Honda Marine BF135A Manual 692 Pages
The Honda Marine BF135A is a powerful and reliable 4-stroke, 4-cylinder outboard motor with a displacement of 2,354 cm3. It's designed for a variety of boats and applications, offering a balance of performance and efficiency. Featuring a forced water circulation cooling system, electronic fuel injection, and a robust construction, this engine provides dependable operation for both leisurely cruising and challenging water activities.
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PREFACE
This manual covers the construction, function and
serving procedures for the Honda BF135A•BF150A
outboard motors.
All information contained in this manual is based on the
latest product information available at the time of
printing. We reserve the right to make changes at anytime
without notice.
No part of this publication may be reproduced, stored in
a retrieval system, or transmitted, in any form, by any
means, electronic, mechanical, photocopying, recording,
or otherwise, without prior written permission of the
publisher. This includes text, figures, and tables.
As you read this manual, you will find information that is
preceded by a NOTICE symbol. The purpose of this
message is to help prevent damage to the outboard
motor, other property, or the environment.
CONTENTS
SPECIFICATIONS
SERVICE INFORMATION
MAINTENANCE
ENGINE COVER/COVER LOCK
PROGRAMMED-FUEL INJECTION
ALTERNATOR
ENGINE REMOVAL/INSTALLATION
THERMOSTAT/RELIEF VALVE/FLUSH VALVE
SAFETY MESSAGES
Your safety, and the safety of others, are very important.
To help you make informed decisions, we have provided
safety messages and other safety information throughout
this manual. Of course, it is not practical or possible to
warn you about all the hazards associated with servicing
these outboard motors. You must use your own good
judgment.
You will find important safety information in a variety of
forms, including:
• Safety Labels –– on the engine cover.
• Safety messages –– Preceded by a safety alert symbol
and one of three signal words, DANGER, WARNING,
or CAUTION.
These signal words mean:
DANGER
WARNING
CAUTION
CRANKSHAFT PULLEY/CAM CHAIN
CYLINDER HEAD/VALVES
OIL PUMP/FLYWHEEL
CRANKCASE/BALANCER
CYLINDER BLOCK/CRANKSHAFT/PISTONS
PROPELLER/GEAR CASE/EXTENSION CASE/
OIL CASE
MOUNTING CASE/STERN BRACKET/SWIVEL
CASE/POWER TRIM/TILT ASSEMBLY
STEERING ROD/REMOTE CONTROL BOX
You WILL be KILLED or
SERIOUSLY HURT if you don't
follow instructions.
You CAN be KILLED or
SERIOUSLY HURT if you don't
follow instructions.
You CAN be HURT if you don't
follow instructions.
• Instructions –– how to service this outboard motor
correctly and safely.
Honda Motor Co., Ltd.
Service Publications Office
Date of lssue: November, 2003
© Honda Motor Co., Ltd.
CABLES/SHIFT LINK BRACKET/SHIFT ARM/
NEUTRAL SWITCH
ELECTRICAL EQUIPMENT
OPERATION
SYSTEM DIAGRAM/WIRING DIAGRAM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
21
INDEX
1. SPECIFICATIONS ........................................................ 1-1
1. SPECIFICATIONS .................................................. 1-1
2. DIMENSIONAL DRAWINGS.................................. 1-4
2. SERVICE INFORMATION ............................................ 2-1
1. THE IMPORTANCE OF PROPER SERVICING ...... 2-1
2. IMPORTANT SAFETY PRECAUTIONS ................ 2-1
3. SERVICE RULES .................................................... 2-2
4. SYMBOLS USED IN THIS MANUAL .................... 2-2
5. SERIAL NUMBER LOCATIONS ............................ 2-2
6. MAINTENANCE STANDARDS .............................. 2-3
7. TORQUE VALUES .................................................. 2-7
8. SPECIAL TOOLS .................................................. 2-10
9. TROUBLESHOOTING .......................................... 2-14
a. ENGINE····························································· 2-14
HARD STARTING ············································· 2-14
CYLINDER COMPRESSION TEST··················· 2-15
ENGINE DOES NOT RUN SMOOTHLY ·········· 2-16
b. IGNITION (POWER) SYSTEM ························· 2-20
ENGINE DOES NOT START ···························· 2-20
FUSE LOAD CHART········································· 2-21
FUSE BOX CONNECTION TABLE··················· 2-22
c. STARTER SYSTEM ·········································· 2-23
ENGINE DOES NOT START ·····························2-23
d. IGNITION SYSTEM ·········································· 2-25
ENGINE IS HARD TO START ·························· 2-25
e. FUEL SYSTEM ················································· 2-28
ENGINE IS HARD TO START ·························· 2-28
f. CHARGING SYSTEM ······································· 2-30
BATTERY UNDER CHARGED ·························· 2-30
ACG INDICATOR LINE INSPECTION ·············· 2-31
g. ALERT SYSTEM ··············································· 2-32
OIL ALERT SYSTEM ········································ 2-32
OVERHEAT ALERT SYSTEM ··························· 2-32
ALTERNATOR WARNING SYSTEM················ 2-32
FULL WATER (IN WATER SEPARATOR)
WARNING SYSTEM········································· 2-32
MIL WARNING SYSTEM ································· 2-32
WARNING SYSTEM········································· 2-32
WARNING BUZZER SOUNDS
CONTINUOUSLY·············································· 2-33
OIL PRESSURE INSPECTION·························· 2-35
INTERMITTENT PROLONGED SOUND OF
WARNING BUZZER KEEPS SOUNDING········ 2-37
INTERMITTENT SHORT SOUND OF
WARNING BUZZER KEEPS SOUNDING········ 2-38
h. SHIFT MECHANISM ········································ 2-39
i. POWER TRIM/TILT ASSEMBLY ······················ 2-40
POWER TRIM/TILT ASSEMBLY DOES
NOT MOVE ························································2-40
POWER TRIM/TILT ASSEMBLY DOES
NOT HOLD························································ 2-41
POWER TRIM/TILT MOTOR DOES
NOT MOVE······················································· 2-42
POWER TRIM/TILT ASSEMBLY QUICK
REFERENCE CHART········································· 2-43
CHECK POINT ·················································· 2-44
10. CABLE/HARNESS ROUTING .............................. 2-45
11. TUBE ROUTING .................................................. 2-66
12. LUBRICATION ...................................................... 2-77
3. MAINTENANCE ............................................................ 3-1
1. MAINTENANCE SCHEDULE ................................ 3-1
2. ENGINE OIL............................................................ 3-2
3. OIL FILTER .............................................................. 3-3
4. GEAR CASE OIL .................................................... 3-4
5. SPARK PLUGS ...................................................... 3-6
6. VALVE CLEARANCE .............................................. 3-9
7. FUEL STRAINER (LOW PRESSURE SIDE) ........ 3-15
8. FUEL STRAINER (HIGH PRESSURE SIDE) ........ 3-18
9. WATER SEPARATOR with WATER LEVEL
SENSOR .............................................................. 3-19
10. IDLING .................................................................. 3-22
11. SHIFT CONTROL CABLE .................................... 3-24
12. THROTTLE CONTROL CABLE/
THROTTLE LINK .................................................. 3-26
13. REMOTE CONTROL LEVER FRICTION .............. 3-28
14. ALTERNATOR BELT ............................................ 3-28
4. ENGINE COVER/COVER LOCK .................................. 4-1
1. ENGINE COVER .................................................... 4-2
2. FRONT SEPARATE COVER.................................... 4-7
3. L./R. ENGINE UNDER COVERS ............................ 4-9
4. UNDER COVER FRONT BRACKET/
L./R. SIDE COVER BRACKETS ............................ 4-20
5. PROGRAMMED-FUEL INJECTION ............................ 5-1
1. SERVICE PRECAUTIONS ...................................... 5-2
2. CIRCUIT DIAGRAM................................................ 5-3
3. VACUUM CONNECTIONS .................................... 5-5
4. PARTS LOCATION/
ECM TERMINAL LAYOUT .................................... 5-6
5. TROUBLESHOOTING .......................................... 5-11
6. TROUBLESHOOTING WITH
HDS TESTER ........................................................ 5-13
a. TROUBLESHOOTING GUIDE BY DTC············ 5-15
b. TROUBLESHOOTING ······································ 5-18
MIL DOES NOT COME ON······························ 5-18
MIL COMES ON BUT DTC CODE DOES NOT
APPEAR ···························································· 5-21
ALERT SYSTEM INITIAL OPERATION IS
FAULTY ····························································· 5-23
NEUTRAL SWITCH MALFUNCTION ·············· 5-26
TACHOMETER MALFUNCTION ······················ 5-27
ECM TROUBLESHOOTING ····························· 5-28
MAP SENSOR TROUBLESHOOTING ············· 5-28
CKP SENSOR TROUBLESHOOTING ·············· 5-30
ECT SENSOR 1 TROUBLESHOOTING ··········· 5-33
TP SENSOR TROUBLESHOOTING················· 5-34
CMP SENSOR TROUBLESHOOTING ············· 5-36
IAT SENSOR TROUBLESHOOTING················ 5-38
BARO SENSOR TROUBLESHOOTING ··········· 5-39
IAC VALVE TROUBLESHOOTING ··················· 5-41
VTEC SOLENOID VALVE
TROUBLESHOOTING ······································ 5-42
KNOCK SENSOR TROUBLESHOOTING ········ 5-43
A/F SENSOR HEATER TROUBLESHOOTING ······················································· 5-44
A/F SENSOR TROUBLESHOOTING················ 5-49
ECT SENSOR 2 TROUBLESHOOTING ··········· 5-51
ECT SENSOR 3 TROUBLESHOOTING ··········· 5-52
EOP SWITCH (HIGH PRESSURE SIDE)
TROUBLESHOOTING ······································ 5-54
ECT SENSOR 4 TROUBLESHOOTING ··········· 5-55
7. TROUBLESHOOTING WITHOUT
HDS TESTER ........................................................5-57
a. TROUBLESHOOTING GUIDE·························· 5-59
b. TROUBLESHOOTING ······································ 5-61
MIL DOES NOT COME ON······························ 5-61
MIL ON BUT MIL DOES NOT BLINK WITH
SCS CIRCUIT SHORTED·································· 5-64
ALERT SYSTEM INITIAL OPERATION IS
FAULTY ····························································· 5-66
NEUTRAL SWITCH MALFUNCTION ·············· 5-70
TACHOMETER MALFUNCTION ······················ 5-70
MAP SENSOR TROUBLESHOOTING ············· 5-71
CKP SENSOR TROUBLESHOOTING ·············· 5-72
ECT SENSOR 1 TROUBLESHOOTING ··········· 5-74
TP SENSOR TROUBLESHOOTING················· 5-75
CMP SENSOR TROUBLESHOOTING ············· 5-77
IAT SENSOR TROUBLESHOOTING················ 5-78
BARO SENSOR TROUBLESHOOTING ··········· 5-80
IAC VALVE TROUBLESHOOTING ··················· 5-81
VTEC SOLENOID VALVE TROUBLESHOOTING ······················································· 5-82
KNOCK SENSOR TROUBLESHOOTING ········ 5-83
ECT SENSOR 2 TROUBLESHOOTING ··········· 5-84
ECT SENSOR 3 TROUBLESHOOTING ··········· 5-86
EOP SWITCH (HIGH PRESSURE SIDE)
TROUBLESHOOTING ······································ 5-87
ECT SENSOR 4 TROUBLESHOOTING ··········· 5-89
A/F SENSOR HEATER TROUBLESHOOTING ······················································· 5-90
A/F SENSOR TROUBLESHOOTING················ 5-92
8. IDLE CONTROL SYSTEM .................................... 5-93
TROUBLESHOOTING ······································ 5-93
IDLE ADJUSTING SCREW
ADJUSTMENT ················································· 5-94
THROTTLE BODY INSPECTION/
CLEANING ························································ 5-95
IAC VALVE REPLACEMENT····························· 5-95
9. FUEL SUPPLY SYSTEM ...................................... 5-96
TROUBLESHOOTING ······································ 5-96
PGM-FI MAIN RELAY HARNESS
INSPECTION····················································· 5-97
INJECTOR HARNESS INSPECTION ············· 5-100
HOW TO RELIEVE FUEL PRESSURE············ 5-102
FUEL PRESSURE MEASUREMENT·············· 5-102
FUEL LINE INSPECTION································ 5-104
FUEL INJECTOR INSPECTION······················ 5-105
PRESSURE REGULATOR INSPECTION········ 5-106
FUEL PUMP (HIGH PRESSURE SIDE)
INSPECTION··················································· 5-107
10. IAB (INTAKE AIR BYPASS) CONTROL
SYSTEM ............................................................ 5-109
IAB CONTROL VALVE INSPECTION ············· 5-109
SHUTTER VALVE DIAPHRAGM
INSPECTION··················································· 5-110
11. VAPOR SEPARATOR/FUEL PUMP (HIGH
PRESSURE SIDE ) .............................................. 5-111
12. SILENCER CASE/THROTTLE BODY/
INTAKE MANIFOLD .......................................... 5-128
13. FUEL INJECTOR/PRESSURE REGULATOR...... 5-136
14. FUEL PUMP (LOW PRESSURE SIDE) .............. 5-142
15. FUEL STRAINER (LOW PRESSURE SIDE)/
WATER SEPARATOR.......................................... 5-144
16. EOP (ENGINE OIL PRESSURE) SWITCH (HIGH
PRESSURE SIDE) .............................................. 5-146
17. EOP (ENGINE OIL PRESSURE) SWITCH (LOW
PRESSURE SIDE) .............................................. 5-146
18. ECT (ENGINE COOLANT TEMPERATURE)
SENSOR 1 .......................................................... 5-147
19. ECT (ENGINE COOLANT TEMPERATURE)
SENSOR 2, 3, 4 .................................................. 5-148
20. BARO (BAROMETRIC PRESSURE)
SENSOR ..............................................................5-149
21. KNOCK SENSOR................................................ 5-149
22. CMP (CAMSHAFT POSITION) SENSOR .......... 5-149
23. CKP (CRANKSHAFT POSITION) SENSOR ...... 5-150
24. VTEC SOLENOID VALVE.................................... 5-150
25. VAPOR CHAMBER/CHECK VALVE .................... 5-151
26. EXHAUST MANIFOLD ...................................... 5-152
6. ALTERNATOR .............................................................. 6-1
1. SILENCER DUCT .................................................... 6-2
2. ALTERNATOR ........................................................ 6-5
7. ENGINE REMOVAL/INSTALLATION .......................... 7-1
1. REMOVAL .............................................................. 7-2
2. INSTALLATION ...................................................... 7-6
8. THERMOSTAT/RELIEF VALVE/FLUSH VALVE.......... 8-1
1. THERMOSTAT ........................................................ 8-2
2. WATER RELIEF TUBE/RELIEF VALVE .................. 8-5
3. FLUSH VALVE ...................................................... 8-10
9. CRANKSHAFT PULLEY/CAM CHAIN ........................ 9-1
1. DISASSEMBLY ...................................................... 9-2
2. ASSEMBLY ............................................................ 9-9
10. CYLINDER HEAD/VALVES........................................ 10-1
1. CYLINDER HEAD COVER REMOVAL.................. 10-2
2. CYLINDER HEAD COVER DISASSEMBLY.......... 10-4
3. CAMSHAFT/ROCKER ARM DISASSEMBLY ...... 10-5
4. CAMSHAFT/ROCKER ARM INSPECTION ........ 10-13
5. CYLINDER HEAD ASSEMBLY REMOVAL ........ 10-19
6. CYLINDER HEAD ASSEMBLY
DISASSEMBLY .................................................. 10-20
7. CYLINDER HEAD ASSEMBLY INSPECTION .... 10-23
8. VALVE GUIDE REPLACEMENT ........................ 10-26
9. VALVE SEAT RECONDITIONING ...................... 10-28
10. CYLINDER HEAD ASSEMBLY ASSEMBLY ...... 10-30
11. CYLINDER HEAD ASSEMBLY
INSTALLATION .................................................. 10-32
12. CAMSHAFT/ROCKER ARM ASSEMBLY .......... 10-34
13. CYLINDER HEAD COVER ASSEMBLY.............. 10-38
14. CYLINDER HEAD COVER INSTALLATION ...... 10-40
11. OIL PUMP/FLYWHEEL .............................................. 11-1
1. EOP SWITCH/OIL FILTER FLANGE .................... 11-2
2. OIL PUMP ............................................................ 11-6
3. FLYWHEEL.......................................................... 11-12
12. CRANKCASE/BALANCER ........................................ 12-1
1. CRANKCASE/BALANCER CASE ASSEMBLY
REMOVAL ............................................................ 12-2
2. BALANCER CASE ASSEMBLY
DISASSEMBLY .................................................... 12-5
3. INSPECTION ........................................................ 12-6
4. BALANCER CASE ASSEMBLY ASSEMBLY ...... 12-7
5. CRANKCASE/BALANCER CASE ASSEMBLY
INSTALLATION .................................................... 12-8
13. CYLINDER BLOCK/CRANKSHAFT/PISTONS .......... 13-1
1. DISASSEMBLY .................................................... 13-2
2. INSPECTION ........................................................ 13-8
3. BEARING SELECTION ...................................... 13-15
4. ASSEMBLY ........................................................ 13-19
14. PROPELLER/GEAR CASE/EXTENSION CASE/
OIL CASE.................................................................... 14-1
1. PROPELLER .......................................................... 14-2
2. GEAR CASE ASSEMBLY [*1].............................. 14-3
3. WATER PUMP/SHIFT ROD [*1] .......................... 14-7
4. PROPELLER SHAFT HOLDER
ASSEMBLY [*1] ................................................ 14-17
5. PROPELLER SHAFT/PROPELLER
SHAFT HOLDER [*1] ........................................ 14-18
6. VERTICAL SHAFT/BEVEL GEAR [*1]................ 14-27
7. SHIM SELECTION [*1] ...................................... 14-35
8. SHIM POSITION [*1] ........................................ 14-40
9. BACKLASH ADJUSTMENT [*1] ...................... 14-41
10. GEAR CASE ASSEMBLY [*2]............................ 14-42
11. WATER PUMP/SHIFT ROD [*2] ........................ 14-46
12. PROPELLER SHAFT HOLDER
ASSEMBLY [*2] ................................................ 14-56
13. PROPELLER SHAFT/PROPELLER
SHAFT HOLDER [*2] ........................................ 14-57
14. VERTICAL SHAFT/BEVEL GEAR [*2]................ 14-68
15. SHIM SELECTION [*2] ...................................... 14-77
16. SHIM POSITION [*2] ........................................ 14-84
17. BACKLASH ADJUSTMENT [*2] ...................... 14-85
18. ANODE METAL/WATER SCREEN .................... 14-88
19. EXTENSION CASE/LOWER RUBBER
MOUNT .............................................................. 14-89
20. OIL CASE ............................................................ 14-94
15. MOUNTING CASE/STERN BRACKET/SWIVEL
CASE/POWER TRIM/TILT ASSEMBLY .................... 15-1
1. MOUNTING CASE .............................................. 15-2
2. STERN BRACKET/SWIVEL CASE
REMOVAL/INSTALLATION ................................15-10
3. STERN BRACKET/SWIVEL CASE/
POWER TRIM/TILT ASSEMBLY ........................ 15-14
4. POWER TRIM/TILT ASSEMBLY ........................ 15-36
5. AIR BLEEDING .................................................. 15-48
6. BLOW PRESSURE INSPECTION ...................... 15-50
7. POWER TILT MOTOR ASSEMBLY.................... 15-53
16. STEERING ROD/REMOTE CONTROL BOX ............ 16-1
1. STEERING ROD.................................................... 16-1
2. REMOTE CONTROL BOX (OPTIONAL
PART) .................................................................... 16-2
3. CONTROL PANEL (OPTIONAL PART) ................ 16-7
4. INSPECTION ........................................................ 16-9
17. CABLES/SHIFT LINK BRACKET/SHIFT ARM/
NEUTRAL SWITCH .................................................... 17-1
1. REMOTE CONTROL CABLE/GROMMET ............ 17-2
2. SHIFT LINK BRACKET/NEUTRAL
SWITCH .............................................................. 17-11
3. SEAL HOLDER.................................................... 17-20
18. ELECTRICAL EQUIPMENT ........................................ 18-1
1. STARTER MOTOR................................................ 18-1
2. STARTER CABLE................................................ 18-15
3. ECM/PGM-FI MAIN RELAY/FUSE BOX ............ 18-19
4. POWER TILT RELAY/CONNECTOR
BRACKET A ........................................................ 18-27
19. OPERATION .............................................................. 19-1
1. DOHC (SWING ARM TYPE) + VTEC .................. 19-1
2. CHAIN DRIVE CAM DRIVE SYSTEM .................. 19-2
3. INDEPENDENT CYLINDER HEAD/CYLINDER
BLOCK COOLING SYSTEM................................ 19-3
4. AIR/FUEL RATIO O2 FEEDBACK CONTROL
BY A/F SENSOR .................................................. 19-4
20. WIRING DIAGRAM/SYSTEM DIAGRAM ................ 20-1
Abbreviations
ACG
A/F
API
Approx.
