Page 1 F150A FL150A F150B FL150B SERVICE MANUAL 63P-28197-3P-12...
Page 2: Specification
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...
Page 3: Table Of Contents
Contents General information Specification Technical feature and description Rigging information Troubleshooting Electrical system Fuel system Power unit Lower unit Bracket unit Maintenance Index Appendix...
Page 5: General Information
General information Safety while working ............ 0-1 Rotating part ................0-1 Hot part ..................0-1 Electric shock ................0-1 Propeller ..................0-1 Handling of gasoline ..............0-1 Ventilation .................. 0-1 Self-protection ................0-2 Working with crane ..............0-2 Handling of gas torch ..............0-2 Part, lubricant, and sealant ............
Page 6: Safety While Working
Safety while working Safety while working Handling of gasoline • Gasoline is highly flammable. Keep gaso- To prevent an accident or injury and to pro- line and all flammable products away from vide quality service, observe the following heat, sparks, and open flames. safety procedures.
Page 7: Self-Protection
Yamaha, when servicing or repairing the out- • If the outboard motor does not have three board motor. or more points to be suspended, support it...
Page 8: Handling Of Sealant
Safety while working Handling of sealant Non-reusable part • Wear protective gloves to protect your skin, Always use new gaskets, seals, O-rings, cot- when using the sealants. ter pins, and so on, when installing or assem- • See the material safety data sheet issued bling parts.
Page 9: How To Use This Manual
How to use this manual How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the following information as a guide for effective and quality service. •...
Page 10: Abbreviation
PORT Port side Power Trim and Tilt Reverse Research Octane Number Society of Automotive Engineers Shift Dampener System STBD Starboard side Transistor-Controlled Ignition Top Dead Center Throttle Position Sensor Up side Y-COP Yamaha Customer Outboard Protection YDIS Yamaha Diagnostic System...
Page 11: Lubricant, Sealant, And Thread Locking Agent
Lubricant, sealant, and thread locking agent Symbol Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication points. Symbol Name Application Yamaha 4-stroke motor oil Lubricant Hypoid gear oil Lubricant Water resistant grease Lubricant (Yamaha grease A)
Page 12 Lubricant, sealant, and thread locking agent Symbol Name Application ThreeBond 1401 Thread locking agent ThreeBond 1530D Sealant LOCTITE 271 (red) Thread locking agent LOCTITE 242 (blue) Thread locking agent LOCTITE 572 (white) Sealant Silicone sealant Sealant...
Page 13: Special Service Tool
Special service tool Special service tool For all markets except U.S.A. and Canada. Special service tools with part numbers 90890-06883 and FIM20000ME are distributed by the Marine Service Division. Special service tools with part numbers other than 90890-06883 and FIM20000ME are distributed by the Parts Division.
Page 14 Special service tool Test harness (3 pins) Fuel pressure gauge 90890-06846 90890-06753 Ignition tester (spark gap tester) Leakage tester 90890-06754 90890-06840 Test harness (2 pins) Small end bearing installer 90890-06792 90890-06528 Test harness (3 pins) Vacuum gauge 90890-06791 90890-03159 Test harness (2 pins) Fuel injection meter 90890-06867 FIM20000ME...
Page 15 Special service tool Compression gauge Hydro puller kit 90890-03160 90890-06593 Compression gauge extension Valve spring compressor 90890-06563 90890-04019 Flywheel holder Valve spring compressor attachment 90890-06522 90890-06320 Flywheel stopper Valve guide remover/installer 90890-06598 90890-06801 Flywheel puller Valve guide installer 90890-06521 90890-06810 0-10...
Page 16 Special service tool Valve guide reamer Valve seat cutter 60° 90890-06804 90890-06324 Valve lapper Valve seat cutter 30° 90890-04101 90890-06326 Valve seat cutter holder Oil filter wrench 90890-06316 90890-06830 Valve seat cutter 30° Driver rod L3 90890-06327 90890-06652 Valve seat cutter 45° Needle bearing attachment 90890-06325 90890-06611...
Page 17 Special service tool Bearing separator Ring nut wrench extension 90890-06534 90890-06513 Gear puller Ring nut wrench 4 90890-06540 90890-06512 Piston ring compressor Bearing housing puller claw L 90890-05158 90890-06502 Needle bearing attachment Stopper guide plate 90890-06653 90890-06501 Shift rod socket Center bolt 90890-06681 90890-06504...
Page 18 Special service tool Stopper guide stand Bearing inner race attachment 90890-06538 90890-06640 Bearing puller assembly Needle bearing attachment 90890-06535 90890-06654 Driver rod SS Drive shaft holder 6 90890-06604 90890-06520 Needle bearing attachment Pinion nut holder 90890-06610 90890-06715 Bearing depth plate Needle bearing attachment 90890-06603 90890-06608...
Page 19 Special service tool Ball bearing attachment Bearing outer race attachment 90890-06636 90890-06619 Driver rod LL Ball bearing attachment 90890-06605 90890-06633 Needle bearing attachment Bearing outer race puller assembly 90890-06612 90890-06523 Bearing outer race attachment Backlash indicator 90890-06628 90890-06706 Driver rod LS Magnet base plate 90890-06606 90890-07003...
Page 20 Special service tool Dial gauge set Needle bearing attachment 90890-01252 90890-06607 Magnet base B Ring nut wrench 90890-06844 90890-06578 Pinion height gauge Bearing inner race attachment 90890-06671 90890-06660 Slide hammer handle Ball bearing attachment 90890-06531 90890-06629 Puller head PTT hydraulic gauge adapter 90890-06514 90890-06863 0-15...
Page 21 Special service tool Hydraulic pressure gauge 90890-06776/06800 Cylinder end screw wrench 90890-06591 Trim & tilt wrench 90890-06587 Power tilt wrench 90890-06560 PTT piston vice attachment 90890-06572 0-16...
Page 22: Specification
Specification Model feature ..............1-1 General feature ................. 1-1 Model name designation ............1-2 Serial number ................1-3 Model data ................. 1-4 Dimension and weight ............... 1-4 Performance ................1-4 Power unit ................. 1-5 Lower unit .................. 1-5 Bracket unit ................1-5 Fuel and oil requirement ............
Page 23 Specification Specified tightening torque ..........1-17 Rigging information ..............1-17 Electrical system ..............1-17 Fuel system ................1-17 Power unit ................1-18 Lower unit (regular rotation model) ......... 1-19 Lower unit (counter rotation model) ......... 1-19 Bracket unit ................1-19 PTT unit ...................
Page 24: Model Feature
(162.9 cu. in) engine • Low exhaust emissions conform to EU regulations • Y-COP (standard for European market and optional for Oceanian market) • Tilt limiter (F150A, FL150A [optional for European and Oceanian markets]) a. Power unit • Shimless valve lifter •...
Page 25: Model Name Designation
Model feature Model name designation F 150 A E T L None: 2-stroke E: Enduro F: 4-stroke L: Counter rotating propeller Model category T: High thrust (4-stroke) D: Twin rotating propeller K: Kerosene Z: HPDI Output horsepower Example: 6/9.9/75/150/250/300 Model generation A/B/C/D/F/G/H/J/L/N/P/Q/R/S/T/U/V/X/Y (Repeat from A) Level 1: Starting method M: Manual start...
Page 26: Serial Number
Model feature Serial number The outboard motor serial number is indi- cated on a label affixed to the port clamp bracket. YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON 1. Model name 2. Approved model code 3. Transom height 4.
Page 27: Model Data
Model data Model data Dimension and weight Overall length 862 mm (33.9 in) Overall width 511 mm (20.1 in) Overall height L F150AET 1714 mm (67.5 in) FL150AET 1714 mm (67.5 in) Overall height X 1842 mm (72.5 in) Transom height L F150AET 516 mm (20.3 in) FL150AET 516 mm (20.3 in) Transom height X...
Page 28: Power Unit
Model data Power unit Type 4-stroke, DOHC L Cylinder quantity Total displacement 2670.0 cm (162.9 cu. in) Bore × stroke 94.0 × 96.2 mm (3.70 × 3.79 in) Compression ratio 9.00 : 1 Control system Remote control Starting system Electric starter Fuel system Fuel injection Ignition control system...
Page 29: Fuel And Oil Requirement
Model data Fuel and oil requirement Recommended fuel Regular unleaded gasoline Minimum fuel octane number RON 90 Recommended engine oil 4-stroke motor oil Engine oil grade *1, *2 API SE, SF, SG, SH, SJ, SL SAE 5W-30, 10W-30, 10W-40 Total engine oil quantity (oil pan capacity) *3 5.2 L (5.50 US qt, 4.58 Imp.qt) Gear oil type Hypoid gear oil...
Page 30: Electrical Technical Data
Electrical technical data Electrical technical data Ignition timing control system Spark plug 1.0–1.1 mm (0.039–0.043 in) Spark plug wire Resistance (#1) 4.6–10.9 kΩ at 20 °C (68 °F) Resistance (#2) 3.3–8.0 kΩ at 20 °C (68 °F) Resistance (#3) 3.8–9.3 kΩ at 20 °C (68 °F) Resistance (#4) 4.2–10.0 kΩ...
Page 31: Fuel Injection Control System
Electrical technical data Shift position switch Input voltage 4.75–5.25 V Fuel injection control system Water detection switch Input voltage 4.75–5.25 V Fuel injector Input voltage 12 V 11.50–12.50 Ω at 20 °C (68 °F) Resistance (reference data) High-pressure fuel pump Input voltage 12 V 0.5–10.0 Ω...
Page 32: Charging System
Electrical technical data Charging system Lighting coil Output peak voltage (reference data) 11.0 V at cranking (unloaded) 50.0 V at 1500 r/min (unloaded) 110.0 V at 3500 r/min (unloaded) 0.2–0.3 Ω at 20 °C (68 °F) Resistance (reference data) Fuse 50.0 A Rectifier Regulator Output voltage...
Page 33: Gauge/Sensor
Electrical technical data Gauge/sensor Water pressure sensor Input voltage 4.75–5.25 V Output voltage (reference data) 2.5 V at 392.0 kPa (3.92 kgf/cm , 56.8 psi) 4.5 V at 784.0 kPa (7.84 kgf/cm , 113.7 psi) Speed sensor Input voltage 4.75–5.25 V Output voltage (reference data) 2.5 V at 392.0 kPa (3.92 kgf/cm , 56.8 psi)
Page 34: Fuel System Technical Data
Fuel system technical data Fuel system technical data Fuel system Fuel pressure (reference data) 300.0 kPa (3.00 kgf/cm , 43.5 psi) within 3 sec- onds after engine start switch turned to ON 260.0 kPa (2.60 kgf/cm , 37.7 psi) at engine idle speed Fuel filter assembly Fuel inlet holding pressure...
Page 35: Power Unit Technical Data
Power unit technical data Power unit technical data Power unit Compression pressure Minimum (reference data) *1 880.0 kPa (8.80 kgf/cm , 127.6 psi) Engine oil Oil pressure *2 320.0 kPa (3.20 kgf/cm , 46.4 psi) at 60 °C (140 °F) with SL 10W-30 engine oil and at 700 r/min 500.0 kPa (5.00 kgf/cm , 72.5 psi) at 62 °C...
Page 36: Crankcase Assembly
Power unit technical data Valve lifter Outside diameter 30.970–30.980 mm (1.2193–1.2197 in) Valve lifter clearance (reference data) 0.020–0.055 mm (0.0008–0.0022 in) Valve spring Free length 48.08 mm (1.8929 in) Tilt limit 1.7 mm (0.07 in) Valve stem Diameter (Intake) 5.477–5.492 mm (0.2156–0.2162 in) Diameter (Exhaust) 5.464–5.479 mm (0.2151–0.2157 in) Runout (Intake and exhaust)
Page 37 Power unit technical data Piston ring (Oil) Dimension height (B) 2.400–2.470 mm (0.0945–0.0972 in) Dimension width (T) 2.300–2.700 mm (0.0906–0.1063 in) End gap (reference data) 0.15–0.60 mm (0.0059–0.0236 in) Side clearance 0.04–0.13 mm (0.0016–0.0051 in) Connecting rod Small end inside diameter 21.022–21.037 mm (0.8276–0.8282 in) Big end inside diameter 53.025–53.045 mm (2.0876–2.0884 in)
Page 38: Lower Unit Technical Data
Lower unit technical data Lower unit technical data Lower unit assembly (regular rotation model) Lower unit Holding pressure 69.0 kPa (0.69 kgf/cm , 10.0 psi) Gear backlash Forward gear backlash *1 F150AET 0.15–0.61 mm (0.0059–0.0240 in) F150BET 0.15–0.68 mm (0.0059–0.0268 in) Reverse gear backlash *1 F150AET 0.33–0.67 mm (0.0130–0.0264 in) F150BET 0.33–0.74 mm (0.0130–0.0291 in)
Page 39: Bracket Unit Technical Data
Bracket unit technical data Bracket unit technical data PTT system Hydraulic pressure Down 5.85–8.85 MPa (58.5–88.5 kgf/cm 848.3–1283.3 psi) 11.2–13.2 MPa (112.0–132.0 kgf/cm 1624.0–1914.0 psi) Motor commutator Standard diameter 22.00 mm (0.8661 in) Limit 21.00 mm (0.8268 in) Standard undercut 1.50 mm (0.0591 in) Limit 1.00 mm (0.0394 in)
Page 40: Specified Tightening Torque
Specified tightening torque Specified tightening torque Specified tightening torques are provided for specific nuts, bolts, and screws. When tightening these fasteners, follow the tightening torque specifications indicated throughout the manual to meet the design aims of the outboard motor. Rigging information Tightening torques Part to be tightened Screw size...
Page 41: Power Unit
Specified tightening torque Power unit Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb Spark plug — 18.4 14.8 Power unit mounting bolt 31.0 Apron screw PTT motor lead bolt Flywheel magnet nut — 27.0 199.1 Drive sprocket bolt Timing belt tensioner bolt —...
Page 42: Lower Unit (Regular Rotation Model)
Specified tightening torque Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb Connecting rod bolt 17.0 90° 22.1 Main bearing cap bolt 90° 10.3 20.7 Crankcase bolt 22.1 90° Lower unit (regular rotation model) Tightening torques Part to be tightened Screw size N·m kgf·m...
Page 43: General Tightening Torque
Specified tightening torque Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb 14.8 Oil pan assembly bolt 31.0 Drain bolt — 20.7 Oil strainer bolt Oil pan bolt 14.8 Exhaust manifold bolt 14.8 Muffler bolt 14.8 Self-locking nut —...
Page 44: Technical Feature And Description
Fail-safe control ................. 2-6 Additional features ............2-7 Y-COP (standard for European market and optional for Oceanian market) ........... 2-7 Tilt limiter (F150A, FL150A [optional for European and Oceanian markets]) ..............2-8 YDIS ..................2-9 Overview ................... 2-9 New functions ................2-10 Logging ..................
Page 45 Technical feature and description Trim ram retraction when there is no load on the tilt ram and trim ram ................... 2-21 Stationary condition ..............2-22 Shock-absorbing function ............2-22...
Page 46: Electronic Control System
Electronic control system Electronic control system This model uses an electronic fuel injection control, digital ignition control, over-revving control, alert control, idle speed control, vapor shut-off valve control, which has been newly added to this model, and fail-safe control. The engine ECM performs these controls based on data received from each sensor and switch.
Page 47 Electronic control system 1. Pulser coil 2. TPS 3. Air pressure sensor 4. Oil pressure sensor 5. Engine temperature sensor 6. Air temperature sensor 7. Thermoswitch 8. Shift cut-off switch 9. Shift position switch 10. Water detection switch 11. Water pressure sensor (optional) 12.
Page 48: Engine Ecm Component
Electronic control system Engine ECM component...
Page 49 Electronic control system Determines the engine operating conditions according to the 1. Engine ECM input signals from the sensors, and sends output signals to operate the actuators to perform the various control functions. Detects the engine speed. 2. Pulser coil Detects the crankshaft angle.
Page 50: Engine Speed Control
When engine speed is more than a Fuel injection will be skipped 6302–6551 r/min predetermined level for cylinders #1, #4 and #3. (F150A, FL150A) Fuel injection for all cylinders Over 6551 r/min Over- will be skipped. revving Fuel injection will be skipped control 5751–5852 r/min...
Page 51: Fail-Safe Control
Electronic control system Fail-safe control If the electrical components malfunction, the engine ECM controls the ignition and fuel injection as shown in the table. Trouble Item Trouble conditions to be detected code No signal is sent from one of two sensors 4 or more Pulser coil consecutive times.
Page 52: Additional Features
Additional features Additional features Y-COP (standard for European market and optional for Oceanian market) Y-COP consists of a transmitter and a receiver. The receiver transmits an authorization ID to the engine ECM. If an authorization ID is not received or if the transmitted authorization ID does not match the registered ID in the engine ECM, the receiver cannot perform data communication with the engine ECM.
Page 53: Tilt Limiter (F150A, Fl150A [Optional For European And Oceanian Markets])
Additional features Tilt limiter (F150A, FL150A [optional for European and Oceanian markets]) The outboard motors (with applicable serial numbers) covered by this manual can be fitted with an optional tilt limiter that allows the tilt-up action to be halted at a set angle, preventing the outboard motor from coming into contact with the motor well when tilted up.
Page 54: Ydis
• For menu levels, see “Function” (4-2). • For details of operation methods, see the YDIS (Ver. 2.00 or later) instruction manual. • These tools are restricted for use by Yamaha service technicians of distributors or dealers only. ECM RecGraph...
Page 55: New Functions
YDIS New functions • By connecting the YDIS using CAN-Line, the CAN bus monitor function can check the names of devices connected to the digital network, the bus load, and the number of error frames. This enables checking of the connection status of the digital network. 3.
Page 56: Logging
YDIS Logging In version 2.00, it is possible to configure items to be logged, and logging intervals. Configure log- ging, and disconnect the USB cable between the computer and the adapter to start logging. Because the computer is not connected during logging, the adapter can be placed within the top cowling (K-Line).
Page 57: Power Unit System
Power unit system Power unit system Shimless valve lifter Newly designed valve lifters “1” have been adopted in place of the valve shims previously used “2”. The valve lifters are available in different thicknesses “a”. Therefore, the valve clearance “b” can be adjusted by replacing the current valve lifter with a new valve lifter of the appropriate thickness.
Page 58: Fuel System
Fuel system Fuel system Fuel diagram 6. Vapor separator 10. Pressure regulator 11. Fuel rail 9. High-pressure fuel pump Fuel injector Fuel injector Fuel injector Fuel injector 15. Fuel cooler 8. Filter 13. Intake manifold 7. Float chamber Combustion Combustion Combustion Combustion chamber #4...
Page 59: Vapor Gas Diagram
Fuel system Vapor gas diagram TIP: When the engine is running, air is drawn from the atmosphere to purge the vapor gas that has accu- mulated in the canister into the combustion chambers. 2. Filter 3. Canister 7. Filter 1. Vapor separator 4.
Page 60: Lubrication System
5. Main gallery 4. Oil filter 17. Relief valve 3. Oil pump 2. Oil strainer 1. Oil pan 1. Oil pan 11. Balancer (F150A, FL150A) 2. Oil strainer 12. Crankcase 3. Oil pump 13. Camshaft journal 4. Oil filter 14. Camshaft 5.
Page 61: Cooling System
Cooling system Cooling system Cooling diagram 9. Thermostat 7 Cylinder block 8. Cylinder head 7. Cylinder block 10. PCV 6. Exhaust cover 11. Upper case 17. Flushing (muffler) device 5. Exhaust guide 4. Oil pan 12. Lower case 3. Water pump 14.
Page 62: Intake And Exhaust System
Intake and exhaust system Intake and exhaust system Intake and exhaust diagram 4. Exhaust cover 5. Exhaust guide 1. Intake silencer 6. Exhaust manifold 2. Throttle body 3. Intake manifold 8. Propeller boss 7. Muffler 1. Intake silencer A. Intake air flow 2.
Page 63: Lower Unit
Lower unit Lower unit Propeller (SDS) The optional Shift Dampener System (SDS) uses a damper “1” to reduce the shock when the out- board motor is shifted into gear, and eliminates the clunk that is sometimes heard. When shifting gears, the protrusions “a” on the dedicated spacer “2” transmit the rotational force of the propeller shaft directly to the propeller “3”.
Page 64: Ptt Unit
PTT unit PTT unit Trim-up and tilt-up function Pushing the UP button on the PTT switch causes the PTT motor “1” to activate the gear pump “2”, generating the PTT fluid pressure. The PTT fluid pressure opens the up-main valve “3” at the same time pushing the shuttle piston “4”, and this opens the down-main valve “5”.
Page 65: Trim-Down And Tilt-Down Function
PTT unit Trim-down and tilt-down function Pushing the DN button on the PTT switch causes the PTT motor “1” to activate the gear pump “2”, generating the PTT fluid pressure. The PTT fluid pressure opens the down-main valve “3” at the same time pushing the shuttle piston “4”, and this opens the up-main valve “5”.
Page 66: Trim Ram Retraction When Tilting The Outboard Motor Up
