Yamaha | F150 | Service manual | Yamaha F150 Service manual

F150A
FL150A
SERVICE MANUAL
290503
63P-28197-3F-11
NOTICE
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 a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.
Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.
Important information
1
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
F150A, FL150A
SERVICE MANUAL
©2003 by Yamaha Motor Co., Ltd.
1st Edition, July 2003
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in the Netherlands
Contents
General information
Specifications
Periodic checks and adjustments
Fuel system
Power unit
Lower unit
Bracket unit
GEN
INFO
SPEC
CHK
ADJ
FUEL
POWR
LOWR
BRKT
–
Electrical systems
Troubleshooting
Index
+
ELEC
TRBL
SHTG
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
How to use this manual ................................................................................. 1-1
Manual format............................................................................................ 1-1
Symbols..................................................................................................... 1-2
Safety while working......................................................................................1-3
Fire prevention........................................................................................... 1-3
Ventilation..................................................................................................1-3
Self-protection ........................................................................................... 1-3
Parts, lubricants, and sealants ..................................................................1-3
Good working practices .............................................................................1-4
Disassembly and assembly ....................................................................... 1-4
Identification...................................................................................................1-5
Applicable models .....................................................................................1-5
Serial number ............................................................................................ 1-5
Features and benefits .................................................................................... 1-6
Crankshaft and cylinder.............................................................................1-6
Balancer .................................................................................................... 1-7
Piston and piston ring ................................................................................ 1-7
Connecting rod .......................................................................................... 1-8
Cylinder head cover................................................................................... 1-8
Intake system ............................................................................................ 1-9
Top cowling ............................................................................................. 1-10
64E type power trim and tilt unit ..............................................................1-11
Cooling system ........................................................................................ 1-12
Lubrication system...................................................................................1-13
Fuel system ............................................................................................. 1-15
Rectifier Regulator...................................................................................1-16
Isolator..................................................................................................... 1-16
Technical tips ...............................................................................................1-17
Electronic control system.........................................................................1-17
ECM.........................................................................................................1-17
Fail-safe control ....................................................................................... 1-18
Warning control ....................................................................................... 1-19
Shift cut control........................................................................................ 1-20
Over-revolution control ............................................................................1-20
Fuel pump control....................................................................................1-20
Propeller selection ....................................................................................... 1-21
Propeller size........................................................................................... 1-21
Selection.................................................................................................. 1-21
63P3F11
Predelivery checks ......................................................................................1-22
Checking the fuel system ........................................................................1-22
Checking the gear oil level ...................................................................... 1-22
Checking the engine oil level................................................................... 1-22
Checking the battery................................................................................ 1-22
Checking the outboard motor mounting height........................................ 1-23
Checking the remote control cables ........................................................ 1-23
Checking the steering system .................................................................1-24
Checking the gear shift and throttle operation.........................................1-24
Checking the power trim and tilt system.................................................. 1-24
Checking the engine start switch and engine stop lanyard switch ..........1-24
Checking the cooling water pilot hole ......................................................1-25
Test run ................................................................................................... 1-25
Break-in ................................................................................................... 1-25
After test run ............................................................................................ 1-25
63P3F11
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
How to use this manual
1
Manual format
The format of this manual has been designed to make service procedures clear and easy to understand. Use the information below as a guide for effective and quality service.
1 Parts are shown and detailed in an exploded diagram and are listed in the components list.
2 Tightening torque specifications are provided in the exploded diagrams and after a numbered
step with tightening instructions.
3 Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant
and lubrication point.
4 The components list consists of part names and part quantities, as well as bolt and screw dimensions.
5 Service points regarding removal, checking, and installation are shown in individual illustrations
to explain the relevant procedure.
NOTE:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”
LOWR
3
Lower unit
2
1
Lower unit
LOWR
Lower unit
Removing the drive shaft
1. Remove the drive shaft assembly and
pinion, and then pull out the forward
gear.
S62Y6740K
CAUTION:
S62Y6850K
No.
Part name
Q’ty
1
Lower unit
1
2
Plastic tie
1
3
Hose
1
4
Check screw
1
5
Gasket
6
Dowel pin
2
7
Bolt
4
8
Drain screw
1
2
Not reusable
Disassembling the drive shaft
9
Grommet
1
Bolt
1
M10
11
Bolt
1
M8
12
Thrust washer
1
13
Propeller
1
14
Washer
1
Washer
1
16
Cotter pin
1
17
Propeller nut
1
18
Trim tab
1
6-5
1. Install the pinion nut 1, tighten it finger
tight, and then remove the drive shaft
bearing 2 using a press.
Not reusable
M10
10
15
Drive shaft holder 4 1: 90890-06518
Pinion nut holder 2: 90890-06505
Socket adapter 2 3: 90890-06507
Remarks
Do not reuse the bearing, always replace
it with a new one.
Bearing separator 1: 90890-06534
2. Remove the needle bearing from the forward gear.
40 mm
45 mm
60 mm
CAUTION:
CAUTION:
• Do not press the drive shaft threads a
directly.
• Do not reuse the bearing, always
replace it with a new one.
Not reusable
Bearing inner race attachment 3:
90890-06639
62Y5A11
Do not reuse the bearing, always replace
it with a new one.
Stopper guide plate 2: 90890-06501
Stopper guide stand 3:
90890-06538
Bearing puller 4: 90890-06535
Bearing puller claw 1 5:
90890-06536
Disassembling the forward gear
1. Remove the taper roller bearing from the
forward gear using a press.
4
6-19
62Y5A11
5
1-1
63P3F11
How to use this manual
Symbols
The symbols below are designed to indicate the content of a chapter.
General information
Fuel system
GEN
INFO
Bracket unit
FUEL
Specifications
BRKT
Power unit
SPEC
Electrical systems
POWR
Periodic checks and adjustments Lower unit
CHK
ADJ
–
ELEC
+
Troubleshooting
TRBL
SHTG
LOWR
Symbols 1 to 6 indicate specific data.
1
2
3
4
5
6
T.
R.
1
2
3
4
5 Specified measurement
6 Specified electrical value
(resistance, voltage, electric current)
Special tool
Specified oil or fluid
Specified engine speed
Specified tightening torque
Symbols 7 to C in an exploded diagram indicate the grade of lubricant and the lubrication point.
7
8
9
0
A
E
7
8
9
0
A
M
B
D
C
C
I
G
Apply Yamaha 4-stroke motor oil
Apply gear oil
Apply water resistant grease (Yamaha grease A)
Apply molybdenum disulfide grease
A Apply corrosion resistant grease
(Yamaha grease D)
B Apply low temperature resistant grease
(Yamaha grease C)
C Apply injector grease
Symbols D to I in an exploded diagram indicate the type of sealant or locking agent and the application point.
D
E
GM
F
4
D Apply Gasket Maker
E Apply Yamabond No. 4
F Apply LOCTITE 271 (red)
63P3F11
G
H
I
LT
LT
LT
271
242
572
SS
G Apply LOCTITE 242 (blue)
H Apply LOCTITE 572
I Apply silicon sealant
1-2
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Safety while working
1
To prevent an accident or injury and to
ensure quality service, follow the safety procedures provided below.
Fire prevention
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
Parts, lubricants, and sealants
Use only genuine Yamaha parts, lubricants,
and sealants or those recommended by
Yamaha, when servicing or repairing the outboard motor.
Ventilation
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled
in large quantities they may cause loss of
consciousness and death within a short time.
When test running an engine indoors (e.g., in
a water tank) be sure to do so where adequate ventilation can be maintained.
Under normal conditions, the lubricants mentioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1. Maintain good standards of personal and
industrial hygiene.
2. Change and wash clothing as soon as
possible if soiled with lubricants.
Self-protection
Protect your eyes by wearing safety glasses
or safety goggles during all operations involving drilling and grinding, or when using an air
compressor.
Protect your hands and feet by wearing protective gloves and safety shoes when necessary.
1-3
3. Avoid contact with skin. Do not, for
example, place a soiled rag in your
pocket.
4. Wash hands and any other part of the
body thoroughly with soap and hot water
after contact with a lubricant or lubricant
soiled clothing has been made.
5. To protect your skin, apply a protective
cream to your hands before working on
the outboard motor.
63P3F11
Safety while working
6. Keep a supply of clean, lint-free cloths for
wiping up spills, etc.
Disassembly and assembly
1. Use compressed air to remove dust and
dirt during disassembly.
Good working practices
Special service tools
Use the recommended special service tools
to protect parts from damage. Use the right
tool in the right manner—do not improvise.
Tightening torques
Follow the tightening torque specifications
provided throughout the manual. When tightening nuts, bolts, and screws, tighten the
large sizes first, and tighten fasteners starting
in the center and moving outward.
Non-reusable parts
Always use new gaskets, seals, O-rings, cotter pins, circlips, etc., when installing or
assembling parts.
63P3F11
2. Apply engine oil to the contact surfaces
of moving parts before assembly.
3. Install bearings with the manufacture
identification mark in the direction indicated in the installation procedure. In
addition, be sure to lubricate the bearings
liberally.
4. Apply a thin coat of water-resistant
grease to the lip and periphery of an oil
seal before installation.
5. Check that moving parts operate normally after assembly.
1-4
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Identification
1
Applicable models
This manual covers the following models.
Applicable models
F150AET, FL150AET
Serial number
The outboard motor serial number is
stamped on a label attached to the port
clamp bracket.
1
2
3
4
Model name
Approved model code
Transom height
Serial number
Model name
Approved
model code
F150AET
63P
FL150AET
64P
1-5
Starting
serial No.
L: 1000017–
X: 1000044–
L: 1000013–
X: 1000009–
63P3F11
Identification / Features and benefits
Features and benefits
1
Crankshaft and cylinder
The center of the crankshaft is offset 10 mm (0.39 in) from the center of the cylinder to make more
space to incorporate the throttle body assembly.
This design produces good engine balance and allows a compact design.
Exhaust gas from each cylinder flows directly into the exhaust manifold to obtain a compact design
for the exhaust system.
2
1
3
4
5
6
1
2
3
4
5
6
S63P1070
Throttle body assembly
Oil/gas separator
Direct exhaust system
Rectifier Regulator
Offset 10 mm (0.39 in)
Balancer shafts
63P3F11
1-6
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Balancer
A two-piece balancer is used in the crankcase to reduce the secondary forces of inertia produced by
reciprocating pistons.
The balancer shaft 1 is driven by the gear on the crankshaft.
The balancer shaft 2 is driven by the gear on the balancer shaft 1.
The two counterrotating balancer shafts rotate at twice the speed of the crankshaft and reduce the
forces of inertia of the connecting rods and each balancer shaft.
Therefore, engine vibration is reduced.
1
2
3
4
S63P1080
1 Balancer shaft 1
2 Balancer shaft 2
3 Piston secondary force of inertia
4 Balancer force of inertia
Piston and piston ring
A forged piston has been adopted for durability.
Hard chromium plating is applied to the piston rings.
The top and 2nd piston rings differ and are identified by a mark on each ring.
Install the piston rings on the piston with the identification marks facing up.
1
2
R
1
2
3
4
45˚
RN
45˚
3
2
1
4
S63P1090
Top ring
2nd ring
Upper oil ring rail
Lower oil ring rail
1-7
63P3F11
Features and benefits
Connecting rod
A direction mark for installing the connecting rod to the crankshaft in the proper direction is on the
connecting rod cap.
The direction mark should face the flywheel.
The connecting rod and connecting rod cap are manufactured as a single piece. Then, they are split
using impact force. Only use the connecting rods and connecting rod caps in their original combinations, do not interchange them.
1
S63P1100
1 Direction mark
Cylinder head cover
The oil/gas separator is used to obtain low emissions and is built into the cylinder head cover to
obtain a compact design.
The gas and oil flow is shown below.
1
2
:È
:É
S63P1110
1 Intake silencer
2 Cylinder head cover (with gas/oil separator)
È Blowby gas
É Oil
63P3F11
1-8
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Intake system
Multi-point, group fuel injection with four separate throttle valves is adopted for the intake system.
Intake air volume is calculated according to engine speed, Intake air pressure, and throttle position,
and then the fuel injection volume is determined by the intake air volume to obtain a precise air and
fuel ratio under all operating conditions.
The cylinders are grouped, #1/#4 and #2/#3. Fuel is injected twice during each full cycle of each cylinder, once during the exhaust stroke and once during the compression stroke. Fuel is injected during the compression stroke of the #1 cylinder and the exhaust stroke of the #4 cylinder and during
the exhaust stroke of the #1 cylinder and the compression stroke of the #4 cylinder. The same
occurs during the compression and exhaust strokes of the #2 and #3 cylinders.
This allows a simpler fuel injection control system.
1
Initial injection timing
BTDC10
#1
#3
#4
#2
cylinder
cylinder
cylinder
cylinder
Compression
Combustion
Exhaust
Intake
Intake
Compression
Combustion
Exhaust
Exhaust
Intake
Compression
Combustion
Combustion
Exhaust
Intake
Compression
S63P1120
1 Four separate throttle valve
1-9
63P3F11
Features and benefits
The shape of the fuel injectors is the same for the F115, F150, F200 and F225.
Therefore, each fuel injector is identified by color because the specifications of each fuel injector are
different.
È
É
Ê
F115
732
F150
Ë
Ì
F200
F225
Í
741
731
S63P1130
È Model
É Injector color
Ê First three digits
Ë Orange
Ì Yellow
Í Ivory
Top cowling
Water is separated from the intake air and flows down through the drain hoses before draining out
through the bottom cowling.
The structure of the top cowling helps to prevent water from accumulating in the top cowling and
entering the power unit.
1
2
3
:È
S63P1140
1 Water separator
2 Air (including water)
3 Drain hoses
È Water
63P3F11
1-10
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
64E type power trim and tilt unit
The 64E type clamp bracket and power trim and tilt unit used for current V4 and V6 outboard motors
have been adopted.
This allows easier interchanging of Yamaha outboards with the same classification because the
mounting dimensions are the same.
For the power trim and tilt unit, only the impact absorber valve opening pressure of the tilt piston
fluid circuit has been changed. The pressure is distinguished from those of other models by an identification mark stamped on the power trim and tilt unit.
È
S63P1150
È
Identification mark
1-11
Applicable models
YA
Carbureted V4 and V6 (2.6)
YB
N/A
YC
Electronic fuel injected V6 (2.6), HPDI (2.6),
VX200 (200H), VX225 (225G), and VX250 (250C)
YD
F115 (F115A), LF115 (FL115A), and (F100B)
YE
VZ225 (Z225H) and VZ250 (Z250F)
YF
F150 (F150A) and LF150 (FL150A)
63P3F11
Features and benefits
Cooling system
The cooling water flow diagram is as follows.
To cool the propeller damper, the cooling system is designed so that fresh cooling water is taken in
from the front of the trim tab and supplied to the exhaust passage of the lower case to cool the
exhaust gas.
Cooling water also accumulates around the exhaust muffler to cool the upper case and reduce
exhaust noise.
Thermostat
Cylinder block
Pressure control valve
Cylinder head
Cylinder block
Upper case
Exhaust cover
Exhaust guide
Lower case
Fuel cooler
Oil pan
Water pump
Cooling water pilot hole
Propeller boss
Trim tab
Water inlet
Sea / River / Lake
3
4
1
2
:È
S63P1170
1 Exhaust manifold
2 Muffler
3 Exhaust gas
63P3F11
4 Water
È Water
1-12
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Lubrication system
The lubrication oil flow diagram is as follows.
Crankcase
Cylinder head
Cylinder sleeve
Camshaft
Piston
Balancer
journal
Crankpin
IN/EX valve
Camshaft journal
Crankshaft main journal
Main passage
Oil filter
Oil pressure sensor
Oil filter bracket
Relief valve
Oil pump
Oil strainer
Oil pan
S63P1260
There is a small hole in the relief valve to allow oil to drain from the oil filter bracket so that it does
not remain in the oil filter. This prevents oil from spilling out when replacing the oil filter.
1
2
:È
S63P1180
1 Relief valve
2 Oil filter bracket
È Oil
1-13
63P3F11
Features and benefits
A dual oil drain system is adopted.
An oil drain bolt is located on the bottom of the oil pan.
A long dipstick guide, which reaches the bottom of the oil pan, can also be used to pump out the oil
completely with an oil-extracting tool.
2
1
S63P1190
1 Drain bolt
2 Dipstick guide
63P3F11
1-14
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Fuel system
A fuel pressure regulator is incorporated onto the outlet of the electric fuel pump to obtain a compact
design and simple fuel delivery.
Fuel discharged from the pressure regulator returns to the vapor separator after being cooled in the
fuel cooler.
The pressure check valve is incorporated onto the fuel rail for easier servicing of the fuel system.
Fuel tank
Fuel filter (fuel tank)
Vapor separator
Primer pump
Fuel filter
(69J type)
Fuel pump
Pressure
check valve
Fuel rail
Electric fuel pump
Fuel cooler
Pressure regulator
Fuel
injector
1
Fuel
injector
2
Fuel
injector
3
Fuel
injector
4
1
2
:È
3
S63P1200
1 Pressure regulator
2 Vapor separator
3 Fuel cooler
È Fuel flow
1-15
63P3F11
Features and benefits
Rectifier Regulator
A water-cooled Rectifier Regulator is incorporated onto the exhaust outer cover.
This allows for a compact engine design and produces a large electric current output for charging
the battery under low engine speed.
40
35
30
25
È
20
15
10
5
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
É
S63P1210
È Charging current (A)
É Engine speed (r/min)
Isolator
An isolator is incorporated into the Rectifier Regulator. If a second battery is used, connect an
optional isolator lead.
Isolator lead P/N: 69J-81949-00 (3.8 m/12.5 ft)
68F-81949-00 (2.7 m/9 ft)
3.8 m (12.5 ft)/2.7 m (9 ft)
1
S63P1220
1 Red tube
63P3F11
1-16
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Technical tips
1
Electronic control system
The electronic control system consists of the sensors and the ECM (electronic control module).
Under various conditions, the ECM provides the best suitable engine operation.
2
4
3
5
1
6
1
2
3
4
Intake air pressure sensor
Engine temperature sensor
Throttle position sensor
Pulser coil
7
5
6
7
8
8
S63P1230
Thermoswitch
Intake air temperature sensor
ECM
Oil pressure sensor
ECM
This engine is controlled by the ECM to obtain precise combustion under various operating conditions for high power output, low fuel consumption, and low emissions.
The ECM controls the ignition timing, the fuel injection timing, and the fuel injection volume and
ensures that optimum ignition timing and an optimum air and fuel ratio can be achieved under all
operating conditions such as starting the engine, normal operation, and quick acceleration.
The self-diagnostic function is incorporated into the ECM, and can quickly detect a malfunction
when a personal computer is used with the optional software installed. (Refer to the “Yamaha Diagnostic System Instruction Manual”.)
È
63P-00
63P-10
63P-20
É
EUR
USA, CAN, OCE
JPN
S63P1240
È ECM identification
É Destination
1-17
63P3F11
Technical tips
Fail-safe control
If the electrical components malfunction, the ECM controls the ignition and fuel injection as shown in
the table.
Malfunctioning item
Details
Ignition control
Fuel control
Pulser coil
No signal received during
four consecutive crankshaft
rotations
Fixed to BTDC 10°
Fixed to BTDC 10°
Throttle position
sensor
Output voltage is 0.3 V or
lower or 4.7 V or higher
Controlled according to the basic
injection map
Controlled by Intake
air pressure and
engine speed
Intake air pressure
sensor
Output voltage is 0.2 V or
lower or 4.5 V or higher
Normal control
Fuel injection volume is controlled by
the throttle position
sensor
Engine temperature
sensor
Output voltage is 0.18 V or
lower or 4.93 V or higher
Normal control
Normal control
Intake air temperature sensor
Output voltage is 0.10 V or
lower or 4.61 V or higher
Normal control
Normal control
Neutral switch
Switch is off when starting
the outboard motor
Normal control
Normal control
Thermoswitch
The switch is on when the
engine temperature is 40 °C
(104 °F) or lower or the
switch is off when the engine
temperature is 130 °C
(266 °F) or higher.
Normal control
Normal control
Shift cut switch
Output voltage is 4.50 V or
higher, the switch is on when
the outboard motor is
started, or both the shift cut
switch and neutral switch are
on for 5 seconds
Normal control
Normal control
Oil pressure sensor
Output voltage is 0.3 V or
lower or 4.8 V or higher
Normal control
Normal control
During fail-safe control, the engine idle speed increases to 900 r/min except if the neutral switch is
off when the outboard motor is started.
63P3F11
1-18
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Warning control
This outboard motor is equipped with warning control functions to avoid serious engine damage.
The engine speed is limited to approximately 2,000 r/min if the engine overheats, if the oil pressure
is low, or if a dual engine system (DES) is operated.
When a switch turns on, the engine speed is controlled as shown in the table.
Thermoswitch
Engine
temperature
sensor
Oil pressure
sensor
On
130 °C
(266 °F) or
higher
(0.63 V or
lower)
Below
specified oil
pressure due
to engine
speed
Overheat warning
indicator lights and
buzzer sounds
Oil pressure
warning
indicator lights
and buzzer
sounds
DES
signal
On
Buzzer
sounds
Engine speed
Less than
2,000 r/min
2,000 r/min
or more
Fuel injection
begins again in the
cylinder order #3,
#4, and #1
Fuel injection is
shut off in the
cylinder order #1,
#4, and #3.
NOTE:
• The warning indicators light for 3 seconds after the engine start switch is
turned on.
• The buzzer sounds if the lanyard is
removed from the engine stop lanyard
switch while starting the outboard
motor.
Fuel injection is shut off in the cylinder order #1, #4, and #3 at 2.5-second intervals when the engine
is running at 2,000 r/min or more.
Fuel injection to the #2 cylinder is not shut off.
When the throttle-opening angle is 30 degrees or less, fuel injection to the #3 cylinder will begin
again.
When the engine speed decreases to less than 2,000 r/min, fuel injection will begin again in the cylinder order #3, #4, and #1 at 0.2-second intervals.
The warning control mode deactivates when the engine speed is less than 1,600 r/min or the throttle-opening angle is less than 7 degrees.
1-19
63P3F11
Technical tips
Shift cut control
This outboard motor is equipped with a shift cut control system for easier shifting.
This device misfires and retards the ignition of some cylinders to fluctuate the engine speed
instantly when the engine is running from 400 to 2,000 r/min. This allows smooth engagement
and/or disengagement of the dog clutch.
When shifting, the ignition is shut off as shown in the table.
Engine speed
(r/min)
Shift cut
switch
less than 400
400 to 729
730 to 2,000
2,001 or more
Off
N/A
N/A
N/A
N/A
Retards ignition
timing
Misfires the #1
and #4 cylinders,
and then retards
ignition timing
N/A
On
N/A
N/A: No misfire control
Over-revolution control
This outboard motor is equipped with an over-revolution control system to protect the engine.
If the engine speed exceeds 6,200 r/min, the fuel injection is shut off as shown in the table below.
Engine speed (r/min)
6,199 or less
Injected cylinder
#1, #2, #3, and #4
6,200 to 6,300
#2 and #3
6,301 to 6,550
#2
6,551 or more
None
Note
Normal operation
Over-revolution control mode
Fuel pump control
The electric fuel pump operates for 3 seconds after the engine start switch is turned on and continues to operate while the engine is running.
The electric fuel pump stops 1 second after the engine is stopped.
NOTE:
After the engine start switch is turned on, all of the fuel injectors are driven to prevent them from
sticking before the electric fuel pump is driven.
63P3F11
1-20
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Propeller selection
1
The performance of a boat and outboard
motor will be critically affected by the size
and type of propeller you choose. Propellers
greatly affect boat speed, acceleration,
engine life, fuel economy, and even boating
and steering capabilities. An incorrect choice
could adversely affect performance and
could also seriously damage the engine.
Use the following information as a guide for
selecting a propeller that meets the operating
conditions of the boat and the outboard
motor.
Regular rotation model
Propeller size (in)
Material
13 1/2 × 23 - M
13 3/4 × 21 - M
14 × 19 - M
Aluminum
14 1/2 × 17 - M
15 1/4 × 15 - M
13 3/8 × 23 - M
13 3/8 × 25 - M
13 3/4 × 17 - M2
13 3/4 × 19 - M2
13 3/4 × 21 - M
Propeller size
The size of the propeller is indicated on the
propeller boss end.
14 1/2 × 15 - M
14 1/2 × 21 - M
14 1/2 × 23 - M
Stainless
14 1/2 × 25 - M
×
a
-
b c
14 1/2 × 27 - M
14 7/8 × 21 - M
15 × 19 - M
15 1/4 × 15 - M
15 1/4 × 17 - M
S69J1100
a Propeller diameter (in inches)
b Propeller pitch (in inches)
c Propeller type (propeller mark)
Selection
When the engine speed is at the full throttle
operating range (5,000–6,000 r/min), the
ideal propeller for the boat is one that provides maximum performance in relation to
boat speed and fuel consumption.
15 3/4 × 13 - M
Counter rotation model
Propeller size (in)
14 × 19 - ML
14 1/2 × 17 - ML
Material
Aluminum
13 3/8 × 23 - ML
13 3/4 × 17 - ML1
13 3/4 × 19 - ML1
13 3/4 × 21 - ML
14 1/2 × 23 - ML
Stainless
14 7/8 × 21 - ML
15 1/4 × 15 - ML
15 1/4 × 17 - ML
15 1/4 × 19 - ML
1-21
63P3F11
Propeller selection / Predelivery checks
Predelivery checks
1
To make the delivery process smooth and
efficient, the predelivery checks should be
completed as explained below.
Checking the engine oil level
1. Check the engine oil level.
Checking the fuel system
1. Check that the fuel hoses are securely
connected and that the fuel tank is full
with fuel.
NOTE:
• If the engine oil is above the maximum level
mark (H), extract sufficient oil with an oil
changer or drain it until the level is between
(H) and (L).
• If the engine oil is below the minimum level
mark (L), add sufficient oil until the level is
between (H) and (L).
Recommended engine oil:
4-stroke motor oil
API: SE, SF, SG, SH, or SJ
SAE: 10W-30 or 10W-40
Oil capacity:
Without oil filter replacement:
5.2 L (5.5 US qt, 4.6 Imp qt)
CAUTION:
This is a 4-stroke engine. Never use premixed fuel.
Checking the battery
1. Check the capacity, electrolyte level, and
specified gravity of the battery.
Checking the gear oil level
1. Check the gear oil level.
Recommended battery capacity:
CCA/EN: 711 A
20HR/IEC: 100 Ah
Electrolyte specified gravity:
1.280 at 20 °C (68 °F)
2. Check that the positive and negative battery leads are securely connected.
S60V1290
63P3F11
1-22
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Checking the outboard motor
mounting height
1. Check that the anti-cavitation plate is
aligned with the bottom of the boat. If the
mounting height is too high, cavitation
will occur and propulsion will be reduced.
Also, the engine speed will increase
abnormally and cause the engine to
overheat. If the mounting height is too
low, water resistance will increase and
reduce engine efficiency.
NOTE:
The optimum mounting height is affected by
the combination of the boat and the outboard
motor. To determine the optimum mounting
height, test run the outboard motor at different heights.
1
2
S63P1040
3. Check that the center of the set pin a is
aligned with the alignment mark b on
the bottom cowling.
b
a
S63P3270
2. Check that the clamp brackets are
secured with the clamp bolts.
c
Checking the remote control cables
1. Set the remote control lever to the neutral position and fully close the throttle
lever.
2. Check that the stopper 1 on the throttle
lever 2 contacts the fully closed stopper
2 on the cylinder block.
1-23
S69J3370
CAUTION:
The shift/throttle cable joint must be
screwed in a minimum of 8.0 mm (0.31 in)
c.
63P3F11
Predelivery checks
Checking the steering system
1. Check the steering friction for proper
adjustment.
2. Check that
smoothly.
the
steering
operates
Checking the power trim and tilt
system
1. Check that the outboard motor tilts up
and down smoothly when operating the
power trim and tilt unit.
2. Check that there is no abnormal noise
produced when the outboard motor is
tilted up or down.
3. Check that there is no interference with
wires or hoses when the tilted-up outboard motor is steered.
4. Check that the trim meter points down
when the outboard motor is tilted all the
way down.
3. Check that there is no interference with
wires or hoses when the outboard motor
is steered.
Checking the gear shift and throttle
operation
1. Check that the gear shift operates
smoothly when the remote control lever
is shifted from neutral to forward or
reverse.
Checking the engine start switch and
engine stop lanyard switch
1. Check that the engine starts when the
engine start switch is turned to START.
2. Check that the engine turns off when the
engine start switch is turned to OFF.
2. Check that the throttle operates smoothly
when the remote control lever is shifted
from forward or reverse to the fully open
position a.
N
F
S60V1070
R
a
3. Check that the engine turns off when the
engine stop lanyard is pulled from the
engine stop lanyard switch.
a
S69J1210
63P3F11
1-24
1
2
3
4
5
6
7
8
9
GEN
INFO
General information
Checking the cooling water pilot
hole
1. Check that cooling water is discharged
from the cooling water pilot hole.
a
È 0
b
1
c
2
10
S69J1240
È Hour
After test run
1. Check for water in the gear oil.
Test run
2. Check for fuel leakage in the cowling.
1. Start the engine, and then check that the
gear shift operates smoothly.
3. Flush the cooling water passage with
fresh water using the flushing kit and with
the engine running at idle.
2. Check the engine idle speed after the
engine has been warmed up.
3. Operate at trolling speed.
4. Run the outboard motor for 1 hour at
2,000 r/min or at half throttle, then for
another hour at 3,000 r/min or at 3/4
throttle.
5. Check that the outboard motor does not
tilt up when shifting into reverse and that
water does not flow in over the transom.
NOTE:
The test run is part of the break-in operation.
Break-in
During the test run, perform the break-in
operation in the following three stages.
1. One hour a at 2,000 r/min or at approximately half throttle
2. One hour b at 3,000 r/min or 3/4 throttle
and 1 minute out of every 10 at full throttle
3. Eight hours c at any speed, however,
avoid running at full speed for more than
5 minutes
1-25
63P3F11
SPEC
Specifications
General specifications................................................................................... 2-1
Maintenance specification ............................................................................2-3
Power unit..................................................................................................2-3
Lower unit ..................................................................................................2-6
Electrical .................................................................................................... 2-7
Dimensions................................................................................................2-9
Tightening torques....................................................................................... 2-11
Specified torques.....................................................................................2-11
General torques....................................................................................... 2-13
63P3F11
1
2
3
4
5
6
7
8
9
SPEC
Specifications
General specifications
Item
Dimension
Overall length
Overall width
Overall height
(L)
(X)
Boat transom height
(L)
(X)
Weight
(with aluminium propeller)
(L)
(X)
(with stainless propeller)
(L)
(X)
Performance
Maximum output
Full throttle operating range
Maximum fuel consumption
Engine idle speed
Power unit
Type
Cylinder quantity
Total displacement
Bore × stroke
Compression ratio
Control system
Starting system
Fuel system
Ignition system
Maximum generator output
Spark plug
Cooling system
Exhaust system
Lubrication system
2-1
2
Unit
Model
F150AET
FL150AET
mm (in)
mm (in)
822 (32.4)
511 (20.1)
mm (in)
mm (in)
1,714 (67.5)
1,842 (72.5)
mm (in)
mm (in)
508 (20.0)
635 (25.0)
kg (lb)
kg (lb)
214.0 (472)
218.0 (481)
kg (lb)
kg (lb)
216.0 (476)
220.0 (485)
kW (hp)
r/min
L (US gal,
lmp gal)/hr
r/min
110.3 (150) at 5,500 r/min
5,000–6,000
55.8 (14.7, 12.3) at 6,000 r/min
cm3 (cu. in)
mm (in)
V, A
700 ± 50
4-stroke L
4
2,670 (162.9)
94.0 × 96.2 (3.70 × 3.79)
9.0
Remote control
Electric
Fuel injection
TCI
12, 35
LFR5A-11 (NGK)
Water
Propeller boss
Wet sump
63P3F11
General specifications
Item
Fuel and oil
Fuel type
Fuel minimum rating
Engine oil
Engine oil grade
Engine oil quantity
(without oil filter replacement)
(with oil filter replacement)
Gear oil type
Gear oil grade
Gear oil quantity
Bracket unit
Trim angle
(at 12° boat transom)
Tilt-up angle
Steering angle
Drive unit
Gear shift positions
Gear ratio
Reduction gear type
Clutch type
Propeller shaft type
Propeller direction (rear view)
Propeller mark
Electrical
Battery minimum capacity(*2)
CCA/EN
20HR/IEC
Unit
RON(*1)
PON
API
SAE
L (US qt,
lmp qt)
L (US qt,
lmp qt)
SAE
cm3 (US oz,
lmp oz)
Model
F150AET
FL150AET
Regular unleaded gasoline
91
86
4-stroke motor oil
SE, SF, SG, SH, or SJ
10W-30 or 10W-40
5.2 (5.5, 4.6)
5.4 (5.7, 4.8)
Hypoid gear oil
90
980 (33.1, 34.6)
870 (29.4, 30.7)
Degree
–4.0 to 16.0
Degree
Degree
70.0
35.0 + 35.0
F-N-R
2.00 (28/14)
Spiral bevel gear
Dog clutch
Spline
Clockwise
Counterclockwise
M
ML
A
Ah
711
100
(*1)
RON: Research Octane Number
PON: Pump Octane Number =
(RON + Motor Octane Number)/2
(*2) CCA: Cold Cranking Ampere
EN: European Norm (European standard)
IEC: International Electrotechnical Commission
63P3F11
2-2
1
2
3
4
5
6
7
8
9
SPEC
Specifications
Maintenance specification
2
Power unit
Item
Power unit
Minimum compression
pressure(*1)
Lubrication oil pressure(*2)
Cylinder head
Warpage limit
(lines indicate straightedge
position)
Camshaft cap inside diameter
Cylinders
Bore size
Taper limit
Out-of-round limit
Pistons
Piston diameter (D)
Measuring point (H)
Piston-to-cylinder clearance
Piston pin boss bore
Piston rings
Top ring
Dimension B
Dimension T
End gap
Side clearance
2nd piston ring
Dimension B
Dimension T
End gap
Side clearance
Unit
kPa
(kgf/cm2, psi)
kPa
(kgf/cm2, psi)
Model
F150AET
FL150AET
880 (8.8, 128)
450 (4.5, 65.3) at engine idle speed
mm (in)
0.10 (0.0039)
mm (in)
25.000–25.021 (0.9843–0.9851)
mm (in)
mm (in)
mm (in)
94.000–94.017 (3.7008–3.7014)
0.08 (0.0032)
0.05 (0.0020)
mm (in)
mm (in)
mm (in)
mm (in)
93.928–93.934 (3.6979–3.6982)
5.0 (0.20)
0.075–0.080 (0.0030–0.0031)
21.004–21.015 (0.8269–0.8274)
mm (in)
mm (in)
mm (in)
mm (in)
1.17–1.19 (0.0461–0.0469)
2.80–3.00 (0.1102–0.1181)
0.15–0.30 (0.0059–0.0118)
0.04–0.08 (0.0016–0.0031)
mm (in)
mm (in)
mm (in)
mm (in)
1.17–1.19 (0.0461–0.0469)
3.70–3.90 (0.1457–0.1535)
0.30–0.45 (0.0118–0.0177)
0.03–0.07 (0.0012–0.0028)
(*1)
Measure conditions:
Ambient temperature 20 °C (68 °F), wide open throttle, with spark plugs removed from all cylinders.
The figures are for reference only.
(*2) The figures are for reference only.
2-3
63P3F11
Maintenance specification
Item
Oil ring
Dimension B
Dimension T
End gap
Side clearance
Camshafts
Intake (A)
Exhaust (A)
Intake and
exhaust (B)
Camshaft journal diameter
Camshaft journal oil clearance
Camshaft runout limit
Valves
Valve clearance (cold)
Intake
Exhaust
Head diameter (A)
Intake
Exhaust
Face width (B)
Intake
Exhaust
Seat contact width (C)
Intake
Exhaust
Margin thickness (D)
Intake
Exhaust
Stem diameter
Intake
Exhaust
Guide inside diameter
Intake and exhaust
Stem-to-guide clearance
Intake and exhaust
Stem runout limit
Valve springs
Free length
Minimum free length
Tilt limit
63P3F11
Unit
Model
F150AET
FL150AET
mm (in)
mm (in)
mm (in)
mm (in)
2.40–2.47 (0.0945–0.0972)
2.30–2.70 (0.0906–0.1063)
0.15–0.60 (0.0059–0.0236)
0.04–0.13 (0.0016–0.0051)
mm (in)
mm (in)
mm (in)
45.300–45.400 (1.7835–1.7874)
44.350–44.450 (1.7461–1.7500)
35.950–36.050 (1.4154–1.4193)
mm (in)
mm (in)
mm (in)
24.960–24.980 (0.9827–0.9835)
0.020–0.060 (0.0008–0.0024)
0.03 (0.0012)
mm (in)
mm (in)
0.20 ± 0.03 (0.008 ± 0.001)
0.34 ± 0.03 (0.013 ± 0.001)
mm (in)
mm (in)
34.85–35.15 (1.37–1.38)
29.85–30.15 (1.18–1.19)
mm (in)
mm (in)
2.11 (0.0831)
2.43 (0.0957)
mm (in)
mm (in)
1.10–1.40 (0.0433–0.0551)
1.40–1.70 (0.0551–0.0669)
mm (in)
mm (in)
0.70 (0.0276)
1.00 (0.0394)
mm (in)
mm (in)
5.477–5.492 (0.2156–0.2162)
5.464–5.479 (0.2151–0.2157)
mm (in)
5.504–5.522 (0.2167–0.2174)
mm (in)
mm (in)
0.025–0.058 (0.0010–0.0023)
0.01 (0.0004)
mm (in)
mm (in)
mm (in)
44.20 (1.7402)
42.60 (1.6771)
1.5 (0.06)
1
2
3
4
5
6
7
8
9
2-4
SPEC
Specifications
Item
Valve lifters
Valve lifter outside diameter
Valve lifter-to-cylinder head
clearance
Valve shims
Valve shim thickness
(in 0.020 mm increments)
Connecting rods
Big-end inside diameter
Crankpin oil clearance
Big-end bearing thickness
Green
Blue
Red
Crankshaft
Crankshaft journal diameter
Crankpin diameter
Crankpin width
Runout limit
Crankcase
Crankshaft main journal oil
clearance
Upper crankcase main journal
bearing thickness
Green
Red
Yellow
Lower crankcase main journal
bearing thickness
Green
Red
Yellow
Blue + green
Main journal bearing #3
thickness (lower)
Green
Red
Yellow
2-5
Unit
Model
F150AET
FL150AET
mm (in)
mm (in)
32.982–32.997 (1.2985–1.2990)
0.020–0.055 (0.0008–0.0022)
mm (in)
2.3–2.9 (0.09–0.12)
mm (in)
mm (in)
53.025–53.045 (2.0876–2.0884)
0.027–0.052 (0.0011–0.0020)
mm (in)
mm (in)
mm (in)
1.496–1.502 (0.0589–0.0591)
1.505–1.511 (0.0593–0.0595)
1.514–1.520 (0.0596–0.0598)
mm (in)
mm (in)
mm (in)
mm (in)
51.980–52.000 (2.0465–2.0472)
49.980–50.000 (1.9677–1.9685)
22.00–22.10 (0.8661–0.8701)
0.03 (0.0012)
mm (in)
0.021–0.050 (0.0008–0.0020)
mm (in)
mm (in)
mm (in)
2.506–2.509 (0.0987–0.0988)
2.512–2.515 (0.0989–0.0990)
2.518–2.521 (0.0991–0.0993)
mm (in)
mm (in)
mm (in)
mm (in)
2.506–2.509 (0.0987–0.0988)
2.512–2.515 (0.0989–0.0990)
2.518–2.521 (0.0991–0.0993)
2.524–2.527 (0.0994–0.0995)
mm (in)
mm (in)
mm (in)
2.504–2.509 (0.0986–0.0988)
2.510–2.515 (0.0988–0.0990)
2.516–2.521 (0.0991–0.0993)
63P3F11
Maintenance specification
Item
Oil pump
Discharge
at 97–103 °C (207–217 °F)
with 10W-30 engine oil
Pressure
Relief valve opening pressure
Thermostats
Opening temperature
Fully open temperature
Valve open lower limit
Unit
Model
F150AET
FL150AET
L (US gal,
lmp gal)/min
8.0 (2.113, 1.760) at 700 r/min
kPa
(kgf/cm2, psi)
kPa
(kgf/cm2, psi)
132.0–162.0 (1.32–1.62, 19.1–23.5)
°C (°F)
°C (°F)
mm (in)
58–62 (136–144)
70 (158)
4.3 (0.17)
392–490 (3.92–4.90, 56.84–71.05)
Lower unit
Item
Unit
Gear backlash
Pinion-to-forward gear
mm (in)
Pinion-to-reverse gear
mm (in)
Pinion shims
Forward gear shims
Reverse gear shims
Propeller shaft shims
mm
mm
mm
mm
Propeller shaft
End play
63P3F11
mm (in)
Model
F150AET
FL150AET
0.14–0.46
0.14–0.42
(0.0055–0.0181)
(0.0055–0.0165)
0.32–0.67
0.23–0.58
(0.0126–0.0264)
(0.0090–0.0228)
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
—
0.10, 0.12, 0.15, 0.18,
0.30, 0.40, 0.50
—
0.25–0.35
(0.0098–0.0138)
2-6
1
2
3
4
5
6
7
8
9
SPEC
Specifications
Electrical
Item
Ignition and ignition control
system
Ignition timing (cylinder #1)
Spark plug gap
Ignition coil resistance
Primary coil
(R – B/W)
at 20 °C (68 °F)
Secondary coil
at 20 °C (68 °F)
ECM output peak voltage
(B/O, B/W – B)
at cranking (loaded)
at 1,500 r/min (loaded)
at 3,500 r/min (loaded)
Pulser coil output peak voltage
(W/R, W/B – B)
at cranking (unloaded)
at cranking (loaded)
at 1,500 r/min (loaded)
at 3,500 r/min (loaded)
Pulser coil resistance(*1)
(W/R, W/B – B)
Pulser coil air gap
Throttle position sensor
Input voltage
(O – B)
Output voltage
(P – B)
Intake air temperature sensor
resistance
at 20 °C (68 °F)
Engine temperature sensor
resistance
(B/Y – B/Y)
at 20 °C (68 °F)
at 100 °C (212 °F)
Fuel control system
Fuel injector resistance(*1)
at 20 °C (68 °F)
(*1)
Unit
Model
F150AET
FL150AET
Degree
mm (in)
TDC at engine idle speed
1.0–1.1 (0.039–0.043)
Ω
1.53–2.07
kΩ
12.50–16.91
V
V
V
260
260
270
V
V
V
V
Ω
3.5
3.6
23.9
49.7
459–561
mm (in)
0.3–0.7 (0.0118–0.0276)
V
V
5
0.70 ± 0.02 at engine idle speed
kΩ
2.20–2.70
kΩ
kΩ
54.2–69.0
3.12–3.48
Ω
14.0–15.0
The figures are for reference only.
