Assembling the propeller shaft housing assembly ..................... 8-9
Drive shaft and lower case .............................................. 8-11

Removing the drive shaft.......................................................... 8-12
Disassembling the drive shaft assembly .................................. 8-12
Disassembling the forward gear............................................... 8-12
Disassembling the lower case.................................................. 8-13
Checking the shift rod............................................................... 8-14
Checking the pinion.................................................................. 8-14
Checking the forward gear ....................................................... 8-14
Checking the drive shaft........................................................... 8-14
Checking the lower case .......................................................... 8-14
Assembling the forward gear.................................................... 8-15
Assembling the lower case....................................................... 8-15
Assembling the drive shaft ....................................................... 8-18
Assembling the oil seal housing ............................................... 8-18
Installing the shift rod, drive shaft, and oil seal housing ........... 8-19
Installing the propeller shaft housing assembly........................ 8-20
Installing the water pump ......................................................... 8-20
Checking the lower unit for air leakage .................................... 8-21
Installing the lower unit............................................................. 8-22
Lower unit
Shimming .......................................................................... 8-24

Shimming workflow .................................................................. 8-24
Shimming check sheet ............................................................. 8-25
Measuring the forward gear backlash and
reverse gear backlash before disassembly .............................. 8-27
Shimming procedure ................................................................ 8-31
Shim location............................................................................ 8-31
Selecting the pinion shim (T3).................................................. 8-32
Measuring the forward gear backlash ...................................... 8-34
Adjusting the forward gear shim thickness (T1) ....................... 8-35
Measuring the reverse gear backlash ...................................... 8-36
Adjusting the reverse gear shim thickness (T2) ....................... 8-36
8
Lower unit
Lower unit
15
18
14 New 14 New
16
New 1
20
17 2
20 21
3
New 13 4
12 19
5
6 35 N·m (3.5 kgf·m, 26 lb·ft)
10 8
9
9
New 13
11 9 7
9
40 N·m (4.0 kgf·m, 30 lb·ft)
7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft)

1 Cotter pin 1 20 Dowel pin 2
2 Propeller nut 1 21 Lower unit 1
3 Washer 1
4 Washer 1
5 Propeller 1
6 Spacer 1
7 Bolt M8  25 mm 1
8 Trim tab 1
9 Bolt M10  40 mm 4
10 Bolt M8  60 mm 1
11 Drain screw 1
12 Oil level plug 1
13 Gasket 2
14 Plastic tie 2
15 Nipple 1
16 Hose 1
17 Hose nipple 1
18 Bolt M8  35 mm 1
19 Anode 1
8-1
Lower unit
Removing the lower unit 4. Remove:
• Trim tab bolt
• Trim tab
• Make sure to disconnect the battery ca- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
bles from the battery, and remove the clip a. Mark the trim tab “1” and lower case with
from the engine shut-off switch. an identification mark “a”, and then remove
• When removing the lower unit with the the trim tab “1”.
power unit installed, make sure to sus- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
pend the outboard motor. Otherwise, the
outboard motor could fall suddenly and 5. Remove:
result in severe injuries. • Lower case mounting bolt “2”
• When loosening or tightening the propel- • Lower case mounting bolt “3”
ler nut, do not hold the propeller using • Speedometer hose “4”
your hands. • Anode “5”
TIP:
When disassembling the lower unit, measure 4
the backlash before disassembly. See “Mea-
suring the forward gear backlash and reverse
gear backlash before disassembly” (8-27). 5
1
1. Drain:
• Gear oil
See step 1 in “Changing the gear oil” (10-
18). 3
a
2. Set the gear shift to the N position.
2
3. Remove:
• Propeller nut 2
TIP:
Place a block of wood between the anti-cavita- Checking the propeller
tion plate and the propeller to prevent the pro- 1. Check:
peller from turning. • Propeller blade
• Spline
• Cracked/damaged/worn  Replace the
propeller.
Checking the lower unit anode

1. Check:
• Trim tab
Do not apply grease, oil, or paint to the trim

tab.
8-2
Water pump
Water pump
1
2
11
3 1 12
13
13
4
6
8
7 New
10 New

1 Bolt M8  30 mm 4
2 Cover 1
3 Seal 1
4 Water pump housing 1
5 Insert cartridge 1
6 Impeller 1
7 O-ring 1
8 Impeller key 1
9 Outer plate cartridge 1
10 Gasket 1
11 Rubber seal 1
12 Plate 1
13 Dowel pin 2
8-3
Water pump
Checking the water pump
1. Check:
• Water pump housing
Deformed  Replace.
TIP:
If the engine overheats, the inside of the water
pump housing may be deformed.
Therefore, make sure to remove the insert car-
tridge when checking the water pump housing.
2. Check:
• Impeller
• Insert cartridge
• Outer plate cartridge
Cracked/worn  Replace.
• Impeller key
• Keyway in the drive shaft
Deformed/worn  Replace.
8-4
Propeller shaft housing
3
6
New 16
5
7
9
8
4 1
11 New 17 New
10 New
15 New
14
13 1
12
16 N·m (1.6 kgf·m, 12 lb·ft)

1 Bolt M8  25 mm 2
2 Propeller shaft housing 1
3 Propeller shaft 1
4 Shift plunger 1
5 Spring 1
6 Cross pin 1
7 Dog clutch 1
8 Slider 1
9 Spring 1
10 O-ring 1
11 O-ring 2
12 Washer 1
13 Reverse gear 1
Reverse gear shim
14 —
(T2)
15 Ball bearing 1
16 Oil seal 2
17 Needle bearing 1
8-5
Removing the propeller shaft housing Disassembling the propeller shaft
assembly housing assembly
1. Remove: 1. Remove:
• Bolt “1” • Reverse gear “1”
• Propeller shaft housing assembly “2” • Reverse gear shim(s) (T2) “2”
A
TIP:
Insert flat-head screwdrivers between the pro- 3
peller shaft housing assembly “2” and the low- 1
er case to pry the assembly loose. 6
5
2
4
2
1
B
Disassembling the propeller shaft as-

1
sembly
1. Remove:
• Shift plunger “1”
• Spring “2”
2
• Cross pin “3”
• Dog clutch “4”
• Slider “5”
• Spring “6” A. Worldwide
B. USA and Canada
3 2
4 Stopper guide plate “3”
6 90890-06501
5 Bearing separator “4”
1 90890-06534
Bearing puller assembly “5”
90890-06535
Stopper guide stand “6”
90890-06538
Slide hammer “7”
YB-06096
8-6
2. Remove: 3. Remove:
• Ball bearing “1” • Oil seal “1”
A • Needle bearing “2”
2 A
1 3
3
4
4
2
B
1
5
B
1
6 5
6
2
A. Worldwide
B. USA and Canada 1
The ball bearing remains installed in the
propeller shaft housing
Stopper guide plate “2” A. Worldwide

90890-06501 B. USA and Canada
Stopper guide stand “3”
90890-06538 Driver rod L3 “3”
Bearing puller assembly “4” 90890-06652
90890-06535 Needle bearing attachment “4”
Slide hammer “5” 90890-06614
YB-06096 Driver handle (large) “5”
Bearing puller legs “6” YB-06071
YB-06523 Needle bearing attachment “6”
YB-06112
8-7
Checking the propeller shaft Assembling the propeller shaft as-
1. Check: sembly
• Propeller shaft 1. Install:
Damaged/worn  Replace. • Dog clutch “1”
• Propeller shaft “2”
2. Measure: • Spring (in the slider) “3”
• Propeller shaft runout • Slider “4”
TIP:
• Install the dog clutch “1” onto the propeller
shaft “2” with the “F” mark “a” facing toward
the forward gear.
• Align the hole “b” in the dog clutch “1” with the
hole “c” in the propeller shaft “2”.
c
a
b
Propeller shaft 2
Runout 1
0.02 mm (0.0008 in)
3
Checking the dog clutch 4
1. Check:
• Dog clutch 2. Install:
• Shift plunger • Cross pin “1”
• Slider • Spring (in the dog clutch) “2”
• Cross pin
• Spring TIP:
When installing the cross pin, align the hole in
Checking the propeller shaft housing the dog clutch with the hole “a” in the slider.
1. Check:
• Propeller shaft housing
2
Cracked/damaged  Replace.
Checking the reverse gear 1

a
1. Check:
• Teeth and dogs of the reverse gear
8-8
3. Check:
• Dog clutch operates smoothly Driver rod L3 “2”
90890-06652
Needle bearing attachment “3”
90890-06614
Driver handle (large) “4”
YB-06071
Bearing housing bearing/oil seal
installer “5”
YB-06111
Installation depth “b”

Assembling the propeller shaft hous- 3.0–3.5 mm (0.118–0.138 in)
ing assembly
• Needle bearing “1” (into the propeller shaft • Oil seal “1” (into the propeller shaft hous-
housing) New ing) New
TIP:
TIP: Install an oil seal halfway into the propeller
Face the bearing identification mark “a” on the shaft housing, and then install the other oil
needle bearing toward the propeller. seal.
A
A
a
2 a
2
3
b
3 1 1
B B
a
4 a
4
5
b
5 1 1
A. Worldwide A. Worldwide
B. USA and Canada B. USA and Canada
8-9
Driver rod L3 “2”

90890-06652
Needle bearing attachment “3” 2
90890-06614 1
YB-06071
Oil seal installer “5”
YB-06168
Installation depth “a” Needle bearing attachment “2”

4.0–4.5 mm (0.157–0.177 in) 90890-06608
Bearing cup installer “2”
3. Install: YB-06167
• Original shim(s) (T2) “1”
• Ball bearing “2” 5. Check:
• Reverse gear “3” • Reverse gear movement
Not smooth  Repeat from step 3.
TIP:
Face the bearing identification mark “a” on the 6. Install:
ball bearing toward the propeller. • O-ring (to the propeller shaft hous-
ing) New
a
4
2
1
3
Bearing inner race attachment “4”

90890-06639
YB-06639
4. Install:
• Reverse gear assembly “1”
TIP:
After installation, check that the reverse gear
turns smoothly.
8-10
Drive shaft and lower case

New 9 1
New 10 16
3
8 2 New 4
New 17 New 5
New 11
6
18
12
19 21
7 New 22
23
24
New 20
26
15
13 14
28
25 74 N·m (7.4 kgf·m, 55 lb·ft)
27 1.0 N·m (0.10 kgf·m, 0.73 lb·ft)

1 Cover 1 19 Sleeve 1
Oil seal housing as- 20 Needle bearing 1
2 1
sembly 21 Forward gear 1
3 Oil seal housing 1 22 Taper roller bearing 1
4 O-ring 1 23 Shim (T1) —
5 Oil seal 2 24 Nut 1
6 Washer 1 25 Screw M5  25 mm 1
7 Shift rod 1 Water inlet cover
26 1
8 Plate 1 (STBD)
9 O-ring 1 Water inlet cover
27 1
10 Oil seal 1 (PORT)
11 O-ring 1 28 Lower case 1
12 E-clip 1
13 Shift cam 1
14 Nut 1
15 Pinion 1
16 Drive shaft 1
17 Taper roller bearing 1
18 Shim (T3) —
8-11
Removing the drive shaft B
1. Loosen: a
1
• Pinion nut “1”
2
4
3 2
A. Worldwide
1 B. USA and Canada

90890-06641
3 Bearing splitter plate “4”
YB-06219
Drive shaft holder 3 “2”
90890-06517 Disassembling the forward gear
Driveshaft holder “2” 1. Remove:
YB-06079 • Tapered roller bearing inner race “1”
Pinion nut holder “3” A
90890-06715 2
4
Pinion nut holder “3” 3 1
YB-06715
Disassembling the drive shaft assem-

bly
1. Remove:
• Drive shaft assembly “1”
• Taper roller bearing “2” B
5
6
Do not press the threads “a” of the propel-
ler shaft directly. 1
A
1
a
2
3 A. Worldwide
B. USA and Canada
8-12
Driver rod L3 “2” Needle bearing attachment “2”

90890-06652 90890-06614
Needle bearing attachment “3” Driver rod L3 “3”
90890-06614 90890-06652
Bearing separator “4” Driveshaft needle bearing remov-
90890-06534 er and installer “4”
Roller bearing installer/remover YB-06063
“5” Driver handle (large) “5”
YB-06432 YB-06071
Bearing splitter plate “6”
(commercially available) 2. Remove:
• Tapered roller bearing outer race “1”
Disassembling the lower case • Shim(s) (T1) “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Heat the area of the lower case where the
• Use heat-resistant gloves. Otherwise, tapered roller bearing outer race is to be
burns could result. removed using a gas torch, and then re-
• To prevent fires, remove any flammable move the tapered roller bearing outer race
substances, such as gasoline and oil, “1” and forward gear shim(s) “2”.
around the working area.
• Keep good ventilation while working.
When heating the lower case, heat the en-
tire installation area evenly. Otherwise, the
1. Remove: paint on the lower case could be burned.
• Needle bearing “1”
A TIP:
3
• Before removing the taper roller bearing out-
er race “1”, place some cushioning material
3 under the lower case to catch the outer race
2 when it falls out.
1 • If the taper roller bearing outer race does not
2
come out, lightly tap the lower case torpedo
with a plastic hammer.
B 5
5
4
1
4
2
A. Worldwide
B. USA and Canada 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-13
3. Remove: Checking the shift rod
• Taper roller bearing outer race “1” 1. Check:
• Shim(s) (T3) “2” • Shift rod
• Drive shaft sleeve “3” Bent/worn  Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Heat the area of the lower case where the Checking the pinion
tapered roller bearing outer race is to be 1. Check:
removed using a gas torch, and then re- • Teeth of the pinion
move the tapered roller bearing outer race Cracked/worn  Replace.
“1”, forward gear shim(s) “2” and the drive
shaft sleeve “3”. Checking the forward gear
1. Check:
• Teeth and dogs of the forward gear
When heating the lower case, heat the en- Cracked/worn  Replace.
paint on the lower case could be burned. Checking the drive shaft
1. Check:
TIP: • Drive shaft
• Before removing the taper roller bearing out- Damaged/worn  Replace.
er race “1”, place some cushioning material
under the lower case to catch the outer race 2. Measure:
when it falls out. • Drive shaft runout
• If the taper roller bearing outer race does not Above specification  Replace.
come out, lightly tap the lower case with a
plastic hammer.
Drive shaft
3
Runout
0.5 mm (0.020 in)
2
1
Checking the lower case
1. Check:
• Lower case
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Cracked/damaged  Replace.
8-14
Assembling the forward gear b. Heat the area of the lower case where the
1. Install: tapered roller bearing outer race is to be in-
• Tapered roller bearing inner race “1” New stalled using a gas torch, and then install a
new tapered roller bearing outer race “2”.
A
When heating the lower case, heat the en-

2 paint on the lower case could be burned.
2
1
TIP:
Do not reuse a shim if deformed or scratched.
B
2
1
3
3
1
A. Worldwide
B. USA and Canada

90890-06639 c. While holding the special service tool,
Forward gear bearing installer “3” strike the tool to check that the tapered roll-
YB-06270-A er bearing outer race is installed properly.
TIP:
Assembling the lower case If a high-pitched metallic sound is produced
when the special service tool is struck, the out-
er race is installed properly.
• Use heat-resistant gloves. Otherwise,
burns could result.
A
• To prevent fires, remove any flammable 1 1
substances, such as gasoline and oil, 2
around the working area. 2
• Keep good ventilation while working.
1. Install:
• Forward gear shim(s) (T1) “1”
• Tapered roller bearing outer race “2”
New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the original forward gear shim(s) “1”.
8-15
B A a
3 3 4 c
4
4
b 2
2
3
1
3
A. Worldwide B a
B. USA and Canada d
Driver rod LL “1”

90890-06605 b 5
5
90890-06622 6
Driver handle (large) “3” 1
6
YB-06071
Forward gear outer race installer A. Worldwide
“4” B. USA and Canada
YB-41446
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Driver rod SL “2”
90890-06602
2. Install:
• Needle bearing “1” (in the lower Needle bearing attachment “3”
90890-06614
case) New
Bearing depth plate “4”
TIP: 90890-06603
• Face the bearing identification mark “a” on Driver handle (large) “5”
the needle bearing up. YB-06071
• When using the driver rod, do not strike the Driveshaft needle bearing remov-
special service tool in a manner that will force er and installer “6”
the stopper “c” out of place. YB-06063
• Mark the driver handle at the specified instal-
lation depth “b” with an identification mark “d”, Installation depth “b”
and then install the needle bearing to the 182.5–183.0 mm (7.19–7.20 in)
specified installation depth. Make sure to
measure the depth on the driver handle from
the flange bottom of the special service tool
“5”.
8-16
• Drive shaft sleeve “1” • Taper roller bearing outer race New
• Shim(s) (T3) “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Taper roller bearing outer race “3” New a. While holding the special service tool “1”,
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ strike the tool to check that the taper roller
a. Heat the area of the lower case where the bearing outer race is installed properly. If a
tapered roller bearing outer race is to be in- high-pitched metallic sound is produced
stalled using a gas torch, and then install when the special service tool is struck, the
the drive shaft sleeve “1”, shim(s) (T3) “2” outer race is installed properly.
and the tapered roller bearing outer race A
“3”.
1
1
When heating the lower case, heat the en- 2
paint on the lower case could be burned. 2
TIP:
• Install the drive shaft sleeve with the protru-
sion “a” facing forward. B
• Do not reuse a shim if deformed or scratched. 1
1
3 2
2
2
a 1
A. Worldwide
B. USA and Canada
Driver rod LL “1”

90890-06605
YB-06071
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
90890-06627
Driveshaft bearing installer “2”
YB-06110
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-17
5. Install: Assembling the oil seal housing
• Water inlet cover (STBD) “1” 1. Install:
• Water inlet cover (PORT) “2” • Oil seal “1” New
• Nut “3”
• Water inlet cover screw “4” A
TIP: 2 a
After installing the water inlet covers, make 3
sure that there is no rattling.
3 B
1
2 4 a
4
5
Water inlet cover screw 1

1.0 N·m (0.10 kgf·m, 0.73 lb·ft)
T.
R.
Assembling the drive shaft A. Worldwide

1. Install: B. USA and Canada
• Tapered roller bearing inner race “1” New
Driver rod LS “2”
90890-06606
Ball bearing attachment “3”
90890-06634
1 Driver handle (large) “4”
YB-06071
Bearing installer-Reverse gear
bearing “5”
2 2
YB-06016
Bearing inner race attachment “2” Installation depth “a”