PTT unit Trim ram retraction when tilting the outboard motor up When tilting the outboard motor up, applying the tilt lock lever and pushing the DN button on the PTT switch applies fluid pressure to the tilt cylinder “1” upper chamber, in the same way as when tilting the outboard motor down.
Page 67 PTT unit Stationary condition When the PTT switch is not pushed, the gear pump assembly will not pump the PTT fluid, the up- main valve and down-main valve will remain closed, and the PTT fluid in the system will remain at a constant pressure.
Page 68: Rigging Information
Crate top cover pictograph description ........3-2 Uncrating ................3-3 Uncrating procedure ..............3-3 External dimensions ............3-5 F150A, FL150A, F150B, FL150B ..........3-5 Clamp bracket ................3-6 Outboard motor mounting ..........3-7 Installing the outboard motor ............. 3-7 Rigging grommet mounting ..........3-9 Rigging grommet description .............
Page 69 Rigging information Battery wiring with house (accessory) battery ......3-25 System diagram .............. 3-29 Single outboard motor application (6Y8 Multifunction Meter) ............3-29 Single outboard motor application (conventional gauge) ..3-31 Twin outboard motor application (6Y8 Multifunction Meter) ..3-33 Twin outboard motor application (conventional gauge) ...
Page 70: Important Reminder On Rigging
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.
Page 71: Crate Handling
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. IMPORTANT This unit delivered to carrier in a good condition.
Page 72: Uncrating
Uncrating Uncrating TIP: Uncrating procedure Place a rag “1” between the flywheel magnet and the lifting harness. Wear gloves to avoid injury by sharp steel edges while uncrating. 1. Check the crate for shipping damage. 2. Remove the top cover. 3.
Page 73 Uncrating 11. Remove the steering retainer, and then install a hydraulic steering cylinder or steering cable following the recommen- dation of the manufacturer.
Page 74: External Dimensions
External dimensions External dimensions F150A, FL150A, F150B, FL150B TIP: The dimension values may include reference values. mm (in) L:1032 (40.6) 629 (24.8) X:1148 (45.2) 164 (6.5) 698 (27.5) 75 (3.0) 162(6.4) L:35 (1.4) X:43 (1.7) 646 (25.4) *1. Minimum distance between the outboard motors in twin or triple installation...
Page 75: Clamp Bracket
External dimensions Clamp bracket TIP: The dimension values may include reference values. 180 (7.1) 180 (7.1) mm (in) 163.5 (6.4) 163.5 (6.4) 82 (3.2) 13 (0.5) 102 (4.9) 102 (4.9) 13 (0.5) 125.4 (4.9) 125.4 (4.9)
Page 76: Outboard Motor Mounting
Outboard motor mounting Outboard motor mounting For twin outboard motor installation, place the outboard motors so that the distance from Installing the outboard motor the C/L of each outboard motor to the C/L of Proper mounting of the outboard motor pro- the boat transom are equal on both sides.
Page 77 Outboard motor mounting C/L: Centerline of the transom Drilling plate “1”: 90890-06783 6. Apply sealant to the mounting holes, and then secure the outboard motor using the included mounting bolts “1”, small wash- ers “2”, large washers “3”, and nuts “4”. Make sure that there is no clearance A.
Page 78: Rigging Grommet Mounting
Rigging grommet mounting 7. Install the mounting bolts, and then Installing the shift cable tighten the nuts firmly. Always perform the cable adjustment in Make sure that the clamp brackets do not advance, following the procedures in the bite into the boat transom. remote control operation manual.
Page 79 Rigging grommet mounting TIP: When it is not possible to ensure cable screw-in length of 8.0 mm (0.31 in) or more, remove the shift cable holder “3”, and then reinstall it to the hole “b” or “c” to adjust the length.
Page 80: Installing The Throttle Cable
Rigging grommet mounting Installing the throttle cable 1. Fully screw in the throttle cable joint “1” to the throttle cable “2”. 5. Adjust the throttle cable joint “1”, and then install the throttle cable joint “1” to the pin “2” of the throttle lever 2. 2.
Page 81: Installing The 6Y8 Multifunction Meter Harness
Rigging grommet mounting 6. Install the clip “1”, and then tighten the throttle cable locknut “2” to the specified torque. 4. Connect the trim sensor coupler “a”. Throttle cable locknut “2”: 5 N·m (0.5 kgf·m, 3.7 ft·lb) 7. Check the throttle cable for proper opera- tion.
Page 82: Installing The Main Wiring Harness
Rigging grommet mounting Installing the rigging grommet 1. Route each harness through the proper hole in the rigging grommet. See “Rig- ging grommet description” (3-9). 2. Align the white tape “a” on the battery cable “1” with the inner end of the rigging grommet.
Page 83: Optional Equipment
Optional equipment 6. Install the rigging tube retainer “1”, and then fasten it using the plastic tie “2”. Water pressure sensor “1”: 18 N·m (1.8 kgf·m, 13.3 ft·lb) Optional equipment 2. Remove the plug “1”. Installing the isolator lead 1. Remove the cap “1” from the isolator coupler.
Page 84: Installing The Speed Sensor
Optional equipment Installing the speed sensor 7. Install the speed sensor “1” to the speed sensor adapter “2”, and then tighten the See 6Y8 Multifunction Meter set up manual speed sensor “1” to the specified torque. for details of the components. 1.
Page 85: Installing The Tilt Limiter
Optional equipment 10. Remove the bracket “1” and cap “2” from 3. Install the holder “2” so that the protru- the speed sensor coupler “a”. sion “a” on the magnet lever is aligned with the groove “b” in the through tube “1”, and the protrusion “c”...
Page 86 Optional equipment 7. Remove the junction box cover. 11. Route the tilt limiter leads “1” through the hole in the grommet “2” and into the bot- 8. Disconnect the battery cables “1” and tom cowling. PTT motor leads “2”. TIP: TIP: Pass the tilt limiter leads one by one through To pass the tilt limiter lead through the hole in...
Page 87: Setting The Tilt Limiter
Optional equipment 14. Route the tilt limiter lead “1” in the same 18. Connect the tilt limiter couplers of the manner as the trim sensor lead “2”, and main harness side with the tilt limiter cou- then fasten them using new plastic ties plers “a”...
Page 88 Optional equipment Make sure to keep the clearance of 50.8mm (2.0 in) or more between the out- board motor and the motor well. 1. Check that there is no interference between the steering system and the tilt limiter when the outboard motor is steered.
Page 89: Deactivating The Tilt Limiter
2 short beeps. Oceanian market) Installing Y-COP See the Yamaha Security System Y-COP installation manual. • Install the receiver so that the “UP” mark is facing up. • Do not install the receiver in a location where it will be exposed to water.
Page 90 Y-COP (standard for European market and optional for Oceanian market) 4. Turn the engine start switch to OFF. Initial registration complete. Y-COP unlocked. 5. Push the lock button “1” of the transmit- ter. Check that the buzzer of the receiver will sound 1 short beep.
Page 91: Battery Installation
Battery installation Battery installation • Make sure to connect the battery properly and select the proper cable sizes. Otherwise, a fire could result. • When installing an isolator lead to the positive battery terminal or battery switch, over-cur- rent protection in compliance with ABYC (E-11) must be provided. Do not reverse the battery connections.
Page 92 Battery installation STBD PORT 1. Outboard motor 1. Outboard motor 2. Isolator lead 3. Red 3. Red 4. Black 4. Black 4. Black 1. Outboard motor 3. Red 2. Isolator lead 4. Black 1. Outboard motor 2. Isolator lead 4. Red 5.
Page 93 Battery installation STBD PORT 1. Outboard motor 1. Outboard motor 2. Isolator lead 2. Isolator lead 4. Red 4. Red 5. Black 5. Black ON/OFF ON/OFF 3. Battery switch 3. Battery switch 5. Black 1. Outboard motor 4. Red 2. Isolator lead 5.
Page 94: Battery Wiring With House (Accessory) Battery
Battery installation Battery wiring with house (accessory) battery • When only one battery is used for one engine, connect the positive battery cable and isola- tor lead to the positive battery terminal. If the isolator lead is left unconnected, accidental contact of the isolator lead with the negative terminal of the battery can cause a short cir- cuit, which may result in a fire.
Page 95 Battery installation 1. Outboard motor 2. Isolator lead 3. Red 4. Black 4. Black 5. House battery 1. Outboard motor 4. Black 2. Isolator lead 5. House battery 3. Red 1. Outboard motor 2. Isolator lead 3. Black 4. Red 5.
Page 96 Battery installation STBD 1. Outboard motor PORT 1. Outboard motor 2. Isolator lead 2. Isolator lead 3. Black 5. Red 4. Battery switch 3. Black 5. Red 4. Battery switch ON/OFF 5. Red ON/OFF 3. Black 4. Battery switch 6. House battery 3.
Page 97 Battery installation 1. Outboard motor STBD PORT 1. Outboard motor 2. Isolator lead 2. Isolator lead 3. Black 4. Battery switch 5. Red 3. Black 5. Red 4. Battery switch 5. Red 5. Red 6. House battery 3. Black 3. Black 1.
Page 98: System Diagram
System diagram System diagram Single outboard motor application (6Y8 Multifunction Meter) 3-29...
Page 99 System diagram 1. Engine ECM 2. Speed sensor 3. Trim sensor 4. Main wiring harness 5. Remote control box 6. Fuse (10 A) 7. Power wire 8. Pigtail bus wire 9. Single hub 10. Main bus wire 11. Hub 12. Terminal resistor 13.
Page 100: Single Outboard Motor Application (Conventional Gauge)
System diagram Single outboard motor application (conventional gauge) W(+) Pu/W R Y L Pu/W 3-31...
Page 101 System diagram 1. Remote control box 2. Fuel management meter unit 3. Speedometer unit 4. Tachometer unit 5. Fuel tank (fuel level sensor) 6. Fuel flow sensor 7. GPS 8. Speedometer hose 9. Gauge harness 10. Main wiring harness 11. Fuel hose 12.
Page 102: Twin Outboard Motor Application (6Y8 Multifunction Meter)
System diagram Twin outboard motor application (6Y8 Multifunction Meter) P B P/B R R R 3-33...
Page 103 System diagram 1. Engine ECM 2. Speed sensor 3. Water pressure sensor 4. Trim sensor 5. Main wiring harness 6. Remote control box 7. Engine start switch (with engine shut-off switch) 8. Fuse (10 A) 9. Hub 10. Power wire 11.
Page 104: Twin Outboard Motor Application (Conventional Gauge)
System diagram Twin outboard motor application (conventional gauge) Y AMA HA SPEED Km/ h knot mile TRIP TIME BATT mode W(+) TACH Y AMA HA FUEL MANAGEMENT r/min TACH r/min Km/ L mode ECON SYNC mode mode Pu/W G/R O/B Pu/W Pu/W Gy G...
Page 105 System diagram 1. Remote control box 2. Switch panel 3. Tachometer unit 4. Fuel management meter unit 5. Speedometer unit 6. Fuel tank (fuel level sensor) 7. Fuel flow sensor 8. GPS 9. Speedometer hose 10. Gauge harness 11. Main wiring harness 12.
Page 106: Rigging Recommendation
Rigging recommendation Rigging recommendation Extension length recommendation for battery cable Do not exceed the recommended extension length for the battery cable. Otherwise, the elec- trical system could be damaged or operate improperly. To extend the length of battery cables, follow the requirements in the tables for battery capacity, cable size, and ambient temperature.
Page 107: 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 (F150A, FL150A): 5000–6000 r/min Full throttle operating range (F150B, FL150B): 4500–5500 r/min...
Page 108 Propeller selection Blade Dia. (in) Pitch (in) Mark Material Part number Remarks 13 3/8 Stainless steel 6G5-45930-00 14 1/4 Stainless steel 68F-45972-00 14 1/4 Stainless steel 68F-45978-00 13 3/4 Stainless steel 68F-45974-00 13 3/4 Stainless steel 68F-45976-00 15 1/4 Stainless steel 6R4-45976-A0 15 1/4 Stainless steel...
Page 109 Propeller selection Blade Dia. (in) Pitch (in) Mark Material Part number Remarks 14 1/4 Stainless steel 68G-45972-00 14 1/4 Stainless steel 68G-45978-00 13 3/4 Stainless steel 68G-45974-00 13 3/4 Stainless steel 68G-45976-00 15 1/4 Stainless steel 6R1-45976-A0 15 1/4 Stainless steel 6R1-45978-A0 15 1/4 Stainless steel...
Page 110 Propeller selection — MEMO — 3-41...
Page 111: Troubleshooting
Troubleshooting YDIS ..................4-1 Basic components ..............4-1 Function ..................4-2 Connecting the communication cable ........4-5 Outboard motor troubleshooting ........4-6 Troubleshooting procedure ............4-6 Troubleshooting the power unit using the YDIS ......4-6 Trouble code and checking step ..........4-8 Troubleshooting the power unit using the diagnostic flash indicator ................
Page 112 YDIS YDIS The Yamaha Diagnostic System uses precision fault diagnosis to offer better serviceability at a time when there is increasing demand for service tools for electronically controlled products. It provides quick, reliable, safe, and reasonable service, and is intended to obtain customer satisfaction. The Yamaha Diagnostic System features updated software and expanded tool functions that allow it to respond to new models and technologies, maintaining compatibility with regulations.
Page 113: Ydis
YDIS Function YDIS version 2.00 comprises the following items. Items in grey do not apply to the models covered by this manual. 1. Start 2. Engine 3. Diagnosis 4. Diagnosis 5. Diagnosis Record 6. Engine Record 7. Engine operating hours by RPM 8.
Page 114 YDIS 1. Start 17. ECM Rec Graph 2. Engine 18. Logging 3. Diagnosis 19. Record Set 4. Diagnosis 20. Show Data 5. Diagnosis Record 21. Clear Data 6. Engine Record 22. Boat System 7. Engine operating hours by RPM 23. Tilt Limiter 8.
Page 115 31. Communication List By connecting the YDIS to a hub via a CAN-Line, displays the name of Yamaha genuine parts connected to the Digital Network (6Y8 Meter). This enables checking that connections are correct.
Page 116: Connecting The Communication Cable
YDIS Connecting the communication cable CAN-Line 2. Adapter cap 3. Adapter 4. USB cable 1. CAN-Line harness 5. Hub 5. Hub 1. CAN-Line harness 4. USB cable 2. Adapter cap 5. Hub 3. Adapter K-Line 2. Adapter cap 1. Adapter a.
Page 117: Outboard Motor Troubleshooting
Outboard motor troubleshooting Outboard motor troubleshooting Troubleshooting procedure 1. Before troubleshooting the outboard motor, check that fresh fuel of the specified type has been used. 2. Check that all electrical connections are secure and free from corrosion, and that the battery is fully charged.
Page 118 Outboard motor troubleshooting Trouble code table : Indicate —: Not applicable Code Diagnostic YDIS diagno- Item YDIS diagnosis flash indicator sis record No trouble (functioning properly) — — Pulser coil Engine temperature sensor Battery voltage Air temperature sensor Shift position switch Air pressure sensor Intake air passage Oil pressure sensor...
Page 119: Trouble Code And Checking Step
Outboard motor troubleshooting Trouble code and checking step —: Not applicable Trouble Item Symptom Checking steps code (Condition) page Measure the pulser coil output peak 5-22 voltage. Pulser coil “Check Engine” is displayed. Measure the pulser coil resistance. 5-22 (Irregular signal) Engine stall Check for wiring continuity between the pulser coil and the engine ECM.
Page 120 Outboard motor troubleshooting Trouble Item Symptom Checking steps code (Condition) page Check the O-rings and gaskets of the 6-34 intake manifold. “Check Engine” is displayed. Check the intake manifold for cracks. 6-38 Intake air passage Engine operates normally (Air leakage) Check the vacuum hose.
Page 121: Troubleshooting The Power Unit Using The Diagnostic Flash Indicator
Outboard motor troubleshooting Troubleshooting the power unit using the diagnostic flash indicator 1. Connect the special service tool “1”. TIP: Before performing this diagnosis, make sure to connect all of the electrical wires properly. a. Light on, 0.33 seconds b. Light off, 4.95 seconds c.
Page 122: Troubleshooting The Power Unit (Trouble Code Not Detected)
Outboard motor troubleshooting Troubleshooting the power unit (trouble code not detected) Troubleshooting consists of the following 3 items: Symptom 1: Specific trouble conditions Symptom 2: Trouble conditions of an area or individual part Cause: Trouble causes of symptom 2 — : Not applicable Symptom 1: Engine does not crank.
Page 123 Outboard motor troubleshooting Symptom 2 Cause Checking steps page — Measure the fuel pressure. Check the fuel filter for dirt and obstruc- Clogged filter tions. Fuel leakage Check the fuel line for leakage. Check the high-pressure fuel pump oper- 5-18 ation using the YDIS.
Page 124 Outboard motor troubleshooting Symptom 2 Cause Checking steps page Check the ignition spark. 5-21 Spark plug malfunction Check the spark plugs. 7-25 Measure the spark plug wire resistance. 5-21 Check for wiring harness continuity between the ignition coil and the engine Short, open, or loose connec- ECM.
Page 125 Outboard motor troubleshooting Symptom 1: High engine idle speed Symptom 2 Cause Checking steps page Check the gaskets of the intake manifold 6-34 Air leakage (throttle valve–cyl- and throttle body. inder head) Check the intake manifold for cracks. 6-38 Throttle link and throttle cable 3-11 —...
Page 126 Outboard motor troubleshooting Symptom 1: Discharged battery Symptom 2 Cause Checking steps page Check the battery capacity and specific Battery performance decrease 10-4 gravity. Check the battery cable and terminals — for proper connections. Short, open, or loose connec- tion in charging circuit Check the charging circuit for wiring con- nection and damage.
Page 127: Troubleshooting The Ptt Unit
Outboard motor troubleshooting Troubleshooting the PTT unit Troubleshooting consists of the following 3 items: Symptom 1: Specific trouble conditions Symptom 2: Trouble conditions of an area or individual part Cause: Trouble causes of symptom 2 — : Not applicable Symptom 1: PTT unit does not operate. Symptom 2 Cause Checking steps...
Page 128: Troubleshooting The Lower Unit
Outboard motor troubleshooting Symptom 1: PTT unit does not hold the outboard motor up. Symptom 2 Cause Checking steps page Manual valve open Check the manual valve. 9-60 Insufficient PTT fluid Add sufficient PTT fluid. 10-14 — Check the hydraulic pressure. 9-35 PTT fluid leakage Check the PTT fluid leakage.
Page 129 Outboard motor troubleshooting — MEMO — 4-18...
Page 130: Electrical System
Electrical system Electrical component and wiring harness routing ..5-1 Port ................... 5-1 Junction box assembly .............. 5-3 Rear ................... 5-5 Top .................... 5-6 Bottom cowling ................5-7 ECM circuit ................ 5-9 Circuit diagram ................5-9 ECM coupler layout ..............5-11 Checking the electrical component .......
Page 131 Electrical system Checking the thermoswitch ............. 5-25 Checking the shift cut-off switch ..........5-26 Checking the shift position switch ........... 5-26 Checking the engine shut-off switch ........5-27 Starting unit and component ......... 5-27 Checking the starter relay ............5-27 Checking the engine start switch ..........
Page 132: Electrical Component And Wiring Harness Routing
Electrical component and wiring harness routing Electrical component and wiring harness routing Port 1. Engine ECM 9. Oil pressure sensor 2. Starter motor 10. Fuse holder 3. Thermoswitch A. Run the pulser coil lead under the 4. Rectifier Regulator breather hose and the wiring harness. 5.
Page 133 Electrical component and wiring harness routing D. Install the ignition coil lead, water pres- sure sensor lead, vapor shut-off valve lead, and speed sensor lead to the holder. E. Install the ignition coil lead, vapor shut-off valve lead, and speed sensor lead to the holder.
Page 134: Junction Box Assembly
Electrical component and wiring harness routing Junction box assembly 1. Engine ECM 9. Fuse (20 A) (engine start switch, PTT 2. PTT relay switch) 3. Starter relay 10. Fuse (20 A) (engine ECM, ISC valve, fuel 4. Diode (connect to the PTT relay) injector, high-pressure fuel pump, ignition 5.
Page 135 “a”. lead, and isolator lead, and tilt limiter B. Do not fasten the starter motor lead lead (F150A, FL150A) to the holder. using a plastic tie. F. Route the ground lead between the PTT relay and the starter relay.
Page 136: Rear
Electrical component and wiring harness routing Rear 1. Spark plug wire B. Fasten the spark plug wires #1 and #2 2. High-pressure fuel pump coupler using the holder. 3. Fuel injector D. Fasten the spark plug wires #2 and #4 4.
Page 137: Top
3. Lighting coil (stator assembly) tion box. 4. Pulser coil E. Bend the engine temperature sensor 5. Engine temperature sensor lead, and then fasten it using the holder. 6. TPS F. Fasten the engine temperature sensor lead using the plastic tie. A. F150A, FL150A...