Assy.
ATDC
ATF
ATT
Alternator
Air Fuel Ratio
American Petroleum Institute
Approximately
Assembly
After Top Dead Center
Automatic Transmission Fluid
Attachment
BAT
BDC
BTDC
BARO
Battery
Bottom Dead Center
Before Top Dead Center
Barometric Pressure
CKP
Comp.
CMP
CYL
Crankshaft Position
Complete
Camshaft Position
Cylinder
DLC
Data Link Connector
ECT
ECM
EOP
EX
Engine Coolant Temperature
Engine Control Module
Engine Oil Pressure
Exhaust
F
Front or Forward
GND
Ground
IAB
IAC
IAT
I.D.
IG or IGN
IN
INJ
Intake Air Bypass
Idle Air Control
Intake Air Temperature
Inside Diameter
Ignition
Intake
Injection
L.
Left
MAP
MIL
Manifold Absolute Pressure
Malfunction Indicator Lamp
O.D.
OP
Outside Diameter
Optional Part
PGM-FI
P/N
Programmed-Fuel Injection
Part Number
Qty
Quantity
R.
Right
SAE
SCS
STD
SW
Society of Automotive Engineers
Service Check Signal
Standard
Switch
TDC
TP
Top Dead Center
Throttle Position
Bl Black
Y Yellow
Bu Blue
G Green
R Red
W White
Br Brown
O Orange
Lb Light blue
Lg Light green
P Pink
Gr Gray
1.SPECIFICATIONS
1. SPECIFICATIONS
2. DIMENSIONAL DRAWINGS
1. SPECIFICATIONS
• DIMENSIONS AND WEIGHTS
Model
BF135A
Description code
Types
BARJ
LC
BASJ
LD
LCD
BARJ
XC
XD
Overall length
845 mm (33.3 in)
Overall width
580 mm (22.8 in)
Overall height
BASJ
1,665 mm (65.6 in)
XCC
XCD
1,790 mm (70.5 in)
Dry weight (*1)
220 kg (485 lbs)
223 kg (492 lbs)
226 kg (498 lbs)
Operating weight (including oil)
228 kg (503 lbs)
231 kg (509 lbs)
234 kg (516 lbs)
*1: With propeller mounted.
Model
BF150A
Description code
Types
BANJ
LC
BAPJ
LD
LCD
BANJ
XC
Overall length
845 mm (33.3 in)
Overall width
580 mm (22.8 in)
Overall height
1,665 mm (65.6 in)
BAPJ
XD
XCC
XCD
1,790 mm (70.5 in)
Dry weight (*1)
220 kg (485 lbs)
223 kg (492 lbs)
226 kg (498 lbs)
Operating weight (including oil)
228 kg (503 lbs)
231 kg (509 lbs)
234 kg (516 lbs)
*1: With propeller mounted.
• FRAME
Model
Types
Transom height (*1)
BF135A•BF150A
LC
LD
LCD
XC
508 mm (20.0 in)
72°
Tilting stage
Stageless
Swivel angle
30° right and left
Trim angle
– 4° to 16°
1-1
XCC
635 mm (25.0 in)
Tilting angle
*2: Transom angle is at 12°.
XD
XCD
• TYPES OF Honda BF135A•BF150A OUTBOARD MOTORS
It may be necessary to refer to this chart for reference purposes when reading this manual.
Model
BF135A•BF150A
Types
LC
LD
LCD
XC
XD
XCC
XCD
Shaft length type
L
L
L
XL
XL
XL
XL
Remote control
(○)
(○)
(○)
(○)
(○)
(○)
(○)
Control panel
(○)
(○)
(○)
(○)
(○)
(○)
(○)
○
○
○
○
Counter rotation
Power trim/tilt
L: Long shaft
○
○
XL: Extra-long shaft
○
○
○
○
(○): Optional part
1-2
• ENGINE
Model
Description code
Type
BF135A
BF150A
BEARJ
BEANJ
4-stroke, D.O.H.C., 4-cylinder
4-stroke, D.O.H.C., VTEC, 4-cylinder
Displacement
2,354 cm3 (143.6 cu-in)
Bore x stroke
87 x 99 mm (3.4 x 3.9 in)
Rated power (Full throttle range)
Maximum torque
Compression ratio
Fuel consumption ratio
100.7 kW (135 HP)
at 5,000 – 6,000 min–1 (rpm)
196 N.m (20.0 kgf.m, 145 lbf.ft)
111.9 kW (150 HP)
at 5,000 – 6,000 min–1 (rpm)
202 N.m (20.6 kgf.m, 149 lbf.ft)
9.6 : 1
350 g/kW.h (257 g/HP.h, 0.575 lb/HP.h)
320 g/kW.h (235 g/HP.h, 0.526 lb/HP.h)
Cooling system
Forced water circulation by impeller pump with thermostat
Ignition system
Full transistorized, battery ignition
Ignition timing
0˚ ± 2˚ at 750 min–1 (rpm) B.T.D.C.
Spark plug
IZFR6K11 (NGK), SKJ20DR-M11 (DENSO)
Fuel supply system
Programmed fuel injection
Fuel injection system
Electronic control
Fuel injection nozzle
Multi-hole type
Fuel pipe
Rubber tubes
Lubrication system
Pressure lubrication by trochoid pump
Lubrication capacity
7.35r (7.8 US qt, 6.5 lmp qt)
[with oil filter replacement: 6.7r (7.1 US qt, 5.9 lmp qt)]
[without oil filter replacement: 6.5r (6.9 US qt, 5.7 lmp qt)]
Starting system
Stopping system
Electric starter
Primary circuit ground
Fuel used
Unleaded gasoline with a pump octane number 86 or higher
Fuel pump
Electric and mechanical plunger type
Exhaust system
Underwater type
Recommended oil
SAE 10W-30
• LOWER UNIT
Clutch
Dog clutch (Forward – Neutral – Reverse)
Gear ratio
0.467 (14/30)
Reduction
Spiral bevel
Gear case oil capacity
0.98r (1.04 US qt, 0.86 lmp qt)
Propeller rotating direction
Clockwise (viewed from rear): LC, LD, XC and XD types
Counterclockwise (viewed from rear): LDC, XCC and XCD types
Propeller driving system
Spline
1-3
1-4
508 mm (20.0 in)
[635 mm (25.0 in)]
1,665 mm (65.6 in)
[1,790 mm (70.5 in)]
30°
382 mm
(15.0 in)
2. DIMENSIONAL DRAWINGS
[ ]: Extra-long shaft type
845 mm (33.3 in)
580 mm
(22.8 in)
12°
28.5 mm
(1.12 in)
57.5 ± 0.5 mm
(2.26 ± 0.02 in)
ø30 -0.020
-0.041
(ø1.2 -0.0008
-0.0016 )
0
ø24.9 -0.1
0
(ø0.98 -0.003
)
ø16.9 +0.03
-0.04
(ø0.67 +0.001
-0.002 )
M18 x 1.5
ANSI INV. S 16/32 x 15T x 30 x 1.5 mm
• PROPELLER SHAFT
ø4
(ø0.2)
7 mm
(0.3 in)
56.5 mm
(2.22 in)
151 mm (5.9 in)
1-5
2. SERVICE INFORMATION
1. THE IMPORTANCE OF PROPER SERVICING
2. IMPORTANT SAFETY PRECAUTIONS
3. SERVICE RULES
4. SYMBOLS USED IN THIS MANUAL
5. SERIAL NUMBER LOCATIONS
6. MAINTENANCE STANDARDS
7. TORQUE VALUES
8. SPECIAL TOOLS
9. TROUBLESHOOTING
10. CABLE/HARNESS ROUTING
11. TUBE ROUTING
12. LUBRICATION
1. THE IMPORTANCE OF PROPER SERVICING
Proper servicing is essential to the safety of the operator and
the reliability of the outboard motor. Any error or oversight
made by the technician while servicing can easily result in
faulty operation, damage to the outboard motor or injury to the
operator.
WARNING
Improper servicing can cause an unsafe condition
that can lead to serious injury or death.
Follow the procedures and precautions in this
shop manual carefully.
Some of the most important precautions are given below.
However, we cannot warn you of every conceivable hazard that
can arise in performing maintenance or repairs. Only you can
decide whether or not you should perform a given task.
2. IMPORTANT SAFETY PRECAUTIONS
WARNING
Failure to properly follow maintenance
instructions and precautions can cause you to be
seriously hurt or killed.
Follow the procedures and precautions in this
shop manual carefully.
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate
clothing and using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and
the skills required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles, or face shields any time you hammer, drill, grind, or work
around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye
protection.
• Use other protective wear when necessary, for example, gloves or safety shoes. Handling hot or sharp parts can cause
severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have engine-powered equipment up in the air.
Any time you lift an outboard motor with a hoist, make sure that the hoist hook is securely attached to the outboard
motor.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise.
This will help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers, and clothing are
out of the way.
Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be
careful when working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.
2-1
3. SERVICE RULES
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's
design specifications may damage the unit.
2. Use the special tools designed for the product.
3. Install new gaskets, O-rings, etc. when reassembling.
4. When torquing bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the specified torque
diagonally, unless a particular sequence is specified.
5. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
6. After reassembly, check all parts for proper installation and operation.
7. Many screws used in this machine are self-tapping. Be aware that cross-threading or overtightening these screws will
strip the threads and ruin the hole.
8. Use only metric tools when servicing this unit. Metric bolts, nuts and screws are not interchangeable with non-metric
fasteners. The use of incorrect tools and fasteners will damage the unit.
4. SYMBOLS USED IN THIS MANUAL
As you read this manual, you may find the following symbols with the instructions.
A special tool is required to perform the procedure.
Apply grease.
(Molybdenum : Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1 : 1).
disulfide oil)
Apply oil.
○ x ○ (○)
Indicates the diameter, length, and quantity of metric flange bolts used.
P. 1-1
Indicates the reference page.
5. SERIAL NUMBER LOCATIONS
The engine serial number is stamped on the right side of the cylinder block and the product identification number is
located on the right side of the stern bracket. Always specify these numbers when inquiring about the engine or when
ordering parts in order to obtain the correct parts for the outboard motor being serviced.
ENGINE SERIAL NUMBER
PRODUCT IDENTIFICATION NUMBER
2-2
6. MAINTENANCE STANDARDS
• ENGINE
Unit: mm (in)
Parts
Engine
Item
Standard
Service limit
Idle speed (in neutral)
750 ± 50 min (rpm)
–
Trolling speed
650 ± 50 min–1 (rpm)
–
Cylinder compression
[kPa (kgf/cm2, psi) at 200 min–1 (rpm)]
1,532 – 1,728
(15.6 – 17.6, 222 – 250)
930
(9.5, 135)
Compression gap between cylinders
[kPa (kgf/cm2, psi)]
–
200 (2.0, 28)
1.0 – 1.1 (0.039 – 0.043)
1.3 (0.051)
Spark plugs
Gap
Valves
Valve clearance
Overall length
Valve O.D.
Stem O.D.
Stem-to-guide clearance
Valve seats
Valve guides
Rocker arms
–
–
IN
108.7 – 109.5 (4.28 – 4.31)
–
EX
108.3 – 109.1 (4.26 – 4.30)
–
IN
34.85 – 35.15 (1.372 – 1.384)
–
EX
29.85 – 30.15 (1.175 – 1.187)
–
IN
5.475 – 5.485 (0.2156 – 0.2159)
5.445 (0.2144)
EX
5.450 – 5.460 (0.2146 – 0.2150)
5.420 (0.2134)
IN
0.030 – 0.055 (0.0012 – 0.0022)
0.08 (0.003)
EX
0.055 – 0.080 (0.0022 – 0.0031)
0.11 (0.004)
1.25 – 1.55 (0.049 – 0.061)
2.0 (0.08)
Seat installation height
IN/EX
44.0 – 44.6 (1.73 – 1.76)
–
Guide I.D.
IN/EX
5.51 – 5.53 (0.217 – 0.218)
5.55 (0.219)
IN
15.2 – 16.2 (0.60 – 0.64)
–
EX
15.5 – 16.5 (0.61 – 0.65)
–
Free length
Rocker arm I.D.
IN
49.64 (1.954)
–
EX
49.64 (1.954)
–
IN
17.019 – 17.035 (0.6700 – 0.6707)
–
EX
17.012 – 17.039 (0.6698 – 0.6708)
–
IN/EX
16.983 – 16.994 (0.6686 – 0.6690)
–
Rocker arm-to-rocker arm
shaft clearance
IN
0.025 – 0.052 (0.0010 – 0.0020)
0.08 (0.003)
EX
0.018 – 0.056 (0.0007 – 0.0022)
0.08 (0.003)
Skirt O.D.
A
86.98 – 86.99 (3.4244 – 3.4248)
86.93 (3.4224)
B
86.97 – 86.98 (3.4240 – 3.4244)
86.92 (3.4220)
0.02 – 0.04 (0.001 – 0.002)
0.05 (0.002)
21.960 – 21.963 (0.8646 – 0.8647)
–
Piston-to-cylinder clearance
Piston pin bore I.D.
2-3
0.21 – 0.25 (0.008 – 0.010)
0.28 – 0.32 (0.011 – 0.013)
IN/EX
Rocker arm shaft O.D.
Pistons
IN
EX
Seat width
Guide extrusion amount
Valve springs
–1
Unit: mm (in)
Parts
Pistons
Piston pins
Piston rings
Item
Standard
Service limit
1.23 – 1.24 (0.0484 – 0.0488)
1.25 (0.0492)
Second
1.24 – 1.25 (0.0488 – 0.0492)
1.25 (0.0492)
Oil
2.005 – 2.025 (0.0789 – 0.0797)
2.05 (0.081)
Pin O.D.
21.961 – 21.965 (0.8646 – 0.8648)
21.953 (0.8643)
Pin-to-pin bore clearance
–0.005 – +0.002 (–0.0002 – +0.0001)
0.005 (0.0002)
Ring groove width
Top
Ring side clearance
Ring end gap
Ring thickness
Cylinder head
Cylinder block
Top
0.045 – 0.070 (0.0018 – 0.0028)
0.13 (0.005)
Second
0.040 – 0.065 (0.0016 – 0.0026)
0.13 (0.005)
Top
0.20 – 0.35 (0.008 – 0.014)
0.6 (0.02)
Second
0.50 – 0.65 (0.020 – 0.026)
0.75 (0.030)
Oil
0.20 – 0.70 (0.008 – 0.028)
0.8 (0.031)
Top
1.170 – 1.185 (0.0461 – 0.0467)
–
Second
1.175 – 1.190 (0.0463 – 0.0469)
–
–
0.05 (0.002) Min.
Warpage
Camshaft journal I.D.
29.000 – 29.024 (1.1417 – 1.1427)
–
Head height
103.95 – 104.05 (4.093 – 4.096)
–
Cylinder sleeve I.D.