90890-06644 0–0.5 mm (0–0.02 in)
YB-06644
8-18
Installing the shift rod, drive shaft, and
oil seal housing
1. Install:
1
• O-ring “1” (to the plate) New
• Oil seal “2” (to the plate) New
• E-clip “3”
• Plate “4”
• O-ring “5” New
• Shift rod “6”
2
5
2 3
4
6
5. Tighten:
1
2. Install:
• Shift cam “1”
• Shift rod “2” 2
3
2
3
Drive shaft holder 3 “2”

90890-06517
Driveshaft holder “2”
YB-06079
1 Pinion nut holder “3”
90890-06715
3. Install: Pinion nut holder “3”
• Forward gear assembly YB-06715
4. Install: Pinion nut “1”

• Drive shaft assembly “1” 74 N·m (7.4 kgf·m, 55 lb·ft)
T.
R.
• Pinion “2”
6. Check:
TIP: • Drive shaft movement
When installing the pinion “2”, lift up the drive Not smooth  Repeat from step 1.
shaft “1” slightly, and then align the pinion
splines with the shaft splines.
8-19
7. Install: 3. Tighten:
• Washer “1” • Propeller shaft housing bolt “1”
• Oil seal housing assembly “2”
• Cover “3” 1
3
2
1
1
Propeller shaft housing bolt “1”

16 N·m (1.6 kgf·m, 12 lb·ft)
T.
R.
Installing the water pump

1. Install:
• Plate “1”
Installing the propeller shaft housing
• Rubber seal “2”
assembly
• Dowel pin “3”
1. Install:
• Washer “1” (to the propeller shaft) • Gasket “4” New
• Propeller shaft assembly “2” (to the propel- • Outer plate cartridge “5”
ler shaft housing assembly)
5
2
2 4 3 1
3
2. Install:
• Shift plunger “1”
• Propeller shaft housing assembly “2”
8-20
2. Install:
• Impeller key “1” TIP:
• Impeller “2” When installing the water pump housing, apply
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
grease to the inside of the insert cartridge, and
a. Install the impeller key “1”. then turn the drive shaft clockwise while push-
ing down on the water pump housing.
b. Align the slot “a” in the impeller “2” with the
impeller key “1”, and then install the impel- 4
ler “2”.
3
a
2
2 1
1
Checking the lower unit for air leakage

1. Check:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • No air leakage
Air leakage  Repair the location of the
3. Install:
leak.
• Insert cartridge “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the oil level plug “1”, and then in-
a. Aligning the protrusion “a” on the insert
stall the leakage tester “2”.
cartridge with the groove “b” of the water
pump housing “2”.
2 a
1
2
b
1
Leakage tester “2”

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
90890-06840
4. Install: Leakage tester “2”
• O-ring “1” New (commercially available)
• Water pump housing assembly “2”
• Seal “3”
• Cover “4”
Do not turn the drive shaft counterclock-

wise, otherwise the water pump impeller
may be damaged.
8-21
b. Apply the specified pressure. Check that 2. Set the gear shift to the N position.
the pressure is maintained in the lower unit
for 10 seconds or more.
Do not overpressurize the lower unit. Oth-

erwise, the oil seals could be damaged.
R 1
Lower unit N
Holding pressure F
68.6 kPa (0.69 kgf/cm², 9.9 psi)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Shift rod socket “1”
90890-06681
Installing the lower unit Shift rod socket “1”
YB-06681
• Make sure to disconnect the battery ca- 3. Install:

bles from the battery, and remove the clip • Dowel pin “1”
from the engine shut-off switch. • Speedometer hose “2”
• When installing the lower unit with the • Hose joint
power unit installed, make sure to sus-
• Plastic tie New
pend the outboard motor. Otherwise, the
• Lower unit
outboard motor could fall suddenly and
• Lower case mounting bolt “3”
result in severe injuries.
• Lower case mounting bolt “4”
• When loosening or tightening the propel-
• Trim tab “5” (original position)
ler nut, do not hold the propeller using
• Anode “6”
your hands.
1. Check that the pin “a” is aligned with the

2
alignment mark “b” on the shift bracket “1”.
a 1
1
1 6
5
4
3
3
3
Lower case mounting bolt “3” and

“4”
T.
R.
40 N·m (4.0 kgf·m, 30 lb·ft)
8-22
• Spacer“1” • Cotter pin “1” New
• Propeller “2”
• Washer “3” TIP:
• Washer “4” If the slots in the propeller nut “2” are not
• Propeller nut “5” aligned with the cotter pin hole, tighten the pro-
peller nut until they are aligned.
TIP:
Place a block of wood between the anti-cavita-
tion plate and the propeller to prevent the pro-
peller from turning.
1
3 4
5
2
2 6. Fill:
1
• Gear oil
See step 2 in “Changing the gear oil” (10-
18).
Propeller nut “5”

35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
8-23
Shimming
Shimming
Shimming workflow
1. Remove the water pump

assembly.
2. Measure the backlash before

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

3. Within specification? thickness (T1) and reverse
gear shim thickness (T2).
4. YES
12. Install the water pump
assembly.
1. Remove the water pump assembly. 8. Select the pinion shims (T3).
2. Measure the backlash before disassem- 9. Assemble the lower unit.
bly. 10. Measure the backlash.
3. Within specification? 11. Adjust the forward gear shim thickness
4. YES (T1) and reverse gear shim thickness
5. Shimming is not required. (T2).
6. NO 12. Install the water pump assembly.
7. Disassemble the lower unit.
TIP:
• Make sure to drain the gear oil before measuring the backlash.
• If the backlash is within specification, shimming is not required.
• When assembling the original inner parts and a new lower case, shimming is required.
• When replacing the pinion, forward gear, reverse gear, bearings, drive shaft, or propeller shaft hous-
ing, shimming is required.
8-24
Shimming
Shimming check sheet
Lower case deviation
Serial number P F R Remarks
Pinion height
Measurements (mm)
Measuring point “a”
Measuring point “b”
Measuring point “c”
Measuring point “d”
Average
Round-down average
(M)
Forward gear backlash

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

Measurements (mm)
Before disassembly After disassembly
Average
Round-down average
8-25
Shimming
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
Reverse gear shim (T2) 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
8-26
Shimming
Measuring the forward gear backlash b. Set up the special service tools “1”, “2”,
and reverse gear backlash before dis- and “3”, and then tighten the center bolt “3”
assembly temporarily.
1. Install: A
2
• Lower unit (onto a repair stand) 1
2. Remove:
• Water pump assembly 3
See “Water pump” (8-3). 1
3. Measure:
• Forward gear backlash
• Reverse gear backlash B 2
Out of specification  See “Selecting the 1
pinion shim (T3)” (8-32).
Forward gear backlash 3

0.18–0.65 mm (0.0071–0.0256
in)
Reverse gear backlash 1
0.75–1.22 mm (0.0295–0.0480
in)
A. Worldwide
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ B. USA and Canada
a. Set the gear shift to the N position.
Bearing housing puller claw L “1”

90890-06502
Bearing housing puller “1”
YB-06207
Stopper guide plate “2”
90890-06501
R 1
Universal Puller “2”
N YB-06117
F Center bolt “3”
90890-06504
Shift rod socket “1”
90890-06681 c. Turn the lower unit so that the propeller
Shift rod socket “1” shaft is pointing down.
YB-06681
d. Turn the drive shaft 10 turns or more to
seat the tapered roller bearing.
8-27
Shimming
e. While holding the drive shaft to prevent it
from turning, tighten the center bolt “1” to 3 a
A 4
2
1
1
Backlash indicator “1”

1 90890-06706
Backlash indicator rod “1”
YB-06265
Handle holder “3”
EU0-23814-30 (2 required) *1
*1. Order from Yamaha Parts Distribution
A. Worldwide Center.
B. USA and Canada
Handle stopper nut “4” (shimming)
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
T.
R.
Center bolt “1” (shimming)

5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
j. Set up the special service tools “1”, “2”,

R.
and “3”, and then place another special

f. Place the lower unit in an upright position. service tool “4” on the handle stopper “5” to
apply a load.
g. Install the special service tool “1” onto the
drive shaft at the lowest possible position,
the point where the shaft diameter is 16.0
mm (0.63 in). 4
3
h. Wrap 5 layers of tape “2” around the drive
shaft.
5
i. Install the handle stopper “3” in the upper 1
end “a” position of the tape “2” on the drive
shaft, and then tighten the nuts “4” to the
specified torque.
8-28
Shimming
Magnet base plate “1” TIP:

90890-07003 • Measure the backlash at 4 points: “a”, “b”, “c”,
Backlash adjustment plate “1” and “d”, turning the drive shaft 180 clockwise
YB-07003 after each measurement.
Dial gauge set “2” • Write down the measurement data in the
90890-03238 shimming check sheet.
Dial indicator gauge “2”
YU-03097
Magnet base B “3”
90890-06844
Magnetic base stand “3” a
YU-A8438
Pinion height gauge “4”
90890-06668 b
Pinion height gauge “4” d
YB-06668
k. Turn the drive shaft slowly clockwise and

counterclockwise, and then measure the c
backlash between where the drive shaft
stops in each direction. m. Determine the backlash average, and then
round down the average to 2 decimal plac-
TIP: es.
• Do not turn the drive shaft using too much
force. Otherwise, the forward gear will turn, Example:
leading to incorrect measurements. (mm)
• A knocking sound may be heard when the
drive shaft is rotated, but this is the sound of Measurement point “a” 0.30
the pinion contacting the reverse gear and Measurement point “b” 0.36
does not affect the backlash measurement. Measurement point “c” 0.34
Measurement point “d” 0.33
Average 0.3325
Round-down average 0.33
n. Check that the forward gear backlash av-

erage is within specification.
TIP:
Adjust the shim thicknesses if the forward gear
backlash is out of specification.
o. Remove the special service tools from the

propeller shaft.
l. Turn the drive shaft 180 clockwise, and

then measure the backlash again.
8-29
Shimming
p. Apply a load to the reverse gear by install-
ing the propeller “1”, washer “2”, washer
“3”, and propeller nut “4” (without installing
the spacer “5”).
q. Tighten the propeller nut “4” to the speci-

fied torque.
4
3
2
Propeller nut “4” (shimming)

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
r. Repeat steps k–m to measure the reverse

gear backlash.
s. Check that the reverse gear backlash av-

erage is within specification.
TIP:
Adjust the shim thicknesses if the reverse gear
backlash is out of specification.
t. Remove the special service tools and pro-

peller.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• Water pump assembly
See “Installing the water pump” (8-20).
8-30
Shimming
Shimming procedure
• Before selecting the forward gear shim (T1) and reverse gear shims (T2), make sure to select the pin-
ion 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 T2
8-31
Shimming
Selecting the pinion shim (T3)
• Spray anti-rust lubricant on the bearing be- When tightening the pinion nut, check that
fore installation. Do not apply gear oil to the the drive shaft turns smoothly.
parts. Otherwise, correct measurements
cannot be obtained.
• Keep the parts free of foreign material, such d. Check that there is a gap “a” between the
as dirt and lint. pinion “1” and the special service tool “3”.
Be careful not to damage the measurement If there is no gap and the drive shaft does
plane surface of the special service tool. not turn, the special service tool could be
Otherwise, correct measurements cannot damaged.
be obtained.
TIP:
1. Select: If there is no gap, the pinion shims (T3) may
• Pinion shim (T3) not have been removed.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disassemble the lower unit. 2
1
b. Install the taper roller bearing “1” and drive
shaft between “a” and “b” of the special
service tool “2”, and then tighten the pinion
a a
height gauge bolts “c” temporarily.
TIP:
3
Do not install the pinion shim(s) (T3).
e. Install the special service tool “1” to the

drive shaft spline and hold the special ser-
a vice tool “1”.
2
f. Tighten the pinion nut “2” to the specified
torque.
1
1
b
c c

90890-06668 2
YB-06668
c. Install the pinion “1” and pinion nut “2”, and

then tighten the pinion nut “2” temporarily.
8-32
Shimming
j. Recheck the gap “a” between the pinion
Drive shaft holder 3 “1” “1” and the special service tool “2”.
90890-06517
Driveshaft holder “1” TIP:
YB-06079 If there is no gap, the shim(s) (T3) may not
have been removed.
Pinion nut “2”

74 N·m (7.4 kgf·m, 55 lb·ft)
T.
R.
1
g. Place the pinion so that it is facing up, and
then hold it in the upright position.
a a
h. Turn the drive shaft 10 turns or more to
seat the taper roller bearing.
2
i. Tighten the pinion height gauge bolts “1” to
the specified torques in 4 stages so that k. Measure the distance between the pinion
the distance “a” between the upper part “1” and the special service tool “2”.
and the lower part of the special service
tools “2” become equal. TIP:
• When measuring the distance, insert the end
of the thickness gauge straight into the gap at
the measurement point. Do not insert the
thickness gauge at an angle.
2 • Measure the distance at 4 points: “a”, “b”, “c”,
and “d”.
• Write down the measurement data in the
shimming check sheet.
a a
a
1 d
Pinion height gauge bolt “1” 1 c

1st: 1.0 N·m (0.10 kgf·m, 0.73
T.
R.
lb·ft) 2
2nd: 2.0 N·m (0.20 kgf·m, 1.5
lb·ft)
3rd: 3.0 N·m (0.30 kgf·m, 2.2
lb·ft)
4th: 4.0 N·m (0.40 kgf·m, 3.0
lb·ft)
8-33
Shimming
l. Determine the distance average, and then (T3) = 0.60 mm from the “Pinion shim (T3)
round down the average to 2 decimal plac- selection table”.
es.
Pinion height mea-
Example: surement (M)
(mm) 0.18 0.19 0.20
Measurement point “a” 0.20 Stamped value –2 
Measurement point “b” 0.20 on the lower –3  0.60

case (P) –4
Measurement point “c” 0.19
Measurement point “d” 0.18 n. Remove the special service tools, and
Average 0.1925 then install the determined pinion shim(s)
Round-down average (M) 0.19 (T3).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
m. Determine the pinion shim (T3) thickness
adjustment using the “Pinion shim (T3) se- Measuring the forward gear backlash
lection table” according to the rounded av- • Spray anti-rust lubricant on the gear and
erage (M) and the deviation (P) stamped bearings before installation. Do not apply
on the lower case. See “Pinion shim (T3) gear oil to the parts. Otherwise, correct mea-
selection table” (A-18). surements cannot be obtained.
• Keep the parts free of foreign material, such
TIP: as dirt and lint.
The (P) mark “a” is stamped on the trim tab • When measuring the forward gear or reverse
mounting surface of the lower case in 0.01 mm gear backlash, use the original bearings and
units. If the (P) mark is unreadable, replace the shim(s).
lower case.
1. Install:
• Forward gear shim (T1)
Pinion shims • Tapered roller bearing outer race
0.10/0.12/0.15/0.18/0.30/0.40/
0.50 mm TIP:
• If the original forward gear shim(s) (T1) are
Example:
missing, install new shims with a combined
(M) = 0.19
thickness of 0.50 mm.
(P) = –3
• Do not reuse a shim if deformed or scratched.
2. Install:
+2 +4
• Forward gear assembly
• Drive shaft
• Pinion
a See “Installing the shift rod, drive shaft,
–3
and oil seal housing” (8-19).
• Propeller shaft housing assembly
See “Installing the propeller shaft housing
assembly” (8-20).
3. Check:
• Drive shaft movement
Not smooth  Repeat from step 2.
8-34
Shimming
4. Measure:
• Forward gear backlash TIP:
See step 3 in “Measuring the forward gear • If the shim thickness adjustment value is pos-
backlash and reverse gear backlash be- itive, increase the current shim thickness by
fore disassembly” (8-27). that amount and, if the value is negative, de-
Out of specification  See “Adjusting the crease the current shim thickness by that
forward gear shim thickness (T1)” (8-35). amount.
• The gray-colored area on the selection chart
Forward gear backlash indicates the range of the specified backlash.
0.18–0.65 mm (0.0071–0.0256 Shimming is not required if the measured
in) backlash is within the gray-colored area.
• The values for the shim thickness adjust-
Adjusting the forward gear shim thick- ments specified in the selection chart are in-
tended to obtain the median value within the
ness (T1)
range for the specified forward gear or re-
1. Remove:
verse gear backlash.
• Tapered roller bearing outer race
• The table that follows the selection chart
• Forward gear shim (T1)
shows the shim thickness adjustments for the
2. Measure: points marked on the chart.
• Thickness of original forward gear shim
(T1) in 2 places. Example:
Backlash measurement (BL1) = 0.10 mm
TIP: “a”
Forward gear shim (T1) thickness adjust-
ment = –0.17 mm “b”
3. Select: The current shim thickness must be de-
• Forward gear shim (T1) creased by 0.17 mm.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 0.30
a. Determine the forward gear shim (T1) 0.20
B (mm)
thickness adjustment using the “Forward 0.10

gear shim (T1) selection chart” according 0
to the backlash measurement (BL1) from –0.10
“Measuring the forward gear backlash”. b –0.20
See “Forward gear shim (T1) selection –0.30
chart” (A-19). –0.40
0 5 10 15 20 25 30 35
a
A (1/100 mm)
A 0 5 10 15 20 25 30 35
B –0.23 –0.20 –0.17 –0.15 –0.12 –0.09 –0.07 –0.0
A. Backlash measurement (BL1)

B. Shim thickness adjustment
8-35
Shimming
b. Calculate the new forward gear shim (T1) Measuring the reverse gear backlash
thickness. • Spray anti-rust lubricant on the gears and
bearings before installation. Do not apply
TIP: gear oil to the parts. Otherwise, correct mea-
• Use the lowest number of shims to obtain the surements cannot be obtained.
required shim thickness. • Keep the parts free of foreign material, such
• If the calculated shim thickness cannot be ob- as dirt and lint.
tained with a combination of the available • When measuring the forward gear or reverse
shims, increase or decrease the shim thick- gear backlash, use the original bearings and
ness by 0.01 mm. shims.
Calculation formula:
1. Install:
New forward gear shim (T1) thickness =
• Reverse gear shim (T2)
Current forward gear shim thickness +
shim thickness adjustment
See “Installing the propeller shaft housing
Example: assembly” (8-20).
Use the following formula when the shim
TIP:
thickness adjustment value is positive.
• If the original reverse gear shims (T2) are
Current forward gear shim thickness =
missing, install new shims with a combined
0.50 mm
thickness of 0.50 mm.
Shim thickness adjustment = 0.20 mm
• Do not reuse a shim if deformed or scratched.
New forward gear shim (T1) thickness =
0.50 mm + 0.20 mm = 0.70 mm
Use the following formula when the shim 2. Measure:
thickness adjustment value is negative. • Reverse gear backlash
Current forward gear shim thickness = See step 3 in “Measuring the forward gear
0.50 mm backlash and reverse gear backlash be-
Shim thickness adjustment = –0.17 mm fore disassembly” (8-27).
New forward gear shim (T1) thickness = Out of specification  See “Adjusting the
0.50 mm + (–0.17 mm) = 0.33 mm reverse gear shim thickness (T2)” (8-36).
Available shim thicknesses Reverse gear backlash