Page 138: Bottom Cowling
Electrical component and wiring harness routing Bottom cowling 1. Shift cut-off switch 7. 6Y8 Multifunction Meter communication 2. Shift position switch lead 3. PTT switch 8. Trim meter lead 4. 6Y8 Multifunction Meter communication 9. Isolator lead coupler 10. Trim sensor lead 5.
Page 139 Electrical component and wiring harness routing A. Regular rotation model B. Counter rotation model D. Route the wiring harness along the groove in the bottom cowling. E. Install the PTT motor lead and isolator lead to the holder. F. Align the white paint mark on the flushing hose with the outer end of the grommet.
Page 140: Ecm Circuit
ECM circuit ECM circuit Circuit diagram TIP: The circled numbers in the illustration indicate the engine ECM terminal numbers. 1. Pulser coil #1 23. Fuel injector #1 24. Fuel injector #2 2. Pulser coil #2 25. Fuel injector #3 3. TPS 26.
Page 141 ECM circuit 1. Pulser coil #1 2. Pulser coil #2 3. TPS 4. Air pressure sensor 5. Oil pressure sensor 6. Water pressure sensor 7. Speed sensor 8. Ground 9. Engine temperature sensor 10. Air temperature sensor 11. Shift cut-off switch 12.
Page 142: Ecm Coupler Layout
ECM circuit ECM coupler layout 1 2 3 4 5 6 7 8 9 10111213141516171819202122 23242526272829303132333435363738394041424344 Connecting part Color Connecting part Color Shift position switch Blue/Green Multifunction White Meter Ground Black Tachometer Green Air pressure sensor Pink/Green Alert buzzer Pink Pink Engine shut-off switch White...
Page 143: Checking The Electrical Component
Checking the electrical component Checking the electrical TIP: component • Before measuring the peak voltage, check Using the YDIS all of the wiring harnesses for corrosion. When checking the TPS, ISC valve, high- Also, make sure that the wiring harnesses pressure fuel pump, fuel injector, or each are connected properly and that the battery sensor, use the YDIS.
Page 144: Using The Digital Tester
“a”, connect the negative battery The electrical technical data applies to the lead to the terminal “b”, and then check measurements taken using the Yamaha rec- for continuity between the terminals “c”, ommended tester. and “d”. Replace the relay if out of speci- The resistance values shown are the values fication.
Page 145: Checking The Engine Ecm Circuit
Engine control unit and component Wiring harness continuity: Main relay input voltage: Terminal 32–Ground Terminal “a”–Terminal “b” Terminal 42–Ground 12 V (battery voltage) 3. Measure the input voltage at the engine 5. Turn the engine start switch to OFF, and ECM coupler terminal and ground.
Page 146: Checking The Tps
Engine control unit and component TPS output voltage and throttle valve opening angle (reference data): Item Fully closed “a” Fully open “b” Output 0.703 V 4.033 V voltage Opening 0.1° 83.2° angle 4. Disconnect the TPS coupler “a”, and then measure the TPS input voltage at the TPS coupler.
Page 147: Checking The Oil Pressure Sensor
6. Install the oil pressure sensor. See “Cyl- inder block (F150A, FL150A)” (7-52). 2. Turn the engine start switch to ON, and then measure the input voltage at the oil 7. Connect the oil pressure sensor coupler.
Page 148: Checking The Fuel Injector
Fuel control unit and component Water detection switch continuity: Continuity: Float position “B” No continuity: Float position “A” 6. Install the fuel cup assembly. See “Fuel filter” (6-7). 7. Connect the water detection switch cou- pler. Water detection switch input voltage: Blue/White (L/W)–Black (B) Checking the fuel injector 4.75–5.25 V...
Page 149: Checking The High-Pressure Fuel Pump
Fuel control unit and component Fuel injector resistance (reference data): High-pressure fuel pump resistance 11.50–12.50 Ω at 20 °C (68 °F) (reference data): 0.5–10.0 Ω 6. Connect the fuel injector couplers. 6. Connect the high-pressure fuel pump Checking the high-pressure fuel coupler.
Page 150: Charging Unit And Component
Charging unit and component 5. Check that the vapor shut-off valve 3. Measure the lighting coil output peak opens and the negative pressure is voltage between all combinations of the released when the battery leads are connectors. Replace the stator assembly connected to the vapor shut-off valve if below specification.
Page 151 Charging unit and component 2. Connect the special service tool “1”, and 4. Set the digital circuit tester to the diode then measure the Rectifier Regulator mode, and then check the Rectifier Reg- output voltage. ulator for continuity. TIP: Do not use peak voltage adapter B when measuring the Rectifier Regulator output volt- age.
Page 152: Ignition Unit And Component
Ignition unit and component 3. Check the ignition spark using the YDIS Rectifier Regulator continuity “Stationary test”. (testing diode mode): Tester probe Display value (reference data) (–) Do not touch any of the connections of the special service tool. 0.439 V 0.434 V 0.440 V 0.436 V...
Page 153: Checking The Pulser Coil
Ignition unit and component 2. Turn the engine start switch to ON, and Ignition coil output peak voltage: then measure the input voltage at the #1, #4 “A”: ignition coil coupler terminal and ground. Black/Orange (B/O)–Ground #2, #3 “B”: Black/White (B/W)–Ground Loaded r/min Cranking...
Page 154: Checking The Air Temperature Sensor
Ignition unit and component 3. Measure the pulser coil output peak volt- Checking the air temperature sensor age. 1. Measure the ambient temperature. 2. Connect the YDIS to display “Intake air TIP: temperature”. • When measuring the pulser coil output peak voltage under the cranking (unloaded) 3.
Page 155: Checking The Air Pressure Sensor
Ignition unit and component Air temperature sensor resistance (reference data): 2.2–2.7 kΩ at 20 °C (68 °F) G/W G 0.32 kΩ at 80 °C (176 °F) 9. Install the air temperature sensor, and then connect the air temperature sensor coupler. Vacuum/pressure pump gauge set “1”: Checking the air pressure sensor 90890-06945...
Page 156: Checking The Thermoswitch
128.0 kΩ at 5 °C (41 °F) 54.20–69.00 kΩ at 20 °C (68 °F) 3.120–3.480 kΩ at 100 °C (212 °F) 7. Install the engine temperature sensor. See “Cylinder block (F150A, FL150A)” (7-52). 8. Connect the engine temperature sensor coupler.
Page 157: Checking The Shift Cut-Off Switch
Ignition unit and component c. No continuity Shift cut-off switch resistance: d. Continuity 4.465–4.935 kΩ at “a” position at Thermoswitch continuity temperature: 20 °C (68 °F) 0 Ω at “b” position at 20 °C (68 °F) “e”: 84–90 °C (183–194 °F) “f”: 68–82 °C (154–180 °F) 6.
Page 158: Checking The Engine Shut-Off Switch
Starting unit and component Starting unit and component Shift position switch continuity: Checking the starter relay Continuity: 1. Measure the input voltage between the Switch position “a” starter relay terminal “a” and ground. No continuity: Switch position “b” 6. Install the shift position switch. See “Shift rod and shift bracket”...
Page 159: Checking The Engine Start Switch
Starting unit and component 4. Install the starter relay, and then connect the starter relay leads. Checking the engine start switch 1. Disconnect the 10-pin coupler or engine start switch coupler. 2. Check the engine start switch for continu- ity. 2.
Page 160: Y-Cop (Standard For European Market And Optional For Oceanian Market)
Y-COP (standard for European market and optional for Oceanian market) Y-COP (standard for European market and optional for Oceanian market) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) Part name Q’ty Remarks Cover Control unit assembly Transmitter Screw 15 mm...
Page 161: Checking Y-Cop
Y-COP (standard for European market and optional for Oceanian market) Checking Y-COP 1. Disconnect the Y-COP coupler “a”, and then measure the Y-COP input voltage. 3. Measure the Y-COP buzzer input voltage. Y-COP buzzer input voltage: Y-COP input voltage: Yellow (Y)–Ground Red (R)–Black (B) 12 V (battery voltage) 12 V (battery voltage)
Page 162: Checking The Button Cell Battery
Do not connect the connectors “a” and “b”. Otherwise, Y-COP may not operate properly. 2. Push the Yamaha logo on the transmitter cover “1” and remove the button cell battery “2”. Do not touch the button cell battery directly.
Page 163 Y-COP (standard for European market and optional for Oceanian market) 3. Measure the button cell battery voltage. TIP: When disposing of button cell battery, make Transmitter screw “2”: sure to follow local disposal regulations. 0.1 N·m (0.01 kgf·m, 0.1 ft·lb) Button cell battery voltage - CR2016 (reference data): 3 V 4.
Page 164: Starter Motor
Starter motor Starter motor Part name Q’ty Remarks Brush spring Brush assembly Brush holder assembly Starting motor gear assembly Washer set Bracket Bolt 117 mm Screw 16 mm Planetary gear Plate Stator Armature Clutch assembly Washer set Bracket Bracket Outer gear 5-33...
Page 165 Starter motor Part name Q’ty Remarks Pinion shaft Pinion Pinion stopper set Bolt 37 mm Cover Lever assembly Seal set Not reusable Magnet switch Washer 5-34...
Page 166: Removing The Starter Motor
Starter motor Removing the starter motor Pipe “3”: (commercially available) “a”: 21.0 mm (0.83 in) “b”: 26.0 mm (1.02 in) Before removing the starter motor, make 3. Remove the pinion stopper “1”, pinion sure to disconnect the negative battery “2”, and spring “3”. terminal.
Page 167 Starter motor 7. Remove the E-clip “1”, and then remove 9. Remove the stator “1”. the clutch assembly “2”. 10. Remove the armature “2”, along with the brush holder assembly “3”, from the TIP: bracket “4”. Push the clutch assembly “2” down com- pletely onto the pinion shaft “3”...
Page 168: Checking The Armature (Starter Motor)
Starter motor Commutator standard undercut “a”: 0.8 mm (0.03 in) Wear limit: 0.2 mm (0.01 in) 4. Check armature continuity. Checking the armature (starter Replace if out of specification. motor) 1. Check the commutator. Clean using 600-grit sandpaper and compressed air if dirty.
Page 169: Assembling The Starter Motor
Starter motor 3. Install the armature “1”, along with the Brush holder assembly continuity: brush holder assembly “2”, to the bracket Brush “a”–brush “b” “3”, and then install the stator “4”. Brush “a”–Terminal “e” Brush “b”–Terminal “e” TIP: Brush “c”–brush “d” Align the holes “a”...
Page 170: Installing The Starter Motor
Starter motor TIP: Make sure that the clutch assembly “1” does not come out from the pinion shaft “2”. 9. Install the spring “1”, pinion “2”, pinion stopper “3”, and clip “4”. 7. Install the pinion shaft assembly “1”, the lever “2”, a new rubber seal “3”, the plan- etary gears “4”, the outer gear “5”, and the plate “6”.
Page 171: 6Y8 Multifunction Meter Sensor
6Y8 Multifunction Meter sensor 6Y8 Multifunction Meter sensor Water pressure sensor output voltage Checking the water pressure sensor (reference data): (optional) Blue/White (L/W)–Black (B) 1. Disconnect the water pressure sensor 2.5 V at 392.0 kPa coupler “a”. (3.92 kgf/cm , 56.8 psi) 4.5 V at 784.0 kPa 2.
Page 172: Ptt System
PTT system PTT relay input voltage: Terminal “a”–Terminal “b” 12 V (battery voltage) 3. Disconnect the battery power source, ground lead, PTT motor leads, and PTT relay coupler. Before disconnecting the PTT relay termi- nals, make sure to disconnect the battery negative terminal.
Page 173: Checking The Ptt Switch (On Bottom Cowling)
PTT system Checking the PTT switch (on bottom cowling) 1. Disconnect the PTT switch coupler “a”. G/W G 2. Measure the input voltage between the PTT switch coupler terminal and ground. PTT relay continuity: Terminal “c”–Terminal “e” PTT switch input voltage: Terminal “b”–Terminal “d”...
Page 174: Checking The Tilt Limiter (Optional)
PTT system Tilt limiter input voltage: Sky blue (Sb)–Ground 12 V (battery voltage) 3. Connect the battery leads to the tilt lim- iter couplers. 4. Loosen the screw “1”, and then measure the output voltage when sliding the mag- net “2” against the tilt limiter. 2.
Page 175 PTT system — MEMO — 5-44...
Page 176: Fuel System
Fuel system Hose routing ..............6-1 Fuel hose ................... 6-1 Air hose, pressure regulator hose, and vapor gas hose .... 6-2 Blowby hose and cooling water hose ........6-4 Fuel line ................6-5 Reducing the fuel pressure ............6-5 Measuring the fuel pressure ............6-5 Checking the pressure regulator ..........
Page 177 Fuel system Installing the throttle link ............6-23 Throttle body ..............6-25 Removing the throttle body assembly ........6-26 Checking the TPS ..............6-26 Installing the throttle body assembly ........6-26 Throttle body and throttle link adjustment ....6-27 Adjusting the TPS ..............6-27 Adjusting the throttle link ............
Page 178: Hose Routing
Hose routing Hose routing Fuel hose 1. Fuel hose (primer pump to joint) 12. Fuel hose (fuel cooler to vapor separator) 2. Fuel hose (joint to fuel filter assembly) a. Primer pump 3. Fuel hose (fuel filter assembly to joint) b.
Page 179: Air Hose, Pressure Regulator Hose, And Vapor Gas Hose
Hose routing Air hose, pressure regulator hose, and vapor gas hose 1. Vapor gas hose (vapor separator to joint) 9. Vapor gas hose (canister atmospheric 2. Vapor gas hose (vapor separator to joint) port to filter) 3. Vapor gas hose (joint to filter) 10.
Page 180 Hose routing f. Joint g. Joint h. Filter k. Joint m. Pressure regulator...
Page 181: Blowby Hose And Cooling Water Hose
Hose routing Blowby hose and cooling water hose 1. Blowby hose (cylinder head cover to a. Fuel cooler intake silencer) b. Cooling water pilot hole (on the bottom 2. Blowby hose (cylinder head cover to cyl- cowling) inder block) 3. Cooling water hose (exhaust cover to fuel cooler) 4.
Page 182: Fuel Line
Fuel line Fuel line Reducing the fuel pressure Before servicing the high-pressure fuel line or vapor separator, make sure to reduce the fuel pressure in the fuel line. Otherwise, pressurized fuel could spray out. Fuel pressure gauge “2”: 1. Remove the cap “1”. 90890-06753 2.
Page 183 Fuel line 3. Disconnect the pressure regulator hose “1”, and then connect the special service tool “2” to the pressure regulator “3”. 4. Block the end of the pressure regulator hose “1” using a rubber plug “4”. Vacuum/pressure pump gauge set “2”: 90890-06945 5.
Page 184: Fuel Filter
Fuel filter Fuel filter 5 N·m (0.5 kgf·m, 3.7 ft·lb) Part name Q’ty Remarks Joint Plastic tie Hose Joint to joint Hose Joint to fuel filter assembly M6 × 30 mm Bolt M6 × 14 mm Bolt Collar Grommet Bracket Hose Fuel filter assembly to joint Fuel filter assembly...
Page 185: Removing The Fuel Filter Assembly
Fuel filter Removing the fuel filter assembly Cover the fuel components using a rag to prevent fuel from spilling out. 1. Disconnect the fuel hoses “1” and “2”. 2. Disconnect the water detection switch coupler “a”. Checking the fuel filter assembly 1.
Page 186: Disassembling The Fuel Filter Assembly
Fuel filter When cleaning the fuel cup assembly, do not remove the clip and float. 2. Check the water detection switch. See “Checking the water detection switch” (5- 16). Checking the primer pump 1. Connect the special service tool “1” to the primer pump inlet “a”.
Page 187: Installing The Fuel Filter Assembly
Fuel filter 8. Install the fuel hose “1” to the holders “2” and “3”. 9. Connect the fuel hose “1”, and then fas- ten it using the plastic tie “4”. Fuel cup assembly “3”: 5 N·m (0.5 kgf·m, 3.7 ft·lb) Installing the fuel filter assembly 1.
Page 188: Fuel Pump
Fuel pump Fuel pump 10 N·m (1.0 kgf·m, 7.4 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks M6 × 35 mm Screw Cover Fuel pump body 2 Diaphragm Spring Fuel pump body 1...
Page 189 Fuel pump 10 N·m (1.0 kgf·m, 7.4 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks O-ring Not reusable Hose Joint to fuel pump Hose Joint to fuel pump 6-12...
Page 190: Removing The Fuel Pump Assembly
Fuel pump Removing the fuel pump assembly Cover the fuel components using a rag to prevent fuel from spilling out. 1. Disconnect the fuel hoses “1”, “2”, “3”, “4”, and “5”. Vacuum/pressure pump gauge set “1”: 90890-06945 Specified positive pressure: 50.0 kPa (0.50 kgf/cm , 7.3 psi) 3.
Page 191: Disassembling The Fuel Pump Assembly
Fuel pump Specified positive pressure: 50.0 kPa (0.50 kgf/cm , 7.3 psi) Disassembling the fuel pump assembly 1. Remove the cover “1”, diaphragm “2”, and fuel pump body 2 “3”. 5. Remove the diaphragm “1”, plunger “2”, and springs “3” and “4”. 2.
Page 192: Installing The Fuel Pump Assembly
Fuel pump 5. While holding fuel pump body 1 “1” in place, insert a flathead screwdriver into the hole “a” in the plunger “2” and turn it 90° until the tab “b” on the diaphragm is aligned with the slot “c” in fuel pump body 1 “1”.
Page 193 Fuel pump Fuel pump bolt “3”: 10 N·m (1.0 kgf·m, 7.4 ft·lb) 2. Connect the fuel hoses “1”, “2”, “3”, “4”, and “5”, and then fasten them using the plastic ties “6”. 6-16...
Page 194: Canister And Vapor Shut-Off Valve
Canister and vapor shut-off valve Canister and vapor shut-off valve Part name Q’ty Remarks Hose Filter to joint Plastic tie Joint Hose Joint to bottom cowling Clamp Filter Vapor shut-off valve Hose Canister to filter Canister M6 × 16 mm Bolt Bracket Hose...
Page 195: Removing The Canister
Canister and vapor shut-off valve Removing the canister 1. Disconnect the vapor gas hoses “1” and “2”. 2. Remove the spark plug wires from the holders. 3. Remove the vapor gas hose “3” from the holders “4”. 3. Remove the vapor shut-of valve “1”. 4.
Page 196: Checking The Vapor Shut-Off Valve
Canister and vapor shut-off valve Dimension “a”: 100.0 mm (3.93 in) 3. Connect the vapor gas hoses “1” and “2”, and then fasten them using the plastic Vacuum/pressure pump gauge set “1”: ties “3”. 90890-06945 TIP: 4. Apply the specified positive pressure and Connect the vapor gas hose “1”...
Page 197 Canister and vapor shut-off valve 2. Connect the vapor gas hoses “3” and “4”, and then fasten them using the plastic ties “5”. 3. Install the vaper gas hose “4” to the holder “6”. 4. Connect the vapor gas hoses “1”, “2”, and “3”, and then fasten them using the plastic ties “4”.
Page 198: Intake Silencer
Intake silencer Intake silencer 6 N·m (0.6 kgf·m, 4.4 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) Part name Q’ty Remarks Intake silencer assembly O-ring Not reusable Collar Collar Grommet × Bolt 20 mm Clamp × Bolt 45 mm 6-21...
Page 199: Throttle Link
Throttle link Throttle link Part name Q’ty Remarks × Bolt 35 mm Collar Wave washer Throttle cam Roller × Bolt 25 mm Collar Throttle lever 1 Washer Spring Throttle link rod Throttle lever 2 6-22...
Page 200: Removing The Throttle Link
Throttle link Removing the throttle link 1. Remove the clip “1” and throttle cable joint “2”. 5. Disconnect the throttle link joint assembly “1”. 2. Remove the throttle link rod “1” from the throttle cam “2”. 6. Remove the collar “1”, wave washer “2”, throttle lever 1 “3”, washer “4”, and roller “5”.
Page 201 Throttle link 2. Install throttle lever 1 “5” to cylinder block. 7. Install the throttle link rod “1” to the throt- 3. Install the spring “1” so that the spring tle cam “2”. end “a” fits into the groove “b” in the throt- tle cam “2”, and then install the washer “3”, wave washer “4”, and collar “5”.
Page 202: Throttle Body
Throttle body Throttle body 13 N·m (1.3 kgf·m, 9.6 ft·lb) Part name Q’ty Remarks Throttle link joint 1 Throttle link joint 2 Bracket × Bolt 16 mm × Bolt 20 mm × Bolt 70 mm Throttle body assembly × Screw 12 mm O-ring Not reusable...
Page 203: Removing The Throttle Body Assembly
Throttle body Removing the throttle body assembly 1. Disconnect the TPS coupler “a”. 2. Install new gaskets “1”. 3. Install the throttle body assembly “2”, and then tighten the throttle body assembly 2. Remove the brackets “1”. bolts “3” to the specified torque. 3.
Page 204: Throttle Body And Throttle Link Adjustment
Throttle body and throttle link adjustment 4. Tighten the locknut “1”. Throttle body and throttle link Adjusting the throttle valve reference adjustment opening angle Adjusting the throttle link If there is dirt in the passages in the throttle 1. Turn throttle lever 2 “1” until it contacts body, it may affect the intake air pressure and the stopper “a”...
Page 205 Throttle body and throttle link adjustment 4. Loosen the TPS screws “1” and adjust TIP: the position of the TPS “2” to get the Warm up the engine so that the engine tem- specified output voltage. perature displayed on the YDIS screen is 51 °C (123.8 °F) or more.
Page 206 Throttle body and throttle link adjustment TIP: • To increase the output voltage, turn the TPS “2” in direction “a”. • To decrease the output voltage, turn the TPS “2” in direction “b”. Vacuum gauge “2”: 90890-03159 TPS output voltage: 0.70–0.72 V 14.