2-7
63P3F11
Maintenance specification
Item
Starter motor
Type
Output
Cranking time limit
Brushes
Standard length
Wear limit
Commutator
Standard diameter
Wear limit
Mica
Standard undercut
Wear limit
Charging system
Fuse
Stator coil output peak voltage
(G – G)
at cranking (unloaded)
at 1,500 r/min (unloaded)
at 3,500 r/min (unloaded)
Stator coil resistance(*1)
at 20 °C (68 °F)
(G – G)
Rectifier Regulator output
peak voltage
(R – B)
at 1,500 r/min (unloaded)
at 3,500 r/min (unloaded)
Power trim and tilt system
Trim sensor
Setting resistance
(P – B)
Resistance
(P – B)
Fluid type
Brushes
Standard length
Wear limit
Commutator
Standard limit
Wear limit
Mica
Standard undercut
Wear limit
(*1)
Unit
Model
F150AET
FL150AET
kW
Second
Sliding gear
1.40
30
mm (in)
mm (in)
15.5 (0.61)
9.5 (0.37)
mm (in)
mm (in)
29.0 (1.14)
28.0 (1.10)
mm (in)
mm (in)
0.5–0.8 (0.02–0.03)
0.2 (0.01)
A
20, 30, 50
V
V
V
12
50
110
Ω
0.20–0.30
V
V
13.0
13.0
Ω
Ω
9–11
9–378.8
ATF Dexron II
mm (in)
mm (in)
9.8 (0.39)
4.8 (0.19)
mm (in)
mm (in)
22.0 (0.87)
21.0 (0.83)
mm (in)
mm (in)
1.3 (0.05)
0.8 (0.03)
1
2
3
4
5
6
7
8
9
The figures are for reference only.
63P3F11
2-8
SPEC
Specifications
Dimensions
Exterior
660 (26.0)
35˚
256 (10.1) 433 (17.0)
mm (in)
L: 1,032 (40.7)
X: 1,148 (45.2)
629 (24.8)
164 (6.5)
698 (27.5)
˚
L: 60
X: 80 (2.4)
(3.1)
L: 787 (31.0)
X: 864 (34.0)
162(6.4)
66
16 (0.6)
45 (1.8)
455 (17.9)
769 (30.1)
210 (8.3) L: 516 (20.3)
X: 643 (25.3)
L: 946 (37.2)
X: 1,073 (42.2)
915 (36.0)
75 (3.0)
27(1.1)
1 2˚
L: 35 (1.4)
X: 43 (1.7)
4˚
646 (25.4)
S63P2010
2-9
63P3F11
Maintenance specification
Clamp bracket
mm (in)
1
2
3
4
5
6
7
8
9
180 (7.1)
180 (7.1)
163.5 (6.4)
50.8 (2.0)
163.5 (6.4)
55.5 (2.2)
254 (10.0)
367 (14.4)
13 (0.5)
18.5 (0.7)
82 (3.2)
13 (0.5)
125.4 (4.9)
125.4 (4.9)
S63P2020
63P3F11
2-10
SPEC
Specifications
Tightening torques
2
Specified torques
Part to be tightened
Thread size
Fuel system
Fuel filter holder bolt
Fuel filter bracket bolt
Fuel pump mounting bolt
Fuel pump screw
Fuel cooler bolt
Vapor separator mounting bolt
Fuel rail mounting bolt
Throttle body mounting bolt
Power unit
Power unit mounting bolt
Apron bolt
Apron screw
Flywheel magnet nut
Starter motor bolt
Starter motor terminal nut
Starter relay lead bolt
Ignition coil bolt
Oil filter
PTT relay nut
PTT motor lead bolt
Positive battery cable nut
Timing belt tensioner bolt
Drive sprocket bolt
Driven sprocket bolt
Camshaft cap bolt
1st
2nd
Cylinder head cover plate screw
Cylinder head cover bolt
Cylinder head bolt
Spark plug
Engine temperature sensor
Cylinder block plug
Engine hanger bolt
Oil pressure sensor
2-11
M6
M6
M6
ø6
M6
M6
M8
M8
8
8
10
4
5
5
13
13
0.8
0.8
1.0
0.4
0.5
0.5
1.3
1.3
5.9
5.9
7.4
3.0
3.7
3.7
9.6
9.6
M8
M10
M6
ø6
(M24)
M8
(M8)
M6
M6
—
(M6)
M6
(M8)
—
M5
M10
M10
20
42
8
4
270
29
9
4
7
18
4
4
9
39
7
60
8
17
2
8
8
14
28
19
37
14.8
31.0
5.9
3.0
199.1
21.4
6.6
3.0
5.2
13.3
3.0
3.0
6.6
28.8
5.2
44.3
5.9
12.5
1.5
5.9
5.9
10.3
20.7
14.0
27.3
—
—
M14
M6
—
25
15
23
12
18
2.0
4.2
0.8
0.4
27.0
2.9
0.9
0.4
0.7
1.8
0.4
0.4
0.9
3.9
0.7
6.0
0.8
1.7
0.2
0.8
0.8
1.4
2.8
1.9
3.7
90°
2.5
1.5
2.3
1.2
1.8
M7
ø4
1st
2nd
1st
2nd
1st
2nd
3rd
Tightening torques
N·m
kgf·m
ft·lb
M6
M8
18.4
11.1
17.0
8.9
13.3
63P3F11
Tightening torques
Part to be tightened
Exhaust cover bolt
Thermostat cover bolt
Thread size
1st
2nd
1st
2nd
Oil filter union bolt
1st
2nd
1st
2nd
Oil pump screw
Crankcase bolt
Main bearing cap bolt
Connecting rod cap
Lower unit (regular rotation model)
Gear oil drain screw
Gear oil check screw
Lower case mounting bolt
Trim tab bolt
Propeller nut
Ring nut
Cooling water inlet cover screw
Pinion nut
Lower unit (counter rotation model)
Gear oil drain screw
Gear oil check screw
Lower case mounting bolt
Trim tab bolt
Propeller nut
Ring nut
Cooling water inlet cover screw
Pinion nut
Bracket unit
Shift rod detent bolt
Flushing hose adapter screw
Upper mount bracket bolt
63P3F11
M6
M14
M18
—
Exhaust cover plug
Balancer bolt
M6
M6
M8
—
1st
2nd
1st
2nd
1st
2nd
1st
2nd
3rd
M8
M10
M10
—
Tightening torques
N·m
kgf·m
ft·lb
6
0.6
4.4
12
1.2
8.9
6
0.6
4.4
12
1.2
8.9
23
2.3
17.0
55
5.5
40.6
34
3.4
25.1
7
0.7
5.2
13
1.3
9.6
18
1.8
13.3
31
3.1
22.9
4
0.4
3.0
14
1.4
10.3
26
2.6
19.2
30
3.0
22.1
90°
30
3.0
22.1
90°
23
2.3
17.0
43
4.3
31.7
90°
—
—
M10
M10
(M18)
—
—
(M16)
9
9
47
42
52
142
4
93
0.9
0.9
4.7
4.2
5.2
14.2
0.4
9.3
6.6
6.6
34.7
31.0
38.4
104.7
3.0
68.6
—
—
M10
M10
(M18)
—
—
(M16)
9
9
47
42
52
142
4
93
0.9
0.9
4.7
4.2
5.2
14.2
0.4
9.3
6.6
6.6
34.7
31.0
38.4
104.7
3.0
68.6
—
ø6
M10
18
3
54
1.8
0.3
5.4
13.3
2.2
39.8
2-12
1
2
3
4
5
6
7
8
9
SPEC
Specifications
Part to be tightened
Muffler assembly bolt
Engine oil drain bolt
Baffle plate screw
Muffler bolt
Exhaust manifold bolt
Oil pan bolt
Oil strainer bolt
Upper mounting nut
Lower mounting nut
Trim stopper nut
Self-locking nut
Trim sensor cam screw
Grease nipple
Power trim and tilt unit
Reservoir cap
Reservoir mounting bolt
PTT motor mounting bolt
Gear pump cover bolt
Gear pump housing mounting bolt
Manual valve
Trim cylinder end screw
Tilt cylinder end screw
Tilt piston nut
Thread size
M8
M10
M14
ø5
M8
M8
M8
M6
(M14)
(M14)
(M10)
—
ø6
—
—
M6
M6
—
—
—
—
—
—
Tightening torques
N·m
kgf·m
ft·lb
20
2.0
14.8
42
4.2
31.0
27
2.7
20.0
4
0.4
3.0
20
2.0
14.8
20
2.0
14.8
20
2.0
14.8
10
1.0
7.4
74
7.4
54.6
74
7.4
54.6
48
4.8
35.4
15
1.5
11.1
2
0.2
1.5
3
0.3
2.2
0.7
5
5
6
8
3
78
130
96
General torques
This chart specifies tightening torques for
standard fasteners with a standard ISO
thread pitch. Tightening torque specifications
for special components or assemblies are
provided in applicable sections of this manual. To avoid warpage, tighten multi-fastener
assemblies in a crisscross fashion and progressive stages until the specified torque is
reached. Unless otherwise specified, torque
specifications require clean, dry threads.
Components should be at room temperature.
2-13
Nut (A)
Bolt (B)
8 mm
10 mm
12 mm
14 mm
17 mm
M5
M6
M8
M10
M12
0.07
0.5
0.5
0.6
0.8
0.3
7.8
13.0
9.6
0.5
3.7
3.7
4.4
5.9
2.2
57.5
96.0
70.8
General torque
specifications
N·m kgf·m ft·lb
5
0.5
3.6
8
0.8
5.8
18
1.8
13
36
3.6
25
43
4.3
31
63P3F11
CHK
ADJ
Periodic checks and adjustments
Special service tools .....................................................................................3-1
Maintenance interval chart............................................................................3-2
Top cowling .................................................................................................... 3-3
Checking the top cowling...........................................................................3-3
Fuel system .................................................................................................... 3-3
Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector) ..............3-3
Checking the fuel filter ............................................................................... 3-3
Power unit....................................................................................................... 3-4
Checking the engine oil .............................................................................3-4
Changing the engine oil using an oil changer............................................3-4
Changing the engine oil by draining it .......................................................3-5
Replacing the oil filter ................................................................................ 3-5
Checking the timing belt ............................................................................3-6
Replacing the timing belt ...........................................................................3-6
Checking the valve clearance.................................................................... 3-6
Checking the spark plugs ..........................................................................3-6
Checking the thermostat............................................................................3-7
Checking the cooling water passage.........................................................3-8
Control system ............................................................................................... 3-8
Checking the engine idle speed ................................................................3-8
Adjusting the throttle link and throttle cable............................................... 3-8
Adjusting the throttle link and throttle cable operation
(using a thickness gauge)...................................................................... 3-10
Checking the gear shift operation............................................................ 3-11
Checking the ignition timing..................................................................... 3-12
Power trim and tilt unit ................................................................................ 3-13
Checking the power trim and tilt operation .............................................. 3-13
Checking the power trim and tilt fluid level .............................................. 3-13
Lower unit ..................................................................................................... 3-13
Checking the gear oil level ...................................................................... 3-13
Changing the gear oil .............................................................................. 3-14
Checking the lower unit for air leakage ...................................................3-15
Checking the propeller............................................................................. 3-15
General..........................................................................................................3-15
Checking the anodes............................................................................... 3-15
Checking the battery................................................................................ 3-16
Lubricating the outboard motor................................................................3-16
63P3F11
1
2
3
4
5
6
7
8
9
CHK
ADJ
Periodic checks and adjustments
Special service tools
3
Oil filter wrench
90890-06830
Digital tachometer
90890-06760
Timing light
90890-03141
Leakage tester
90890-06840
3-1
63P3F11
Special service tools / Maintenance interval chart
Maintenance interval chart
3
Use the following chart as a guideline for general maintenance.
Adjust the maintenance intervals according to the operating conditions of the outboard motor.
Initial
Every
Refer to
page
Item
Remarks
Anodes (external)
Battery
Cooling water passages
Top cowling
Fuel filter
(can be disassembled)
Fuel system
Gear oil
Lubrication points
Engine idle speed
(EFI models)
PCV (Pressure Control Valve)
Power trim and tilt unit
Propeller and cotter pin
Shift link/shift cable
Thermostat
Throttle link/throttle cable/
throttle pick-up timing
Water pump
Engine oil
Oil filter
Spark plugs
Check/replace
Check/charge
Clean
Check
Check/replace
3-15
3-16
3-8
3-3
3-3
Check
Change
Lubricate
Check/adjust
3-3
3-14
3-16
3-8
Timing belt
10 hours 50 hours 100 hours 200 hours
(1 month) (3 months) (6 months) (1 year)
Check
Check
Check/replace
Check/adjust
Check
Check/adjust
5-37
3-13
3-15
3-11
3-7
3-8, 3-10
Check
Check/change
Change
Clean/adjust/
replace
Check/replace
6-9, 6-37
3-4
3-5
3-6
3-6, 5-16
NOTE:
When operating in salt water, turbid or muddy water, the engine should be flushed with clean water
after each use.
Every
Item
Timing belt
Valve clearance (DOHC)
Anodes (internal)
Balancer
Remarks
Replace
Check/adjust
Check/replace
Replace
500 hours
(2.5 years)
1,000 hours
(5 years)
2,000 hours
(10 years)
Refer to
page
5-16
5-12
—
—
NOTE:
When using lead or high-sulfur gasoline, checking valve clearance may be required more frequently
than every 500 hours.
63P3F11
3-2
1
2
3
4
5
6
7
8
9
CHK
ADJ
Periodic checks and adjustments
Top cowling
3
Checking the top cowling
1. Check the fitting by pushing the cowling
with both hands. Adjust if necessary.
S63P3030
Fuel system
3
Checking the fuel joint and fuel
hoses (fuel joint-to-fuel injector)
2. Loosen the bolts 1.
3. Move the hook 2 up or down slightly to
adjust its position.
1. Remove the spark plug wire cover.
2. Check the low-pressure fuel hose connections and fuel joints for leaks.
Replace if necessary. Also, check the
fuel filter 1, fuel pumps 2, and fuel filter
3 for leaks or deterioration. Replace if
necessary.
3. Check the high-pressure fuel hose connections for leaks. Replace if necessary.
Also, check the vapor separator 4, fuel
rail 5, fuel injectors 6, pressure regulator 7, and fuel cooler 8 for leaks or
deterioration. Replace if necessary.
NOTE:
• To loosen the fitting, move the hook in
direction a.
• To tighten the fitting, move the hook in
direction b.
4. Tighten the bolts.
5. Check the fitting again and, if necessary,
repeat steps 2–4.
6. Check the top cowling hose for cracks or
damage. Replace if necessary.
Checking the fuel filter
1. Check the fuel filter element 1 for dirt
and residue and check the fuel filter cup
2 for foreign substances and cracks.
Clean the cup with straight gasoline and
replace the element if necessary.
3-3
63P3F11
Top cowling / Fuel system / Power unit
Changing the engine oil using an oil
changer
1. Start the engine, warm it up, and then
turn it off.
2. Remove the engine oil dipstick and oil
filler cap 1.
NOTE:
Be sure not to spill any fuel when removing
the fuel filter cup.
Power unit
3
Checking the engine oil
1. Place the outboard motor in an upright
position.
3. Insert the tube of the oil changer 2 into
the dipstick guide 3.
2. Remove the engine oil dipstick, wipe it
clean, and then insert it back into the oil
filler hole.
3. Remove the dipstick again to check the
oil level and to check the oil for discoloration and its viscosity.
3
2
S63P3070
4. Operate the oil changer to extract the oil.
NOTE:
• Change the oil if it appears milky or dirty.
• If the engine oil is above the maximum level
mark (H), extract sufficient oil using an oil
changer or drain it until the level is between
(H) and (L).
• If the engine oil is below the minimum level
mark (L), add sufficient oil until the level is
between (H) and (L).
63P3F11
NOTE:
Be sure to clean up any oil spills.
5. Pour the specified amount of the recommended engine oil into the oil filler hole.
Recommended engine oil:
4-stroke motor oil
API: SE, SF, SG, SH, or SJ
SAE: 10W-30 or 10W-40
Oil quantity:
Without oil filter replacement:
5.2 L (5.5 US qt, 4.6 Imp qt)
3-4
1
2
3
4
5
6
7
8
9
CHK
ADJ
Periodic checks and adjustments
6. Install the oil filler cap and dipstick, and
then start the engine and warm it up for 5
minutes.
7. Turn the engine off, and then check the
oil level and correct it if necessary.
Changing the engine oil by draining
it
1. Start the engine, warm it up, and then
turn it off.
2. Remove the engine oil dipstick and oil
filler cap 1.
Recommended engine oil:
4-stroke motor oil
API: SE, SF, SG, SH, or SJ
SAE: 10W-30 or 10W-40
Oil quantity:
Without oil filter replacement:
5.2 L (5.5 US qt, 4.6 Imp qt)
6. Install the oil filler cap and dipstick, and
then start the engine and warm it up for 5
minutes.
7. Turn the engine off, and then check the
oil level and correct it if necessary.
Replacing the oil filter
1. Extract the engine oil with an oil changer
or drain it.
2. Place a rag under the oil filter, and then
remove the oil filter using a 72.5 mm (2.9
in) oil filter wrench.
3. Place a drain pan under the drain hole,
and then remove the drain bolt 2 and let
the oil drain completely.
1
S63P3090
NOTE:
• Wait more than 5 minutes after turning the
engine off to replace the oil filter.
• Be sure to clean up any oil spills.
NOTE:
Be sure to clean up any oil spills.
4. Install the drain bolt, and then tighten it to
the specified torque.
T.
R.
Drain bolt:
27 N·m (2.7 kgf·m, 20.0 ft·lb)
Oil filter wrench 1: 90890-06830
3. Apply a thin coat of engine oil to the Oring of the new oil filter.
4. Install the oil filter, and then tighten it to
the specified torque using a 72.5 mm
(2.9 in) oil filter wrench.
5. Pour the specified amount of the recommended engine oil into the oil filler hole.
3-5
63P3F11
Power unit
a
E
b
S63P3040
Replacing the timing belt
S63P3100
T.
R.
Oil filter:
18 N·m (1.8 kgf·m, 13.3 ft·lb)
5. Pour the specified amount of the recommended engine oil into the oil filler hole.
Recommended engine oil:
4-stroke motor oil
API: SE, SF, SG, SH, or SJ
SAE: 10W-30 or 10W-40
Oil quantity:
With oil filter replacement:
5.4 L (5.7 US qt, 4.8 Imp qt)
6. Install the oil filler cap and dipstick, and
then start the engine and warm it up for 5
minutes.
NOTE:
For replacement procedures, see Chapter 5,
“Replacing the timing belt.”
Checking the valve clearance
NOTE:
For checking procedures, see Chapter 5,
“Checking the valve clearance.”
Checking the spark plugs
1. Disconnect the spark plug wires, and
then remove the spark plugs.
2. Clean the electrodes 1 with a spark plug
cleaner or wire brush. Replace the spark
plug if necessary.
7. Turn the engine off, and then check the
oil level and correct it if necessary.
Checking the timing belt
1. Remove the flywheel magnet cover.
2. While turning the flywheel magnet clockwise, check the interior a and the exterior b of the timing belt for cracks,
damage, or wear. Replace if necessary.
3. Turn the crankshaft clockwise two turns
to take up slack in the timing belt.
63P3F11
3. Check the electrodes for erosion and
excessive carbon or other deposits, and
the gasket for damage. Replace the
spark plug if necessary.
3-6
1
2
3
4
5
6
7
8
9
CHK
ADJ
Periodic checks and adjustments
4. Check the spark plug gap a. Adjust if out
of specification.
3. Suspend the thermostat in a container of
water.
4. Place a thermometer in the water and
slowly heat the water.
Specified spark plug:
LFR5A-11 (NGK)
Spark plug gap a:
1.0–1.1 mm (0.039–0.043 in)
5. Install the spark plugs, tighten them finger tight b, then to the specified torque
using a spark plug wrench c.
S69J5E40
5. Check the thermostat valve opening at
the specified water temperatures.
Replace if out of specification.
Water
temperature
T.
R.
Spark plug:
25 N·m (2.5 kgf·m, 18.4 ft·lb)
Checking the thermostat
1. Remove the flywheel magnet cover.
2. Remove the cover 1 and thermostat 2.
2
1
Valve lift a
58–62 °C
(136–144 °F)
0.05 mm
(0.0020 in)
(valve begins to lift)
above
70 °C (158 °F)
more than
4.3 mm (0.17 in)
6. Install the thermostat and cover, and
then tighten the cover bolts to the specified torques in two stages.
T.
R.
Thermostat cover bolt:
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
S63P3110
3-7
63P3F11
Power unit / Control system
Checking the cooling water passage
1. Check the cooling water inlet cover 1
and cooling water inlet for clogs. Clean if
necessary.
1
S63P3140
Digital tachometer: 90890-06760
1
Engine idle speed: 700 ± 50 r/min
1
Adjusting the throttle link and
throttle cable
S60V3130
2. Place the lower unit in water, and then
start the engine.
3. Check for water flow at the cooling water
pilot hole. If there is no water flow, check
the cooling water passage inside the outboard motor.
NOTE:
• Be sure to synchronize the throttle valves
before adjusting the throttle cable.
• For synchronizing procedures, see Chapter
4, “Synchronizing the throttle valves.”
1. Remove the intake silencer.
2. Loosen the locknut 1, remove the clip
2, and then disconnect the throttle cable
joint 3.
3. Loosen the locknut 4, and then disconnect the throttle link rod joint 5 and the
link rod joint 6.
45
Control system
6
3
Checking the engine idle speed
1. Start the engine and warm it up for 5 minutes.
2. Attach the special service tool to spark
plug wire #1 1, and then check the
engine idle speed.
63P3F11
2 1
3
S63P3150
3-8
1
2
3
4
5
6
7
8
9
CHK
ADJ
Periodic checks and adjustments
4. Turn throttle lever 1 7 and the throttle
cam 8 counterclockwise so that they are
in the positions shown in the illustration.
a
7
8
0
A
S63P3160
5. Check that the throttle valves are fully
closed, and then adjust the throttle link
rod joint to align its hole with the ball joint
9 on throttle lever 1.
S63P3180
NOTE:
If there is no clearance, loosen the locknut 4
and the throttle link rod joint one turn, and
then repeat steps 6 and 8.
9
9. Operate throttle lever 2 to check that the
throttle valves fully close and fully open.
b
S63P3170
B
6. Connect the throttle link rod joint 5, and
then tighten the locknut 4.
7. Connect the link rod joint 6.
8. Contact the stopper 0 on the throttle
lever 2 to the fully closed stopper A on
the cylinder block and check for clearance a between the throttle cam roller
and the throttle cam.
3-9
S63P3190
NOTE:
The throttle valves are fully open when the
throttle cam roller B is within the range b
shown in the illustration.
63P3F11
Control system
10. Contact the stopper 0 on the throttle
lever 2 to the fully closed stopper A on
the cylinder block and check that throttle
cam roller B is aligned with the alignment mark c.
Adjusting the throttle link and
throttle cable operation
(using a thickness gauge)
1. Remove the intake silencer.
2. Loosen the locknut 1, remove the clip
2, and then disconnect the throttle cable
joint 3.
B
3. Contact the stopper 4 on the throttle
lever 2 to the fully closed stopper 5 on
the cylinder block and adjust the throttle
link rod joint 6 so that the specified
clearance a between the throttle cam
roller and the throttle cam is obtained.
c
0
A
a
S63P3200
6
11. Adjust the position of the throttle cable
joint until its hole is aligned with the set
pin on throttle lever 2.
2 1
4
5
3
S63P3220
d
S63P3210
CAUTION:
The throttle cable joint must be screwed
in a minimum of 8.0 mm (0.31 in) d.
Clearance a: 0.5 mm (0.02 in)
4. Connect the throttle link rod joint 6, and
then tighten the locknut 7.
7
12. Connect the cable joint, install the clip,
and then tighten the locknut.
13. Check the throttle cable for smooth operation and, if necessary, repeat steps 1–
12.
63P3F11
6
S63P3230
3-10
1
2
3
4
5
6
7
8
9
CHK
ADJ
Periodic checks and adjustments
5. Operate throttle lever 2 to check that the
throttle valves fully close and fully open.
b
d
8
S63P3210
S63P3240
NOTE:
The throttle valves are fully open when the
throttle cam roller 8 is within the range b
shown in the illustration.
6. Contact the stopper 4 on the throttle
lever 2 to the fully closed stopper 5 on
the cylinder block and check that throttle
cam roller 8 is aligned with the alignment mark c.
CAUTION:
The throttle cable joint must be screwed
in a minimum of 8.0 mm (0.31 in) d.
8. Connect the cable joint, install the clip,
and then tighten the locknut.
9. Check the throttle cable for smooth operation and, if necessary, repeat steps 1–8.
Checking the gear shift operation
1. Check that the gear shift operates
smoothly when shifting it from neutral to
forward or reverse. Adjust the shift cable
length if necessary.
2. Set the gear shift to the neutral position.
8
3. Loosen the locknut 1, remove the clip
2, and then disconnect the shift cable
joint 3.
c
4
5
3
S63P3250
7. Adjust the position of the throttle cable
joint until its hole is aligned with the set
pin on throttle lever 2.
1
2
4
S63P3260
4. Adjust the position of the shift lever until
the pin on the lever is aligned with the
line on the shift position switch plate 4.
5. Align the center of the set pin a with the
alignment mark b on the bottom cowling.
3-11
63P3F11
Control system
1
b
a
S63P3270
6. Adjust the position of the shift cable joint
until its hole is aligned with the set pin.
S63P3140
Digital tachometer: 90890-06760
3. Attach the special service tool to spark
plug wire #1.
c
S69J3370
CAUTION:
The shift cable joint must be screwed in a
minimum of 8.0 mm (0.31 in) c.
S63P3280
Timing light: 90890-03141
7. Connect the cable joint, install the clip,
and then tighten the locknut.
8. Check the gear shift for smooth operation
and, if necessary, repeat steps 3–7.
4. Check that the “TDC” mark a on the flywheel magnet is aligned with the mark b
on the pointer.
Checking the ignition timing
1. Start the engine and warm it up for 5 minutes.
2. Attach the special service tool to spark
plug wire #1 1, and then check the
engine idle speed.
a
b
S63P3290
Ignition timing at engine idle speed:
TDC
63P3F11
3-12
1
2
3
4
5
6
7
8
9
CHK
ADJ
Periodic checks and adjustments
Power trim and tilt unit
3
Checking the power trim and tilt
operation
1. Fully tilt the outboard motor up and down
a few times and check the entire trim and
tilt range for smooth operation. Check the
power trim and tilt fluid level if necessary.
NOTE:
Be sure to listen to the winding sound of the
power trim and tilt motor for smooth operation.
WARNING
After tilting up the outboard motor, be
sure to support it with the tilt stop lever.
Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit
should lose fluid pressure.
2. Remove the reservoir cap 2, and then
check the fluid level in the reservoir.
2. Fully tilt the outboard motor up, and then
support it with the tilt stop lever 1 to
check the lock mechanism of the lever.
1
2
S60X3030
NOTE:
If the fluid is at the correct level, the fluid
should overflow out of the filler hole when the
reservoir cap is removed.
3. If necessary, add sufficient fluid of the
recommended type until it overflows out
of the filler hole.
S60X3020
Recommended power trim and tilt
fluid:
ATF Dexron II
Checking the power trim and tilt fluid
level
1. Fully tilt the outboard motor up, and then
support it with the tilt stop lever 1.
4. Install the reservoir cap, and then tighten
it to the specified torque.
1
T.
R.
Reservoir cap:
0.7 N·m (0.07 kgf·m, 0.5 ft·lb)
Lower unit
3
Checking the gear oil level
1. Fully tilt the outboard motor down.
2. Remove the check screw 1, and then
check the gear oil level in the lower case.
S60X3020
3-13
63P3F11
Power trim and tilt unit / Lower unit
3. Check the oil for metal and discoloration,
and its viscosity. Check the internal parts
of the lower case if necessary.
4. Insert a gear oil tube or gear oil pump
into the drain hole and slowly fill the gear
oil until oil flows out of the check hole and
no air bubbles are visible.
1
S60V3320
NOTE:
If the oil is at the correct level, the oil should
overflow out of the check hole when the
check screw is removed.
3. If necessary, add sufficient gear oil of the
recommended type until it overflows out
of the check hole.
Recommended gear oil:
Hypoid gear oil
SAE: 90
4. Install the check screw.
Changing the gear oil
1. Tilt the outboard motor up slightly.
2. Place a drain pan under the drain screw
1, remove the drain screw, then the
check screw 2 and let the oil drain completely.
Recommended gear oil:
Hypoid gear oil
SAE: 90
Oil quantity:
Regular rotation model:
980 cm3
(33.1 US oz, 34.6 Imp oz)
Counter rotation model:
870 cm3
(29.4 US oz, 30.7 Imp oz)
5. Install the check screw and quickly install
the drain screw.
63P3F11
3-14
1
2
3
4
5
6
7
8
9
CHK
ADJ
Periodic checks and adjustments
Checking the lower unit for air
leakage
1. Remove the check screw 1, and then
install the special service tool.
S69J3580
General
3
Checking the anodes
1. Check the anodes and trim tab for
scales, grease, or oil. Clean if necessary.
Leakage tester: 90890-06840
2. Apply the specified pressure to check
that the pressure is maintained in the
lower unit for at least 10 seconds.
CAUTION:
Do not over pressurize the lower unit, otherwise the oil seals can be damaged.
NOTE:
Cover the check hole with a rag when removing the tester from the lower unit.
S63P3300
Lower unit holding pressure:
70 kPa (0.7 kgf/cm2, 10 psi)
3. If pressure drops below specification,
check the drive shaft and propeller shaft
oil seals for damage.
S60X3080
Checking the propeller
1. Check the propeller blades and splines
for cracks, damage, or wear. Replace if
necessary.
3-15
63P3F11
Lower unit / General
CAUTION:
Do not oil, grease, or paint the anodes or
the trim tab, otherwise they will be ineffective.
2. Replace the anodes or trim tab if excessively eroded.
Checking the battery
1. Check the battery electrolyte level. If the
level is at or below the minimum level
mark a, add distilled water until the level
is between the maximum and minimum
level marks.
a
Batteries generate explosive, hydrogen
gas. Always follow these preventive measures:
• Charge batteries in a well-ventilated
area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
• DO NOT SMOKE when charging or handling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
NOTE:
• Batteries vary per manufacturer. The procedures mentioned in this manual may not
always apply, therefore, consult the instruction manual of the battery.
• Disconnect the negative battery lead first,
then the positive battery lead.
Electrolyte specific gravity:
1.280 at 20 °C (68 °F)
S69J3620
Lubricating the outboard motor
2. Check the specific gravity of the electrolyte. Fully charge the battery if out of
specification.
1. Apply water resistant grease to the areas
shown.
WARNING
Battery electrolyte is dangerous; it contains sulfuric acid which is poisonous and
highly caustic.
Always follow these preventive measures:
• Avoid bodily contact with electrolyte as
it can cause severe burns or permanent
eye injury.
• Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
• SKIN – Wash with water.
• EYES – Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
• Drink large quantities of water or milk
followed with milk of magnesia, beaten
egg, or vegetable oil. Get immediate
medical attention.
63P3F11
A
S63P3310
3-16
1
2
3
4
5
6
7
8
9
CHK
ADJ
Periodic checks and adjustments
NOTE:
Apply grease to the grease nipple until it
flows from the bushings a.
2. Apply low temperature resistant grease
to the areas shown.
A
S63P3320
A
C
S63P3340
S60X3090
3. Apply corrosion resistant grease to the
areas shown.
A
S60X3100
A
S60X3120
3-17
63P3F11
FUEL
Fuel system
Special service tools .....................................................................................4-1
Hose routing ...................................................................................................4-2
Fuel and blowby hoses..............................................................................4-2
Fuel filter, fuel pump, and intake silencer ................................................... 4-3
Checking the fuel pumps ...........................................................................4-7
Disassembling a fuel pump ....................................................................... 4-7
Checking the diaphragm and valves .........................................................4-8
Assembling a fuel pump ............................................................................4-8
Intake assembly and vapor separator.......................................................... 4-9
Measuring the fuel pressure .................................................................... 4-13
Checking the pressure regulator ............................................................. 4-13
Checking the check valve........................................................................4-14
Reducing the fuel pressure...................................................................... 4-15
Checking the vapor separator .................................................................4-15
Synchronizing the throttle valves............................................................. 4-16
Adjusting the throttle position sensor.......................................................4-17
Adjusting the throttle position sensor
(when disassembling or replacing the throttle body) ............................. 4-18
63P3F11
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
Special service tools
Vacuum/pressure pump gauge set
90890-06756
4
Test harness (3 pins)
90890-06793
Fuel pressure gauge
90890-06786
Digital circuit tester
90890-03174
Vacuum gauge
90890-03159
Digital tachometer
90890-06760
4-1
63P3F11
Special service tools / Hose routing
Hose routing
4
Fuel and blowby hoses
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
Blowby hoses
Fuel hose (fuel tank-to-fuel filter)
Fuel hoses (fuel filter-to-fuel pumps)
Fuel hoses (fuel pumps-to-fuel filter)
Fuel hose (fuel filter-to-vapor separator)
High-pressure fuel hose (vapor separator-to-fuel rail)
Fuel hose (pressure regulator-to-fuel cooler)
Fuel hose (fuel cooler-to-vapor separator)
63P3F11
4-2
FUEL
Fuel system
Fuel filter, fuel pump, and intake silencer
4
14 13
12
7
6
11
6
5
10
8
9
4
15
3
2
T.
R.
10 N · m (1.0 kgf · m, 7.4 ft · Ib)
1
S63P4070
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
4-3
Part name
Intake assembly
Bolt
Bolt
Intake silencer
Bolt
Grommet
Collar
Bolt
Fuel pump
Bolt
Fuel filter
Bolt
Grommet
Collar
Holder
Q’ty
1
5
2
1
2
4
2
6
2
4
1
2
2
2
1
Remarks
M8 × 40 mm
M8 × 20 mm
M6 × 45 mm
M6 × 20 mm
M6 × 30 mm
M6 × 30 mm
63P3F11
Fuel filter, fuel pump, and intake silencer
4
A
1
8
7
6
9
4
A
2
8
10
7
5
9
A
9
3
8
7
6
A
S63P4080
No.
1
2
3
4
5
6
7
8
9
10
Part name
Throttle lever 1
Throttle cam
Throttle lever 2
Throttle link rod
Bolt
Bolt
Collar
Wave washer
Washer
Spring
63P3F11
Q’ty
1
1
1
1
1
2
3
3
3
1
Remarks
M6 × 35 mm
M6 × 25 mm
4-4
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
4
T.
R.
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
7
3
8
4
5
T.
9
R.
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
1
10
2
11
6
12
13
S63P4040
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
4-5
Part name
Bolt
Bracket
Bolt
Washer
Holder
Cap
O-ring
Fuel filter element
Float
Spring
O-ring
Cup
Nut
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
1
Remarks
M6 × 14 mm
M6 × 16 mm
Not reusable
Not reusable
63P3F11
Fuel filter, fuel pump, and intake silencer
4
T.
R.
4 N · m (0.4 kgf · m, 3.0 ft · Ib)
1
13 14
11
12
2
10
12
11
15
3
13
14
4
9
6
8
5
7
S63P4050
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Part name
Screw
Cover
Fuel pump body 2
Fuel pump body 1
Plunger
Spring
Nut
Spring
Pin
Diaphragm
Nut
Spring
Valve
Screw
Gasket
63P3F11
Q’ty
3
1
1
1
1
1
3
1
1
1
2
2
2
2
1
Remarks
ø6 × 35 mm
Not reusable
4-6
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
Checking the fuel pumps
1. Place a drain pan under the fuel hose
connections, and then disconnect the
fuel hoses from the fuel pumps.
6. Apply the specified positive pressure and
check that there is no air leakage. Disassemble the fuel pump if necessary.
2. Connect the special service tool to the
fuel pump inlet.
3. Cover the fuel pump outlet with a finger,
and then apply the specified positive
pressure. Check that there is no air leakage.
S63P4110
Specified pressure:
50 kPa (0.5 kgf/cm2, 7.3 psi)
S63P4090
Vacuum/pressure pump gauge set:
90890-06756
NOTE:
Assemble the fuel pump valve to the fuel
pump body, and moisten the inside of the fuel
pump with gasoline to ensure a good seal.
Disassembling a fuel pump
1. Disassemble the fuel pump as shown.
Specified pressure:
50 kPa (0.5 kgf/cm2, 7.3 psi)
4. Apply the specified negative pressure
and check that there is no air leakage.