Forward shims 0.75–1.22 mm (0.0295–0.0480
0.10/0.12/0.15/0.18/0.30/0.40/ in)
0.50 mm
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Adjusting the reverse gear shim thick-
ness (T2)
4. Install: 1. Remove:
• Determined forward gear shim (T1) • Propeller shaft housing assembly
• Tapered roller bearing outer race • Reverse gear shim (T2)
2. Measure:
• Thickness of original reverse gear shim
(T2) in 2 places.
TIP:
8-36
Shimming
3. Select: –0.10
• Reverse gear shim (T2) –0.20
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ –0.30
a. Determine the reverse gear shim (T2)
b –0.40
thickness adjustment using the “Reverse –0.50
B (mm)
gear shim (T2) selection chart” according –0.60
to the backlash measurement (BL2) from –0.70
“Measuring the reverse gear backlash”. –0.80
See “Reverse gear shim (T2) selection
0 5 10 15 20 25 30 35
chart” (A-19). a
A (1/100 mm)
TIP: A 0 5 10 15 20 25 30 35
• If the shim thickness adjustment value is pos-
B –0.53 –0.50 –0.47 –0.45 –0.42 –0.39 –0.37 –0.3
itive, increase the current shim thickness by
that amount and, if the value is negative, de- A. Backlash measurement (BL2)
crease the current shim thickness by that B. Shim thickness adjustment
amount.
• The gray-colored area on the selection chart b. Calculate the new reverse gear shim (T2)
indicates the range of the specified backlash. thickness.
Shimming is not required if the measured
backlash is within the gray-colored area. TIP:
• The values for the shim thickness adjust- • Use the lowest number of shims to obtain the
ments specified in the selection chart are in- required shim thickness.
tended to obtain the median value within the • If the calculated shim thickness cannot be ob-
range for the specified forward gear or re- tained with a combination of the available
verse gear backlash. shims, increase or decrease the shim thick-
• The table that follows the selection chart ness by 0.01 mm.
shows the shim thickness adjustments for the
Calculation formula:
points marked on the chart.
New reverse gear shim (T2) thickness =
Current reverse gear shim thickness +
Example: shim thickness adjustment
Backlash measurement (BL2) = 0.20 mm
“a” Example:
Reverse gear shim (T2) thickness adjust- Use the following formula when the shim
ment = –0.42 mm “b” thickness adjustment value is positive.
The current shim thickness must be de- Current reverse gear shim thickness =
creased by 0.42 mm. 1.00 mm
Shim thickness adjustment = 0.17 mm
1.00 mm + 0.17 mm = 1.17 mm
Use the following formula when the shim
thickness adjustment value is negative.
Current reverse gear shim thickness =
1.00 mm
Shim thickness adjustment = –0.42 mm
1.00 mm + (–0.42 mm) = 0.58 mm
8-37
Shimming
Available shim thicknesses

Reverse shims
0.10/0.12/0.15/0.18/0.30/0.40/
0.50 mm
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• Determined reverse gear shim (T2)
8-38
Bracket unit
Friction plate (tiller handle model) ................................... 9-1

Installing the friction plate........................................................... 9-2
Tiller handle (tiller handle model) ..................................... 9-3

Assembling the tiller handle ....................................................... 9-5
Electrical component (tiller handle) ................................. 9-8

Assembling the electrical component......................................... 9-9
Shift rod and shift bracket............................................... 9-10
Bottom cowling ................................................................ 9-11
Upper case assembly and mount ................................... 9-13

Removing the upper case ........................................................ 9-14
Installing the upper case .......................................................... 9-14
Upper case ........................................................................ 9-15

Disassembling the upper case ................................................. 9-16
Checking the drive shaft bushing ............................................. 9-16
Assembling the upper case ...................................................... 9-16
Oil pan and exhaust guide .............................................. 9-18

Checking the oil pan and exhaust guide .................................. 9-19
Checking the oil strainer........................................................... 9-19
Checking the exhaust guide anode .......................................... 9-19
Assembling the oil pan and exhaust guide............................... 9-19
Steering arm ..................................................................... 9-21

Removing the steering arm ...................................................... 9-22
Installing the steering arm ........................................................ 9-22
Bracket unit
Hydro tilt ........................................................................... 9-24

Removing the hydro tilt assembly ............................................ 9-25
Checking the hydro tilt.............................................................. 9-25
Checking the hydro tilt anode................................................... 9-25
Installing the hydro tilt assembly .............................................. 9-25
PTT unit ............................................................................. 9-26

Removing the PTT unit............................................................. 9-27
Bleeding the PTT unit............................................................... 9-27
Installing the PTT unit............................................................... 9-28
Clamp bracket and swivel bracket ................................. 9-30

Checking the clamp bracket anode .......................................... 9-31
Installing the clamp bracket...................................................... 9-31
Adjusting the trim sensor cam .................................................. 9-31
PTT motor ......................................................................... 9-33

Removing the PTT motor ......................................................... 9-34
Disassembling the PTT motor .................................................. 9-34
Checking the armature (PTT motor)......................................... 9-34
Checking the brush .................................................................. 9-35
Assembling the PTT motor....................................................... 9-36
Installing the PTT motor ........................................................... 9-37
PTT gear pump ................................................................. 9-38

Checking the gear pump .......................................................... 9-40
Checking the gear pump housing............................................. 9-40
Checking the filter..................................................................... 9-40
Checking the valve seal ........................................................... 9-40
PTT cylinder...................................................................... 9-41 9

Removing the trim and tilt ram assembly ................................. 9-42
Checking the PTT cylinder and piston...................................... 9-42
Checking the absorber valve.................................................... 9-43
Assembling the trim and tilt ram assembly............................... 9-43
Installing the trim and tilt ram assembly ................................... 9-43
Friction plate (tiller handle model)

7 7 N·m (0.7 kgf·m, 5.2 lb·ft)
8 25
9 8
26
17
11 21
22
1
2 4 6 23
24 18
20
10 5
10 3 19
14
32 N·m (3.2 kgf·m, 24 lb·ft) 13

12 13 18
40 N·m (4.0 kgf·m, 30 lb·ft) 12
6 N·m (0.6 kgf·m, 4.4 lb·ft)
32 N·m (3.2 kgf·m, 24 lb·ft)
20 15
16

1 Self-locking nut 1 20 Washer 2
2 Washer 1 21 Collar 1 Black
3 Bolt M12  80 mm 1 22 Steering lock lever 1
4 Collar 1 23 Cap 1
5 Wave washer 1 24 Steering lock shaft 1
6 Washer 1 25 Bolt M5  20 mm 1
7 Washer 2 26 Bracket 1
8 Bushing 2
9 Tiller handle assembly 1
10 Self-locking nut 2
11 Tiller handle bracket 1
12 Bolt M6  12 mm 2
13 Spring washer 2
14 Friction plate 1
15 Nut 1
16 Nut 1
17 Steering lock washer 1
18 Friction piece 2
19 Collar 1
9-1
Installing the friction plate 3. Move the steering lock lever “1” to the
1. Install: maximum.
• Steering lock shaft “1”
• Steering lock lever “2”
• Washer “3”
• Bracket “4”
TIP: 1
Face the “TOP” mark on the steering lock lever
“2” up.
1 4
4
4. Install:
• Friction plate assembly “1”
3 • Washer “2”
a • Bolt “3”
2
1
2. Install: 2
• Bolt “1”
• Washer “2”
• Collar “3” (black)
• Friction piece “4” 3 2
• Friction plate “5”
• Collar “6” 5. Install:
• Washer “7” • Tiller handle
• Friction adjusting nut “8” See “Installing the tiller handle” (3-9).
• Friction plate nut “9”
6. Tighten:
1 • Friction adjusting nut “1”
3
4
2
6
4 1
7 9
8 Friction adjusting nut “1”
6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
Bolt “1”
7. Check:
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
• Steering lock lever operation

Incorrect  Retighten the friction adjusting
nut.
9-2
21
35 36
3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
19
20
45 10 4
22
4
43 22
41
40 42 9
39 41 30
23 7 3
38 24 32 31
New
38 8
37 18 28
New 1 29
16 44
33
B 17 1 2 2
5 6
15 1 27
14 1 New
A 11
1 34
12 13 2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
26 25
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)

1 Screw M6  15 mm 6 20 Screw M6  16 mm 2
2 Clip 2 21 Shift lever 1
3 Holder 1 22 Bushing 2
4 Clamp 2 23 Cotter pin 1
5 Shift cable 1 Throttle friction adjust-
24 1
6 Throttle cable 1 er
7 Bracket 1 25 Bolt M6  30 mm 2
8 Bolt M6  30 mm 2 26 Control link assembly 1
9 Holder 1 27 Plastic tie 3
10 Holder 1 28 Screw M3  15 mm 2
11 Screw M6  15 mm 1 29 Neutral switch 1
12 PTT switch 1 30 Shift link 1
13 Cap 1 31 E-clip 1
14 Screw M6  15 mm 1 32 Throttle lever 1
15 Cap 1 33 Drive gear 1
16 Screw M5  22 mm 1 34 Throttle rod 1
17 Throttle grip 1 35 Nut 1
18 Bushing 1 36 Friction piece 1
19 Bolt M8  40 mm 1 37 Cotter pin 1
9-3
21
35 36
3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
19
20
45 10 4
22
4
43 22
41
40 42 9
39 41 30
23 7 3
38 24 32 31
New
38 8
37 18 28
New 1 29
16 44
33
B 17 1 2 2
5 6
15 1 27
14 1 New
A 11
1 34
12 13 2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
26 25
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)

38 Washer 2
39 Plate 1
40 Collar 1
41 Retainer 2
42 Spring 1
43 Bushing 1
44 Cap 1
45 Grease nipple 1
A. PTT model
B. Hydro tilt model
9-4
Assembling the tiller handle
3
1. Assemble: 4
• Tiller handle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pass the throttle shaft “1” through the fric-
tion piece “2” and tiller handle “3”.
b. Install the bushing “4”, retainers “5”, and

spring “6”. 2
2 1
1 2
2
4 6 5 f. Align the marks “a” and “b”, and align the

cutouts “c” and “d”, and then install the
3
control link assembly “1”.
5
TIP:
c. Install the collar “1”, the washers “2”, the Route the neutral switch lead under the control
plate “3”, and a new cotter pin “4”. link assembly “1”. See “Tiller handle (tiller han-
dle model)” (5-11).
c
2 1 2 3 2 d a
b
1
3 4
2 1
3
4
d. Install the neutral switch “1”, and then fas-

ten it using the new plastic ties “2”.
g. Install the nut “1”, the throttle friction ad-
e. Install the throttle arm “3” and bushing “4”. juster “2”, and a new cotter pin “3”.
3 1
9-5
h. Face the section “a” of the plate “1” toward
the throttle friction adjuster “2”. Throttle grip screw “2”
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
T.
R.
i. Align the slot “b” in the bushing “3” with the PTT switch screw “5”
protrusion “c” on the tiller handle, and then 2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
install the bushing “3”.
n. Check that the throttle grip operates
c smoothly. Also, check that the marks “a”
and “b” are aligned, and that the cutouts
“c” and “d” are aligned.
c
1 2
d a
b
b
a
3 1
j. Align the mark “a” on the throttle grip “1”

with the protrusion “b” on the tiller handle,
and then install the throttle grip “1”.
k. Tighten the throttle grip screw “2” to the

o. Check that the shift link lever operates
specified torque. smoothly when the shift lever is moved
from the N position to the F or R position.
l. Install the cap “3” or PTT switch “4”, and
then tighten the PTT switch screw “5” to
p. Check that the neutral switch “1” operates
the specified torque. properly.
m. Install the shift lever “6”.
a 6 1
1
A 2
N
3
B R F
5
4
A. Hydro tilt model
B. PTT model
9-6
q. Connect the connectors “a” of the PTT
switch Red (R) lead, Sky blue (Sb) lead,
and Light green (Lg) lead (PTT model).
a
Lg b 2
a
Sb
1
r. Connect the connectors “a” of the neutral

switch Brown (Br) leads, and then install
Grease nipple “2”
the holders “1” and “2” and the bracket “3”.
3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1 Br
2
3 2
a
1
s. Install the shift cable “1”, throttle cable “2”,

clips “3”, and cable clamps “4”.
4 2 3
3
3
4 2
A
4 1
t. Connect the alert indicator couplers “a”

and “b”, and then install the cover “1”.
u. Install the grease nipple “2”, and then tight-

en it to the specified torque.
9-7
Electrical component (tiller handle)

13
15
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
5 N·m (0.5 kgf·m, 3.7 lb·ft)

14 2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
16
12
2
15
11 2
3
3
12 5
4
11
17 1
9 6 7
10

1 Cover 1
2 Clamp 2
4 Plate 1
5 Alert indicator 1
6 Grommet 1
7 Gasket 1
8 Bolt M6  15 mm 1
9 Bracket 1
10 Buzzer 1
11 Engine shut-off switch 1
12 Engine start switch 1
Extension wire har-
13 1
ness
14 Alert indicator harness 1
15 Trolling switch 1
16 Grommet 1
17 Tiller handle 1
9-8
Assembling the electrical component g. Align the white tapes “a” on the extension
1. Assemble: wire harness “1” and alert indicator har-
• Electrical component ness “2” with the inner end of the grommet
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ “3”.
a. Install the engine start switch “1” so that
the hole “a” is facing up, and then tighten
the engine start switch nut “2” to the spec-
ified torque. 2
b. Pass the extension wire harness “3”, alert a

indicator harness “4”, and trolling switch
lead “5” through the grommet “6”, and then 3
install them.
1
c. Connect the engine start switch coupler
h. Install the alert indicator “1”, and then tight-
“b”.
en the alert indicator screws “2” to the
specified torque.
d. Install the engine shut-off switch “7”, and
then tighten the engine shut-off switch nut
“8” to the specified torque. 2
2
e. Connect the engine shut-off switch con-
nectors “c” 1
f. Install the buzzer “9”, and then connect the

buzzer connectors “d”.
5
4
6 5
3
b
3 4
Alert indicator screw “2”

9 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
d
R.
c 1 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7
8 2
Engine start switch nut “2”

4.4 N·m (0.44 kgf·m, 3.2 lb·ft)
T.
R.
Engine shut-off switch nut “8”

2.3 N·m (0.23 kgf·m, 1.7 lb·ft)
9-9
Shift rod and shift bracket
Shift rod and shift bracket

New 4
5
6 7
9
8 3
6 18 N·m (1.8 kgf·m, 13 lb·ft)
2
10
11

Shift rod detent bolt
1 1
M12  23 mm
2 Spring 1
3 Ball 1
4 Cotter pin 1
5 Washer 1
6 Bushing 2
7 Bracket 1
8 Bolt M5  14 mm 1
9 Bushing 1
10 Shift rod 1
11 Grommet 1
9-10
Bottom cowling
Bottom cowling
5 N·m (0.5 kgf·m, 3.7 lb·ft)
14 15
19
14 5 16
12 5 18
13 5 5 21 30
5 6 15
21 33 5
13 17 43 31 34
21 35
11 28 1 44 32 37 36
9 27
12 8 42 38
5 7 1 10 44
5 43
6
41
42
21
26 2 20 45
2 3 1
1
41
21 39 2
3 3
23
21
24
25 29
21 2
3 A
23 40
22
4

1 Bolt M6  30 mm 4 20 Water outlet 1
2 Grommet 4 21 Bolt M6  20 mm 7
3 Collar 4 22 Bracket 1
4 Rubber seal 1 23 Clamp 2
5 Plastic tie 8 24 Bracket 1
6 Hose 1 25 Clamp 1
7 Hose joint 1 26 Plate 1
8 Hose joint 1 27 Holder 1
9 Gasket 1 28 Holder 1
10 Screw M6  19 mm 2 29 Bracket 1
11 Adapter 1 30 Spring 1
12 Cap 1 31 Hook 1
13 Grommet 1 32 Bolt M6  14 mm 1
14 Hose joint 2 33 Lever 1
15 Holder 2 34 Bushing 1
16 Hose 1 35 Cowling lock lever 1
17 Hose 1 36 Washer 1
18 Clip 1 37 Wave washer 1
19 Hose 1 38 Bushing 1
9-11
Bottom cowling
5 N·m (0.5 kgf·m, 3.7 lb·ft)

14 15
19
14 5 16
12 5 18
13 5 5 21 30
5 6 15
21 33 5
13 17 43 31 34
21 35
11 28 1 44 32 37 36
9 27
12 8 42 38
5 7 1 10 44
5 43
6
41
42
21
26 2 20 45
2 3 1
1
41
21 39 2
3 3
23
21
24
25 29
21 2
3 A
23 40
22
4

39 Cover 1
40 PTT switch 1
41 Grommet 2
42 Grommet 2
43 Collar 2
44 Grommet 2
45 Bottom cowling 1
A. PTT model
9-12
Upper case assembly and mount

6 7
8 9
24 N·m (2.4 kgf·m, 18 lb·ft)
12
10 14
16
13
15 18 16 15 14
17
11 18
15 12
3 17 13
14
16
11
18
1
5 10
4
5 2
4 1
1 Bolt M6  7 mm 1
2 Ground lead 1
4 Nut 2
5 Washer 2
6 Bolt M8  30 mm 3
7 Bolt M8  175 mm 2
8 Upper mount 1
9 Plate 1
10 Bolt M8  30 mm 4
11 Cover 2
12 Cap 2
13 Bolt M12  170 mm 2
14 Washer 2
15 Rubber washer 2
16 Washer 2
17 Lower mount 2
18 Washer 2
9-13
Removing the upper case
1. Drain: TIP:
• Engine oil Tighten the lower mount cover bolts temporar-
ily.
2. Remove:
• Upper case assembly
TIP:
Before removing the upper case assembly,
loosen the upper mount bolts “1” and lower 2 7
mount cover bolts (PORT and STBD) “2”.
4
1
1 3
8
6 5
9
3. Install:
• Upper case assembly “1”
• Washer “3”
• Upper mounting nut “4”
• Lower mounting nut “5”
2 1
Installing the upper case