A or I
87.01 – 87.02 (3.4256 – 3.4260)
87.07 (3.4279)
B or II
87.00 – 87.01 (3.4252 – 3.4256)
87.07 (3.4279)
–
0.05 (0.002)
0.07 (0.003) Max.
0.10 (0.004)
Gap between upper and lower points –
of sleeve I.D.
Warpage
Connecting
rods
Small end I.D.
23.969 – 23.982 (0.9437 – 0.9442)
–
Small end-to-piston pin clearance
0.005 – 0.015 (0.0002 – 0.0006)
0.02 (0.001)
Big end axial clearance
Crankshaft
0.15 – 0.35 (0.006 – 0.014)
0.4 (0.02)
Connecting rod bearing oil clearance
0.032 – 0.066 (0.0013 – 0.0026)
0.077 (0.0030)
Journal O.D.
No. 1, 2, 4, 5
54.984 – 54.992 (2.1647 – 2.1650)
–
No. 3
54.976 – 55.000 (2.1644 – 2.1654)
–
Main
Pin
47.976 – 48.000 (1.8888 – 1.8898)
–
Journal cylindricity
0.005 (0.0002) Max.
0.010 (0.0004)
Journal roundness
0.005 (0.0002) Max.
0.010 (0.0004)
Crankshaft runout
0.03 (0.001) Max.
0.04 (0.002)
Crankshaft axial clearance
Main bearing oil clearance
Thrust metal side clearance
0.10 – 0.35 (0.004 – 0.014)
0.45 (0.018)
No. 1, 2, 4, 5
0.017 – 0.041 (0.0007 – 0.0016)
0.05 (0.002)
No. 3
0.025 – 0.049 (0.0010 – 0.0019)
0.055 (0.0022)
0.10 – 0.35 (0.004 – 0.014)
0.45 (0.018)
2-4
Unit: mm (in)
Parts
Item
Camshaft
Camshaft axial clearance
Camshaft runout
0.05 – 0.20 (0.002 – 0.008)
0.4 (0.02)
0.03 (0.001) Max.
0.4 (0.02)
28.955 – 28.970 (1.1400 – 1.1405)
–
No. 2 – No. 5
28.925 – 28.940 (1.1388 – 1.1394)
–
IN:PRI/SEC
32.626 – 32.931 (1.2845 – 1.2965)
–
Camshaft oil clearance
Oil pump
Service limit
No. 1
Journal O.D.
Cam height
Standard
IN:MID
35.369 – 35.654 (1.3925 – 1.4037)
–
EX
33.927 – 34.212 (1.3357 – 1.3469)
–
No. 1
0.030 – 0.069 (0.0012 – 0.0027)
0.15 (0.006)
No. 2 – No. 5
0.060 – 0.099 (0.0024 – 0.0039)
0.15 (0.006)
Body I.D.
Inner rotor-to-outer rotor clearance
Outer rotor-to-oil pump body clearance
84.000 – 84.030 (3.3071 – 3.3083)
–
0.04 – 0.16 (0.002 – 0.006)
0.20 (0.008)
0.02 – 0.07 (0.001 – 0.003)
0.12 (0.005)
Outer rotor height
9.480 – 9.500 (0.3732 – 0.3740)
–
Pump body depth
9.520 – 9.550 (0.3748 – 0.3760)
–
0.14 – 0.19 (0.006 – 0.007)
0.20 (0.008)
Outer rotor-to-oil body side clearance
Vapor separator Float height
28.5 – 33.5 (1.12 – 1.32)
–
Fuel pump
Discharge volume
[with pump operated for 2 sec. at 12V]
45 mR (1.5 Us oz, 1.6 Imp oz)
or more
–
Fuel line
Fuel pressure [kPa (kgf/cm2, psi)]
270 – 320 (2.8 – 3.3, 40 – 47)
–
Alternator
Brush length
10.5 (0.41)
8.4 (0.33)
Brush spring pressure
3.2 N (0.33 kgf, 0.73 lbf)
–
Rotor coil resistance
2.9 Ω
–
Slip ring O.D.
Belt tension
Measured at the center of belt
between the pulleys with belt
tension gauge.
Belt deflection
Measured with 98 N (10 kgf, 22 lbf)
of force applied to the center of belt
between the pulleys)
Starter motor
Brush length
Insulator length (Mica depth)
14.0 (0.55)
392 – 490 N
(40 – 50 kgf, 88 – 100 lbf)
–
New
belt
490 – 588 N
(50 – 60 kgf, 110 – 132 lbf)
–
Used
belt
10.6 – 11.1
(0.42 – 0.44)
–
New
belt
10.1 – 10.6
(0.40 – 0.42)
–
12.3 (0.48)
7.0
0.4 – 0.5 (0.016 – 0.020)
0.2 (0.008)
Commutator O.D.
29.4 (1.16)
28.8 (1.13)
Commutator runout
–
0.1 (0.004)
PRI: Primary, MID: Mid, SEC: Secondary
2-5
14.4 (0.57)
Used
belt
• FRAME
Unit: mm (in)
Parts
Propeller
shaft
Vertical
shaft
Item
Shaft O.D.
Standard
Service limit
At forward bevel gear
(LC, LD, XC and XD types)
24.987 – 25.000 (0.9837 – 0.9843)
24.966 (0.9829)
At reverse bevel gear
(LCD, XCC and XCD types)
24.987 – 25.000 (0.9837 – 0.9843)
24.966 (0.9829)
At needle bearing
30.007 – 30.020 (1.1814 – 1.1819)
29.990 (1.1807)
28.556 – 28.575 (1.1242 – 1.1250)
28.545 (1.1238)
Shaft O.D. (at needle bearing)
2-6
7. TORQUE VALUES
Item
• ENGINE
Lower block bolt (*1)
Crankcase bolt
Oil case bolt
Lower block orifice
Oil jet bolt
No.1 camshaft holder 10 mm sealing bolt
Cylinder head bolt (*2)
Cylinder head cover nut
Spark plug
Connecting rod bolt (*3)
Crankshaft pulley bolt
Balancer chain guide bolt
Balancer driven sprocket bolt
Balancer case assembly bolt (8 x 50 mm/8 x 75 mm)
(8 x 55 mm)
(10 x 105 mm)
Balancer holder bolt
Chain case special bolt
Chain case bolt
Chain case cover bolt
Cam chain tensioner bolt
Cam chain guide bolt
Cam chain guide B bolt
Cam chain tensioner arm bolt
Exhaust camshaft sprocket bolt
VTC flange bolt
Camshaft holder bolt
Camshaft collar bolt
CMP pulse plate bolt
Valve adjusting lock nut (IN side)
Valve adjusting lock nut (EX side)
Oil filter
Oil drain plug bolt
Throttle body bolt
IAC valve bolt
Injector base bolt, nut
Fuel pipe bolt
Pressure regulator nut
IAB control valve bolt
Thread dia. (mm)
and pitch (length)
N.m
Torque value
kgf.m
lbf.ft
M11 x 1.5
M8 x 1.25
M6 x 1.0
M10 x 1.25
M10 x 1.0
M8 x 0.75 (Special bolt)
M10 x 1.0 (Special bolt)
M11 x 1.5
M6 x 1.0
M14 x 1.25
M8 x 0.75 (Special bolt)
M16 x 1.5
M6 x 1.0
M10 x 1.25
M8 x 1.25
M8 x 1.25
M10 x 1.25
M6 x 1.0
M8 x 1.25
M6 x 1.0 (Special bolt)
M6 x 1.0
M6 x 1.0 (SH bolt)
M6 x 1.0
M6 x 1.0
M6 x 1.0
M8 x 1.25
M8 x 1.25 (Special bolt)
M10 x 1.25
M12 x 1.25 (Special bolt)
M8 x 1.25
M6 x 1.0
M14 x 1.0 (Special bolt)
M14 x 1.0 (Special bolt)
M7 x 0.75
M7 x 0.75
M20 x 1.5
M12 x 1.5
M8 x 1.25
M8 x 1.25
M8 x 1.25
M8 x 1.25
M18 x 1.0
M5 x 0.8
29
26
12
34
10
16
20
39
12
18
20
245
12
44
22
27
44
12
27
12
12
12
12
12
12
22
22
72
113
22
12
39
39
20
14
12
23
22
22
24
22
27
5.4
3.0
2.7
1.2
3.5
1.0
1.6
2.0
4.0
1.2
1.8
2.0
25.0
1.2
4.5
2.2
2.8
4.5
1.2
2.8
1.2
1.2
1.2
1.2
1.2
1.2
2.2
2.2
7.3
11.5
2.2
1.2
4.0
4.0
2.0
1.4
1.2
2.3
2.2
2.2
2.4
2.2
2.8
0.55
22
20
9
25
7
12
14
29
9
13
14
181
9
33
16
20
33
9
20
9
9
9
9
9
9
16
16
53
83
16
9
29
29
14
10
9
17
16
16
17
16
20
4.0
*1: Tighten the lower block bolts to 29 N.m (3.0 kgf.m, 22 lbf.ft) first, then tighten them to additional 56° (Angle method).
*2: Tighten the new cylinder head bolts to 39 N.m (4.0 kgf.m, 29 lbf.ft) (Snag torque), then tighten them to additional 278°.
(Tighten to 90° at first, then to 90°, and to 98° in this order) (Angle method).
At assembly, tighten the lower block bolts to 39 N.m (4.0 kgf.m, 29 lbf.ft) (Snag torque), then tighten them to
additional 180°. (Tighten to 90° at first, then to 90° in this order) (Angle method).
*3: Tighten the connecting rod bolts to 20 N.m (2.0 kgf.m, 14 lbf.ft) (Snag torque), then tighten them to additional 90°
(Angle method).
• SH bolt: Small head bolt.
2-7
Item
• ENGINE
Mounting case bolt
Thread dia. (mm)
and pitch (length)
M12 x 1.25
M10 x 1.25
M8 x 1.25
M10 x 1.25
M6 x 1.0
M8 x 1.25
M12 x 1.0
M10 x 1.25
M8 x 1.25
M14 x 1.5
M10 x 1.25
M5 screw
M5
M6 screw
PT 1／8
M10 x 1.25
M10 x 1.25
M18 x 1.5
M12 x 1.25
M5 x 0.8
M6 x 1.0
M8 x 1.25
M10 x 1.25
M8 x 1.25
M5 screw
M5 screw
M6 x 1.0
M8 x 1.25
M8 x 1.25
M6 x 1.0
M5 screw
M5 screw
M5 screw
M5 screw
M4 screw
N.m
Torque value
kgf.m
lbf.ft
6.5
4.5
2.7
4.5
1.2
3.3
12.0
4.5
2.7
11.2
4.5
0.25
0.5
0.6
0.8
2.2
1.2
4.3
3.2
0.35
0.5
2.7
4.0
2.7
0.35
0.35
1.2
2.7
2.7
1.2
0.35
0.35
0.35
0.35
0.21
0.21
1.2
1.2
47
33
20
33
9
24
87
33
20
81
33
1.8
3.6
4.3
5.8
16
9
31
23
2.5
3.6
20
29
20
2.5
2.5
9
20
20
9
2.5
2.5
2.5
2.5
1.5
1.5
9
9
Mounting case nut
Plug hole coil bolt
Flywheel boss bolt
Flywheel bolt
Alternator bolt
nut
Alternator pulley lock nut
Starter motor bolt
Starter motor front bracket screw
Starter motor bolt screw
Starter solenoid switch screw
EOP switch (Low pressure side)
EOP switch (High pressure side)
ECT sensor
A/F sensor
Knock sensor
MAP sensor bolt
ECM bolt
Intake manifold bolt, nut
Exhaust manifold bolt
Exhaust guide bolt
Water separator body screw
Fuel strainer body screw
Fuel pump (low pressure side) bolt
Vapor separator assembly bolt
Vapor separator stay bolt
Service check bolt
Vapor separator cover screw
Water jacket cover screw
Strainer cover screw
Pump cover screw
Pump harness assembly screw
Float pin screw
Fuel pump case bolt
Plate stay A bolt
M6 x 1.0
M6 x 1.0
64
44
26
44
12
32
118
44
26
110
44
2.5
5
6
8
22
12
42
31
3.4
5
26
39
26
3.4
3.4
12
26
26
12
3.4
3.4
3.4
3.4
2.1
2.1
12
12
• GEAR CASE
Propeller shaft holder bolt
18 mm castle nut (*1)
Gear case bolt
Oil level bolt
Oil drain bolt
Water screen screw
Sensor nipple
Bearing holder (LCD, XCC and XCD types only)
Impeller housing bolt
64 mm lock nut
Pinion gear nut
M10 x 1.25
M18 x 1.5
M10 x 1.25
M8 x 1.25
M8 x 1.25
M5 x 0.8
M8 x 1.0
M100 x 2.0
M8 x 1.25
M64 x 1.5
M18 x 1.0
34
1
34
3.4
3.4
1
3
191
19.7
123
142
3.5
0.1
3.5
0.35
0.35
0.1
0.3
19.5
2.0
12.5
14.5
25
0.7
25
2.5
2.5
0.7
2.2
141
14
90
105
• EXTENSION CASE/MOUNTING CASE
Extension case bolt
Lower rubber mounting bolt
Upper rubber mounting bolt
M10 x 1.25
M12 x 1.25
M12 x 1.25
39
83
83
4.0
8.5
8.5
29
61
61
*1: If the split pin cannot be set by tightening the 18 mm castle nuts to 1 N.m (0.1 kgf.m, 0.7 lbf.ft), tighten the 18 mm
castle nut until the split pin can be set. Note that the maximum torque of the 18 mm castle nut is 44 N.m (4.5 kgf.m,
33 lbf.ft).
2-8
Item
• STERN BRACKET
7/8-14 UNF self-locking nut
25 x 2.0 mm self-locking nut
10 mm self-locking nut
• POWER TRIM/TILT ASSEMBLY
Cylinder cap comp.
Rod guide comp.
Manual valve
Socket bolt A/B
Power tilt motor assembly bolt
Power tilt motor assembly code holder screw
Oil tank bolt
Oil tank cap
• FRAME/ELECTRICAL
Grease fitting
Neutral switch nut
Starter motor B terminal washer-nut
Alternator B terminal washer-nut
Alternator fuse box B terminal washer-nut
Alternator fuse box bolt
Fuse box bracket bolt
PGM-FI main relay bolt
ECM bracket bolt
L./R. engine under cover screw
Starter motor bolt
Thread dia. (mm)
and pitch (length)
7/8-14 UNF
M25 x 2.0
M10 x 1.25
M14 x 1.5
1/4-20 UNF
M4 screw
M6 x 1.0
M20 x 1.0
M8 x 1.25
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 x 1.0
M6 screw
M10 x 1.25
N.m
Torque value
kgf.m
lbf.ft
34
34
34
3.5
3.5
3.5
25
25
25
162
78
3.5
8.5
5
1.4
5
2.5
16.5
8.0
0.35
0.85
0.5
0.14
0.5
0.25
119
58
2.5
6.1
3.6
1.0
3.6
1.8
3
2.5
11
8
8
5
5
5
5
4.5
44
0.3
0.25
1.1
0.8
0.8
0.5
0.5
0.5
0.5
0.45
4.5
2.2
1.8
8
5.8
5.8
3.6
3.6
3.6
3.6
3.3
33
N.m
Torque value
kgf.m
lbf.ft
• Use the standard torque values for the bolts, nuts and screws that are not listed in this table.
STANDARD TORQUE VALUES
Item
Thread dia. (mm)
and pitch (length)
Screw
5 mm
6 mm
4.2
9
0.42
0.9
3.0
6.5
Bolt and nut
5 mm
6 mm
8 mm
10 mm
12 mm
5.2
10
21.5
34
54
0.52
1.0
2.15
3.5
5.5
3.8
7
16
25
40
Flange bolt and nut
6 mm (SH bolt)
6 mm (CT bolt)
6 mm
8 mm
10 mm
9
12
12
26
39
0.9
1.2
1.2
2.7
4.0
6.5
9
9
20
29
• CT bolt: Self-tapping bolt
• SH bolt: Small head bolt
2-9
8. SPECIAL TOOLS
• Special tools applicable to the parts except gear case
Tool name
1
2
3
4
5
6
7
8
9
10
Ring gear holder
SCS service check connector
Test harness
Float level gauge
Oil pressure gauge attachment
Fuel pressure gauge set
Oil pressure gauge set
Valve guide driver, 5.5 mm
Pin driver, 6.0 mm
Attachment, 32 x 35 mm
Tool number
Application
070PB-ZY60100
070PZ-ZY30100
070PZ-ZY60100
07401-0010000
07406-0030000
07406-0040003
07506-3000001
07742-0010100
07744-0010500
07746-0010100
Flywheel boss, flywheel removal/installation
ECU troubleshooting, idling adjustment
ECU troubleshooting
Vapor separator float level inspection
Oil pressure test
Fuel pressure inspection
Oil pressure test
Valve guide removal/installation
Balancer shaft hold
22 x 35 x 7 mm water seal installation,
Lower mount center hosing removal
Alternator front bearing installation
Alternator rear bearing, Chain case oil seal
installation
Alternator front bearing removal,
14 x 26 x 8 mm water seal installation
Alternator rear bearing installation
Alternator rear bearing installation
Lower mount center housing installation
14 x 26 x 8 mm water seal installation
Alternator front bearing removal/installation
Mounting case needle bearing installation
Lower mount center housing removal
22 x 35 x 7 mm water seal installation
Driver for 10 through 13, 17 through 21,
33 through 35 and 48
Valve keeper removal/installation
11 Attachment, 37 x 40 mm
12 Attachment, 52 x 55 mm
07746-0010200
07746-0010400
13 Attachment, 24 x 26 mm
07746-0010700
14
15
16
17
18
19
20
21
22
Driver, 22 mm I.D.
Attachment, 15 mm I.D.
Driver, 40 mm I.D.