Page 207: Fuel Injector
Fuel injector Fuel injector 13 N·m (1.3 kgf·m, 9.6 ft·lb) 10 mm (0.39 in) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 12 mm (0.47 in) 13 N·m (1.3 kgf·m, 9.6 ft·lb) Part name Q’ty Remarks Holder × Bolt 18 mm Fuel rail Clamp O-ring set Not reusable...
Page 208: Removing The Fuel Injector
Fuel injector Removing the fuel injector Cover the fuel components using a rag to prevent fuel from spilling out. 1. Reduce the fuel pressure. See “Reducing the fuel pressure” (6-4). 2. Disconnect the fuel injector couplers “a” and fuel pump coupler “b”. 3.
Page 209: Checking The Fuel Rail And Fuel Injector
Fuel injector 4. Remove the fuel cooler “1”. Fuel injection volume: 132–152 cm (132–152 cc)/30 sec Test fuel: Dry sorbent (viscosity: 1.2 ± 0.02 mm specific gravity: 0.774 [15 °C]) Test fuel temperature: 21 ± 1 °C (room temperature and test fuel temperature should be the same) Test fuel pressure: 300 ±...
Page 210: Installing The Fuel Injector
Fuel injector Installing the fuel injector Fuel rail bolt “2”: 1. Install a new O-ring “1” and a new rubber 13 N·m (1.3 kgf·m, 9.6 ft·lb) seal “2” to the fuel injector “3”. 5. Install the fuel pump coupler “a” to the fuel rail.
Page 211: Intake Manifold And Vapor Separator
Intake manifold and vapor separator Intake manifold and vapor separator 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) Part name Q’ty Remarks Dowel Gasket Not reusable Hose with filter Hose to joint Holder Plastic tie Hose Joint to joint Joint Hose...
Page 212 Intake manifold and vapor separator 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) Part name Q’ty Remarks Filter Hose Filter to vapor separator Wiring harness × Screw 15 mm Air pressure sensor Filter O-ring Not reusable ×...
Page 213 Intake manifold and vapor separator 5 N·m (0.5 kgf·m, 3.7 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) Part name Q’ty Remarks Intake manifold Hose Fuel cooler to vapor separator Hose Pressure regulator to fuel cooler 6-36...
Page 214: Draining The Fuel
Intake manifold and vapor separator Draining the fuel 1. Loosen the vapor separator drain screw “1”, and then remove the cap “2”. 2. Push the air valve “3” inward. 4. Remove the intake manifold “1” and dow- els “2”. 3. Tighten the vapor separator drain screw to the specified torque.
Page 215: Checking The Fuel Filter
Intake manifold and vapor separator 6. Remove the drain hose “1” and fuel hose 10. Disconnect the vapor gas hose with filter “2”. “1” and vapor gas hoses “2” and “3”. 7. Disconnect the fuel hoses “1”, “2”, and Checking the fuel filter “3”, and remove the fuel filter “4”.
Page 216: Installing The Vapor Separator
Intake manifold and vapor separator Installing the vapor separator 7. Connect the fuel hose “6”, and then fas- ten it using the clamp “7”. 1. Connect the vapor gas hoses “1” and “2” and vapor gas hose with filter “3” to the joint “4”.
Page 217: Installing The Intake Manifold
Intake manifold and vapor separator 13. Route the fuel hose “2” through the gap 19. Fasten the fuel filter “1”, vapor gas hose “c” in the intake manifold. with filter “2”, and air hose “3” using the plastic ties “4”. Installing the intake manifold 1.
Page 218 Intake manifold and vapor separator 5. Connect the ISC valve coupler “a” and air pressure sensor coupler “b”. 6. Install the holder “1” to the intake mani- fold. 6-41...
Page 219: Vapor Separator And High-Pressure Fuel Pump
Vapor separator and high-pressure fuel pump Vapor separator and high-pressure fuel pump 2 N·m (0.2 kgf·m, 1.5 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) Part name Q’ty Remarks ×...
Page 220: Disassembling The Vapor Separator
Vapor separator and high-pressure fuel pump Disassembling the vapor separator 1. Remove the pressure regulator “1”. 5. Disconnect the lead coupler “a”. 6. Remove the needle valve assembly “1”. 2. Remove the cover “1”, gasket “2”, and fil- ter holder “3”. 7.
Page 221: Assembling The Vapor Separator
Vapor separator and high-pressure fuel pump Float chamber plate screw “3”: 2 N·m (0.2 kgf·m, 1.5 ft·lb) 2. Connect the lead coupler “a”. 3. Install the needle valve assembly “1”, and then tighten the needle valve screw “2” to the specified torque. 2.
Page 222 Vapor separator and high-pressure fuel pump 9. Install a new gasket “1”, the filter holder “2”, and the cover “3”, and then tighten the float chamber cover screws “4” to the specified torque. Float chamber cover screw “4”: 2 N·m (0.2 kgf·m, 1.5 ft·lb) 10.
Page 223 Power unit Power unit (check and adjustment) ......... 7-1 Checking the compression pressure ......... 7-1 Checking the oil pressure ............7-1 Checking the valve clearance ........... 7-1 Adjusting the valve clearance ............ 7-3 Power unit assembly ............7-5 Removing the power unit ............7-7 Installing the power unit .............
Page 224: Power Unit
Checking the thermostat ............7-50 Checking the exhaust cover anode ......... 7-50 Installing the exhaust cover ............. 7-51 Cylinder block (F150A, FL150A) ........7-52 Removing the oil pump assembly ........... 7-54 Removing the oil filter bracket ..........7-54 Removing the balancer assembly ........... 7-54 Disassembling the oil pump ............
Page 225 Power unit Removing the oil filter bracket ..........7-60 Removing the crankcase cover ..........7-60 Disassembling the oil pump ............ 7-60 Checking the oil pump ............. 7-60 Assembling the oil pump ............7-60 Installing the oil pump assembly ..........7-60 Installing the crankcase cover ..........
Page 226: Power Unit (Check And Adjustment)
Power unit (check and adjustment) Power unit (check and Checking the oil pressure 1. Connect the YDIS to display “Oil pres- adjustment) sure”. Checking the compression pressure 1. Start the engine, warm it up for 5 min- 2. Start the engine and warm it up until the utes, and then stop it.
Page 227 Power unit (check and adjustment) 4. Remove the canister. See “Removing the canister” (6-18). 5. Disconnect the spark plug wires “1”, and then remove the blowby hoses “2” and “3”, all of the spark plugs, and cylinder head cover “4”. 6.
Page 228: Adjusting The Valve Clearance
Power unit (check and adjustment) 10. Measure the intake and exhaust valve 15. Install the canister. See “Installing the clearances of the specified cylinders. canister” (6-19). Adjust if out of specification. See “Adjust- 16. Install the fuel pump assemblies. See ing the valve clearance”...
Page 229 Power unit (check and adjustment) 4. Remove the driven sprockets, camshaft 12. Install the flywheel magnet. See “Install- caps, and camshafts. See “Removing the ing the flywheel magnet” (7-15). driven sprocket and camshaft” (7-35). 5. Remove the valve lifters. See step 1 in “Removing the cylinder head”...
Page 230: Power Unit Assembly
Power unit assembly Power unit assembly 4 N·m (0.4 kgf·m, 3.0 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) Part name Q’ty Remarks Grommet Cover Cover Apron M6 × 40 mm Screw M8 ×...
Page 231 Power unit assembly 4 N·m (0.4 kgf·m, 3.0 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) Part name Q’ty Remarks Dipstick guide M6 × 16 mm Bolt Dipstick...
Page 232: Removing The Power Unit
Power unit assembly Removing the power unit 1. Remove the clip “1” and throttle cable “2”. 6. Disconnect the fuel hose “1”. 2. Disconnect the battery cables “1”. 3. Remove the junction box cover “2”. 7. Disconnect the vapor gas hose “1”. 4.
Page 233 Power unit assembly 12. Disconnect the shift cut-off switch cou- pler “a” and shift position switch coupler “b”. 10. Remove the 6Y8 Multifunction Meter har- ness coupler “a” and gauge harness cou- pler “b” from the bracket “1”. 13. Disconnect the cooling water pilot hose “1”.
Page 234: Installing The Power Unit
Power unit assembly 16. Install the lifting harnesses to the engine hangers “1”. 17. Suspend the power unit. Power unit mounting bolt (M8) “3”: 18. Remove the power unit mounting bolts 20 N·m (2.0 kgf·m, 14.8 ft·lb) “2”, “3”, and “4”, and then remove the Power unit mounting bolts (M10) “4”...
Page 235 Power unit assembly 5. Connect the cooling water pilot hose “1”. A. 6Y8 Multifunction Meter B. Conventional gauge harness 8. Install the 6Y8 Multifunction Meter har- ness coupler “a” and gauge harness cou- pler “b” to the bracket “1”. 6. Connect the shift cut-off switch coupler “a”...
Page 236 Power unit assembly 11. Connect the vapor gas hose “1”, and PTT motor lead bolt “2”: then fasten it using the clamp “2”. 4 N·m (0.4 kgf·m, 3.0 ft·lb) 15. Install the junction box cover “1”. 16. Connect the battery cables “2”, and then tighten the battery cable nut “3”...
Page 237: Flywheel Magnet
Flywheel magnet Flywheel magnet 270 N·m (27.0 kgf·m, 199.1 ft·lb) Part name Q’ty Remarks Width across flats: 36 mm Washer Apply oil on both sides of the washer. Base assembly M6 × 30 mm Screw Stator assembly Pulser coil Holder Bracket M6 ×...
Page 238: Removing The Flywheel Magnet
Flywheel magnet Removing the flywheel magnet 1. Loosen the flywheel magnet nut. Apply force in the direction of the arrow to prevent the flywheel holder “1” from slip- ping off easily. A. Conventional special service tool B. New special service tool Flywheel puller “1”: 90890-06521 Hydro puller kit “4”: 90890-06593 Removing the stator assembly...
Page 239: Installing The Stator Assembly
Flywheel magnet 3. Remove the holders “1” and “2” and blowby hose “3”. 4. Remove the wiring harness “1” from the holders “2”. 2. Install the wiring harness “1” to the hold- ers “2”. 5. Remove the stator assembly “1” and pulser coil “2”.
Page 240: Installing The Flywheel Magnet
Flywheel magnet 5. Connect the pulser coil coupler “a”, and then install the pulser coil coupler “a” to the bracket “1”. Installing the flywheel magnet 1. Install the Woodruff key “1”, and then install the flywheel magnet “2” and fly- wheel magnet nut “3”.
Page 241: Timing Belt
Timing belt Timing belt 39 N·m (3.9 kgf·m, 28.8 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks Timing belt Timing belt tensioner Plate Dowel M6 × 10 mm Screw Plate Drive sprocket M5 × 40 mm Bolt 7-16...
Page 242: Removing The Timing Belt
Timing belt Removing the timing belt 3. Remove the timing belt “1” from the driven sprocket side. When the timing belt is not installed, do not turn the crankshaft or driven sprocket. Otherwise, the pistons and valves could collide with each other and be damaged. 1.
Page 243: Installing The Timing Belt
Timing belt Do not apply grease or oil to the timing belt. Drive sprocket bolt “4”: 3. Adjust the timing belt to the specified 7 N·m (0.7 kgf·m, 5.2 ft·lb) installation height “a”. Installing the timing belt When the timing belt is not installed, do not turn the crankshaft or driven sprocket.
Page 244 Timing belt 5. Turn the crankshaft clockwise 2 full turns, and then check that the mark “a” in the drive sprocket and the protrusion “b” on the cylinder block are aligned. Also, check that the “I” marks “c” and “d” on the driven sprockets are aligned.
Page 245: Starter Motor
Starter motor Starter motor 30 N·m (3.0 kgf·m, 22.1 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) Part name Q’ty Remarks Terminal Starter motor M8 × 45 mm Bolt M6 ×...
Page 246: Removing The Starter Motor
Starter motor Removing the starter motor 1. Remove the cap “1” and terminal “2”, and then disconnect the positive lead “3”. Starter motor mounting bolt “2”: 30 N·m (3.0 kgf·m, 22.1 ft·lb) 2. Connect the starter motor lead “1”, and 2.
Page 247 Starter motor Terminal nut “3”: 9 N·m (0.9 kgf·m, 6.6 ft·lb) 7-22...
Page 248: Rectifier Regulator And Ignition Coil
Rectifier Regulator and ignition coil Rectifier Regulator and ignition coil 25 N·m (2.5 kgf·m, 18.4 ft·lb) 10 11 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks Rectifier Regulator Gasket Not reusable M6 × 30 mm Bolt M6 × 16 mm Bolt Spark plug wire #1 Spark plug wire #2...
Page 249 Rectifier Regulator and ignition coil 25 N·m (2.5 kgf·m, 18.4 ft·lb) 10 11 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks Hose Exhaust cover to fuel cooler Spark plug 7-24...
Page 250: Removing The Rectifier Regulator
Rectifier Regulator and ignition coil Removing the Rectifier Regulator 3. Remove the ignition coils “3”. 1. Disconnect the Rectifier Regulator cou- pler “a”, and then remove the ground lead “1”. 2. Remove the Rectifier Regulator “1”. Checking the spark plug 1.
Page 251: Installing The Ignition Coil
Rectifier Regulator and ignition coil Installing the ignition coil 1. Install the ignition coils “1”, and then tighten the ignition coil bolts “2” to the specified torque. 2. Install the wiring harness “3” to the hold- ers “4”, and then connect the ignition coil couplers “a”.
Page 252: Fuse Box
Fuse box Fuse box Part name Q’ty Remarks Fuse box assembly Fuse 50 A M5 × 10 mm Screw Fuse 20 A Relay Fuse 30 A M5 × 20 mm Screw Cover Gasket Fuse puller Fuse 20 A, Spare Fuse 30 A, Spare 7-27...
Page 253: Wiring Harness
Wiring harness Wiring harness 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks Wiring harness Cover ø6 × 19 mm Screw Wiring harness M6 × 16 mm Bolt Plastic tie M6 ×...
Page 254 Wiring harness 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks Grommet Collar Grommet Junction box M6 × 16 mm Bolt ø6 × 19 mm Screw Holder ø6 ×...
Page 255: Removing The Wiring Harness
Wiring harness Removing the wiring harness 6. Remove the 10-pin wiring harness cou- pler “a” from the holder “1”. 1. Disconnect the thermoswitch connectors “a”. 7. Remove the joint connectors “b”. 2. Remove the bracket “1”. 8. Remove the junction box “1” along with the wiring harness.
Page 256: Installing The Wiring Harness
Wiring harness 12. Disconnect the air temperature sensor coupler “c”, and then remove the YDIS coupler “d”. 13. Remove the holder “5” and plastic ties “6” and “7”. PTT relay lead nut “5”: 4 N·m (0.4 kgf·m, 3.0 ft·lb) Starter relay lead bolt “6”: 4 N·m (0.4 kgf·m, 3.0 ft·lb) 5.
Page 257 Wiring harness 12. Install the bracket “1”. 7. Install the joint connectors “a”. 8. Install the 10-pin wiring harness coupler “b” to the holder “1”. 13. Connect the thermoswitch connectors “a”. 9. Connect the engine temperature sensor coupler “a”. 10. Install the ground leads “1”. 11.
Page 258: Camshaft
Camshaft Camshaft 2 N·m (0.2 kgf·m, 1.5 ft·lb) 60 N·m (6.0 kgf·m, 44.3 ft·lb) 8 10 9 N·m (0.9 kgf·m, 6.6 ft·lb) 17 N·m (1.7 kgf·m, 12.5 ft·lb) Part name Q’ty Remarks M6 × 42 mm Bolt Bracket Grommet Collar M6 ×...
Page 259 Camshaft 2 N·m (0.2 kgf·m, 1.5 ft·lb) 60 N·m (6.0 kgf·m, 44.3 ft·lb) 8 10 9 N·m (0.9 kgf·m, 6.6 ft·lb) 17 N·m (1.7 kgf·m, 12.5 ft·lb) Part name Q’ty Remarks Camshaft Oil seal Not reusable Dowel Camshaft Driven sprocket M10 ×...
Page 260: Removing The Driven Sprocket And Camshaft
Camshaft Removing the driven sprocket and Checking the driven sprocket camshaft 1. Check the driven sprockets. Replace if cracked, damaged, or worn. Checking the camshaft When the timing belt is not installed, do 1. Measure the cam lobe height “a” and not turn the crankshaft or driven sprock- width “b”.
Page 261: Installing The Driven Sprocket And Camshaft
Camshaft 63P EX 63P IN Camshaft journal diameter “a”: 24.960–24.980 mm (0.9827–0.9835 in) Cylinder head journal inside diameter “b”: 25.000–25.021 mm (0.9843–0.9851 in) Installing the driven sprocket and camshaft When the timing belt is not installed, do not turn the crankshaft or driven sprock- ets.
Page 262 Camshaft 6. Install the driven sprockets “1”. 7. Secure the camshaft using a wrench, and then tighten the driven sprocket bolts “2” to the specified torque. Driven sprocket bolt “2”: 60 N·m (6.0 kgf·m, 44.3 ft·lb) 8. Install the cylinder head cover. See step 11 in “Checking the valve clearance”...
Page 263: Cylinder Head
Cylinder head Cylinder head 14 N·m (1.4 kgf·m, 10.3 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 28 N·m (2.8 kgf·m, 20.7 ft·lb) 19 20 28 N·m (2.8 kgf·m, 20.7 ft·lb) 56 N·m (5.6 kgf·m, 41.3 ft·lb) 90° Part name Q’ty Remarks Valve lifter Valve cotter...
Page 264 Cylinder head 14 N·m (1.4 kgf·m, 10.3 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 28 N·m (2.8 kgf·m, 20.7 ft·lb) 19 20 28 N·m (2.8 kgf·m, 20.7 ft·lb) 56 N·m (5.6 kgf·m, 41.3 ft·lb) 90° Part name Q’ty Remarks M8 × 55 mm Bolt Plug Gasket...
Page 265: Removing The Cylinder Head
Cylinder head Removing the cylinder head TIP: 1. Remove the valve lifters “1”. Make sure to keep the parts in the order of removal. TIP: Make sure to keep the parts in the order of removal. 2. Remove the cylinder head “1”. Valve spring compressor “1”: 90890-04019 Valve spring compressor attachment “2”: Do not scratch or damage the mating sur-...
Page 266: Checking The Cylinder Head
Cylinder head Checking the cylinder head 1. Remove carbon deposits from the com- bustion chambers, and then check the cylinder head for damage and scratches. 2. Check the cylinder head warpage using a straightedge “1” and a thickness gauge “2” in 7 directions. Replace the cylinder head if above specification.
Page 267: Checking The Valve Guide
Cylinder head Replacing the valve guide Valve stem diameter “a”: After replacing a valve guide, check the valve Intake: seat contact area. 5.477–5.492 mm (0.2156–0.2162 in) Exhaust: 1. Remove the valve guide “1” from the 5.464–5.479 mm (0.2151–0.2157 in) combustion chamber side. 4.
Page 268: Checking The Valve Seat
Cylinder head 4. Measure the valve seat contact width “a” TIP: where the blueing dye is adhered to the • To ream the valve guide, turn the valve valve face. Reface the valve seat if the guide reamer clockwise. valve is not seated properly or if the valve •...
Page 269 Cylinder head a. Slag or rough surface 3. Adjust the top edge of the valve seat con- tact width using a 30° cutter. 30˚ Valve seat cutter holder: 90890-06316 Intake: Valve seat cutter 30°: 90890-06327 Valve seat cutter 45°: 90890-06325 a.
Page 270: Checking The Cylinder Head And Cylinder Block Anode
Cylinder head Example: a. Previous contact width • If the valve seat contact area is too wide 7. After refacing the valve seat to the speci- and situated in the center of the valve face, fied contact width, apply a thin, even cut the top edge of the valve seat using a layer of lapping compound onto the valve 30°...
Page 271: Installing The Cylinder Head
Cylinder head 2. Install the valve “1”, valve spring seat “2”, valve spring “3”, and valve spring retainer “4” in this order, and then install the spe- cial service tools “5” and “6”. Installing the cylinder head 1. Install the dowels “1”, a new gasket “2”, the cylinder head “3”, and the cylinder head bolts “4”...
Page 272 Cylinder head 4. Tighten the cylinder head bolts “2” to the specified torques in 2 stages and in the order [11], [12], and so on. [10] [17] [15] [13] [11] [12] [14] [16] [20] [19] [18] Cylinder head bolt “1” [1]–[10] (M10): 1st: 28 N·m (2.8 kgf·m, 20.7 ft·lb) 2nd: 56 N·m (5.6 kgf·m, 41.3 ft·lb) 3rd: 90°...
Page 273: Exhaust Cover
Exhaust cover Exhaust cover 6 N·m (0.6 kgf·m, 4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 56 N·m (5.6 kgf·m, 41.3 ft·lb) Part name Q’ty Remarks...
Page 274 Exhaust cover 6 N·m (0.6 kgf·m, 4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 6 N·m (0.6 kgf·m, 4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 56 N·m (5.6 kgf·m, 41.3 ft·lb) Part name Q’ty Remarks Spring...
Page 275: Removing The Exhaust Cover
Exhaust cover Removing the exhaust cover 1. Remove the thermoswitch “1”, thermo- stat “2”, and PCV “3”. Checking the thermostat 1. Suspend the thermostat in a container of water. 2. Place a thermometer in the water, and then heat the water slowly. 2.
Page 276: Installing The Exhaust Cover
Exhaust cover 4. Install the thermoswitch “6”. Do not apply grease, oil, or paint to the 5. Install the grommet “7”, the PCV “8”, the anodes. spring “9”, a new gasket “10”, and the cover “11”. Installing the exhaust cover 1.
Page 277: Cylinder Block (F150A, Fl150A)
Cylinder block (F150A, FL150A) Cylinder block (F150A, FL150A) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb)
Page 278 Cylinder block (F150A, FL150A) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb)
Page 279: Removing The Oil Pump Assembly
Cylinder block (F150A, FL150A) Removing the oil pump assembly 1. Remove the oil pump assembly “1”. Disassembling the oil pump 1. Remove the oil pump cover “1”, gasket Removing the oil filter bracket “2”, outer rotor “3”, inner rotor “4”, and oil seals “5”...
Page 280: Installing The Oil Pump Assembly
Cylinder block (F150A, FL150A) Oil pump cover screw “5”: 4 N·m (0.4 kgf·m, 3.0 ft·lb) Installing the oil pump assembly 1. Fill the oil pump assembly with engine oil through the oil passage. Driver rod L3 “3”: 90890-06652 Needle bearing attachment “4”: 90890-06611 2.