1. Install:
• Plate
• Upper mounting bolt 3
• Upper mount
• Upper mount bolt (temporarily tighten)
5 2
2. Install: 5
3
• Washer “1”
• Rubber washer “2”
• Washer “3” Upper mounting nut “4”
• Lower mounting bolt “4” 24 N·m (2.4 kgf·m, 18 lb·ft)
T.
R.
• Lower mount “5”

• Washer “6” 4. Tighten:
• Cap “7” • Upper mount bolt
• Lower mount cover “8” • Lower mount cover bolt
• Lower mount cover bolt “9”
9-14
Upper case
Upper case
21 N·m (2.1 kgf·m, 15 lb·ft) 11
21 N·m (2.1 kgf·m, 15 lb·ft) 2
10
12 1
6 20
9
8
6
20
8
4 New
6 3
7
5
13
18
19 New
27 N·m (2.7 kgf·m, 20 lb·ft)
A 15 New
14
17
16 27 N·m (2.7 kgf·m, 20 lb·ft)

1 Clip 1 20 Dowel pin 2
2 Hose 1 A. L-transom model
3 Drain bolt 1
4 Gasket 1
5 Damper 1
6 Bolt M8  30 mm 4
7 Upper case 1
8 Dowel pin 2
9 Rubber seal 1
10 Guide 1
11 Screw M5  16 mm 2
12 Baffle plate 1
13 Grommet 1
14 Plug M14  12 mm 1
15 Gasket 1
16 Circlip 1
17 Drive shaft bushing 1
18 Rubber seal 1
19 Rubber seal 1
9-15
Upper case
Disassembling the upper case Assembling the upper case
1. Remove: 1. Install:
• Circlip “1” • Drive shaft bushing “1”
• Drive shaft bushing “2” • Circlip “2”
A A 3
4
3
4
3
1
1 4 2
2 B 3
3
B 4
4
1
4 2
1
3
A. Worldwide
1 B. USA and Canada
Driver rod L3 “3”

2 90890-06652
YB-06071
Needle bearing attachment “4”
A. Worldwide 90890-06611
B. USA and Canada
Driveshaft needle bearing installer
and remover “4”
Stopper guide plate “3” YB-06196
90890-06501
Reverse gear bearing remover “3”
YB-41707
Pinion Gear Bushing Installer “4”
90890-06601
Pinion gear bushing installer “4”
YB-06029-4
Checking the drive shaft bushing

1. Check:
• Drive shaft bushing
9-16
Upper case
2. Install:
• Plug gasket New
• Plug
• Guide
• Baffle plate
• Cooling water pipe rubber seal
• Cooling water pipe
• Muffler rubber seal New
• Dowel pin
• Muffler rubber seal New
• Upper case assembly
• Upper case bolt
• Drain bolt gasket New
• Drain bolt
Plug
27 N·m (2.7 kgf·m, 20 lb·ft)
T.
R.
Upper case bolt

21 N·m (2.1 kgf·m, 15 lb·ft)
Drain bolt
27 N·m (2.7 kgf·m, 20 lb·ft)
9-17
Oil pan and exhaust guide

19 New 11 N·m (1.1 kgf·m, 8.1 lb·ft)
18 27 New
28 8 New
7
21
26
15 12 20 New
25 5
24 23 22
New 3 5
6 New
11 11
16
9
16 9
15
3 New
17 9 4
13
New 14
9
1
9 1
10
9 9
1 2
1
1 Bolt M6  25 mm 6 20 Gasket 1
2 Muffler 1 21 Bolt M5  12 mm 1
3 Gasket 2 22 Bolt M6  20 mm 1
4 Plate 1 23 Plate 1
5 Bolt M6  50 mm 3 24 Cover 1
6 Gasket 1 25 Anode 1
7 Exhaust manifold 1 26 Grommet 1
8 Gasket 1 27 Oil seal 1
9 Bolt M6  25 mm 10 28 Exhaust guide 1
10 Oil pan 1
11 Dowel pin 2
12 Gasket 1
13 Pipe 1
14 Rubber seal 1
15 Bolt M6  25 mm 3
16 Bolt M6  16 mm 2
17 Oil strainer 1
18 Cover 1
19 Gasket 1
9-18
Checking the oil pan and exhaust B
guide
1. Clean: 1 2
• Removed parts
2. Check:
• Exhaust guide
• Exhaust manifold
• Muffler 3
• Oil pan
Corroded/cracked  Replace. A. Worldwide
B. USA and Canada
Checking the oil strainer
1. Check: Driver rod L3 “2”
• Oil strainer 90890-06652
Dirt/residue  Clean. Driver handle (large) “2”
YB-06071
Checking the exhaust guide anode Needle bearing attachment “3”
1. Check:
90890-06611
• Anode
Bearing cup installer “3”
YB-06167
Do not apply grease, oil, or paint to the an-

ode.
Assembling the oil pan and exhaust

guide
1. Install:
• Oil seal “1” New
• Anode grommet
• Anode
• Anode cover
• Anode bolt
• Anode plate
• Anode plate bolt
A
1 2
9-19
• Exhaust guide gasket New • Exhaust manifold bolt
• Oil pan bolt
• Relief valve gasket New
• Relief valve cover
Exhaust manifold bolt
• Oil strainer
11 N·m (1.1 kgf·m, 8.1 lb·ft)
T.
R.
• Cooling water pipe gasket “1”
• Cooling water pipe “2”
5. Install:
• Cooling water pipe rubber seal “3” New
• Muffler gasket New
• Dowel pin “4”
• Muffler plate
• Oil pan “5”
• Muffler
• Oil pan bolt “6” (temporarily tighten)
3 6
LT
572 5
LT
572
4
LT
572
1
3. Install:
• Exhaust manifold gasket “1” New
• Exhaust manifold “2”
• Exhaust manifold bolt “3” (temporarily
tighten)
• Exhaust manifold gasket “4” New
4 3
3
2
9-20
Steering arm
Steering arm
A 7 6
8
20 N·m (2.0 kgf·m, 15 lb·ft)
9
7
10
4 New
11 3
12
4 New
2
5
1
1 Circlip 1
2 Steering yoke 1
3 Bushing 1
4 O-ring 2
5 Bushing 2
7 Washer 2
8 Steering hook 1
9 Stud bolt 2
10 Steering arm 1
11 Washer 1
12 Bushing 1
A. Remote control model
9-21
Steering arm
Removing the steering arm b
1. Remove:
• Circlip “1”
• Steering yoke “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the steering yoke “2” by striking it
using a copper hammer.
2 a
1 1 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Installing the steering arm 2. Install:

1. Install: • Circlip “1”
• Washer (to the steering arm) • Stud bolt
• Bushing (to the steering arm)
TIP:
• O-ring (to the steering arm) New Hold the steering arm, and then strike the
• Bushing (to the steering arm) steering yoke using a copper hammer until the
• Steering arm groove “a” for installing the circlip is visible.
• Bushing (to the swivel bracket)
• O-ring (to the swivel bracket) New
• Bushing (to the swivel bracket)
• Steering yoke
a
TIP:
Make sure that the steering yoke “1” is facing
the same direction as the steering arm “2”
(aligning “a” with “b”).
1
Stud bolt
20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
9-22
Steering arm
3. Inject:
• Grease
TIP:
Inject grease into the grease nipple “1” until it
comes out from both the upper and lower
bushings “a”.
1 a
9-23
Hydro tilt
Hydro tilt
7 14
15
16
10
10
9
8 1 11
2
6 13
12
6
2
1 5
3
4

1 Bolt M8  15 mm 2
2 Washer 2
3 Shaft 1
4 Collar 1
5 Collar 1
6 Bushing 2
7 E-clip 2
8 Shaft 1
9 Bushing 1
10 Bushing 2
11 Hydro tilt assembly 1
12 Screw M6  25 mm 1
13 Anode 1
14 Bolt M6  10 mm 1
15 Tilt lock lever 1
16 Cap 1
9-24
Hydro tilt
Removing the hydro tilt assembly Installing the hydro tilt assembly
1. Install:
• Anode
When removing the hydro tilt assembly • Bushing (to the hydro tilt, clamp bracket,
with the power unit installed, make sure to and swivel bracket)
suspend the outboard motor. • Tilt lock lever
• Tilt lock lever cap
TIP: • Hydro tilt unit
Fully tilt the swivel bracket up, and then sup- • Shaft (upper side)
port it using the tilt support knob “1”. • E-clip
• Collar
• Shaft (lower side)
1
Checking the hydro tilt

1. Check:
• Hydro tilt unit
Damage/gas leakage/oil leakage/bent 
Replace.
• Do not disassemble or puncture the hydro

tilt unit, as high-pressure gas is con-
tained.
• Do not apply heat or fire to the hydro tilt
unit, as high-pressure gas is contained.
Checking the hydro tilt anode

1. Check:
• Anode

ode.
9-25
PTT unit
PTT unit
1 2
1
10
3 New
13
13
14
5
11
12
10
6
8
9
6
5
7

1 Plastic tie 2
2 Corrugated tube 1
3 Plastic tie 2
4 Bolt M6  10 mm 2
5 Bolt M8  15 mm 2
6 Washer 2
7 Shaft 1
8 Bushing 2
9 Bushing 1
10 E-clip 2
11 Shaft 1
12 PTT unit 1
13 Bushing 2
14 Bushing 1
9-26
PTT unit
Removing the PTT unit
Manual valve “1”
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
T.
R.
When removing the PTT unit with the power
unit installed, make sure to suspend the c. Remove the reservoir cap “1”, and then
outboard motor. check the fluid level.
TIP:
TIP: If the fluid is at the proper level, a small amount
Fully tilt the swivel bracket up, and then sup- of fluid should flow out of the filler hole.
port it using the tilt support knob “1”.
d. If the fluid is below the proper level, add

Bleeding the PTT unit the recommended fluid.
e. Install the reservoir cap, and then tighten it

Before removing the reservoir cap, make to the specified torque.
sure that the trim and tilt ram is fully ex-
tended. Otherwise, fluid could be expelled Reservoir cap
forcefully from the PTT unit due to internal 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
pressure.
1. Bleed:
• PTT unit
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the PTT unit in an upright position.
b. Turn the manual valve “1” counterclock-

wise to check that it is closed.
9-27
PTT unit
f. Connect the battery jumper leads to the j. Remove the reservoir cap, and then check
PTT motor lead “1” to fully retract the trim the fluid level.
and tilt ram.
TIP:
TIP: If the fluid is below the proper level, add the
If the trim and tilt ram does not move down eas- recommended PTT fluid. Repeat steps c–i until
ily, push on the trim and tilt ram to assist oper- the fluid is at the proper level.
ation.
k. Install a new O-ring and the reservoir cap,
and then tighten the reservoir cap to the
1
G L specified torque.
Reservoir cap
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Installing the PTT unit

1. Install:
Ram PTT motor lead Battery • Bushing (to the PTT unit, clamp bracket,
and swivel bracket)
Green (G) (+)
Retract • PTT unit
Blue (L) (–) • Shaft (upper side)
• E-clip
g. Reverse the connection between the bat- • Shaft (lower side)
tery jumper leads and the PTT motor lead • Washer
“1” to fully extend the trim and tilt ram. • Shaft bolt
• Ground lead
TIP:
• Ground lead bolt
If the trim and tilt ram does not move up easily,
pull on the trim and tilt ram to assist operation. 2. Route:
• PTT motor lead
1 • Plastic tie New

L G ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Route the PTT motor lead “1” through the
hole “a” in the clamp bracket “2” (STBD),
and then fasten the PTT motor lead to the
clamp bracket (STBD) with a new plastic
tie “3”.
2
a
Ram PTT motor lead Battery 3
Blue (L) (+)
Extend 1
Green (G) (–)
h. Repeat steps f and g to fully extend and re-

tract the trim and tilt ram 4 or 5 times.
i. Fully extend the trim and tilt ram. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9-28
PTT unit
3. Install:
• Plastic tie New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fasten the PTT motor lead “1” and the
speedometer hose “2” at the white tape “a”
with a new plastic tie “3”.
1
2
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• Corrugated tube
• Plastic tie
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the corrugated tube “1”, and then
fasten it with the plastic ties “2”.
1
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9-29
Clamp bracket and swivel bracket

A 23
24 22 N·m (2.2 kgf·m, 16 lb·ft)
19
21 22
20 A 9
6
8
13
10
17
7 18
25
15
26 13
A
11 12
A 14
3 18 16
4 A 1
2 A 17
1 3
B
5
11
3.0 N·m (0.30 kgf·m, 2.2 lb·ft)

1 Screw M6  15 mm 2 20 Stopper knob 1
2 Trim sensor 1 21 Stopper shaft 1
3 Bolt M6  14 mm 2 22 Bushing 1
4 Ground lead 1 23 Bolt M6  14 mm 1
5 Ground lead 1 24 Holder 1
6 Self-locking nut 1 25 Bolt M6  25 mm 2
7 Clamp bracket (STBD) 1 26 Anode 1
8 Screw M5  35 mm 1 A. PTT model
9 Trim sensor cam 1 B. Hydro tilt model
10 Swivel bracket 1
11 Grease nipple 2
12 Clamp 1
13 Bushing 2
14 Bolt M8  20 mm 1
15 Through tube 1
16 Clamp bracket (PORT) 1
17 Bolt M10  50 mm 2
18 Stopper 2
19 Pin 1
9-30
Checking the clamp bracket anode 2. Inject:
1. Check: • Grease
• Anode ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Eroded (1/2 or more)  Replace. a. Inject grease into the grease nipples until
There is grease, oil, or scales.  Clean. grease comes out from the bushings “a”.
a
ode.
Installing the clamp bracket

1. Install:
• Anode
• Tilt support shaft bushing
• Tilt support shaft ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Tilt support knob
• Pin Adjusting the trim sensor cam
• Trim sensor (PTT model) 1. Adjust:
• Swivel bracket bushing • Trim sensor setting resistance
• Clamp bracket (PORT) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Through tube a. Fully tilt the swivel bracket down.

• Swivel bracket
b. Loosen the trim sensor cam screw “1”.
• Trim sensor cam (PTT model)
• Clamp bracket (STBD) c. Measure the trim sensor setting resis-
• Self-locking nut tance. Adjust if out of specification.
• Stopper
• Ground lead TIP:
• Clamp (PTT model) • To decrease the resistance, turn the trim sen-
• Grease nipple sor cam in direction “a”.
• Holder (PTT model) • To increase the resistance, turn the trim sen-
sor cam in direction “b”.
Self-locking nut
22 N·m (2.2 kgf·m, 16 lb·ft)
T.
R.
Grease nipple
c d
3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
a
TIP:
Secure the trim sensor lead “1” using the
clamp “2” and holder “3”.
1 b
1 Digital circuit tester

90890-03243
3 1 2 Digital multimeter
YU-34899-A
9-31
Setting resistance
9–11  (F30A, F30BET, F30HA,
F40A, F40FET, F40HA)
Terminal “c”–Terminal “d”
d. Tighten the screw “1” so that the gap “a”

between the ends of the trim sensor cam is
within specification.
1
a
Trim sensor cam end gap “a”

16.0–19.0 mm (0.63–0.75 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Trim sensor setting resistance
Out of specification  Repeat from step 1.
9-32
PTT motor
PTT motor
2 6
2
1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
7 9 10 7 N·m (0.7 kgf·m, 5.2 lb·ft)
3 8
12
10 11
4 New 12
12
5
18
13
12
New 14
New 15
19 New
16
17

1 PTT motor assembly 1
3 Stator 1
4 O-ring 1
5 Armature 1
7 PTT motor lead 1
8 Brush 1
9 Brush assembly 1
10 Spring 2
11 Holder 1
12 Bolt M6  20 mm 4
13 Base 1
14 Oil seal 1
15 O-ring 1
16 Spring 1
17 Joint 1
18 Reservoir cap 1
19 O-ring 1
9-33
PTT motor
Removing the PTT motor
2
Before removing the reservoir cap, make
sure that the trim and tilt ram is fully ex- 1 1
tended. Otherwise, fluid could be expelled
forcefully from the PTT unit due to internal
pressure.
1. Drain:
• PTT fluid Checking the armature (PTT motor)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1. Check:
a. Fully extend the trim and tilt ram. • Commutator
Dirty  Clean using 600-grit sandpaper
b. Remove the reservoir cap “1”, and then and compressed air.
drain the PTT fluid.
2. Measure:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Commutator diameter “a”
Disassembling the PTT motor Below specification  Replace the arma-
1. Remove: ture.
• Screw “1”
• Stator “2”
Secure the end of the armature shaft using

a pair of pliers, and then remove the arma-
ture along with the motor base assembly.
Otherwise, the armature could separate
from the motor base assembly due to the a
magnetic force of the stator “2” and dam-
age the brushes.
Standard commutator diameter
17.60 mm (0.6929 in) (F30A,
F30BET, F30HA, F40A,
F40FET, F40HA)
Wear limit
16.60 mm (0.6535 in) (F30A,
F40FET, F40HA)
9-34
PTT motor
3. Measure: Checking the brush
• Commutator undercut “a” 1. Measure:
Below specification  Replace the arma- • Brush length
ture. Below specification  Replace the brush.
b
a
a. Standard brush length

Standard commutator undercut b. Wear limit
1.50 mm (0.0591 in) (F30A,
F40FET, F40HA) Standard brush length
7.00 mm (0.2756 in) (F30A,
Wear limit
1.35 mm (0.0532 in) (F30A,
F30BET, F30HA, F40A, F40FET, F40HA)
F40FET, F40HA) Wear limit
3.5 mm (0.14 in) (F30A, F30BET,
F30HA, F40A, F40FET, F40HA)
4. Check:
• Armature continuity
Out of specification  Replace the arma- 2. Check:
ture. • Circuit breaker continuity
No continuity  Replace.
Do not touch the bimetal “a”. Otherwise,

a the operation of the circuit breaker could be
b d affected.
c
Digital circuit tester a