S60C4060
S63P4100
Specified pressure:
30 kPa (0.3 kgf/cm2, 4.4 psi)
5. Connect the special service tool to the
fuel pump outlet.
4-7
63P3F11
Fuel filter, fuel pump, and intake silencer
2. Push down on the plunger and the diaphragm, turn fuel pump body 1 1
approximately 90° to a position where the
pin 2 can be removed easily, and then
remove the pin.
Assembling a fuel pump
NOTE:
Clean the parts and soak the valves and the
diaphragm in gasoline before assembly to
obtain prompt operation of the fuel pumps
when starting the engine.
1. Align the plunger and diaphragm installation holes a, and then install the plunger
into the diaphragm.
2. Push down on the plunger and the diaphragm, and then install the pin 1.
3. Slowly let up on the plunger and diaphragm, and then remove them.
3. Turn fuel pump body 1 2 approximately
90°, and then push down on the plunger
several times to make sure that the pin
does not come out.
Checking the diaphragm and valves
1. Check the diaphragm 1 for tears and the
valves 2 for cracks. Replace if necessary.
1
2
NOTE:
Make sure that the gasket and diaphragm are
kept in place through the assembly process.
S60C4090
63P3F11
4-8
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
Intake assembly and vapor separator
4
5
6
7
4
3
8
2
T.
R.
5 N · m (0.5 kgf · m, 3.7 ft · Ib)
1
9
T.
R.
5 N · m (0.5 kgf · m, 3.7 ft · Ib)
S63P4010
No.
1
2
3
4
5
6
7
8
9
4-9
Part name
Bolt
Fuel cooler
Vapor separator
Fuel hose
Fuel hose
Hose
Electric fuel pump coupler
Intake assembly
Bolt
Q’ty
2
1
1
1
1
1
1
1
3
Remarks
M6 × 25 mm
M6 × 35 mm
63P3F11
Intake assembly and vapor separator
4
6
4
8
7
5
17
1
12
13
2
15
14
16
9
3
10
11
S63P4030
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
O-ring
Float chamber
Drain screw
Pressure regulator
Screw
O-ring
Cover
Screw
Electric fuel pump
Filter
Filter holder
O-ring
Collar
Needle valve
Screw
Float
Pin
63P3F11
Q’ty
1
1
1
1
2
1
1
7
1
1
1
1
1
1
1
1
1
Remarks
Not reusable
M6 × 12 mm
Not reusable
ø4 × 16 mm
Not reusable
ø4 × 8 mm
4-10
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
4
T.
R.
23
21
14
10
13 N · m (1.3 kgf · m, 9.6 ft · Ib)
22
27
28
26
24
T.
R.
13 N · m (1.3 kgf · m, 9.6 ft · Ib)
15
20
11
25
12
16
13
5
3
6
8
29
9
4
32
33
30
17
1
7
31
8
28
2
27
18
19
2
S63P4020
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
4-11
Part name
Fuel rail
Bolt
O-ring
Rubber damper
Fuel injector
Rubber seal
Electric fuel pump lead
Gasket
Intake manifold
Screw
Intake air pressure sensor
O-ring
O-ring
Screw
Idle speed control
O-ring
Gasket
Q’ty
1
2
4
4
4
4
1
4
1
2
1
1
1
3
1
1
2
Remarks
M8 × 25 mm
Not reusable
Not reusable
Not reusable
Not reusable
ø5 × 15 mm
Not reusable
Not reusable
ø4 × 15 mm
Not reusable
Not reusable
63P3F11
Intake assembly and vapor separator
4
T.
R.
23
21
14
10
13 N · m (1.3 kgf · m, 9.6 ft · Ib)
22
27
28
26
24
T.
R.
13 N · m (1.3 kgf · m, 9.6 ft · Ib)
15
20
11
25
12
16
13
5
3
6
8
29
9
4
32
33
30
17
1
7
31
8
28
2
27
18
19
2
S63P4020
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Part name
Collar
Grommet
Bracket
Screw
Screw
Throttle position sensor
O-ring
Throttle body #1
Bolt
Bracket
Screw
Throttle joint link rod
Spring
Throttle body #2
Bracket
Screw
63P3F11
Q’ty
6
3
1
4
2
1
1
1
6
2
4
1
1
1
1
4
Remarks
ø6 × 16 mm
ø4 × 12 mm
Not reusable
M8 × 70 mm
ø6 × 16 mm
ø6 × 16 mm
4-12
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
Measuring the fuel pressure
WARNING
1. Remove the cap 1.
2. Connect the fuel pressure gauge to the
pressure check valve.
1
S63P4130
Fuel pressure gauge: 90890-06786
• Before measuring the fuel pressure,
make sure that the drain screw is tightened securely.
• Do not loosen the drain screw while
measuring the fuel pressure. Loosening
the drain screw can cause fuel to spray
out creating a fire hazard.
• After measuring the fuel pressure, cover
the end of the hose with a clean, dry rag,
point the hose downward, and then
loosen the drain screw to drain the
remaining fuel from the hose and gauge.
• When storing the fuel pressure gauge,
make sure that the drain screw is tightened securely.
Checking the pressure regulator
WARNING
• When connecting the fuel pressure
gauge, first cover the connection
between the gauge and the pressure
check valve with a clean, dry rag to prevent fuel from leaking out.
• Gently screw in the gauge until it is
firmly connected.
1. Remove the cap 1.
2. Connect the fuel pressure gauge to the
pressure check valve.
3. Disconnect the pressure regulator hose,
and then connect the special service
tools to the pressure regulator.
3. Turn the engine start switch to ON, and
then measure the fuel pressure within 3
seconds.
NOTE:
The fuel pressure decreases 3 seconds after
the engine start switch is turned to ON.
1
S63P4140
Fuel pressure (reference data):
310 kPa (3.1 kgf/cm2, 45.0 psi)
4. Start the engine, warm it up
utes, and then measure the
sure. If below specification,
high-pressure fuel line and
separator.
for 5 minfuel prescheck the
the vapor
Fuel pressure gauge: 90890-06786
Vacuum/pressure pump gauge set:
90890-06756
Fuel pressure (reference data):
260 kPa (2.6 kgf/cm2, 37.7 psi)
4-13
63P3F11
Intake assembly and vapor separator
WARNING
• When connecting the fuel pressure
gauge, first cover the connection
between the gauge and the pressure
check valve with a clean, dry rag to prevent fuel from leaking out.
• Gently screw in the gauge until it is
firmly connected.
4. Start the engine and let it idle.
5. Check that the fuel pressure reduces
when vacuum pressure is applied to the
pressure regulator. If the fuel pressure
does not reduce, replace the pressure
regulator.
WARNING
• Before measuring the fuel pressure,
make sure that the drain screw is tightened securely.
• Do not loosen the drain screw while
measuring the fuel pressure. Loosening
the drain screw can cause fuel to spray
out creating a fire hazard.
• After measuring the fuel pressure, cover
the end of the hose with a clean, dry rag,
point the hose downward, and then
loosen the drain screw to drain the
remaining fuel from the hose and gauge.
• When storing the fuel pressure gauge,
make sure that the drain screw is tightened securely.
Vacuum/pressure pump gauge set:
90890-06756
NOTE:
Check that no air comes out of the opposite
end of the check valve.
Checking the check valve
1. Connect the special service tool to the
check valve.
2. Apply pressure to each check valve port.
Replace if necessary.
63P3F11
4-14
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
Reducing the fuel pressure
Checking the vapor separator
1. Remove the cap 1.
1. Check the needle valve for bends or
wear. Replace if necessary.
2. Cover the pressure check valve a of the
fuel rail with a rag, and then press in the
pressure check valve a using a thin
screwdriver to release the fuel pressure.
1
a
2. Check the float for deterioration. Replace
if necessary.
S63P4160
WARNING
Always reduce the fuel pressure in the
high-pressure fuel line before servicing
the line or the vapor separator. If the fuel
pressure is not released, pressurized fuel
may spray out.
S63P4180
3. Place a container under the vapor separator drain hose, and then loosen the
drain screw 2.
3. Check the filter for dirt or residue. Clean
if necessary.
4. Remove the cap 3.
5. Drain the fuel from the vapor separator
drain hose by pressing the valve using a
thin screwdriver.
S63P4190
4-15
63P3F11
Intake assembly and vapor separator
Synchronizing the throttle valves
CAUTION:
Do not adjust the throttle valve when it is
operating properly. Excess adjustment
may cause poor engine performance.
1. Remove the caps 1, and then attach the
special service tool to the intake manifold
as shown.
NOTE:
For best results, use a vacuum gauge (commercially available), like 2 or 3 shown in the
illustration, that has four adapters.
2. Start the engine and warm it up for 5 minutes.
3. Attach the special service tool to spark
plug wire #1 4, and then check the
engine idle speed.
1
4
S63P4250
Digital tachometer: 90890-06760
S63P4210
Vacuum gauge: 90890-03159
Engine idle speed: 700 ± 50 r/min
4. Check the vacuum pressure of all cylinders.
2
1
3
S63P4220
63P3F11
4-16
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
5. Turn the synchronizing screw 5 so that
the vacuum pressure of cylinder #3 or #4
is within 4 kPa (30 mmHg) based on the
vacuum pressure of cylinder #1 or #2.
1. Remove the intake silencer.
2. Disconnect the throttle joint link rod 1
from the throttle lever 1.
1
b
a
5
S63P4230
Direction a
Vacuum pressure is
increase.
Direction b
Vacuum pressure is
decrease.
S63P4260
3. Check that the throttle valves are in the
fully closed position.
Example
Check results:
Cylinder
#1
#2
#3
#4
kPa
(mmHg)
49
(370)
48
(360)
45
(340)
44
(330)
S63P4270
Adjust the difference of the vacuum pressure
between cylinders #1 and #4 within 4 kPa (30
mmHg).
4. Connect the test harness (3 pins) to the
throttle position sensor.
Check results:
Cylinder
#1
#2
#3
#4
kPa
(mmHg)
49
(370)
48
(360)
52
(390)
53
(400)
Adjust the difference of the vacuum pressure
between cylinders #2 and #4 within 4 kPa (30
mmHg).
Adjusting the throttle position
sensor
NOTE:
• Be sure to adjust the throttle valve’s opening before measuring the throttle position
sensor output voltage.
• When measuring the throttle position sensor output voltage, set the digital tester to
the manual range.
4-17
S63P8130
Test harness (3 pins): 90890-06793
5. Turn the engine start switch to ON.
6. Measure the throttle position sensor output voltage with the throttle valves fully
closed. If the output voltage is out of
specification, adjust the throttle position
sensor.
63P3F11
Intake assembly and vapor separator
NOTE:
To measure the output voltage, connect the
positive tester probe to the pink wire of the
test harness and the negative tester probe to
the orange wire of the test harness.
1
Digital circuit tester: 90890-03174
S63P4280
Throttle position sensor output
voltage:
Pink (P) – Black (B)
0.70 ± 0.02 V
4. Loosen the throttle stop screw 2 and
fully close the throttle valves #1 and #2.
2
7. Install the intake silencer.
8. Start the engine and measure the throttle
position sensor output voltage again.
Adjust the throttle position sensor if out of
specification.
Throttle position sensor output
voltage at engine idle speed:
Pink (P) – Black (B)
0.70 ± 0.02 V
Adjusting the throttle position
sensor (when disassembling or
replacing the throttle body)
1. Install the intake assembly.
2. Connect the test harness (3 pins) to the
throttle position sensor.
S63P4240
5. Turn the engine start switch to ON.
6. Loosen the throttle position sensor screw
and adjust the throttle position sensor
output voltage to specification.
Throttle position sensor output
voltage:
Pink (P) – Black (B)
0.70 ± 0.02 V
7. Operate the throttle valves several times.
8. Slowly tighten the synchronizing screw
and stop when the throttle position sensor output voltage begins to change.
9. Tighten the throttle stop screw until it
lightly contacts the throttle body lever.
S63P8130
Test harness (3 pins): 90890-06793
10. Operate the throttle valves several times
and make sure that the throttle position
sensor output voltage does not change.
11. Tighten the throttle position sensor
screw.
3. Loosen the synchronizing screw 1.
63P3F11
4-18
1
2
3
4
5
6
7
8
9
FUEL
Fuel system
12. Install the throttle joint link rod 3 so the
throttle cam roller 4 is aligned with the
alignment mark a as shown.
a
3
4
S63P4290
NOTE:
Make sure that the throttle position sensor
output voltage does not change when installing the throttle joint link rod.
13. Install the intake silencer.
14. Start the engine and measure the throttle
position sensor output voltage. Adjust the
throttle position sensor again if out of
specification.
Throttle position sensor output
voltage at engine idle speed:
Pink (P) – Black (B)
0.70 ± 0.02 V
15. Check the throttle valve is synchronized.
4-19
63P3F11
Intake assembly and vapor separator
— MEMO —
1
2
3
4
5
6
7
8
9
63P3F11
4-20
POWR
Power unit
Special service tools .....................................................................................5-1
Power unit....................................................................................................... 5-3
Checking the compression pressure .......................................................5-11
Checking the oil pressure ........................................................................5-11
Checking the oil pressure sensor ............................................................ 5-12
Checking the valve clearance.................................................................. 5-12
Replacing the timing belt .........................................................................5-16
Removing the power unit.........................................................................5-18
Removing the oil filter .............................................................................. 5-20
Removing the timing belt and sprockets.................................................. 5-20
Checking the timing belt and sprockets...................................................5-21
Installing the sprockets and timing belt....................................................5-21
Cylinder head ...............................................................................................5-23
Removing the cylinder head .................................................................... 5-28
Checking the valve springs...................................................................... 5-28
Checking the valves ................................................................................ 5-29
Checking the valve guides....................................................................... 5-29
Replacing the valve guides...................................................................... 5-30
Checking the valve seat ..........................................................................5-31
Refacing the valve seat ...........................................................................5-31
Checking the camshaft ............................................................................5-33
Checking the cylinder head ..................................................................... 5-34
Installing the valves ................................................................................. 5-34
Installing the cylinder head ...................................................................... 5-35
Removing the exhaust cover ................................................................... 5-37
Checking the pressure control valve .......................................................5-37
Installing the pressure control valve ........................................................ 5-37
63P3F11
Cylinder block ..............................................................................................5-38
Disassembling the cylinder block ............................................................ 5-41
Checking the balancer assembly............................................................. 5-41
Checking the piston diameter .................................................................. 5-41
Checking the cylinder bore ...................................................................... 5-42
Checking the piston clearance ................................................................5-42
Checking the piston rings ........................................................................5-42
Checking the piston ring grooves ............................................................ 5-43
Checking the piston ring side clearance.................................................. 5-43
Checking the connecting rod big end side clearance ..............................5-43
Checking the crankshaft ..........................................................................5-44
Checking the crankpin oil clearance........................................................ 5-45
Selecting the connecting rod bearing ......................................................5-46
Checking the crankshaft main journal oil clearance ................................5-47
Selecting the crankshaft main bearing ....................................................5-48
Disassembling the oil pump..................................................................... 5-49
Checking the oil pump ............................................................................. 5-49
Assembling the oil pump .........................................................................5-49
Assembling the pistons and cylinder block.............................................. 5-50
Installing the power unit...........................................................................5-55
63P3F11
1
2
3
4
5
6
7
8
9
POWR
Power unit
Special service tools
5
Compression gauge
90890-03160
Flywheel puller
90890-06521
Compression gauge extension
90890-06563
Valve spring compressor
90890-04019
Test harness (3 pins)
New: 90890-06869
Current: 90890-06769
Valve spring compressor attachment
90890-06320
Flywheel holder
90890-06522
Oil filter wrench
90890-06830
5-1
Valve guide remover/installer
90890-06801
Valve guide installer
90890-06810
63P3F11
Special service tools
Valve guide reamer
90890-06804
1
2
3
4
5
6
7
8
9
Piston ring compressor
90890-05158
Valve seat cutter holder
90890-06316
Valve seat cutter
90890-06324, 90890-06325, 90890-06326,
90890-06327
Needle bearing attachment
90890-06611, 90890-06654
Driver rod L3
90890-06652
63P3F11
5-2
POWR
Power unit
Power unit
5
T.
1
R.
2
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
13
5
E
7
3
6
12
4
LT
E
LT
572
572
10
11
T.
R.
8
42 N · m (4.2 kgf · m, 31.0 ft · Ib)
14
8
15
16
T.
9
R.
20 N · m (2.0 kgf · m, 14.8 ft · Ib)
T.
R.
4 N · m (0.4 kgf · m, 3.0 ft · Ib)
S63P5560
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
5-3
Part name
Dipstick
Bolt
Dipstick guide
O-ring
Flywheel magnet cover
Power unit
Spark plug wire cover
Dowel
Gasket
Bolt
Bolt
Bolt
Bolt
Apron
Screw
Nut
Q’ty
1
1
1
1
1
1
1
2
1
4
8
3
4
1
2
2
Remarks
M6 × 20 mm
Not reusable
Not reusable
M10 × 35 mm
M10 × 140 mm
M8 × 35 mm
M6 × 16 mm
ø6 × 40 mm
63P3F11
Power unit
5
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part name
Nut
Washer
Flywheel magnet
Bolt
Holder
Bracket
Collar
Holder
Stator coil bracket
Hose
Plastic tie
Woodruff key
Stator coil
Screw
63P3F11
Q’ty
1
1
1
4
1
2
2
1
1
1
1
1
1
4
1
2
3
4
5
6
7
8
9
Remarks
M6 × 35 mm
Not reusable
ø6 × 30 mm
5-4
POWR
Power unit
5
C
1
T.
2
R.
29 N · m (2.9 kgf · m, 21.4 ft · Ib)
8
10
9
9
3
4
8
11
12
5
T.
R.
9 N · m (0.9 kgf · m, 6.6 ft · Ib)
T.
14
R.
7
6
13
7 N · m (0.7 kgf · m, 5.2 ft · Ib)
T.
R.
18 N · m (1.8 kgf · m, 13.3 ft · Ib)
E
T.
R.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
5-5
Part name
Starter motor
Bolt
Terminal
Nut
Cap
Bolt
Starter motor lead
Ignition coil
Holder
Holder
Bracket
Holder
Bolt
Oil filter
4 N · m (0.4 kgf · m, 3.0 ft · Ib)
Q’ty
1
3
1
1
1
1
1
2
2
1
2
2
4
1
S63P5580
Remarks
M8 × 45 mm
M6 × 10 mm
M6 × 25 mm
63P3F11
Power unit
5
3
1
7
3
2
2
4
8
6
4
9
4
5
1
10
13
11
12
7
9
9
10
11
S63P5600
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Part name
Grommet
Fuse holder
Terminal plate
Terminal
Terminal
Fuse holder
Fuse
Screw
Fuse
Relay
Fuse
Screw
Screw
63P3F11
Q’ty
1
1
4
8
8
1
2
4
2
1
1
6
3
Remarks
50 A
ø5 × 10 mm
20 A
30 A
ø3 × 10 mm
ø5 × 20 mm
5-6
1
2
3
4
5
6
7
8
9
POWR
Power unit
5
29
26
2
27
28
24
1
25
3 4
16
22
5
17
23
9
21
20
11
67
6
19
7
8
10
8
18
12
15
13
14
T.
R.
4 N · m (0.4 kgf · m, 3.0 ft · Ib)
S63P5610
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
5-7
Part name
Junction box
ECM
Bolt
Wiring harness
Bolt
Washer
Nut
Cap
Power trim and tilt relay
Bolt
Starter relay
Holder
Bolt
Cap
Screw
Grommet
Plastic tie
Q’ty
1
1
4
1
1
2
2
2
1
2
1
1
1
1
1
1
2
Remarks
M6 × 16 mm
M6 × 20 mm
M6 × 20 mm
M6 × 10 mm
ø6 × 19 mm
Not reusable
63P3F11
Power unit
5
29
26
2
27
28
24
1
25
3 4
16
22
5
17
23
9
21
20
11
67
6
19
7
8
10
8
18
12
15
13
14
T.
R.
4 N · m (0.4 kgf · m, 3.0 ft · Ib)
S63P5610
No.
18
19
20
21
22
23
24
25
26
27
28
29
Part name
Holder
Bolt
Intake air temperature sensor
Grommet
Screw
Bracket
Screw
Holder
Collar
Grommet
Bolt
Wiring harness
63P3F11
Q’ty
1
1
1
1
1
1
1
1
3
3
3
1
Remarks
M6 × 12 mm
ø6 × 19 mm
ø6 × 19 mm
M6 × 35 mm
5-8
1
2
3
4
5
6
7
8
9
POWR
Power unit
5
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
5-9
Part name
Timing belt
Timing belt tensioner
Bolt
Drive sprocket
Plate
Woodruff key
Bolt
Driven sprocket
Oil seal
Dowel
Camshaft
Camshaft
Camshaft cap
Camshaft cap
Bolt
Bolt
Gasket
Q’ty
1
1
4
1
1
1
2
2
2
2
1
1
2
8
4
16
1
Remarks
M5 × 40 mm
M10 × 35 mm
M7 × 48 mm
M7 × 37 mm
Not reusable
63P3F11
Power unit
5
No.
18
19
20
21
22
23
24
25
26
27
28
Part name
Screw
Plate
Grommet
Cylinder head cover
Bolt
Holder
Bolt
Clamp
Hose
Dowel
Dowel
63P3F11
Q’ty
8
1
6
1
15
2
2
2
1
4
1
1
2
3
4
5
6
7
8
9
Remarks
ø4 × 8 mm
M6 × 30 mm
M6 × 10 mm
5-10
POWR
Power unit
Checking the compression pressure
1. Start the engine, warm it up for 5 minutes, and then turn it off.
2. Remove the engine stop lanyard from the
engine stop lanyard switch on the remote
control box.
3. Remove the spark plug wire cover and all
spark plugs, and then install the special
service tools into a spark plug hole.
NOTE:
• If the compression pressure increases,
check the pistons and piston rings for wear.
Replace if necessary.
• If the compression pressure does not
increase, check the valve clearance, valve,
valve seat, cylinder sleeve, cylinder head
gasket, and cylinder head. Adjust or
replace if necessary.
Checking the oil pressure
1. Place a rag under the oil pressure sensor.
2
2. Remove the oil pressure sensor, and
then install an oil pressure gauge 1 to
the oil pressure sensor installation hole.
1
S63P5010
1
CAUTION:
Before removing the spark plugs, blow
compressed air in the spark plug well to
clear out any dirt or dust that may fall into
the cylinder.
S63P5020
Compression gauge 1:
90890-03160
Compression gauge extension 2:
90890-06563
4. Fully open the throttle, crank the engine
until the reading on the compression
gauge stabilizes, and then check the
compression pressure.
Minimum compression pressure
(reference data):
880 kPa (8.8 kgf/cm2, 128 psi)
NOTE:
Use a general pressure gauge.
3. Start the engine and warm it up for 5 minutes.
4. Check the oil pressure. Check the oil
pump, oil leakage, and oil strainer if out
of specification.
Oil pressure (reference data):
450 kPa (4.5 kgf/cm2, 65.3 psi) at
engine idle speed
5. If the compression pressure is below
specification and the compression pressure for each cylinder is unbalanced, add
a small amount of engine oil to the cylinder, and then check the pressure again.
5-11
63P3F11
Power unit
Checking the oil pressure sensor
Checking the valve clearance
1. Connect the test harness (3 pins) to the
oil pressure sensor.
1. Remove the flywheel magnet cover and
spark plug wire cover.
2. Start the engine and warm it up for 5 minutes.
2. Disconnect the fuel hoses from the fuel
pumps.
3. Measure the oil pressure sensor input
voltage. Check the wiring harness connection or replace the ECM if out of specification.
3. Disconnect the spark plug wires 1, and
remove the blowby hoses 2, spark
plugs, and cylinder head cover 3.
4. Measure the oil pressure sensor output
voltage. Replace if out of specification.
2
2
3
1
S63P5030
2.8 V
S63P5050
4. Turn the flywheel magnet clockwise and
align the “TDC” mark a on the flywheel
magnet with the pointer b, and check
that “I” marks c and d on the driven
sprockets are aligned.
c
d
a
b 450 kpa
(4.5 kgf/cm2,
65.3 psi)
S63P5040
a: Output voltage
b: Oil pressure
Test harness (3 pins):
New: 90890-06869
Current: 90890-06769
a
20
Oil pressure sensor input voltage:
Orange (O) – Black (B)
5V
Oil pressure sensor output voltage
(reference data):
Pink/white (P/W) – Black (B)
2.8 V at engine idle speed
63P3F11
10
-10
TDC
b
S63P5060
NOTE:
Do not turn the flywheel magnet counterclockwise.
5-12
1
2
3
4
5
6
7
8
9
POWR
Power unit
5. Check the intake valve clearance for cylinders #1 and #2, and exhaust valve
clearance for cylinders #1 and #3. Adjust
if out of specification.
6. Turn the flywheel magnet 360° clockwise.
7. Check the intake valve clearance for cylinders #3 and #4, and exhaust valve
clearance for cylinders #2 and #4. Adjust
if out of specification.
EX
IN
9. Using a hexagon wrench, turn the timing
belt tensioner 4 clockwise to push the
timing belt, increase strength gradually,
and then insert a ø5.0 mm (0.2 in) pin 5
into the hole g.
NOTE:
Leave the pin inserted into the timing belt
tensioner until the timing belt has been
installed.
10. Remove the timing belt 6 from the
driven sprockets.
6
#1
#2
5
#3
#4
4
g
S63P5080
11. Remove the driven sprockets.
e
f
S63P5070
NOTE:
• Check the valve clearance when the engine
is cold.
• Note the measurement.
Valve clearance:
Intake e:
0.20 ± 0.03 mm (0.008 ± 0.001 in)
Exhaust f:
0.34 ± 0.03 mm (0.013 ± 0.001 in)
S63P5090
NOTE:
Hold the camshaft using a wrench, and be
careful not to damage the driven sprocket.
12. Remove the camshaft caps in the order
shown in the illustration.
8. Turn the flywheel magnet 360° clockwise
and align the “TDC” mark on the flywheel
magnet with the pointer, and check that
the “I” marks on the driven sprockets are
aligned.
5-13
63P3F11
Power unit
1
5
1
5
2
2
4
4
3
3
17. Install the necessary valve shim into the
valve lifter.
18. Install the camshafts into the cylinder
head with new oil seals.
E
S63P5100
13. Remove the camshafts.
14. Remove the valve shim 7 from the valve
lifter 8 using compressed air.
63P IN
E
63P EX
M
S63P5110
S63P5C70
NOTE:
Do not mix the valve train parts. Keep them
organized in their proper groups.
NOTE:
Install the camshafts so that the dowels are
facing inward and that they are aligned with
the mating surface of the cylinder head.
15. Measure the valve shim thickness using
a micrometer, and then note the measurement.
16. Select the necessary valve shim by calculating its thickness using the following
formula.
Necessary valve shim thickness =
Removed valve shim thickness +
Measured valve clearance – Specified
valve clearance
Example:
If the “Removed valve shim thickness” is 2.10
mm, the “Measured valve clearance” is 0.30
mm and the “Specified valve clearance” is
0.20 mm, then the “Necessary valve shim
thickness” = 2.10 + 0.30 – 0.20 = 2.20 mm
63P3F11
5-14
1
2
3
4
5
6
7
8
9
POWR
Power unit
19. Install the camshaft caps, and then
tighten them to the specified torques in
two stages and in the sequence shown in
the illustration.
21. Check that “I” marks c and d on the
driven sprockets are aligned. Adjust if
necessary.
d
c
2
E
E
5
5
1
1
4
4
2
2
3
3
1
2
S63P5140
3
4
5
6
7
8
9
10
S63P5120
NOTE:
• Install the camshaft caps in the proper position as shown and with the stamped numbers facing upside down.
• Apply engine oil to the camshaft cap bolts
before installation.
T.
R.
Camshaft cap bolt:
1st: 8 N·m (0.8 kgf·m, 5.9 ft·lb)
2nd: 17 N·m (1.7 kgf·m, 12.5 ft·lb)
20. Install the driven sprockets, and then
tighten the bolts to the specified torque.
22. Install the timing belt 6, turn the belt
from the drive sprocket side a half turn
counterclockwise to align it, and then
remove the pin 5.
6
5
S63P5C90
23. Turn the flywheel magnet clockwise two
turns, and then check that all alignment
marks are aligned.
S63P5130
NOTE:
Apply engine oil to the driven sprocket bolts
before installation.
T.
R.
5-15
Driven sprocket bolt:
60 N·m (6.0 kgf·m, 44.3 ft·lb)
-10
20
10
TDC
S63P5160
63P3F11
Power unit
NOTE:
Do not turn the flywheel magnet counterclockwise.
c
d
24. Check the valve clearances. Adjust if
necessary.
25. Install the spark plugs, and then tighten
them to the specified torque.
26. Install the cylinder head cover bolts, and
then tighten them to the specified torques
in two stages.
T.
R.
Spark plug:
25 N·m (2.5 kgf·m, 18.4 ft·lb)
Cylinder head cover bolt:
1st: 8 N·m (0.8 kgf·m, 5.9 ft·lb)
2nd: 8 N·m (0.8 kgf·m, 5.9 ft·lb)
27. Install the blowby hoses, and connect the
spark plug caps.
28. Install the spark plug wire cover and flywheel magnet cover.
a
20
10
-10
TDC
b
S63P5060
NOTE:
Do not turn the flywheel magnet counterclockwise.
3. Loosen the flywheel magnet nut.
Replacing the timing belt
1. Remove the flywheel magnet cover.
2. Turn the flywheel magnet clockwise and
align the “TDC” mark a on the flywheel
magnet with the pointer b, and check
that “I” marks c and d on the driven
sprockets are aligned.
CAUTION:
Apply force in the direction of the arrows
shown to prevent the flywheel holder from
slipping off easily.
Flywheel holder: 90890-06522
63P3F11
5-16
1
2
3
4
5
6
7
8
9
POWR
Power unit
4. Remove the flywheel magnet.
6. Using a hexagon wrench, turn the timing
belt tensioner 5 clockwise to push the
timing belt, increase strength gradually,
and then insert a ø5.0 mm (0.2 in) pin 6
into the hole e.
NOTE:
Leave the pin inserted into the timing belt
tensioner until the timing belt has been
installed.
7. Remove the timing belt 7 from the
driven sprocket side.
7
6
CAUTION:
To prevent damage to the engine or tools,
screw in the puller set bolts evenly and
completely so that the puller plate is parallel to the flywheel magnet.
NOTE:
Apply force to the crankshaft end until the flywheel magnet comes off the tapered portion
of the crankshaft.
e
5
S63P5310
8. Check that “I” marks c and d on the
driven sprockets are aligned, and that the
“ ” mark f on the plate is aligned with
the “I” mark g on the cylinder block.
Align if necessary.
c
d
Flywheel puller: 90890-06521
5. Disconnect the stator coil coupler 1 and
pulser coil coupler 2, and remove the
blowby hose 3 and stator assembly 4.
g
f
S63P5320
5-17
63P3F11
Power unit
9. Install a new timing belt 7 from the drive
sprocket side with its part number in the
upright position, turn the belt a half turn
counterclockwise to align it, and then
remove the pin 6.
7
6
13. Install the flywheel magnet.
S63P5330
CAUTION:
CAUTION:
• Do not twist, turn inside out, or bend the
timing belt beyond the maximum limit of
25 mm (1.0 in) h, otherwise it can be
damaged.
• Do not get oil or grease on the timing
belt.
Apply force in the direction of the arrows
shown to prevent the flywheel holder from
slipping off easily.
NOTE:
Apply engine oil to the flywheel magnet nut
before installation.
Flywheel holder: 90890-06522
10. Turn the drive sprocket clockwise two
turns, and then check that all alignment
marks are aligned.
T.
R.
NOTE:
Do not turn the drive sprocket counterclockwise.
Flywheel magnet nut:
270 N·m (27.0 kgf·m, 199.1 ft·lb)
14. Install the flywheel magnet cover.
Removing the power unit
11. Install the stator assembly, and blowby
hose, and connect the pulser coil coupler
and stator coil coupler.
12. Install the Woodruff key.
NOTE:
It is recommended to loosen the flywheel
magnet nut before removing the power unit to
improve working efficiency.
1. Remove the flywheel magnet cover.
63P3F11
5-18
1
2
3
4
5
6
7
8
9
POWR
Power unit
2. Disconnect the battery leads 1.
6
1
S63P5420
S63P5380
3. Disconnect the throttle cable 2 and shift
cable 3.
3
7. Disconnect the PTT switch coupler, shift
cut switch coupler, neutral switch coupler, cooling water pilot hose, and flushing hose.
8. Remove the apron 7.
2
S63P5390
7
4. Remove the junction box cover, and then
disconnect the PTT motor leads 4.
S63P5430
9. Remove the power unit by removing the
bolts 8.
4
S63P5400
5. Disconnect the fuel hose 5.
8
8
8
S63P5440
10. Remove the flywheel magnet.
5
S63P5410
6. Remove the dipstick guide 6.
5-19
63P3F11
Power unit
NOTE:
Be sure to clean up any oil spills.
Oil filter wrench: 90890-06830
Removing the timing belt and
sprockets
1. Turn the drive sprocket clockwise and
align the “ ” mark a on the plate with
the “I” mark b on the cylinder block, and
check that “I” marks c and d on the
driven sprockets are aligned.
c
d
CAUTION:
To prevent damage to the engine or tools,
screw in the puller set bolts evenly and
completely so that the puller plate is parallel to the flywheel magnet.
b
a
NOTE:
Apply force to the crankshaft end until the flywheel magnet comes off the tapered portion
of the crankshaft.
S63P5450
Flywheel puller: 90890-06521
Removing the oil filter
NOTE:
Do not turn the drive sprocket counterclockwise.
1. Place a rag under the oil filter, and then
remove the filter using a 72.5 mm (2.9 in)
oil filter wrench.
63P3F11
5-20
1
2
3
4
5
6
7
8
9
POWR
Power unit
2. Using a hexagon wrench, turn the timing
belt tensioner 1 clockwise to push the
timing belt, increase strength gradually,
and then insert a ø5.0 mm (0.2 in) pin 2
into the hole e.
Checking the timing belt and
sprockets
1. Check the interior and exterior of the timing belt for cracks, damage, or wear.
Replace if necessary.
3. Remove the timing belt 3 from the
driven sprocket side.
3
2
1
e
S63P5460
4. Remove the timing belt tensioner.
2. Check the drive sprocket 1 and driven
sprockets 2 for cracks, damage, or
wear. Replace if necessary.
NOTE:
Do not remove the pin 2 from the timing belt
tensioner.
5. Remove the drive sprocket and plate.
6. Remove the cylinder head cover, and
then remove the driven sprockets.
Installing the sprockets and timing
belt
1. Install the driven sprockets 1, and then
tighten the bolts to the specified torque.
2. Check that “I” marks a and b on the
driven sprockets are aligned.
S63P5090
NOTE:
Hold the camshaft using a wrench, and be
careful not to damage the driven sprocket.
5-21
3. Install a new gasket and the cylinder
head cover 2, and then tighten the bolts
to the specified torques in two stages.
63P3F11
Power unit
T.
2
S1280B
b
R.
a
1
E
Drive sprocket bolt:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
Timing belt tensioner bolt:
39 N·m (3.9 kgf·m, 28.8 ft·lb)
6. Install the timing belt 5 from the drive
sprocket side with its part number in the
upright position, turn the belt a half turn
counterclockwise to align it, and then
remove the pin 6.
5
6
S63P5470
T.
R.
Driven sprocket bolt:
60 N·m (6.0 kgf·m, 44.3 ft·lb)
Cylinder head cover bolt:
1st: 8 N·m (0.8 kgf·m, 5.9 ft·lb)
2nd: 8 N·m (0.8 kgf·m, 5.9 ft·lb)
S63P5150
7. Turn the drive sprocket clockwise two
turns, and then check that the alignment
marks are aligned.
4. Install the drive sprocket 3 and timing
belt tensioner 4, and then tighten the
bolts to the specified torques.
5. Check that the “ ” mark c on the plate
is aligned with the “I” mark d on the cylinder block. Align if necessary.
S63P5500
NOTE:
Do not turn the drive sprocket counterclockwise.
63P3F11
5-22
1
2
3
4
5
6
7
8
9
POWR
Power unit
Cylinder head
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
5-23
Part name
Bolt
Valve shim
Valve lifter
Valve cotter
Valve spring retainer
Valve spring
Valve seal
Valve guide
Bolt
Spark plug
Bolt
Bolt
Cover
Grommet
Anode
Cylinder head
Exhaust valve
5
Q’ty
10
16
16
32
16
16
16
16
10
4
2
2
2
2
2
1
8
Remarks
M8 × 55 mm
Not reusable
Not reusable
M10 × 120 mm
M8 × 40 mm
M6 × 20 mm
63P3F11
Cylinder head
5
No.
18
19
20
21
22
23
Part name
Intake valve
Gasket
Collar
Anode
Screw
Anode
63P3F11
Q’ty
8
1
2
1
3
2
1
2
3
4
5
6
7
8
9
Remarks
Not reusable
ø6 × 16 mm
5-24
POWR
Power unit
5
T.
R.
23 N · m (2.3 kgf · m, 17.0 ft · Ib)
R.
12 N · m (1.2 kgf · m, 8.9 ft · Ib)
9
T.
R.
44 5
45
8
T.
4
6 N · m (0.6 kgf · m, 4.4 ft · lb)
12 N · m (1.2 kgf · m, 8.9 ft · lb)
1
2
17
E
16
R.
7 15
T.
6
23 N · m (2.3 kgf · m, 17.0 ft · Ib)
18
19 20
1 2
21
24
T.
15 N · m (1.5 kgf · m, 11.1 ft · Ib)
R.
25
22
4746
A
LT
47 46
572
26
32 33
4746
27 28
40
10
E
12
3
30
31 35
29
41
47
46
11
LT
A
34
271
47
46
42
36
37
43
E
55 N · m (5.5 kgf · m, 40.6 ft · Ib)
T.
R.
R.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
5-25
Part name
Engine temperature sensor
Washer
Bolt
Plug
Washer
Engine hanger
Bolt
Bolt
Bracket
O-ring
Oil pressure sensor
O-ring
Oil filter bracket
Bolt
Gasket
Exhaust cover
Bolt
R.
T.
18 N · m (1.8 kgf · m, 13.3 ft · Ib)
13
T.
12
23
38
34
34 N · m (3.4 kgf · m, 25.1 ft · Ib)
14
LT
39
572
35
S63P5630
Q’ty
1
1
1
1
1
1
2
1
1
1
1
2
1
4
1
1
19
Remarks
M14 × 12 mm
M6 × 20 mm
M6 × 16 mm
Not reusable
Not reusable
M6 × 40 mm
Not reusable
M6 × 30 mm
63P3F11
Cylinder head
5
T.
R.
23 N · m (2.3 kgf · m, 17.0 ft · Ib)
R.
12 N · m (1.2 kgf · m, 8.9 ft · Ib)
9
T.
R.
44 5
45
8
T.
4
6 N · m (0.6 kgf · m, 4.4 ft · lb)
12 N · m (1.2 kgf · m, 8.9 ft · lb)
1
2
17
E
16
R.
7 15
T.
6
23 N · m (2.3 kgf · m, 17.0 ft · Ib)
18
19 20
1 2
21
T.
R.
24
15 N · m (1.5 kgf · m, 11.1 ft · Ib)
25
22
4746
A
LT
47 46
572
26
32 33
4746
27 28
40
10
E
12
3
30
31 35
29
41
47
46
11
LT
A
34
271
47
46
42
36
37
43
E
55 N · m (5.5 kgf · m, 40.6 ft · Ib)
T.
R.
R.
Part name
Gasket
Thermostat
Cover
Thermoswitch
Holder
Bolt
Gasket
Rectifier Regulator
Bolt
Anode
Grommet
Cover
Bolt
Bolt
Washer
Plug
Grommet
63P3F11
R.
T.