Page 281: Installing The Oil Filter Bracket
Cylinder block (F150A, FL150A) 2. Apply a thin, even layer of sealant onto [12] the mating surface of the balancer assembly. [10] [11] 3. Align the marks “a” on the balancer shafts with the marks “b”. Balancer assembly bolt “2”: 1st: 18 N·m (1.8 kgf·m, 13.3 ft·lb)
Page 282 Cylinder block (F150A, FL150A) Oil filter wrench “2”: 90890-06830 Oil filter “1”: 18 N·m (1.8 kgf·m, 13.3 ft·lb) 7-57...
Page 283: Cylinder Block (F150B, Fl150B)
Cylinder block (F150B, FL150B) Cylinder block (F150B, FL150B) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 34 N·m (3.4 kgf·m, 25.1 ft·lb) 31 N·m (3.1 kgf·m, 22.9 ft·lb)
Page 284 Cylinder block (F150B, FL150B) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 34 N·m (3.4 kgf·m, 25.1 ft·lb) 31 N·m (3.1 kgf·m, 22.9 ft·lb)
Page 285: Removing The Oil Pump Assembly
Cylinder block (F150B, FL150B) Removing the oil pump assembly 2. Install the crankcase cover “1”, and then tighten the crankcase cover bolts “2” and See “Removing the oil pump assembly” (7- “3” to the specified torque in 2 stages and 54).
Page 286: Crankcase
Crankcase Crankcase 30 N·m (3.0 kgf·m, 22.1 ft·lb) 14 N·m (1.4 kgf·m, 10.3 ft·lb) 28 N·m (2.8 kgf·m, 20.7 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 90° Part name Q’ty Remarks Crankcase...
Page 287 Crankcase 30 N·m (3.0 kgf·m, 22.1 ft·lb) 14 N·m (1.4 kgf·m, 10.3 ft·lb) 28 N·m (2.8 kgf·m, 20.7 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 23 N·m (2.3 kgf·m, 17.0 ft·lb) 90° Part name Q’ty Remarks Piston pin...
Page 288: Disassembling The Cylinder Block
Crankcase Disassembling the cylinder block 1. Remove the crankcase “1”. 2. Remove the main bearing cap “1”. 4. Remove the crankshaft “1”, crankshaft journal bearings “2”, thrust bearing “3”, and oil seal “4”. 3. Remove the connecting rod bolts “1” and connecting rod caps “2”, and then remove the piston and connecting rod assemblies “3”.
Page 289: Checking The Piston Diameter
Crankcase Checking the cylinder bore Bearing separator “2”: 90890-06534 1. Measure the cylinder bore (D –D ) at Gear puller “3”: 90890-06540 measuring points “a”, “b”, and “c”, and in General cylindrical tool “4”: directions “d” (D ) and “e” (D a = 19.9 mm (0.78 in) b = 90.0 mm (3.54 in) 6.
Page 290: Checking The Piston Ring End Gap
Crankcase Checking the piston ring end gap Checking the piston ring side 1. Level the piston ring “1” in the cylinder clearance using a piston crown at the specified 1. Measure the piston ring side clearance. measuring point “a”. 2. Measure the piston ring end gap “b”. Piston ring side clearance: Top ring “a”: 0.04–0.08 mm (0.0016–0.0031 in)
Page 291: Checking The Piston Pin Diameter
Crankcase Checking the piston pin diameter Connecting rod small end inside diameter 1. Measure the piston pin diameter “a”. “b”: 21.022–21.037 mm (0.8276–0.8282 in) Connecting rod big end inside diameter “c”: 53.025–53.045 mm (2.0876–2.0884 in) Checking the connecting rod big end side clearance 1.
Page 292: Checking The Big End Oil Clearance
Crankcase Crankshaft journal diameter “a”: TIP: 51.980–52.000 mm Do not place the Plastigauge (PG-1) over the (2.0465–2.0472 in) oil hole in the crankpin of the crankshaft. Crankpin diameter “b”: 49.980–50.000 mm (1.9677–1.9685 in) Crankpin width “c”: 22.000–22.100 mm (0.8661–0.8701 in) 2.
Page 293: Selecting The Crankpin Bearing
Crankcase TIP: In the third tightening stage for the connect- ing rod bolts “1”, mark the connecting rod bolts and the connecting rod cap with identifi- cation marks “a”, and then tighten the bolts 90° from the marks on the connecting rod cap.
Page 294 Crankcase Upper bearing Lower bearing color color “a” Green Green “b” Green Blue “c” Blue Blue “d’ Blue “e” Example: If the connecting rod big end inside diameter is “35” and the crankpin mark is “81”, select the bearing colors in “d”. The upper bearing color is blue and the lower bearing color is red.
Page 295: Crankpin Bearing Selection Table
Crankcase Crankpin bearing selection table 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 A. Connecting rod big end inside diameter B. Crankpin mark 7-70...
Page 296: Checking The Journal Oil Clearance
Crankcase Checking the journal oil clearance 6. Install the main bearing cap “1”, and then tighten the main bearing cap bolts “2” to 1. Clean the crankshaft journal bearings, the specified torques in 2 stages and in crankshaft journals, and bearing portions the order [1], [2], and so on.
Page 297: Selecting The Crankshaft Journal Bearing
Crankcase 7. Install the crankcase “1”, and then tighten 8. Remove the crankcase, and then mea- the crankcase bolts “2” and “3” to the sure the width of the compressed Plasti- specified torques in 2 stages and in the gauge (PG-1) each crankshaft...
Page 298 Crankcase J5 J4 J3 J2 J1 b 20 21 31 32 33 2. Select the suitable colors “1” for the crankshaft journal bearing from the “Crankshaft journal bearing selection table”. J1/J2/ Upper bearing Lower bearing J4/J5 color color “a” Green Green “b”...
Page 299: Crankshaft Journal Bearing Selection Table
Crankcase Crankshaft journal bearing selection table 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 A. Cylinder block mark B. Crankshaft journal mark 7-74...
Page 300: Assembling The Cylinder Block
Crankcase Assembling the cylinder block TIP: 1. Install a new collar “1” by striking it using • Make sure that the “2R” mark “a” on the a plastic hammer. 2nd ring “2” and “R” mark “b” on the top ring “1”...
Page 301 Crankcase Piston ring compressor “1”: 90890-05158 7. Install the crankshaft journal bearings “1” and thrust bearing “2” into the cylinder block “3”. 9. Install the connecting rod caps “1” to the piston and connecting rod assemblies, TIP: and then tighten new connecting rod •...
Page 302 Crankcase Connecting rod bolt “2”: 1st: 13 N·m (1.3 kgf·m, 9.6 ft·lb) 2nd: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 3rd: 90° 10. Install the crankshaft journal bearings “1” into the main bearing cap. Main bearing cap bolts “2”: 1st: 30 N·m (3.0 kgf·m, 22.1 ft·lb) 2nd: 90°...
Page 303 Crankcase TIP: In the second tightening stage for the M10 bolts “3”, mark the M10 bolts and the crank- case with identification marks “a”, and then tighten the bolts 90° from the marks on the crankcase. [13] [14] [10] [12] [11] Crankcase bolts “3”...
Page 304 Lower unit Lower unit (regular rotation model, L-transom model) ..... 8-1 Removing the lower unit ............8-3 Disassembling the propeller (SDS propeller) ......8-3 Checking the propeller .............. 8-3 Checking the lower unit anode ..........8-3 Assembling the propeller (SDS propeller) ......... 8-4 Lower unit (regular rotation model, X-transom model) ....
Page 305 Lower unit Checking the lower case ............8-23 Assembling the forward gear ........... 8-23 Assembling the drive shaft housing ......... 8-23 Assembling the lower case ............8-24 Installing the drive shaft ............8-25 Installing the propeller shaft housing assembly ....... 8-26 Installing the shift rod ..............
Page 306: Lower Unit
Lower unit Water pump and shift rod (counter rotation model) ..8-51 Removing the water pump and shift rod ........8-53 Disassembling the water pump housing ........8-53 Checking the water pump and shift rod ........8-53 Assembling the water pump housing ........8-53 Propeller shaft housing (counter rotation model) ..
Page 307 Lower unit Shimming check sheet ............8-67 Measuring the forward gear backlash and reverse gear backlash before disassembly ......8-69 Shimming procedure ............... 8-72 Shim location ................8-72 Selecting the pinion shim (T3) ..........8-73 Selecting the propeller shaft shim (T4) ........8-73 Measuring the forward gear backlash ........
Page 308: Lower Unit
Lower unit (regular rotation model, L-transom model) Lower unit (regular rotation model, L-transom model) 43 N·m (4.3 kgf·m, 31.7 ft·lb) 55 N·m (5.5 kgf·m, 40.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) Part name Q’ty...
Page 309 Lower unit (regular rotation model, L-transom model) 43 N·m (4.3 kgf·m, 31.7 ft·lb) 55 N·m (5.5 kgf·m, 40.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) Part name Q’ty Remarks...
Page 310: Removing The Lower Unit
Lower unit (regular rotation model, L-transom model) Removing the lower unit TIP: When disassembling the lower unit, measure the backlash before disassembly. See “Mea- • Make sure to disconnect the battery suring the forward gear backlash and reverse cables from the battery, and remove the gear backlash before disassembly”...
Page 311: Assembling The Propeller (Sds Propeller)
Lower unit (regular rotation model, L-transom model) Do not apply grease, oil, or paint to the trim tab. Assembling the propeller (SDS propeller) 1. Place a new damper “1” in the propeller “2”. TIP: Align the mark “a” on the damper “1” with the mark “b”...
Page 312 Lower unit (regular rotation model, L-transom model) A. Before tightening the propeller nut “3” to the specified torque. B. After tightening the propeller nut “3” to the specified torque. Installation depth “a” (reference data): 9.4 mm (0.37 in)
Page 313 Lower unit (regular rotation model, X-transom model) Lower unit (regular rotation model, X-transom model) 43 N·m (4.3 kgf·m, 31.7 ft·lb) 55 N·m (5.5 kgf·m, 40.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) Part name...
Page 314 Lower unit (regular rotation model, X-transom model) 43 N·m (4.3 kgf·m, 31.7 ft·lb) 55 N·m (5.5 kgf·m, 40.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) Part name Q’ty...
Page 315: Removing The Lower Unit
Lower unit (regular rotation model, X-transom model) Removing the lower unit Disassembling the propeller (SDS propeller) See “Disassembling the propeller (SDS pro- peller)” (8-3). • Make sure to disconnect the battery cables from the battery, and remove the Checking the propeller clip from the engine shut-off switch.
Page 316: Water Pump And Shift Rod (Regular Rotation Model)
Water pump and shift rod (regular rotation model) Water pump and shift rod (regular rotation model) Part name Q’ty Remarks Shift rod E-clip O-ring Not reusable Plate M6 × 20 mm Bolt Oil seal Not reusable Collar Spacer Washer Wave washer Impeller Outer plate cartridge Gasket...
Page 317 Water pump and shift rod (regular rotation model) Part name Q’ty Remarks O-ring Not reusable Insert cartridge O-ring Not reusable Water pump housing M8 × 45 mm Bolt Seal Cover 8-10...
Page 318: Removing The Water Pump And Shift Rod
Water pump and shift rod (regular rotation model) Removing the water pump and shift 1. Remove the water pump housing “1”, O-ring “2”, dowels “3”, collar “4”, spacer “5”, washers “6”, wave washer “7”, and impeller “8”. 2. Remove the Woodruff key “9”, outer plate cartridge “10”, and gasket “11”.
Page 319: Assembling The Water Pump Housing
Water pump and shift rod (regular rotation model) TIP: If the engine overheats, the inside of the water pump housing may be deformed. Therefore, make sure to remove the insert cartridge when checking the water pump housing. 2. Check the impeller, insert cartridge, and outer plate cartridge.
Page 320: Propeller Shaft Housing (Regular Rotation Model)
5.54 mm (0.22 in) (reference data) Ball 4.74 mm (0.19 in) (reference data) Ball 8.72 mm (0.34 in) (reference data) Spring Dog clutch F150A: Six teeth Dog clutch F150B: Ten teeth Cross pin Spring Propeller shaft Reverse gear shim (T2) —...
Page 321 Propeller shaft housing (regular rotation model) 145 N·m (14.5 kgf·m, 106.9 ft·lb) Part name Q’ty Remarks Needle bearing Not reusable Oil seal Not reusable Claw washer Ring nut 8-14...
Page 322: Removing The Propeller Shaft Housing Assembly
Propeller shaft housing (regular rotation model) Removing the propeller shaft housing assembly 1. Straighten the bent tab “1” on the claw washer. Bearing housing puller claw L “1”: 90890-06502 Stopper guide plate “2”: 90890-06501 Center bolt “3”: 90890-06504 2. Loosen the ring nut. 5.
Page 323: Disassembling The Propeller Shaft Housing Assembly
Propeller shaft housing (regular rotation model) 3. Remove the oil seals “1” along with the needle bearing “2”. Disassembling the propeller shaft housing assembly Driver rod L3 “3”: 90890-06652 1. Remove the reverse gear “1” and thrust Needle bearing attachment “4”: washer “2”.
Page 324: Assembling The Propeller Shaft Assembly
Propeller shaft housing (regular rotation model) Assembling the propeller shaft assembly 1. Install the spring “1”, balls “2”, “3”, and “4”, and slider “5”. TIP: When installing the slider “5”, make sure that the balls do not fall out of position. Assembling the propeller shaft housing assembly 1.
Page 325 Propeller shaft housing (regular rotation model) TIP: Install an oil seal halfway into the propeller shaft housing, and then install the other oil seal. Needle bearing attachment “2”: 90890-06654 5. Check that the reverse gear turns smoothly. Bearing inner race attachment “2”: 6.
Page 326: Drive Shaft And Lower Case (Regular Rotation Model)
Drive shaft and lower case (regular rotation model) Drive shaft and lower case (regular rotation model) 95 N·m (9.5 kgf·m, 70.1 ft·lb) 1 N·m (0.1 kgf·m, 0.7 ft·lb) Part name Q’ty Remarks Thrust bearing Pinion shim (T3) — O-ring Not reusable Needle bearing Not reusable Drive shaft housing...
Page 327 Drive shaft and lower case (regular rotation model) 95 N·m (9.5 kgf·m, 70.1 ft·lb) 1 N·m (0.1 kgf·m, 0.7 ft·lb) Part name Q’ty Remarks Water inlet cover (PORT) M5 × 45 mm Screw Needle bearing Not reusable Pinion Pinion nut 8-20...
Page 328: Removing The Drive Shaft
Drive shaft and lower case (regular rotation model) Removing the drive shaft 1. Remove the cover “1”, drive shaft hous- ing “2”, pinion shims “3”, and thrust bear- ing “4”. 2. Remove the oil seals “1”. 2. Loosen the pinion nut, and then remove the pinion “1”, drive shaft “2”, and sleeve.
Page 329: Disassembling The Lower Case
Drive shaft and lower case (regular rotation model) Needle bearing attachment “2”: 90890-06608 Bearing separator “3”: 90890-06534 2. Remove the needle bearings from the forward gear. Disassembling the lower case • Use heat-resistant gloves. Otherwise, burns could result. • To prevent fires, remove any flammable substances, such as gasoline and oil, 3.
Page 330: Checking The Lower Case
Drive shaft and lower case (regular rotation model) Drive shaft runout: 1.0 mm (0.039 in) Needle bearing attachment “2”: 90890-06654 Checking the lower case Assembling the drive shaft housing 1. Check the lower case. Replace if cracked or damaged. 1. Install a new needle bearing “1” in the drive shaft housing at the specified instal- Assembling the forward gear lation depth “a”.
Page 331: Assembling The Lower Case
Drive shaft and lower case (regular rotation model) When heating the lower case, heat the entire installation area evenly. Otherwise, the paint on the lower case could be burned. TIP: Do not reuse a shim if deformed or scratched. Bearing outer race attachment “2”: 90890-06628 Driver rod LS “3”: 90890-06606 Installation depth “a”:...
Page 332: Installing The Drive Shaft
Drive shaft and lower case (regular rotation model) Installing the drive shaft Driver rod LL “1”: 90890-06605 1. Install the forward gear assembly “1”. Bearing outer race attachment “2”: 90890-06619 4. Install a new needle bearing “1” in the lower case. TIP: •...
Page 333: Installing The Propeller Shaft Housing Assembly
Drive shaft and lower case (regular rotation model) 2. Install the original reverse gear shims “1”, propeller shaft housing assembly “2”, and key “3”. 5. Tighten the pinion nut “1” to the specified torque. 3. Install the claw washer “1”. TIP: Make sure to fit the protrusion “a”...
Page 334: Installing The Shift Rod
Drive shaft and lower case (regular rotation model) Ring nut “1”: 145 N·m (14.5 kgf·m, 106.9 ft·lb) 5. Bend one of the 4 tabs on the claw washer outward, and then bend the other 3 tabs inward. 4. Check that the shift rod operates smoothly.
Page 335: Checking The Lower Unit For Air Leakage
Drive shaft and lower case (regular rotation model) 4. Align the slot “a” in the impeller “2” with TIP: the Woodruff key “1”, and then install the While turning the drive shaft clockwise, push impeller “2”. the water pump housing down to install it. 5.
Page 336: Installing The Lower Unit (L-Transom Model)
Drive shaft and lower case (regular rotation model) Installing the lower unit (L-transom 5. Install the lower unit “3”, and then tighten the lower case mounting bolts “5” and “6” model) to the specified torque. 6. Install the trim tab “7” to its original posi- •...
Page 337: Installing The Lower Unit (X-Transom Model)
Drive shaft and lower case (regular rotation model) 9. Place a block of wood between the anti- Installing the lower unit (X-transom cavitation plate and the propeller to pre- model) vent the propeller from turning, and then tighten the propeller nut to the specified torque.
Page 338 Drive shaft and lower case (regular rotation model) Lower case mounting bolts “10” and “11”: 48 N·m (4.8 kgf·m, 35.4 ft·lb) 7. Install the trim tab and propeller. See steps 6–9 in “Installing the lower unit (L- transom model)” (8-29). 8.
Page 339: Shimming (Regular Rotation Model)
Shimming (regular rotation model) Shimming (regular rotation model) 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.
Page 340: Shimming Check Sheet
Shimming (regular rotation model) Shimming check sheet Lower case deviation Serial number Remarks Pinion height (mm) Measurements Measuring point #1 Measuring point #2 Measuring point #3 Measuring point #4 Average Round-down average Forward gear backlash (mm) Measurements Before disassembly After disassembly Measuring point #1 Measuring point #2 Measuring point #3...
Page 341 Shimming (regular rotation model) Forward gear shim (T1) thickness adjustment 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 adjustment in 2 places (mm) Number of shim(s) Subtotal 0.10 0.12 0.15...
Page 342: Measuring The Forward Gear Backlash And Reverse Gear Backlash Before Disassembly
Shimming (regular rotation model) Measuring the forward gear backlash and reverse gear backlash before disassembly 1. Install the lower unit onto a repair stand. 2. Remove the water pump assembly. 3. Set the gear shift to the N position. Center bolt “1” (shimming): 5 N·m (0.5 kgf·m, 3.7 ft·lb) 8.
Page 343 Shimming (regular rotation model) TIP: TIP: • After installing the handle holder, pull the • The resistance of the spring increases the drive shaft upward to remove any free play. force required to turn the drive shaft. There- • Do not press the spring more than 5.0 mm fore, to obtain correct measurements, con- (0.197 in).
Page 344 0.36 Adjust the shim thicknesses if the reverse Measurement point “d” 0.34 gear backlash is out of specification. Measurement point “e” 0.33 Reverse gear backlash (F150A): Average 0.3325 0.33–0.67 mm (0.0130–0.0264 in) Round-down average 0.33 Reverse gear backlash (F150B): 15. Check that the forward gear backlash 0.33–0.74 mm (0.0130–0.0291 in)
Page 345: Shimming Procedure
Shimming (regular rotation model) Shimming procedure • Before selecting the forward gear shim (T1) and reverse gear shims (T2), make sure to select the pinion shims (T3). • When assembling the lower unit to measure the backlash after selecting the pinion shims (T3), do not apply gear oil, grease, or sealant to the parts.
Page 346: Selecting The Pinion Shim (T3)
Shimming (regular rotation model) Selecting the pinion shim (T3) Pinion height gauge “1”: 90890-06671 • Spray anti-rust lubricant on the bearing before installation. Do not apply gear oil to 2. Tighten the drive shaft housing bolts “1”. the parts. Otherwise, correct measure- ments cannot be obtained.
Page 347 Shimming (regular rotation model) 5. Install the special service tool “1” to the drive shaft spline and hold the special service tool “1”. 6. Tighten the pinion nut “2” to the specified 8. Turn the drive shaft 10 turns or more to torque.
Page 348: Measuring The Forward Gear Backlash
3–15 in “Measuring the forward gear backlash and reverse gear backlash (T3) = 0.95 mm from the “Pinion shim (T3) before disassembly” (8-35). selection table”. Forward gear backlash (F150A): Pinion height 0.15–0.61 mm (0.0059–0.0240 in) measurement (M) Forward gear backlash (F150B): 0.23...
Page 349 10 15 20 25 30 35 “Measuring the forward gear backlash”. –0.26 –0.22 –0.19 –0.16 –0.12 –0.09 –0.06 –0.02 See “Forward gear shim (T1) selection chart (F150A)” (A-13) or “Forward gear A. Backlash measurement (BL1) shim (T1) selection chart (F150B)” (A- B. Shim thickness adjustment 14).