90890-03243
Digital multimeter
YU-34899-A
Armature continuity
3. Check:
“a” “b” “c” “d”
• PTT motor base
Cracks/damage  Replace the PTT motor
assembly.
9-35
PTT motor
Assembling the PTT motor 3. Install:
• Armature
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Do not apply grease or oil to the commuta- a. Push the brushes “1” into the brush holder,
tor of the armature. and then install the armature “2”.
2
1. Install:
• Oil seal “1” New 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
4. Install:
• Stator “1”
• Screw “2”
2. Install:
• Spring “1”
• Brash assembly “2” Secure the end of the armature shaft using
• Brush holder “3” a pair of pliers, and then install the arma-
• Brush “4” ture along with the motor base assembly.
• Screw “5” Otherwise, the armature could separate
• O-ring “6” New from the motor base assembly due to the
• PTT motor lead “7” magnetic force of the stator “1” and dam-
age the brushes.
Do not touch the bimetal “a”. Otherwise,

TIP:
the operation of the circuit breaker could be
Align the marks “a”.
affected.
1
7 5 6 1
5
2 2
1
3 2
a
a
4
9-36
PTT motor
Installing the PTT motor
1. Install:
• Joint
• Spring
• O-ring (to the motor base) New
• PTT motor assembly
• PTT motor mounting bolt
• O-ring (to the reservoir cap) New
• Reservoir cap
PTT motor mounting bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
Reservoir cap
7 N·m (0.7 kgf·m, 5.2 lb·ft)
9-37
PTT gear pump
PTT gear pump

2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 10 10
13
14
14
20 New 15 15
16
1 11
18 New 17 16
19 17
24 New
22 12 New
New 21 25
22
23
New 29 New
1
31 27 New
30
25 26
26 29 New
27 2
New 28 New
28 New
11 N·m (1.1 kgf·m, 8.1 lb·ft)
4 3
5
9
1 40 7 New
39 8 New 4
38 3
34 38 6
37 New
9 N·m (0.9 kgf·m, 6.6 lb·ft) New 36 37
35
New 33
6 N·m (0.6 kgf·m, 4.4 lb·ft) 32

1 Bolt M6  75 mm 3 20 O-ring 1
2 Gear pump housing 1 21 O-ring 1
3 Ball 2 22 Manual valve seat 2
4 Absorber valve pin 2 23 Spring 1
5 Spring 2 24 Adapter 1
6 O-ring 2 25 Main valve assembly 2
7 Filter 1 26 Main valve 2
8 O-ring 1 27 O-ring 2
10 Bolt M4  25 mm 4 29 O-ring 2
11 Gear pump assembly 1 30 Shuttle piston 1
13 Spring 1 32 Valve lock screw 1
14 Valve pin 1 33 O-ring 1
15 Valve seal 1 34 Relief valve assembly 1
16 Filter 2 35 Relief valve 1
18 Circlip 1 37 Valve seal 1
19 Manual valve 1 38 Valve pin 1
9-38
PTT gear pump
2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) 10 10
13
14
14
20 New 15 15
16
1 11
18 New 17 16
19 17
24 New
22 12 New
New 21 25
22
23
New 29 New
1
31 27 New
30
25 26
26 29 New
27 2
New 28 New
28 New
11 N·m (1.1 kgf·m, 8.1 lb·ft)
4 3
5
9
1 40 7 New
39 8 New 4
38 3
34 38 6
37 New
9 N·m (0.9 kgf·m, 6.6 lb·ft) New 36 37
35
New 33
6 N·m (0.6 kgf·m, 4.4 lb·ft) 32

39 Spring 1
40 Lock screw 1
9-39
PTT gear pump
Checking the gear pump
1. Check:
• Gear pump shaft
It does not rotate smoothly  Replace the
gear pump assembly.
Checking the gear pump housing

1. Check:
• Gear pump housing
Corrosion/cracks  Replace the gear
pump assembly.
Checking the filter

1. Check:
• Down-relief valve filter
Dirt/residue  Clean.
Clogged/damaged  Replace.
Checking the valve seal

1. Check:
• Main valve
• Shuttle piston
• Absorber valve pin
• Relief valve
• Valve seal
• Valve pin
• Manual valve
• Manual valve seat
• Spring
Damage/wear  Replace.
9-40
PTT cylinder
PTT cylinder
61 N·m (6.1 kgf·m, 45 lb·ft)
5 New
2 New
4 New
3 New 6
7 New
8
90 N·m (9.0 kgf·m, 66 lb·ft)

Trim and tilt ram as-
1 1
sembly
2 Dust seal 1
3 O-ring 1
4 O-ring 1
5 O-ring 1
6 Free piston assembly 1
7 O-ring 1
8 Cylinder 1
9-41
PTT cylinder
Removing the trim and tilt ram assem- 4. Remove:
bly • Free piston
1. Loosen: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Trim cylinder end screw “1” a. Cover the tilt cylinder using a rag “1”, and
then blow compressed air through the hole
A
“a” to remove the free piston “2”.
2
1 When removing the free piston, never look

into the tilt cylinder opening because the
free piston and PTT fluid could be expelled
forcefully.
B 1
1 2
A. Worldwide a
B. USA and Canada
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Cylinder end screw wrench “2”
90890-06591 5. Remove:
Trim cylinder wrench “2” • Tilt piston
YB-06175-2B • Tilt cylinder end screw
• Absorber valve
2. Remove:
Checking the PTT cylinder and piston
• Trim and tilt ram assembly
1. Check:
3. Drain: • PTT body
• PTT fluid Corroded/cracked  Replace.
• Inner surface of the PTT body
• Tilt cylinder end screw
• Outer surface of the tilt piston
• Outer surface of the free piston
Cracks/scratched  Replace.
Rust  Clean using 400–600-grit sandpa-
per.
Bent/corroded  Replace.
9-42
PTT cylinder
Checking the absorber valve 5 1
1. Check: 3
• Absorber valve 4 2
Dirt/residue  Clean. 1
1 3
Assembling the trim and tilt ram as-
sembly
1. Install:
• Dust seal “1” New
• O-ring “2” New 1 2
1
1
Tilt piston bolt “1”
61 N·m (6.1 kgf·m, 45 lb·ft)
T.
3
R.
2
2 Installing the trim and tilt ram assem-
3
bly
1. Install:
• Gear pump
2. Install: See “PTT gear pump” (9-38)
• Tilt cylinder end screw “1”
• Tilt piston “2” 2. Add the recommended fluid through the
PTT body hole “a”.
1
a
3. Install:
• Ball “1”
• Absorber valve pin “2”
• Spring “3”
• Washer “4”
• Tilt piston bolt “5”
Fluid quantity (reference quantity)

60% at tilt cylinder
9-43
PTT cylinder
• O-ring “1” New • Trim cylinder end screw “1”
• Free piston “2” A
2 2
B
4. Install: 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1
a. Place the tilt cylinder end screw “1” at the
bottom of the trim and tilt ram.
b. Install the trim and tilt ram assembly into

the cylinder.
A. Worldwide
B. USA and Canada
Cylinder end screw wrench “2”

90890-06591
Trim cylinder wrench “2”
YB-06175-2B
1
Trim cylinder end screw “1”
90 N·m (9.0 kgf·m, 66 lb·ft)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9-44
Maintenance
Outline ............................................................................... 10-1

Maintenance interval chart 1 .................................................... 10-1
Maintenance interval chart 2 .................................................... 10-3
Predelivery check............................................................. 10-4

Checking the engine oil level.................................................... 10-7
Checking the battery ................................................................ 10-7
Checking the cooling water pilot hole....................................... 10-8
Checking the gear oil level ....................................................... 10-8
Checking the outboard motor mounting height ........................ 10-9
Checking the power trim and tilt unit ........................................ 10-9
Checking the hydro tilt unit ....................................................... 10-9
General periodic maintenance ...................................... 10-11

Checking the engine idle speed/noise.................................... 10-14
Checking the cooling water inlet............................................. 10-14
Changing the engine oil using an oil changer ........................ 10-14
Changing the engine oil by removing the drain bolt ............... 10-15
Replacing the oil filter ............................................................. 10-17
Changing the gear oil ............................................................. 10-18
Checking the gear oil level ..................................................... 10-19
Greasing points ...................................................................... 10-19
Greasing the clamp bracket bolt (through tube) ..................... 10-20
Checking the PTT fluid level................................................... 10-20
Checking the cowling lock lever ............................................. 10-21
10
Outline
Outline
• To obtain long product life, Yamaha strongly recommends that the specified periodic checks and
maintenance be performed according to the maintenance interval charts.
• If replacement parts are necessary, use only genuine Yamaha parts of equivalent design and quality.
Any parts of inferior quality may cause a malfunction, and the resulting loss of control could endanger
the operator and passengers. Yamaha genuine parts and accessories are available from Yamaha
dealers.
• The service intervals provided in the maintenance interval charts are based upon “typical” operating
conditions that include speed variations, sufficient time for engine warm up and cool-down, medium
to light load, and an average cruising speed in the 3000–4000 r/min range. If your normal operating
conditions are more intensive, more frequent servicing will be required, especially the engine oil and
gear oil changes. Examples of the intensive operation will be: wide-open-throttle, trolling, or idling op-
eration for extended periods of time, carrying heavy loads, and frequent starting and stopping or shift-
ing. In most cases, the frequent maintenance pays off in increased engine life and greater owner
satisfaction.
• The maintenance cycle on these charts is based on usage of 100 hours per year and regular flushing
of the cooling water passages. Adjust the maintenance frequency when operating the engine under
adverse conditions, such as extended trolling.
• Disassembly or repairs may be necessary depending on the outcome of maintenance checks.
• Expendable or consumable parts and lubricants will lose their effectiveness over time and through
normal usage regardless of the warranty period.
• When operating the outboard motor in salt water, or in muddy, turbid (cloudy), or acidic water, flush
the engine using clean water after each use.
Maintenance interval chart 1

The “●” symbol indicates the check-ups which the owners or operators may carry out themselves.
The “○” symbol indicates work to be carried out by a Yamaha dealer.
Initial Every
Item Actions 20 hours 100 hours 300 hours 500 hours
(3 months) (1 year) (3 years) (5 years)
Inspection or replace-
Anode(s) (external) ●/○
ment as necessary
Anode(s) (internal) *1 ○
ment as necessary
Anode(s) (internal) *2 Replacement ○
Battery (electrolyte level,
Inspection ●/○ ●/○
terminal)
Battery (electrolyte level, Fill, charging or replac-
○
terminal) ing as necessary
Cooling water leakage ○ ○
ment as necessary
Cowling lock lever Inspection ●/○
Engine starting condi-
tion/noise
Engine idle speed/noise Inspection ●/○ ●/○
Engine oil Replacement ●/○ ●/○
10-1
Outline
Initial Every
Engine oil filter (car-
Replacement ●/○
tridge)
Fuel filter (can be disas- Inspection or replace-
●/○ ●/○
sembled) ment as necessary
Fuel line (High pressure) Inspection ● ●
Fuel line (High pressure) ○ ○
ment as necessary
Fuel line (Low pressure) Inspection ● ●
Fuel line (Low pressure) ○ ○
ment as necessary
Fuel pump ○
ment as necessary
Fuel/engine oil leakage Inspection ○ ○
Gear oil Replacement ●/○ ●/○
Greasing points Greasing ●/○ ●/○
Clamp bracket bolt
Inspection and greasing ○
(through tube)
Impeller/water pump Inspection or replace-
○
housing ment as necessary
Impeller/water pump
Replacement ○
housing
Power trim and tilt unit Inspection ●/○ ●/○
Propeller/propeller nut/ Inspection or replace-
●/○ ●/○
cotter pin ment as necessary
Inspection, adjustment
Shift link/shift cable or replacement as nec- ○ ○
essary
Spark plug(s) ●/○
ment as necessary
Spark plug caps/spark Inspection or replace-
○ ○
plug wires ment as necessary
Water from the cooling
water pilot hole
Inspection, adjustment
Throttle link/throttle ca-
or replacement as nec- ○ ○
ble
essary
Thermostat ○
ment as necessary
Timing belt ○
ment as necessary
10-2
Outline
Initial Every
Inspection and adjust-
Valve clearance ○
ment
Cooling water inlet Inspection ●/○ ●/○
Main switch/stop switch ○ ○
ment as necessary
Wire harness connec-
tions/wire coupler con- ○ ○
ment as necessary
nections
(Yamaha)
Inspection ○ ○
Meter/gauge
Fuel tank (Yamaha por- Inspection and cleaning
○
table tank) as necessary
*1. Cylinder head
*2. Exhaust cover, exhaust guide
Maintenance interval chart 2

Every
Item Actions
1000 hours
Exhaust guide/exhaust Inspection or replace-
○
manifold ment as necessary
Timing belt Replacement ○
10-3
Predelivery check
Predelivery check
To make the delivery process smooth and efficient, complete the predelivery checks as explained in
the following procedures.
Item Procedures See
Check the oil level using the dipstick.
Engine oil level 10-7
Oil is not at the proper level  Add or extract engine oil.
Check the battery electrolyte level.
Below the minimum level mark  Add distilled water.
Battery 10-7
Check the specific gravity of the electrolyte.
Below specification  Fully charge the battery.
Start the engine. —
Cooling water pilot Check that the cooling water is discharged from the cooling water
hole 10-8
pilot hole.
2-12
Not discharged  Check the cooling system.
Check that the engine starts when the engine start switch is turned
to START. 5-35
Main switch/stop Out of specification  Check the engine start switch.
switch Start the engine. Check that the engine stops when the engine
start switch is turned to OFF. 5-35
Out of specification  Check the engine start switch.
Check that the engine stops when the clip is removed from the en-
Engine shut-off
gine shut-off switch. 5-33
switch
Out of specification  Check the engine shut-off switch.
Check the fuel line connection.
Disconnect  Connect.
Fuel line 2-15
Check all the fuel lines for leakage.
Leaking  Check the related parts.
Check the gear oil level.
Gear oil 10-8
Below the proper level  Add the recommended gear oil.
Check that the gear shift operates smoothly when the remote con-
trol lever or gear shift lever is moved from the N position to the F
or R position. 3-6
Not smooth  Adjust the shift cable joints or check the related
parts.
Shift and throttle op- Check that the throttle operates smoothly when the remote control
eration lever is moved from the F or R position to the fully open position
(remote control model).
Check that the throttle operates smoothly when the throttle grip is 3-6
turned to the fully open position (tiller handle model).
Not smooth  Adjust the throttle cable joints or check the related
parts.
Outboard motor Check the outboard motor mounting height.
10-9
mounting height Improper  Adjust.
10-4
Predelivery check
Item Procedures See

Check the PTT unit operation.
Not smooth  Check the PTT fluid level and PTT motor electric 10-9
current when the relief valve operate.
Check that there is no abnormal noise produced when the out-
PTT unit board motor is tilted up or down. 9-26
Abnormal noise  Overhaul PTT unit.
Steer the tilted-up outboard motor.
Interference  Check the hose and wire harness routing, or 9-28
mounting of the outboard motor.
Check that the outboard motor tilts up and down when the tilt lock
lever is in the release position.
Operation is not smooth  Check the clamp brackets, hydro tilt
unit, and swivel bracket.
Check that the outboard motor keeps variable tilt position when the
tilt lock lever is in the lock position.
Hydro tilt system Outboard motor tilts up or down  Check the hydro tilt unit. 10-9
Fully tilt the outboard motor up, and then support it using the tilt
support knob.
Outboard motor is not supported  Check the tilt support knob.
Steer the tilted-up outboard motor.
Hose interference  Check the hose routing.
Check that the steering operates smoothly.
Not smooth  Check the steering arm, swivel bracket, helm unit 9-30
or related parts.
Steering system
Check that the there is no interference with hose or leads when the
2-15
outboard motor is steered.
5-1
Interference  Check the hose and wire harness routing.
Check the shift cable when the remote control lever or gear shift
lever is moved to the N position.
3-6
Not at the proper position  Adjust the shift cable joints or check
the related parts.
Shift cable/throttle ca- Check the throttle cable when the remote control lever is moved to
ble the N position (remote control model).
Check the throttle cable when the throttle grip is turned to the fully
3-6
closed position (tiller handle model).
Not at the proper position  Adjust the throttle cable joint or check
the related parts.
10-5
Predelivery check
Item Procedures See