Pilot, 12 mm
Pilot, 15 mm
Pilot, 20 mm
Pilot, 30 mm
Pilot, 22 mm
Driver
07746-0020100
07746-0020200
07746-0030100
07746-0040100
07746-0040300
07746-0040500
07746-0040700
07746-0041000
07749-0010000
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
Valve spring compressor
Valve spring compressor attachment
Valve seat cutter, 45° 35 mm
Valve seat cutter, 45° 33 mm
Valve seat cutter, 32° 38.5 mm
Valve seat cutter, 32° 33 mm
Valve seat cutter, 60° 30 mm
Valve seat cutter, 60° 37.5 mm
Cutter holder, 5.5 mm
Sensor socket wrench, 22 x 150L
Attachment, 28 x 30 mm
Oil seal driver attachment, 72 mm
Oil seal driver
Oil filter wrench
Valve guide reamer, 5.525 mm
Socket wrench, 19 mm
Handle
Pulley holder attachment, HEX 50 mm
Belt tension gauge
Air supply
Stem seal driver
07757-0010000
07757-PJ10100
07780-0010400
07780-0010800
07780-0012400
07780-0012900
07780-0014000
07780-0014100
07781-0010101
07906-PD10000
07946-1870100
07947-6340201
07947-SB00100
07HAA-PJ70101
07HAH-PJ70100
07JAA-001020A
07JAB-001020B
07JAB-0010400
07JGG-0010101
07LAJ-PR30102
07PAD-0010000
2-10
Valve seat reconditioning (IN)
Valve seat reconditioning (EX)
Valve seat reconditioning (IN)
Valve seat reconditioning (EX)
Valve seat reconditioning (EX)
Valve seat reconditioning (IN)
Valve seat reconditioning (IN/EX)
A/F sensor removal/installation
Mounting case needle bearing installation
Oil pump body oil seal installation
Oil pump cover oil seal installation
Oil filter removal/installation
Valve guide reaming
Crankshaft pulley bolt removal/installation
Alternator belt tension inspection
VTEC system, VTEC valve inspection
Valve stem seal A/B installation
Tool name
Tool number
44 Pin wrench, 6 mm
45 Pin wrench, 4 mm
46 Oil pressure gauge joint A
07SPA-ZW10100
07SPA-ZW10200
07SPJ-ZW10100
47
48
49
50
51
07SPJ-ZW10200
07ZAD-PNA0100
07ZAJ-PNA0101
07ZAJ-PNA0200
07ZAJ-PNA0300
Oil pressure gauge joint B
Oil seal driver attachment, 96
VTEC air adapter
VTEC air stopper
Air joint adapter
1
Piston rod comp. removal/installation
Rod guide comp. removal/installation
Power trim/tilt assembly blow pressure
inspection
Crankshaft oil seal installation
VTEC system, VTEC valve inspection
4
3
7
2
6
5
10 – 13
8
Application
14
9
15
16
23
17 – 21
24
22
27, 28
25, 26
29, 30
35
31
36
34
33
32
37
38
40
39
41
42
46
43
44
49
45
47
48
51
50
2-11
• Special tools applicable to all types of gear case
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Tool name
Tool number
Application
Outer driver attachment, 30 x 37
Gauge adapter, 110 mm
Attachment, 32 x 35 mm
Attachment, 62 x 68 mm
Pilot, 35 mm
Driver
Lock nut wrench, 30/64 mm
Remover weight
Remover handle
Bearing remover, 30 mm
Oil seal driver
Oil seal driver attachment, 21 mm
Oil seal driver attachment, 27.5 x 44 mm
Driver handle, 15 x 280 mm
Driver shaft, B
070PD-ZY60200
070PJ-ZY30100
07746-0010100
07746-0010500
07746-0040800
07749-0010000
07916-MB00002
07741-0010201
07936-3710100
07936-8890300
07947-SB00100
07947-ZV00100
07948-9540000
07949-3710001
07964-MB00200
30 x 37 x 26 mm needle bearing installation
Vertical shaft pinion gear shim adjustment
23 x 36 x 6 mm water seal installation
30 x 37 x 26 mm needle bearing installation
Needle bearing (outer race) removal
Driver for 3 and 12
Vertical shaft lock nut removal/installation
30 x 37 x 26 mm needle bearing removal
30 x 45 x 7 mm water seal installation
12 x 21 x 6 mm oil seal installation
Needle bearing installation
Needle bearing (outer race) removal
30 x 62 x 40 mm taper roller bearing
installation
Needle bearing installation
Vertical shaft pinion gear nut removal/
installation
Forward bevel gear backlash inspection
16 Attachment, 78 x 90 mm
17 Vertical shaft holder
07GAD-SD40101
07SPB-ZW10200
18
19
20
21
22
23
07SPC-ZW0010Z
07SPC-ZW0011Z
07SPJ-ZW0030Z
07SPK-ZW10100
07VMF-KZ30200 Needle bearing installation
07ZMD-MBW0200 Needle bearing (outer race) removal
Puller jaws
Puller bolt
Backlash indicator tool
Backlash indicator attachment
Shaft installer, 15 x 370 mm
Bearing driver attachment, 37 mm
• Special tools applicable to LC, LD, XC and XD types of gear case
Tool name
Tool number
Application
24 Driver handle, 480 mm
070GD-0010100
50 x 90 x 28 mm taper bearing (outer
race) installation
25 Taper bearing installer attachment
26 Remover weight
070PF-ZY60100
07741-0010201
27
28
29
30
31
32
33
07936-3710100
070PC-ZY3A100
07746-0010500
07746-0040800
07747-0010300
07749-0010000
07NAD-P200100
or
07NAD-P20A100
Remover handle
Bearing race puller
Attachment, 62 x 68 mm
Pilot, 35 mm
Attachment, 27.2
Driver
Oil seal driver, 52 x 55 mm
50 x 90 x 28 mm taper bearing (outer
race) removal
Reverse bevel gear installation
Reverse bevel gear removal/installation
Reverse bevel gear removal
Driver for 29, 30, 31 and 33
50 x 90 x 28 mm taper bearing (inner race)
installation
• Special tools applicable to LCD, XCC and XCD types of gear case
Tool name
Tool number
Application
34 Remover weight
07741-0010201
35
36
37
38
07936-3710100
070PC-ZY3A100
07WPC-ZW50100
070PD-ZY60100
Reverse bevel gear, 50 x 90 x 28 mm
radial ball bearing removal [Puller jaws of
the bearing race puller (07LPC-ZV30100)
are removed and replaced with the puller
jaws of part number 07WPC-ZW50100.]
50 x 90 x 28 mm taper bearing (outer race)
removal
50 x 90 x 28 mm taper bearing (inner race/
outer race) installation
Remover handle
Bearing race puller
Puller jaws, 25 mm
Taper bearing driver attachment
39 Attachment, 62 x 68 mm
2-12
07746-0010500
• Special tools applicable to LCD, XCC and XCD types of gear case
Tool name
40
41
42
43
Tool number
Pilot, 35 mm
Attachment, 27.2
Driver
Oil seal driver, 65 mm
44 Backlash indicator tool
45 Backlash indicator attachment
46 Pin spanner wrench, 110 mm
1
2
8, 26, 34
Application
07746-0040800
07747-0010300
07749-0010000
07JAD-PL90100
or
07JAD-PL9A100
07SPJ-ZW0030Z
07SPK-ZW10100
07WAA-S1G0100
3
4, 29, 39
Reverse bevel gear backlash inspection
Bearing holder assembly removal/installation
6, 32, 42
5, 30, 40
16
7
12
11
10
9, 27, 35
Forward bevel gear removal
Forward bevel gear removal
Driver for 38, 39, 40 and 41
50 x 90 x 20 mm radial ball bearing
installation
13
17
18
15
14, 24
19
21, 45
20, 44
22
25
23
28, 36
43
31, 41
33
37
38
46
2-13
BF135A•BF150A
9. TROUBLESHOOTING
a. ENGINE
• HARD STARTING
• Use a known-good battery for troubleshooting.
Turn the ignition switch ON. Check whether
the MIL comes ON for 2 seconds.
Does not come ON.
Perform ignition (power) system troubleshooting (P. 2-20).
Comes ON.
Check whether the warning buzzer sounds
twice.
Does not sound.
Perform warning system troubleshooting if the
warning buzzer sounds twice but keeps
sounding (intermittent sound).
Sounds.
Check whether the starter motor turns.
Does not turn.
Perform starting system troubleshooting (P. 223).
No fuel or low level.
Add fuel and restart the engine.
Turns.
Check the fuel level in the fuel tank.
Fuel level OK.
Remove the vapor separator drain screw
and check whether the fuel flows out freely.
Fuel flow restricted.
Fuel flows freely.
• When gasoline overflow from the vapor separator is detected, check the vapor separator (P. 5-111 thru. 120).
Remove the spark plugs and check for wet
fouled electrodes.
Abnormal.
Perform the following checks.
• Check for collapsed or pinched fuel line.
• Check whether the air vent knob of the tank
is closed.
• Check the primer bulb for air leakage.
• Squeeze the primer bulb and check whether
the fuel reaches the vapor separator.
If there is no problem, perform fuel supply system troubleshooting (P. 5-96).
Perform fuel supply system troubleshooting
(P. 5-96).
Normal.
Dry the spark plug electrodes and check
whether the engine starts.
Does not start.
Check whether the cylinder compression is
normal (P. 2-15).
Compression OK.
Perform ignition system troubleshooting (P.
2-25).
2-14
Low compression.
Perform the following checks and adjustments.
• Check valve clearance(P. 3-9)
• Check valve timing (P. 9-12)
• Check for loose cylinder head
• Check for damaged cylinder head gasket,
valves and valve seats.
• Check for worn pistons, piston rings and
cylinders.
BF135A•BF150A
• CYLINDER COMPRESSION TEST
THROTTLE ARM
1) Move the remote control lever to the “N” (Neutral) position.
2) Remove the clip of the emergency stop switch.
3) Remove the engine cover and disconnect the fuel injector
connectors of each cylinder.
4) Disconnect the ignition coil connector of each cylinder and
remove the spark plugs.
THROTTLE CONTROL CABLE
5) Disconnect the throttle control cable from the throttle arm.
6) Install a compression gauge in the No. 1 plug hole.
7) Set the throttle in the full throttle position by pulling the throttle arm against the full throttle stopper with hand as shown.
8) Set the ignition switch in the “START” position and turn the
starter motor. Measure the cylinder compression.
9) Check the compression on all cylinders.
Cylinder
compression
THROTTLE ARM
1,352 - 1,728 kPa (15.6 - 17.6 kgf/cm2,
222 - 250 psi) at 200 min-1 (rpm)
COMPRESSION GAUGE
(Commercially available)
2-15
BF135A•BF150A
• ENGINE DOES NOT RUN SMOOTHLY
• Perform “g. ALERT SYSTEM” (P. 2-32) troubleshooting when the warning buzzer sounds.
Perform the following troubleshooting when the warning buzzer does not sound but the engine does not run smoothly.
Engine starts, but stalls
soon. Idle speed is not
stable or stalls.
2-16
Faulty spark plug.
Replace or clean (P. 3-8).
Secondary air being sucked.
• Loosely tightened IAC valve, damaged gasket
• Loosely tightened throttle body,
damaged seal ring
• Loosely tightened intake manifold,
damaged seal ring
• Damaged fuel injector seal ring
• Loosely tightened injector base,
damaged gasket
• Retighten the IAC valve. Replace
the gasket if damaged (P. 5-95).
• Retighten the throttle body.
Replace the seal ring if damaged
(P. 5-131).
• Retighten the intake manifold (P.
5-132).
• Replace the fuel injector O-ring if
damaged (P. 5-136).
• Retighten the injector base.
Replace the gasket if damaged
(P. 5-139).
Low pressure fuel system faulty.
Perform fuel supply system troubleshooting (P. 5-96).
High pressure fuel system faulty.
Perform fuel supply system troubleshooting (P. 5-96).
Idle control system faulty.
Perform idle control system troubleshooting (P. 5-93).
BF135A•BF150A
Engine speed does not
increase.
Throttle link and/or cable misadjusted.
Adjust the throttle link and/or cable
(P. 3-26).
Propeller mismatched.
Replace with the correct propeller.
High pressure fuel strainer clogged.
Replace the (high pressure) fuel
strainer (P. 3-18).
Low pressure fuel strainer clogged.
Replace the (low pressure) fuel
strainer (P. 3-15).
Low pressure fuel system faulty.
Perform fuel supply system troubleshooting (P. 5-96).
High pressure fuel system faulty.
Perform fuel supply system troubleshooting (P. 5-96).
Valve clearance misadjusted.
Adjust the valve clearance (P. 3-9).
Variable intake system faulty.
Perform variable intake system
troubleshooting (P. 5-109).
Neutral switch faulty (BF150A only).
Replace the neutral switch (P. 1711)
Low-octane gasoline used.
Use the recommended gasoline.
VTEC system faulty (BF150A only).
Perform VTEC system troubleshooting (P. 5-42 or 5-82).
2-17
BF135A•BF150A
Engine starts, but stalls
soon. Idle speed is not
stable or stalls.
2-18
Throttle link and/or cable misadjusted.
Adjust the throttle link and/or cable
(P. 3-26).
Throttle shaft not move smoothly.
Check the throttle body and clean if
necessary (P. 5-95).
Idle control system faulty.
Perform idle control system troubleshooting (P. 5-93).
Secondary air being sucked.
• Loosely tightened IAC valve, damaged gasket
• Loosely tightened throttle body,
damaged seal ring
• Loosely tightened intake manifold,
damaged seal ring
• Damaged fuel injector seal ring
• Loosely tightened injector base,
damaged gasket
• Retighten the IAC valve. Replace
the gasket if damaged (P. 5-95).
• Retighten the throttle body.
Replace the seal ring if damaged
(P. 5-132).
• Retighten the intake manifold (P.
5-133).
• Replace the fuel injector O-ring if
damaged (P. 5-136).
• Retighten the injector base.
Replace the gasket if damaged
(P. 5-139).
BF135A•BF150A
Engine sometimes misfires or stalls.
Excessive engine speed
Water in the fuel.
• Check for water in the low pressure fuel strainer. Replace if necessary (P. 3-15).
• Check for water in the water separator and drain if necessary (P.
3-19).
• Check for water in the fuel tank
and drain if necessary.
High pressure fuel strainer clogged.
Replace the (high pressure) fuel
strainer (P. 3-18).
Low pressure fuel strainer clogged.
Replace the (low pressure) fuel
strainer (P. 3-15).
Fuel tube faulty.
• Check for pinched or collapsed
tube line and correct if necessary.
• Check the air vent knob of the
tank. Open the air vent knob if it is
closed.
• Check the primer bulb for air leakage. Replace if necessary.
High pressure fuel system faulty.
Perform fuel supply system troubleshooting (P. 5-96).
Propeller mismatched.
Replace with the correct propeller.
Propeller faulty.
Replace the propeller.
Outboard installation setting incorrect (e.g. transom height, tilt angle,
etc.)
Adjust the installation setting.
2-19
BF135A•BF150A
b. IGNITION (POWER) SYSTEM
• ENGINE DOES NOT START
Turn the ignition switch ON. Check
whether the warning buzzer sounds
twice.
Does not
sound.
Check for blown No. 3 (10A), No. 7
(30A) and the No. 4 (15A) fuses.
Are the fuses normal?
NO
Replace the blown fuse(s).
Remove the cause of the
blown fuse(s) before replacement (see FUSE LOAD
CHART on P. 2-20).
NO
Replace the PGM-FI main
relay.
NO
Replace the ignition switch.
NO
Replace or repair the main
wire harness.
YES
Sounds.
Check the PGM-FI main relay.
Is the main relay normal?
YES
Check the ignition switch.
Is the ignition switch normal?
YES
Check the power line of the main
wire harness.
Is the main wire harness normal?
YES
Perform MIL troubleshooting of “MIL
DOES NOT COME ON” (P. 5-18 or
5-61).
Check the No. 5 (10A) fuse.
Is the fuse normal?
NO
Replace the No. 5 (10A) fuse.
Remove the cause of the blown fuse
before replacement (see FUSE LOAD
CHART on P. 2-20).
Does not come ON.
Open in the wire harness between the
indicator light and No. 5 (10A) fuse.
• Replace or repair the wire harness.
• Replace the indicator light.
YES
Turn the ignition switch ON and check
whether the alternator indicator light
comes ON (with the engine stopped).
Comes ON.
Perform the following checks and
repair if necessary.
• Open in the wire between the MIL
and ECM.
• Blown MIL.
If there is no problem, replace the
ECM with a new one and recheck.
2-20
BF135A•BF150A
• FUSE LOAD CHART
POWER TILT
SWITCH
W/Bl
To ALTERNATOR (DETECTION
TERMINAL)
Lg
To POWER TRIM/TILT RELAY
Lb
To POWER TRIM/TILT RELAY
Bl/R
To ECM
Bl/Y
To BUZZER
Bl/Y
To INDICATOR LIGHT
Bl/Y
To TACHOMETER
Bl/Y
To TRIM METER
Bl/Y
To VOLTMETER (OPTION)
Bl/Y
To HOUR METER (OPTION)
POWER TRIM/
TILT SWITCH
No. 3 (10A)
FUSE
Bl/Y
IGNITION
SWITCH
Bl/W
W/Bl
BATTERY
Bl/Y
No. 1 (30A)
FUSE
A/F RELAY
W/G
No. 7 (30A)
FUSE
PGM-FI MAIN RELAY
Y/Bl
MAIN
No. 2 (10A)
FUSE
No. 6 (15A)
FUSE
W/Y
To A/F SENSOR
G/O
To ECM (LAF)
No. 4 (15A)
FUSE
W/Bl
W/Y
W
W/G
Y/Bl
To ECM (LGP1, LGP2)
Y/Bl
To INJECTOR
Y/Bl
To CKP SENSOR
Y/Bl
To CMP SENSOR
Y/G
To IGNITION COIL
No. 5 (10A)
FUSE
START
Bl/Bu
ALTERNATOR
(90A) FUSE
FUEL
W/R
Y/R
Y/R
To ALTERNATOR (IG TERMINAL)
Y/R
To INDICATOR LIGHT (ACG, MIL)
Y/R
To IAB CONTROL VALVE
Y/R
To DATA LINK CONNECTOR
Lg/R
To ECM (FLR1, FLR2)
Bu/R
To FUEL PUMP
W
To STARTER MAGNETIC
SWITCH
W
To ALTERNATOR (OUTPUT
TERMINAL)
Bl
NEUTRAL SWITCH
2-21
BF135A•BF150A
• FUSE BOX CONNECTION TABLE
Fuse No.