Page 350: Measuring The Reverse Gear Backlash
Do not apply See “Forward gear shim (T1) selection gear oil to the parts. Otherwise, correct chart (F150A)” (A-13) or “Reverse gear measurements cannot be obtained. shim (T2) selection chart (F150B)” (A- • Keep the parts free of foreign material, 14).
Page 351 Shimming (regular rotation model) Available shim thicknesses: 0.10 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 mm –0.10 –0.20 5. Install the determined reverse gear shims –0.30 (T2) and propeller shaft housing assem- –0.40 bly. 65 70 75 80 85 A (1/100 mm) 65 70 75 80 85 0.34 0.30 0.27 0.10 –0.14 –0.17 –0.21 –0.24...
Page 352: Lower Unit
Lower unit (counter rotation model, L-transom model) Lower unit (counter rotation model, L-transom model) 43 N·m (4.3 kgf·m, 31.7 ft·lb) 55 N·m (5.5 kgf·m, 40.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) Part name Q’ty...
Page 353 Lower unit (counter rotation model, L-transom model) 43 N·m (4.3 kgf·m, 31.7 ft·lb) 55 N·m (5.5 kgf·m, 40.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) Part name Q’ty Remarks...
Page 354: Removing The Lower Unit
Lower unit (counter rotation model, L-transom model) Removing the lower unit 1. Drain the gear oil. 2. Remove the propeller, trim tab, and lower unit. See steps 2–7 in “Removing the lower unit” (8-3). TIP: When disassembling the lower unit, measure the backlash before disassembly.
Page 355 Lower unit (counter rotation model, X-transom model) Lower unit (counter rotation model, X-transom model) 43 N·m (4.3 kgf·m, 31.7 ft·lb) 55 N·m (5.5 kgf·m, 40.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) Part name...
Page 356 Lower unit (counter rotation model, X-transom model) 43 N·m (4.3 kgf·m, 31.7 ft·lb) 55 N·m (5.5 kgf·m, 40.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) Part name Q’ty...
Page 357: Removing The Lower Unit
Lower unit (counter rotation model, X-transom model) Removing the lower unit 1. Drain the gear oil. 2. Remove the propeller and trim tab. See steps 2–6 in “Removing the lower unit” (8-3). 3. Remove the lower unit and extension. See step 3 in “Removing the lower unit” (8-8).
Page 358: Water Pump And Shift Rod (Counter Rotation Model)
Water pump and shift rod (counter rotation model) Water pump and shift rod (counter rotation model) Part name Q’ty Remarks Shift rod E-clip O-ring Not reusable Plate M6 × 20 mm Bolt Oil seal Not reusable Collar Spacer Washer Wave washer Impeller Outer plate cartridge Gasket...
Page 359 Water pump and shift rod (counter rotation model) Part name Q’ty Remarks O-ring Not reusable Insert cartridge O-ring Not reusable Water pump housing M8 × 45 mm Bolt Seal Cover 8-52...
Page 360: Removing The Water Pump And Shift Rod
Water pump and shift rod (counter rotation model) Removing the water pump and shift 1. Remove the water pump. See steps 1–4 in “Removing the water pump and shift rod” (8-11). 2. Remove the shift rod “1”. Disassembling the water pump housing See “Disassembling the water pump hous- ing”...
Page 361: Propeller Shaft Housing (Counter Rotation Model)
Propeller shaft housing (counter rotation model) Propeller shaft housing (counter rotation model) 145 N·m (14.5 kgf·m, 106.9 ft·lb) Part name Q’ty Remarks Slider Ball 5.54 mm (0.22 in) (reference data) Ball 4.74 mm (0.19 in) (reference data) Ball 8.72 mm (0.34 in) (reference data) Spring Dog clutch FL150A: Six teeth...
Page 362 Propeller shaft housing (counter rotation model) 145 N·m (14.5 kgf·m, 106.9 ft·lb) Part name Q’ty Remarks Propeller shaft housing Needle bearing Not reusable Oil seal Not reusable Claw washer Ring nut 8-55...
Page 363: Removing The Propeller Shaft Housing Assembly
Propeller shaft housing (counter rotation model) Removing the propeller shaft 3. Heat the area of the propeller shaft housing “1” where the taper roller bearing housing assembly outer race is to be installed using a gas 1. Remove the ring nut and claw washer. torch, and then remove the forward gear See steps 1–3 in “Removing the propel- assembly “2”.
Page 364: Checking The Propeller Shaft
Propeller shaft housing (counter rotation model) Assembling the propeller shaft housing assembly and forward gear • Use heat-resistant gloves. Otherwise, burns could result. • To prevent fires, remove any flammable substances, such as gasoline and oil, around the working area. •...
Page 365 Propeller shaft housing (counter rotation model) When heating the propeller shaft housing, heat the entire installation area evenly. Otherwise, the propeller shaft housing could be damaged. Ring nut wrench “4”: 90890-06578 7. Install the spring “1”, balls “2”, “3”, and “4”, and slider “5”.
Page 366 Propeller shaft housing (counter rotation model) 9. Install the cross pin “1”, and then install the spring “2”. 10. Install a new O-ring “1”. 8-59...
Page 367: Drive Shaft And Lower Case (Counter Rotation Model)
Drive shaft and lower case (counter rotation model) Drive shaft and lower case (counter rotation model) 95 N·m (9.5 kgf·m, 70.1 ft·lb) 1 N·m (0.1 kgf·m, 0.7 ft·lb) Part name Q’ty Remarks Thrust bearing Pinion shim (T3) — O-ring Not reusable Needle bearing Not reusable Drive shaft housing...
Page 368 Drive shaft and lower case (counter rotation model) 95 N·m (9.5 kgf·m, 70.1 ft·lb) 1 N·m (0.1 kgf·m, 0.7 ft·lb) Part name Q’ty Remarks Reverse gear Water inlet cover (PORT) M5 × 45 mm Screw Needle bearing Not reusable Pinion Pinion nut 8-61...
Page 369: Removing The Drive Shaft
Drive shaft and lower case (counter rotation model) Removing the drive shaft Disassembling the lower case See steps 1 and 2 in “Removing the drive shaft” (8-21). • Use heat-resistant gloves. Otherwise, Removing the reverse gear burns could result. 1. Remove the reverse gear “1” and thrust •...
Page 370: Checking The Pinion
Drive shaft and lower case (counter rotation model) 3. Remove the needle bearing. See step 3 TIP: in “Disassembling the lower case” (8-22). Do not reuse a shim if deformed or scratched. Checking the pinion See “Checking the pinion” (8-22). 2.
Page 371: Assembling The Drive Shaft Housing
Drive shaft and lower case (counter rotation model) 4. Install the needle bearing and water inlet 2. Install the claw washer and ring nut. See covers. See steps 4 and 5 in “Assembling steps 3–5 in “Installing the propeller shaft the lower case”...
Page 372: Installing The Lower Unit (X-Transom Model)
Drive shaft and lower case (counter rotation model) Installing the lower unit (X-transom model) 1. Check that the shift rod is in the N posi- tion. See steps 1 and 2 in “Installing the lower unit (L-transom model)” (8-29). 2. Install the extension and lower unit. See steps 2–6 in “Installing the lower unit (X- transom model)”...
Page 373: Shimming (Counter Rotation Model)
Shimming (counter rotation model) Shimming (counter rotation model) 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) and propeller shaft shims (T4).
Page 374 Shimming (counter rotation model) Shimming check sheet Lower case deviation Serial number Remarks Pinion height (mm) Measurements Measuring point #1 Measuring point #2 Measuring point #3 Measuring point #4 Average Round-down average Forward gear backlash (mm) Measurements Before disassembly After disassembly Measuring point #1 Measuring point #2 Measuring point #3...
Page 375 Shimming (counter rotation model) Forward gear shim (T2) thickness adjustment 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 (T1) thickness adjustment in 2 places (mm) Number of shim(s) Subtotal 0.10 0.12 0.15...
Page 376: Measuring The Forward Gear Backlash And Reverse Gear Backlash Before Disassembly
Shimming (counter rotation model) Measuring the forward gear backlash and reverse gear backlash before disassembly Two washers (90201-26M00) are required for the reverse gear backlash measurement in the counter rotation model. Prepare the washers before starting the shimming proce- dure. 1.
Page 377 Shimming (counter rotation model) TIP: TIP: • After installing the handle holder, pull the • The resistance of the spring increases the drive shaft upward to remove any free play. force required to turn the drive shaft. There- • Do not press the spring more than 5.0 mm fore, to obtain correct measurements, con- (0.197 in).
Page 378 Shimming (counter rotation model) 13. Determine the backlash average, and then round down the average to 2 decimal places. Example: (mm) Measurement point “a” 0.30 Measurement point “b” 0.36 Measurement point “c” 0.34 Measurement point “d” 0.33 Washer “1”: 90201-26M00 Average 0.3325 18.
Page 379: Shimming Procedure
Shimming (counter rotation model) Shimming procedure • Before selecting the forward gear shims (T2) and reverse gear shims (T1), make sure to select the pinion shims (T3). • When assembling the lower unit to measure the backlash after selecting the pinion shims (T3), do not apply gear oil, grease, or sealant to the parts.
Page 380: Selecting The Pinion Shim (T3)
Shimming (counter rotation model) Selecting the pinion shim (T3) TIP: See “Selecting the pinion shim (T3)” (8-39). In the “Propeller shaft shim (T4) selection table”, use the rounded measurement value Selecting the propeller shaft shim for the free play measurement. (T4) 1.
Page 381: Measuring The Forward Gear Backlash
Shimming (counter rotation model) 8. Calculate the new propeller shaft shim Measuring the forward gear backlash (T4) thickness. • Spray anti-rust lubricant on the gears and bearings before installation. Do not apply gear oil to the parts. Otherwise, correct TIP: measurements cannot be obtained.
Page 382 Shimming (counter rotation model) 3. Determine the forward gear shim (T2) A. Backlash measurement (BL2) thickness adjustment using the “Forward B. Shim thickness adjustment gear shim (T2) selection chart” according 4. Calculate new forward gear shim (T2) to the backlash measurement (BL2) from thickness.
Page 383: Measuring The Reverse Gear Backlash
Shimming (counter rotation model) Measuring the reverse gear backlash 2. Measure the thickness of original reverse gear shim (T1) in 2 places. • Spray anti-rust lubricant on the gear and bearings before installation. Do not apply gear oil to the parts. Otherwise, correct TIP: measurements cannot be obtained.
Page 384 Shimming (counter rotation model) = 0.86 mm 0.30 Available shim thicknesses: 0.20 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.10 0.50 mm –0.10 5. Install the determined reverse gear shims –0.20 (T1) and roller bearing outer race. –0.30 10 15 20 25 30 35 A (1/100 mm) 10 15 20 25 30 35 –0.28 –0.24 –0.21 –0.18 –0.14 –0.11 –0.08 –0.04...
Page 385 Shimming (counter rotation model) — MEMO — 8-78...
Page 386: Bracket Unit
Bracket unit Shift rod and shift bracket ..........9-1 Removing the shift rod and shift bracket ........9-3 Disassembling the shift bracket ..........9-3 Assembling the shift bracket ............. 9-3 Installing the shift rod and shift bracket ........9-4 PTT switch and cowling lock lever ........9-6 Removing the PTT switch ............
Page 387 Bracket unit PTT unit ................9-33 Removing the PTT unit ............9-34 Checking the hydraulic pressure ..........9-35 Bleeding the PTT unit .............. 9-37 Installing the PTT unit .............. 9-39 PTT cylinder ..............9-41 Removing the tilt ram and trim ram ......... 9-43 Disassembling the tilt ram ............
Page 388 Shift rod and shift bracket Shift rod and shift bracket 2.5 N·m (0.25 kgf·m, 1.84 ft·lb) 2.5 N·m (0.25 kgf·m, 1.84 ft·lb) 1 N·m (0.1 kgf·m, 0.7 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) Part name Q’ty Remarks...
Page 389 Shift rod and shift bracket 2.5 N·m (0.25 kgf·m, 1.84 ft·lb) 2.5 N·m (0.25 kgf·m, 1.84 ft·lb) 1 N·m (0.1 kgf·m, 0.7 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) Part name Q’ty Remarks Washer Bracket Ball 6.34 mm (0.25 in) (reference data)
Page 390: Removing The Shift Rod And Shift Bracket
Shift rod and shift bracket Removing the shift rod and shift bracket 1. Remove the shift bracket assembly “1”. 2. Remove the shift position switch “1”. 2. Remove the shift lever “1” and shift rod assembly “2”. 3. Remove the shift cut-off switch “1”. 3.
Page 391: Installing The Shift Rod And Shift Bracket
Shift rod and shift bracket 2. Install the shift position switch “1” and plate “2”, and then tighten the shift posi- tion switch screws “3” to the specified torque. Shift position switch screw “3”: Shift bracket bolt “3”: 2.5 N·m (0.25 kgf·m, 1.84 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) 3.
Page 392 Shift rod and shift bracket Shift rod detent bolt “6”: 18 N·m (1.8 kgf·m, 13.3 ft·lb) 3. Install a new O-ring “1” to the shift rod assembly “2”. 4. Install the grommet “3” to the upper case. 5. Install the shift lever “4” to the set pin “a” of the shift rod assembly “2”.
Page 393: Ptt Switch And Cowling Lock Lever
PTT switch and cowling lock lever PTT switch and cowling lock lever 5 N·m (0.5 kgf·m, 3.7 ft·lb) Part name Q’ty Remarks Gasket Regular rotation model PTT switch Regular rotation model M6 × 20 mm Bolt Holder Cover Regular rotation model Cowling lock lever (rear) Cowling lock lever (front) Bushing...
Page 394 PTT switch and cowling lock lever 5 N·m (0.5 kgf·m, 3.7 ft·lb) Part name Q’ty Remarks Hook Grommet Hose Hose joint to exhaust cover Plastic tie Hose joint Hose joint Gasket Adapter ø6 × 19 mm Screw Clamp PTT switch Counter rotation model Cover Counter rotation model...
Page 395: Removing The Ptt Switch
PTT switch and cowling lock lever Removing the PTT switch 1. Remove the holder “1”, and then remove the PTT switch “2”. STBD Removing the flushing hose 1. Remove the adapter “1” and hose joints PORT “2”, and “3”. A. Regular rotation model B.
Page 396: Installing The Cowling Lock Lever
PTT switch and cowling lock lever 2. Pass the flushing hose “2”, trim sensor Flushing hose adapter screw “2”: lead “3”, and PTT motor leads “4” 5 N·m (0.5 kgf·m, 3.7 ft·lb) through the grommet “1”, and then fasten them using the plastic ties “5” around the Installing the cowling lock lever grommet “1”.
Page 397 PTT switch and cowling lock lever STBD PORT A. Regular rotation model B. Counter rotation model 9-10...
Page 398 Bottom cowling Bottom cowling Part name Q’ty Remarks M6 × 20 mm Bolt Holder Bracket Bracket Bracket Clamp Holder Grommet Collar Rubber seal Water outlet Grommet M8 × 35 mm Bolt Grommet Collar Rubber seal 9-11...
Page 399 Bottom cowling Part name Q’ty Remarks Bottom cowling Grommet 9-12...
Page 400 Upper case and mounts Upper case and mounts 55 N·m (5.5 kgf·m, 40.6 ft·lb) 72 N·m (7.2 kgf·m, 53.1 ft·lb) 72 N·m (7.2 kgf·m, 53.1 ft·lb) Part name Q’ty Remarks Self-locking nut Washer M10 × 40 mm Bolt Cover Cover Washer Lower mount Washer...
Page 401: Upper Case And Mounts
Upper case and mounts 55 N·m (5.5 kgf·m, 40.6 ft·lb) 72 N·m (7.2 kgf·m, 53.1 ft·lb) 72 N·m (7.2 kgf·m, 53.1 ft·lb) Part name Q’ty Remarks M10 × 45 mm Bolt Washer M14 × 203 mm Bolt M6 × 10 mm Bolt Nipple Plastic tie...
Page 402: Removing The Upper Case
Upper case and mounts Removing the upper case Installing the upper case 1. Drain the remaining engine oil. 1. Install the washers “1” and “2”, upper mounts “3”, washer “4”, and collar “5” to 2. Disconnect the ground lead “1”. the upper mount bolts “6”.
Page 403 Upper case and mounts 6. Install the ground lead (STBD) “2”, wash- Upper mount bolt “1”: ers “3”, upper mounting nuts “4”, and 55 N·m (5.5 kgf·m, 40.6 ft·lb) lower mounting nuts “5”, and then tighten the upper mounting nuts “4” and lower 9.
Page 404: Upper Case
Upper case Upper case 20 N·m (2.0 kgf·m, 14.8 ft·lb) 42 N·m (4.2 kgf·m, 31.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 28 N·m (2.8 kgf·m, 20.7 ft·lb) Part name Q’ty Remarks Upper case Circlip Bushing Rubber seal Dowel M6 × 15 mm Screw Baffle plate M8 ×...
Page 405: Disassembling The Upper Case
Upper case Disassembling the upper case Checking the drive shaft bushing 1. Remove the drain bolt “1”. 1. Check the bushing. Replace if cracked or worn. Assembling the upper case 1. Install the bushing “1”, and then install the circlip “2”. 2.
Page 406 Upper case 10 11 Baffle plate screw “3”: 4 N·m (0.4 kgf·m, 3.0 ft·lb) Oil pan assembly bolt (M8) “10”: 20 N·m (2.0 kgf·m, 14.8 ft·lb) Oil pan assembly bolt (M10) “11”: 42 N·m (4.2 kgf·m, 31.0 ft·lb) 7. Install a new gasket “1” and the drain bolt “2”, and then tighten the drain bolt “2”...
Page 407: Oil Pan And Exhaust Manifold
Oil pan and exhaust manifold Oil pan and exhaust manifold 20 N·m (2.0 kgf·m, 14.8 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) Part name Q’ty Remarks Exhaust guide Gasket Not reusable Gasket...
Page 408 Oil pan and exhaust manifold 20 N·m (2.0 kgf·m, 14.8 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) Part name Q’ty Remarks Dowel Muffler M8 × 35 mm Bolt 9-21...
Page 409: Disassembling The Oil Pan And Exhaust Manifold
Oil pan and exhaust manifold Disassembling the oil pan and 3. Check the oil pan. Replace if corroded or cracked. exhaust manifold 1. Remove the muffler “1”, plate “2”, and Checking the oil strainer exhaust manifold “3”. 1. Check the oil strainer. Clean if there is dirt or residue.
Page 410 Oil pan and exhaust manifold Exhaust manifold bolt: 20 N·m (2.0 kgf·m, 14.8 ft·lb) Oil pan bolt: 20 N·m (2.0 kgf·m, 14.8 ft·lb) 5. Install the rubber seal “1” and water pipe “2”. 6. Install the dowels “3”, new gaskets “4”, the plate “5”, and the muffler “6”.
Page 411 Steering arm Steering arm Part name Q’ty Remarks Steering arm Washer Bushing O-ring Not reusable Bushing Steering yoke Circlip Grommet 9-24...
Page 412: Removing The Steering Arm
Steering arm Removing the steering arm 1. Remove the circlip “1”, and then remove the steering yoke “2” by striking it using a copper hammer. 2. Install the bushing “1”, a new O-ring “2”, the bushing “3”, and the washer “4”. 2.
Page 413 Steering arm 4. Hold the steering arm “1”, and then strike the steering yoke “2” using a copper hammer until the groove “a” for installing the circlip is visible. 5. Install the circlip “3”. 6. Inject grease into the grease nipple “1” until grease comes out from both the upper and lower bushings “a”.
Page 414 Clamp bracket and swivel bracket Clamp bracket and swivel bracket 3 N·m (0.3 kgf·m, 2.2 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 27 28 Part name Q’ty Remarks Self-locking nut Clamp bracket (STBD) Grease nipple...
Page 415: Clamp Bracket And Swivel Bracket
Clamp bracket and swivel bracket 3 N·m (0.3 kgf·m, 2.2 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 27 28 Part name Q’ty Remarks Washer Anode Plate M6 × 30 mm Bolt Ground lead Bushing...
Page 416 Clamp bracket and swivel bracket 3 N·m (0.3 kgf·m, 2.2 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 48 N·m (4.8 kgf·m, 35.4 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 27 28 Part name Q’ty Remarks M6 × 15 mm Screw Trim sensor 9-29...
Page 417: Removing The Clamp Bracket
Clamp bracket and swivel bracket Removing the clamp bracket 1. Remove the PTT unit. See “Removing the PTT unit” (9-34). 2. Remove the plastic tie “1”. 9. Remove the spring “1”, hook “2”, and pins “3”. 3. Remove the anode “1” and ground lead “2”.
Page 418 Clamp bracket and swivel bracket 4. Install the trim sensor “1”, and then tighten the trim sensor screw “2” to the specified torque. Distance “a”: 30.3–30.6 mm (1.19–1.20 in) 2. Install the bushings “1” and “2”, collar “3”, Trim sensor screw “2”: distance collar assembly “4”, and tilt stop 4 N·m (0.4 kgf·m, 3.0 ft·lb) levers “5”...
Page 419: Adjusting The Trim Sensor Cam
Clamp bracket and swivel bracket Self-locking nut “3”: 15 N·m (1.5 kgf·m, 11.1 ft·lb) Grease nipple “9”: 3 N·m (0.3 kgf·m, 2.2 ft·lb) 11. Inject grease into the grease nipples until grease comes out from the bushings “a”. Digital circuit tester: 90890-03189 Trim sensor setting resistance: Terminal “c”–Terminal “d”...
Page 420 PTT unit PTT unit 39 N·m (3.9 kgf·m, 28.8 ft·lb) Part name Q’ty Remarks Upper mounting shaft Circlip Bushing PTT unit Ground lead M6 × 10 mm Bolt M10 × 30 mm Bolt Washer Lower mounting shaft Plastic tie 9-33...
Page 421: Removing The Ptt Unit
PTT unit Removing the PTT unit When removing the PTT unit with the power unit installed, make sure to sus- pend the outboard motor. 1. Fully tilt the swivel bracket up, and then support it using the tilt stop lever “1”. 5.
Page 422: Checking The Hydraulic Pressure
PTT unit Checking the hydraulic pressure 4. If the fluid is below the proper level, add the recommended fluid. Check the hydraulic pressure. Check the internal parts if out of specification. Recommended PTT fluid: ATF Dexron II 1. Place the PTT unit in an upright position. 5.