Start the engine, and then check that the gear shift operates prop-
—
erly.
Warm up the engine, and then check the engine idle speed. 10-14
Out of specification  Perform the troubleshooting procedures. 4-3
Operate the boat at trolling speed. —
Test run Operate the outboard motor according to the break-in procedure. —
Check that the outboard motor does not tilt up when reverse oper-
ation. 9-26
Tilt up  Check the PTT unit.
Check that the power trim operates smoothly while cruising.
9-26
Not smooth  Check the PTT unit.
Operate the engine under load (in gear with a propeller installed)
—
for 10 hours.
For the first hour of operation:
Operate the engine at varying speeds up to 2000 r/min or approx- —
imately 1/2 throttle.
For the second hour of operation:
Increase the engine speed until the boat is on plane (but do not ful-
Break-in —
ly open the throttle), and then back off on the throttle while keeping
the boat at a planing speed.
For the remaining 8 hours of operation:
Operate the engine at any engine speed. However, do not operate —
the engine at full throttle for more than 5 minutes at a time.
After the first 10 hours of operation:
—
Operate the engine normally.
Check for water in the gear oil.
8-21
Oil is milky  Check the lower case for airtightness and oil seal.
Check all the fuel lines for leakage.
2-8
After test run Leaking  Check the connection or replace affected parts.
Flush the cooling water passages using fresh water.
When using the equipped flashing device, flush the cooling water —
passages without starting the engine.
10-6
Predelivery check
Checking the engine oil level Checking the battery
Make sure that the engine is filled with en- Battery electrolyte is dangerous; it con-
gine oil before operating the outboard mo- tains sulfuric acid, which is poisonous and
tor for the first time. Otherwise, the engine highly caustic. Always follow these preven-
could be damaged severely. tive measures:
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
1. Check:
injury.
• Engine oil level
• Wear protective eye gear when handling
Not at the proper level  Add or extract
or working near batteries.
the engine oil.
Antidote (EXTERNAL):
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• SKIN - Wash with water.
a. Place the outboard motor in an upright po-
• EYES - Flush with water for 15 minutes
sition.
and get immediate medical attention.
Antidote (INTERNAL):
If the outboard motor is not level, the oil lev- • Drink large quantities of water or milk fol-
el indicated on the dipstick may not be cor- lowed with milk of magnesia, beaten egg,
rect. or vegetable oil. Get immediate medical
attention.
Batteries generate explosive, hydrogen
b. Start the engine and warm it up for 5–10 gas. Always follow these preventive mea-
minutes. sures:
• Charge batteries in a well-ventilated area.
c. Stop the engine and leave it off for 5–10 • Keep batteries away from fire, sparks, or
minutes. open flames (for example, welding equip-
ment and lighted cigarettes).
d. Remove the top cowling.
• DO NOT SMOKE when charging or han-
dling batteries.
e. Remove the dipstick “1” and wipe it clean.
KEEP BATTERIES AND ELECTROLYTE
f. Insert the dipstick “1” completely for a cor- OUT OF REACH OF CHILDREN.
rect measurement and remove it again.
1. Check:
g. Check that the oil level indicated on the • Battery electrolyte level
dipstick “1” is between the upper mark “a” Below the minimum level mark “a”  Add
and the lower mark “b”. If the engine oil is distilled water until the level is between the
not at the proper level, add or extract en- maximum and minimum level marks.
gine oil.
a
a
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
10-7
Predelivery check
2. Check:
• Specific gravity of the electrolyte
Below specification  Fully charge the
battery.
TIP:
• Batteries vary depending on the manufactur-
er. The procedures mentioned in this manual
may not always apply. Therefore, see the in-
struction manual of the battery.
• Disconnect the negative battery cable first,
Checking the gear oil level
and then disconnect the positive battery ca-
1. Check:
ble.
• Gear oil level
Below the proper level  Add the recom-
Recommended battery capacity mended gear oil.
Battery rating (CCA/SAE) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
380–1150 A (F30A, F30EHA, a. Place the outboard motor in an upright po-
F30HA, F40A, F40EHA, F40FE- sition.
HD_*EC2, F40HA)
Battery rating (MCA/ABYC) b. Remove the oil level plug “1”, and gasket
502–1370 A (F30A, F30EHA, “2”, and then check the gear oil level.
F30HA, F40A, F40EHA, F40FE-
TIP:
HD_*EC2, F40HA) If the oil is at the proper level, a small amount
Battery rating (RC/SAE) of oil should flow out of the check hole.
124 minutes (F30A, F30EHA,
F30HA, F40A, F40EHA, F40FE-
HD_*EC2, F40HA)
Battery rating (CCA/EN) 2
430–1080 A 1
Battery rating (20HR/IEC)
70 Ah
Electrolyte specific gravity
1.280 at 20 C (68 F)
Checking the cooling water pilot hole

1. Place the lower unit in water, and then start c. Install a new gasket and the oil level plug,
the engine. and then tighten the oil level plug to the
specified torque.
2. Check:
• Cooling water is discharged from the cool- Oil level plug
ing water pilot hole. 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
Not discharged  Check the cooling pas- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

sages for clog.
10-8
Predelivery check
Checking the outboard motor mount- Checking the power trim and tilt unit
ing height 1. Check:
1. Check: • Power trim and tilt unit
• Outboard motor mounting height Abnormal noise  Check the PTT unit.
Improper  Adjust. Interference  Check the hose and wire
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ harness routing, or mounting of the out-
a. Check that the anti-cavitation plate “1” is board motor.
aligned with the bottom of the boat “2”. Does not display  Adjust the trim sensor
cam. See “Adjusting the trim sensor cam”
TIP: (9-31).
• If the mounting height is too high, cavitation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
will occur and propulsion will decrease. Be- a. Check that there is no abnormal noise pro-
sides, the engine speed will increase abnor- duced when the outboard motor is tilted up
mally and cause the engine to overheat. or down.
• If the mounting height is too low, water resis-
tance will increase, which will decrease en- b. Check that there is no interference with ca-
gine efficiency and performance. bles, hoses, leads, or the boat when the
• The appropriate mounting height depends on tilted-up outboard motor is steered.
the combination of the boat and outboard mo-
tor. To determine the appropriate mounting c. Check that the trim meter, on the boat’s
height, test run the outboard motor at differ- gauge, displays full down when the out-
ent heights. board motor is in the full-down position.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the hydro tilt unit

1. Check:
• Hydro tilt unit operation
Not operate  Replace.
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check that the outboard motor tilts up and
down smoothly when the tilt lock lever “1”
2 is in the release position “a”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
2. Check:
• Mount bolts
Loosen  Tighten.
10-9
Predelivery check
b. Check that the outboard motor does not tilt
up or down when the tilt lock lever “1” is in
the lock position “a”.
c. Fully tilt the outboard motor up, and then

support it using the tilt support knob “1”.
Check that the tilt support knob locks in
place properly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Steer the tilted-up outboard motor.
Interference  Check the hose and wire
harness routing, or mounting of the out-
board motor.
10-10
General periodic maintenance

Item Procedures See
7-41
7-46
Check the anodes.
8-2
Anodes Eroded (1/2 or more worn out)  Replace.
9-19
Adhered grease, oil, paint, or scales  Clean.
9-25
9-31
Check the battery electrolyte level.
Below the minimum level mark  Add distilled water.
Battery 10-7
Check the specific gravity of the electrolyte.
Below specification  Fully charge the battery.
Check the cooling water inlets.
Cooling water inlets 10-14
Clogged  Clean.
Start the engine. —
Cooling water pilot Check that the cooling water is discharged from the cooling water
hole 10-8
pilot hole.
2-12
Not discharged  Check the cooling system.
Engine idle speed Check the engine idle speed. 10-14
Check the oil level using the dipstick.
10-7
Not at the proper level  Add or extract the engine oil.
Engine oil Check the engine oil.

Replacement interval has been exceeded/deterioration  10-14
Change. 10-15
Milky  Overhaul the outboard motor.
Oil filter Replace the oil filter. 5-35
Check that the engine starts when the engine start switch is turned
to START. 5-30
Main switch/stop Out of specification  Check the engine start switch.
switch Start the engine. Check that the engine stops when the engine
start switch is turned to OFF. 5-35
Out of specification  Check the engine start switch.
Check that the engine stops when the clip is removed from the en-
Engine shut-off
gine shutoff switch. 5-33
switch
Out of specification  Check the engine shut-off switch.
Exhaust guide Check the exhaust guide and exhaust manifold.
9-19
Exhaust manifold Corroded/cracked/damaged  Replace.
10-11
Item Procedures See

Check the fuel filter element.
Dirt/residue  Replace.
Water accumulated  Drain.
Checking the fuel cup assembly.
Fuel filter Foreign material  Clean. 6-5
Checking the fuel inlet or fuel outlet holding pressure.
Out of specification  Replace the O-ring, fuel cup assembly, or
fuel filter assembly.
Check the fuel strainer
Cracked/damage  Replace.
Fuel strainer Dirt/residue  Replace. 6-22
Check the fuel strainer holding pressure.
Check the operation of the fuel pump using the YDIS “Stationary
Fuel pump test” and check the operating sound. 5-24
Not sound  Check the fuel pump internal parts.
Check the fuel line.
Fuel leakage 2-15
Check the engine oil line.
Engine oil leakage 2-10
Check the gear oil level.
10-19
Below the proper level  Add the recommended gear oil.
Gear oil Check the gear oil.

Replacement interval has been exceeded/deterioration  10-18
Change. 8-1
Milky  Overhaul the lower unit.
Greasing Apply lubricants. 10-19
Check the propeller blade and spline.
Propeller 8-2
Cracked/damaged/worn  Replace.
Propeller nut
Cotter pin Check the installed condition of propeller nut and cotter pin.
8-22
Improperly installed  Reinstall.
Check that a small amount of fluid flows out of the filler hole.
PTT fluid level 10-20
Below the proper level  Add the recommended fluid.
Check the PTT unit operation.
10-20
PTT operation is not smoothly  Check the PTT fluid level.
Check the tilt support knob.
PTT unit operation Tilt support knob locks in place not properly  Check the related 9-27
parts.
Check the PTT fluid leakage.
9-26
10-12
Item Procedures See

Check the shift cable when the remote control lever or gear shift
lever is moved to the N position.
Shift link/shift cable 3-6
Not at the proper position  Adjust the shift cable joints or check
the related parts.
Clean the electrodes using a spark plug cleaner. —
Check the spark plug.
Electrodes are damaged/worn or insulator is abnormal color 
Spark plug
Replace. 7-40
Check the spark plug gap.
Spark plug caps/ Measure the spark plug cap resistance. 5-29
spark plug wires Out of specification  Replace. 5-30
Check the throttle cable when the remote control lever is moved to
the N position (remote control model).
Throttle link/throttle Check the throttle cable when the throttle grip is turned to the fully
3-6
cable closed position (tiller handle model).
Not at the proper position  Adjust the throttle cable joint or check
the related parts.
Check the timing belt.
Timing belt 7-15
Cracked/damage/worn  Replace.
Measure the thermostat valve opening.
Thermostat 7-46
Check the fitting by pushing the top cowling.
Cowling lock lever 10-21
Looseness/rattling  Adjust or replace the top cowling stopper.
Check the valve clearance.
Valve clearance 7-2
Out of specification  Adjust.
Check the water pump housing.
Deformed  Replace.
Check the impeller, insert cartridge, and outer plate cartridge.
Water pump 8-4
Check the impeller key and keyway in the drive shaft.
Deformed/worn  Replace.
Wire harness
Check the wire harness coupler and lead coupler connections. —
Lead
(Yamaha)
Check the meter/gauge display. —
Meter/gauge
Check the fuel tank
Fuel tank (Yamaha Cracked/damage  Replace.
—
portable tank) Leaking  Check the related parts.
Dirt/residue  Clean.
10-13
Checking the engine idle speed/noise
1. Check:
• Engine idling speed a
Out of specification  Perform the trouble-
shooting procedures. See “Troubleshoot- 2
ing procedure” (4-3).
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the engine idle speed using the
YDIS. See the YDIS (Ver. 2.33 or later) in-
struction manual.
Idle speed (in neutral) Water inlet cover screw “3”

750–850 r/min 1.0 N·m (0.10 kgf·m, 0.73 lb·ft)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the cooling water inlet Changing the engine oil using an oil
1. Check: changer
• Cooling water inlet
Clogged  Clean.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Change the engine oil after the first 20
a. Remove the water inlet covers “1”. hours of operation or 3 months, and every
100 hours or at 1-year intervals thereafter.
b. Mark the trim tab “2” with an identification
mark “a”, and then remove the trim tab “2”.
1. Warm up:
• Engine
c. Check the water inlet covers and water in-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
lets. Clean if clogged.
d. Install the water inlet covers “1” and trim sition.
tab “2”, and then tighten the water inlet
cover screw “3” to the specified torque.
If the outboard motor is not level, the oil lev-
TIP: el indicated on the dipstick may not be cor-
After installing the water inlet covers “1”, make rect.
sure that there is no rattling.
b. Start the engine and warm it up for 5–10
minutes.
c. Stop the engine and leave it off for 5–10

1 minutes.
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3
2. Remove:
• Top cowling
10-14
3. Drain:
• Engine oil Engine oil quantity (without oil fil-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ter replacement)
a. Remove the oil filler cap “1”. 1.5 L (1.59 US qt, 1.32 Imp.qt)
b. Leave the outboard motor off for 5–10 min-

utes.
1
c. Remove the dipstick “1” and wipe it clean.
d. Insert the dipstick “1” completely for a cor-

e. Check that the oil level indicated on the

dipstick “1” is between the upper mark “a”
b. Remove the dipstick “1” and extract the
and the lower mark “b”.
engine oil using the oil changer “2”.
1
a
1
b
2
f. Start the engine and check that the oil

pressure alert indicator does not come on.
Also, check that there is no oil leakage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
If the oil pressure alert indicator comes on
4. Fill: or if there is oil leakage, stop the engine
• Recommended engine oil and find the cause. Continued operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ with a problem could cause severe engine
a. Fill the engine with the specified amount of damage.
the recommended engine oil through the
oil filler hole. Install the oil filler cap and dip- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
stick.
5. Install:
• Top cowling
Do not overfill the engine with engine oil.
Otherwise, the engine could be damaged or Changing the engine oil by removing
oil could leak. If the engine oil is above the the drain bolt
upper level, extract the excess engine oil
until the oil is at the proper level.
Change the engine oil after the first 20
hours of operation or 3 months, and every
100 hours or at 1-year intervals thereafter.
10-15
1. Warm up:
• Engine Drain bolt “2”
See step 1 in “Changing the engine oil us- 27 N·m (2.7 kgf·m, 20 lb·ft)
T.
R.
ing an oil changer” (10-14).
5. Fill:
2. Remove: • Recommended engine oil
• Top cowling ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the engine with the specified amount of
3. Drain: the recommended engine oil through the
• Engine oil oil filler hole. Install the oil filler cap.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the oil filler cap “1”.
Do not overfill the engine with engine oil.
Otherwise, the engine could be damaged or
oil could leak. If the engine oil is above the
1 upper level, extract the excess engine oil
Engine oil quantity (without oil fil-

ter replacement)
1.5 L (1.59 US qt, 1.32 Imp.qt)
b. Place a drain pan “1” under the engine oil
drain hole. b. Leave the outboard motor off for 5–10 min-
utes.
c. Remove the drain bolt “2”.
c. Remove the dipstick “1” and wipe it clean.
d. Insert the dipstick “1” completely for a cor-

2
e. Check that the oil level indicated on the
dipstick “1” is between the upper mark “a”
and the lower mark “b”.
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a
4. Install: 1
• Drain bolt “2”
b
10-16
f. Start the engine and check that the oil
pressure alert indicator does not come on.
Also, check that there is no oil leakage. 1
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
damage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Oil filter wrench “1”

90890-01426
6. Install:
• Top cowling
YB-01426
Replacing the oil filter
1. Warm up: b. Install a new oil filter “1”.
• Engine
See step 1 in “Changing the engine oil us-
ing an oil changer” (10-14).
2. Remove:
• Top cowling
3. Drain:
• Engine oil 1
See step 3 in “Changing the engine oil us-
ing an oil changer” (10-14) or step 2 in
Oil filter “1”
“Changing the engine oil by removing the
18 N·m (1.8 kgf·m, 13 lb·ft)
T.
drain bolt” (10-15).

R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP:
If the engine oil was changed by removing the 5. Fill:
drain bolt, install the drain bolt. See step 3 in • Recommended engine oil
“Changing the engine oil by removing the drain ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
bolt” (10-15). a. Fill the engine with the specified amount of
the recommended engine oil through the
oil filler hole. Install the oil filler cap.
4. Replace:
• Oil filter
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Do not overfill the engine with engine oil.
a. Place a rag under the oil filter, and then re- Otherwise, the engine could be damaged or
move the oil filter. oil could leak. If the engine oil is above the
upper level, extract the excess engine oil
TIP:
Make sure to clean up any oil spills.
Engine oil quantity (with oil filter

replacement)
1.7 L (1.80 US qt, 1.50 Imp.qt)
10-17
b. Install the oil filler cap and dipstick, and e. After the gear oil has been drained, check
then start the engine and warm it up for 5– the used oil. Pressure test the lower case
10 minutes. and inspect the oil seal for damage if the oil
is milky. See “Checking the lower unit for
c. Stop the engine, and then leave it off for 5– air leakage” (8-21).
10 minutes.
d. Check the oil level.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5
4
6. Install:
• Top cowling
3
2
Changing the gear oil
1
Never get under the lower unit while it is tilt-
ed.
1. Drain: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Gear oil
2. Fill:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Tilt the outboard motor so that the drain • Gear oil
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
screw is at the lowest point.
b. Place a drain pan “1” under the gear oil sition.
drain hole.
b. Insert the gear oil pump into the drain hole,
c. Remove the drain screw “2” and gasket and then fill the lower unit slowly with gear
“3”. oil until oil flows out of the check hole and
no air bubbles are visible.
If there is a significant amount of metal par- c. Install a new gasket “1” and the oil level
ticles on the magnetic drain screw, the low- plug “2”.
er unit may have a problem. 1
2
d. Remove the oil level plug “4” and gasket

“5” and let the oil drain completely.
After the gear oil has been drained, check

the used oil. If the oil is milky, water is get-
ting into the lower case, which can cause
gear damage.
10-18
Gear oil quantity

0.430 L (0.455 US qt, 0.378
Imp.qt)
Oil level plug “2”

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
d. Remove the gear oil pump, and then install

a new gasket “1” and the drain screw “2”.
TIP:
Before installing the magnetic drain screw,
make sure to remove all metal particles.
1 2
Drain screw “2”

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the gear oil level

1. Check the gear oil level. See “Checking
the gear oil level” (10-8).
Greasing points
1. Apply:
• Specified lubrication points
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply water resistant grease to the speci-
fied lubrication points.
10-19
b. Apply low temperature resistant grease to
the specified lubrication point.
c. Apply corrosion resistant grease to the

specified lubrication point.
4. Assemble the hydraulic steering cylinder
or steering cable to the through tube.
Checking the PTT fluid level
Never get under the outboard motor while it

is tilted.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1. Check:
• PTT fluid level
Greasing the clamp bracket bolt ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
(through tube) a. Fully tilt the outboard motor up, and then
1. Remove the hydraulic steering cylinder or support it using the tilt support knob “1”.
steering cable from the through tube.
2. Clean inside of the through tube and the

hydraulic steering cylinder rod or steering
cable. 1
3. Apply a sufficient amount of grease to the

inside of the through tube and to the hy-
draulic steering cylinder rod or steering ca-
ble.
10-20
b. Remove the reservoir cap “1” and O-ring Checking the cowling lock lever
“2”, and then check the fluid level in the 1. Check:
reservoir. • Top cowling fitting
Looseness/ratting  Adjust.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Before removing the reservoir cap, make a. Check the fitting by pushing the top cowl-
sure that the trim and tilt ram is fully ex- ing.
tended. Otherwise, fluid could be expelled
forcefully from the PTT unit due to internal
pressure.
TIP:
If the fluid is at the proper level, a small amount
of fluid should flow out of the filler hole when
the reservoir cap is removed.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• Top cowling fitting
Looseness/rattling  Replace the cowling
seal.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the nuts “1”.
2 1
b. Move the hook “2” up or down slightly to
c. If the fluid is below the proper level, add adjust its position.
the recommended fluid.
TIP:
d. Install a new O-ring and the reservoir cap, • To loosen the fitting, move the hook in direc-
and then tighten the reservoir cap to the tion “a”.
specified torque. • To tighten the fitting, move the hook in direc-
tion “b”.
Reservoir cap
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a
1
2
c. Tighten the nut.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
10-21
Appendix
Specification .......................................................................A-1
Wiring diagram .................................................................A-14