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
18 N · m (1.8 kgf · m, 13.3 ft · Ib)
13
T.
12
23
38
34
34 N · m (3.4 kgf · m, 25.1 ft · Ib)
14
LT
39
572
35
S63P5630
Q’ty
1
1
1
1
1
3
1
1
6
1
1
1
1
1
1
1
1
Remarks
Not reusable
M6 × 30 mm
Not reusable
M6 × 30 mm
M8 × 40 mm
M6 × 20 mm
M14 × 12 mm
5-26
1
2
3
4
5
6
7
8
9
POWR
Power unit
5
T.
R.
23 N · m (2.3 kgf · m, 17.0 ft · Ib)
R.
12 N · m (1.2 kgf · m, 8.9 ft · Ib)
9
T.
R.
44 5
45
8
T.
4
6 N · m (0.6 kgf · m, 4.4 ft · lb)
12 N · m (1.2 kgf · m, 8.9 ft · lb)
1
2
17
E
16
R.
7 15
T.
6
23 N · m (2.3 kgf · m, 17.0 ft · Ib)
18
19 20
1 2
21
24
T.
15 N · m (1.5 kgf · m, 11.1 ft · Ib)
R.
25
22
4746
A
LT
47 46
572
26
32 33
4746
27 28
40
10
E
12
3
30
31 35
29
41
47
46
11
LT
A
34
271
47
46
42
36
37
43
E
55 N · m (5.5 kgf · m, 40.6 ft · Ib)
T.
R.
R.
No.
35
36
37
38
39
40
41
42
43
44
45
46
47
5-27
Part name
Pressure control valve
Spring
Gasket
Cover
Bolt
Washer
Plug
Holder
Bolt
Anode
Screw
Anode
Screw
R.
T.
18 N · m (1.8 kgf · m, 13.3 ft · Ib)
13
T.
12
23
38
34
34 N · m (3.4 kgf · m, 25.1 ft · Ib)
14
LT
39
572
35
S63P5630
Q’ty
1
1
1
1
3
1
1
1
1
1
1
7
7
Remarks
Not reusable
M6 × 20 mm
M18 × 17 mm
M6 × 12 mm
ø5 × 27 mm
63P3F11
Cylinder head
Removing the cylinder head
1. Remove the camshaft caps in the
sequence shown.
1
5
1
5
2
2
4
4
3
3
4. Remove the intake valve and exhaust
valves.
S63P5100
2. Remove the camshafts and cylinder
head bolts in the sequence shown.
B
A
F
E
J
0
9G
7
5
C
I
4
6
8
NOTE:
Be sure to keep the valves, springs, and
other parts in the order as they were
removed.
H
1 2
D
3
S63P5170
CAUTION:
Do not scratch or damage the mating surfaces of the cylinder head and cylinder
block.
3. Remove the valve shim 1 from the valve
lifter 2 using compressed air.
NOTE:
Do not mix the valve train parts. Keep them
organized in their proper groups.
63P3F11
Valve spring compressor 3:
90890-04019
Valve spring compressor
attachment 4:
90890-06320
Checking the valve springs
1. Measure the valve spring free length a.
Replace if out of specification.
Valve spring free length a:
44.20 mm (1.7402 in)
5-28
1
2
3
4
5
6
7
8
9
POWR
Power unit
2. Measure the valve spring tilt b. Replace
if out of specification.
Valve stem diameter b:
Intake:
5.477–5.492 mm
(0.2156–0.2162 in)
Exhaust:
5.464–5.479 mm
(0.2151–0.2157 in)
4. Measure the valve stem runout. Replace
if out of specification.
Valve spring tilt limit b:
1.5 mm (0.06 in)
Checking the valves
1. Check the valve face for pitting or wear.
Replace if necessary.
2. Measure the valve margin thickness a.
Replace if out of specification.
Valve stem runout:
0.01 mm (0.0004 in)
Checking the valve guides
NOTE:
Before checking the valve guide make sure
that the valve stem diameter is within specification.
Valve margin thickness a:
Intake: 0.70 mm (0.0276 in)
Exhaust: 1.00 mm (0.0394 in)
1. Measure the valve guide inside diameter
a.
3. Measure the valve stem diameter b.
Replace if out of specification.
a
S69J5770
Valve guide inside diameter a:
5.504–5.522 mm
(0.2167–0.2174 in)
5-29
63P3F11
Cylinder head
2. Calculate the valve stem-to-valve guide
clearance as follows. Replace the valve
guide if out of specification.
Valve stem-to-valve guide clearance
= valve guide inside diameter – valve
stem diameter:
Intake and exhaust:
0.025–0.058 mm
(0.0010–0.0023 in)
Valve guide remover/installer:
90890-06801
Valve guide installer: 90890-06810
3. Insert the special service tool into the
valve guide 2, and then ream the valve
guide.
Replacing the valve guides
1. Remove the valve guide 1 by striking
the special service tool from the combustion chamber side.
NOTE:
• Turn the valve guide reamer clockwise to
ream the valve guide.
• Do not turn the reamer counterclockwise
when removing the reamer.
1
S69J5790
Valve guide reamer: 90890-06804
Valve guide remover/installer:
90890-06801
2. Install a new valve guide 2 by striking
the special service tool from the camshaft side until the valve guide installer
3 contacts the cylinder head.
4. Measure the valve guide inside diameter.
Valve guide inside diameter:
5.504–5.522 mm
(0.2167–0.2174 in)
3
2
E
S69J5800
NOTE:
Apply engine oil to the surface of the new
valve guide.
63P3F11
5-30
1
2
3
4
5
6
7
8
9
POWR
Power unit
Checking the valve seat
1. Eliminate carbon deposits from the valve
with a scraper.
2. Apply a thin, even layer of Mechanic’s
blueing dye (Dykem) onto the valve seat.
3. Lap the valve slowly on the valve seat
with a valve lapper (commercially available) as shown.
Valve seat contact width a:
Intake:
1.1–1.4 mm (0.043–0.055 in)
Exhaust:
1.4–1.7 mm (0.055–0.067 in)
4. Measure the valve seat contact width a
where the blueing dye is adhered to the
valve face. Reface the valve seat if the
valve is not seated properly or if the valve
seat contact width is out of specification.
Replace the valve guide if the valve seat
contact is uneven.
Refacing the valve seat
1. Reface the valve seat with the valve seat
cutter.
Valve seat cutter holder:
90890-06316
Valve seat cutter:
30° (intake): 90890-06327
30° (exhaust): 90890-06326
45° (intake and exhaust):
90890-06325
60° (intake and exhaust):
90890-06324
2. Cut the surface of the valve seat with a
45° cutter by turning the cutter clockwise
until the valve seat face has become
smooth.
5-31
63P3F11
Cylinder head
b
60˚
S69J5890
S63P5240
b Previous contact width
5. Use a 45° cutter to adjust the contact
width of the valve seat to specification.
b
c
a Slag or rough surface
45˚
CAUTION:
Do not over cut the valve seat. Be sure to
turn the cutter evenly downward at a pressure of 40–50 N (4–5 kgf, 8.8–11 lbf) to
prevent chatter marks.
3. Use a 30° cutter to adjust the contact
width of the top edge of the valve seat.
S69J5900
b Previous contact width
c Specified contact width
6. If the valve seat contact area is too wide
and situated in the center of the valve
face, use a 30° cutter to cut the top edge
of the valve seat, a 60° cutter to cut the
bottom edge to center the area and set
its width.
b
30˚
S69J5880
b Previous contact width
4. Use a 60° cutter to adjust the contact
width of the bottom edge of the valve
seat.
63P3F11
b Previous contact width
5-32
1
2
3
4
5
6
7
8
9
POWR
Power unit
7. If the valve seat contact area is too narrow and situated near the top edge of the
valve face, use a 30° cutter to cut the top
edge of the valve seat. If necessary, use
a 45° cutter to center the area and set its
width.
CAUTION:
Do not get the lapping compound on the
valve stem and valve guide.
10. After every lapping procedure, be sure to
clean off any remaining lapping compound from the cylinder head and the
valve.
11. Check the valve seat contact area of the
valve again.
Checking the camshaft
b Previous contact width
1. Measure the cam lobe. Replace if out of
specification.
8. If the valve seat contact area is too narrow and situated near the bottom edge of
the valve face, use a 60° cutter to cut the
bottom edge of the valve seat. If necessary, use a 45° cutter to center the area
and set its width.
b Previous contact width
9. Apply a thin, even layer of lapping compound onto the valve seat, and then lap
the valve using a valve lapper (commercially available).
Cam lobe a:
Intake:
45.300–45.400 mm
(1.7835–1.7874 in)
Exhaust:
44.350–44.450 mm
(1.7461–1.7500 in)
Cam lobe b:
Intake and exhaust:
35.950–36.050 mm
(1.4154–1.4193 in)
2. Measure the camshaft runout. Replace if
out of specification.
5-33
63P3F11
Cylinder head
Checking the cylinder head
1. Eliminate carbon deposits from the combustion chambers and check for deterioration.
2. Check the cylinder head warpage using a
straightedge 1 and thickness gauge 2
in seven directions as shown. Replace if
out of specification.
1
2
S63P5180
Camshaft runout limit:
0.03 mm (0.0012 in)
S63P5190
3. Measure the camshaft journal diameter
c and cylinder head journal inside diameter d. Replace the camshaft and cylinder head if out of specification.
c
S63P5200
d
S69J5970
Camshaft journal diameter c:
24.960–24.980 mm
(0.9827–0.9835 in)
Camshaft cap inside diameter d:
25.000–25.021 mm
(0.9843–0.9851 in)
Cylinder head warpage limit:
0.10 mm (0.0039 in)
Installing the valves
1. Install a new valve seal 1 into the valve
guide.
4. Calculate the camshaft oil clearance e
as follows. Replace the camshaft and
cylinder head as a set if out of specification.
Camshaft oil clearance e =
Camshaft cap inside diameter d –
Camshaft journal diameter c:
0.020–0.060 mm
(0.0008–0.0024 in)
63P3F11
5-34
1
2
3
4
5
6
7
8
9
POWR
Power unit
2. Install the valve 2, valve spring 3, and
valve spring retainer 4 in the sequence
shown, and then attach the special service tool.
S63P5210
NOTE:
Apply engine oil to the valve shims and valve
lifters before installation.
Installing the cylinder head
NOTE:
The valve spring can be installed in any
direction.
Valve spring compressor 5:
90890-04019
Valve spring compressor
attachment 6:
90890-06320
3. Compress the valve spring, and then
install the valve cotter 7 using a thin
screwdriver with a small amount of
grease applied to it.
1. Install a new gasket and the cylinder
head, and then tighten the bolts to the
specified torques in the sequence
shown.
G
E
9
0
E
5
6
1
A
B4
D
F
8
2
C
J I H
3
7
a
90˚
S63P5220
CAUTION:
Do not reuse the cylinder head gasket,
always replace it with a new one.
4. Lightly tap the valve spring retainer with
a plastic hammer to set the valve cotter
securely.
5-35
63P3F11
Cylinder head
3. Install the camshaft caps, and then
tighten the bolts to the specified torques
in two stages and in the sequence
shown.
2
E
E
5
5
1
1
4
4
2
2
3
3
3
4
5
7
8
9
10
R.
2. Install the camshafts into the cylinder
head with new oil seals.
2
6
T.
Cylinder head bolt (M10):
1st: 19 N·m (1.9 kgf·m, 14.0 ft·lb)
2nd: 37 N·m (3.7 kgf·m, 27.3 ft·lb)
3rd: 90°
Cylinder head bolt (M8):
1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb)
2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb)
1
NOTE:
• Apply engine oil to the cylinder head bolts
before installation.
• Tighten the M10 bolts to the specified
torques in two stages first, and then make a
mark a on the M10 bolts and the cylinder
head, and then tighten the bolts 90° from
the mark.
• Tighten the M8 bolts to the specified
torques in two stages.
S63P5120
NOTE:
• Install the camshaft caps in the proper position as shown and with the stamped numbers facing upside down.
• Apply engine oil to the camshaft cap bolts
before installation.
E
63P IN
E
T.
R.
63P EX
Camshaft cap bolt:
1st: 8 N·m (0.8 kgf·m, 5.9 ft·lb)
2nd: 17 N·m (1.7 kgf·m, 12.5 ft·lb)
M
S63P5110
S63P5C70
NOTE:
Install the camshafts so that the dowels are
facing inward and that they are aligned with
the mating surface of the cylinder head.
63P3F11
5-36
1
2
3
4
5
6
7
8
9
POWR
Power unit
Removing the exhaust cover
Installing the pressure control valve
1. Remove the cover 1 and thermostat 2.
1. Install a new gasket and the pressure
control valve, and then tighten the bolts.
2
1
LT
S63P3110
572
S63P5670
2. Remove the exhaust cover bolts in the
sequence shown.
Checking the pressure control valve
1. Remove the pressure control valve.
2. Check the pressure control valve 1 for
wear or damage. Replace if necessary.
3. Check the grommet 2 for deformation.
Replace if necessary.
4. Check the spring 3 for fatigue or deformation. Replace if necessary.
2
1
3
S60V5610
5-37
63P3F11
Cylinder head / Cylinder block
Cylinder block
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Engine hanger
Bolt
Oil filler cap
O-ring
Oil filler neck
Gasket
Bolt
Seal
Balancer assembly
Bolt
Bolt
O-ring
Plug
Oil pump assembly
Oil seal
O-ring
Gasket
63P3F11
5
Q’ty
1
3
1
1
1
1
2
2
1
10
2
1
1
1
1
2
1
1
2
3
4
5
6
7
8
9
Remarks
M6 × 20 mm
Not reusable
M6 × 45 mm
Not reusable
M8 × 55 mm
M6 × 40 mm
Not reusable
Not reusable
Not reusable
Not reusable
5-38
POWR
Power unit
5
No.
18
19
20
5-39
Part name
Oil seal
Oil seal
Bolt
Q’ty
1
2
4
Remarks
Not reusable
Not reusable
M6 × 40 mm
63P3F11
Cylinder block
5
T.
R.
T.
R.
30 N · m (3.0 kgf · m, 22.1 ft · Ib)
90˚
1
2
1
2
30 N · m (3.0 kgf · m, 22.1 ft · Ib)
90˚
6
3
5
4
1
S1280B
1
E
E
E
7
2
E
8
E
11
9
17
16
15
13
E
9
9
9
12
14
T.
R.
14 N · m (1.4 kgf · m, 10.3 ft · lb)
26 N · m (2.6 kgf · m, 19.2 ft · Ib)
1
2
T.
R.
E
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Bolt
Bolt
Crankcase
Main bearing cap
Collar
Cylinder block
Oil seal
Crankshaft
Main bearing
Oil seal
Connecting rod bearing
Piston/connecting rod assembly
Connecting rod cap
Bolt
Oil ring
2nd piston ring
Top ring
63P3F11
10
Q’ty
10
10
1
1
10
1
1
1
10
1
8
4
4
8
4
4
4
1
2
3
UP
63
P
E
23 N · m (2.3 kgf · m, 17.0 ft · Ib)
43 N · m (4.3 kgf · m, 31.7 ft · Ib)
90˚
S63P5650
Remarks
M10 × 85 mm
M8 × 55 mm
Not reusable
Not reusable
Not reusable
5-40
1
2
3
4
5
6
7
8
9
POWR
Power unit
Disassembling the cylinder block
1. Remove the oil pump.
2. Remove the balancer bolts in the
sequence shown.
NOTE:
• Be sure to keep the bearings in the order as
they were removed.
• Mark each piston with an identification
number a of the corresponding cylinder.
• Do not mix the connecting rods and caps.
Keep them organized in their proper
groups.
5. Remove the main bearing cap bolts in
the sequence shown.
3. Remove the crankcase bolts in the
sequence shown.
6. Remove the crankshaft.
Checking the balancer assembly
NOTE:
Do not remove the plugs 1 from the crankcase.
1. Check the teeth of the balancer shaft
gear for cracks or wear. Replace the balancer assembly if necessary.
4. Remove the connecting rod bolts and the
connecting rod caps, and then remove
the connecting rod and piston assemblies.
Checking the piston diameter
1. Measure the piston outside diameter at
the specified measuring point. Replace if
out of specification.
5-41
63P3F11
Cylinder block
3. Calculate the out-of-round limit. Replace
the cylinder block if out of specification.
Out-of-round limit:
D2–D1 (measuring point a)
D6–D5 (measuring point c)
0.05 mm (0.0020 in)
Checking the piston clearance
1. Replace the piston and piston rings as a
set, or the cylinder block, or all parts if
out of specification.
Piston diameter a:
93.928–93.934 mm
(3.6979–3.6982 in)
Measuring point b:
5.0 mm (0.20 in) up from the
bottom of the piston skirt
Piston clearance:
0.075–0.080 mm
(0.0030–0.0031 in)
Checking the piston rings
Checking the cylinder bore
1. Measure the cylinder bore (D1–D6) at
measuring points a, b, and c, and in
direction d (D1, D3, D5), which is parallel
to the crankshaft, and direction e (D2,
D4, D6), which is at a right angle to the
crankshaft.
c
b
a
D2
D1
d
D4
D3
e
D6
D5
S69J5B70
a 20 mm (0.8 in)
b 60 mm (2.4 in)
c 100 mm (3.9 in)
Cylinder bore (D1–D6):
94.000–94.017 mm
(3.7008–3.7014 in)
2. Calculate the taper limit. Replace the cylinder block if out of specification.
Taper limit:
D1–D5 (direction d)
D2–D6 (direction e)
0.08 mm (0.0032 in)
63P3F11
1. Check the piston ring dimensions of B
and T. Replace if out of specification.
Piston ring dimensions:
Top ring a:
B: 1.17–1.19 mm
(0.0461–0.0469 in)
T: 2.80–3.00 mm
(0.1102–0.1181 in)
Second ring b:
B: 1.17–1.19 mm
(0.0461–0.0469 in)
T: 3.70–3.90 mm
(0.1457–0.1535 in)
Oil ring c:
B: 2.40–2.47 mm
(0.0945–0.0972 in)
T: 2.30–2.70 mm
(0.0906–0.1063 in)
5-42
1
2
3
4
5
6
7
8
9
POWR
Power unit
2. Level the piston ring 1 in the cylinder
with a piston crown.
3. Check the piston ring end gap d at the
specified measuring point. Replace if out
of specification.
Piston ring groove:
Top ring a:
1.23–1.25 mm (0.048–0.049 in)
Second ring b:
1.22–1.24 mm (0.048–0.049 in)
Oil ring c:
2.51–2.53 mm (0.099–0.100 in)
Checking the piston ring side
clearance
1. Measure the piston ring side clearance.
Replace the piston and piston rings as a
set if out of specification.
a
b
Piston ring end gap d:
Top ring:
0.15–0.30 mm
(0.0059–0.0118 in)
Second ring:
0.30–0.45 mm
(0.0118–0.0177 in)
Oil ring:
0.15–0.60 mm
(0.0059–0.0236 in)
Measuring point e: 20 mm (0.8 in)
Checking the piston ring grooves
1. Measure the piston ring grooves.
Replace the piston if out of specification.
a
b
c
S63P5730
Piston ring side clearance:
Top ring a:
0.04–0.08 mm
(0.0016–0.0031 in)
Second ring b:
0.03–0.07 mm
(0.0012–0.0028 in)
Oil ring c:
0.04–0.13 mm
(0.0016–0.0051 in)
Checking the connecting rod big end
side clearance
1. Measure the connecting rod big end side
clearance a. Replace the connecting
rod or crankshaft, or both if out of specification.
c
S63P5720
5-43
63P3F11
Cylinder block
Connecting rod big end side
clearance a:
0.14–0.31 mm (0.006–0.012 in)
Checking the crankshaft
1. Check the teeth of the crankshaft gear
for cracks or wear. Replace the crankshaft if necessary.
Crankshaft journal diameter a:
51.980–52.000 mm
(2.0465–2.0472 in)
Crankpin diameter b:
49.980–50.000 mm
(1.9677–1.9685 in)
Crankpin width c:
22.00–22.10 mm
(0.8661–0.8701 in)
3. Measure the crankshaft runout. Replace
the crankshaft if out of specification.
2. Measure the crankshaft journal diameter
a, crankpin diameter b, and crankpin
width c. Replace the crankshaft if out of
specification.
S63P5550
Crankshaft runout limit:
0.03 mm (0.0012 in)
63P3F11
5-44
1
2
3
4
5
6
7
8
9
POWR
Power unit
Checking the crankpin oil clearance
1. Clean the bearings and the connecting
rod.
2. Install the upper bearing into the connecting rod 1 and the lower bearing into
the connecting rod cap 2.
NOTE:
Install the connecting rod bearings in their
original positions.
3. Put a piece of Plastigauge (PG-1) onto
the crankpin, parallel to the crankshaft.
NOTE:
Make sure that the mark a of the connecting
rod faces towards the flywheel magnet side
of the crankshaft.
5. Tighten the connecting rod bolts to the
specified torques in three stages.
NOTE:
Be sure not to put the Plastigauge (PG-1)
over the oil hole in the crankpin of the crankshaft.
4. Install the connecting rod to the crankpin
3.
5-45
NOTE:
• Reuse the removed connecting rod bolts
when checking the oil clearance.
• Do not turn the connecting rod until the
crankpin oil clearance measurement has
been completed.
• Make a mark b on the connecting rod
bolts, connecting rod caps, and then tighten
the bolts 90° from the mark.
63P3F11
Cylinder block
Example:
T.
R.
Connecting rod bolt:
1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb)
2nd: 43 N·m (4.3 kgf·m, 31.7 ft·lb)
3rd: 90°
6. Remove the connecting rod cap and
measure the width of the compressed
Plastigauge (PG-1) on each crankpin.
Replace the connecting rod bearing if out
of specification.
Connecting rod big
end inside diameter a
Numerical value
in table
53.035 mm
35
3. Check the crankpin mark b on the
crankshaft.
P1
P4
P2
P3
b
P1 P2 P3 P4
S63P5530
Crankpin oil clearance:
0.027–0.052 mm
(0.0011–0.0020 in)
Selecting the connecting rod bearing
1. When replacing the connecting rod bearing, select the suitable bearing as follows.
2. Measure the connecting rod big end
inside diameter a.
a
S60C5980
NOTE:
Reuse the connecting rod bolts.
63P3F11
5-46
1
2
3
4
5
6
7
8
9
POWR
Power unit
4. Select the suitable color c for the connecting rod bearing from the table.
c
c
S63P5800
Connecting rod big end inside
diameter a
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
80
h
81
82
83
g
Crankpin mark b
84
85
NOTE:
• Example: If the connecting rod big end
inside diameter a is “35” and the crankpin
mark b is “81,” then select the bearing colors in “g.”
• If the connecting rod inside diameter cannot be measured, measure the crankpin oil
clearance using Plastigauge (PG-1) and
select the suitable combination of upper
and lower bearings from the table above so
that the oil clearance is within specification.
Checking the crankshaft main
journal oil clearance
1. Clean the bearings, main journals, and
bearing portions of the crankcase and
cylinder block.
86
2. Place the cylinder block upside down on
a bench.
87
88
f
89
90
91
3. Install half of the bearings 1 and the
crankshaft 2 into the cylinder block 3.
92
93
e
94
95
96
97
98
99
d
00
Upper bearing
color
Lower bearing
color
d
Green
Green
e
Green
Blue
f
Blue
Blue
g
Blue
Red
h
Red
Red
NOTE:
Install the main bearings in their original positions.
4. Put a piece of Plastigauge (PG-1) on
each main journal parallel to the crankshaft.
5-47
63P3F11
Cylinder block
Selecting the crankshaft main
bearing
1. When replacing the main bearing, select
the suitable bearing as follows.
2. Check the crankshaft journal mark a on
the crankshaft and the cylinder block
mark b on the cylinder block.
J1
J2
J3
J4
J5
NOTE:
Do not put the Plastigauge (PG-1) over the
oil hole in the main journals of the crankshaft.
5. Install the remaining half of the bearings
into the main bearing cap and crankcase.
NOTE:
Install the main bearings in their original positions.
J2 J3
J1
J4
J5
a
S63P5540
6. Install the main bearing cap and crankcase onto the cylinder block and apply
engine oil to the threads of the bolts.
7. Remove the main bearing cap and crankcase, and then measure the width of the
compressed Plastigauge (PG-1) on each
main journal. Replace the main bearing if
out of specification.
Crankshaft main journal oil
clearance:
0.021–0.050 mm
(0.0008–0.0020 in)
63P3F11
5-48
1
2
3
4
5
6
7
8
9
POWR
Power unit
3. Select the suitable color c for the main
bearing from the table.
c
c
S63P5850
Cylinder block mark b
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
80
Checking the oil pump
81
Crankshaft journal mark a
82
i
83
84
85
h
86
87
88
g
89
1. Check the gear teeth for cracks or wear
and the oil pump case for scratches.
Replace the oil pump assembly if necessary.
90
91
Assembling the oil pump
f
92
1. Install a new oil seal into the oil pump
housing.
93
94
e
95
96
97
98
d
99
00
Upper bearing
color
Lower bearing
color
d
Green
Green
e
Green
Red
f
Red
Red
g
Red
Yellow
h
Yellow
Yellow
i
Yellow
Blue + green
NOTE:
• Example: If the crankshaft journal mark a
is “89” and the cylinder block mark b is
“28,” then select the bearing colors in “g.”
• Main bearing #3 is a thrust bearing.
Needle bearing attachment 1:
90890-06654
Driver rod L3 2: 90890-06652
2. Apply grease to new oil seals, and then
install them into the oil pump housing.
Disassembling the oil pump
1. Remove the screws 1 and disassemble
the oil pump.
5-49
63P3F11
Cylinder block
T.
Screw 8:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
R.
Assembling the pistons and cylinder
block
1. Install the oil ring 1, second ring 2, and
top ring 3 onto the pistons with the “RN”
mark a of the second ring and the “R”
mark a of the top ring facing upward.
Needle bearing attachment 3:
90890-06611
Driver rod L3 4: 90890-06652
2. Offset the piston ring end gaps as
shown.
a
#3
3. Install a new oil seal into the oil pump
housing.
45˚
45˚
#2
UP
63P
RN
UP
63P
1
#1,#4
#5
#5
#4
2
#3
#2
#1
E
3
R
a
S63P5930
General pipe 5:
a = 45 mm (1.77 in)
4. Install a new oil seal 6 and the gasket
7, and then tighten the screws 8 to the
specified torque.
63P3F11
CAUTION:
Do not scratch the pistons or break the
piston rings.
NOTE:
After installing the piston rings, check that
they move smoothly.
5-50
1
2
3
4
5
6
7
8
9
POWR
Power unit
3. Install the upper bearing into the connecting rod 4 and the lower bearing into
the connecting rod cap 5.
NOTE:
Install the connecting rod bearings in their
original positions.
NOTE:
Apply engine oil to the inner oil seal before
installation.
4. Install half of the main bearings 6 and
the thrust bearing 7 into the cylinder
block 8.
6. Install half of the main bearings A into
the main bearing cap B.
NOTE:
Install the main bearings in their original positions.
NOTE:
Install the main bearings in their original positions.
5. Set the crankshaft 9 and oil seal 0 into
the cylinder block as shown.
7. Tighten the main bearing cap bolts to the
specified torques in two stages and in the
sequence shown.
5-51
63P3F11
Cylinder block
NOTE:
Apply engine oil to the side of the pistons and
piston rings before installation.
Piston ring compressor:
90890-05158
9. Install the connecting rod caps 5 to the
connecting rods, and then tighten the
connecting rod bolts to the specified
torques in three stages.
c
NOTE:
• Main bearing cap bolts 1–6 can be
reused three times.
• Apply engine oil to the main bearing cap
bolts before installation.
• Make a mark b on the main bearing caps
and main bearing cap bolts, and then
tighten the main bearing cap bolts 90° from
the mark.
T.
R.
Main bearing cap bolt:
1st: 30 N·m (3.0 kgf·m, 22.1 ft·lb)
2nd: 90°
8. Install the piston with the “UP” mark on
the piston crown facing towards the flywheel magnet.
5
E
d
S63P5A20
CAUTION:
Do not reuse the connecting rod bolts,
always replace them with new ones.
NOTE:
• Make sure that the mark c of the connecting rod faces towards the flywheel magnet
side of the crankshaft.
• Apply engine oil to the connecting rod bolts
before installation.
• Make a mark d on the connecting rod bolts
and connecting rod caps, and then tighten
the bolts 90° from the mark.
T.
R.
63P3F11
90˚
Connecting rod bolt:
1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb)
2nd: 43 N·m (4.3 kgf·m, 31.7 ft·lb)
3rd: 90°
5-52
1
2
3
4
5
6
7
8
9
POWR
Power unit
10. Install half of the main bearings A into
the crankcase.
11. Apply sealant to the mating surface of
the crankcase.
R.
12. Install the crankcase onto the cylinder
block.
T.
NOTE:
• Install the main bearings in their original
positions.
• Do not get any sealant on the main bearings.
NOTE:
• Crankcase bolts 1–4 can be reused three
times.
• Apply engine oil to the crankcase bolts
before installation.
• Tighten crankcase bolts 1–4 to the specified torques in two stages first, and then
tighten crankcase bolts 5–D to the specified torques in two stages.
• Make a mark e on the crankcase and
crankcase bolts, and then tighten crankcase bolts 1–4 90° from the mark.
1–4 Crankcase bolt (M10):
1st: 30 N·m (3.0 kgf·m, 22.1 ft·lb)
2nd: 90°
5–D Crankcase bolt (M8):
1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb)
2nd: 26 N·m (2.6 kgf·m, 19.2 ft·lb)
14. Align the keyway f in the crankshaft
with the cylinder block and crankcase
mating surfaces.
13. Tighten the crankcase bolts to the specified torques in two stages and in the
sequence shown.
15. Align the marks g on the balancer shafts
with the alignment marks h.
5-53
63P3F11
Cylinder block
16. Apply sealant to the mating surface of
the balancer assembly.
NOTE:
Do not get any sealant inside the balancer
assembly.
18. After installing the balancer assembly
onto the crankcase, apply sealant around
the periphery of the seals C, and then
install them onto the balancer assembly.
19. Align the oil pump gear with the crankshaft, and then install the oil pump D.
17. Install the balancer assembly onto the
crankcase, and then tighten the balancer
assembly bolts to the specified torques in
two stages and in the sequence shown.
i
i
D
S63P5A90
T.
R.
1–0 Balancer bolt (M8):
1st: 18 N·m (1.8 kgf·m, 13.3 ft·lb)
2nd: 31 N·m (3.1 kgf·m, 22.9 ft·lb)
A, B Balancer bolt (M6):
1st: 7 N·m (0.7 kgf·m, 5.2 ft·lb)
2nd: 13 N·m (1.3 kgf·m, 9.6 ft·lb)
63P3F11
NOTE:
• Before installing the oil pump, be sure to fill
it with a small amount of engine oil through
the oil passage i.
• When installing the oil pump, install it so
that the oil seal does not get damaged.
5-54
1
2
3
4
5
6
7
8
9
POWR
Power unit
20. Before installing the oil filter, be sure to
fill it with engine oil through the oil passage j of the oil filter bracket.
j
S63P5B20
T.
R.
21. Install the oil filter, and then tighten it to
the specified torque using a 72.5 mm
(2.9 in) oil filter wrench.
Exhaust cover bolt:
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
23. Install the thermostat E and cover F.
E
F
NOTE:
Apply a thin coat of engine oil to the O-ring of
the new oil filter before installation.
S63P5C50
T.
R.
Oil filter wrench: 90890-06830
T.
R.
Oil filter:
18 N·m (1.8 kgf·m, 13.3 ft·lb)
22. Install a new gasket and the exhaust
cover, and then tighten the bolts to the
specified torques in two stages and in the
sequence shown.
Thermostat cover bolt:
1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
Installing the power unit
1. Clean the power unit mating surface, and
install the dowels 1 and a new gasket
2.
2. Install the power unit 3 by installing the
bolts 4 and bolts 5, then tightening
them to the specified torque.
3. Install the apron 6, then tighten them to
the specified torque.
5-55
63P3F11
Cylinder block
6. Connect the fuel hose 8.
3
2
1
1
8
S63P5B80
4
LT
4
572
5
LT
572
LT
572
S63P5B40
7. Connect the PTT motor leads 9, and
then install the junction box cover.
9
6
S63P5B90
S63P5B50
R.
R.
4. Connect the PTT switch coupler, shift cut
switch coupler, neutral switch coupler,
cooling water pilot hose, and flushing
hose.
T.
T.
Power unit mounting bolt (M8) 4:
20 N·m (2.0 kgf·m, 14.8 ft·lb)
Power unit mounting bolt (M10) 5:
42 N·m (4.2 kgf·m, 31.0 ft·lb)
Apron bolt:
8 N·m (0.8 kgf·m, 5.9 ft·lb)
Apron screw:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
PTT motor lead bolt:
4 N·m (0.4 kgf·m, 3.0 ft·lb)
8. Connect the shift cable 0 and throttle
cable A, and then adjust their lengths.
For adjustment procedures, see Chapter
3, “Adjusting the throttle link and throttle
cable” and “Checking the gear shift operation.”
0
A
5. Install the dipstick guide 7.
S63P5B60
7
S63P5C80
63P3F11
5-56
1
2
3
4
5
6
7
8
9
POWR
Power unit
9. Connect the battery leads B.
Flywheel holder: 90890-06522
T.
R.
Flywheel magnet nut:
270 N·m (27.0 kgf·m, 199.1 ft·lb)
13. Install all parts removed during disassembly.
B
S63P5C10
T.
R.
Positive battery cable nut:
9 N·m (0.9 kgf·m, 6.6 ft·lb)
10. Install the stator coil assembly.
11. Install the Woodruff key.
12. Install the flywheel magnet.
CAUTION:
Apply force in the direction of the arrows
shown to prevent the flywheel holder from
slipping off easily.
NOTE:
Apply engine oil to the flywheel magnet nut
before installation.
5-57
63P3F11
Cylinder block
— MEMO —
1
2
3
4
5
6
7
8
9
63P3F11
5-58
LOWR
Lower unit
Special service tools .....................................................................................6-1
Lower unit (regular rotation model) ............................................................. 6-4
Removing the lower unit ............................................................................6-8
Removing the water pump and shift rod.................................................... 6-8
Checking the water pump and shift rod .....................................................6-9
Propeller shaft housing (regular rotation model) ..................................... 6-10
Removing the propeller shaft housing assembly..................................... 6-12
Disassembling the propeller shaft assembly ...........................................6-12
Disassembling the propeller shaft housing.............................................. 6-12
Checking the propeller shaft housing ......................................................6-13
Checking the propeller shaft.................................................................... 6-13
Assembling the propeller shaft assembly ................................................ 6-14
Assembling the propeller shaft housing...................................................6-14
Drive shaft and lower case (regular rotation model) ................................6-16
Removing the drive shaft.........................................................................6-17
Disassembling the drive shaft housing ....................................................6-17
Disassembling the forward gear ..............................................................6-17
Disassembling the lower case .................................................................6-17
Checking the pinion and forward gear.....................................................6-18
Checking the bearings............................................................................. 6-18
Checking the drive shaft ..........................................................................6-18
Checking the lower case .........................................................................6-18
Assembling the lower case...................................................................... 6-19
Assembling the forward gear................................................................... 6-19
Assembling the drive shaft housing......................................................... 6-19
Installing the drive shaft...........................................................................6-20
Installing the propeller shaft housing .......................................................6-21
Installing the water pump and shift rod....................................................6-21
Installing the lower unit ............................................................................6-23
Shimming (regular rotation model) ............................................................ 6-25
Shimming.................................................................................................6-26
Selecting the pinion shims....................................................................... 6-26
Selecting the forward gear shims ............................................................ 6-27
Selecting the reverse gear shims ............................................................ 6-28
Backlash (regular rotation model)..............................................................6-29
Measuring the forward and reverse gear backlash .................................6-29
63P3F11
Lower unit (counter rotation model) .......................................................... 6-32
Removing the lower unit ..........................................................................6-36
Removing the water pump and shift rod.................................................. 6-36
Checking the water pump and shift rod ...................................................6-37
Propeller shaft housing (counter rotation model) .................................... 6-38
Removing the propeller shaft housing assembly..................................... 6-40
Disassembling the propeller shaft assembly ...........................................6-40
Disassembling the forward gear ..............................................................6-40
Disassembling the propeller shaft housing.............................................. 6-41
Checking the propeller shaft housing ......................................................6-41
Checking the propeller shaft.................................................................... 6-41
Assembling the propeller shaft housing...................................................6-41
Drive shaft and lower case (counter rotation model) ...............................6-44
Removing the drive shaft.........................................................................6-46
Disassembling the drive shaft housing ....................................................6-46
Disassembling the reverse gear ..............................................................6-46
Disassembling the lower case .................................................................6-46
Checking the pinion and reverse gear.....................................................6-47
Checking the bearings............................................................................. 6-47
Checking the drive shaft ..........................................................................6-47
Checking the lower case .........................................................................6-47
Assembling the lower case...................................................................... 6-47
Assembling the reverse gear................................................................... 6-48
Assembling the drive shaft housing......................................................... 6-48
Installing the drive shaft...........................................................................6-49
Installing the propeller shaft housing .......................................................6-49
Installing the water pump and shift rod....................................................6-50
Installing the lower unit ............................................................................6-52
Shimming (counter rotation model) ........................................................... 6-54
Shimming.................................................................................................6-55
Selecting the pinion shims....................................................................... 6-55
Selecting the reverse gear shims ............................................................ 6-56
Selecting the forward gear shims ............................................................ 6-57
Selecting the propeller shaft shims.......................................................... 6-58
Backlash (counter rotation model)............................................................. 6-60
Measuring the forward and reverse gear backlash .................................6-60
63P3F11
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
Special service tools
6
Ring nut wrench 4
90890-06512
Bearing separator
90890-06534
Ring nut wrench extension
90890-06513
Stopper guide stand
90890-06538
Bearing housing puller claw L
90890-06502
Bearing puller assembly
90890-06535
Stopper guide plate
90890-06501
Needle bearing attachment
90890-06610, 90890-06612, 90890-06653,
90890-06654
Center bolt
90890-06504
6-1
Driver rod L3
90890-06652
63P3F11
Special service tools
Driver rod SS
90890-06604
Bearing outer race puller assembly
90890-06523
Bearing depth plate
90890-06603
Ball bearing attachment
90890-06633, 90890-06636, 90890-06629
Bearing inner race attachment
90890-06640, 90890-06660
Bearing outer race attachment
90890-06619
Drive shaft holder 6
90890-06520
Driver rod LL
90890-06605
Pinion nut holder
New: 90890-06715
Current: 90890-06505
Driver rod LS
90890-06606
63P3F11
6-2
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
Shift rod push arm
90890-06052
Magnet base plate
90890-07003
Pinion height gauge
90890-06710
Dial gauge set
90890-01252
Digital caliper
90890-06704
Magnet base B
90890-06844
Shimming plate
90890-06701
Ring nut wrench
90890-06578
Backlash indicator
90890-06706
Outer race puller claw B
90890-06533
6-3
63P3F11
Special service tools / Lower unit (regular rotation model)
Lower unit (regular rotation model)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Lower unit
Check screw
Gasket
Bolt
Drain screw
Grommet
Bolt
Bolt
Spacer
Propeller
Washer
Washer
Cotter pin
Propeller nut
Trim tab
Dowel
Water pipe
63P3F11
Q’ty
1
1
2
6
1
1
1
1
1
1
1
1
1
1
1
2
1
6
1
2
3
4
5
6
7
8
9
Remarks
Not reusable
M10 × 45 mm
M10 × 44 mm
M10 × 70 mm / L-transom model
Not reusable
X-transom model
X-transom model
6-4
LOWR
Lower unit
6
No.