Page 423 PTT unit 8. Connect the battery jumper leads to the 11. Install the main valve “1”, and then PTT motor lead “1” to fully retract the tighten it to the specified torque. PTT rams. TIP: Install the main valve “1” quickly before any fluid flows out of the hole.
Page 424: Bleeding The Ptt Unit
PTT unit PTT hydraulic gauge adapter “1”: PTT motor lead Battery 90890-06863 Blue (L) Extend Hydraulic pressure gauge “2”: Green (G) (–) 90890-06776/06800 17. Remove the special service tools. 14. Repeat steps 2–4 to check the fluid level. 15. Connect the battery jumper leads to the Be careful when removing the special ser- PTT motor lead “1”...
Page 425 PTT unit Manual valve “1”: PTT motor lead Battery 3 N·m (0.3 kgf·m, 2.2 ft·lb) Blue (L) Extend Green (G) (–) 3. Check the fluid level. See steps 2–4 in “Checking the hydraulic pressure” (9-35). 6. Repeat steps 4 and 5 to fully extend and retract the PTT rams 4 or 5 times.
Page 426: Installing The Ptt Unit
PTT unit Installing the PTT unit • After tilting the swivel bracket up, make sure to support it using the tilt stop lever. • When installing the PTT unit with the power unit installed, make sure to sus- pend the outboard motor. 1.
Page 427 PTT unit 7. Install the ground lead “1”. 8. Fasten the PTT motor lead and trim sen- sor lead using the plastic ties “1”. 9-40...
Page 428: Ptt Cylinder
PTT cylinder PTT cylinder 160 N·m (16.0 kgf·m, 118.0 ft·lb) 150 N·m (15.0 kgf·m, 110.6 ft·lb) 65 N·m (6.5 kgf·m, 47.9 ft·lb) 160 N·m (16.0 kgf·m, 118.0 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks Tilt ram Dust seal Not reusable O-ring...
Page 429 PTT cylinder 160 N·m (16.0 kgf·m, 118.0 ft·lb) 150 N·m (15.0 kgf·m, 110.6 ft·lb) 65 N·m (6.5 kgf·m, 47.9 ft·lb) 160 N·m (16.0 kgf·m, 118.0 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks Dust seal Not reusable Circlip Free piston O-ring...
Page 430: Removing The Tilt Ram And Trim Ram
PTT cylinder Removing the tilt ram and trim ram Cylinder end screw wrench “2”: 90890-06591 4. Tighten the manual valve “1” to the spec- Before removing the tilt cylinder end ified torque. screw, make sure that the PTT rams are fully extended.
Page 431: Disassembling The Tilt Ram
PTT cylinder Disassembling the trim ram 1. Remove the O-ring “1” and backup ring “2”. Trim & tilt wrench “2”: 90890-06587 Disassembling the tilt ram 1. Remove the tilt piston absorber valves Checking the tilt cylinder and trim “1” and O-ring “2”. cylinder 1.
Page 432: Assembling The Trim Ram
PTT cylinder 6. Install the plate “3”, washer “4”, and tilt piston screw “5”, and then tighten the tilt piston screw “5” to the specified torque. 2. Install the tilt cylinder end screw “1” and tilt piston “2”. Tilt piston screw “5”: 7 N·m (0.7 kgf·m, 5.2 ft·lb) Assembling the trim ram 3.
Page 433: Installing The Trim Ram
PTT cylinder 4. Install the trim ram assemblies, and then tighten the trim cylinder end screws “1” to the specified torque. Installing the trim ram 1. Install a new O-ring “1” to the free piston “2”. Trim & tilt wrench “2”: 90890-06587 Trim cylinder end screw “1”: 160 N·m (16.0 kgf·m, 118.0 ft·lb) Installing the tilt ram...
Page 434 PTT cylinder Cylinder end screw wrench “2”: 90890-06591 Tilt cylinder end screw “1”: 150 N·m (15.0 kgf·m, 110.6 ft·lb) 9-47...
Page 435: Ptt Motor
PTT motor PTT motor 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks Armature Stator M5 × 20 mm Screw M6 × 25 mm Bolt M4 × 16 mm Screw Circuit breaker Brush holder Brush Spring O-ring...
Page 436 PTT motor 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks Circlip Filter O-ring Not reusable 9-49...
Page 437: Removing The Reservoir
PTT motor Removing the reservoir 1. Remove the reservoir “1” and O-ring “2”. Secure the end of the armature shaft using a pair of pliers, and then remove the TIP: armature along with the motor base Place a container under the PTT unit to catch assembly.
Page 438: Checking The Armature (Ptt Motor)
PTT motor Checking the armature (PTT motor) 1. Check the commutator. Clean using 600- grit sandpaper and compressed air if dirty. Armature continuity: Continuity: “a”–“b” No continuity: 2. Measure the commutator diameter “a”. “a”–“c” Replace the armature if below specifica- “a”–“d”...
Page 439: Checking The Reservoir
PTT motor 3. Check the PTT motor base. Replace the PTT motor assembly if the base is cracked or damaged. Checking the reservoir 4. Push the brushes “1” and “2” into the 1. Check the reservoir. Replace if cracked holders, and then install the armature “3”. or damaged.
Page 440: Installing The Ptt Motor
PTT motor Installing the PTT motor When assembling the PTT unit, do not use a rag. Otherwise, dust and particles could get on the PTT unit components, causing poor performance. 1. Install the joint “1”. 2. Install a new O-ring “1” and the reservoir “2”, and then tighten the reservoir mount- Make sure that the deeper end of the ing bolts “3”...
Page 441 PTT gear pump PTT gear pump 7 N·m (0.7 kgf·m, 5.2 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 40 41 7 N·m (0.7 kgf·m, 5.2 ft·lb) 11 N·m (1.1 kgf·m, 8.1 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) Part name Q’ty Remarks...
Page 442 PTT gear pump 7 N·m (0.7 kgf·m, 5.2 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 40 41 7 N·m (0.7 kgf·m, 5.2 ft·lb) 11 N·m (1.1 kgf·m, 8.1 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) Part name Q’ty Remarks...
Page 443 PTT gear pump 7 N·m (0.7 kgf·m, 5.2 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 40 41 7 N·m (0.7 kgf·m, 5.2 ft·lb) 11 N·m (1.1 kgf·m, 8.1 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) Part name Q’ty Remarks...
Page 444: Removing The Gear Pump Assembly
PTT gear pump Removing the gear pump assembly 1. Remove the plate “1”, filter “2”, backup ring “3”, wave washer “4”, protection valves “5” and “6”, and gear pump assembly “7”. 4. Remove the main valves “1” and shuttle piston “2”, and then remove the O-rings “3”, “4”, “5”, and “6”.
Page 445: Checking The Gear Pump
PTT gear pump 4. Remove the valve seat “1” and O-ring “2”. A. Up-relief valve B. Down-relief valve 2. Remove the bracket “1” and O-rings “2” and “3”. Checking the gear pump 1. Check the drive gear and driven gear. Replace the gear pump assembly if dam- aged or worn.
Page 446: Assembling The Gear Pump
PTT gear pump Assembling the gear pump Lubricate the parts using ATF Dexron II dur- ing assembly. When assembling the PTT unit, do not use a rag. Otherwise, dust and particles could get on the PTT unit components, causing poor performance. 1.
Page 447: Assembling The Gear Pump Housing
PTT gear pump Main valve “4”: 11 N·m (1.1 kgf·m, 8.1 ft·lb) 4. Install the manual valve seat “1”, spring “2”, adapter “3”, spring “4”, and manual A. Up-relief valve valve seat “5”. B. Down-relief valve Installation height “a” (reference data): 5.
Page 448: Installing The Gear Pump Assembly
PTT gear pump Plug “2”: 4 N·m (0.4 kgf·m,, 3.0 ft·lb) 8. Install the spacers “1” and “2”, the port plugs “3”, and new O-rings “4” and “5”. Gear pump bolt “8”: 7 N·m (0.7 kgf·m, 5.2 ft·lb) Installing the gear pump assembly Lubricate the parts using ATF Dexron II dur- ing assembly.
Page 449 PTT gear pump — MEMO — 9-62...
Page 450: Maintenance
Maintenance Outline ................10-1 Maintenance interval chart 1 ........... 10-1 Maintenance interval chart 2 ........... 10-3 Predelivery check ............10-4 Checking the battery ............... 10-4 Checking the cooling water pilot hole ........10-5 Checking the engine oil level ........... 10-5 Checking the main switch/stop switch/choke switch ....
Page 451 Maintenance Adjusting the shift link/shift cable .......... 10-15 Checking the spark plug ............10-15 Checking the timing belt ............10-15 Replacing the timing belt ............10-15 Checking the thermostat ............10-15 Adjusting the throttle link/throttle cable/ throttle pick-up timing ............10-15 Checking the cowling lock lever ..........
Page 452: Outline
• If replacement parts are necessary, use only genuine Yamaha parts of equivalent design and qual- ity. Any parts of inferior quality may cause a malfunction, and the resulting loss of control could endanger the operator and passengers.
Page 453 Outline Initial Every Item Actions 20 hours 100 hours 300 hours 500 hours (3 months) (1 year) (3 years) (5 years) Engine oil Replacement Engine oil filter (cartridge) Replacement Fuel filter (can be Inspection or replacement disassembled) as necessary Fuel line (High pressure) Inspection Fuel line (High pressure) Inspection or replacement...
Page 454 (5 years) Main switch/stop switch/ Inspection or replacement choke switch as necessary Wire harness Inspection or replacement connections/wire coupler as necessary connections (Yamaha) Meter/gauge Inspection Maintenance interval chart 2 Every Item Actions 1000 hours Exhaust guide/exhaust Inspection or replacement manifold...
Page 455: Predelivery Check
Predelivery check Predelivery check To make the delivery process smooth and efficient, complete the predelivery checks as explained in the following procedures. Checking the battery Battery electrolyte is dangerous; it con- tains sulfuric acid, which is poisonous 2. Check the specific gravity of the electro- and highly caustic.
Page 456: Checking The Cooling Water Pilot Hole
Predelivery check Checking the cooling water pilot hole 1. Start the engine, and then check that cooling water is discharged from the cooling water pilot hole. Checking the main switch/stop switch/choke switch 1. Check that the engine starts when the engine start switch is turned to START.
Page 457: Checking The Fuel Line
Predelivery check 3. Install a new gasket and the check screw, and then tighten the check screw to the specified torque. Check screw: 9 N·m (0.9 kgf·m, 6.6 ft·lb) Checking the shift link/shift cable and throttle link/throttle cable/ throttle pick-up timing A.
Page 458: Checking The Power Trim And Tilt Unit
Predelivery check 2. Check that the mark “a” on the bushing TIP: “1” and the mark “b” on the plate “2” are The appropriate mounting height depends on aligned. the combination of the boat and outboard motor. To determine the appropriate mount- ing height, test run the outboard motor at dif- ferent heights.
Page 459: Break-In
General periodic maintenance Break-in Operate the engine under load (in gear with a When flushing the cooling water pas- propeller installed) for 10 hours as follows: sages, do not start the engine. Otherwise, the water pump could be damaged and 1.
Page 460: Checking The Cooling Water Pilot Hole
1. Start the engine and warm it up for 5–10 minutes. 2. Check the engine idle speed using the Yamaha genuine tachometer (on-board meter) or the YDIS. See the YDIS (Ver. 2.00 or later) instruction manual. 4. Install the water inlet covers and trim tab,...
Page 461: Checking The Engine Oil Level
General periodic maintenance 8. Remove the dipstick “1” and wipe it clean. 9. Insert the dipstick “1” completely for a correct measurement and remove it again. 10. Check that the oil level indicated on the dipstick “1” is between the upper mark “a” and the lower mark “b”.
Page 462: Checking The Exhaust Guide/Exhaust Manifold
General periodic maintenance Checking the exhaust guide/exhaust manifold 1. Check the exhaust guide and exhaust manifold. See “Checking the oil pan and exhaust manifold” (9-22). Checking the main switch/stop switch/choke switch 1. Check the engine start switch and engine shut-off switch. See “Checking the main Oil filter wrench “1”: 90890-06830 switch/stop switch/choke switch”...
Page 463: Checking The Gear Oil Level
General periodic maintenance 4. Remove the check screw “4” and gasket Recommended gear oil: “5” and let the oil drain completely. Hypoid gear oil API: GL-4 SAE: 90 After the gear oil has been drained, check Oil quantity: the used oil. If the oil is milky, water is get- Regular rotation model: ting into the lower case, which can cause 0.980 L (1.036 US qt, 0.862 lmp qt)
Page 464 General periodic maintenance TIP: Make sure to set the gear shift to the R posi- tion before injecting grease into the grease nipple on the shift rod. 2. Apply low temperature resistant grease to the specified lubrication point. 3. Apply corrosion resistant grease to the specified lubrication point.
Page 465: Checking The Pcv
General periodic maintenance Before removing the reservoir cap, make sure that the PTT ram is fully extended. Otherwise, fluid could be expelled force- fully from the unit due to internal pres- sure. TIP: If the fluid is at the proper level, a small Checking the PCV amount of fluid should flow out of the filler hole when the reservoir cap is removed.
Page 466 General periodic maintenance 3. Check the PTT unit for fluid leakage. 2. Loosen the bolts “1”. Adjusting the shift link/shift cable 3. Move the hook “2” up or down slightly to adjust its position. 1. Disconnect the shift cable, and then adjust it.
Page 467: Index
Changing the gear oil ......10-11 gas hose ...........6-2 Charging unit and component ....5-19 Assembling the cylinder block....7-75 Charging unit and starting unit (F150A, FL150A Assembling the cylinder head ....7-45 [except for European and Oceanian markets] Assembling the drive shaft and F150B, FL150B) ........A-8...
Page 468 Index Checking the cylinder head.......7-41 Checking the oil pan and Checking the cylinder head and cylinder block exhaust manifold ........9-22 anode ............7-45 Checking the oil pressure ......7-1 Checking the diaphragm and valve...6-14 Checking the oil pressure sensor ..... 5-16 Checking the dog clutch....8-16, 8-57 Checking the oil pump .....
Page 469 Crate handling..........3-2 Engine control unit and component ..5-13 Crate top cover pictograph description ..3-2 Engine control unit and fuel unit ....A-2 Cylinder block (F150A, FL150A)....7-52 Engine ECM component......2-3 Cylinder block (F150B, FL150B)....7-58 Engine speed control........2-5 Cylinder head..........7-38 Exhaust cover...........
Page 470 Installing the outboard motor ...... 3-7 Function ............4-2 Installing the power unit......7-9 Fuse box ...........7-27 Installing the propeller shaft housing F150A, FL150A, F150B, FL150B....3-5 assembly ........8-26, 8-64 Installing the PTT motor ......9-53 Installing the PTT switch......9-9 Installing the PTT unit....... 9-39 General feature ...........1-1...
Page 471 Index Outboard motor mounting instructions ..3-1 Outboard motor troubleshooting ....4-6 Logging .............2-12 Outline ............10-1 Lower unit ..........2-19 Overview........... 2-10 Lower unit (counter rotation model)......1-19 Lower unit (counter rotation model, L-transom Part, lubricant, and sealant......0-2 model) .............8-45 Pinion shim (T3) selection table ....A-12 Lower unit (counter rotation model, X-transom Port .............
Page 472 Throttle link ..........6-22 Reverse gear shim (T2) selection chart Tightening torque........0-3 (F150A) ..........A-13 Tilt limiter (F150A, FL150A [optional for Reverse gear shim (T2) selection chart European and Oceanian markets])... 2-9 (F150B) ..........A-14 Timing belt ..........7-16 Rigging grommet description ......3-9...
Page 473 Index Troubleshooting the power unit using the YDIS............4-6 Troubleshooting the PTT unit...4-16, 4-17 Twin outboard motor application (conventional gauge).............3-35 Twin outboard motor application (6Y8 Multifunction Meter) ........3-33 Uncrating.............3-3 Uncrating procedure ........3-3 Upper case..........9-17 Upper case and mounts......9-13 Using the digital tester ......5-13 Using the YDIS .........5-12 Vapor gas diagram........2-15 Vapor separator and high-pressure fuel pump...
Page 474 Index — MEMO —...
Page 476 Oct. 2011 – ** × 2 ABE...
Page 477: Appendix
Legend symbols in the wiring diagrams Ignition unit ................A-4 Charging unit and starting unit (F150A, FL150A for European and Oceanian markets) .... A-6 Charging unit and starting unit (F150A, FL150A [except for European and Oceanian markets] and F150B, FL150B) ................ A-8 1.
Page 478 Engine control unit and fuel unit 1. Engine ECM 2. Oil pressure sensor 3. ISC valve 4. Speed sensor 5. Water pressure sensor 6. High-pressure fuel pump 7. Fuel injector 8. Vapor shut-off valve 9. Water detection switch 10. Joint connector 1 11.
Page 479 Engine control unit and fuel unit 12. Fuse box 14. Starter motor 15. PTT relay 13. Battery 1 23 Pu/G 11. Joint connector 2 22 44 Pu/B 1. Engine ECM Pu/R Pu/Y 10. Joint connector 1 9. Water detection switch 7.
Page 480 Ignition unit 1. Engine ECM 2. Pulser coil 3. Thermoswitch 4. Ignition coil 5. Air pressure sensor 6. TPS 7. Engine temperature sensor 8. Shift position switch 9. Shift cut-off switch 10. Air temperature sensor 11. Joint connector 1 12. Joint connector 2 13.
Page 481 Ignition unit 13. Fuse box 15. Starter motor 16. PTT relay 14. Battery 1 23 12. Joint connector 2 22 44 1. Engine ECM 11. Joint connector 1 3. Thermoswitch #1, #4 #2, #3 6. TPS 8. Shift position switch 10.
Page 482 Charging unit and starting unit (F150A, FL150A for European and Oceanian markets) 1. Engine ECM 2. PTT relay 3. PTT motor 4. Starter relay 5. Starter motor 6. PTT switch 7. Trim sensor 8. Tilt limiter 9. Joint connector 1 10.
Page 483 Charging unit and starting unit 13. Rectifier Regulator 12. Stator assembly (F150A, FL150A for European and Oceanian markets) 11. Fuse box 15. House (accessory) AC 1 battery AC 1 AC 1 14. Battery 1 23 10. Joint connector 2 22 44 1.
Page 484 Charging unit and starting unit (F150A, FL150A [except for European and Oceanian markets] and F150B, FL150B) 1. Engine ECM 2. PTT relay 3. PTT motor 4. Starter relay 5. Starter motor 6. PTT switch 7. Trim sensor 8. Joint connector 1 9.
Page 485 Charging unit and starting unit (F150A, FL150A [except for 12. Rectifier Regulator European and Oceanian markets] and F150B, FL150B) 11. Stator assembly 10. Fuse box 14. House (accessory) battery AC 1 AC 1 AC 1 13. Battery 1 23 9. Joint connector 2 22 44 1.
Page 486 Control unit 1. 703 remote control 2. Engine start switch 3. Engine shut-off switch 4. PTT switch 5. ON 6. OFF 7. START 8. Clip removed 9. Clip installed 10. UP 11. Free 12. DN 13. Neutral switch 14. Switch panel (6R5-82570-05) 15.
Page 487 Control unit 14. Switch panel (6R5-82570-05) 2. Engine start switch 3. Engine shut-off switch 5. ON 1. 703 remote control 6. OFF 8. Clip removed 2. Engine start switch 4. PTT switch 7. START 9. Clip installed 3. Engine shut-off switch 16.
Page 488 Shim selection table and chart (regular rotation model) Pinion shim (T3) selection table (mm) 0.01 0.02 0.03 0.04 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...
Page 489 Forward gear shim (T1) selection chart (F150A) 1.20 1.10 1.00 0.90 0.80 0.70 0.60 0.50 0.40 0.30 0.20 0.10 –0.10 –0.20 –0.30 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...
Page 490 Forward gear shim (T1) selection chart (F150B) 1.20 1.10 1.00 0.90 0.80 0.70 0.60 0.50 0.40 0.30 0.20 0.10 –0.10 –0.20 –0.30 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) 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 –0.28 –0.25 –0.21 –0.18 –0.15 –0.11 –0.08 –0.04 –0.01 0.02 0.06 0.09 0.13 0.16 0.19 0.23 0.26 0.29 0.33 0.36 0.40 0.43 0.46 0.50 0.53 0.57 0.60 0.63 0.67 0.70 0.73 0.77 0.80 0.84 0.87 0.90 0.94 0.97 1.00 1.04 1.07...
Page 491 Shim selection table and chart (counter rotation model) Pinion shim (T3) selection table See “Pinion shim (T3) selection table” (A-12) Propeller shaft shim (T4) selection table The shim thickness does not have to be adjusted for the gray-colored cell. (mm) –0.3 –0.2 –0.1 +0.1 +0.2 +0.3 +0.4 +0.5 +0.6 +0.7 +0.8 +0.9 +1.0 +1.1 +1.2 +1.3 +1.4 +1.5 +1.6 +1.7 +1.8 +1.9 +2.0 +2.1 +2.2 +2.3 +2.4 +2.5 +2.6 A.
Page 492 Forward gear shim (T2) selection chart (FL150A) 0.30 0.20 0.10 –0.10 –0.20 –0.30 –0.40 –0.50 –0.60 –0.70 –0.80 –0.90 –1.00 –1.10 –1.20 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) 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 0.19 0.16 0.12 0.09 0.06 0.02 –0.01 –0.05 –0.08 –0.11 –0.15 –0.18 –0.22 –0.25 –0.28 –0.32 –0.35 –0.38 –0.42 –0.45 –0.49 –0.52 –0.55 –0.59 –0.62 –0.66 –0.69 –0.72 –0.76 –0.79 –0.82 –0.86 –0.89 –0.93 –0.96 –0.99 –1.03 –1.06 –1.09 –1.13 –1.16...
Page 493 Forward gear shim (T2) selection chart (FL150B) 0.30 0.20 0.10 –0.10 –0.20 –0.30 –0.40 –0.50 –0.60 –0.70 –0.80 –0.90 –1.00 –1.10 –1.20 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) 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 0.22 0.18 0.15 0.12 0.08 0.05 0.02 –0.02 –0.06 –0.09 –0.12 –0.16 –0.19 –0.22 –0.26 –0.29 –0.33 –0.36 –0.39 –0.43 –0.46 –0.49 –0.53 –0.56 –0.60 –0.63 –0.67 –0.70 –0.73 –0.77 –0.80 –0.83 –0.87 –0.90 –0.93 –0.97 –1.00 –1.04 –1.07 –1.10 –1.14...