How to use the wiring diagram ................................................. A-14
Engine control unit, fuel unit, and ignition unit.......................... A-15
Charging unit, starting unit, and PTT unit................................. A-16
Control unit ............................................................................... A-17
Shim selection table and chart .......................................A-18

Pinion shim (T3) selection table ............................................... A-18
Forward gear shim (T1) selection chart.................................... A-19
Reverse gear shim (T2) selection chart ................................... A-19
A
Specification
Model data
Dimension and weight
F30BEHD F30BET F40FEHD F40FET
Model F30HA F40FED F40HA
F30EHA F30A F40EHA F40A
Overall length 1362 mm (53.6 in) 698 mm (27.5 in) 1362 mm (53.6 in) 698 mm (27.5 in)
Overall width 384 mm (15.1 in)
1228 mm (48.3 in) 1228 mm (48.3 in)
Overall height S — 1228 mm (48.3 in) (RUS) — 1228 mm (48.3 in)
(F30BET_EUR) (F40FEHD_EUR)
1350 mm (53.1 in)
1350 mm (53.1 in)
(F40EHA, F40FE-
Overall height L 1350 mm (53.1 in) (F30A, F30BET_CHN/ 1350 mm (53.1 in) (EUR) 1350 mm (53.1 in) —
HD_*EC2/EUR/NME/
EUR)
OTH)
414 mm (16.3 in) 414 mm (16.3 in)
Motor transom height S — 414 mm (16.3 in) (RUS) — 414 mm (16.3 in)
(F30BET_EUR) (F40FEHD_EUR)
536 mm (21.1 in)
536 mm (21.1 in) (F30A, (F40EHA, F40FE-
Motor transom height L 536 mm (21.1 in) 536 mm (21.1 in) (EUR) 536 mm (21.1 in) —
F30BET_CHN/EUR) HD_*EC2/EUR/NME/
OTH)
94 kg (207 lb) 98 kg (216 lb) (F40FEH-
Dry weight (AL) S — 91 kg (201 lb) (RUS) — 94 kg (207 lb)
(F30BET_EUR) D_EUR)
102 kg (225 lb) (F40EHA,
98 kg (216 lb) (F30A,
Dry weight (AL) L 102 kg (225 lb) 105 kg (231 lb) 95 kg (209 lb) (EUR) F40FEHD_*EC2/EUR/ 105 kg (231 lb) —
F30BET_CHN/EUR)
NME/OTH)
* Dry weight: With AL (aluminum) propeller
Performance
Rated power 22.1 kW (30 HP) 29.4 kW (40 HP)
Full throttle operating
5000–6000 r/min
range
Maximum fuel consump- 11.5 L/h at 5500 r/min (3.0 US gal/h at 5500 r/min, 2.5 Imp.gal/h at 5500
13.6 L/h at 5500 r/min (3.6 US gal/h at 5500 r/min, 3.0 Imp.gal/h at 5500 r/min)
tion (reference data) r/min)
Idle speed (in neutral) 750–850 r/min
Power unit
Type 4-stroke SOHC L3 6 valves
Total displacement 747 cm³ (45.6 c.i.)
Bore  stroke 65.0  75.0 mm (2.56  2.95 in)
Compression ratio 9.4 : 1
Throttle & shift control
Handle gear shift & grip handle Remote control Handle gear shift & grip handle Remote control
system
Starting system Electric starter
Fuel system Fuel injection
A-1
Starting carburetion sys-
Fuel injection
tem
Ignition system CDI
Advance type Microcomputer
Maximum generator out-
17 A
put
Maximum charging
13 A
capacity
Spark plug (NGK) DPR6EB-9
Firing order 1-2-3
Steering system Tiller handle Remote steering Tiller handle Remote steering
Cooling system Water
Exhaust system Through propeller boss
Lubrication system Wet sump
Lower unit
Gear shift positions Forward-neutral-reverse
Gear ratio 2.00 (26/13)
Gear type Spiral bevel gear
Clutch type Dog clutch
Propeller fitting mecha-
Spline
nism
Propeller direction (rear
Clockwise
view)
Propeller mark G
Bracket unit
Trim angle -3 ~ +9  -3 ~ +16  -3 ~ +9  -3 ~ +16 
Full Tilt-up angle 65  66  65  66 
Tilt support angle 54 
Steering angle 40+40 
Trim and tilt system Hydro tilt Power trim and tilt Hydro tilt Power trim and tilt
Fuel and oil

Regular unleaded gas-
Regular unleaded gas-
oline (F40A,
oline (EUR)
Recommended fuel Regular unleaded gasoline Regular unleaded gasoline F40FET_EUR)
Unleaded gasoline
Unleaded gasoline
(RUS)
(F40FET_RUS)
A-2
Min. research octane
90
number (RON)
Min. pump octane num- 86 (F40EHA, F40FE-
86 (F30EHA) 86 86 (F30A) — 86 86 (F40A)
ber (PON) HD_*EC2)
YAMALUBE 4 or 4- YAMALUBE 4 or 4- YAMALUBE 4 or 4- YAMALUBE 4 or 4-
stroke outboard motor stroke outboard motor stroke outboard motor stroke outboard motor
YAMALUBE 4M FC-W YAMALUBE 4 or 4- YAMALUBE 4M FC-W
Recommended engine oil (F30BEHD) oil (F30BET) oil (F40FEHD) oil (F40FET)
or 4-stroke outboard stroke outboard motor or 4-stroke outboard
oil YAMALUBE 4M FC-W YAMALUBE 4M FC-W YAMALUBE 4M FC-W YAMALUBE 4M FC-W
motor oil oil motor oil
or 4-stroke outboard or 4-stroke outboard or 4-stroke outboard or 4-stroke outboard
motor oil (F30EHA) motor oil (F30A) motor oil (F40EHA) motor oil (F40A)
Recommended engine SAE 10W-30/10W-40/5W-30
oil grade 1 API SE/SF/SG/SH/SJ/SL
Recommended engine SAE 15W-40/20W-40/20W-50
oil grade 2 API SH/SJ/SL
Engine oil quantity (total
1.9 L (2.01 US qt, 1.67 Imp.qt)
amount)
Engine oil quantity (with-
1.5 L (1.59 US qt, 1.32 Imp.qt)
out oil filter replacement)
Engine oil quantity (with
1.7 L (1.80 US qt, 1.50 Imp.qt)
oil filter replacement)
YAMALUBE outboard YAMALUBE outboard
YAMALUBE outboard YAMALUBE outboard
gear oil or Hypoid gear gear oil or Hypoid gear
gear oil or Hypoid gear gear oil or Hypoid gear
oil (F30BEHD) Yamalube Marine YAMALUBE outboard oil (F40FEHD) Yamalube Marine
oil (F30BET) oil (F40FET)
Recommended gear oil Yamalube Marine Gearcase Lube or gear oil or Hypoid gear Yamalube Marine Gearcase Lube or
Yamalube Marine Yamalube Marine
Gearcase Lube or Hypoid gear oil oil Gearcase Lube or Hypoid gear oil
Gearcase Lube or Gearcase Lube or
Hypoid gear oil Hypoid gear oil
Hypoid gear oil (F30A) Hypoid gear oil (F40A)
(F30EHA) (F40EHA)
Recommended gear oil
SAE 90 API GL-4
grade
Gear oil quantity 0.430 L (0.455 US qt, 0.378 Imp.qt)
* Recommended engine oil and gear oil grade: Meeting both API and SAE requirements.
Battery requirement
Battery rating (CCA/ 380–1150 A (F40EHA,
380–1150 A (F30EHA) 380–1150 A 380–1150 A (F30A) — 380–1150 A 380–1150 A (F40A)
SAE) F40FEHD_*EC2)
Battery rating (MCA/ 502–1370 A (F40EHA,
502–1370 A (F30EHA) 502–1370 A 502–1370 A (F30A) — 502–1370 A 502–1370 A (F40A)
ABYC) F40FEHD_*EC2)
124 minutes (F40EHA,
Battery rating (RC/SAE) 124 minutes (F30EHA) 124 minutes 124 minutes (F30A) — 124 minutes 124 minutes (F40A)
F40FEHD_*EC2)
Battery rating (CCA/EN) 430–1080 A
Battery rating (20HR/
70 Ah
IEC)
A-3
1.64 m (5.4 ft) 1.64 m (5.4 ft)
1.64 m (5.4 ft) 1.64 m (5.4 ft)
(F30BEHD) (F40FEHD)
Battery cable length 2.24 m (7.3 ft) (F30BET) 1.64 m (5.4 ft) 2.24 m (7.3 ft) (F40FET)
2.24 m (7.3 ft) 2.24 m (7.3 ft)
2.24 m (7.3 ft) (F30A) 2.24 m (7.3 ft) (F40A)
(F30EHA) (F40EHA)
Battery cable conductor
15 mm² (AWG 5)
cross sectional area
PTT system
ATF Dexron II ATF Dexron II
(F30BET) (F40FET)
Recommended fluid — Power Trim and Tilt — Power Trim and Tilt
Power Trim and Tilt Power Trim and Tilt
fluid or ATF Dexron II fluid or ATF Dexron II
fluid or ATF Dexron II fluid or ATF Dexron II
(F30A) (F40A)
Electrical system technical data

Ignition timing control system
Spark plug
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)
Cap resistance 5.0 k
Ignition coil
Primary coil resistance 0.180–0.240 
Secondary coil resis-
3.26–4.88 k
tance
Pulser coil
Air gap 0.35–1.35 mm (0.014–0.053 in)
Resistance 152.0–228.0 
Output peak voltage at
cranking (unloaded) (ref- 5.0 V
erence data)
cranking (loaded) (refer- 2.7 V
ence data)
cranking (loaded) (refer- 6.5 V
ence data)
1500 r/min (loaded) (ref- 9.8 V
erence data)
A-4
Ignition timing
Idle speed (in neutral) ATDC7.0  ATDC8.0 
Rated speed BTDC20.0 
Intake air pressure sensor
Input voltage 5V
Thermo sensor
Resistance at 20 C (68
2.49 k
F)
Resistance at 60 C (140
0.589 k
F)
Resistance at 100 C
0.193 k
(212 F)
Shift position switch
Input voltage 12 V
Fuel injection control system

Water detection switch
Input voltage 5V
Fuel injector
Input voltage 12 V
Resistance (reference
12.00 
data)
High-pressure fuel pump
Input voltage 12 V
1.4–1.7 
data)
Vapor shut-off valve
Input voltage 12 V
Resistance 30.0–34.0 
A-5
Engine speed control system
TPS
Throttle valve opening
angle at throttle valve
0.10 
fully closed (reference
data)
Throttle valve opening
angle at throttle valve
75.3 
fully open (reference
data)
Input voltage 5V
Oil pressure switch
Input voltage 12 V
Working pressure 29.40–58.80 kPa (0.294–0.588 kgf/cm², 4.26–8.53 psi)
PTT system
Trim sensor
Free position resistance — 239–379  — 239–379 
Setting resistance — 9–11  — 9–11 
Charging system
Lighting coil
cranking (unloaded) (ref- 14.0 V
erence data)
1500 r/min (unloaded) 45.0 V
(reference data)
3500 r/min (unloaded) 102.0 V
(reference data)
0.5610–0.7590 
data)
Rectifier/Regulator
Output voltage at 1500 r/
min (unloaded) (refer- 13 V
ence data)
Output voltage at 3500 r/
min (unloaded) (refer- 13 V
ence data)
A-6
Starting system
Starter motor
Type Sliding gear
Output 0.90 kW
Cranking time limit 30 sec
Standard brush length 12.3 mm (0.48 in)
Wear limit 5.5 mm (0.22 in)
Standard commutator
29.4 mm (1.16 in)
diameter
Standard commutator
0.5 mm (0.02 in)
undercut
Y-COP
Receiver
Input voltage 12 V
Buzzer
Input voltage 12 V
Button cell battery - CR2016
Battery voltage (refer-
3V
ence data)
Gauge/sensor
Water pressure sensor
Input voltage 5V
Output voltage at 392
kPa (3.92 kgf/cm², 56.8 2.5 V
psi) (reference data)
kPa (7.84 kgf/cm², 113.7 4.5 V
Speed sensor
Input voltage 5V
kPa (3.9 kgf/cm², 57 psi) 2.5 V
(reference data)
kPa (7.8 kgf/cm², 114 4.5 V
A-7
Fuel system technical data
Fuel system
Fuel line
Fuel pressure at engine
start switch to “ON” 280 kPa (2.8 kgf/cm², 40.6 psi)
within 3 seconds
Fuel pressure at engine
230 kPa (2.3 kgf/cm², 33.4 psi)
idle speed
Primer pump
Positive pressure 170.0 kPa (1.70 kgf/cm², 24.7 psi)
Fuel joint
Holding pressure (posi-
50.0 kPa (0.5 kgf/cm², 7.25 psi)
tive pressure)
Fuel strainer
Holding pressure (posi-
200.0 kPa (2.0 kgf/cm², 29.00 psi)
tive pressure)
Fuel filter assembly
Fuel inlet holding pres-
200 kPa (2.0 kgf/cm², 29.0 psi)
sure (positive pressure)
Fuel outlet holding pres-
80 kPa (0.8 kgf/cm², 11.6 psi)
sure (negative pressure)
Fuel pump
50.0 kPa (0.50 kgf/cm², 7.3 psi)
30.0 kPa (0.3 kgf/cm², 4.4 psi)
sure (negative pressure)
Fuel outlet holding pres-
50.0 kPa (0.50 kgf/cm², 7.3 psi)
Vapor separator tank
Float height 40.7–42.7 mm (1.60–1.68 in)
Power unit technical data

Power unit
Compression pressure
Minimum (reference
840.0 kPa (8.40 kgf/cm², 121.8 psi)
data)
A-8
Engine oil
Engine oil pressure at
idle speed (reference 230.0 kPa (2.30 kgf/cm², 33.4 psi)
data)
Engine oil pressure at
3000 r/min (reference 480.0 kPa (4.80 kgf/cm², 69.6 psi)
data)
* For the checking method, see “Checking the oil pressure” (7-1). The figures are for reference only.
Thermostat
Valve opening tempera-
58–62 C (136–144 F)
ture
Fully open temperature 70 C (158 F)
Fully open stroke 3.0 mm (0.12 in)
Cylinder head assembly

Cylinder head
Warpage limit 0.10 mm (0.0039 in)
Journal inside diameter 37.000–37.025 mm (1.4567–1.4577 in)
Camshaft
Cam lobe height IN 30.737–30.837 mm (1.2101–1.2141 in)
Limit 30.587 mm (1.2042 in)
Cam lobe height EX 30.933–31.033 mm (1.2178–1.2218 in)
Limit 30.783 mm (1.2119 in)
Journal diameter 36.925–36.945 mm (1.4537–1.4545 in)
Runout 0.030 mm (0.0012 in)
Valve clearance
Valve clearance IN (cold
0.15–0.25 mm (0.0059–0.0098 in)
engine)
Valve clearance EX
0.25–0.35 mm (0.0098–0.0138 in)
(cold engine)
Valve
Margin thickness IN 0.80–1.20 mm (0.0315–0.0472 in)
Margin thickness EX 1.00–1.40 mm (0.0394–0.0551 in)
Seat contact width IN 1.20–1.60 mm (0.0472–0.0630 in)
Limit 2.050 mm (0.0807 in)
Seat contact width EX 1.20–1.60 mm (0.0472–0.0630 in)
Limit 2.050 mm (0.0807 in)
A-9
Valve stem
Diameter IN 5.475–5.490 mm (0.2156–0.2161 in)
Limit 5.445 mm (0.2144 in)
Diameter EX 5.460–5.475 mm (0.2150–0.2156 in)
Limit 5.430 mm (0.2138 in)
Runout limit IN 0.01 mm (0.0004 in)
Runout limit EX 0.01 mm (0.0004 in)
Valve guide
Inside diameter IN 5.500–5.512 mm (0.2165–0.2170 in)
Clearance IN 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.070 mm (0.0028 in)
Inside diameter EX 5.500–5.512 mm (0.2165–0.2170 in)
Clearance EX 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.070 mm (0.0028 in)
Installation height 16.30–16.70 mm (0.6417–0.6575 in)
Valve spring
Free length IN 39.85 mm (1.57 in)
Limit 37.86 mm (1.49 in)
Tilt limit IN 1.7 mm (0.07 in)
Free length EX 39.85 mm (1.57 in)
Limit 37.86 mm (1.49 in)
Tilt limit EX 1.7 mm (0.07 in)
Rocker arm shaft
Outside diameter IN 15.971–15.991 mm (0.6288–0.6296 in)
Outside diameter EX 15.971–15.991 mm (0.6288–0.6296 in)
Rocker arm
Inside diameter IN 16.000–16.018 mm (0.6299–0.6306 in)
Inside diameter EX 16.000–16.018 mm (0.6299–0.6306 in)
Crankcase assembly
Cylinder
Bore 65.000–65.015 mm (2.5591–2.5596 in)
Limit 65.100 mm (2.5630 in)
Piston
Diameter 64.950–64.965 mm (2.5571–2.5577 in)
Limit 64.910 mm (2.5555 in)
A-10
1st oversize diameter 65.200–65.215 mm (2.5669–2.5675 in)
2nd oversize diameter 65.450–65.465 mm (2.5768–2.5774 in)
Measuring point 5.0 mm (0.20 in)
Piston clearance 0.035–0.065 mm (0.0014–0.0026 in)
Limit 0.115 mm (0.0045 in)
Ring groove (Top) 1.21–1.23 mm (0.0476–0.0484 in)
Ring groove (2nd) 1.51–1.53 mm (0.0594–0.0602 in)
Ring groove (Oil) 2.52–2.54 mm (0.0992–0.1000 in)
Pin boss inside diameter 15.974–15.985 mm (0.6289–0.6293 in)
Limit 16.005 mm (0.6301 in)
Pin outside diameter 15.965–15.970 mm (0.6285–0.6287 in)
Limit 15.955 mm (0.6281 in)
Piston ring (Top)
Type Barrel
Height (B) 1.170–1.190 mm (0.0461–0.0469 in)
Width (T) 2.300–2.500 mm (0.0906–0.0984 in)
End gap 0.15–0.30 mm (0.0059–0.0118 in)
Limit 0.500 mm (0.0197 in)
End gap measuring
10.0 mm (0.39 in)
point
Side clearance 0.02–0.06 mm (0.0008–0.0024 in)
Limit 0.110 mm (0.0043 in)
Piston ring (2nd)
Type Taper
Height (B) 1.470–1.490 mm (0.0579–0.0587 in)
Width (T) 2.600–2.800 mm (0.1024–0.1102 in)
End gap 0.30–0.50 mm (0.0118–0.0197 in)
Limit 0.700 mm (0.0276 in)
Limit 0.110 mm (0.0043 in)
Piston ring (Oil)
Height (B) 2.360–2.480 mm (0.0929–0.0976 in)
Width (T) 2.750 mm (0.1083 in)
End gap 0.20–0.70 mm (0.0079–0.0276 in)
A-11
Connecting rod
Small end inside diame-
15.985–15.998 mm (0.6293–0.6298 in)
ter
Big end inside diameter 36.000–36.024 mm (1.4173–1.4183 in)
Big end side clearance 0.050–0.220 mm (0.0020–0.0087 in)
Limit 0.27 mm (0.0106 in)
Big end oil clearance 0.016–0.040 mm (0.0006–0.0016 in)
Limit 0.070 mm (0.0028 in)
Crankshaft
Journal diameter 42.984–43.000 mm (1.6923–1.6929 in)
Crankshaft pin diameter 32.984–33.000 mm (1.2986–1.2992 in)
Runout 0.03 mm (0.0012 in)
Limit 0.04 mm (0.0016 in)
Crankshaft pin width 21.00–21.07 mm (0.8268–0.8295 in)
Journal oil clearance 0.012–0.036 mm (0.0005–0.0014 in)
Limit 0.066 mm (0.0026 in)
Lower unit technical data