Fuse capacity
Connect to
1
30A
A/F sensor heater
2
10A
High pressure side fuel pump
3
10A
Power trim/tilt relay, Alternator (detection terminal), Ignition switch, PGM-FI main relay,
Warning buzzer, Indicator light (oil, overheat), Meters
4
15A
ECM, Fuel injector, CMP sensor, CKP sensor
5
10A
Alternator (IG terminal), A/F relay, Indicator light (MIL, ACG), IAB control valve,
data link connector
6
15A
Ignition coil
7
30A
PGM-FI main relay
FUSE BOX
ALTERNATOR (90A) FUSE
2-22
BF135A•BF150A
c. STARTING SYSTEM
• ENGINE DOES NOT START
• Before starting troubleshooting, check each wire for connection and correct as necessary.
Check whether the remote control
lever is in the “N” (Neutral) position.
Move the remote control lever in the
“N” (Neutral) position.
Not in “N” (Neutral)
position.
In “N” (Neutral) position.
Check whether the engine turns with
the ignition switch in the “START” position.
Does not
turn.
Check by sound whether the starter
motor is turning.
Is the starter motor turning?
YES
NO
Check the No. 3 (10A) fuse and the
No. 7 (30A) fuse.
Are the fuses normal?
Engine turns.
NO
Replace the blown fuse(s).
Remove the cause of the
blown fuse(s) before replacement (see FUSE LOAD
CHART on P. 2-20).
NO
Perform charging system
troubleshooting (P. 2-29).
NO
Remove corrosion from the
terminals and connect the terminals securely.
NO
Replace the neutral switch.
NO
Replace the PGM-FI main
relay.
YES
Check the battery for charging level.
Is the battery fully charged?
• Check the overrunning
clutch and replace as necessary.
• Check the starter motor
magnetic clutch and replace
as necessary.
• Check the planetary gear
and replace as necessary.
YES
Check the battery terminals for connection and corrosion.
Are the battery terminals in good
condition
YES
Check the neutral switch (P. 17-13).
Is the switch in good condition?
YES
Check the PGM-FI main relay (P. 1824). Is the PGM-FI main relay in
good condition?
YES
To P. 2-24 (A).
To P. 2-24 (B).
2-23
BF135A•BF150A
From P. 2-23 (A)
From P. 2-23 (B)
Check the ignition switch (P. 16-9).
Is the ignition switch in good condition?
NO
Replace the ignition switch.
NO
Repair or replace the wire harness.
YES
Replace the starter motor with a new
one and recheck.
Does the starter motor turn?
YES
Replace the starter motor.
Check the engine speed.
Is it normal?
YES
Perform ignition system troubleshooting (P. 2-25).
NO
Charge the battery.
NO
Remove corrosion from the terminals
and connect the terminals securely.
NO
Check inside the engine and repair the
faulty parts.
NO
Check the battery for charging level.
Is the battery fully charged?
YES
Check the battery terminals for connection and corrosion.
Are the battery terminals in good condition?
YES
Replace the starter motor with a new
one and recheck.
Does the starter motor turn?
YES
Replace the starter motor.
2-24
BF135A•BF150A
d. IGNITION SYSTEM
• ENGINE IS HARD TO START
* Before troubleshooting, turn the ignition switch ON and check whether the MIL comes ON for 2 seconds and the warning buzzer sounds twice intermittently.
If the MIL does not come ON or the warning buzzer does not sound, perform power system troubleshooting (P. 2-20).
Check the No. 6 (15A) fuse.
Is the fuse normal?
NO
• Check for short in the wire harness of the
No. 6 (10A) fuse load line. Replace or repair
the wire harness as necessary.
• Replace the No. 6 (15A) fuse.
NO
Set the clip securely.
NO
Replace the spark plugs.
YES
Wet fouled spark plugs.
YES
Replace the spark plugs.
NO
Replace the emergency stop switch.
YES
Replace or repair the wire harness.
YES
Check whether the emergency stop switch
clip is disconnected.
Is the clip set securely?
YES
Measure the spark plug gap.
Standard plug gap: 1.0 – 1.1 mm
Service limit: 1.3 mm
Is the spark plug gap within the service
limit?
YES
Clean the spark plugs and install them.
Start the engine according to the starting
procedure.
Does the engine start?
NO
Install the new spark plugs and restart.
Does the engine start?
NO
Check the emergency stop switch.
Is the emergency stop switch normal?
YES
Check for short in the black/red wire of the
emergency stop switch.
Is there continuity between the harness
side black/red terminal and the black terminal?
NO
To P. 2-26
2-25
BF135A•BF150A
From P. 2-25
Check the CKP sensor connector.
Is the connector connected securely?
No
Connect the CKP sensor connector properly
and recheck.
No
Replace or repair the wire harness. (Open circuit in the wire between the No. 6 (15A) fuse
and the ignition coil.)
No
• Replace or repair the wire harness. (Open
circuit in the wire harness between the ignition coil and the engine ground.)
• Check the engine ground and repair as necessary.
Yes
Check for open circuit in the ignition coil’s
power line.
1 Disconnect the 3P connectors from
each of the ignition coils.
2 Turn the ignition switch ON. Measure
the voltage between the No. 3
(Yellow/Green) terminal of each harness side 3P connector and the engine
ground.
Ignition coil
harness side
3P connector
Viewing from
terminal side
Is there the battery voltage?
Yes
Check for open circuit in the ignition coil’s
ground line.
1 Turn the ignition switch OFF.
2 Check for continuity between the No. 2
(Black/White) terminal of the respective
harness side 3P connectors and the
engine ground.
Ignition coil
harness side
3P connector
Viewing from
terminal side
Is there continuity?
Yes
To P. 2-27
2-26
BF135A•BF150A
From P. 2-26
Check for short circuit in the ignition coil’s
signal line.
1 Turn the ignition switch OFF. Check for
continuity between the No. 1 (Blue,
Blue/Black, White/Green, Blue/Red) terminal of the respective harness side 3P
connectors and the engine ground.
Yes
Replace or repair the wire harness (Short circuit in the wire harness between the ignition
coil and the ECM).
Yes
Replace the ignition coil.
No. 1 ignition coil: Blue
No. 2 ignition coil: Blue/Black
No. 3 ignition coil: White/Green
No. 4 ignition coil: Blue/Red
Ignition coil
harness side
3P connector
Viewing from
terminal side
Is there continuity?
No
Replace the ignition coil and recheck.
Does the engine start?
No
Substitute a known-good ECM and
recheck.
2-27
BF135A•BF150A
e. FUEL SYSTEM
• ENGINE IS HARD TO START
• When the gasoline is flowing out of the vapor separator, check the vapor separator (P. 5-112 thru. 5-120).
Turn the ignition switch ON and check
the fuel pump operation.
Is there the operation sound for 2 seconds after the ignition switch is ON?
NO
Check the No. 2 (10A) fuse.
Is the fuse normal?
NO
• Check for short in the wire
harness between the No. 2
(10A) fuse and the fuel
pump. Replace or repair the
wire harness as necessary.
• Replace the No. 2 (10A)
fuse.
NO
Replace the PGM-FI main
relay.
NO
Replace or repair the wire harness (Open circuit in the
ground line).
YES
Yes
Check the PGM-FI main relay.
Is the PGM-FI main relay normal?
YES
Check for open circuit in the fuel
pump ground line.
1 Turn the ignition switch OFF and
disconnect the fuel pump 2P connector.
2 Check for continuity between the
No. 2 (Black/White) terminal of the
harness side 2P connector and
the engine ground.
Fuel pump
harness side
2P connector
Viewing from
terminal side
Is there continuity?
YES
To P. 2-29 (A)
2-28
To P. 2-29 (B)
BF135A•BF150A
From P. 2-28 (A)
From P. 2-28 (B)
Check for open circuit in the fuel
pump power line.
1 Disconnect the main relay 2P
connector.
2 Check for continuity between the
No. 1 (Blue/Red) terminal of the
harness side main relay 2P connector and the No. 1 (Blue/Red)
terminal of the fuel pump 2P connector.
PGM-FI main
Fuel pump
relay harness
harness side
side 2P
2P connector
connector
NO
Replace or repair the wire harness (Open circuit in the fuel
pump power line).
NO
Replace the (high pressure)
fuel pump.
Viewing from
terminal side
Is there continuity?
YES
Check the (high pressure) fuel pump
(P. 5-107).
Is the fuel pump normal?
YES
Substitute a known-good ECM and
recheck.
Check the low pressure fuel system (P.
5-96).
Is the low pressure fuel system normal?
NO
Repair the faulty part.
NO
Repair the faulty part.
YES
Check the high pressure fuel system
(P. 5-96).
Is the high pressure fuel system normal?
YES
Perform idle control system troubleshooting. If it is normal, Substitute a
known-good ECM and recheck
2-29
BF135A•BF150A
f. CHARGING SYSTEM
• BATTERY UNDER CHARGED
Is the alternator belt tension correct
(Inspection: P. 3-29)?
NO
Adjust the alternator belt tension (P. 3-29).
YES
Replace the battery.
NO
Replace or repair the wire harness (Open in
the wire between the alternator and No. 5
fuse).
NO
Replace or repair the wire harness (Open in
the wire between the alternator and the ignition switch).
YES
Start the engine and let it idle to warm up.
Measure the voltage between the battery
terminals when the engine speed is 3,000
min-1 (rpm).
Is the voltage between the terminals 13.5V
or above?
NO
Check for open circuit in the IG line.
1 Turn the ignition switch OFF and disconnect the alternator 4P connector.
2 Measure the voltage between the No. 2
(Yellow/Red) terminal of the alternator 4P
connector and the engine ground.
Alternator
harness side 4P
connector
Viewing from terminal side
Is there the battery voltage with the ignition
switch ON?
Yes
Check for open circuit in the BAT line.
1 Turn the ignition switch OFF and disconnect the alternator 4P connector.
2 Measure the voltage between the No. 1
(White/Black) terminal of the alternator
4P connector and the engine ground.
Alternator
harness side 4P
connector
Viewing from terminal side
Is there the battery voltage with the ignition
switch ON?
Yes
Disassemble and service the alternator (P.
6-9).
2-30
BF135A•BF150A
• ALTERNATOR INDICATOR LINE INSPECTION
Turn the ignition switch ON.
Does the alternator indicator
lightcome ON?
YES
Start the engine.
Does the alternator indicator
light go OFF?
Yes
End of inspection (Good)
YES
Replace or repair the wire harness (Short in the wire
between the ECM and the
alternator).
NO
Replace or repair the wire harness (Open in the wire
between the ECM and alternator).
NO
• Check the alternator indicator light bulb. Replace the
bulb as necessary.
• If the bulb is normal, replace
the alternator indicator light.
No
NO
Check for short circuit in the L
line.
1 Stop the engine and disconnect the alternator 4P connector.
Does the alternator indicator
light come ON with the ignition
switch ON?
NO
Disassemble and service the
alternator.
Check the No. 5 (15A) fuse.
Is the fuse normal?
NO
• Check for short circuit in the
wire harness of the No. 5
(10A) fuse load line. Replace
or repair the main harness if
necessary.
• Replace the No. 5 (15A)
fuse.
NO
Check for open circuit in the
wire harness (White/Blue)
between the ECM and the
alternator.
Is the wire harness normal?
YES
Check for open circuit in the L
line.
1 Stop the engine and disconnect the alternator 4P connector.
2 Connect the No. 4 (White/
Blue) terminal of the alternator 4P connector to the body
to short using a jumper wire.
Alternator
harness side 4P
connector
Viewing from
terminal side
Does the alternator indicator
light come ON with the ignition
switch ON?
YES
Check the alternator indicator
light.
Is the alternator indicator light
normal?
YES
Substitute a known-good ECM
and recheck.
YES
Disassemble and service the
alternator (P. 6-9).
2-31
BF135A•BF150A
g. ALERT SYSTEM
• OIL ALERT SYSTEM
When the oil pressure switch (low pressure side) detects low oil pressure, the ECM receives the signal from the oil pressure switch and decreases the engine speed gradually to 1,800 min-1 (rpm). The warning buzzer sounds and the oil indicator light goes OFF this time. When the problem is removed, the engine speed increases gradually and the engine is
restored to the normal running.
• OVERHEAT ALERT SYSTEM
When the ECM detects overheat by receiving the signal from the thermo sensor, it decreases the engine speed gradually to 1,800 min-1 (rpm). The warning buzzer sounds and the overheat indicator light comes ON. When the problem is
not removed within 20 seconds, the ECM decreases the engine speed further until it stops. When the problem is removed
during this control, the ECM increases the engine speed gradually until the engine is restored to the normal running.
• ALTERNATOR WARNING SYSTEM
The IC regulator is equipped in the alternator to detect the disconnected sensor terminal, disconnected output terminal,
overcharge and undercharge when generation stops. When a problem is detected, the IC regulator turns the alternator
indicator lightON and the ECM sounds the warning buzzer (intermittent prolonged sound) by receiving the signal from
the IC regulator.
• FULL WATER (IN WATER SEPARATOR) WARNING SYSTEM
When the water level in the water separator is above the specified level, the water level sensor detects the condition and
transmits the signal to the ECM to sound the warning buzzer.
• MIL WARNING SYSTEM
The MIL indicator light comes ON and the buzzer sounds (intermittent prolonged sound) when the ECM detects a problem by its diagnostic function.
• WARNING SYSTEM
Condition
Indicator light
Warning indicator light
Warning buzzer
Oil indicator
light (Green)
Overheat
indicator
light (Red)
ACG
indicator
light (Red)
MIL
(Red)
ON for 2 sec.
ON for 2 sec.
ON
ON for 2 sec.
Sounds twice
2 sec. after turning ignition switch ON
OFF
OFF
ON
OFF
Stop
Normal operation
ON
OFF
OFF
OFF
Stop
Engine oil pressure dropped
OFF
OFF
OFF
OFF
Continuous sound
Overheat
ON
ON
OFF
OFF
Continuous sound
MIL faulty
ON*1
OFF*2
OFF
ON
Intermittent
prolonged sound
Alternator faulty
ON
OFF
ON
OFF
Intermittent
prolonged sound
Water separator full
ON
OFF
OFF
OFF
Intermittent short
sound
Ignition switch ON (Initial check)
When two or more problems occur simultaneously, warning for each problem is indicated simultaneously.
When a problem occurred simultaneously with the malfunction of the MIL:
*1: The oil indicator light blinks when a problem with the high pressure oil pressure switch is detected.
*2: The overheat indicator light blinks when a problem with the overheat sensor is detected.
The warning buzzer of the prolonged sound takes precedence over the short sound.
Example: When the problems with the alternator and full water separator are detected simultaneously, the warning
buzzer is the intermittent prolonged sound.
Example: When the overheat and a problem with the alternator are detected simultaneously, the warning buzzer is the
continuous sound.
2-32
BF135A•BF150A
• WARNING BUZZER SOUNDS CONTINUOUSLY
Check the indicator light.
Is the overheat indicator light
ON?
YES
To P. 2-36
NO (OFF)
Is the oil indicator light OFF?
NO
(ON)
Check the oil indicator light.
Is the oil indicator light normal?
NO
Replace the oil indicator light.
NO
Replace the buzzer.
YES
Replace or repair the wire harness (Short in wire harness
between the buzzer and ECM).
YES
Check the warning buzzer.
Is the warning buzzer normal?
YES (OFF)
YES
Check for short in the buzzer
line.
1 Turn the ignition switch OFF
and disconnect the remote
control cable 14P connector.
2 Check for continuity between the No. 7 (Yellow/
Green) terminal and the
engine ground
Remote control cable
14P connector
Viewing from terminal
side
Is there continuity?
NO
Substitute a known-good ECM
and recheck.
Stop the engine and check the
oil level.
Is the oil level correct?
No
Add the oil to the correct level.
Yes
To P. 2-34
2-33
BF135A•BF150A
From P. 2-33
Start the engine.
Is the oil indicator light ON with
the engine idling?
YES
Snap the engine (4,000 min-1
/rpm or above under no load)
and check the oil indicator and
warning buzzer.
Do the oil indicator light come
ON and the buzzer stop sounding?
YES
Normal (End of inspection)
YES
Replace the oil pressure
switch.
YES
Replace or repair the wire harness (Short in the wire harness between the high pressure side oil pressure switch
and ECM).
NO
Replace or repair the wire harness (Short in the wire harness between the low pressure side oil pressure switch
and ECM).
NO
NO
Disconnect the high pressure
side oil pressure switch 2P connector.
Do the oil indicator light come
ON and the buzzer stop sounding?
NO
Check for short in the high pressure side oil pressure switch
line.
1 Turn the ignition switch OFF.
2 Check for continuity between
the No. 1 (Green/Red) terminal of the harness side oil
pressure switch 2P connector and the engine ground.
Oil pressure
switch 2P
connector
Viewing from
terminal side
Is there continuity?
NO
Substitute a known-good ECM
and recheck.
Disconnect the low pressure
side oil pressure switch wire.
Do the oil indicator light come
ON and the warning buzzer
stop sounding?
NO
Check for short in the low pressure side oil pressure switch
line.
1 Turn the ignition switch OFF.
2 Check for continuity between
the oil pressure switch terminal and the engine ground.
Is there continuity?