18
19
20
6-5
Part name
Extension
Bolt
Bolt
Q’ty
1
6
1
Remarks
X-transom model
M10 × 45 mm / X-transom model
M10 × 200 mm / X-transom model
63P3F11
Lower unit (regular rotation model)
6
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Shift rod
Oil seal
Oil seal housing
O-ring
Spring
Circlip
Bolt
Hose nipple
O-ring
Woodruff key
Bolt
Cover
Seal
Water pump housing
O-ring
Insert cartridge
O-ring
63P3F11
Q’ty
1
1
1
1
1
1
3
1
1
1
4
1
1
1
1
1
1
1
2
3
4
5
6
7
8
9
Remarks
Not reusable
Not reusable
M6 × 20 mm
Not reusable
M8 × 45 mm
Not reusable
Not reusable
6-6
LOWR
Lower unit
6
No.
18
19
20
21
22
23
24
25
26
6-7
Part name
Collar
Spacer
Washer
Wave washer
Impeller
Outer plate cartridge
Gasket
Dowel
Dowel
Q’ty
1
1
2
1
1
1
1
2
2
Remarks
Not reusable
63P3F11
Lower unit (regular rotation model)
Removing the lower unit
1. Drain the gear oil. For draining procedures, see Chapter 3, “Changing the
gear oil.”
2. Set the gear shift to the neutral position,
and place a block of wood between the
anti-cavitation plate and propeller to keep
the propeller from turning, and then
remove the propeller nut and propeller.
È X-transom model
WARNING
• Do not hold the propeller with your
hands when loosening or tightening it.
• Be sure to disconnect the battery leads
from the battery and the engine stop lanyard from the engine stop lanyard
switch.
• Put a block of wood between the anticavitation plate and propeller to keep
the propeller from turning.
NOTE:
Check that there is no oil on the spline and
check it for wear.
Removing the water pump and shift
rod
1. Remove the water pump assembly and
shift rod assembly 1.
3. Mark the trim tab 1 at the area shown,
and then remove it.
4. Loosen the bolts, and then remove the
lower unit from the upper case.
63P3F11
6-8
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
Checking the water pump and shift
rod
1. Check the water pump housing for deformation. Replace if necessary.
S69J6045
S69J6030
2. Check the impeller 1 and insert cartridge 2 for cracks or wear. Replace if
necessary.
1
2
S63P6050
3. Check the Woodruff key 3 and the keyway a in the drive shaft for wear.
Replace if necessary.
a
3
S69J6040
4. Check the shift rod for cracks or wear.
Replace if necessary.
6-9
63P3F11
Lower unit (regular rotation model) / Propeller shaft housing (regular rotation model)
Propeller shaft housing (regular rotation model)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Shift rod joint
Ball
Shift slider
Ball
Ball
Spring
Dog clutch
Cross pin
Spring
Propeller shaft
Reverse gear shim
Washer
Reverse gear
Thrust washer
Ball bearing
O-ring
Propeller shaft housing
63P3F11
Q’ty
1
2
1
2
2
1
1
1
1
1
—
1
1
1
1
1
1
6
1
2
3
4
5
6
7
8
9
Remarks
Not reusable
Not reusable
6-10
LOWR
Lower unit
6
No.
18
19
20
21
22
23
24
25
6-11
Part name
Straight key
Needle bearing
Oil seal
Claw washer
Ring nut
Cooling water inlet cover
Nut
Screw
Q’ty
1
1
2
1
1
2
1
1
Remarks
Not reusable
63P3F11
Propeller shaft housing (regular rotation model)
Removing the propeller shaft
housing assembly
1. Straighten the claw washer tabs a, and
then remove the ring nut and claw
washer.
Disassembling the propeller shaft
housing
1. Remove the reverse gear and thrust
washer.
Ring nut wrench 4 1: 90890-06512
Ring nut wrench extension 2:
90890-06513
2. Pull out the propeller shaft housing
assembly.
Bearing housing puller claw L 3:
90890-06502
Stopper guide plate 4: 90890-06501
Center bolt 5: 90890-06504
Bearing separator 1: 90890-06534
Stopper guide plate 2: 90890-06501
Stopper guide stand 3:
90890-06538
Bearing puller assembly 4:
90890-06535
Disassembling the propeller shaft
assembly
1. Remove the spring 1, then the cross pin
2, dog clutch 3, balls 4, spring 5, shift
slider 6, and shift rod joint 7.
63P3F11
6-12
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
2. Remove the ball bearing.
Stopper guide plate 5: 90890-06501
Stopper guide stand 6:
90890-06538
Bearing puller assembly 7:
90890-06535
2. Check the teeth and dogs of the reverse
gear for cracks or wear. Replace the
gear if necessary.
S62Y6640
3. Check the bearings for pitting or rumbling. Replace if necessary.
3. Remove the oil seals and needle bearing.
S69J6115
Checking the propeller shaft
1. Check the propeller shaft for bends or
wear. Replace if necessary.
Needle bearing attachment 8:
90890-06653
Driver rod L3 9: 90890-06652
Checking the propeller shaft housing
1. Clean the propeller shaft housing using a
soft brush and cleaning solvent, and then
check it for cracks. Replace if necessary.
2. Check the dog clutch, shift rod joint and
shift slider for cracks or wear. Replace if
necessary.
6-13
63P3F11
Propeller shaft housing (regular rotation model)
NOTE:
• Install the needle bearing with the manufacture identification mark a facing toward the
oil seal (propeller side).
• When using the driver rod, do not strike the
special service tool in a manner that will
force the stopper c out of place.
Assembling the propeller shaft
assembly
1. Install the dog clutch as shown.
Driver rod SS 1: 90890-06604
Needle bearing attachment 2:
90890-06610
Bearing depth plate 3: 90890-06603
Depth b:
24.75–25.25 mm (0.974–0.994 in)
2. Apply grease to new oil seals, and then
install them into the propeller shaft housing to the specified depth.
NOTE:
Install the dog clutch 1 with the “F” mark a
facing toward the shift slider.
Assembling the propeller shaft
housing
1. Install the needle bearing into the propeller shaft housing to the specified depth.
NOTE:
Install an oil seal halfway into the propeller
shaft housing, then the other oil seal.
Bearing inner race attachment 4:
90890-06640
Depth d:
4.75–5.25 mm (0.187–0.207 in)
63P3F11
6-14
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
3. Install the thrust washer 5 and new ball
bearing 6 onto the reverse gear 7 using
a press.
NOTE:
Install the ball bearing with the manufacture
identification mark e facing outward (propeller side).
Needle bearing attachment 8:
90890-06654
4. Install the reverse gear assembly into the
propeller shaft housing using a press.
Needle bearing attachment 9:
90890-06654
6-15
63P3F11
Propeller shaft housing (regular rotation model) / Drive shaft and lower case (regular rotation model)
Drive shaft and lower case (regular rotation model)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Drive shaft
Sleeve
Cover
Oil seal
Bolt
Drive shaft housing
Needle bearing
O-ring
Pinion shim
Thrust bearing
Lower case
Needle bearing assembly
Pinion
Forward gear shim
Taper roller bearing assembly
Needle bearing
Forward gear
63P3F11
Q’ty
1
1
1
2
4
1
1
1
—
1
1
1
1
—
1
2
1
6
1
2
3
4
5
6
7
8
9
Remarks
Not reusable
M8 × 25 mm
Not reusable
Not reusable
6-16
LOWR
Lower unit
Removing the drive shaft
1. Remove the drive shaft, drive shaft housing, and pinion, and then pull out the forward gear.
1
1
S69J6186
2
S68S6360J
Drive shaft holder 6 1: 90890-06520
Pinion nut holder 2:
New: 90890-06715
Current: 90890-06505
Disassembling the drive shaft
housing
CAUTION:
Do not reuse the bearing, always replace
it with a new one.
Bearing separator 1: 90890-06534
2. Remove the needle bearings from the
forward gear using a chisel.
1. Remove the cover, oil seals, and needle
bearing.
S68S6160
CAUTION:
Do not reuse the bearing, always replace
it with a new one.
Needle bearing attachment 1:
90890-06610
Driver rod L3 2: 90890-06652
Disassembling the forward gear
Disassembling the lower case
1. Remove the taper roller bearing outer
race and shim(s).
1. Remove the taper roller bearing from the
forward gear using a press.
6-17
63P3F11
Drive shaft and lower case (regular rotation model)
NOTE:
Install the claws as shown.
Bearing outer race puller
assembly 1:
90890-06523
2. Remove the needle bearing.
Checking the drive shaft
1. Check the drive shaft for bends or wear.
Replace if necessary.
Ball bearing attachment 2:
90890-06636
Driver rod LL 3: 90890-06605
Checking the pinion and forward
gear
1. Check the teeth of the pinion, and the
teeth and dogs of the forward gear for
cracks or wear. Replace if necessary.
S69J6210
Checking the lower case
1. Check the skeg and torpedo for cracks or
damage. Replace the lower case if necessary.
S69J6200
Checking the bearings
1. Check the bearings for pitting or rumbling. Replace if necessary.
63P3F11
6-18
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
Assembling the lower case
1. Install the original shim(s) and taper roller
bearing outer race.
NOTE:
Apply gear oil or grease to the needle bearing before installation.
Assembling the forward gear
1. Install new needle bearings into the forward gear to the specified depth.
CAUTION:
Add or remove shim(s), if necessary, if
replacing the forward gear or lower case.
Bearing outer race attachment 1:
90890-06619
Driver rod LL 2: 90890-06605
2. Install the needle bearing outer case into
the lower case.
Needle bearing attachment 1:
90890-06612
Driver rod SS 2: 90890-06604
Bearing depth plate 3: 90890-06603
Depth a:
20.95–21.45 mm (0.825–0.844 in)
Depth b:
4.45–4.95 mm (0.175–0.195 in)
2. Install a new taper roller bearing into the
forward gear using a press.
NOTE:
Apply gear oil to the needle bearing outer
case before installation.
Ball bearing attachment 3:
90890-06633
Bearing outer race puller
assembly 4:
90890-06523
3. Install the needle bearing into the needle
bearing outer case.
6-19
Needle bearing attachment 4:
90890-06654
Assembling the drive shaft housing
1. Install the needle bearing into the drive
shaft housing to the specified depth.
63P3F11
Drive shaft and lower case (regular rotation model)
2. Install the drive shaft housing 1, thrust
bearing 2, and original shim(s) 3 onto
the drive shaft 4.
Needle bearing attachment 1:
90890-06610
Driver rod SS 2: 90890-06604
Bearing depth plate 3: 90890-06603
Depth a:
5.75–6.25 mm (0.226–0.246 in)
2. Apply grease to a new oil seals, and then
install them into the drive shaft housing
to the specified depth.
CAUTION:
Add or remove shim(s), if necessary, if
replacing the drive shaft housing or drive
shaft.
3. Install the sleeve, drive shaft and drive
shaft housing into the lower case, then
the pinion and pinion nut, and then
tighten the nut to the specified torque.
5
6
S63P6310
NOTE:
Install an oil seal halfway into the drive shaft
housing, then the other oil seal.
Ball bearing attachment 4:
90890-06633
Driver rod LS 5: 90890-06606
NOTE:
Install the drive shaft by lifting it up slightly,
then aligning it with the pinion and the spline
of the drive shaft.
Drive shaft holder 6 5: 90890-06520
Pinion nut holder 6:
New: 90890-06715
Current: 90890-06505
Depth b:
0.25–0.75 mm (0.010–0.030 in)
Installing the drive shaft
T.
R.
1. Install the forward gear into the lower
case.
Pinion nut:
93 N·m (9.3 kgf·m, 68.6 ft·lb)
4. Tighten the drive shaft housing bolts.
63P3F11
6-20
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
Installing the propeller shaft housing
1. Install the washer 1 and propeller shaft
assembly 2 into the propeller shaft
housing assembly 3.
2. Apply grease to a new O-ring, and then
install it onto the propeller shaft housing.
NOTE:
• To secure the ring nut, bend one tab a of
the claw washer into a slot in the ring nut.
• Bend all other tabs toward the propeller
shaft housing assembly.
Ring nut wrench 4 9: 90890-06512
Ring nut wrench extension 0:
90890-06513
T.
R.
3. Install the original shim(s) 4 and propeller shaft housing assembly 5 into the
lower case, and then install the straight
key 6, claw washer 7, and ring nut 8.
Ring nut 8:
142 N·m (14.2 kgf·m, 104.7 ft·lb)
Installing the water pump and shift
rod
1. Install the shift rod assembly 1.
CAUTION:
Add or remove shim(s), if necessary, if
replacing the reverse gear, ball bearing,
propeller shaft housing, thrust washer, or
lower case.
4. Tighten the ring nut to the specified
torque.
6-21
2. Install a new gasket 2, the outer plate
cartridge 3, and dowels 4.
63P3F11
Drive shaft and lower case (regular rotation model)
NOTE:
• The collar and spacer should fit together
firmly.
• While pulling the drive shaft up, install the
collar with an appropriate tool a that fits
over the drive shaft as shown.
6. Install the new O-ring A and insert cartridge B into the pump housing C.
C
A
c b
A
B
b
c
3. Install the Woodruff key into the drive
shaft.
4. Align the groove in the impeller 5 with
the Woodruff key 6, and then install the
impeller onto the drive shaft.
S63P6360
NOTE:
Align the insert cartridge projections b with
the holes c in the pump housing.
5. Install the washers 7, wave washer 8,
spacer 9, and collar 0 onto the drive
shaft.
63P3F11
6-22
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
7. Install the new O-ring D and pump housing assembly E into the lower case,
tighten the bolts F, and then install the
seal G and cover H.
Shift rod push arm: 90890-06052
3. Install the two dowels 1 into the lower
unit.
4. Install the lower unit into the upper case,
and then tighten the lower case mounting
bolts 2 to the specified torque.
NOTE:
• When installing the pump housing, apply
grease to the inside of the housing, and
then turn the drive shaft clockwise while
pushing down the pump housing.
• Align the cover projection d with the hole
e in the pump housing.
5. Install the trim tab 3 to its original position, and then tighten the trim tab bolt 4
to the specified torque.
Installing the lower unit
1. Set the gear shift to the neutral position
at the lower unit.
2. Align the center of the set pin a with the
alignment mark b on the bottom cowling.
È X-transom model
T.
R.
b
a
6-23
Lower case mounting bolt 2:
47 N·m (4.7 kgf·m, 34.7 ft·lb)
Trim tab bolt 4:
42 N·m (4.2 kgf·m, 31.0 ft·lb)
S63P3270
63P3F11
Drive shaft and lower case (regular rotation model)
T.
R.
6. Install the propeller and propeller nut,
and then tighten the nut finger tight.
Place a block of wood between the anticavitation plate and propeller to keep the
propeller from turning, and then tighten
the nut to the specified torque.
Propeller nut 5:
52 N·m (5.2 kgf·m, 38.4 ft·lb)
1
2
3
4
5
6
7
8
9
WARNING
• Do not hold the propeller with your
hands when loosening or tightening it.
• Be sure to disconnect the battery leads
from the battery and the engine stop lanyard from the engine stop lanyard
switch.
• Put a block of wood between the anticavitation plate and propeller to keep
the propeller from turning.
NOTE:
If the grooves in the propeller nut 5 do not
align with the cotter pin hole, tighten the nut
until they are aligned.
63P3F11
6-24
LOWR
Lower unit
Shimming (regular rotation model)
6
F
P
R
B4
T3
A3
B3
61.0
T1
T2
B1 37.0
16.3
A1
A2
B2
S63P6390
6-25
63P3F11
Shimming (regular rotation model)
Shimming
T.
R.
NOTE:
• Shimming is not required when assembling
the original lower case and inner parts.
• Shimming is required when assembling the
original inner parts and a new lower case.
• Shimming is required when replacing the
inner part(s).
Pinion nut:
93 N·m (9.3 kgf·m, 68.6 ft·lb)
3. Measure the distance (M4) between the
special service tool and the pinion as
shown.
Selecting the pinion shims
1. Install the special service tools onto the
drive shaft 1.
Digital caliper 4: 90890-06704
4. Turn the thrust bearing 5 two or three
times to seat the drive shaft housing 6,
and then measure the housing height
(M3) as shown.
NOTE:
• Select the shim thickness (T3) by using the
specified measurement(s) and the calculation formula.
• Install the special service tool onto the drive
shaft so that the shaft is at the center of the
hole.
• Tighten the wing nuts another 1/4 of a turn
after they contact the fixing plate 2.
NOTE:
Measure the thrust bearing at three points to
find the height average.
Pinion height gauge 3:
90890-06710
2. Install the pinion and pinion nut, and then
tighten the nut to the specified torque.
63P3F11
6-26
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
5. Calculate the pinion shim thickness (T3)
as shown in the examples below.
Example:
If “T3” is 0.53 mm, then the pinion shim is
0.52 mm.
If “T3” is 0.78 mm, then the pinion shim is
0.75 mm.
Selecting the forward gear shims
1. Turn the taper roller bearing outer race
1 two or three times to seat the rollers,
and then measure the bearing height
(M1) as shown.
NOTE:
“P” is the deviation of the lower case dimension from standard. The “P” mark a is
stamped on the trim tab mounting surface of
the lower case in 0.01 mm units. If the “P”
mark is unreadable, assume that “P” is zero
and check the backlash when the unit is
assembled.
T1
S63P6430
Calculation formula:
Pinion shim thickness (T3) =
80.00 + P/100 – M3 – M4
Example:
If “M3” is 46.68 mm and “M4” is 32.49 mm
and “P” is (–5), then
T3 = 80.00 + (–5)/100 – 46.68 – 32.49 mm
= 80.00 – 0.05 – 46.68 – 32.49 mm
= 0.78 mm
6. Select the pinion shim(s) (T3) as follows.
Calculated numeral
at 1/100 place
Rounded numeral
1, 2
0
3, 4, 5
2
6, 7, 8
5
9, 10
8
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
6-27
NOTE:
• Select the shim thickness (T1) by using the
specified measurement(s) and the calculation formula.
• Measure the bearing outer race at three
points to find the height average.
Shimming plate 2: 90890-06701
Digital caliper 3: 90890-06704
2. Calculate the forward gear shim thickness (T1) as shown in the examples
below.
63P3F11
Shimming (regular rotation model)
Selecting the reverse gear shims
1. Install the ball bearing, thrust washer,
and reverse gear onto the propeller shaft
housing.
2. Measure the gear height (M2) from the
thrust washer on the propeller shaft
housing.
NOTE:
“F” is the deviation of the lower case dimension from standard. The “F” mark a is
stamped on the trim tab mounting surface of
the lower case in 0.01 mm units. If the “F”
mark is unreadable, assume that “F” is zero
and check the backlash when the unit is
assembled.
T2
S63P6450
Calculation formula:
Forward gear shim thickness (T1) =
28.60 + F/100 – M1
Example:
If “M1” is 28.08 mm and “F” is (+5), then
T1 = 28.60 + (+5)/100 – 28.08 mm
= 28.60 + 0.05 – 28.08 mm
= 0.57 mm
3. Select the forward gear shim(s) (T1) as
follows.
Calculated numeral
at 1/100 place
Rounded numeral
1, 2
0
3, 4, 5
2
6, 7, 8
5
9, 10
8
NOTE:
• Select the shim thickness (T2) by using the
specified measurement(s) and the calculation formula.
• Measure the reverse gear at three points to
find the height average.
Shimming plate 1: 90890-06701
Digital caliper 2: 90890-06704
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
Example:
If “T1” is 0.57 mm, then the forward gear
shim is 0.55 mm.
If “T1” is 0.60 mm, then the forward gear
shim is 0.58 mm.
63P3F11
6-28
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
3. Calculate the reverse gear shim thickness (T2) as shown in the examples
below.
Example:
If “T2” is 0.77 mm, then the reverse gear
shim is 0.78 mm.
If “T2” is 0.79 mm, then the reverse gear
shim is 0.80 mm.
Backlash
(regular rotation model)
6
Measuring the forward and reverse
gear backlash
1. Remove the water pump assembly.
NOTE:
“R” is the deviation of the lower case dimension from standard. The “R” mark a is
stamped on the trim tab mounting surface of
the lower case in 0.01 mm units. If the “R”
mark is unreadable, assume that “R” is zero
and check the backlash when the unit is
assembled.
Calculation formula:
Reverse gear shim thickness (T2) =
M2 – 29.90 – R/100
Example:
If “M2” is 30.70 mm and “R” is (+3), then
T2 = 30.70 – 29.90 – (+3)/100 mm
= 30.70 – 29.90 – 0.03 mm
= 0.77 mm
2. Set the gear shift to the neutral position
at the lower unit.
Shift rod push arm: 90890-06052
3. Install the special service tools so that it
pushes against the propeller shaft.
4. Select the reverse gear shim(s) (T2) as
follows.
Calculated numeral
at 1/100 place
Rounded numeral
1, 2
2
3, 4, 5
5
6, 7, 8
8
9, 10
10
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
6-29
NOTE:
Tighten the center bolt while turning the drive
shaft until the drive shaft can no longer be
turned.
63P3F11
Shimming (regular rotation model) / Backlash (regular rotation model)
Bearing housing puller claw L 1:
90890-06502
Stopper guide plate 2: 90890-06501
Center bolt 3: 90890-06504
4. Install the backlash indicator onto the
drive shaft (22.4 mm [0.88 in] in diameter), then the dial gauge onto the lower
unit.
5. Set the lower unit upside down.
Forward gear
backlash
Shim thickness
Less than
0.14 mm (0.0055 in)
To be decreased by
(0.30 – M) × 0.67
More than
0.46 mm (0.0181 in)
To be increased by
(M – 0.30) × 0.67
M: Measurement
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
8. Remove the special service tools from
the propeller shaft.
9. Apply a load to the reverse gear by
installing the propeller 8, the spacer 9
(without the washer 0), then the washer
A as shown.
NOTE:
Install the dial gauge so that the plunger a
contacts the mark b on the backlash indicator.
Backlash indicator 4: 90890-06706
Magnet base plate 5: 90890-07003
Dial gauge set 6: 90890-01252
Magnet base B 7: 90890-06844
NOTE:
Tighten the propeller nut B while turning the
drive shaft until the drive shaft can no longer
be turned.
6. Slowly turn the drive shaft clockwise and
counterclockwise and measure the backlash when the drive shaft stops in each
direction.
Forward gear backlash:
0.14–0.46 mm (0.0055–0.0181 in)
7. Add or remove shim(s) if out of specification.
63P3F11
6-30
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
10. Slowly turn the drive shaft clockwise and
counterclockwise and measure the backlash when the drive shaft stops in each
direction.
Reverse gear backlash:
0.32–0.67 mm (0.0126–0.0264 in)
11. Add or remove shim(s) if out of specification.
Reverse gear
backlash
Shim thickness
Less than
0.32 mm (0.0126 in)
To be increased by
(0.50 – M) × 0.67
More than
0.67 mm (0.0264 in)
To be decreased by
(M – 0.50) × 0.67
M: Measurement
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
12. Remove the special service tools, and
then install the water pump assembly.
6-31
63P3F11
Backlash (regular rotation model) / Lower unit (counter rotation model)
Lower unit (counter rotation model)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Lower unit
Check screw
Gasket
Bolt
Drain screw
Grommet
Bolt
Bolt
Spacer
Propeller
Washer
Washer
Cotter pin
Propeller nut
Trim tab
Dowel
Water pipe
63P3F11
Q’ty
1
1
2
6
1
1
1
1
1
1
1
1
1
1
1
2
1
6
Remarks
Not reusable
M10 × 45 mm
M10 × 44 mm
M10 × 70 mm / L-transom model (for Europe)
Not reusable
X-transom model
X-transom model
6-32
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
6
No.
18
19
20
6-33
Part name
Extension
Bolt
Bolt
Q’ty
1
6
1
Remarks
X-transom model
M10 × 45 mm / X-transom model
M10 × 200 mm / X-transom model
63P3F11
Lower unit (counter rotation model)
6
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Shift rod
Oil seal
Oil seal housing
O-ring
Spring
Circlip
Bolt
Hose nipple
O-ring
Woodruff key
Bolt
Cover
Seal
Water pump housing
O-ring
Insert cartridge
O-ring
63P3F11
Q’ty
1
1
1
1
1
1
3
1
1
1
4
1
1
1
1
1
1
1
2
3
4
5
6
7
8
9
Remarks
Not reusable
Not reusable
M6 × 20 mm
Not reusable
M8 × 45 mm
Not reusable
Not reusable
6-34
LOWR
Lower unit
6
No.
18
19
20
21
22
23
24
25
26
6-35
Part name
Collar
Spacer
Washer
Wave washer
Impeller
Outer plate cartridge
Gasket
Dowel
Dowel
Q’ty
1
1
2
1
1
1
1
2
2
Remarks
Not reusable
63P3F11
Lower unit (counter rotation model)
Removing the lower unit
1. Drain the gear oil. For draining procedures, see Chapter 3, “Changing the
gear oil.”
2. Set the gear shift to the neutral position,
and place a block of wood between the
anti-cavitation plate and propeller to keep
the propeller from turning, and then
remove the propeller nut and propeller.
È X-transom model
WARNING
• Do not hold the propeller with your
hands when loosening or tightening it.
• Be sure to disconnect the battery leads
from the battery and the engine stop lanyard from the engine stop lanyard
switch.
• Put a block of wood between the anticavitation plate and propeller to keep
the propeller from turning.
NOTE:
Check that there is no oil on the spline and
check it for wear.
Removing the water pump and shift
rod
1. Remove the water pump assembly and
shift rod assembly 1.
3. Mark the trim tab 1 at the area shown,
and then remove it.
4. Loosen the bolts, and then remove the
lower unit from the upper case.
63P3F11
6-36
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
Checking the water pump and shift
rod
1. Check the water pump housing for deformation. Replace if necessary.
S69J6360
S69J6030
2. Check the impeller 1 and insert cartridge 2 for cracks or wear. Replace if
necessary.
1
2
S63P6050
3. Check the Woodruff key 3 and the keyway a in the drive shaft for wear.
Replace if necessary.
a
3
S69J6040
4. Check the shift rod for cracks or wear.
Replace if necessary.
6-37
63P3F11
Lower unit (counter rotation model) / Propeller shaft housing (counter rotation model)
Propeller shaft housing (counter rotation model)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Shift rod joint
Ball
Shift slider
Ball
Ball
Spring
Dog clutch
Cross pin
Spring
Forward gear shim
Forward gear
Thrust washer
Taper roller bearing assembly
Propeller shaft
Thrust bearing
Propeller shaft shim
O-ring
63P3F11
Q’ty
1
2
1
2
2
1
1
1
1
—
1
1
1
1
1
—
1
6
1
2
3
4
5
6
7
8
9
Remarks
Not reusable
Not reusable
6-38
LOWR
Lower unit
6
No.
18
19
20
21
22
23
24
25
26
6-39
Part name
Propeller shaft housing
Straight key
Needle bearing
Oil seal
Claw washer
Ring nut
Cooling water inlet cover
Nut
Screw
Q’ty
1
1
1
2
1
1
2
1
1
Remarks
Not reusable
63P3F11
Propeller shaft housing (counter rotation model)
Removing the propeller shaft
housing assembly
1. Straighten the claw washer tabs a, and
then remove the ring nut and claw
washer.
1
2
3
S63P6500
Disassembling the forward gear
Ring nut wrench 4 1: 90890-06512
Ring nut wrench extension 2:
90890-06513
2. Pull out the propeller shaft housing
assembly.
1. Remove the bearing outer race, taper
roller bearing, and thrust washer from the
forward gear.
1
S63P6510
Bearing separator 1: 90890-06534
Bearing housing puller claw L 3:
90890-06502
Stopper guide plate 4: 90890-06501
Center bolt 5: 90890-06504
Disassembling the propeller shaft
assembly
1. Remove the spring 1, then the cross pin
2, dog clutch 3, shift slider, balls,
spring, and shift rod joint.
2. Remove the forward gear assembly.
63P3F11
6-40
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
Disassembling the propeller shaft
housing
3. Check the bearings for pitting or rumbling. Replace if necessary.
1. Remove the oil seals and needle bearing.
S69J6410
Checking the propeller shaft
Needle bearing attachment 1:
90890-06653
Driver rod L3 2: 90890-06652
1. Check the propeller shaft for bends or
wear. Replace if necessary.
Checking the propeller shaft housing
1. Clean the propeller shaft housing using a
soft brush and cleaning solvent, and then
check it for cracks or damage. Replace if
necessary.
S69J6415
2. Check the dog clutch, shift rod joint, and
shift slider for cracks or wear. Replace if
necessary.
2. Check the teeth and dogs of the forward
gear for cracks or wear. Replace the
gear if necessary.
Assembling the propeller shaft
housing
1. Install the needle bearing into the propeller shaft housing to the specified depth.
S62Y6640
6-41
63P3F11
Propeller shaft housing (counter rotation model)
Depth d:
4.75–5.25 mm (0.187–0.207 in)
3. Install the original shim(s) 5 and thrust
bearing 6 with the propeller shaft into
the propeller shaft housing.
5
6
NOTE:
• Install the needle bearing with the manufacture identification mark a facing toward the
oil seal (propeller side).
• When using the driver rod, do not strike the
special service tool in a manner that will
force the stopper c out of place.
S63P6540
CAUTION:
Driver rod SS 1: 90890-06604
Needle bearing attachment 2:
90890-06610
Bearing depth plate 3: 90890-06603
Depth b:
24.75–25.25 mm (0.974–0.994 in)
Add or remove shim(s), if necessary, if
replacing the propeller shaft, thrust bearing, or propeller shaft housing.
4. Install a new taper roller bearing 7 and
the bearing outer race 8 into the propeller shaft housing using a press.
2. Apply grease to new oil seals, and then
install them into the propeller shaft housing to the specified depth.
NOTE:
Install an oil seal halfway into the propeller
shaft housing, then the other oil seal.
Ring nut wrench 9: 90890-06578
Bearing inner race attachment 4:
90890-06640
63P3F11
6-42
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
5. Install the thrust washer 0, forward gear
A, and dog clutch B using a press.
NOTE:
Install the dog clutch B with the “F” mark e
facing toward the forward gear.
Ring nut wrench 9: 90890-06578
6. Install the spring C, balls, and shift slider
D into the propeller shaft, and then
install the cross pin E and spring F.
D
F
C
E
S63P6570
6-43
63P3F11
Propeller shaft housing (counter rotation model) / Drive shaft and lower case (counter rotation model)
Drive shaft and lower case (counter rotation model)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Drive shaft
Sleeve
Cover
Oil seal
Bolt
Drive shaft housing
Needle bearing
O-ring
Pinion shim
Thrust bearing
Lower case
Needle bearing
Pinion
Nut
Reverse gear shim
Roller bearing
Thrust bearing
63P3F11
Q’ty
1
1
1
2
4
1
1
1
—
1
1
1
1
1
—
1
1
6
1
2
3
4
5
6
7
8
9
Remarks
Not reusable
M8 × 25 mm
Not reusable
6-44
LOWR
Lower unit
6
No.
18
19
6-45
Part name
Needle bearing
Reverse gear
Q’ty
2
1
Remarks
Not reusable
63P3F11
Drive shaft and lower case (counter rotation model)
Removing the drive shaft
1. Remove the drive shaft assembly and
pinion, and then pull out the reverse gear
and thrust bearing.
1
1
S67H6270R
2
Bearing separator 1: 90890-06534
S68S6360J
Drive shaft holder 6 1: 90890-06520
Pinion nut holder 2:
New: 90890-06715
Current: 90890-06505
2. Remove the needle bearings from the
reverse gear using a chisel.
Disassembling the drive shaft
housing
1. Remove the cover, oil seals, and needle
bearing.
S68S6160
Disassembling the lower case
1. Remove the roller bearing and shim(s).
Needle bearing attachment 1:
90890-06610
Driver rod L3 2: 90890-06652
Disassembling the reverse gear
1. Remove the roller bearing inner race
from the reverse gear using a press.
63P3F11
Bearing outer race puller
assembly 1:
90890-06523
Outer race puller claw B 2:
90890-06533
6-46
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
2. Remove the needle bearing from the
lower case.
S69J6210
Checking the lower case
Ball bearing attachment 3:
90890-06636
Driver rod LL 4: 90890-06605
1. Check the skeg and torpedo for cracks or
damage. Replace the lower case if necessary.
Checking the pinion and reverse
gear
1. Check the teeth of the pinion, and the
teeth and dogs of the reverse gear for
cracks or wear. Replace if necessary.
Assembling the lower case
1. Install the original shim(s) and roller
bearing into the lower case.
S69J6200
Checking the bearings
1. Check the bearings for pitting or rumbling. Replace if necessary.
CAUTION:
Add or remove shim(s), if necessary, if
replacing the reverse gear roller bearing
or lower case.
Checking the drive shaft
1. Check the drive shaft for bends or wear.
Replace if necessary.
6-47
Ball bearing attachment 1:
90890-06629
Driver rod LL 2: 90890-06605
63P3F11
Drive shaft and lower case (counter rotation model)
2. Install the needle bearing outer case into
the lower case.
Depth a:
20.95–21.45 mm (0.825–0.844 in)
Depth b:
4.45–4.95 mm (0.175–0.195 in)
2. Install the roller bearing inner race into
the reverse gear using a press.
NOTE:
Apply gear oil to the needle bearing outer
case before installation.
Ball bearing attachment 3:
90890-06633
Bearing outer race puller
assembly 4:
90890-06523
3. Install the needle bearing into the needle
bearing outer case.
Bearing inner race attachment 4:
90890-06660
Assembling the drive shaft housing
1. Install the needle bearing into the drive
shaft housing to the specified depth.
NOTE:
Apply gear oil or grease to the needle bearing before installation.
Assembling the reverse gear
1. Install new needle bearings into the
reverse gear to the specified depth.
Needle bearing attachment 1:
90890-06610
Driver rod SS 2: 90890-06604
Bearing depth plate 3: 90890-06603
Depth a:
5.75–6.25 mm (0.226–0.246 in)
Needle bearing attachment 1:
90890-06612
Driver rod SS 2: 90890-06604
Bearing depth plate 3: 90890-06603
63P3F11
6-48
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
2. Apply grease to new oil seals, and then
install them into the drive shaft housing
to the specified depth.
3. Install the sleeve, drive shaft, and drive
shaft housing into the lower case, then
the pinion and pinion nut, and then
tighten the nut to the specified torque.
5
6
S63P6310
NOTE:
Install an oil seal halfway into the drive shaft
housing, then the other oil seal.
Ball bearing attachment 4:
90890-06633
Driver rod LS 5: 90890-06606
NOTE:
Install the drive shaft by lifting it up slightly,
then aligning it with the pinion and the spline
of the drive shaft.
Drive shaft holder 6 5: 90890-06520
Pinion nut holder 6:
New: 90890-06715
Current: 90890-06505
Depth b:
0.25–0.75 mm (0.01–0.03 in)
Installing the drive shaft
T.
2. Install the drive shaft housing 1, thrust
bearing 2, and original shim(s) 3 onto
the drive shaft 4.
R.
1. Install the reverse gear into the lower
case.
Pinion nut:
93 N·m (9.3 kgf·m, 68.6 ft·lb)
Installing the propeller shaft housing
1. Install the original shim(s) 1 and propeller shaft housing assembly 2 into the
lower case, and then install the straight
key 3, claw washer 4, and ring nut 5.
CAUTION:
Add or remove shim(s), if necessary, if
replacing the drive shaft housing or drive
shaft.
6-49
63P3F11
Drive shaft and lower case (counter rotation model)
CAUTION:
Add or remove shim(s), if necessary, if
replacing the forward gear, taper roller
bearing, propeller shaft housing, thrust
washer, or lower case.
2. Tighten the ring nut to the specified
torque.
NOTE:
• To secure the ring nut, bend one tab a of
the claw washer into a slot in the ring nut.
• Bend all other tabs toward the propeller
shaft housing assembly.
2. Install a new gasket 2, the outer plate
cartridge 3, and dowels 4.
Ring nut wrench 4 6: 90890-06512
Ring nut wrench extension 7:
90890-06513
T.
R.
Ring nut 5:
142 N·m (14.2 kgf·m, 104.7 ft·lb)
Installing the water pump and shift
rod
1. Install the shift rod assembly 1.
63P3F11
6-50
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
3. Install the Woodruff key into the drive
shaft.
4. Align the groove in the impeller 5 with
the Woodruff key 6, and then install the
impeller onto the drive shaft.
NOTE:
Align the insert cartridge projections b with
the holes c in the pump housing.
7. Install the new O-ring D and pump housing assembly E into the lower case,
tighten the bolts F, and then install the
seal G and cover H.
5. Install the washers 7, wave washer 8,
spacer 9, and collar 0 onto the drive
shaft.
NOTE:
• The collar and spacer should fit together
firmly.
• While pulling the drive shaft up, install the
collar with an appropriate tool a that fits
over the drive shaft as shown.
NOTE:
• When installing the pump housing, apply
grease to the inside of the housing, and
then turn the drive shaft clockwise while
pushing down the pump housing.
• Align the cover projection d with the hole
e in the pump housing.
6. Install the new O-ring A and insert cartridge B into the pump housing C.
C
A
c b
A
B
b
c
S63P6360
6-51
63P3F11
Drive shaft and lower case (counter rotation model)
Installing the lower unit
1. Set the gear shift to the neutral position
at the lower unit.
1
2
3
4
5
6
7
8
9
2. Align the center of the set pin a with the
mark b on the bottom cowling.
b
a
S63P3270
È X-transom model
T.
R.
Lower case mounting bolt 2:
47 N·m (4.7 kgf·m, 34.7 ft·lb)
Trim tab bolt 4:
42 N·m (4.2 kgf·m, 31.0 ft·lb)
Shift rod push arm: 90890-06052
3. Install the two dowels 1 into the lower
unit.
4. Install the lower unit into the upper case,
and then tighten the lower case mounting
bolts 2 to the specified torque.
5. Install the trim tab 3 to its original position, and then tighten the bolt 4 to the
specified torque.
63P3F11
6-52
LOWR
Lower unit
T.
R.
6. Install the propeller and propeller nut,
and then tighten the nut finger tight.
Place a block of wood between the anticavitation plate and propeller to keep the
propeller from turning, and then tighten
the nut to the specified torque.
Propeller nut 5:
52 N·m (5.2 kgf·m, 38.4 ft·lb)
WARNING
• Do not hold the propeller with your
hands when loosening or tightening it.
• Be sure to disconnect the battery leads
from the battery and the engine stop lanyard from the engine stop lanyard
switch.
• Put a block of wood between the anticavitation plate and propeller to keep
the propeller from turning.
NOTE:
If the grooves in the propeller nut 5 do not
align with the cotter pin hole, tighten the nut
until they are aligned.
6-53
63P3F11
Drive shaft and lower case (counter rotation model) / Shimming (counter rotation model)
Shimming (counter rotation model)
6
F
P
1
2
3
4
5
6
7
8
9
R
B4
T3
A3
B3
61.0
T1
T2
T4
B1 36.5
B2
A1
16.7
A2
A4
A5
B5
B6
63P3F11
B7
S63P6740
6-54
LOWR
Lower unit
Shimming
T.
R.
NOTE:
• Shimming is not required when assembling
the original lower case and inner parts.
• Shimming is required when assembling the
original inner parts and a new lower case.
• Shimming is required when replacing the
inner part(s).
Pinion nut:
93 N·m (9.3 kgf·m, 68.6 ft·lb)
3. Measure the distance (M4) between the
special service tool and the pinion as
shown.
Selecting the pinion shims
1. Install the special service tools onto the
drive shaft 1.
Digital caliper 4: 90890-06704
4. Turn the thrust bearing 5 two or three
times to seat the drive shaft housing 6,
and then measure the housing height
(M3) as shown.
NOTE:
• Select the shim thickness (T3) by using the
specified measurement(s) and the calculation formula.
• Install the special service tool onto the drive
shaft so that the shaft is at the center of the
hole.
• Tighten the wing nuts another 1/4 of a turn
after they contact the fixing plate 2.
NOTE:
Measure the thrust bearing at three points to
find the height average.