This manual is also suitable for:

Fl150a F150b Fl150b

Yamaha F150A Service Manual

Table of Contents

Specification 1

Model Feature

Model Data

Electrical Technical Data

Fuel System Technical Data

Power Unit Technical Data

Lower Unit Technical Data

Bracket Unit Technical Data

Specified Tightening Torque

Technical Feature and Description 2

Electronic Control System

Additional Features

Ydis

Power Unit System

Fuel System

Lubrication System

Cooling System

Intake and Exhaust System

Lower Unit

PTT Unit

Rigging Information 3

Important Reminder on Rigging

Crate Handling

Uncrating

External Dimensions

Outboard Motor Mounting

Rigging Grommet Mounting

Optional Equipment

Y-COP (Standard for European Market and Optional for Oceanian Market)

Battery Installation

System Diagram

Rigging Recommendation

Propeller Selection

Troubleshooting 4

Ydis

Outboard Motor Troubleshooting

Electrical System 5

Electrical Component and Wiring Harness Routing

ECM Circuit

Checking the Electrical Component

Engine Control Unit and Component

Fuel Control Unit and Component

Charging Unit and Component

Ignition Unit and Component

Starting Unit and Component

Y-COP (Standard for European Market and Optional for Oceanian Market)

Starter Motor

6Y8 Multifunction Meter Sensor

PTT System

Fuel System 6

Hose Routing

Fuel Line

Fuel Filter

Fuel Pump

Canister and Vapor Shut-Off Valve

Intake Silencer

Throttle Link

Throttle Body

Throttle Body and Throttle Link Adjustment

Fuel Injector

Intake Manifold and Vapor Separator

Vapor Separator and High-Pressure Fuel Pump

Power Unit 7

Power Unit (Check and Adjustment)

Power Unit Assembly

Flywheel Magnet

Timing Belt

Starter Motor

Rectifier Regulator and Ignition Coil

Fuse Box

Wiring Harness

Camshaft

Cylinder Head

Exhaust Cover

Cylinder Block (F150A, FL150A)

Cylinder Block (F150B, FL150B)

Crankcase

Quick Links