YES
YES
To P. 2-35
2-34
Substitute a known-good ECM
and recheck.
BF135A•BF150A
From P. 2-34
Check the oil pressure.
Is the oil pressure within the
specification?
No
Perform the following checks
and repair or replace as necessary.
• Clogged oil strainer
• Clogged oil filter
• Faulty oil pump
• Clogged oil passage
Yes
Oil pressure switch is faulty.
Yes
Replace the oil pressure switch
and start the engine.
Do the oil indictor light come ON
and the buzzer stop sounding?
No
Substitute a known-good ECM
and recheck.
• OIL PRESSURE INSPECTION
OIL PRESSURE
GAUGE SET
07506-3000001
1) Remove the switch cover. Remove the 4 mm screw and the
oil pressure switch wire.
2) Remove the oil pressure switch.
3) Install the oil pressure gauge attachment as shown.
TORQUE: 8 N • m (0.8 kgf • m, 5.8 lbf • ft)
4) Install the oil pressure gauge set.
5) Start the engine and measure the oil pressure.
Oil pressure
0.147 MPa (1.5 kgf/cm2, 21.3 psi)
at 2,050 min-1 (rpm)
6) Clean the threads of the switch and apply the liquid gasket
(Three Bond 1215 or equivalent) to the indicated area.
Install the oil pressure switch to the specified torque.
TORQUE: 8.3 N • m (0.85 kgf • m, 6.1 lbf • ft)
OIL PRESSURE GAUGE
ATTACHMENT
07406-0030000
LIQUID
GASKET
APPLICATION
AREA
2-35
BF135A•BF150A
From P. 2-33
Stop the engine and check the
water screen.
Is the water screen clogged?
YES
Clean the water screen.
NO
• Check the water pump and
replace if necessary.
• Check the water tube for
blockage and deformation.
Replace if necessary.
YES
The system is restored to normal operation.
NO
Replace the thermostat.
NO
Start the engine and check the
water check port with the engine
idling.
Does the cooling water flow
through the water check port
continuously?
YES
Put the outboard motor into gear
and let the engine idle for a few
minutes to cool it down.
Do the overheat indicator light
go OFF and the warning buzzer
stop sounding?
NO
Check the thermostat.
Is the thermostat normal?
YES
Perform ECT sensor 2, 3, and 4
troubleshooting (P. 5-51, 52, and
55 or 5-84. 86, and 89).
2-36
BF135A•BF150A
• INTERMITTENT PROLONGED SOUND OF WARNING BUZZER KEEPS SOUNDING
Is the MIL ON?
YES
Perform MIL troubleshooting (P.
5-18 or 5-61).
NO
Check for open in the indicator
light power line.
1 Turn the ignition switch OFF
and disconnect the indicator
light 3P connector.
2 Turn the ignition switch ON.
Measure the voltage between the No. 3 (Yellow/Black)
terminal of the harness side
3P connector and the engine
ground.
NO
Is the alternator indicator light
ON?
Yes
NO
Replace or repair the wire harness (Open in the wire harness between the indicator
light and No. 5 (10A) fuse).
Harness side
connector
Viewing from
terminal side
Is there the battery voltage?
Yes
• Check for blown bulb. Replace
if necessary.
• If the bulb is not blown out,
replace the indicator light.
Is the alternator belt tension
correct?
No
Adjust the alternator belt tension.
NO
Replace the fuse.
NO
Replace the fuse.
NO
Check the load. If there is no
problem, replace the battery.
YES
Is the alternator fuse (90A) normal?
YES
Check the alternator 4P connector for connection.
Is the alternator 4P connector
connected properly?
YES
Measure the voltage between
the measurement battery terminals.
Is the voltage 13.5V or above?
YES
Perform alternator troubleshooting (P. 2-31).
2-37
BF135A•BF150A
• INTERMITTENT SHORT SOUND OF WARNING BUZZER KEEPS SOUNDING
Stop the engine. Check the water separator and the low pressure fuel strainer.
Is the water accumulated in the water separator and/or low pressure fuel strainer?
YES
Drain the water from the water separator
and/or the low pressure fuel strainer (P. 3-15).
YES
Replace the water level sensor in the water
separator.
YES
Replace or repair the wire harness (Short in
the wire between the water level sensor and
ECM).
NO
Disconnect the water level sensor 2P connector.
Does the buzzer stop sounding with the
ignition switch turned ON?
NO
Check for short in the water level sensor
line.
1 Turn the ignition switch OFF.
2 Check for continuity between the No. 2
(Green/Red) terminal of the water level
switch harness side 2P connector and
the engine ground.
Water level switch
harness side
2P connector
Viewing from
terminal side
Is there continuity?
NO
Substitute a known-good ECM and
recheck.
2-38
BF135A•BF150A
h. SHIFT MECHANISM
Shift lever does not move.
Shift cable corroded or stuck with
salt.
Replace: P. 15-3
Shift cable misadjusted.
Adjust: P. 3-25
Shift arm damaged.
Replace: P. 17-11
Shift detent arm damaged.
Replace: P. 17-12
Shift rod
twisted.
Replace: P. 14-4, 9, 43, and 48
and shift rod A bent or
Shift shaft A and/or B bent.
Replace: P. 15-3
In gear case assembly:
• Clutch shifter damaged
• Shift slider damaged
Replace: P. 14-18 and 57
2-39
BF135A•BF150A
i. POWER TRIM/TILT ASSEMBLY
• POWER TRIM/TILT ASSEMBLY DOES NOT MOVE
Check the motor sound.
Does not sound
Perform troubleshooting of “POWER
TRIM/TILT MOTOR DOES NOT TURN” (P. 242).
Loose
Tighten the manual valve securely.
Leaking
Replace the O-ring and oil seal at the leaking
point.
Low level
Add the oil to the specified level (P. 15-47).
Air in the system
Bleed air from the system (P. 15-48).
Sounds
Check the manual valve for looseness.
Tight
Check for oil leakage from power trim/tilt
assembly.
OK
Check the oil level with the piston rods fully
extended (P. 15-47).
OK
Check for air in the system.
No air
Power trim/tilt assembly faulty.
Repair the faulty part(s) by referring to
POWER TRIM/TILT ASSEMBLY QUICK
REFERENCE CHART (P. 2-43).
2-40
BF135A•BF150A
• POWER TRIM/TILT ASSEMBLY DOES NOT HOLD
Check the manual valve for tightness.
Loose
Tighten the manual valve securely.
Leaking
Replace the O-ring and oil seal of the leaking
point.
Leaking
Replace the power trim/tilt assembly.
Abnormal
Replace the motor assembly or gear pump
assembly.
Low level
Add the oil to the specified level (P. 15-47).
Air in the system
Bleed air from the system (P. 15-48).
Tight
Check for oil leakage from the power
trim/tilt assembly.
Not leaking
Check for oil leakage from the cylinder surface.
Not leaking
Check the hydraulic pressure (P. 15-50).
Normal
Check the oil level (P. 15-47).
Normal
Check for air in the system.
No air in the system
Replace the power trim/tilt assembly.
2-41
BF135A•BF150A
• POWER TRIM/TILT MOTOR DOES NOT TURN
Connect the 12V battery directly to the
motor terminals and check whether
the motor turns.
Does not turn.
Turns
Check for open circuit in the motor
wire.
Open
circuit
Replace the front bracket.
Overheats
Cool down the motor.
Abnormal
Replace the breaker.
No open circuit
Check the motor for overheating.
Does not overheat
Check the breaker inside the motor.
Normal
Check for oil inside the motor.
Oil
Replace the motor assembly.
No oil
Disassemble the motor and replace
the faulty parts.
Check the power trim/tilt relay (P. 1829).
Abnormal
Replace the power trim/tilt relay.
Abnormal
Replace the power trim/tilt switch.
Normal
Check the power trim/tilt switch (P. 1610).
Normal
Replace or repair the wire harness.
2-42
BF135A•BF150A
• POWER TRIM/TILT ASSEMBLY QUICK REFERENCE CHART
Symptom
Does
not
tilt up
Does
not tilt
down
Pressure check
Lower chamber
hydraulic presDoes not hold
sure lower than
spec. or presLowers Extends sure drops.
—
—
—
—
Upper chamber
hydraulic pressure lower than
spec. or pressure drops.
—
—
—
Check point
(See page 2-44)
Check/repair method
Motor assembly
Check the motor assembly.
Manual valve
Check that the manual valve is installed
securely. Replace if it is damaged.
Check the O-ring surface for damage
and replace if necessary.
If there is no damage, clean the O-ring
and install on the manual valve properly.
Backup ring
O-ring
(Piston rod B)
Check the backup ring for damage and
replace if necessary.
Check the O-ring surface for damage
and replace if necessary.
If the backup ring and O-ring are normal, clean and install on the piston rod
B properly.
Backup ring
O-ring
(Free piston)
Check the backup ring for damage and
replace if necessary.
Check the O-ring surface for damage
and replace if necessary.
If the backup ring and O-ring are normal, clean and install on the free piston
properly.
Check valve
(Free piston)
Check the ball seat and the neighboring
area for damage and replace the free
piston as an assembly if necessary. (Do
not disassemble the free piston.)
—
—
—
O-ring
(Piston rod comp.)
Check the O-ring surface for damage
and replace if necessary.
—
—
—
Shock relief valve
(Piston rod comp.)
Check the ball seat and the neighboring
area for damage and replace the piston
rod comp. as an assembly if necessary.
(Do not disassemble the piston rod
comp.)
—
—
—
Dust seal, O-ring
(Cylinder cap)
Check the dust seal and O-ring for damage and foreign material (oil leakage).
Replace if necessary.
Oil (ATF)
Check the oil level and add the oil if
necessary.
Pump assembly
If the pump turns idle or excessively
heavy, replace the pump assembly. (Do
not disassemble the pump assembly.)
Up relief valve
The valves are built in the pump assembly. Replace the pump assembly if necessary. (Do not disassemble the pump
assembly.)
—
—
—
—
—
—
—
—
—
—
Down relief valve
—
—
Lower chamber
check valve
—
—
Lower chamber
spool valve
Upper chamber
check valve
—
2-43
—
Upper chamber
spool valve
BF135A•BF150A
• CHECK POINTS
LOWER CHAMBER SPOOL VALVE
PUMP
UP RELIEF VALVE
UPPER CHAMBER
SPOOL VALVE
DOWN RELIEF
VALVE
UPPER CHAMBER
CHECK VALVE
MANUAL VALVE
LOWER CHAMBER
CHECK VALVE
DUST SEAL/O-RING
PISTON ROD ASSEMBLY
MOTOR
OIL (ATF)
SHOCK
RELIEF VALVE
PUMP ASSEMBLY
O-RING/
BACKUP RING
O-RING
FREE PISTON
O-RING/
BACKUP RING
CHECK VALVE
O-RING/
BACKUP
RING
2-44
10. CABLE/HARNESS ROUTING
After securing the cables and harnesses with the harness band
clips, cut the end of the harness band clips so that the projected
length is 5 – 10 mm (0.2 – 0.4 in) as shown.
[1]
HARNESS
BAND CLIP
5 – 10 mm
(0.2 – 0.4 in)
[6] ALTERNATOR FUSE
CABLE (WHITE CABLE)
[3]
VTEC SOLENOID VALVE
1P CONNECTOR [BF150A only]
[2] HARNESS BAND CLIP
Connect the cable to the
alternator B terminal as shown.
[4] A/F (AIR FUEL RATIO)
SENSOR 4P CONNECTOR
60°
[1] WATER RELIEF TUBE A
[5] ALTERNATOR
4P CONNECTOR
[16]
A/F (AIR FUEL RATIO) SENSOR
[15]
VTEC SOLENOID
VALVE [BF150A only]
[14]
WATER TUBE CLAMP
Set the water relief
tube A in the clamp
of the larger diameter
side and the main
wire harness in the
clamp of the smaller
diameter side.
[13]
ECT (ENGINE
COOLANT
TEMPERATURE)
SENSOR 3
2P CONNECTOR
[12]
ECT (ENGINE
COOLANT
TEMPERATURE)
SENSOR 3
[11] COVER LOCK
CABLE B
2-45
[7]
HARNESS BAND CLIP
Clamp the alternator
fuse cable and the
main wire harness.
[8]
ECT (ENGINE
COOLANT
TEMPERATURE)
SENSOR 1
2P CONNECTOR
[9] EOP (ENGINE OIL
PRESSURE)
SWITCH (HIGH
PRESSURE SIDE)
2P CONNECTOR
[10]
EOP (ENGINE OIL
PRESSURE) SWITCH
(LOW PRESSURE
SIDE)
[1] HARNESS BAND CLIP
Clamp the main wire harness and
the ECT sensor 3 wire as shown.
[1]-1 ECT (ENGINE COOLANT
TEMPERATURE) SENSOR 3
WIRE
[2]
ECT (ENGINE
COOLANT
TEMPERATURE)
SENSOR 4
[1]-2
ENGINE SIDE
[3]
ECT (ENGINE
COOLANT
TEMPERATURE)
SENSOR 4
2P CONNECTOR
[1]-3 MAIN WIRE HARNESS
[4]
A/F (AIR FUEL RATIO)
SENSOR 4P CONNECTOR
[18]
HARNESS BAND
CLIP
[5]
VTEC SOLENOID
VALVE
1P CONNECTOR
[BF150A only]
[17]
A/F (AIR FUEL
RATIO) SENSOR
[6]
ALTERNATOR
4P CONNECTOR
[16]
WATER TUBE
CLAMP
[7]
ALTERNATOR
FUSE CABLE
(WHITE CABLE)
[15] MAIN WIRE
HARNESS
[8]
ECT (ENGINE
COOLANT
TEMPERATURE)
SENSOR 1
2P CONNECTOR
[14]
ECT (ENGINE
COOLANT
TEMPERATURE)
SENSOR 3
2P CONNECTOR
[13]
ECT (ENGINE COOLANT
TEMPERATURE) SENSOR 3
[11] VTEC SOLENOID
VALVE
[BF150A only]
[12] HARNESS BAND CLIP
Clamp the main wire harness and
the ECT sensor 3 wire as shown.
[12]-1ECT (ENGINE COOLANT
TEMPERATURE) 3 WIRE
[12]-2
ENGINE SIDE
[12]-3 MAIN WIRE HARNESS
2-46
[10]
EOP (ENGINE OIL
PRESSURE)
SWITCH
(LOW PRESSURE
SIDE)
[9]
EOP (ENGINE OIL
PRESSURE)
SWITCH (HIGH
PRESSURE SIDE)
2P CONNECTOR
[3] HARNESS BAND CLIP
Clamp the VTEC solenoid valve wire [BF150A
only] and the A/F sensor wire as shown.
[3]-1
A/F (AIR FUEL
RATIO) SENSOR
4P CONNECTOR
[3]-2
INSIDE
[3]-3 VTEC SOLENOID VALVE
WIRE [BF150A only]
[2] A/F (AIR FUEL RATIO)
SENSOR 4P CONNECTOR
[4]
MAIN WIRE
HARNESS
[5]
ECT (ENGINE
COOLANT
TEMPERATURE
SENSOR 4
2P CONNECTOR
[1]
HARNESS BAND
CLIP
[8] VTEC SOLENOID VALVE
[BF150A only]
2-47
[7]
VTEC SOLENOID VALVE
1P CONNECTOR
[BF150A only]
[6]
ECT (ENGINE
COOLANT
TEMPERATURE)
SENSOR 4
[1]
ALTERNATOR
4P CONNECTOR
[2] ALTERNATOR FUSE
CABLE (WHITE CABLE)
[3]
MAIN WIRE
HARNESS
[4]
ECT (ENGINE
COOLANT
TEMPERATURE)
SENSOR 1
[5]
ECT (ENGINE
COOLANT
TEMPERATURE)
SENSOR 1
2P CONNECTOR
[6]
EOP (ENGINE OIL
PRESSURE) SWITCH
(HIGH PRESSURE
SIDE) 2P CONNECTOR
[8] HARNESS BAND CLIP
Clamp the alternator
fuse cable and the
main wire harness as
shown.
[7]
EOP (ENGINE OIL
PRESSURE) SWITCH
(LOW PRESSURE SIDE)
[10] CKP (CRANKSHAFT
POSITION) SENSOR
[9]
CKP (CRANKSHAFT
POSITION) SENSOR
3P CONNECTOR
[11]
HARNESS BAND
CLIP
2-48
[5] ALTERNATOR FUSE BOX B TERMINAL
Install the alternator fuse box B terminal
at 30° from the horizontal line as shown.
[5]-1 ALTERNATOR FUSE
BOX B TERMINAL
[2] FUSE BOX
[3] ALTERNATOR
FUSE BOX (90A)
30°
[1] HARNESS BAND CLIP
Clamp the alternator
fuse cable and the
main wire harness.
[4] WIRE HARNESS
CLIP
[6] STARTER CABLE
[26]
ALTERNATOR
FUSE CABLE
(WHITE CABLE)
[7] MAIN WIRE
HARNESS
[25]
ENGINE SPEED
CHECK CONNECTOR
[BLUE CONNECTOR]
(2P CONNECTOR)
[8]
OFFSET HARNESS
BAND
[9]
HARNESS BAND
CLIPS
[24]PGM-FI MAIN RELAY
4P CONNECTOR
[10]
A/F (AIR FUEL
RATIO) RELAY
[23]
DLC (DATA LINK
CONNECTOR) [RED
CONNECTOR]
(4P CONNECTOR)
[11]
ECM CONNECTOR C
(6P CONNECTOR)
[22]
PGM-FI MAIN RELAY
2P CONNECTOR
[12]
STARTER CABLE
1P CONNECTOR
(WHITE CABLE)
[21]
PGM-FI MAIN RELAY
6P CONNECTOR
[13]
A/F (AIR FUEL
RATIO) RELAY
4P CONNECTOR
[20]
POWER TILT SWITCH
3P CONNECTOR
[4] WIRE HARNESS
CLIP
[19]
POWER TILT SWITCH
WIRE
[15] HARNESS
CLIP
[18]
STARTER CABLE
3P CONNECTOR
[17]
ECM (ENGINE CONTROL
MODULE)
2-49
[16] ECM CONNECTOR B
(34P CONNECTOR)
[15] HARNESS CLIP
[14]
ECM CONNECTOR A
(26P CONNECTOR)
[1] HARNESS BAND CLIP
[2] ALTERNATOR FUSE BOX (90A)
[16]
PGM-FI MAIN RELAY
[3]
STARTER CABLE
[15]
ALTERNATOR FUSE
CABLE (WHITE CABLE)
[14]
STARTER CABLE
3P CONNECTOR
[4]
MAIN WIRE
HARNESS
[13]
PGM-FI MAIN RELAY
CONNECTOR WIRE
[5]
ALTERNATOR
FUSE CABLE
[12] HARNESS BAND
CLIPS
[11]
PGM-FI MAIN RELAY
CONNECTOR
[1]
HARNESS BAND
CLIP
[10] POWER TILT
SWITCH WIRE
[9] WIRE HARNESS CLIP
Clamp the alternator fuse
cable, PGM-FI main relay
wire and the power tilt switch
wire at the grommet.