5. Calculate the pinion shim thickness (T3)
as shown in the examples below.
Pinion height gauge 3:
90890-06710
2. Install the pinion and pinion nut, and then
tighten the nut to the specified torque.
6-55
63P3F11
Shimming (counter rotation model)
Selecting the reverse gear shims
1. Turn the thrust bearing 1 two or three
times to seat the roller bearing 2, and
then measure the bearing height (M1) as
shown.
NOTE:
“P” is the deviation of the lower case dimension from standard. The “P” mark a is
stamped on the trim tab mounting surface of
the lower case in 0.01 mm units. If the “P”
mark is unreadable, assume that “P” is zero
and check the backlash when the unit is
assembled.
T1
S63P6760
Calculation formula:
Pinion shim thickness (T3) =
80.00 + P/100 – M3 – M4
Example:
If “M3” is 46.68 mm and “M4” is 32.49 mm
and “P” is (–5), then
T3 = 80.00 + (–5)/100 – 46.68 – 32.49 mm
= 80.00 – 0.05 – 46.68 – 32.49 mm
= 0.78 mm
6. Select the pinion shim(s) (T3) as follows.
Calculated numeral
at 1/100 place
Rounded numeral
1, 2
0
3, 4, 5
2
6, 7, 8
5
9, 10
8
NOTE:
• Select the shim thickness (T1) by using the
specified measurement(s) and the calculation formula.
• Measure the roller bearing at three points to
find the height average.
Digital caliper 3: 90890-06704
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
Example:
If “T3” is 0.53 mm, then the pinion shim is
0.52 mm.
If “T3” is 0.78 mm, then the pinion shim is
0.75 mm.
63P3F11
6-56
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
2. Calculate the reverse gear shim thickness (T1) as shown in the examples
below.
Example:
If “T1” is 0.90 mm, then the reverse gear
shim is 0.88 mm.
If “T1” is 1.15 mm, then the reverse gear
shim is 1.12 mm.
Selecting the forward gear shims
1. Install the thrust washer 1 and taper
roller bearing 2 onto the forward gear.
NOTE:
“F” is the deviation of the lower case dimension from standard. The “F” mark a is
stamped on the trim tab mounting surface of
the lower case in 0.01 mm units. If the “F”
mark is unreadable, assume that “F” is zero
and check the backlash when the unit is
assembled.
2. Measure the gear height (M2) from the
thrust washer on the taper roller bearing.
Calculation formula:
Reverse gear shim thickness (T1) =
29.10 + F/100 – M1
Example:
If “M1” is 28.25 mm and “F” is (+5), then
T1 = 29.10 + (+5)/100 – 28.25 mm
= 29.10 + 0.05 – 28.25 mm
= 0.90 mm
T2
S63P6790
3. Select the reverse gear shim(s) (T1) as
follows.
Calculated numeral
at 1/100 place
Rounded numeral
1, 2
0
3, 4, 5
2
6, 7, 8
5
9, 10
8
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
6-57
NOTE:
• Select the shim thickness (T2) by using the
specified measurement(s) and the calculation formula.
• Measure the forward gear at three points to
find the height average.
63P3F11
Shimming (counter rotation model)
Shimming plate 3: 90890-06701
Digital caliper 4: 90890-06704
3. Calculate the forward gear shim thickness (T2) as shown in the examples
below.
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
Example:
If “T2” is 0.33 mm, then the forward gear
shim is 0.35 mm.
If “T2” is 0.79 mm, then the forward gear
shim is 0.80 mm.
Selecting the propeller shaft shims
1. Turn the taper roller bearing outer race
1 two or three times to seat the rollers,
and then measure the bearing height
(M6) as shown.
NOTE:
“R” is the deviation of the lower case dimension from standard. The “R” mark a is
stamped on the trim tab mounting surface of
the lower case in 0.01 mm units. If the “R”
mark is unreadable, assume that “R” is zero
and check the backlash when the unit is
assembled.
T´4
S63P6820
Calculation formula:
Forward gear shim thickness (T2) =
M2 – 29.50 – R/100
Example:
If “M2” is 29.84 mm and “R” is (+1), then
T2 = 29.84 – 29.50 – (+1)/100 mm
= 29.84 – 29.50 – 0.01 mm
= 0.33 mm
4. Select the forward gear shim(s) (T2) as
follows.
Calculated numeral
at 1/100 place
Rounded numeral
1, 2
2
3, 4, 5
5
6, 7, 8
8
9, 10
10
63P3F11
NOTE:
• Select the shim thickness (T’4) by using the
specified measurement(s) and the calculation formula.
• Measure the taper roller bearing at three
points to find the height average.
Shimming plate 2: 90890-06701
Digital caliper 3: 90890-06704
6-58
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
2. Install the thrust bearing 4 onto the propeller shaft 5, and then measure the
propeller shaft flange and thrust bearing
thickness (M7) as shown.
3. Calculate the propeller shaft shim thickness (T4) as shown in the examples
below.
4. Round the numerals for the propeller
shaft shim(s) (T4) as follows.
Calculated numeral
at 1/100 place
Rounded numeral
1, 2
0
3, 4, 5
2
6, 7, 8
5
9, 10
8
Example:
If “T4” is 0.94 mm, then the propeller shaft
shim is 0.92 mm.
If “T4” is 1.00 mm, then the propeller shaft
shim is 0.98 mm.
5. Calculate and select the propeller shaft
shim thickness (T’4) as shown in the
examples below.
Calculation formula 2:
Propeller shaft shim thickness (T’4) =
T4 – 0.30
a
b
S69J6626
NOTE:
“A” and “B” are the deviation of the propeller
shaft housing dimension from standard. The
“A” mark a and “B” mark b are stamped on
the propeller shaft housing in 0.01 mm units.
If the “A” mark or “B” mark is unreadable,
assume that “A” and “B” are zero and check
the free play when the unit is assembled.
Calculation formula 1:
Propeller shaft shim thickness (T4) =
29.30 – A/100 + B/100 – M6 – M7
Example:
If “T4” is 0.92 mm, then
T’4 = 0.92 – 0.30 mm
= 0.62 mm
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
6. If the “A” mark or “B” mark is unreadable,
measure the propeller shaft free play as
shown.
7. Install the shim(s) 6, thrust bearing 4,
propeller shaft 5, and taper roller bearing 7 into the propeller shaft housing.
Example:
If “M6” is 15.70 mm and “M7” is 12.55 mm
and “A” is (+6) and “B” is (–5), then
T4 = 29.30 – (+6)/100 + (–5)/100 – 15.70 – 12.55 mm
= 29.30 – 0.06 – 0.05 – 15.70 – 12.55 mm
= 0.94 mm
6-59
63P3F11
Shimming (counter rotation model) / Backlash (counter rotation model)
8. Measure the propeller shaft free play.
Repeat steps 1–7 if out of specification.
NOTE:
Tighten the center bolt while turning the drive
shaft until the drive shaft can no longer be
turned.
Propeller shaft free play:
0.25–0.35 mm (0.0098–0.0138 in)
Bearing housing puller claw L 1:
90890-06502
Stopper guide plate 2: 90890-06501
Center bolt 3: 90890-06504
Magnet base B 8: 90890-06844
Dial gauge set 9: 90890-01252
Backlash
(counter rotation model)
6
Measuring the forward and reverse
gear backlash
1. Remove the water pump assembly.
4. Install the backlash indicator onto the
drive shaft (22.4 mm [0.88 in] in diameter), then the dial gauge onto the lower
unit.
2. Set the gear shift to the neutral position
at the lower unit.
Shift rod push arm: 90890-06052
3. Install the special service tools so that it
pushes against the propeller shaft.
63P3F11
6-60
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
5. Set the lower unit upside down.
8. Remove the special service tools from
the propeller shaft.
9. Install the propeller 8, the spacer 9
(without the washer 0), then the washer
A as shown.
NOTE:
Install the dial gauge so that the plunger a
contacts the mark b on the backlash indicator.
Backlash indicator 4: 90890-06706
Magnet base plate 5: 90890-07003
Dial gauge set 6: 90890-01252
Magnet base B 7: 90890-06844
6. Slowly turn the drive shaft clockwise and
counterclockwise and measure the backlash when the drive shaft stops in each
direction.
NOTE:
Tighten the propeller nut B while turning the
propeller until the propeller can no longer be
turned.
10. Turn the shift rod to the reverse position
c with the shift rod push arm.
11. Turn the drive shaft clockwise until the
dog clutch C is fully engaged.
Forward gear backlash:
0.14–0.42 mm (0.0055–0.0165 in)
7. Add or remove shim(s) if out of specification.
Forward gear
backlash
Shim thickness
Less than
0.14 mm (0.0055 in)
To be increased by
(0.28 – M) × 0.67
More than
0.42 mm (0.0165 in)
To be decreased by
(M – 0.28) × 0.67
12. Turn the shift rod to the neutral position
d with the shift rod push arm.
13. Turn the drive shaft counterclockwise
approximately 30°.
M: Measurement
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
6-61
63P3F11
Backlash (counter rotation model)
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and
0.50 mm
17. Remove the special service tools, and
then install the water pump assembly.
14. Turn the shift rod to the reverse position
c with the shift rod push arm.
15. Slowly turn the drive shaft clockwise and
counterclockwise and measure the backlash when the drive shaft stops in each
direction.
NOTE:
When measuring the reverse gear backlash,
turn the shift rod push arm towards the
reverse position c with force.
Reverse gear backlash:
0.23–0.58 mm (0.0090–0.0228 in)
16. Add or remove shim(s) if out of specification.
Reverse gear
backlash
Shim thickness
Less than
0.23 mm (0.0090 in)
To be decreased by
(0.41 – M) × 0.67
More than
0.58 mm (0.0228 in)
To be increased by
(M – 0.41) × 0.67
M: Measurement
63P3F11
6-62
1
2
3
4
5
6
7
8
9
LOWR
Lower unit
— MEMO —
6-63
63P3F11
BRKT
Bracket unit
Special service tools .....................................................................................7-1
Bottom cowling .............................................................................................. 7-2
Upper case, steering arm, swivel bracket and clamp brackets ................. 7-6
Draining the engine oil............................................................................. 7-12
Disassembling the oil pan........................................................................7-12
Checking the oil strainer ..........................................................................7-12
Assembling the oil pan ............................................................................7-12
Removing the steering arm ..................................................................... 7-14
Installing the steering arm ....................................................................... 7-14
Installing the upper case..........................................................................7-15
Clamp brackets ............................................................................................ 7-16
Removing the clamp brackets .................................................................7-18
Installing the clamp brackets ................................................................... 7-18
Adjusting the trim sensor cam .................................................................7-18
Power trim and tilt unit ................................................................................ 7-20
Removing the power trim and tilt unit ......................................................7-27
Checking the hydraulic pressure ............................................................. 7-28
Disassembling the power trim and tilt motor............................................7-30
Checking the power trim and tilt motor ....................................................7-31
Assembling the power trim and tilt motor ................................................ 7-33
Removing the reservoir ...........................................................................7-33
Disassembling the gear pump housing ...................................................7-34
Checking the gear pump .........................................................................7-35
Assembling the gear pump housing ........................................................ 7-35
Disassembling the tilt cylinder and trim cylinder...................................... 7-37
Checking the tilt cylinder and trim cylinder .............................................. 7-38
Assembling the tilt piston and trim pistons .............................................. 7-39
Assembling the power trim and tilt unit....................................................7-40
Bleeding the power trim and tilt unit ........................................................ 7-43
Installing the power trim and tilt unit ........................................................ 7-44
Bleeding the power trim and tilt unit (built-in) ..........................................7-45
Power trim and tilt electrical system.......................................................... 7-46
Checking the fuse....................................................................................7-47
Checking the power trim and tilt relay .....................................................7-47
Checking the power trim and tilt switch ...................................................7-47
Checking the trim sensor.........................................................................7-48
63P3F11
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
Special service tools
7
Up relief fitting
90890-06773
Down relief fitting
90890-06774
Hydraulic pressure gauge
90890-06776
Trim and tilt wrench
New: 90890-06587
Current: 90890-06548
7-1
63P3F11
Special service tools / Bottom cowling
Bottom cowling
7
11
12
A
13
10
3
7
4
5
6
A
16
14
A
7
34
9
2
17
A
33
15
20
18
24 19
1
8
A
21
22
28
23
25
26
27
32
A
T.
R.
T.
R.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
3 N · m (0.3 kgf · m, 2.2 ft · Ib)
31
18 N · m (1.8 kgf · m, 13.3 ft · Ib)
Part name
Bracket
Shift cut switch
Bracket
Neutral switch
Screw
Plate
Bushing
Grease nipple
Bolt
Bolt
Screw
Plate
Bushing
Washer
Shift lever
Bushing
Shift rod
63P3F11
29 30
Q’ty
1
1
1
1
2
1
2
1
1
2
2
1
1
1
1
1
1
S63P7080
Remarks
ø4 × 16 mm
M6 × 50 mm
ø4 × 16 mm
7-2
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
7
11
12
A
13
10
3
7
4
5
6
A
16
14
A
7
34
9
2
17
A
33
15
20
18
24 19
1
8
A
21
22
28
23
25
26
27
32
A
T.
R.
T.
R.
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
7-3
3 N · m (0.3 kgf · m, 2.2 ft · Ib)
31
18 N · m (1.8 kgf · m, 13.3 ft · Ib)
Part name
Spacer
Bushing
Bolt
Bracket
Ball
Bolt
Grease nipple
Spacer
Circlip
Grommet
Screw
Adapter
Hose joint
Flushing hose
Grommet
Trim sensor coupler
PTT motor lead
29 30
Q’ty
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
S63P7080
Remarks
M6 × 35 mm
ø6 × 20 mm
63P3F11
Bottom cowling
7
34
31
30
22
29
23 20
24
19
26
25
27 28
21
A
15 14 13
18
32
A
11
4
5
LT
572
12 9
17
9
16
33
10
6 1
3
7
8
2
S63P7070
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Bottom cowling
Rubber seal
Grommet
Bolt
Grommet
Grommet
Collar
Cowling lock lever
Bushing
Plate
Bolt
Wave washer
Lever
Washer
Bolt
Stay
Bolt
63P3F11
Q’ty
1
1
2
4
4
4
4
2
4
2
4
2
2
2
2
2
2
Remarks
M8 × 35 mm
M6 × 30 mm
M6 × 20 mm
M6 × 20 mm
7-4
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
7
34
31
30
22
29
23 20
24
19
26
25
27 28
21
A
15 14 13
18
32
A
11
4
5
LT
572
12 9
17
9
16
33
10
6 1
3
7
8
2
S63P7070
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
7-5
Part name
Grommet
Holder
Bolt
Retaining plate
Bolt
Cable holder
Bolt
Cable holder
Bolt
Cable holder
Bolt
Bracket
Bolt
Power trim and tilt switch
Water outlet
Cover
Rubber trim
Q’ty
1
1
1
1
2
1
2
1
1
1
1
2
4
1
1
1
1
Remarks
M6 × 20 mm
M6 × 30 mm
M6 × 20 mm
M6 × 20 mm
M6 × 20 mm
M6 × 20 mm
63P3F11
Bottom cowling / Upper case, steering arm, swivel bracket and clamp brackets
Upper case, steering arm, swivel bracket and clamp brackets
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Upper case assembly
Cover
Ground lead
Bolt
Bolt
Adapter
Plastic tie
Hose
Circlip
Nut
Nut
Washer
Steering yoke
Washer
Bushing
O-ring
Bushing
63P3F11
Q’ty
1
2
1
1
1
1
1
1
1
2
2
4
1
2
1
2
2
7
1
2
3
4
5
6
7
8
9
Remarks
M6 × 10 mm
M6 × 17 mm
Not reusable
Not reusable
7-6
BRKT
Bracket unit
7
No.
18
19
20
21
22
23
7-7
Part name
Steering arm
Washer
Washer
Trim stopper
Nut
Bolt
Q’ty
1
2
2
2
2
4
Remarks
63P3F11
Upper case, steering arm, swivel bracket and clamp brackets
7
T.
R.
54 N · m (5.4 kgf · m, 39.8 ft · Ib)
16
LT
572
30
T.
R.
4 N · m (0.4 kgf · m, 3.0 ft · Ib)
T.
R.
20 N · m (2.0 kgf · m, 14.8 ft · Ib)
22
17
2120
19 18
5
T.
R.
6
A
23
LT
27 N · m (2.7 kgf · m, 20.0 ft · Ib)
T.
R.
42 N · m (4.2 kgf · m, 31.0 ft · Ib)
271
24
3
LT
LT
572
572
2
1
25
9
10
12
13
7
15
11
28
29
27
4
26
14
A
8
S63P7100
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Upper case
Dowel
Grommet
Damper
Screw
Baffle plate
Drive shaft bushing
Circlip
Cap
Bolt
Washer
Washer
Washer
Lower mount
Washer
Bolt
Bolt
63P3F11
Q’ty
1
2
1
1
2
1
1
1
2
2
2
2
2
2
2
3
2
Remarks
ø5 × 15 mm
M14 × 225 mm
M10 × 45 mm
M14 × 205 mm
7-8
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
7
T.
R.
54 N · m (5.4 kgf · m, 39.8 ft · Ib)
16
LT
572
30
T.
R.
4 N · m (0.4 kgf · m, 3.0 ft · Ib)
T.
R.
20 N · m (2.0 kgf · m, 14.8 ft · Ib)
22
17
2120
19 18
5
T.
R.
6
A
23
LT
27 N · m (2.7 kgf · m, 20.0 ft · Ib)
T.
R.
42 N · m (4.2 kgf · m, 31.0 ft · Ib)
271
24
3
LT
LT
572
572
2
1
25
9
10
12
13
7
15
11
28
29
27
4
26
14
A
8
S63P7100
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
7-9
Part name
Washer
Washer
Upper mount
Washer
Collar
Bolt
Bolt
Muffler assembly
Gasket
Rubber seal
Washer
Drain bolt
Bracket
Q’ty
2
2
2
2
2
2
4
1
1
1
1
1
1
Remarks
M8 × 30 mm
M10 × 45 mm
Not reusable
M14 × 12 mm
63P3F11
Upper case, steering arm, swivel bracket and clamp brackets
7
20
11
LT
10
572
9
T.
R.
20 N · m (2.0 kgf · m, 14.8 ft · Ib)
8
19
A
T.
R.
10 N · m (1.0 kgf · m, 7.4 ft · Ib)
18
7
6
16
15
17
14
4
12
13
3
5
LT
A
572
2
T.
R.
20 N · m (2.0 kgf · m, 14.8 ft · Ib)
T.
R.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Bolt
Muffler
Dowel
Pipe
Rubber seal
Gasket
Plate
Gasket
Bolt
Exhaust manifold
Gasket
Bolt
Oil pan
Dowel
Bolt
Collar
Oil strainer
63P3F11
Q’ty
8
1
2
1
1
2
1
1
4
1
1
10
1
2
3
3
1
20 N · m (2.0 kgf · m, 14.8 ft · Ib)
LT
1
572
S63P7110
Remarks
M8 × 35 mm
Not reusable
Not reusable
M8 × 60 mm
Not reusable
M8 × 35 mm
M6 × 25 mm
7-10
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
7
20
11
LT
10
572
9
T.
R.
20 N · m (2.0 kgf · m, 14.8 ft · Ib)
8
19
A
T.
R.
10 N · m (1.0 kgf · m, 7.4 ft · Ib)
18
7
6
16
15
17
14
4
12
13
3
5
LT
A
572
2
T.
R.
20 N · m (2.0 kgf · m, 14.8 ft · Ib)
T.
R.
No.
18
19
20
7-11
Part name
Gasket
Gasket
Exhaust guide
Q’ty
1
1
1
20 N · m (2.0 kgf · m, 14.8 ft · Ib)
LT
1
572
S63P7110
Remarks
Not reusable
Not reusable
63P3F11
Upper case, steering arm, swivel bracket and clamp brackets
Draining the engine oil
1. Place a drain pan under the drain hole,
and then remove the drain bolt 1 and let
the oil drain completely.
5
6
2. Remove the upper and lower mounting
nut, and then remove the upper case.
4
S63P7160
3. Remove the muffler assembly from the
upper case.
Checking the oil strainer
Disassembling the oil pan
1. Check the oil strainer for dirt and residue.
Clean if necessary.
1. Remove the muffler 1, plate 2, and
exhaust manifold 3 from the oil pan 4.
Assembling the oil pan
1. Install the new gasket 1 onto the
exhaust guide 2.
2
4
1
2
3
S63P7170
2. Install the oil strainer 3 and bolts, and
then tighten the bolts to the specified
torque.
1
S63P7150
3
2. Remove the oil pan 4 from the exhaust
guide 5.
3. Remove the oil strainer 6 from the
exhaust guide 5.
S63P7180
63P3F11
7-12
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
T.
R.
Oil strainer bolt:
10 N·m (1.0 kgf·m, 7.4 ft·lb)
3. Install the oil pan 4, and then tighten the
bolts finger tight.
8
0
4. Install the exhaust manifold 5 and bolts,
and then tighten the bolts finger tight.
5. Tighten the exhaust manifold bolts 6,
then the oil pan bolts 7, and then tighten
them to the specified torques.
LT
572
9
A
A
4
7
S63P7200
6
5
T.
R.
LT
LT
572
572
Muffler bolt:
20 N·m (2.0 kgf·m, 14.8 ft·lb)
9. Install the muffler assembly A by inserting the tip of the cooling water pipe B
into the joint hole a of the upper case.
10. Install muffler assembly bolts C and D,
and then tighten them to the specified
torques.
S63P7190
C
D
LT
T.
R.
Exhaust manifold bolt 6:
20 N·m (2.0 kgf·m, 14.8 ft·lb)
Oil pan bolt 7:
20 N·m (2.0 kgf·m, 14.8 ft·lb)
572
LT
572
LT
271
A
A
6. Install the plate 8.
B
7. Install the cooling water pipe 9 into the
muffler 0.
A
8. Install the muffler 0 and bolts into the oil
pan, and then tighten the bolts to the
specified torque.
B
a
7-13
S63P7210
63P3F11
Upper case, steering arm, swivel bracket and clamp brackets
T.
R.
Muffler assembly bolt C:
20 N·m (2.0 kgf·m, 14.8 ft·lb)
Muffler assembly bolt D:
42 N·m (4.2 kgf·m, 31.0 ft·lb)
11. Install the upper mounts E and bolts into
the upper case.
12. Install the bracket F and bolts, and then
tighten the bolts to the specified torque.
T.
R.
Upper mount bracket bolt:
54 N·m (5.4 kgf·m, 39.8 ft·lb)
3. Remove the steering arm from the swivel
bracket by pulling the arm off the bracket.
Installing the steering arm
1. Install the washer 1 and bushing 2 onto
the steering arm 3.
2. Place the swivel bracket 4 in an upright
position, and then install the steering arm
onto the swivel bracket.
3. Install the bushing 5, new O-ring 6,
bushing 7, and washer 8 onto the
swivel bracket.
Removing the steering arm
1. Remove the circlip 1.
2. Remove the steering yoke 2 by striking
it with a plastic hammer.
63P3F11
7-14
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
4. Install the steering yoke 9 to the steering arm 3 by aligning the center a of
the yoke with the center b of the steering arm.
Installing the upper case
5. Install the circlip 0.
2. Install the upper mounting nut 2 and
lower mounting nut 3, and then tighten
them to the specified torques.
1. Install the upper and lower mounting
bolts into the swivel bracket 1 simultaneously.
3. Install the covers 4.
6. Inject grease into the grease nipple until
grease comes out from both the upper
and lower bushings c.
T.
R.
7-15
Upper mounting nut 2:
74 N·m (7.4 kgf·m, 54.6 ft·lb)
Lower mounting nut 3:
74 N·m (7.4 kgf·m, 54.6 ft·lb)
63P3F11
Upper case, steering arm, swivel bracket and clamp brackets / Clamp brackets
Clamp brackets
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Swivel bracket
Clamp bracket
Clamp bracket
Self-locking nut
Grease nipple
Ground lead
Washer
Bolt
Washer
Bushing
Trim sensor
Screw
Trim sensor cam
Screw
Clamp
Bolt
Bracket
63P3F11
7
Q’ty
1
1
1
1
6
3
1
1
2
6
1
2
1
1
1
4
2
1
2
3
4
5
6
7
8
9
Remarks
M6 × 11 mm
ø6 × 15 mm
ø6 × 25 mm
M6 × 30 mm
7-16
BRKT
Bracket unit
7
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
7-17
Part name
Anode
Through tube
Bolt
Tilt stop lever
Bush
Collar
Distance collar
Spring pin
Pin
Spring
Spring hook
Bolt
Tilt stop lever
Q’ty
1
1
1
1
4
1
2
2
1
1
1
1
1
Remarks
M8 × 20 mm
M6 × 10 mm
63P3F11
Clamp brackets
Removing the clamp brackets
T.
R.
1. Remove the power trim and tilt unit. For
removal procedures, see “Removing the
power trim and tilt unit.”
Self-locking nut:
15 N·m (1.5 kgf·m, 11.1 ft·lb)
5. Install the power trim and tilt unit, then
the anode.
2. Remove the anode.
3. Remove the bolt and grease nipples, and
then disconnect the ground leads.
NOTE:
Install the ground lead between the power
trim and tilt unit and the anode.
4. Remove the self-locking nut and bolt.
5. Remove the through tube, then disassemble the clamp brackets, trim sensor
cam, and swivel bracket.
6. Remove the trim sensor.
6. Install the ground lead between the
clamp brackets and the swivel bracket.
7. Apply water resistant grease through the
grease nipples.
7. Remove the tilt stop levers.
A
A
Installing the clamp brackets
1. Install the tilt stop levers onto the swivel
bracket assembly.
2. Install the trim sensor 1 and bushings
onto the swivel bracket assembly.
a
1
LT
A
271
S63P7320
S60X7140
3. Assemble the clamp brackets, washers,
and swivel bracket, and then install the
through tube.
NOTE:
• Make sure that the trim sensor cam is
installed between the swivel bracket holes.
• Adjust the trim sensor cam after assembly.
4. Install the bolts on the through tube, and
then tighten the self-locking nut to the
specified torque.
63P3F11
NOTE:
Apply the grease until it comes out of the
bushing a.
Adjusting the trim sensor cam
1. Fully retract the power trim and tilt unit.
2. Loosen the trim sensor cam screw 1.
3. Adjust the trim sensor cam 2 where the
specified trim sensor setting resistance is
obtained.
7-18
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
2
Trim sensor resistance:
Pink (P) – Black (B)
238.8–378.8 Ω at 20 °C (68 °F)
B
Gy
P
1
S60X7160
Trim sensor setting resistance:
Pink (P) – Black (B)
9–11 Ω at 20 °C (68 °F)
T.
R.
Trim sensor cam screw 1:
2 N·m (0.2 kgf·m, 1.5 ft·lb)
4. Fully tilt the outboard motor up, and then
support it with the tilt stop lever 3.
3
S60X7170
WARNING
After tilting up the outboard motor, be
sure to support it with the tilt stop lever.
Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit
should lose fluid pressure.
5. Check the trim sensor resistance. If the
resistance is out of specification, adjust
the trim sensor cam position and check
the trim sensor.
7-19
63P3F11
Clamp brackets / Power trim and tilt unit
Power trim and tilt unit
2
7
A
5
3
A
9
9
4
1
8
7
6
7
9
6
9
A
A
A
11
10
LT
242
S60X7010
No.
1
2
3
4
5
6
7
8
9
10
11
Part name
Power trim and tilt unit
PTT motor lead
Shaft
Plastic tie
Circlip
Bolt
Washer
Shaft
Bushing
Bolt
Ground lead
63P3F11
Q’ty
1
2
1
3
1
2
2
1
6
1
1
Remarks
Not reusable
M8 × 16 mm
M6 × 10 mm
7-20
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
7
7
1
T.
R.
0.7 N · m (0.07 kgf · m, 0.5 ft · lb)
T.
8
R.
5 N · m (0.5 kgf · m, 3.7 ft · Ib)
2
9
3
10
4
5
6
T.
R.
5 N · m (0.5 kgf · m, 3.7 ft · Ib)
S60X7180
No.
1
2
3
4
5
6
7
8
9
10
7-21
Part name
Power trim and tilt motor
Reservoir
Reservoir cap
O-ring
O-ring
Bolt
Bolt
O-ring
Filter
Joint
Q’ty
1
1
1
1
1
3
4
1
1
1
Remarks
Not reusable
M6 × 14 mm
M6 × 35 mm
Not reusable
63P3F11
Power trim and tilt unit
7
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part name
Screw
Stator
Armature
O-ring
Screw
Brush holder
Brush 2
Brush 1
Brush holder
Brush spring
PTT motor base
Oil seal
Bearing
Screw
63P3F11
Q’ty
1
1
1
1
2
1
1
1
1
2
1
1
1
2
1
2
3
4
5
6
7
8
9
Remarks
ø4 × 15 mm
Not reusable
ø4 × 12 mm
Not reusable
Not reusable
ø4 × 15 mm
7-22
BRKT
Bracket unit
7
T.
R.
6 N · m (0.6 kgf · m, 4.4 ft · Ib)
1
T.
R.
28
27
26
15
25 16
22
24
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
17
18
19
21
3
4
5
6
7
23
2
20
8
T.
R.
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
9
14
13
12
11
T.
R.
3 N · m (0.3 kgf · m, 2.2 ft · Ib)
10
S60X7200
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
7-23
Part name
Bolt
Gear pump assembly
Ball
Shuttle piston
O-ring
Main valve
Ball
Bolt
Bolt
Circlip
Manual valve
O-ring
O-ring
Backup ring
Spring
Absorber valve pin
Ball
Q’ty
4
1
2
2
2
2
2
1
2
1
1
1
1
1
1
1
1
Remarks
M5 × 16 mm
Not reusable
Not reusable
Not reusable
63P3F11
Power trim and tilt unit
7
T.
R.
6 N · m (0.6 kgf · m, 4.4 ft · Ib)
1
T.
R.
28
27
26
15
25 16
22
24
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
17
18
19
21
3
4
5
6
7
23
2
20
8
T.
R.
8 N · m (0.8 kgf · m, 5.9 ft · Ib)
9
14
13
12
11
T.
R.
3 N · m (0.3 kgf · m, 2.2 ft · Ib)
10
S60X7200
No.
18
19
20
21
22
23
24
25
26
27
28
Part name
Up-relief valve seat
O-ring
Filter
O-ring
Down-relief valve
Valve pin
O-ring
Valve seat
Pin
Ball
O-ring
63P3F11
Q’ty
1
1
2
1
1
1
4
1
1
1
1
Remarks
Not reusable
Not reusable
Not reusable
Not reusable
7-24
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
7
13
1
A
16
15
13
14
T.
R.
15
16
17
18
19
20
130 N · m (13.0 kgf · m, 96.0 ft · lb)
19
18
A
22
23
24
7
8
7
4
21
6
3
11
12
R.
5
6
8
T.
5
9
10
2
78 N · m (7.8 kgf · m, 57.5 ft · lb)
11
12
T.
R.
96 N · m (9.6 kgf · m, 70.8 ft · Ib)
S63P7350
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
7-25
Part name
Tilt ram
Trim ram
Cylinder body
Free piston
Backup ring
O-ring
Dust seal
Seal
Trim cylinder end screw
O-ring
Backup ring
O-ring
Dust seal
Tilt cylinder end screw
O-ring
O-ring
Tilt piston
Q’ty
1
2
1
1
1
1
2
2
2
2
2
2
1
1
1
1
1
Remarks
Not reusable
Not reusable
Not reusable
Not reusable
Not reusable
Not reusable
Not reusable
Not reusable
63P3F11
Power trim and tilt unit
7
13
1
A
16
15
13
14
T.
R.
15
16
17
18
19
20
130 N · m (13.0 kgf · m, 96.0 ft · lb)
19
18
A
22
23
24
7
8
7
4
21
6
3
11
12
R.
5
6
8
T.
5
9
10
2
78 N · m (7.8 kgf · m, 57.5 ft · lb)
11
12
T.
R.
96 N · m (9.6 kgf · m, 70.8 ft · Ib)
S63P7350
No.
18
19
20
21
22
23
24
Part name
O-ring
O-ring
Washer
Nut
Ball
Valve
Spring
63P3F11
Q’ty
1
1
1
1
4
4
4
Remarks
Not reusable
Not reusable
7-26
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
Removing the power trim and tilt unit
1. Fully tilt the outboard motor up, and then
support it with the tilt stop lever 1.
2. Remove the bolt and disconnect the
ground lead at the bottom of the power
trim and tilt unit.
3. Remove the plastic ties, and then pull out
the PTT motor leads.
1
S60X3020
4. Remove the bolts, then the lower mounting shaft.
WARNING
After tilting up the outboard motor, be
sure to support it with the tilt stop lever.
Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit
should lose fluid pressure.
NOTE:
• If the power trim and tilt does not operate,
loosen the manual valve 2 and tilt the outboard motor up manually.
• If the manual valve is loosened, be sure to
tighten it to the specified torque after tilting
the outboard motor up.
T.
R.
7-27
S60X7110
5. Remove the circlip, then the upper
mounting shaft.
Manual valve:
3 N·m (0.3 kgf·m, 2.2 ft·lb)
63P3F11
Power trim and tilt unit
Recommended power trim and tilt
fluid:
ATF Dexron II
3. Install the reservoir cap, and then tighten
it to the specified torque.
T.
R.
Reservoir cap:
0.7 N·m (0.07 kgf·m, 0.5 ft·lb)
4. Fully extend the trim and tilt rams.
5. Remove the circlip 1, then the manual
valve 2.
S60X7120
6. Install the up relief fitting 3 and hydraulic
pressure gauge 4.
NOTE:
Hold the power trim and tilt unit with one
hand, and pull the upper mount shaft out at a
downward angle with the other.
6. Remove the collars.
Checking the hydraulic pressure
1. Remove the reservoir cap, and then
check the fluid level in the reservoir.
S60X7340
NOTE:
If the fluid is at the correct level, the fluid
should overflow out of the filler hole when the
reservoir cap is removed.
NOTE:
Quickly install the special service tools before
any fluid flows out of the hole.
Up relief fitting 3: 90890-06773
Hydraulic pressure gauge 4:
90890-06776
2. If necessary, add sufficient fluid of the
recommended type until it overflows out
of the filler hole.
63P3F11
7-28
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
7. Connect the PTT motor leads to the battery terminals to fully retract the trim and
tilt rams.
Down relief fitting 5: 90890-06774
Hydraulic pressure gauge:
90890-06776
Rams
Down
PTT motor lead
Battery
terminal
Light green (Lg)
+
Sky blue (Sb)
-
10. Remove the reservoir cap, and then
check the fluid level.
8. Reverse the PTT motor leads between
the battery terminals to fully extend the
trim and tilt rams, and then measure the
hydraulic pressure.
S60X7340
NOTE:
If the fluid is at the correct level, the fluid
should overflow out of the filler hole when the
reservoir cap is removed.
Rams
Up
PTT motor lead
Battery
terminal
Sky blue (Sb)
+
Light green (Lg)
-
11. If necessary, add sufficient fluid of the
recommended type until it overflows out
of the filler hole.
Recommended power trim and tilt
fluid:
ATF Dexron II
Hydraulic pressure (up):
10–12 MPa (100–120 kgf/cm2)
9. Replace the up relief fitting with the down
relief fitting 5.
R.
7-29
T.
NOTE:
Quickly install the special service tools before
any fluid flows out of the hole.
12. Install the reservoir cap, and then tighten
it to the specified torque.
Reservoir cap:
0.7 N·m (0.07 kgf·m, 0.5 ft·lb)
63P3F11
Power trim and tilt unit
13. Connect the PTT motor leads to the battery terminals to fully retract the trim and
tilt rams, and then measure the hydraulic
pressure. If out of specification, overhaul
the power trim and tilt unit.
NOTE:
Quickly install the manual valve before any
fluid flows out of the hole.
Disassembling the power trim and
tilt motor
1. Remove the power trim and tilt motor, Oring, gear pump filter, and joint from the
gear pump housing.
Rams
Down
PTT motor lead
Battery
terminal
Light green (Lg)
+
Sky blue (Sb)
-
Hydraulic pressure (down):
6–9 MPa (60–90 kgf/cm2)
S60X7220
14. Reverse the PTT motor leads between
the battery terminals to fully extend the
trim and tilt rams.
Rams
Up
PTT motor lead
Battery
terminal
Sky blue (Sb)
+
Light green (Lg)
-
CAUTION:
• Make sure that the trim and tilt rams are
fully extended when removing the power
trim and tilt motor, otherwise fluid can
spurt out from the unit due to internal
pressure.
• Do not push the trim and tilt rams down
while the power trim and tilt motor is
removed from the power trim and tilt
unit, otherwise fluid can spurt out.
2. Check the gear pump filter for dirt or residue and for damage. Clean or replace if
necessary.
15. Remove the special service tools, and
then install the manual valve and circlip.
T.
R.
Manual valve:
3 N·m (0.3 kgf·m, 2.2 ft·lb)
63P3F11
7-30
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
3. Remove the lead holder 1 and rubber
spacers 2 from the stator, and then slide
them away from the stator.
7. Remove the screw, disconnect the PTT
motor lead (light green) 5, and then
remove the brushes 6.
4. Remove the stator 3.
NOTE:
Place a clean cloth over the end of the armature shaft, hold it with a pair of pliers, and
then carefully slide the stator off of the armature.
CAUTION:
5. Remove the armature from the PTT
motor base.
CAUTION:
Do not allow grease or oil to contact the
commutator.
6. Disconnect the PTT motor lead (sky
blue) 4.
• Do not pull the PTT motor leads out
from the stator.
• Do not touch the bimetal a, otherwise
the operation of the circuit breaker can
be affected.
Checking the power trim and tilt
motor
1. Measure the length of the brushes.
Replace if out of specification.
4
S60X7240
NOTE:
Hold the brush with a screwdriver as shown,
and then disconnect the PTT motor lead (sky
blue).
7-31
Brush length limit a:
4.8 mm (0.19 in)
63P3F11
Power trim and tilt unit
2. Check the brush and circuit breaker for
continuity. Replace if there is no continuity.
CAUTION:
Do not touch the bimetal b, otherwise the
operation of the circuit breaker can be
affected.
3. Measure the commutator diameter.
Replace if out of specification.
Armature continuity
Commutator segments d
Continuity
Segment d –
Armature core e
No continuity
Segment d –
Armature shaft f
No continuity
5. Check the base for cracks or damage.
Replace if necessary.
Commutator diameter limit c:
21.0 mm (0.83 in)
6. Check the bearing and oil seal for damage or wear. Replace if necessary.
4. Check the armature for continuity.
Replace if out of specifications.
S60X7300
NOTE:
If the bearing and oil seal are removed,
always replace them with new ones.
63P3F11
7-32
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
Assembling the power trim and tilt
motor
1. Connect the PTT motor leads 1, and
then tighten the screws 2.
Removing the reservoir
1. Hold the power trim and tilt unit in a vise
using aluminum plates a on both sides.
1
2
S60X7310
CAUTION:
2. Push the brushes 3 into the brush
holder, and then install the armature 4.
Do not use rags or paper to clean the
hydraulic system components. Small
pieces of fibers remaining on them can
cause the system to malfunction.
NOTE:
Place a container under the power trim and
tilt unit to catch the fluid.
2. Remove the reservoir and O-rings.
3. Install the stator onto the base.
S60X7400
CAUTION:
NOTE:
Place a clean cloth over the end of the armature shaft, hold it with a pair of pliers, and
then carefully slide the stator over the armature.
7-33
• Make sure that the trim and tilt rams are
fully extended when removing the reservoir, otherwise fluid can spurt out from
the unit due to internal pressure.
• Do not push the tilt and trim rams down
while the power trim and tilt motor is
removed from the power trim and tilt
unit, otherwise fluid can spurt out.
63P3F11
Power trim and tilt unit
3. Drain the fluid from the reservoir and
check it for damage. Replace if necessary.