Lower unit assembly
Lower unit
Holding pressure 68.6 kPa (0.69 kgf/cm², 9.9 psi)
Gear backlash
Forward gear backlash 0.18–0.65 mm (0.0071–0.0256 in)
Reverse gear backlash 0.75–1.22 mm (0.0295–0.0480 in)
* Figures obtained using the special service tools.
Available shim thicknesses
Pinion shims 0.10/0.12/0.15/0.18/0.30/0.40/0.50 mm
Forward shims 0.10/0.12/0.15/0.18/0.30/0.40/0.50 mm
Reverse shims 0.10/0.12/0.15/0.18/0.30/0.40/0.50 mm
Propeller shaft
Runout 0.02 mm (0.0008 in)
Drive shaft
Runout 0.5 mm (0.020 in)
A-12
Bracket unit technical data
PTT system
Hydraulic pressure
Up — 5.40 Mpa (54.0 kgf/cm², 783.0 psi) — 5.40 Mpa (54.0 kgf/cm², 783.0 psi)
Down — 2.00 Mpa (20.0 kgf/cm², 290.0 psi) — 2.00 Mpa (20.0 kgf/cm², 290.0 psi)
Motor
Standard commutator
— 17.60 mm (0.6929 in) — 17.60 mm (0.6929 in)
diameter
Wear limit — 16.60 mm (0.6535 in) — 16.60 mm (0.6535 in)
Standard commutator
— 1.50 mm (0.0591 in) — 1.50 mm (0.0591 in)
undercut
Standard brush length — 7.00 mm (0.2756 in) — 7.00 mm (0.2756 in)
A-13
Wiring diagram
Wiring diagram
How to use the wiring diagram
Composition of the wiring diagrams
The wiring diagram consists of three categories; “Engine control unit, fuel unit, and ignition unit”,
“Charging unit, starting unit, and PTT unit”, and “Control unit”.
Legend symbols in the wiring diagrams

1 2 3
4 5 6
BZ
1. Double colors wire
2. Not used (vacant)
3. A wire is not included in the selected wiring unit.
4. Alert buzzer
5. Optional parts
6. Continuity
Terminal numbers
• Terminal numbers are indicated for cases where terminal locations of wires are unclear.
• In the coupler illustrations, only the rightmost and leftmost terminal numbers are indicated, and termi-
nal numbers between them are omitted.
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
4 1
8 5
12 9
16 13
A-14
Jul. 2018 ABE
(E)
Engine control unit, fuel unit, and ignition unit 1. Engine ECM
2. Thermo sensor
B R
B
B R
R 3. Pulser coil
a R
B
R R 5. Ignition coil
R
A 6. Water detection switch
Br
14. Starter motor
18. Battery b 7. Shift position switch
17. PTT relay R R 16. Main relay
R Br
8. Fuel injector
Br 9. Vapor shut-off valve
c B
R R 10. High-pressure fuel pump
1
3
4
5
6
7
8
Br
15. Starter relay
11. Throttle body
R
R
L
L
Y/G
R/Y
R/Y
B
W
R
Y
Br
P
B
14. Starter motor
R/Y 1
2
15. Starter relay
R/Y 1 13
R/B 3 16. Main relay
R/Y 4
R/Y 5
R/Y 6 17. PTT relay
18. Battery
18 1
a. Fuse (20A) (engine start switch, PTT
6 P switch)
b. Fuse (30A) (main relay)
9 B/Y
10 B/Y
B
B 20
21
c. Fuse (20A) (starter relay)
B 22 12 24
13 W B 23
14 L/W B 24 A. To tiller handle/remote control
15 G
16
17 B
G/Y
B. To YDIS
18 W/B
1
23 P/G
24 Or
26 B B 1
B 2
28 P/W B 3
B 4
30 L/G
31 G
34 17 32 G/B
33 G/R
34 W/R B 10
B 11
44 35
36 Y
12
B
L
39 B
40 P
41 B/Y 12. Joint connector 1
42 B/W
1. Engine ECM 43 B/Or
44 L
45 Y/G
46 R/Y
48 B
49 G/B
50 Pu/Y
P/G
G/R
G/B
G/Y
B/Y
51 Pu/B
Or
B
L
G
P
B
52 Pu/R
52 43
B/Y
Pu/R
Pu/B
Pu/Y
B/Or
W/R
B/W
B
R/Y
R/Y
R/Y
L/G
B/Y
W/B
R/B
B
B
L/W
B
G/B
R/Y
#1 #2 #3 #1 #2 #3
P/W
B
7. Shift position switch 8. Fuel injector
3. Pulser coil
2. Thermo sensor 9. Vapor shut-off valve 11. Throttle body
4. Oil pressure switch 5. Ignition coil 6. Water detection switch
A-15
Charging unit, starting unit, and PTT unit 1. Engine ECM
2. Speed sensor
B
B 3. Water pressure sensor
Sb
Lg
B 11. Stator assembly 4. PTT motor
R
9. Starter motor 5. PTT switch
a
R
R
6. Trim sensor
G
G
G
R R
R
B
Sb 7. Joint connector 1
15. Battery Lg b R 8. Joint connector 2
B
R R 9. Starter motor
R
10. Starter relay
Br
13. Main relay
c 13. Main relay
R R 11. Stator assembly
14. PTT relay
B
1
3
4
5
6
7
L
R Br
Br
B 13. Main relay
R
R
L
Y/G
R/Y
R/Y
10. Starter relay 14. PTT relay
Br
A 15. Battery
B
R/Y 1
3
a. Fuse (20A) (engine start switch, PTT
R/B
switch)
b. Fuse (30A) (main relay)
W
R
Y
Sb
Br
Lg
P
B
18 1 Lg
Lg 9
10 c. Fuse (20A) (starter relay)
Lg 11
3 W Lg 12 d. Diode (connect to PTT relay)
4 L Or 13
Or 14
Or 15
7 Or Sb
Sb
16
17
A. To tiller handle/remote control
8 L Sb 18 B. To YDIS
Sb 19
12 W/L C. To trolling switch
13 W
d
B Lg B 24 D. To multi-hub
Sb E. To alert indicator (tiller handle/digital
17 B
18 W/B tachometer)
1
F. To conventional gauge (6Y5/6Y7)
25 L/B *1. If the 6Y8/6YC multifunction meter is

26 B selected, connect the coupler.
27 P
B 5
29 Or/W 6
B 7
31 G B 8
17 B 9
34
B 11
44 35
36 Y
12
38 P/W
39 B
40 P 7. Joint connector 1
1. Engine ECM
44 L
45 Y/G
46 R/Y
47 P/B
48 B
L/B
Sb
Lg
Or
Or
P/W
R
P/B
P/B
B
B
L
P
B
P
Or/W
W/B
W/L
R/B
P
52 43
W
L
B
B
*1
C E
D
B
5. PTT switch
2. Speed sensor 3. Water pressure 6. Trim sensor
4. PTT motor
sensor
A-16
Control unit 1. 703 side mount remote control
1. 703 side mount remote control 14. Switch panel (6R5-82570-06)
2. Engine start switch 4. PTT switch 2. Engine start switch
4. PTT switch
W B R Y Br 3. Engine shut-off switch Sb R Lg W B R Y Br 3. Engine shut-off switch 5. ON
5. ON W B 10. UP 5. ON
6. OFF 8. Clip removed
W B 6. OFF
11. Free 6. OFF 8. Clip removed
7. START 9. Clip installed 12. DN 7. START 9. Clip installed 7. START
16. Main wire harness 8. Clip removed
W
W
R
Lg
Br
B
Sb
Y
Y
Br
B
B
W
R A 9. Clip installed
Y Y
B G 10. UP
Lg
Sb
R
BZ W W
11. Free
W
P
B
Br P
R R R L 12. DN
Y Y L
G G B R R
B 13. Neutral switch
B B
W G G Br
Sb B 14. Switch panel (6R5-82570-06)
P P A 15. 704 binnacle mount remote control
Y
Y L
Lg 15. 704 binnacle mount remote control
Br L 4. PTT switch
B B 16. Main wire harness
Br Br Sb R Lg
10. UP 17. Tiller handle (PTT model)
13. Neutral switch 11. Free
18. Trolling switch
12. DN
Y P
19. Tiller handle (Hydro tilt model)
BZ
Lg
Sb
R
Sb
R Lg
Lg R A. To power unit
Sb Br
Br Br Br B. To gauge
Br Br B
13. Neutral switch
17. Tiller handle (PTT model) 17. Tiller handle (Hydro tilt model)
4. PTT switch 2. Engine start switch 3. Engine shut-off switch 18. Trolling switch 2. Engine start switch 3. Engine shut-off switch 18. Trolling switch
Sb R Lg W B R Y Br W B W/L B Or /W W B R Y Br W B W/L B Or /W
10. UP 5. ON 8. Clip removed 10. UP 5. ON 8. Clip removed 10. UP
11. Free 6. OFF 9. Clip installed 11. Free 6. OFF 9. Clip installed 11. Free
12. DN 7. START 12. DN 7. START 12. DN
W
W
B
B
Sb
R
Lg
Br
Br
R
W
R
W
R
R
B
B
B
B
Y
Y
Y
Y
Or/W Or/W
B A B A
W/L W/L
W
W
B
B
G R G R
R Y R Y
Y Y
Lg G Lg G
P W P W
Sb Sb A Sb Sb A
B P B P
P
P
Br Lg Br Lg
W B W B
Br Br
P
P
L Br G L Br G
B Br B B Br B
R B R B
BZ R BZ R
Y Y
Y Y Y Y
13. Neutral switch Y Y 13. Neutral switch Y Y
Gy Gy
P/B P P/B P
P/W G /R A P/W G/R A
G G
A-17
Shim selection table and chart
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 0.17 0.18 0.19 0.20 0.21 0.22 0.23 0.24 0.25 0.26 0.27 0.28 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 0.39 0.40 0.41 0.42 0.43 0.44 0.45 0.46 0.47 0.48
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 0.42 0.45 0.45 0.45 0.48 0.48 0.48 0.50 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75
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 0.45 0.45 0.45 0.48 0.48 0.48 0.50 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75
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 0.45 0.45 0.48 0.48 0.48 0.50 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 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 0.35 0.35 0.35 0.38 0.38 0.38 0.40 0.40 0.42 0.42 0.45 0.45 0.45 0.48 0.48 0.48 0.50 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78
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 0.48 0.48 0.48 0.50 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78
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 0.48 0.48 0.50 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78
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 0.48 0.50 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80
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 0.50 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80
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 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 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 0.40 0.40 0.42 0.42 0.45 0.45 0.45 0.48 0.48 0.48 0.50 0.50 0.52 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82
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 0.52 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85
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 0.55 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85
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 0.55 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85 0.85
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 0.55 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85 0.85 0.88
–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 0.58 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85 0.85 0.88 0.88
–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 0.58 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85 0.85 0.88 0.88 0.88
–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 0.58 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85 0.85 0.88 0.88 0.88 0.90
–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 0.60 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85 0.85 0.88 0.88 0.88 0.90 0.90
–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 0.60 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85 0.85 0.88 0.88 0.88 0.90 0.90 0.92
–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 0.62 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85 0.85 0.88 0.88 0.88 0.90 0.90 0.92 0.92
–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 0.62 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85 0.85 0.88 0.88 0.88 0.90 0.90 0.92 0.92 0.95
–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 0.65 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85 0.85 0.88 0.88 0.88 0.90 0.90 0.92 0.92 0.95 0.95
–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 0.65 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85 0.85 0.88 0.88 0.88 0.90 0.90 0.92 0.92 0.95 0.95 0.95
–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 0.65 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85 0.85 0.88 0.88 0.88 0.90 0.90 0.92 0.92 0.95 0.95 0.95 0.98
–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 0.68 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85 0.85 0.88 0.88 0.88 0.90 0.90 0.92 0.92 0.95 0.95 0.95 0.98 0.98
–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 0.68 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85 0.85 0.88 0.88 0.88 0.90 0.90 0.92 0.92 0.95 0.95 0.95 0.98 0.98 0.98
–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 0.68 0.70 0.70 0.72 0.72 0.75 0.75 0.75 0.78 0.78 0.78 0.80 0.80 0.82 0.82 0.85 0.85 0.85 0.88 0.88 0.88 0.90 0.90 0.92 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-18
Forward gear shim (T1) selection chart
1.10
1.00
0.90
0.80
0.70
0.60
0.50
B (mm)
0.40
0.30
0.20
0.10
0
–0.10
–0.20
–0.30
–0.40
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
A (1/100 mm)
A 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
B –0.23 –0.20 –0.17 –0.15 –0.12 –0.09 –0.07 –0.04 –0.01 0.01 0.04 0.07 0.09 0.12 0.15 0.17 0.20 0.23 0.25 0.28 0.31 0.33 0.36 0.39 0.41 0.44 0.47 0.49 0.52 0.55 0.57 0.60 0.63 0.65 0.68 0.71 0.73 0.76 0.79 0.81 0.84

Reverse gear shim (T2) selection chart

0.70
0.60
0.50
0.40
0.30
0.20
B (mm)
0.10
0
–0.10
–0.20
–0.30
–0.40
–0.50
–0.60
–0.70
–0.80
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
A (1/100 mm)
A 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200
B –0.53 –0.50 –0.47 –0.45 –0.42 –0.39 –0.37 –0.34 –0.31 –0.29 –0.26 –0.23 –0.21 –0.18 –0.15 –0.13 –0.10 –0.07 –0.05 –0.02 0.01 0.03 0.06 0.09 0.11 0.14 0.17 0.19 0.22 0.25 0.27 0.30 0.33 0.35 0.38 0.41 0.43 0.46 0.49 0.51 0.54

A-19
Worldwide:
(6BT)
(6BG)
USA, CAN, AUS, and NZL:

(6BT)
(6BG)
6BG-28197-ZX-11
LIT-18616-03-84
6BG-28197-ZX-11
LIT-18616-03-84
Jul. 2018 ABE
(E)

F30A-F40A Service Manual

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F30A-F40A Service Manual

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Copyright:

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Worldwide:

USA, CAN, AUS, and NZL:

Model information .............................................................. 0-1

Important safety and service information........................ 0-4

How to use this manual ..................................................... 0-7

Specified tightening torque............................................... 0-9

Symbol .............................................................................. 0-10

Special service tool.......................................................... 0-12

USA, CAN, AUS, and NZL

Model name designation

1 Model category F: 4-stroke

Level 2: Control method

Level 3: Trim and tilt method

1 Model category F: 4-stroke

a. Power unit c. Bracket unit

Important safety and service in- Handling of gasoline

Hot parts Ventilation

Parts, lubricants, and sealants

Handling of lubricants and sealants

• During disassembly, cover all openings,

Disposal of used components and

How to use this manual

2nd: 34 N·m (3.4 kgf·m, 25 lb·ft)

Specified tightening torque

General tightening torque

Special tool Tightening torque

Electrical data Replace the part with a new one.

Lubricant, sealant, and thread locking agent

YAMALUBE 4 or YAMALUBE 4M FC-W Lubricant

YAMALUBE outboard gear oil or Yamalube Ma-

ThreeBond 1104J Sealant

ThreeBond 1322D Thread locking agent

ThreeBond 1342J Thread locking agent

Symbol Name Application

ThreeBond 1377B Thread locking agent

ThreeBond 1901 Lubricant

LOCTITE 242 (blue) Thread locking agent

LOCTITE 271 (red) Thread locking agent

LOCTITE 572 (white) Sealant

Special service tool

Vacuum/pressure Test harness (3 pins) Test harness Ignition checker (Spark

Flywheel holder Flywheel puller Crankshaft holder 16 Valve spring compres-

Cylinder end screw

Pressure/vacuum tes- Test harness (3 pins) Test harness Spark checker

Fuel pressure gauge Combination compres- Flywheel magneto Universal Puller

Pinion gear bushing in- Driveshaft needle Trim cylinder wrench

Specification data .............................................................. 1-1

External dimensions .......................................................... 1-1

29 (1.1) 522 (20.6)

*1. Motor transom height

29 (1.1) 522 (20.6)

*1. Motor transom height

192 (7.6) 364 (14.3)

*1. Motor transom height

*1. Motor transom height

29 (1.1) 522 (20.6)

*1. Motor transom height

192 (7.6) 364 (14.3)

*1. Motor transom height

192 (7.6) 364 (14.3)

*1. Motor transom height

Clamp bracket dimensions

180 (7.1) 180 (7.1)

163.5 (6.4) 163.5 (6.4) 69 (2.7)