[8]
POSITIVE (+)
STARTER
CABLE
[5] ALTERNATOR
FUSE CABLE
[6] ELECTRIC PART CASE
Set the alternator fuse cable and the
starter cable in the cable holder of the
electric part case as shown.
[6]-1
ELECTRIC PART
CASE
[6]-2
STARTER
CABLE
[7] HARNESS BAND CLIP
Clamp the alternator fuse
cable and the PGM-FI main
relay connector wire as
shown.
[6]-4
CABLE
HOLDER
2-50
[6]-3
ALTERNATOR FUSE
CABLE
[2]
HARNESS BAND
CLIPS
[1] POWER TILT SWITCH
3P CONNECTOR
[4] STARTER CABLE
[10] PGM-FI MAIN RELAY
CONNECTOR
[3]
HARNESS BAND
CLIP
[9]
POWER TILT
SWITCH WIRE
[4] STARTER CABLE
[5] HARNESS CLIP
[8] WIRE HARNESS CLIP
Clamp the alternator fuse
cable, PGM-FI main relay
wire and the power tilt switch
wire at the grommet.
[11]
8 mm WASHER-NUT (2)
[7]
ALTERNATOR
FUSE CABLE
[6] STARTER CABLE
3P CONNECTOR
[7]
ALTERNATOR FUSE CABLE
[7]
ALTERNATOR FUSE CABLE
[12]
8 mm WASHER
[13]
POSITIVE (+)
STARTER CABLE
90°
[14]
STARTER MOTOR B
TERMINAL
[15]
Connect the alternator fuse
cable terminal and the positive
(+) starter cable terminal so that
they are at right angle to the
vertical center line as shown.
2-51
[13]
POSITIVE (+)
STARTER
CABLE
[1]
POWER TILT
SWITCH
3P CONNECTOR
[2]
STARTER
CABLE
[3] HARNESS BAND CLIP
Clamp the starter
cable.
[4] CLIP A
Clamp the alternator
fuse cable.
[5]
ALTERNATOR
FUSE CABLE
[10]
POWER TILT
SWITCH
[9]
POSITIVE (+) STARTER
CABLE
[5] ALTERNATOR FUSE CABLE
[2]
STARTER
CABLE
[7] NEGATIVE (–) STARTER CABLE
[8] WIRE HARNESS CLIP
Clamp the alternator fuse
cable and the starter cable
and check that the cables
do not interfere with the
shift arm.
2-52
Connect the negative (–) starter
cable by pushing the starter
cable negative (–) terminal
against the projection on the
crankcase.
[7]-2
PROJECTION
[7]-1
STARTER
CABLE
NEGATIVE (-)
TERMINAL
[6] CABLE BRACKET A
Clamp the alternator fuse cable
and the starter cable as shown.
[6]-1
ALTERNATOR
FUSE CABLE
[6]-2
ENGINE
SIDE
[6]-3 STARTER CABLE
<REMOTE CONTROL CABLE GROMMET viewed from outer side of the outboard motor>
[1]
REMOTE CONTROL CABLE
(Shift side)
[2]
REMOTE CONTROL CABLE
(Throttle side)
[3]
REMOTE CONTROL
CABLE
[8]
INDICATOR LIGHT
WIRE
[4]
SPEED SENSOR
TUBE A
[5] BATTERY ISOLATOR
(Optional part)
[7] STARTER CABLE
[6] FUEL TUBE A
[9]
FRONT BRACKET
[10] WHIT TAPE
[11] STARTER CABLE
Install aligning the end of
the white tape on the
starter cable with the end
of the under cover front
bracket.
[12]
REMOTE CONTROL
CABLE GROMMET
[9] FRONT BRACKET
WHITE TAPE
[12] REMOTE CONTROL
CABLE GROMMET
[3]
REMOTE CONTROL
CABLE
[8]
INDICATOR LIGHT
WIRE
2-53
[13] TIE WIRES
Install the remote control cable and
the indicator light wire with the tie
wire on the respective cables set
against the remote control cable
grommet.
[4]
REMOTE CONTROL CABLE
14P CONNECTOR
[3] HARNESS BAND
CLIP
[5] MAIN WIRE
HARNESS
[3] HARNESS
BAND CLIP
[3]
HARNESS
BAND
CLIP
[6]
SPEED
SENSOR
TUBE A
[2] REMOTE CONTROL
CABLE (Throttle side)
[8] TP (THROTTLE
POSITION)
SENSOR
3P CONNECTOR
[7]
POWER TILT RELAY
3P CONNECTOR
[9] TP (THROTTLE
POSITION)
SENSOR
[10]
WATER LEVEL
SENSOR
2P CONNECTOR
[1]
REMOTE CONTROL
CABLE (Shift side)
[11]
COVER
LOCK
CABLE A
[12] TRIM ANGLE
SENSOR
3P CONNECTOR
[21]
STARTER
CABLE
[13] POWER TILT MOTOR
2P CONNECTOR
[20] CABLE BRACKET A
INSTALLATION: P. 2-52
[19]
ALTERNATOR FUSE
CABLE
[18]
INDICATOR LIGHT
6P CONNECTOR
[17] INDICATOR LIGHT
WIRE
2-54
[2]
REMOTE CONTROL
CABLE (Throttle side)
[1]
REMOTE
CONTROL
CABLE (Shift
side)
[6]
SPEED SENSOR
TUBE A
[15]
FUEL TUBE A
[16] STARTER
CABLES
[14] REMOTE CONTROL
CABLE
[1] FRAME GROUND TERMINALS
• Connect the black, blue, green/red
and the green/white wires to the
upper frame ground terminal, and the
green, blue, black/white and the
green/black wires to the lower frame
ground terminal.
• Install by pushing the frame ground
terminals against the corresponding
projections on the crankcase.
[1]-1 PROJECTION
[1]-2
FRAME
GROUND
TERMINAL
[1]-1
PROJECTION
[2]
POWER TILT RELAY
GROUND TERMINAL
Install by pushing the ground
terminal against the projection on
the crankcase.
[6] COVER LOCK
CABLE A
[2]-1
GROUND
TERMINAL
[5]
POWER TILT RELAY
3P CONNECTOR
[2]-2 PROJECTION
[1]-2 FRAME GROUND
TERMINAL
[3]
HARNESS
BAND CLIP
[4] NEUTRAL SWITCH
2P CONNECTOR
[7] TRIM ANGLE
SENSOR 3P
CONNECTOR
[8]
POWER TILT
MOTOR
2P
CONNECTOR
[3]
HARNESS
BAND CLIP
[18]
CLIP A
[17]
STARTER
CABLE
[9] TRIM ANGLE
SENSOR WIRE
[10] POWER TILT
MOTOR WIRE
[16] CABLE BRACKET A
INSTALLATION: P. 2-52
[14] ALTERNATOR
FUSE CABLE
2-55
[15]
NEUTRAL
SWITCH
[11] WIRE BAND
[3]
HARNESS
BAND CLIP
[13]
POWER TILT RELAY
1P CONNECTOR
[14] ALTERNATOR
FUSE CABLE
[12] UNDERCASE
GROMMET C
[1] TP (THROTTLE
POSITION)
SENSOR
3P CONNECTOR
[2] TP (THROTTLE
POSITION)
SENSOR
[3]
HARNESS BAND
CLIP
[4] POWER TILT RELAY
3P CONNECTOR
[5]
WATER LEVEL
SENSOR
3P CONNECTOR
[19] MAIN WIRE
HARNESS
[6] HARNESS CLIP
Clamp the main wire
harness and the
water level sensor
wire at its taped part.
[3] HARNESS
BAND CLIP
[18] HARNESS CLIP
[7]
WIRE HARNESS CLIP
Clamp the power tilt
relay 3P connector,
2P connector and
the 1P connector
wires.
[17] CLIP A
[16] NEUTRAL
SWITCH
2P CONNECTOR
[8]
TRIM ANGLE SENSOR
2P CONNECTOR
[15] ALTERNATOR
FUSE CABLE
[9]
WATER LEVEL SENSOR
WIRE
[14] POWER TILT
MOTOR WIRE
[10] POWER TILT MOTOR
2P CONNECTOR
[12] TRIM ANGLE
SENSOR WIRE
[11] SPEED SENSOR TUBE A
[13] UNDERCASE GROMMET C
• Clamp the power tilt motor wire, trim angle
sensor wire and the speed sensor tube A.
• Install the undercase grommet C aligning the
taped ends of the power tilt motor wire and
the trim angle sensor wire with the end of the
undercase grommet C
• Check that the wires and tube are not
interfering with the front lock of the under
cover front bracket.
2-56
[13]-1
FRONT
LOCK
[13]-7
UNDERCASE
GROMMET C
[13]-2
Wires and
tube are not
interfering
with the front
lock.
[13]-6
SPEED SENSOR
TUBE A
[13]-3 TAPE
[13]-5 TRIM ANGLE
SENSOR WIRE
[13]-4
POWER TILT
MOTOR WIRE
[1] POWER TILT RELAY GROUND TERMINAL
Install pushing the ground
terminal against the projection
on the crankcase.
[2]
HARNESS BAND
CLIP
[3]
POWER TILT
RELAY
[4] WIRE HARNESS CLIP
Clamp the power tilt relay 3P
connector, 2P connector and
the 1P connector wires as
shown.
[1]-1
GROUND
TERMINAL
[1]-2 PROJECTION
[2]
HARNESS BAND
CLIP
[10] MAIN WIRE
HARNESS
[2]
HARNESS BAND
CLIP
[5]
POWER TILT
MOTOR
2P CONNECTOR
[9] NEUTRAL
SWITCH
2P CONNECTOR
[8] CLIP A
[2] HARNESS
BAND CLIP
[7]
ALTERNATOR FUSE
CABLE
[6] POWER TILT RELAY
1P CONNECTOR
[2]
HARNESS BAND
CLIP
[17]
IAT (INTAKE AIR
TEMPERATURE)
SENSOR
[10] MAIN WIRE
HARNESS
[16] IAT (INTAKE AIR
TEMPERATURE)
SENSOR
2P CONNECTOR
[11]
IAC (IDLE AIR
CONTROL) VALVE
2P CONNECTOR
[15]
MAP (MANIFOLD
ABSOLUTE
PRESSURE)
SENSOR
3P CONNECTOR
[12]
IAC (IDLE AIR
CONTROL)
VALVE
[2]
HARNESS BAND
CLIP
[14] MAP (MANIFOLD
ABSOLUTE PRESSURE)
SENSOR
2-57
[13] HARNESS CLIP
Clamp the MAP sensor
wire in the recess of the
intake manifold.
[3] HARNESS BAND CLIP
[6] WIRE BAND
Clamp the main wire harness, BARO
sensor wire and the IAB control valve
wire as shown.
[6]-2
[6]-1 ENGINE
MAIN WIRE
SIDE
HARNESS
Clamp the main wire harness, BARO
sensor wire and the IAB control valve wire
as shown.
[3]-2
MAIN WIRE
[3]-1
HARNESS
ENGINE
SIDE
[3]-4
BARO
(BAROMETRIC
PRESSURE)
SENSOR WIRE
[2]
MAIN WIRE
HARNESS
[3]-3
IAB (IDLE AIR
BYPASS)
CONTROL
VALVE WIRE
[5]
BARO
(BAROMETRIC
PRESSURE)
SENSOR 3P
CONNECTOR
[4]
BARO (BAROMETRIC
PRESSURE) SENSOR
[6]-4
BARO (BAROMETRIC
PRESSURE) SENSOR
WIRE
[6]-3
IAB (IDLE AIR
BYPASS)
CONTROL
VALVE WIRE
[7] ECT (ENGINE
COOLANT
TEMPERATURE)
SENSOR 2
2P CONNECTOR
[8]
ECT (ENGINE
COOLANT
TEMPERATURE)
SENSOR 2
[9]
MAIN WIRE
HARNESS
[10]
HARNESS
BAND CLIP
[1]
HARNESS
BAND
CLIPS
[11]
No.1 FUEL
INJECTOR
2P CONNECTOR
[10]
HARNESS BAND
CLIP
[13]
IAB (IDLE AIR
BYPASS)
CONTROL
VALVE WIRE
[12] WIRE HARNESS CLIP
Clamp the main wire harness and the
overheat sensor 1 wire.
[12]-1
ENGINE
SIDE
[12]-2
MAIN WIRE HARNESS
[12]-1 OVERHEAT SENSOR 1
WIRE
2-58
[2] HARNESS BAND CLIP
Clamp the main wire harness, joint
connector 1 wire and the joint connector 2
wire as shown.
[2]-2 ENGINE SIDE
[2]-1
JOINT
CONNECTOR 2
WIRE
[2]-3
JOINT
CONNECTOR 1
WIRE
[2]-4
MAIN WIRE
HARNESS
[1]
MAIN WIRE HARNESS
[3]
PRESSURE
REGULATOR
RETURN HOSE
[1]
MAIN WIRE
HARNESS
[9]
JOINT CONNECTOR 1 WIRE
[8] JOINT CONNECTOR 2 WIRE
[7] JOINT CONNECTOR ASSEMBLY
[7]-2 ENGINE SIDE
[7]-1
JOINT
CONNECTOR 1
[7]-3 JOINT CONNECTOR 2
2-59
[6]
IAB (IDLE AIR
BYPASS)
CONTROL VALVE
2P CONNECTOR
[5] HOSE CLIP
Clamp the main wire harness
and the pressure regulator
return hose.
[5]-1 ENGINE
SIDE
[5]-2
MAIN WIRE
HARNESS
[5]-3 PRESSURE REGULATOR
RETURN HOSE
[4]
TUBE CLAMP D10.7
Check that the
main wire harness
does not interfere
with the tube
clamp D10.7.
[2] MAIN WIRE
HARNESS
[1] HARNESS BAND CLIP
[3]
No.1 IGNITION COIL
[4] ECT (ENGINE
COOLANT
TEMPERATURE
SENSOR 3
2P CONNECTOR
[17]
No.1 FUEL INJECTOR
2P CONNECTOR
[5]
No.1 IGNITION COIL
3P CONNECTOR
[2]
MAIN WIRE
HARNESS
[6]
No.2 IGNITION COIL
[7]
No.2 IGNITION COIL
3P CONNECTOR
[16]
No.2 FUEL INJECTOR
2P CONNECTOR
[8]
No.3 IGNITION COIL
[15]
No.3 FUEL INJECTOR
2P CONNECTOR
[9]
No.3 IGNITION COIL
3P CONNECTOR
[10]
No.4 IGNITION COIL
[14] COVER LOCK
CABLE A
[13] COVER LOCK
CABLE B
[10]
No.4 IGNITION COIL
[11] No.4 IGNITION COIL
3P CONNECTOR
[1] HARNESS
BAND CLIP
2-60
[11]
No.4 IGNITION COIL
3P CONNECTOR
[12] CMP SENSOR
3P CONNECTOR
[1] HARNESS BAND
CLIP
[18]
CMP (CAMSHAFT
POSITION)
SENSOR
[19]
CMP (CAMSHAFT
POSITION)
SENSOR
3P CONNECTOR
[2] HOSE CLAMP
• Set the fuel hose (high pressure side) in the clamp of the larger
diameter side and the main wire harness in the smaller diameter
side.
• Clamp the fuel hose (high pressure side) at the left-hand side to
the marked point.
[2]-4
[2]-1 ENGINE
HOSE CLAMP
[2]-2 MAIN WIRE
SIDE
HARNESS
[2]-3 FUEL HOSE (HIGH
PRESSURE SIDE)
[2]-3 FUEL HOSE (HIGH
PRESSURE SIDE)
[3]
MAIN WIRE
HARNESS
[1]
HARNESS
BAND CLIP
[2]-5
MARKING
[4]
KNOCK SENSOR
1P CONNECTOR
[5]
KNOCK
SENSOR
[6]
No.2 FUEL INJECTOR
2P CONNECTOR
[7]
No.3 FUEL INJECTOR
2P CONNECTOR
[13]
CABLE
CLIP
[12]
FUEL PUMP
2P CONNECTOR
[11] FUEL HOSE (HIGH
PRESSURE SIDE)
2-61
[10]
COVER LOCK
CABLE A
[9]
No.4 FUEL INJECTOR
2P CONNECTOR
[8]
COVER LOCK
CABLE B
[5] HARNESS BAND CLIP
Clamp the main wire
harness and the knock
sensor wire.
[5]-1 KNOCK SENSOR
WIRE
[3] HARNESS CLIP
Clamp the main wire harness
and the water level sensor
wire at the taped part.