4. Check the reservoir cap and O-ring for
damage. Replace if necessary.
Disassembling the gear pump
housing
1. Remove the gear pump housing.
S60X7430
NOTE:
Make sure that the shuttle pistons and balls
are removed, since they tend to stick to the
gear pump cover.
S60X7410
NOTE:
Make sure that the O-rings, valve pin, and
valve seat assembly are removed.
4. Remove the up-relief valve assembly.
2. Remove the filters, down-relief valve,
and O-ring from the gear pump housing.
S60X7440
S60X7420
NOTE:
Remove the back filter using compressed air,
being careful not to blow the filter out
abruptly.
3. Remove the gear pump cover and drive
gears.
63P3F11
7-34
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
Checking the gear pump
5. Remove the main valves.
1. Clean all the valves, pistons, and balls,
and then check them for damage or
wear. Check the filters for damage or
clogs. Replace if necessary.
2. Check the drive gears for damage or
wear. Replace the gear pump assembly
if necessary.
b
a
S60X7450
WARNING
Never look into the pump housing opening while removing the main valves
because the main valves and power trim
and tilt fluid can be forcefully expelled
out.
NOTE:
To remove the main valves, cover the pump
housing with a clean cloth, and then blow
compressed air through holes a and b
while holding the cloth down.
S63P7010
Assembling the gear pump housing
CAUTION:
6. Remove the manual valve.
Install the components and parts in their
original direction and positions.
1. Install a new O-ring 1, the up-relief valve
seat 2, ball 3, absorber valve pin 4,
and spring 5 into the gear pump housing.
S60X7460
7-35
63P3F11
Power trim and tilt unit
2. Install new O-rings 6 onto the main
valves 7, and then install the main
valves into the gear pump housing.
5. Install the gear pump cover B into the
gear pump housing, and then tighten the
bolts.
B
S60X7520
3. Install the drive gears 8 into the gear
pump housing.
6. Check that the gear pump turns
smoothly, and then tighten the gear
pump cover bolts to the specified torque.
8
T.
R.
Gear pump cover bolt:
6 N·m (0.6 kgf·m, 4.4 ft·lb)
7. Install a new O-ring onto the down-relief
valve.
S60X7500
8. Install the filter, down-relief valve, and filter into the gear pump housing.
4. Install the balls 9, shuttle pistons 0, and
balls A into the gear pump cover.
S60X7530
9. Install a new O-ring onto the manual
valve.
10. Install the manual valve and circlip into
the gear pump housing.
R.
63P3F11
T.
NOTE:
Apply grease to the balls and shuttle pistons
to prevent them from falling out of the gear
pump cover.
Manual valve:
3 N·m (0.3 kgf·m, 2.2 ft·lb)
7-36
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
Disassembling the tilt cylinder and
trim cylinder
1. Loosen the tilt cylinder end screw, and
then remove the tilt piston assembly.
6. Cover the tilt cylinder opening with a
clean cloth 1, and then blow compressed air through the hole a to
remove the free piston 2.
S63P7020
CAUTION:
Make sure that the trim and tilt rams are
fully extended before removing the tilt cylinder end screw.
Trim and tilt wrench:
New: 90890-06587
Current: 90890-06548
WARNING
2. Drain the fluid.
3. Loosen the trim cylinder end screws, and
then remove the trim piston assemblies.
Never look into the tilt cylinder opening
while removing the free piston because
the free piston and power trim and tilt
fluid can be forcefully expelled out.
7. Loosen the trim cylinder end screws, and
then remove the trim piston assemblies.
S63P7030
Trim and tilt wrench:
New: 90890-06587
Current: 90890-06548
4. Drain the fluid.
5. Install the trim piston assemblies, and
then tighten the trim cylinder end screws
finger tight.
7-37
63P3F11
Power trim and tilt unit
Checking the tilt cylinder and trim
cylinder
1. Disassemble the tilt piston assembly.
4. Check the tilt ram for bends or excessive
corrosion. Polish with 400- to 600-grit
sandpaper if there is light rust or replace
if necessary.
5. Check the trim pistons for scratches.
Replace if necessary.
S60X7570
6. Check the trim rams for bends or excessive corrosion. Polish with 400- to 600grit sandpaper if there is light rust or
replace if necessary.
2. Check the tilt piston and free piston for
scratches. Replace if necessary.
3. Blow the tilt piston absorber valve with
compressed air to remove any foreign
material. Check the valve for wear and
the spring for deterioration. Replace if
necessary.
63P3F11
7. Check the inner walls of the trim and tilt
cylinders for scratches. Replace if necessary.
7-38
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
Assembling the tilt piston and trim
pistons
1. Install the new dust seal 1 and new Orings 2 and 3 onto the tilt cylinder end
screw.
T.
R.
Tilt piston nut:
96 N·m (9.6 kgf·m, 70.8 ft·lb)
6. Install a new backup ring E and a new
O-ring F onto the free piston D.
2. Install the tilt cylinder end screw 4 onto
the tilt ram 5.
7. Install a new oil seal G, a new dust seal
H, and a new O-ring I onto each trim
cylinder end screw.
8. Install the backup ring J and a new Oring K onto each trim piston.
3. Install new O-rings 6 and 7 onto the tilt
piston 8.
4. Install the ball 9, valve 0, and spring A,
in this order.
5. Install the tilt piston assembly and
washer B onto the tilt ram 5, and then
tighten the tilt piston nut C to the specified torque.
A
H
H
G
I
J
K
G
J
K
S63P7360
7-39
63P3F11
Power trim and tilt unit
Assembling the power trim and tilt
unit
1. Fill the tilt cylinder with the specified
amount of the recommended fluid
through the hole a.
3. Fill the trim cylinders with the recommended fluid to the correct level through
holes b and c, and d as shown.
Recommended power trim and tilt
fluid:
ATF Dexron II
Fluid quantity:
30 cm3 (1.0 US oz, 1.1 Imp oz)
2. Push the free piston 1 into the tilt cylinder until it bottoms out.
63P3F11
Recommended power trim and tilt
fluid:
ATF Dexron II
7-40
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
4. Install the trim piston assemblies into the
trim cylinders, and then tighten the trim
cylinder end screws to the specified
torque.
S60X7730
T.
R.
Gear pump housing mounting bolt:
8 N·m (0.8 kgf·m, 5.9 ft·lb)
S63P7040
7. Install the O-ring into the reservoir cap.
CAUTION:
• Make sure that the trim rams are fully
extended when installing them.
• Once installed, never push the trim rams
down, otherwise fluid can spurt out.
8. Install the reservoir and O-ring onto the
gear pump housing.
Trim and tilt wrench:
New: 90890-06587
Current: 90890-06548
T.
R.
Trim cylinder end screw:
78 N·m (7.8 kgf·m, 57.5 ft·lb)
T.
R.
5. Install new O-rings, the valve pin, and
valve seat assembly onto the tilt cylinder.
S60X7400
Reservoir mounting bolt:
5 N·m (0.5 kgf·m, 3.7 ft·lb)
9. Fill the tilt cylinder with the recommended
fluid to the correct level through the hole
e as shown.
S60X7720
NOTE:
Refer to the illustration for valve pin and
valve seat assembly installation.
6. Install the gear pump housing.
7-41
Recommended power trim and tilt
fluid:
ATF Dexron II
63P3F11
Power trim and tilt unit
10. Install the tilt piston assembly into the tilt
cylinder, and then tighten the tilt cylinder
end screw to the specified torque.
12. Fill the gear pump housing with the recommended fluid to the correct level as
shown.
Recommended power trim and tilt
fluid:
ATF Dexron II
13. Remove all of the air bubble using a
syringe or suitable tool.
S63P7060
NOTE:
Turn the joint with a screwdriver to bleed the
gear pump.
CAUTION:
• Make sure that the tilt ram is fully
extended when installing it.
• Once installed, never push the tilt ram
down, otherwise fluid can spurt out.
14. Install a new O-ring 4 and the power
trim and tilt motor 5, and then tighten the
bolts 6 to the specified torque.
Trim and tilt wrench:
New: 90890-06587
Current: 90890-06548
T.
R.
Tilt cylinder end screw:
130 N·m (13.0 kgf·m, 96.0 ft·lb)
11. Install the joint 2 and gear pump filter 3
into the gear pump housing.
NOTE:
Align the armature shaft with the recess in
the joint.
T.
R.
63P3F11
PTT motor mounting bolt:
5 N·m (0.5 kgf·m, 3.7 ft·lb)
7-42
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
15. Remove the reservoir cap, and then
check the fluid level in the reservoir.
NOTE:
If the fluid is at the correct level, the fluid
should overflow out of the filler hole when the
reservoir cap is removed.
16. If necessary, add sufficient fluid of the
recommended type until it overflows out
of the filler hole.
Recommended power trim and tilt
fluid:
ATF Dexron II
NOTE:
If the fluid is at the correct level, the fluid
should overflow out of the filler hole when the
reservoir cap is removed.
4. If necessary, add sufficient fluid of the
recommended type until it overflows out
of the filler hole.
Recommended power trim and tilt
fluid:
ATF Dexron II
5. Install the reservoir cap, and then tighten
it to the specified torque.
17. Install the reservoir cap, and then tighten
it to the specified torque.
T.
R.
T.
R.
Reservoir cap:
0.7 N·m (0.07 kgf·m, 0.5 ft·lb)
18. Bleed the power trim and tilt unit.
Reservoir cap:
0.7 N·m (0.07 kgf·m, 0.5 ft·lb)
6. Connect the PTT motor leads to the battery terminals to fully retract the trim and
tilt rams.
19. Check the hydraulic pressure of the
power trim and tilt unit.
Bleeding the power trim and tilt unit
1. Tighten the manual valve 1 by turning it
clockwise.
Rams
Down
PTT motor lead
Battery
terminal
Light green (Lg)
+
Sky blue (Sb)
-
7. Reverse the PTT motor leads between
the battery terminals to fully extend the
trim and tilt rams.
2. Place the power trim and tilt unit in an
upright position.
3. Remove the reservoir cap, and then
check the fluid level in the reservoir.
7-43
63P3F11
Power trim and tilt unit
CAUTION:
After tilting the outboard motor up, be
sure to support it with the tilt stop lever.
2. Install the collars.
3. Lift the power trim and tilt unit up, and
then install the upper mounting shaft.
Rams
Up
PTT motor lead
Battery
terminal
Sky blue (Sb)
+
Light green (Lg)
-
NOTE:
• Repeat this procedure so that the rams go
up and down four or five times (be sure to
wait a few seconds before switching the
leads).
• If the rams do not move up and down easily, push and pull on the rams to assist
operation.
4. Install the circlip.
5. Install the lower mounting shaft, and then
tighten the bolts.
6. Install the plastic ties, route the PTT
motor leads through the hole, and then
install the plastic ties.
7. Connect the ground lead to the bottom of
the power trim and tilt unit, and then
tighten the bolt.
A
A
8. Check the fluid level when the tilt ram is
fully extended. Add sufficient fluid if necessary.
Installing the power trim and tilt unit
1. Fully tilt the outboard motor up, and then
support it with the tilt stop lever 1.
A
A
A
LT
242
S60X7130
1
S60X7820
63P3F11
7-44
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
Bleeding the power trim and tilt unit
(built-in)
1. Fully turn the manual valve counterclockwise.
WARNING
After tilting up the outboard motor, be
sure to support it with the tilt stop lever.
Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit
should lose fluid pressure.
7. Remove the reservoir cap 2, and then
check the fluid level in the reservoir.
2. Fully tilt the outboard motor up, and then
release it to let it lower by its own weight
four to five times.
2
3. Tighten the manual valve by turning it
clockwise.
4. Let the fluid settle for 5 minutes.
5. Push and hold the power trim and tilt
switch in the up position to check that the
outboard motor is fully tilted up.
6. Support the outboard motor with the tilt
stop lever 1.
S60X3030
NOTE:
If the fluid is at the correct level, the fluid
should overflow out of the filler hole when the
reservoir cap is removed.
8. If necessary, add sufficient fluid of the
recommended type to the correct level.
Recommended power trim and tilt
fluid:
ATF Dexron II
1
9. Install the reservoir cap, and then tighten
it to the specified torque.
T.
R.
S60X3020
7-45
Reservoir cap:
0.7 N·m (0.07 kgf·m, 0.5 ft·lb)
NOTE:
Repeat this procedure until the fluid remains
at the correct level.
63P3F11
Power trim and tilt unit / Power trim and tilt electrical system
Power trim and tilt electrical system
1
7
H
I
2 3 4
R
2
R
B
R
17
3
R
4
B
E 1DCBA098765432 G
R
F
5
R
R R R
B
6
Lg Sb
Sb
Lg
Lg
Sb
Lg
9
Sb
R
Lg
UP
FREE
Sb
DOWN
Lg
Sb
R
Lg
Lg
Lg
R
R
Sb
Lg
Sb
Sb
Lg
È
R
Lg
B
Sb
B
Lg
7
Sb
B
B
B
8
É
P
P
Gy
Gy
S63P7270
1
2
3
4
5
6
7
8
9
Fuse holder
Fuse (20 A)
Fuse (50 A)
Battery
Power trim and tilt relay
Power trim and tilt motor
Diode
Trim sensor
Power trim and tilt switch
63P3F11
È To remote control box/switch
panel
É To trim meter
B
Gy
Lg
P
R
Sb
: Black
: Gray
: Light green
: Pink
: Red
: Sky blue
7-46
1
2
3
4
5
6
7
8
9
BRKT
Bracket unit
Checking the fuse
1. Check the fuse for continuity. Replace if
there is no continuity.
3. Connect the light green (Lg) lead to the
positive battery terminal and the black
(B) lead to the negative battery terminal
as shown.
4. Check for continuity between terminals
2 and 3. Replace if there is no continuity.
S69J7525
Checking the power trim and tilt
relay
1. Check the power trim and tilt relay for
continuity. Replace if out of specification.
5. Connect the digital circuit tester between
power trim and tilt relay terminals 1 and
3.
6. Connect the sky blue (Sb) lead to the
positive battery terminal and the black
(B) lead to the negative battery terminal
as shown.
NOTE:
Be sure to set the measurement range a
shown in the illustration when checking for
continuity.
7. Check for continuity between terminals
1 and 3. Replace if there is no continuity.
Power trim and tilt relay continuity
Sky blue (Sb) – Black (B)
Light green (Lg) – Black (B)
Continuity
Terminal 1 – Terminal 4
Terminal 2 – Terminal 4
Continuity
Terminal 1 – Terminal 3
Terminal 2 – Terminal 3
No continuity
2. Connect the digital circuit tester between
power trim and tilt relay terminals 2 and
3.
7-47
Checking the power trim and tilt
switch
1. Check the power trim and tilt switch for
continuity. Replace if out of specification.
63P3F11
Power trim and tilt electrical system
1
2
3
4
5
6
7
8
9
Lead color
Switch
position
Sky blue
(Sb)
Red (R)
Light green
(Lg)
Up
Free
Down
Checking the trim sensor
1. Measure the trim sensor resistance.
Replace if out of specification.
NOTE:
Turn the lever 1 and measure the resistance
as it gradually changes.
Trim sensor resistance:
Pink (P) – Black (B)
238.8–378.8 Ω at 20 °C (68 °F) a
9–11 Ω at 20 °C (68 °F) b
63P3F11
7-48
BRKT
Bracket unit
— MEMO —
7-49
63P3F11
ELEC
–
+
Electrical systems
Special service tools .....................................................................................8-1
Checking the electrical components............................................................ 8-2
Measuring the peak voltage ...................................................................... 8-2
Measuring the lower resistance.................................................................8-2
Electrical components................................................................................... 8-3
Port view.................................................................................................... 8-3
Junction box assembly ..............................................................................8-4
Aft view ...................................................................................................... 8-5
Top view .................................................................................................... 8-6
Wiring harness........................................................................................... 8-7
Ignition and ignition control system ............................................................ 8-9
Checking the ignition spark gap ..............................................................8-11
Checking the spark plug wires.................................................................8-11
Checking the ignition coils ....................................................................... 8-11
Checking the ECM...................................................................................8-12
Checking the pulser coil ..........................................................................8-12
Checking the throttle position sensor ......................................................8-13
Checking the intake air temperature sensor............................................8-13
Checking the engine temperature sensor................................................ 8-13
Checking the thermoswitch ..................................................................... 8-14
Checking the shift cut switch ................................................................... 8-14
Checking the neutral switch..................................................................... 8-14
Fuel control system .....................................................................................8-15
Checking the injectors ............................................................................. 8-17
Checking the main relay ..........................................................................8-17
Checking the electric fuel pump ..............................................................8-17
Starting system ............................................................................................ 8-18
Checking the fuses .................................................................................. 8-19
Checking the starter relay........................................................................8-19
Starter motor ................................................................................................8-20
Removing the starter motor pinion .......................................................... 8-22
Checking the starter motor pinion............................................................ 8-22
Checking the armature ............................................................................8-22
Checking the brushes.............................................................................. 8-23
Checking the magnet switch.................................................................... 8-23
Checking the starter motor operation ......................................................8-23
Charging system .......................................................................................... 8-24
Checking the stator coil ...........................................................................8-25
Checking the Rectifier Regulator............................................................. 8-25
63P3F11
1
2
3
4
5
6
7
8
9
ELEC
–
+
Electrical systems
Special service tools
8
Ignition tester
90890-06754
Test harness (3 pins)
90890-06793
Digital circuit tester
90890-03174
Test harness (3 pins)
90890-06847
Peak voltage adapter B
90890-03172
Test harness (3 pins)
90890-06846
Test harness (2 pins)
90890-06792
Test harness (3 pins)
90890-06791
8-1
63P3F11
Special service tools / Checking the electrical components
Checking the electrical
components
Measuring the lower resistance
8
Measuring the peak voltage
NOTE:
Before troubleshooting the peak voltage,
check that all electrical connections are tight
and free from corrosion, and that the battery
is fully charged to 12 V.
The condition of the ignition system can be
determined by measuring the peak voltage.
Cranking speed is effected by many factors,
such as fouled or weak spark plugs, or a
weak battery. If one of these factors is
present, the peak voltage will be lower than
specification. In addition, if the peak voltage
is lower than specification the engine will not
operate properly.
When measuring a resistance of 10 Ω or less
with the digital circuit tester, the correct measurement cannot be obtained due to the
internal resistance of the tester. To obtain the
correct value, subtract the internal resistance
from the displayed measurement.
NOTE:
To obtain the internal resistance of the digital
circuit tester, connect both of its probes and
check the display.
Correct value =
displayed measurement – internal
resistance
DC V
S69J8020
WARNING
When checking the peak voltage, do not
touch any of the connections of the digital
tester leads.
NOTE:
• Use the peak voltage adapter with the digital circuit tester.
• When measuring the peak voltage, set the
selector on the digital circuit tester to the
DC voltage mode.
• Connect the positive pin on the peak voltage adapter to the positive terminal of the
digital circuit tester.
63P3F11
8-2
1
2
3
4
5
6
7
8
9
–
ELEC
+
Electrical systems
Electrical components
8
Port view
2
3
4
1
5
8
7
6
S63P8010
1
2
3
4
5
6
7
8
ECM
Starter motor
Rectifier Regulator
Thermoswitch
Ignition coil
Oil pressure sensor
Junction box
Fuse holder
8-3
63P3F11
Electrical components
Junction box assembly
1
2
9
8
7
6
5
4
3
S63P8020
1
2
3
4
5
6
7
8
9
ECM
Power trim and tilt relay
Starter relay
Diode
Fuse (30 A)
Main relay
Fuse (20 A)
Fuse (50 A)
Intake air temperature sensor
63P3F11
8-4
1
2
3
4
5
6
7
8
9
ELEC
–
+
Electrical systems
Aft view
1
2
7
3
A
A
6
3
8
A-A
4
5
S63P8030
1
2
3
4
5
6
7
8
Intake air pressure sensor
Throttle position sensor
Fuel injector
Shift cut switch
Neutral switch
Ignition coil
Thermoswitch
Spark plug
8-5
63P3F11
Electrical components
Top view
1
8
2
7
6
3
9
0
A
5
4
S63P8040
1
2
3
4
5
6
7
8
9
0
Fuel injector
Ignition coil
Starter motor
Stator coil
Engine temperature sensor
Throttle position sensor
Idle speed control
Intake air pressure sensor
Shift cut switch
Neutral switch
63P3F11
A Power trim and tilt switch
8-6
1
2
3
4
5
6
7
8
9
–
ELEC
+
Electrical systems
Wiring harness
:
:
:
:
:
:
:
:
:
1
2
3
4
5
6
7
8
9
G
Y/G
P
W
_
_
B/Y
B
L/Y
10
11
12
13
14
15
16
17
18
:
:
:
:
:
:
:
:
:
O
_
O
_
W/R
W/B
_
L
G/B
19
20
21
22
23
24
25
26
27
:
:
:
:
:
:
:
:
:
G
G/R
G/Y
B/O
P/B
P/W
_
W/B
L/W
28
29
30
31
32
33
34
35
36
:
:
:
:
:
:
:
:
:
37
38
39
40
41
42
43
44
Y
P/W
R/Y
L/G
B
P/G
P
B/Y
_
:
:
:
:
:
:
:
:
P
Pu/Y
Pu/B
Pu/R
_
B
Pu/G
B/W
Y
Lg
W
A
L/W
7
2
B
R
G
P
P/B
21
Sb
Br
B
P/W
0
35
46
7
8
9
0
A
9
5
5
B
C
D
34
6
4
Lg
Sb
O
E
B
F
L/G
B
R
8
L/Y
B
P
B
R/Y
W/B
Lg
C
B/Y
B
Sb
B/Y B
B
B
B
B
B
R B
L/W L/W Br
D
B
B
B
B Sb Lg
R/Y
E
W/R
W/B
1
K
:
:
:
:
:
Y/G
R
R
R
R/Y
6
7
8
9
10
:
:
:
:
:
R/Y
R/Y
R/Y
R/Y
R/Y
11
12
13
14
15
:
:
:
:
:
R/Y
R/Y
R/Y
R/Y
R
P/W
P/G
O
G/Y
G
B
1
2
3
4
5
G/R
G/B
J
R/Y
B
I
Pu/G
Pu/R
O
Pu/Y
L
G
B
P
B
G
R/Y
R/Y
Pu/B
G
M
G
L
R/Y
R/Y
R/Y
N
H
R/Y
N
B/O
B/W
Connect to:
1
2
3
4
5
6
7
8
9
0
A
B
C
Fuse holder
Fuse holder
Diagnostic flash indicator
Starter relay
Ground
Power trim and tilt relay
ECM
Intake air temperature sensor
Personal computer for diagnosis
Power trim and tilt switch
Warning indicator
Remote control
Engine temperature sensor
8-7
R/Y
S63P8190
D
E
F
G
H
I
J
K
L
M
N
Throttle position sensor
Neutral switch
Shift cut switch
Fuel injector
Electric fuel pump
Intake air pressure sensor
Idle speed control
Pulser coil
Oil pressure sensor
Thermoswitch
Ignition coil
63P3F11
Electrical components
:
:
:
:
:
:
:
:
:
1
2
3
4
5
6
7
8
9
G
Y/G
P
W
_
_
B/Y
B
L/Y
10
11
12
13
14
15
16
17
18
:
:
:
:
:
:
:
:
:
O
_
O
_
W/R
W/B
_
L
G/B
19
20
21
22
23
24
25
26
27
:
:
:
:
:
:
:
:
:
G
G/R
G/Y
B/O
P/B
P/W
_
W/B
L/W
28
29
30
31
32
33
34
35
36
:
:
:
:
:
:
:
:
:
37
38
39
40
41
42
43
44
Y
P/W
R/Y
L/G
B
P/G
P
B/Y
_
:
:
:
:
:
:
:
:
P
Pu/Y
Pu/B
Pu/R
_
B
Pu/G
B/W
Y
Lg
W
A
L/W
7
2
B
R
G
P
P/B
21
Sb
Br
B
P/W
0
35
46
7
8
9
0
A
9
5
5
B
C
D
34
6
4
Lg
Sb
O
E
B
F
L/G
B
R
8
L/Y
B
P
B
R/Y
W/B
Lg
C
B/Y
B
Sb
B/Y B
B
B
B
B
B
B
B
R B
L/W L/W Br
D
B
B Sb Lg
R/Y
E
W/R
W/B
1
K
B
1
2
3
4
5
:
:
:
:
:
Y/G
R
R
R
R/Y
6
7
8
9
10
:
:
:
:
:
R/Y
R/Y
R/Y
R/Y
R/Y
11
12
13
14
15
:
:
:
:
:
R/Y
R/Y
R/Y
R/Y
R
P/W
G/R
P/G
O
G/B
O
G/Y
G
J
R/Y
B
I
Pu/G
Pu/R
Pu/Y
L
G
B
P
B
G
R/Y
R/Y
Pu/B
G
M
G
L
R/Y
R/Y
R/Y
N
H
R/Y
N
R/Y
B/O
B/W
B
Br
G
Gy
L
Lg
O
P
R
Sb
W
Y
B/O
B/W
: Black
: Brown
: Green
: Gray
: Blue
: Light green
: Orange
: Pink
: Red
: Sky blue
: White
: Yellow
: Black/orange
: Black/white
63P3F11
B/Y
G/B
G/R
G/Y
L/G
L/W
L/Y
P/B
P/G
P/W
Pu/B
Pu/G
Pu/R
Pu/Y
S63P8190
: Black/yellow
: Green/black
: Green/red
: Green/yellow
: Blue/green
: Blue/white
: Blue/yellow
: Pink/black
: Pink/green
: Pink/white
: Purple/black
: Purple/green
: Purple/red
: Purple/yellow
R/Y
W/B
W/R
Y/G
: Red/yellow
: White/black
: White/red
: Yellow/green
8-8
1
2
3
4
5
6
7
8
9
–
ELEC
+
Electrical systems
Ignition and ignition control system
8
3
B
P
B
W/R
B
B
O
R/Y B/O
R/Y B/W
W/B
W/R
W/B
4
W/R
B
B
R/Y
P/W
R/Y
B
5
B/O
R
B/W
R
2 3
B/W
B/W
R
B/W
Y/G
7
B/W
R
2
4
2
B/Y
O
O
W/R W/B
G/B
24
P/W
L/G
L/Y
18 19 20
21 22
3
B
14 15
G/Y B/O
B
1 1
P
12
B
P/G
P
42
44
B
B/W
G
#2/3
#1/4
G/R
6
28 29 30
Y
31 32 33 34 35
2
1
5
7 8 9 10
B/Y
P/W R/Y
37
P
G
1 1
G
G
G
B/Y
B
B/Y
E
B/Y
B/Y
D
B
B/Y
B
8
R/Y
B
R/Y
B/Y
R
R
R/Y5
2 R/Y
Y
P
G/Y 4
1G/R
Y/G
3G/B
F
B
B
G6
B
R
9
B
È
E
1
D
C
B
A
0
9
8
7
6
5
4
3
2
B
B
A
0
A
B
B
G
P
I
F
G
H
1
5 6 7
Y/G
R
6
5
4
3
2
1
O
R/Y R/Y R/Y
12
17
19
R/Y
R
R
H
R
B
P/G
B
B
B
B
L/Y
B
I
L/Y
B
B
L/G
B
C
B
J
L/G
S63P8200
1
2
3
4
5
6
7
8
9
0
Spark plug
Ignition coil
Thermoswitch
Oil pressure sensor
Pulser coil
Stator coil
ECM
Intake air temperature sensor
Fuse holder
Main relay
8-9
A
B
C
D
E
F
G
H
I
J
Fuse (20 A)
Fuse (50 A)
Battery
Rectifier Regulator
Engine temperature sensor
Idle speed control
Throttle position sensor
Intake air pressure sensor
Shift cut switch
Neutral switch
È To remote control box/switch
panel
63P3F11
Ignition and ignition control system
8
3
B
P
B
W/R
B
B
O
R/Y B/O
R/Y B/W
W/B
W/R
W/B
4
W/R
B
B
R/Y
P/W
R/Y
B
5
B/O
R
B/W
R
2 3
B/W
B/W
R
B/W
Y/G
7
B/W
R
2
4
2
B/Y
O
O
W/R W/B
G/B
24
P/W
L/G
L/Y
18 19 20
21 22
3
B
14 15
G/Y B/O
B
1 1
P
12
B
P/G
P
42
44
B
B/W
G
#2/3
#1/4
G/R
6
28 29 30
Y
31 32 33 34 35
2
1
5
7 8 9 10
B/Y
P/W R/Y
37
P
G
1 1
G
G
G
B/Y
B
B/Y
E
B/Y
B/Y
D
B
B/Y
B
8
R/Y
B
R/Y
B/Y
R
R
R/Y5
2 R/Y
Y
P
G/Y 4
1G/R
Y/G
3G/B
F
B
B
G6
B
R
9
B
È
E
1
D
C
B
A
0
9
8
7
6
5
4
3
2
B
B
A
0
A
B
B
G
P
I
F
G
H
1
5 6 7
Y/G
R
6
5
4
3
2
1
O
R/Y R/Y R/Y
12
17
19
R/Y
R
R
H
R
B
P/G
B
B
B
B
L/Y
B
I
L/Y
B
B
C
L/G
B
J
L/G
B
S63P8200
B
G
O
P
R
Y
B/O
B/W
B/Y
G/B
: Black
: Green
: Orange
: Pink
: Red
: Yellow
: Black/orange
: Black/white
: Black/yellow
: Green/black
63P3F11
G/R
G/Y
L/G
L/Y
P/G
P/W
R/Y
W/B
W/R
Y/G
: Green/red
: Green/yellow
: Blue/green
: Blue/yellow
: Pink/green
: Pink/white
: Red/yellow
: White/black
: White/red
: Yellow/green
8-10
1
2
3
4
5
6
7
8
9
ELEC
–
+
Electrical systems
Checking the ignition spark gap
Checking the spark plug wires
1. Remove the spark plug wire cover.
1. Remove the spark plug wires from the
spark plugs.
2. Disconnect the spark plug caps from the
spark plugs.
3. Connect a spark plug cap to the special
service tool.
2. Remove the spark plug wires from the
ignition coil.
3. Measure the spark plug wire resistance.
Replace if out of specification.
S63P8070
S60C8100
Ignition tester: 90890-06754
4. Crank the engine and observe the spark
through the discharge window of the
spark gap tester. Check the ignition system if the spark is weak.
Spark plug wire resistance:
#1: 4.6–10.9 kΩ
#2: 3.3–8.0 kΩ
#3: 3.8–9.3 kΩ
#4: 4.2–10.0 kΩ
Checking the ignition coils
1. Remove the spark plug wires from the
ignition coil.
2. Disconnect the ignition coil coupler.
3. Measure the ignition coil resistance.
Replace if out of specification.
S63P8090
WARNING
• Do not touch any of the connections of
the spark gap tester leads.
• Do not let sparks leak out of the
removed spark plug caps.
• Keep flammable gas or liquids away,
since this test can produce sparks.
S63P8100
NOTE:
The ignition spark gap can also be checked
using the “Stationary test” of the Yamaha
Diagnostic System.
8-11
63P3F11
Ignition and ignition control system
Ignition coil resistance:
Primary coil:
Red (R) – Black/white (B/W)
1.53–2.07 Ω at 20 °C (68 °F)
Secondary coil:
12.50–16.91 kΩ at 20 °C (68 °F)
3. Measure the pulser coil output peak voltage. Replace the pulser coil if below
specification.
Checking the ECM
1. Disconnect a ignition coil coupler.
2. Connect the test harness (2 pins) to the
ignition coil.
S63P8120
Digital circuit tester: 90890-03174
Peak voltage adapter B:
90890-03172
Test harness (3 pins): 90890-06791
3. Measure the ECM output peak voltage. If
below specification, measure the pulser
coil output peak voltage. Replace the
ECM if the output peak voltage of the
pulser coil is above specification.
Pulser coil output peak voltage:
White/red (W/R) – Black (B)
White/black (W/B) – Black (B)
r/min
DC V
S63P8110
Digital circuit tester: 90890-03174
Peak voltage adapter B:
90890-03172
Test harness (2 pins): 90890-06792
Unloaded
Loaded
Cranking
3.5
1,500
3,500
23.9
49.7
3.6
Pulser coil resistance
(use as reference):
459–561 Ω
ECM output peak voltage:
Black/orange (B/O) – Ground
Black/white (B/W) – Ground
r/min
DC V
Loaded
Cranking
1,500
3,500
260
260
270
Checking the pulser coil
1. Remove the flywheel magnet cover and
disconnect the pulser coil coupler.
2. Connect the test harness (3 pins) to the
pulser coil.
63P3F11
8-12
1
2
3
4
5
6
7
8
9
ELEC
–
+
Electrical systems
Checking the throttle position
sensor
Checking the intake air temperature
sensor
1. Remove the flywheel magnet cover.
1. Place the intake air temperature sensor
in a container of water and slowly heat
the water.
2. Connect the test harness (3 pins) to the
throttle position sensor.
3. Turn the engine start switch to ON.
4. Measure the throttle position sensor
input voltage. Check the wiring harness
connection or replace the ECM if out of
specification.
5. Measure the throttle position sensor output voltage. Adjust the throttle position
sensor if out of specification.
S69J8230
2. Measure the intake air temperature sensor resistance. Replace if out of specification.
Intake air temperature sensor
resistance:
at 20 °C (68 °F): 2.20–2.70 kΩ
S63P8130
NOTE:
To measure the output voltage, connect the
positive tester probe to the pink wire of the
test harness and the negative tester probe to
the orange wire of the test harness.
Checking the engine temperature
sensor
1. Place the engine temperature sensor in a
container of water and slowly heat the
water.
Digital circuit tester: 90890-03174
Test harness (3 pins): 90890-06793
Throttle position sensor input
voltage:
Orange (O) – Black (B)
5V
Throttle position sensor output
voltage:
Pink (P) – Black (B)
0.70 ± 0.02 V
8-13
S69J8240
2. Measure the engine temperature sensor
resistance. Replace if out of specification.
Engine temperature sensor
resistance:
Black/yellow (B/Y) –
Black/yellow (B/Y)
at 20 °C (68 °F): 54.2–69.0 kΩ
at 100 °C (212 °F): 3.12–3.48 kΩ
63P3F11
Ignition and ignition control system
Checking the thermoswitch
1. Place the thermoswitches in a container
of water and slowly heat the water.
Switch
position
Lead color
Blue/yellow
(L/Y)
Black (B)
Free a
Push b
Checking the neutral switch
1. Check the neutral switch for continuity.
Replace if there is no continuity.
S69J8250
a
b
2. Check the switch for continuity at the
specified temperatures. Replace if out of
specification.
S69J8270
Switch
position
Lead color
Blue/green
(L/G)
Black (B)
Free a
Push b
a
b
c
d
Temperature
Time
No continuity
Continuity
Thermoswitch continuity
temperature:
Pink (P) – Black (B)
e: 84–90 °C (183–194 °F)
f: 68–82 °C (154–180 °F)
Checking the shift cut switch
1. Check the shift cut switch for continuity.
Replace if there is no continuity.
a
b
S69J8270
63P3F11
8-14
1
2
3
4
5
6
7
8
9
–
ELEC
+
Electrical systems
Fuel control system
8
W/R
B
B
B
W/B
W/R
W/B
W/R
B
B
1
1
#2/3
B/Y
B/Y
B
2 3
Y/G
2
7 8
P
B/Y
12
14 15
O
W/R W/B
10
B
G/B
G
21
28
30
Y
R/Y
32 33 34 35
P/G
P
3G/B
B
0
G6
Pw/Y Pw/B Pw/R
B
B
42 43
B
6
5
4
3
2
1
38 39 40
B/Y
R/Y5
G/Y 4
2 R/Y
G/R
G/Y
B
1G/R
B/Y
O
17 18 19 20
L
9
B/Y
B/Y
#1/4
Pw/G
B
B
B
B
P
Y
P
A
3
O
B
B/Y
B
B
R/Y
È
Y/G
B
P/G
R/Y
R/Y
R/Y
Pu/R
C
#1
Pu/R
4
R/Y
L
E
1
D
C
B
A
0
9
8
7
6
5
4
3
2
L
L
R/Y
R/Y
6
R/Y
Pu/B
5
C
#2
Pu/B
7
R/Y
R/Y
Pu/Y
F
R
L
R/Y
G
R
L
R/Y
R/Y
1
5
Y/G
R/Y
C
R/Y R/Y R/Y
11 12 13
17
R/Y R/Y R/Y
R
#3
Pu/Y
8 9 10
D
R/Y
R/Y
Pu/G
C
#4
Pu/G
B
B
8
B
S63P8210
1
2
3
4
5
6
7
8
9
0
Pulser coil
ECM
Intake air temperature sensor
Fuse holder
Main relay
Fuse (20 A)
Fuse (50 A)
Battery
Engine temperature sensor
Idle speed control
8-15
A
B
C
D
Throttle position sensor
Intake air pressure sensor
Fuel injector
Electric fuel pump
È To remote control box/switch panel
63P3F11
Fuel control system
8
W/R
B
B
B
W/B
W/R
W/B
W/R
B
B
1
1
#2/3
B/Y
B/Y
B
2 3
Y/G
2
7 8
P
B/Y
12
14 15
O
W/R W/B
10
B
G/B
G
21
28
30
Y
R/Y
32 33 34 35
P/G
P
3G/B
B
0
G6
Pw/Y Pw/B Pw/R
B
B
42 43
B
6
5
4
3
2
1
38 39 40
B/Y
R/Y5
G/Y 4
2 R/Y
G/R
G/Y
B
1G/R
B/Y
O
17 18 19 20
L
9
B/Y
B/Y
#1/4
Pw/G
B
B
B
B
P
Y
P
A
3
O
B
B/Y
B
B
R/Y
È
Y/G
B
P/G
R/Y
R/Y
R/Y
Pu/R
C
#1
Pu/R
4
R/Y
L
E
1
D
C
B
A
0
9
8
7
6
5
4
3
2
L
L
R/Y
R/Y
6
R/Y
Pu/B
5
C
#2
Pu/B
7
R/Y
R/Y
Pu/Y
F
R
L
R/Y
G
R
L
R/Y
R/Y
1
5
Y/G
R/Y
C
R/Y R/Y R/Y
11 12 13
17
R/Y R/Y R/Y
R
#3
Pu/Y
8 9 10
D
R/Y
R/Y
Pu/G
C
#4
Pu/G
B
B
8
B
S63P8210
B
G
L
O
P
R
Y
B/Y
G/B
G/R
: Black
: Green
: Blue
: Orange
: Pink
: Red
: Yellow
: Black/yellow
: Green/black
: Green/red
63P3F11
G/Y
P/G
Pu/B
Pu/G
Pu/R
Pu/Y
R/Y
W/B
W/R
Y/G
: Green/yellow
: Pink/green
: Purple/black
: Purple/green
: Purple/red
: Purple/yellow
: Red/yellow
: White/black
: White/red
: Yellow/green
8-16
1
2
3
4
5
6
7
8
9
ELEC
–
+
Electrical systems
Checking the injectors
1. Measure the resistance of the fuel injectors. Replace if out of specification.
1
3
2
S60V8450
Digital circuit tester: 90890-03174
Checking the electric fuel pump
1. Turn the engine start switch to ON.
Fuel injector resistance
(use as reference):
14.0–15.0 Ω at 20 °C (68 °F)
2. Listen for the operating sound of the
electric fuel pump 1. Check the fuel system if there is no sound.
NOTE:
Check the operation of the fuel injectors
using the “Stationary test” of the Yamaha
Diagnostic System.
Checking the main relay
1. Remove the fuse holder cover, and then
remove the fuse holder.
2. Connect the digital circuit tester leads to
the main relay terminals 1 and 2.
3. Connect the positive battery terminal to
the main relay terminal 1.
NOTE:
After the engine start switch is turned to ON,
the electric fuel pump will operate for 3 seconds.
4. Connect the negative battery terminal to
the main relay terminal 3.
5. Check for continuity between the main
relay terminals. Replace if there is no
continuity.
6. Check that there is no continuity between
the relay terminals after disconnecting a
battery terminal from the main relay terminals 1 and 3. Replace if there is continuity.
8-17
63P3F11
Fuel control system / Starting system
Starting system
8
1
I
H
7
3 4
2
R
3 4
B
R
15
17
R
R
B
E 1DCBA098765432 G
F
R
R
R
R R
6
Br/W
B
5
R
Br
B
Br
R
È
R
B
Br
B
S63P8220
1
2
3
4
5
6
7
Fuse holder
Fuse (30 A)
Fuse (20 A)
Fuse (50 A)
Starter relay
Starter motor
Battery
B
Br
R
Br/W
: Black
: Brown
: Red
: Brown/white
È To remote control box/switch panel
63P3F11
8-18
1
2
3
4
5
6
7
8
9
ELEC
–
+
Electrical systems
Checking the fuses
1. Check the fuses for continuity. Replace if
there is no continuity.
S69J8340
Checking the starter relay
1. Connect the digital circuit tester leads to
the starter relay terminals.
2. Connect the positive battery terminal to
the brown (Br) lead.
3. Connect the negative battery terminal to
the black (B) lead.
4. Check for continuity between the starter
relay terminals. Replace if there is no
continuity.
5. Check that there is no continuity between
the starter relay terminals after disconnecting a battery terminal from the brown
or black lead. Replace if there is continuity.
Br
B
S60V8265
8-19
63P3F11
Starting system / Starter motor
Starter motor
8
1
2
3
4
15
5
16
6
7
17
18
19
20
19
21
22
19
8
9
10
27
28
26
11
29
19
30
31
23
12
13
24
14
25
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Part name
Clip
Pinion stopper
Starter motor pinion
Spring
Bolt
Housing
Bearing
Clutch assembly
E-clip
Washer
Bracket
Pinion shaft
Planetary gear
Outer gear
Plate
Armature
Stator
63P3F11
S63P8050
Q’ty
1
1
1
1
2
1
1
1
1
1
1
1
3
1
1
1
1
Remarks
M6 × 35 mm
Not reusable
8-20
1
2
3
4
5
6
7
8
9
ELEC
–
+
Electrical systems
8
1
2
3
4
15
5
16
6
7
17
18
19
20
19
21
22
19
8
9
10
27
28
26
11
29
19
30
31
23
12
13
24
14
25
No.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
8-21
Part name
Brush assembly
Brush spring
Brush holder
Plate
Washer
Bracket
Screw
Bolt
Rubber seal
Shift lever
Spring
Magnet switch assembly
Washer
Nut
S63P8050
Q’ty
1
4
1
1
1
1
2
2
1
1
1
1
1
1
Remarks
ø4 × 15 mm
M6 × 120 mm
63P3F11
Starter motor
Removing the starter motor pinion
1. Slide the pinion stopper 1 down as
shown, and then remove the clip 2.
2. Measure the commutator diameter.
Replace the armature if out of specification.
NOTE:
Remove the clip with a thin screwdriver.
Checking the starter motor pinion
1. Check the teeth of the pinion for cracks
or wear. Replace if necessary.
Commutator diameter limit:
28.0 mm (1.10 in)
3. Measure the commutator undercut a.
Replace the armature if out of specification.
2. Check for smooth operation. Replace if
necessary.
NOTE:
Turn the pinion counterclockwise to check
that it operates smoothly and turn it clockwise
to check that it locks in place.
Checking the armature
1. Check the commutator for dirt. Clean
with 600–grit sandpaper and compressed air if necessary.
63P3F11
Commutator undercut limit a:
0.2 mm (0.01 in)
8-22
1
2
3
4
5
6
7
8
9
ELEC
–
+
Electrical systems
4. Check the armature for continuity.
Replace if out of specifications.
Brush continuity
Brush 1 – Brush 2
No continuity
Checking the magnet switch
1. Connect the tester leads between the
magnet switch terminals as shown.
2. Connect the positive battery lead to the
brown and white (Br/W) lead.
3. Connect the negative battery lead to the
starter motor body.
Armature continuity
Commutator segments b
Continuity
Br/W
Segment – Armature core c No continuity
Segment – Armature shaft d No continuity
Checking the brushes
1. Measure the brush length. Replace the
brush assembly if out of specification.
S69J8450
CAUTION:
Do not connect the battery for more than
one second, otherwise the magnet switch
can be damaged.
4. Check that there is continuity between
the magnet switch terminals. Replace if
there is no continuity.
Brush length limit a:
9.5 mm (0.37 in)
2. Check the brush holder assembly for
continuity. Replace if out of specifications.
2
5. Check that there is no continuity after the
negative battery terminal is removed.
Replace if there is continuity.
NOTE:
The starter motor pinion should be pushed
out while the magnet switch is on.
1
Checking the starter motor operation
1. Check the operation of the starter motor
after installing it onto the power unit.
S69J8440
8-23
63P3F11
Starter motor / Charging system
Charging system
#2/3
8
#1/4
1
G
G
G
G
G
G
2
B
3
R
E
1
D
C
B
A
0
9
8
7
6
5
4
3
2
G
F
R
B
16 17 18 19
R
4
4
R
R
R
I
R
R
H
R
B
B
R
B
B
5
R
R
6
B
B
S63P8230
1
2
3
4
5
6
Stator coil
Rectifier Regulator
Fuse holder
Fuse (50 A)
Accessory battery
Battery
63P3F11
B
G
R
: Black
: Green
: Red
8-24
1
2
3
4
5
6
7
8
9
ELEC
–
+
Electrical systems
Checking the stator coil
1. Disconnect the stator coil coupler.
2. Connect the test harness (3 pins) to the
stator coil.
3. Measure the Rectifier Regulator output
peak voltage. If below specification, measure the stator coil output peak voltage.
Replace the Rectifier Regulator if the output peak voltage of the stator coil is
above specification.
3. Measure the stator coil output peak voltage. Replace the stator coil assembly if
below specification.
S63P8170
Digital circuit tester: 90890-03174
Peak voltage adapter B:
90890-03172
Test harness (3 pins): 90890-06846
S63P8160
Digital circuit tester: 90890-03174
Peak voltage adapter B:
90890-03172
Test harness (3 pins): 90890-06847
Stator coil output peak voltage:
Green (G) – Green (G)
r/min
DC V
Unloaded
Cranking
1,500
3,500
12
50
110
Rectifier Regulator output peak
voltage:
Red (R) – Black (B)
r/min
DC V
Unloaded
1,500
3,500
13.0
13.0
Stator coil resistance
(use as reference):
Green (G) – Green (G)
0.20–0.30 Ω at 20 °C (68 °F)
Checking the Rectifier Regulator
1. Disconnect the Rectifier Regulator coupler.
2. Connect the test harness (3 pins) to the
Rectifier Regulator.
8-25
63P3F11
TRBL
SHTG
Troubleshooting
Special service tools .....................................................................................9-1
Yamaha Diagnostic System ..........................................................................9-2
Introduction................................................................................................9-2
Power unit....................................................................................................... 9-5
Self-diagnosis...............................................................................................9-19
Diagnosing the electronic control system ................................................ 9-19
63P3F11
1
2
3
4
5
6
7
8
9
TRBL
SHTG
Troubleshooting
Special service tools
9
Yamaha Diagnostic System
60V-85300-02
YAMAHA
DIAGNOSTIC
SYSTEM
INSTALLATION MANUAL
Yamaha Diagnostic System
60V-WS853-02
Diagnostic flash indicator B
90890-06865
9-1
63P3F11
Special service tools / Yamaha Diagnostic System
Yamaha Diagnostic System
9
Introduction
Features
The newly developed Yamaha Diagnostic System provides quicker detection and analysis of engine
malfunctions for quicker troubleshooting procedures than traditional methods.
By connecting your computer to the ECM (Electronic Control Module) of an outboard motor using
the communication cable, this software can be used to display sensor data and data stored in the
ECM on a computer’s monitor.
If this software is run on Microsoft Windows® 95, Windows 98, Windows Me, Windows 2000, or
Windows XP the information can be displayed in colorful graphics. Also, the software can be operated using either a mouse or a keyboard.
In addition, the data for the main functions (Diagnosis, Diagnosis record, Engine monitor, and Data
logger) can be saved on a disk or printed out.
Functions
1. Diagnosis: With the engine main switch ON, each sensor’s status and each ECM diagnosis
code or item is displayed. This enables you to find malfunctioning parts and controls quickly.
2. Diagnosis record: Sensors that had been activated and ECM diagnostic codes that have been
recorded are displayed. This allows you to check the outboard motor’s record of malfunctions.
3. Engine monitor: Each sensor status and the ECM data are displayed while the engine is running. This enables you to find malfunctioning parts quickly.
4. Stationary test: With the engine off, the ignition, fuel injection, electric fuel pump, and ISC
valve are checked. These tests can be performed quickly.
5. Active test: With the engine running the ISC valve is checked.
6. Data logger: Displays 13 minutes of recorded data for two or more of the items stored in the
ECM. In addition, the operating time as compared to the engine speed and the total operating
time are displayed. This allows you to check the operating status of the engine.
7. Some files: Lets you select and run other applications while continuing to run the diagnostic
program.
Contents
1. Software (1)
2. Adapter (1)
YAMAHA
DIAGNOSTIC
SYSTEM
3. Communication cable (1)
YAMAHA
DIAGNOSTIC
SYSTEM
INSTALLATION MANUAL
INSTRUCTION MANUAL
4. Instruction Manual (1)
5. Installation Manual (1)
63P3F11
1
2
3
4
5
9-2
1
2
3
4
5
6
7
8
9
TRBL
SHTG
Troubleshooting
Hardware requirements
Make sure that your computer meets the following requirements before using this software.
Computer:
IBM-compatible computer
Operating system:
Microsoft (Windows 95,) Windows 98, Windows Me, Windows 2000, or
Windows XP (English version)
CPU:
Windows 95/98:
Windows Me/2000:
Windows XP:
i486X, 100 MHz or higher (Pentium 100 MHz or higher recommended)
Pentium, 166 MHz or higher (Pentium 233 MHz or higher recommended)
Pentium, 300 MHz or higher (Pentium 500 MHz or higher recommended)
Memory:
Windows 95/98:
Windows Me:
Windows 2000:
Windows XP:
16 MB or more (32 MB or more recommended)
32 MB or more (64 MB or more recommended)
64 MB or more (128 MB or more recommended)
128 MB or more (256 MB or more recommended)
Hard disk free space:
20 MB or more (40 MB or more recommended)
Drive:
CD-ROM drive
Display:
VGA (640 × 480 pixels), (SVGA [800 × 600 pixels] or more recommended)
256 or more colors
Mouse:
Compatible with the operating systems mentioned above
Communication port:
RS232C (Dsub-9 pin) port, USB port
Printer:
Compatible with the operating systems mentioned above
NOTE:
• The amount of memory and the amount of free space on the hard disk differs depending on the
computer.
• Using this software while there is not enough free space on the hard disk could cause errors and
result in insufficient memory.
• This software will not run properly on some computers.
• When starting up this program, do not start other software applications.
• Do not use the screen saver function or the energy saving feature when using this program.
• If the ECM is changed, restart the program.
• Window XP is a multiuser operating system, therefore, be sure to end this program if the login
user is changed.
• The USB adapter cannot be used with Windows 95.
For operating instructions of the Yamaha Diagnostic System, refer to the “Yamaha Diagnostic System Instruction Manual.”
9-3
63P3F11
Yamaha Diagnostic System
Connecting the communication cable to the outboard motor
Models: F(L)150A
Bow view
3-pin communication coupler
S63P9030
63P3F11
9-4
1
2
3
4
5
6
7
8
9
TRBL
SHTG
Troubleshooting
NOTE:
• Before troubleshooting the outboard motor, check the compression pressure, the mounting and
rigging of the outboard motor, and the operation of the engine start switch. Also, make sure that
specified fuel has been used and that the battery is fully charged.
• To diagnose a mechanical malfunction, use the troubleshooting charts for each trouble located in
this chapter. Also, when checking and maintaining the outboard motor, see Chapters 3–8 for safe
maintenance procedures.
• To diagnose a sensor or switch malfunction, use the diagnostic flash indicator to determine the
cause.
Power unit
9
Symptom 1: Engine does not start, or starting the engine is difficult.
Starting system
Check the starter motor operation.
Good operating
condition?
Yes
Check the ignition system and
fuel system.
No
Check the battery lead connections and the starter motor positive terminal for damage and
check that the ground lead bolt
is not loose or that it has not
come off. Check for blown
fuses.
Good condition?
No
Repair or replace the defective
parts.
Yes
Check the starter relay for continuity.
Continued on next page.
9-5
63P3F11
Power unit
Is there continuity?
No
1
2
3
4
5
6
7
8
9
Replace the starter relay.
Yes
Check the wiring harness for
continuity.
Is there continuity?
No
Repair or replace the wiring harness.
Yes
Disassemble and check the
starter motor.
63P3F11
9-6
TRBL
SHTG
Troubleshooting
Ignition system
Check the condition of the spark
plugs.
No
Good condition?
Clean, adjust, or replace the
spark plugs.
Yes
Check the ignition spark using
the spark gap tester.
WARNING
• Do not touch any of the connections of the spark gap tester leads.
• Do not let sparks leak out of the removed spark plug caps.
• Keep flammable gas and liquids away, since this test can produce
sparks.
Good spark?
Yes
Check the pulser coil output
peak voltage or resistance.
No
Good condition?
No
Replace the stator
assembly.
Yes
Check the ignition coil resistance.
Good condition?
Check the starting system or
the fuel system.
No
Repair or replace the defective
parts.
Yes
Check the spark plug wire resistance and the spark plug caps
for salt buildup.
Continued on next page.
9-7
63P3F11
Power unit
Good condition?
No
Repair or replace the spark plug
wires.
Yes
Check the main relay for continuity.
Is there continuity?
No
Replace the main relay.
Yes
Check the ECM output peak
voltage.
Fuel system
Check the electric fuel pump
operation.
Can the operation sound be
heard?
No
Check the fuse holder, fuse,
and wiring harness for continuity.
Yes
Is there continuity?
No
Repair or replace
the defective parts.
Yes
Check the fuel filters for clogs
and the hoses for leaks.
Replace the electrical fuel
pump.
Continued on next page.
63P3F11
9-8
1
2
3
4
5
6
7
8
9
TRBL
SHTG
Troubleshooting
Clogs or leaks?
Yes
Repair or replace the defective
parts.
No
Check the fuel pump
diaphragm.
Cracks or damage?
Yes
Replace the diaphragm.
No
Check the vapor separator
needle valve.
Is the needle valve
bent or worn?
Yes
Replace the needle valve.
No
Check the injector resistance
and check the injectors for
clogs.
Good condition?
No
Replace the injectors.
Yes
Check the starting system or
the ignition system.
9-9
63P3F11
Power unit
Symptom 2: Engine speed at wide open throttle is low, engine speed decreases, or engine
stalls (poor acceleration or poor deceleration).
1
2
3
4
5
6
7
8
9
Check the battery lead connections and check that the ground
lead bolt is not loose or that it
has not come off.
Good condition?
No
Repair or replace the defective
parts.
Yes
Check the throttle position sensor and check that the connector is securely connected.
Good condition?
No
Repair or replace the defective
part.
Yes
Check the throttle valves for
bends or for stuck throttle valve
shafts.
Good condition?
No
Replace the throttle body.
Yes
Check the ignition system or the
fuel system.
63P3F11
9-10
TRBL
SHTG
Troubleshooting
Ignition system
Check the condition of the spark
plugs.
No
Good condition?
Clean, adjust, or replace the
spark plugs.
Yes
Check the ignition spark using
the spark gap tester.
WARNING
• Do not touch any of the connections of the spark gap tester leads.
• Do not let sparks leak out of the removed spark plug caps.
• Keep flammable gas and liquids away, since this test can produce
sparks.
Good spark?
Yes
Check the pulser coil output
peak voltage or resistance.
No
Good condition?
No
Replace the stator
assembly.
Yes
Check the ignition coil resistance.
Good condition?
Check the fuel system.
No
Repair or replace the defective
parts.
Yes
Check the spark plug wire resistance and check the spark plug
caps for salt buildup.
Continued on next page.
9-11
63P3F11
Power unit
Good condition?
No
Repair or replace the spark plug
wires.
Yes
Check the ECM output peak
voltage.
Fuel system
Check the electric fuel pump
operation.
Can the operation sound be
heard?
No
Check the fuse holder, fuse,
and wiring harness for continuity.
Yes
Is there continuity?
No
Repair or replace
the defective parts.
Yes
Check the fuel filters for clogs
and the hoses for leaks.
Good condition?
Replace the electric fuel pump.
No
Repair or replace the defective
parts.
Yes
Check the fuel pump diaphragm.
Continued on next page.
63P3F11
9-12
1
2
3
4
5
6
7
8
9
TRBL
SHTG
Troubleshooting
Cracks or damage?
Yes
Replace the diaphragm.
No
Check the vapor separator needle valve.
Is the needle valve
bent or worn?
Yes
Replace the needle valve.
No
Check the vapor separator
pressure regulator.
Good condition?
No
Replace the pressure regulator.
Yes
Check the injector resistance
and check the injectors for
clogs.
Good condition?
No
Replace the injectors.
Yes
Check the starting system or
the ignition system.
9-13
63P3F11
Power unit
Lubrication system
1
2
3
4
5
6
7
8
9
Check the engine oil level.
At specified level?
No
Add engine oil to the correct
level.
No
Check the oil pump for debris or
oil leaks.
Yes
Check the oil pressure.
Within specification?
Yes
Debris or leaks?
No
Check the oil
passage.
Yes
Clean or replace the defective
parts.
Check the oil pressure sensor.
Good condition?
No
Replace the oil pressure sensor.
Yes
Check the ignition system or the
fuel system.
63P3F11
9-14
TRBL
SHTG
Troubleshooting
Symptom 3: Engine speed not stable at low speeds.
Check the throttle position sensor and check that the connector is securely connected.
Good condition?
No
Repair or replace the defective
part.
No
Repair or replace the defective
parts.
Yes
Check the neutral switch for
continuity.
Is there continuity?
Yes
Check the throttle valve opening
of each cylinder.
Are the throttle
valve openings
incorrect or are
the throttle valve
links worn?
Yes
Replace the throttle body.
No
Check the ignition system or the
fuel system.
9-15
63P3F11
Power unit
Ignition system
Check the condition of the spark
plugs.
No
Good condition?
Clean, adjust, or replace the
spark plugs.
Yes
Check the ignition spark using
the spark gap tester.
WARNING
• Do not touch any of the connections of the spark gap tester leads.
• Do not let sparks leak out of the removed spark plug caps.
• Keep flammable gas and liquids away, since this test can produce
sparks.
Good spark?
Yes
Check the fuel system.
No
Check the ignition coil resistance.
Good condition?
No
Repair or replace the defective
parts.
Yes
Check the spark plug wire resistance and check the spark plug
caps for salt buildup.
Good condition?
No
Repair or replace the spark plug
wires.
Yes
Check the ECM output peak
voltage.
63P3F11
9-16
1
2
3
4
5
6
7
8
9
TRBL
SHTG
Troubleshooting
Fuel system
Check the fuel pump diaphragm.
Cracks or damage?
Yes
Replace the diaphragm.
No
Check the vapor separator needle valve.
Is the needle valve
bent or worn?
Yes
Replace the needle valve.
No
Check the injector resistance
and check the injectors for
clogs.
Good condition?
No
Replace the injectors.
Yes
Check the ignition system.
9-17
63P3F11
Power unit
Symptom 4: Hunting occurs.
Check the throttle valve opening
of each cylinder.
Are the throttle
valves open
excessively?
Yes
1
2
3
4
5
6
7
8
9
Synchronize the throttle valves
or replace the defective parts.
No
Adjust the throttle cable.
Symptom 5: Engine speed rises even when the throttle position is fixed.
Check the throttle cable
operation.
Good condition?
No
Adjust the throttle cable.
Yes
Synchronize the throttle valves.
63P3F11
9-18
TRBL
SHTG
Troubleshooting
Self-diagnosis
9
Diagnosing the electronic control
system
1. Connect the special service tool to the
outboard motor as shown.
• Trouble code indication
Example: The illustration
code number 23.
a: Light on, 0.33 second
b: Light off, 4.95 seconds
c: Light off, 0.33 second
d: Light off, 1.65 seconds
L/W
indicates
S63P9010
NOTE:
When performing this diagnosis, all of the
electrical wires must be properly connected.
Diagnostic flash indicator B:
90890-06865
2. Start the engine and let it idle.
3. Check the flash pattern of the diagnostic
flash indicator to determine if there are
any malfunctions.
• Normal condition
(no defective part or irregular processing is found)
4. If a flash pattern listed in the diagnostic
code chart is displayed, check the malfunctioning part according to the flash
pattern.
NOTE:
When more than one problem is detected,
the light of the diagnostic flash indicator
flashes in the pattern of the lowest numbered
problem. After that problem is corrected, the
light flashes in the pattern of the next lowest
numbered problem. This continues until all of
the problems are detected and corrected.
• Single flash is given every 4.95 seconds.
a: Light on, 0.33 second
b: Light off, 4.95 seconds
9-19
63P3F11
Self-diagnosis
Code
Symptom
1
Normal
13
Incorrect pulser coil signal
15
Incorrect engine temperature
sensor signal
18
Incorrect throttle position sensor
signal
19
Incorrect battery voltage
23
Incorrect intake air temperature
sensor signal
28
Incorrect neutral switch signal
29
Incorrect intake air pressure
sensor signal
37
Incorrect idle speed control
signal
39
Incorrect oil pressure sensor
signal
44
Incorrect engine stop lanyard
switch signal
45
Incorrect shift cut switch signal
46
Incorrect thermoswitch signal
63P3F11
1
2
3
4
5
6
7
8
9
9-20
Index
Numerics
64E type power trim and tilt unit................1-11
A.
Adjusting the throttle link and
throttle cable .............................................3-8
Adjusting the throttle link and throttle cable
operation (using a thickness gauge) .......3-10
Adjusting the throttle position sensor ........4-17
Adjusting the throttle position sensor
(when disassembling or replacing the
throttle body) ...........................................4-18
Adjusting the trim sensor cam...................7-18
Aft view .......................................................8-5
After test run .............................................1-25
Applicable models.......................................1-5
Assembling a fuel pump..............................4-8
Assembling the drive shaft
housing ......................................... 6-19, 6-48
Assembling the forward gear ....................6-19
Assembling the gear pump housing..........7-35
Assembling the lower case ............. 6-19, 6-47
Assembling the oil pan..............................7-12
Assembling the oil pump...........................5-49
Assembling the pistons and
cylinder block ..........................................5-50
Assembling the power trim and tilt motor ...7-33
Assembling the power trim and tilt unit .....7-40
Assembling the propeller shaft
assembly.................................................6-14
Assembling the propeller shaft
housing ......................................... 6-14, 6-41
Assembling the reverse gear ....................6-48
Assembling the tilt piston and
trim pistons..............................................7-39
B.
Backlash (counter rotation model) ............6-60
Backlash (regular rotation model) .............6-29
Balancer......................................................1-7
Bleeding the power trim and tilt unit..........7-43
Bleeding the power trim and tilt unit
(built-in) ...................................................7-45
Bottom cowling............................................7-2
Break-in.....................................................1-25
i-1
C.
Changing the engine oil by draining it ........ 3-5
Changing the engine oil using an
oil changer ................................................ 3-4
Changing the gear oil ............................... 3-14
Charging system....................................... 8-24
Checking the anodes................................ 3-15
Checking the armature ............................. 8-22
Checking the balancer assembly.............. 5-41
Checking the battery........................1-22, 3-16
Checking the bearings.....................6-18, 6-47
Checking the brushes............................... 8-23
Checking the camshaft ............................. 5-33
Checking the check valve......................... 4-14
Checking the compression pressure ........ 5-11
Checking the connecting rod big end
side clearance ........................................ 5-43
Checking the cooling water passage.......... 3-8
Checking the cooling water pilot hole ....... 1-25
Checking the crankpin oil clearance......... 5-45
Checking the crankshaft ........................... 5-44
Checking the crankshaft main journal oil
clearance ................................................ 5-47
Checking the cylinder bore ....................... 5-42
Checking the cylinder head ...................... 5-34
Checking the diaphragm and valves .......... 4-8
Checking the drive shaft ..................6-18, 6-47
Checking the ECM.................................... 8-12
Checking the electric fuel pump ............... 8-17
Checking the electrical components........... 8-2
Checking the engine idle speed ................. 3-8
Checking the engine oil .............................. 3-4
Checking the engine oil level.................... 1-22
Checking the engine start switch and
engine stop lanyard switch ..................... 1-24
Checking the engine temperature
sensor..................................................... 8-13
Checking the fuel filter ................................ 3-3
Checking the fuel joint and fuel hoses
(fuel joint-to-fuel injector) .......................... 3-3
Checking the fuel pumps ............................ 4-7
Checking the fuel system ......................... 1-22
Checking the fuse..................................... 7-47
Checking the fuses ................................... 8-19
Checking the gear oil level ..............1-22, 3-13
Checking the gear pump .......................... 7-35
Checking the gear shift and
throttle operation..................................... 1-24
Checking the gear shift operation............. 3-11
Checking the hydraulic pressure .............. 7-28
Checking the ignition coils ........................ 8-11
Checking the ignition spark gap ............... 8-11
Checking the ignition timing...................... 3-12
63P3F11
Index
Checking the injectors...............................8-17
Checking the intake air temperature
sensor .....................................................8-13
Checking the lower case................. 6-18, 6-47
Checking the lower unit for air leakage.....3-15
Checking the magnet switch .....................8-23
Checking the main relay ...........................8-17
Checking the neutral switch ......................8-14
Checking the oil pressure .........................5-11
Checking the oil pressure sensor..............5-12
Checking the oil pump ..............................5-49
Checking the oil strainer ...........................7-12
Checking the outboard motor mounting
height ......................................................1-23
Checking the pinion and forward gear ......6-18
Checking the pinion and reverse gear ......6-47
Checking the piston clearance..................5-42
Checking the piston diameter ...................5-41
Checking the piston ring grooves..............5-43
Checking the piston ring side clearance ...5-43
Checking the piston rings..........................5-42
Checking the power trim and tilt
fluid level .................................................3-13
Checking the power trim and tilt motor .....7-31
Checking the power trim and tilt
operation .................................................3-13
Checking the power trim and tilt relay.......7-47
Checking the power trim and tilt switch.....7-47
Checking the power trim and tilt system ...1-24
Checking the pressure control valve.........5-37
Checking the pressure regulator...............4-13
Checking the propeller ..............................3-15
Checking the propeller shaft ........... 6-13, 6-41
Checking the propeller shaft
housing ......................................... 6-13, 6-41
Checking the pulser coil............................8-12
Checking the Rectifier Regulator ..............8-25
Checking the remote control cables..........1-23
Checking the shift cut switch.....................8-14
Checking the spark plug wires ..................8-11
Checking the spark plugs............................3-6
Checking the starter motor operation........8-23
Checking the starter motor pinion .............8-22
Checking the starter relay .........................8-19
Checking the stator coil.............................8-25
Checking the steering system...................1-24
Checking the thermostat .............................3-7
Checking the thermoswitch.......................8-14
Checking the throttle position sensor........8-13
Checking the tilt cylinder and
trim cylinder.............................................7-38
Checking the timing belt..............................3-6
Checking the timing belt and sprockets ....5-21
63P3F11
Checking the top cowling............................ 3-3
Checking the trim sensor.......................... 7-48
Checking the valve clearance............3-6, 5-12
Checking the valve guides........................ 5-29
Checking the valve seat ........................... 5-31
Checking the valve springs....................... 5-28
Checking the valves ................................. 5-29
Checking the vapor separator .................. 4-15
Checking the water pump and
shift rod............................................6-9, 6-37
Clamp brackets......................................... 7-16
Connecting rod ........................................... 1-8
Control system............................................ 3-8
Cooling system ......................................... 1-12
Crankshaft and cylinder.............................. 1-6
Cylinder block ........................................... 5-38
Cylinder head ........................................... 5-23
Cylinder head cover.................................... 1-8
D.
Diagnosing the electronic control
system .................................................... 9-19
Dimensions................................................. 2-9
Disassembling a fuel pump ........................ 4-7
Disassembling the cylinder block ............. 5-41
Disassembling the drive shaft
housing ..........................................6-17, 6-46
Disassembling the forward gear ......6-17, 6-40
Disassembling the gear pump housing .... 7-34
Disassembling the lower case .........6-17, 6-46
Disassembling the oil pan......................... 7-12
Disassembling the oil pump...................... 5-49
Disassembling the power trim and tilt
motor ...................................................... 7-30
Disassembling the propeller shaft
assembly .......................................6-12, 6-40
Disassembling the propeller shaft
housing ..........................................6-12, 6-41
Disassembling the reverse gear ............... 6-46
Disassembling the tilt cylinder and
trim cylinder ............................................ 7-37
Disassembly and assembly ........................ 1-4
Draining the engine oil.............................. 7-12
Drive shaft and lower case
(counter rotation model) ......................... 6-44
Drive shaft and lower case
(regular rotation model) .......................... 6-16
i-2
1
2
3
4
5
6
7
8
9
Index
E.
ECM ..........................................................1-17
Electrical .....................................................2-7
Electrical components.................................8-3
Electronic control system ..........................1-17
F.
Fail-safe control ........................................1-18
Features and benefits .................................1-6
Fire prevention ............................................1-3
Fuel and blowby hoses ...............................4-2
Fuel control system...................................8-15
Fuel filter, fuel pump, and intake silencer ...4-3
Fuel pump control .....................................1-20
Fuel system....................................... 1-15, 3-3
G.
General .....................................................3-15
General specifications.................................2-1
General torques ........................................2-13
Good working practices ..............................1-4
H.
Hose routing................................................4-2
How to use this manual...............................1-1
I.
Identification................................................1-5
Ignition and ignition control system.............8-9
Installing the clamp brackets.....................7-18
Installing the cylinder head .......................5-35
Installing the drive shaft .................. 6-20, 6-49
Installing the lower unit ................... 6-23, 6-52
Installing the power trim and tilt unit..........7-44
Installing the power unit ............................5-55
Installing the pressure control valve..........5-37
Installing the propeller shaft
housing ......................................... 6-21, 6-49
Installing the sprockets and timing belt .....5-21
Installing the steering arm.........................7-14
Installing the upper case ...........................7-15
Installing the valves...................................5-34
Installing the water pump and
shift rod ......................................... 6-21, 6-50
Intake assembly and vapor separator.........4-9
Intake system..............................................1-9
Introduction .................................................9-2
Isolator ......................................................1-16
J.
Junction box assembly................................8-4
i-3
L.
Lower unit ..........................................2-6, 3-13
Lower unit (counter rotation model).......... 6-32
Lower unit (regular rotation model)............. 6-4
Lubricating the outboard motor................. 3-16
Lubrication system.................................... 1-13
M.
Maintenance interval chart ......................... 3-2
Maintenance specification .......................... 2-3
Manual format............................................. 1-1
Measuring the forward and
reverse gear backlash ...................6-29, 6-60
Measuring the fuel pressure ..................... 4-13
Measuring the lower resistance.................. 8-2
Measuring the peak voltage ....................... 8-2
O.
Over-revolution control ............................. 1-20
P.
Parts, lubricants, and sealants ................... 1-3
Piston and piston ring ................................. 1-7
Port view..................................................... 8-3
Power trim and tilt electrical system ......... 7-46
Power trim and tilt unit .....................3-13, 7-20
Power unit............................ 2-3, 3-4, 5-3, 9-5
Predelivery checks ................................... 1-22
Propeller selection .................................... 1-21
Propeller shaft housing
(counter rotation model) ......................... 6-38
Propeller shaft housing
(regular rotation model) .......................... 6-10
Propeller size............................................ 1-21
R.
Rectifier Regulator.................................... 1-16
Reducing the fuel pressure....................... 4-15
Refacing the valve seat ............................ 5-31
Removing the clamp brackets .................. 7-18
Removing the cylinder head ..................... 5-28
Removing the drive shaft.................6-17, 6-46
Removing the exhaust cover .................... 5-37
Removing the lower unit ....................6-8, 6-36
Removing the oil filter ............................... 5-20
Removing the power trim and tilt unit ....... 7-27
Removing the power unit.......................... 5-18
Removing the propeller shaft
housing assembly..........................6-12, 6-40
Removing the reservoir ............................ 7-33
Removing the starter motor pinion ........... 8-22
63P3F11
Index
Removing the steering arm.......................7-14
Removing the timing belt and sprockets ...5-20
Removing the water pump and
shift rod ........................................... 6-8, 6-36
Replacing the oil filter..................................3-5
Replacing the timing belt................... 3-6, 5-16
Replacing the valve guides .......................5-30
Y.
Yamaha Diagnostic System ....................... 9-2
1
2
3
4
5
6
7
8
9
S.
Safety while working ...................................1-3
Selecting the connecting rod bearing........5-46
Selecting the crankshaft main bearing......5-48
Selecting the forward gear shims.... 6-27, 6-57
Selecting the pinion shims .............. 6-26, 6-55
Selecting the propeller shaft shims ...........6-58
Selecting the reverse gear shims.... 6-28, 6-56
Selection ...................................................1-21
Self-diagnosis ...........................................9-19
Self-protection.............................................1-3
Serial number..............................................1-5
Shift cut control .........................................1-20
Shimming ........................................ 6-26, 6-55
Shimming (counter rotation model)...........6-54
Shimming (regular rotation model)............6-25
Special service
tools ............ 3-1, 4-1, 5-1, 6-1, 7-1, 8-1, 9-1
Specified torques ......................................2-11
Starter motor .............................................8-20
Starting system .........................................8-18
Symbols ......................................................1-2
Synchronizing the throttle valves ..............4-16
T.
Technical tips ............................................1-17
Test run.....................................................1-25
Tightening torques ....................................2-11
Top cowling....................................... 1-10, 3-3
Top view......................................................8-6
U.
Upper case, steering arm,
swivel bracket and clamp brackets ...........7-6
V.
Ventilation ...................................................1-3
W.
Warning control.........................................1-19
Wiring harness ............................................8-7
63P3F11
i-4
Wiring diagram
F150AET, FL150AET
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
Spark plug
Ignition coil
Thermoswitch
Oil pressure sensor
Diode
Starter relay
Starter motor
Starting battery
Accessory battery
Fuse holder
Fuse (30 A)
Fuse (20 A)
Fuse (50 A)
Intake air temperature sensor
Power trim and tilt relay
Power trim and tilt motor
ECM
Pulser coil
Stator coil
Engine temperature sensor
Rectifier Regulator
Power trim and tilt switch
Trim sensor
Idle speed control
Throttle position sensor
Intake air pressure sensor
Fuel injector
Electric fuel pump
Shift cut switch
Neutral switch
Main relay
È
É
Ê
Ë
Ì
To personal computer for diagnosis
To remote control box/switch panel
To trim meter
To warning indicator
To diagnostic flash indicator
(special service tool)
(*1) Isolator cable (optional)
(*2) Negative cable (commercially available)
Color code
B
Br
G
Gy
L
Lg
O
P
R
Sb
W
Y
B/O
B/W
B/Y
Br/W
G/B
G/R
G/Y
L/G
L/W
L/Y
P/B
P/G
P/W
Pu/B
Pu/G
Pu/R
Pu/Y
R/Y
W/B
W/R
Y/G
: Black
: Brown
: Green
: Gray
: Blue
: Light green
: Orange
: Pink
: Red
: Sky blue
: White
: Yellow
: Black/orange
: Black/white
: Black/yellow
: Brown/white
: Green/black
: Green/red
: Green/yellow
: Blue/green
: Blue/white
: Blue/yellow
: Pink/black
: Pink/green
: Pink/white
: Purple/black
: Purple/green
: Purple/red
: Purple/yellow
: Red/yellow
: White/black
: White/red
: Yellow/green
YAMAHA MOTOR CO., LTD.
Printed in the Netherlands
Jul. 2003 – 1.2 × 1 CR
(E)
F150AET, FL150AET
B/Y
1 2 3 4
G
Y/G
P
W
B/Y
12
14 15
O
W/R W/B
B
L/Y
O
L
G/B
G
26 27 28 29 30
W/B L/W
31 32 33 34 35
B
P/G
P
Y
B/Y
B/Y
B
W/R
G/R
21 22 23 24
B
B/Y
B/Y
B/Y
G
17 18 19 20
G/Y B/O P/B P/W
L/G
J
7 8 9 10
B
G/R G/B R/Y L/G Pu/G Pu/Y Pu/B
W/B
B
W/R
P/W R/Y
37 38 39 40
W/B
B
B
P/W O
B
B/W
B/O
P
P/W
O
W/R
W/B
B/Y
G/R
G/B
G/Y
G
B
P
O
P/G
Pu/R
L
Pu/B
Pu/Y
Pu/G
L/Y
L/G
P/W
P/B
W
Y
P
G
O
P/W
B/W
R
P B
B/W
B/W
R
B/W
B/W
4
3
R
2
2
1
4
2
1 1
3
B
B
B
L/W
Y/G
R/Y
1 1
6
H
B
B
B
#2/3
#1/4
I
B
G
O
O
G/R 1
G/Y 4
6G
R/Y
R/Y 5
123456
Q
R/Y
Pu/R
#1
N
Pu/R
R/Y
L
Sb
Lg
L
R/Y
L
R/Y
G
L
R/Y
R/Y
L
R/Y
Br/W
G
R
P
Lg
Y
Sb
W
Br
B
B
D
R
Y
G
B
B
B/Y
#2
G
K
B
W
Pu/B
R
R
B
É
R/Y
Pu/Y
B
R/Y
Pu/G
B
B
B B
L/Y
B
Lg
Sb
I
B
L/W
P/B
P/W
B
H
R/Y R/Y R/Y R/Y R/Y R/Y
L/Y
B
R
R
R
R
Sb R Lg
E
B
Sb
R
Lg
Sb
R
Lg
R
Lg
(*1) B
T
L/G
Sb
Lg
R
B
L/G
B
Lg
Sb
S
Lg R Sb
RR
11 12 13 14 15 16 17 18 19
R/Y R/Y R/Y R/Y
L/Y
B
L/G
B
1 2 3 4 5 6 7 8 9 10
R
B
B
RR
C
C
F
7
R
Pu/G
Lg Sb
R
Q
#4
U
R
R/Y
R
B
Y/G
Q
Pu/Y
R
Sb
Lg
B/Y
B
R/Y
#3
Br
G
B
R/Y
W/B
B
A
1
D
C
B
A
0
9
8
7
6
5
4
3
2
5
È
Q
R/Y
Pu/B
G
G
G
W/B
P
0
B Sb Lg
E
B
B
P/G
3 G/B
Sb
Lg
B
B
P
2 R/Y
B
Sb
R/Y
Ì
O
O
G
Br
P
G
Lg
R
H
G
B/Y
W/B
R/Y
R/Y
R/Y
R/Y
R/Y
R/Y
B
R/Y
R/Y
R/Y
R
L/W
Br
R
Sb
Lg
B
Sb
Lg
B
Br
L/W
L/W
B
B
B
R/Y
B/O
B
B
B
B
B
B
B
O
W/R
B
B Pu/G B/W
R
L/Y R/Y R/Y R/Y R/Y R/Y
B
P
R/Y
B/W
R/Y
R/Y
G
Pu/R P/G
W/R
W/B
42 43 44
P B
B/O
R/Y
G/Y
L
P Pu/Y Pu/B Pu/R
B/Y
B
B
B
Sb
L/W
UP
FREE
DOWN
Sb
L
Sb
R
Lg
R
B
B (*2)
B
9
8
P
F
P/B
Lg
Sb
Ë
P/W
P
Ê
Gy
M
Gy
S63PWD02
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