[2] WATER LEVEL
SENSOR WIRE
[5]-2 MAIN WIRE
HARNESS
[4] MAIN WIRE
HARNESS
[6]
KNOCK SENSOR
[7]
KNOCK SENSOR
1P CONNECTOR
[1]
WATER LEVEL
SENSOR
2P CONNECTOR
[8]
COVER LOCK
CABLE A
[9]
CABLE CLIP
[13]
UNDERCASE
GROMMET C
INSTALLATION: P. 2-56
[12] 14 mm CLIPS
INSTALLATION: P. 2-63
2-62
[10] SPIRAL TUBE
Wind the spiral tube around the
power tilt motor wire, trim angle
sensor wire and the speed sensor
tube A.
[11] WIRE HARNESS CLIP
Clamp the power tilt motor wire, trim angle
sensor wire and the speed sensor tube A.
Avoid clamping on the spiral tube.
[1] 14 mm CLIPS
• Clamp the power tilt motor wire, trim
[1]-1 SPEED SENSOR
angle sensor wire and the speed sensor
[1]-1 SPEED SENSOR
TUBE A
tube A.
TUBE A
• Install the 14 mm clip aligning the tape
[1]-4 PROJECTIONS
end of the power tilt motor wire with the
14 mm clip end.
• Tighten the two 5 x 10 mm rivet screws
while pushing the respective 14 mm clips
against the corresponding projection of
the mounting case.
[1]-3
[1]-2 TRIM ANGLE
POWER
SENSOR WIRE
TILT
[1]-2
MOTOR
[1]-5
TRIM ANGLE
WIRE
TAPE
SENSOR WIRE
[1]-3
POWER
TILT
MOTOR
WIRE
[1]-7
SPIRAL
TUBE
[1]-5 TAPE
[1]-6
14 mm CLIP (2)
[2] GROUND CABLE
[10] SPIRAL TUBE
Set the spiral tube
on the power tilt
motor wire, trim
angle sensor wire
and the speed
sensor wire as
shown.
[9] TRIM ANGLE SENSOR
[8] TRIM ANGLE
SENSOR WIRE
[7] WIRE HARNESS CLIP
Clamp the power tilt motor wire,
trim angle sensor wire and the
speed sensor tube A. Avoid
clamping on the spiral tube.
[3] POWER TILT
MOTOR WIRE
[4] CORRUGATED TUBE
Wind the corrugated tube
around the power tilt motor
wire. Be sure that the tube is
set upright.
[6]
SPEED
SENSOR
TUBE B
[5] MOTOR CORD BUSHING
Pass the power tilt motor wire,
trim angle sensor wire and the
speed sensor tube B through the
motor cord bushing. Align the
tape end of the power tilt motor
wire with the end of the motor
cord bushing.
[4]-4 CORRUGATED TUBE
[5]-1 TRIM ANGLE
SENSOR WIRE
[5]-2 SPEED SENSOR
TUBE A
[5]-3 POWER TILT
MOTOR WIRE
[5]-4 TAPE
2-63
[4]-2 POWER TILT
MOTOR WIRE
• Side-mount remote control
[2]
IGNITION
SWITCH
[1]
EMERGENCY
STOP SWITCH
[3]
WARNING
BUZZER
[4]
SOLENOID
SWITCH
[6]
INDICATOR
LIGHT
[7] POWER TRIM/TILT
SWITCH
[8]
POWER TRIM/TILT
SWITCH WIRE
[5] REMOTE CONTROL CABLE B
[4]
SOLENOID
SWITCH
[2]
IGNITION
SWITCH
[1]
EMERGENCY
STOP SWITCH
[5] REMOTE CONTROL
CABLE B
[3]
WARNING
BUZZER
*1:
*2:
[5]
REMOTE
CONTROL
CABLE B
*1: Power trim/tilt switch wire routing when the remote
control lever is installed as shown in the drawing A.
*2: Power trim/tilt switch wire routing when the remote
control lever is installed as shown in the drawing B.
[8]
POWER
TRIM/TILT
SWITCH
WIRE
[7]
POWER
TRIM/TILT
SWITCH
[1] View from ignition switch side:
[2] DRAWING A
[3] DRAWING B
[5] REMOTE
CONTROL
LEVER
[4] IGNITION
SWITCH
2-64
• Control panel
[3]
INDICATOR LIGHT
[OIL PRESSURE LIGHT/
OVERHEAT LIGHT]
[4] WARNING BUZZER
[2]
IGNITION SWITCH
[5]
WIRE HARNESS BAND
[1]
EMERGENCY STOP
SWITCH
[6]
SWITCH PANEL HARNESS
CONNECTION: P. 16-8
2-65
11. TUBE ROUTING
[1] WATER RELIEF TUBE A
• Install at approximately
right angles to the
horizontal line.
• After installation, check
the tube for twist, bend,
etc.
[1]-1 Approx. 90°
[1]-2
WATER
RELIEF
TUBE A
[2]
7 x 120 mm TUBE
[3]
TUBE CLAMP D10.5
[13] 7 x 90 mm TUBE
[12] WATER TUBE CLAMP
INSTALLATION: P. 2-45
[11] FUEL TUBE JOINT
[10] 7 x 75 mm TUBE
[8] TUBE CLAMP D25.0
Install at 8 mm (0.3 in)
from the tube end.
[9] 4-WAY JOINT
[8] TUBE CLAMP D25.0
Install at 8 mm (0.3 in)
from the tube end.
[7] WATER TUBE CLAMP B
[6] WATER RELIEF TUBE B
• Install at 33° from the horizontal line.
• After installation, check the tube for
twist, bend, etc.
[4]
WATER
TUBE E
[3] TUBE CLAMP D10.5
[6]-1
Approx.
33°
2-66
[6]-2
WATER
RELIEF
TUBE B
[5] TUBE CLAMP D25.0
[2] TUBE CLAMP D25.0
Install the tube clamp with the lugs facing in the direction
shown.
[2]-1
WATER
RELIEF
TUBE A
[2]-2 <Cylinder head cover viewed from the front>
[1]
WATER RELIEF
TUBE A
[6]
TUBE CLAMP D10.5
[8]
7 x 90 mm TUBE
[6]
TUBE CLAMP D10.5
[7]
FUEL TUBE JOINT
[6] TUBE CLAMP D10.5
[5] 7 x 75 mm TUBE
[4] 7 x 120 mm TUBE
[3] TUBE CLAMP D10.5
Install with the lugs facing
down.
2-67
[3] TUBE CLAMP D10.5
Install with the lugs
facing down.
[2] TUBE CLAMP D10.5
[1] TUBE CLAMPS D10.5
[3]
7 x 160 mm TUBE
[2] TUBE CLAMP D10.5
[4]
WATER RELIEF
TUBE C
[6] 7 x 40 mm TUBE
[1] TUBE CLAMPS D10.5
[5] T-JOINT
[2]
TUBE CLAMP D10.5
[7]
7 x 200 mm TUBE
[8]
12 mm TUBE CLIP B1
[9] 8 x 300 mm TUBE
[2] TUBE CLAMP D10.5
[8]
12 mm TUBE
CLIP B1
[2] TUBE CLAMP D10.5
[9] 8 x 300 mm TUBE
[7] 7 x 200 mm TUBE
2-68
[1] 4 x 7 x 160 mm VINYL TUBE
[2]
FUEL TUBE A
[3]
SPEED SENSOR
TUBE A
[4]
UNDERCASE
GROMMET C
[3] SPEED SENSOR
TUBE A
[2] FUEL TUBE A
[5]
4 x 7 x 160 mm VINYL
TUBE
Insert into the hole in the
under cover front bracket
securely.
[6] RECESS
[7] HOLE
2-69
[8] 3.5 x 430 mm FUEL TUBE
Set in the recess in the
under cover front bracket.
[1] WATER SEPARATOR
with WATER LEVEL
SENSOR
[2] TUBE CLIP B12
[3]
FUEL TUBE C
[2]
TUBE CLIP B12
[6]
FUEL TUBE HOLDER
[5] 14 mm FUEL TUBE
CLIP
[6]
FUEL TUBE HOLDER
2-70
[4] FUEL TUBE A
[4] FUEL TUBE A
[5]
14 mm FUEL TUBE
CLIP
[1] PRESSURE REGULATOR
CONTROL TUBE
Connect the pressure regulator
control tube aligning the marked part
on the tube with the end of the 3.5
mm tube clamp.
[1]-2
[1]-1
3.5 mm
PRESSURE REGULATOR
TUBE
CONTROL TUBE
CLIP
[5] FUEL TUBE CLAMP
Set the breather tube in the clamp of
the larger diameter side and the
pressure regulator control tube in the
smaller diameter side.
[2]
BREATHER
TUBE
[3]
3.5 mm TUBE
CLIPS
[6] TUBE CLAMP D25.0
INSTALLATION: P. 2-67
[4]
18.5 mm
CLAMP
[7] WATER RELIEF
TUBE A
INSTALLATION:
P. 2-66
[1]-3 MARKING
[4]
18.5 mm
CLAMP
[8]
AIR VENT
TUBE D
[20]
DIAPHRAGM
TUBE
[19] IAB CONTROL VALVE
TUBE
[11]
CHECK
VALVE
[18] AIR VENT TUBE A
[17] HOSE CLAMP
Set the air vent tube B in the
clamp of the larger diameter
side and the pressure regulator
return hose in the smaller
diameter side.
[15]
AIR VENT
TUBE B
[14]
T-JOINT
[10]
PRESSURE
REGULATOR
RETURN HOSE
[13] HOSE CLAMP
[16] PIPE CLAMP
Set the air vent tube A in the
clamp of the larger diameter
side and the air vent tube D in
the smaller diameter side.
2-71
[12]
AIR VENT
TUBE C
[9] TUBE CLAMP
D10.7
INSTALLATION:
P. 2-59
Set the air vent tube A in the
clamp of the larger diameter
side
and
the
pressure
regulator return hose in the
smaller diameter side.
[3]
WATER RELIEF TUBE A
INSTALLATION: P. 2-66
[1] BREATHER TUBE
[2]
TUBE CLAMP
D17.0
[4] 14 mm FUEL TUBE CLIP
Install aligning the end of the 14 mm fuel
tube clip with the end of the white mark
on the air vent tube.
[4]-1
AIR VENT
TUBE A
[4]-2
WHITE MARK
[4]-3
14 mm
FUEL TUBE
CLIP
[5] AIR VENT TUBE A
[6] 14 mm FUEL TUBE CLIP
[7] FUEL TUBE B
[8] 14 mm FUEL TUBE CLIP
• Clamp the fuel tube B.
• Check the fuel tube B protection tube
for protrusion from the end of the 14
mm fuel tube clip. The protection tube
should protrude 2 mm (0.1 in) max.
from the clip.
[8]-1
FUEL TUBE B
[6]-1
2 mm (0.1 in)
MAX.
[7] FUEL TUBE B
[13] FUEL TUBE JOINT
[12]
FUEL TUBE D
[9]
14.5 mm TUBE
CLIP B1
[11] 14 mm FUEL TUBE CLIP
Clamp the fuel tube B.
2-72
[9]
14.5 mm
TUBE
CLIP B1
[10] FUEL PUMP
[8]-3
14 mm
FUEL TUBE
CLIP
[2] HOSE CLAMP
Set the fuel tube E in
the clamp of the larger
diameter side and the
7 x 400 mm tube in the
smaller diameter side.
[3]
FUEL HOSE
(HIGH
PRESSURE
SIDE)
[4]
TUBE
CLIP
B12
[5] SENSOR HOSE CLIP
Clamp the fuel hose
(high pressure side)
and the fuel tube B.
[6]
AIR VENT
TUBE A
[7]
14 mm FUEL TUBE
CLIP
[1]
TUBE
CLIP
[8]
14 mm FUEL TUBE
CLIP
INSTALLATION:
P. 2-72
[9]
FUEL TUBE B
[10]
14.5 mm TUBE
CLIP B1
[11] FUEL PUMP
[10]
14.5 mm TUBE
CLIP B1
[19]
7 x 400 mm
TUBE
[4] TUBE CLIP
B12
[13]
FUEL TUBE D
[9]
FUEL TUBE B
[18] FUEL TUBE E
[17]
WATER TUBE F
[16]
AIR VENT
TUBE A
[15] SENSOR HOSE CLIP
• Clamp the fuel tube B and fuel
tube E.
• Install the sensor hose clip
aligning with the end of the
protection tube on the fuel tube E.
[1]
TUBE CLIP
[15]-1
FUEL TUBE B
[15]-4 PROTECTION
TUBE
2-73
[4]
TUBE CLIP
B12
[12]
14 mm FUEL TUBE
CLIP
Clamp the fuel
tube B.
[4] TUBE CLIP B12
[14] FUEL TUBE JOINT
[15]-2
SENSOR HOSE
CLIP
[15]-3
FUEL TUBE E
[3] VAPOR
CHAMBER
[4] HOSE CLAMP
Set the air vent tube B in the
clamp of the larger diameter
side and the pressure regulator
return hose in the smaller
diameter side.
[5]
AIR VENT
TUBE B
[2]
PRESSURE REGULATOR
RETURN HOSE
[6] TUBE CLIP
Clamp the air vent tube
E and the fuel hose
(high pressure side) as
shown.
[7]
FUEL HOSE (HIGH
PRESSURE SIDE)
[1] HOSE CLAMP
INSTALLATION:
P. 2-61
[13]
7 x 400 mm TUBE
[11]
TUBE CLAMP
D10.7
[12] TUBE CLIP
Install with the lugs facing down.
[12]-1
7 x 400 mm
[12]-2 TUBE CLIP
TUBE
[10]
AIR VENT TUBE E
[8] TUBE CLAMP D32.5
[9] OIL TUBE
• Install the oil tube aligning the
projection on the oil tube
installation part with the
projection of the oil tube.
• Install the tube clamp D32.5
with the lugs in the position
shown.
[9]-1
PROJECTION
[9]-4 TUBE CLAMP D32.5
[9]-1
PROJECTION
[12]-3 LUGS
[9]-3 OIL TUBE
[9]-2 LUGS
2-74
[3]
WATER SEPARATOR
with WATER LEVEL
SENSOR
[1]
4 x 7 x 160 mm
VINYL TUBE
INSTALLATION:
P. 2-69
[2]
SPEED SENSOR
TUBE A
[5]
FUEL STRAINER
[4]
FUEL TUBE C
[6]
TUBE CLIP
B12
[7]
MAIN WIRE
HARNESS
[8] HOSE CLAMP
INSTALLATION: P. 2-61
[9]
FUEL HOSE
(HIGH
PRESSURE
SIDE)
[10]
FUEL TUBE E
[11]
WATER TUBE F
[12]
3.5 x 430 mm FUEL TUBE
INSTALLATION: P. 2-69
[18]
UNDERCASE
GROMMET C
INSTALLATION:
P. 2-56
[15] 14 mm CLIP
INSTALLATION:
P. 2-63
[13] WATER CHECK
GROMMET
[16]
FUEL TUBE A
[17] 14 mm FUEL
TUBE CLIP
2-75
[14] 7 x 400 mm TUBE
[15] 14 mm CLIP
INSTALLATION: P. 2-63
[3] SPEED SENSOR TUBE PLATE
Install the speed sensor tube plate
so that the distance between the
end of the plate and the end of the
speed sensor tube B is 15 – 20 mm
(0.6 – 0.8 in).
[2]
SPEED SENSOR
TUBE PLATE
[3]-1
SPEED SENSOR
TUBE B
[3]-1
SPEED
SENSOR
TUBE
PLATE
15 – 20 mm
(0.6 – 0.8 in)
[1]
SPEED SENSOR
TUBE B
[4]
TUBE CLIP B8
[10]
SPEED SENSOR
TUBE A
[6]
WIRE
BAND
[9] JOINT A
[5] SPEED SENSOR
TUBE C
[7] MOTOR CORD BUSHING
INSTALLATION: P. 2-63
[8] SPEED SENSOR TUBE B
• Pass the trim angle sensor wire,
power tilt motor wire and the speed
[8]-1
sensor tube B through the hole in the
MOTOR
motor cord bushing as shown.
CORD
• Install the speed sensor tube B so that
BUSHING
the distance between the end of the
motor cord bushing and the end of
the speed sensor tube B is 10 – 15 mm
(0.4 – 0.6 in).
[8]-6 REAR
[8]-5 SPEED
SENSOR
TUBE B
2-76
[8]-2
UP
[8]-3
TRIM
ANGLE
SENSOR
WIRE
[8]-4
POWER TILT
MOTOR WIRE
[8]-5
SPEED
SENSOR
TUBE B
[8]-1
MOTOR
CORD
BUSHING
[8]-7
WIRE
BANDS
10 – 15 mm
(0.4 – 0.6 in)
[8]-8
SPEED
SENSOR
TUBE A
[8]-9
JOINT A
12. LUBRICATION
Apply oil or marine grease to the following parts.
[1]
[2]
(Marine grease)
①
②
①
③
④
②
⑤
⑥
① DETENT ARM ROLLER
② NEUTRAL SWITCH
[6]
②
① THROTTLE PLATE
② THROTTLE ARM
③ THROTTLE ARM LINK PIN
④ SHIFT SLIDE PIVOT/SHIFT PIVOT PLATE
⑤ LINK PIN
⑥ SHIFT LINK PIN
[3]
②
①
①
① COVER LOCK CABLE B CABLE
END
② R. SIDE LOCK
[5]
① SHIFT ROD A
② VERTICAL SHAFT
[4]
MOUNTING PLATE
PROPELLER SHAFT
2-77
[2]
[1]
[3]
②
(Marine grease)
②
THROTTLE BODY
①
①
① COVER LOCK CABLE A/B
CABLE END
② L. SIDE LOCK
③
① FRONT ROCK CABLE
② FRONT ROCK
③ COVER OPEN SHAFT
[5]
②
[4]
①
① TILTING SHAFT
② TILTING SHAFT (THREADS)
2-78
②
①
① DETENT SPRING ROLLER
② TILTING BRACKET CAM
[1]
COVER LOCK BOLTS
[4]
[5]
①
[3]
②
TILT STOPPER BEARING
SWIVEL CASE
[2]
LOWER CYLINDER BUSHINGS/
COLLAR/WAVE WASHERS
2-79
②
① UPPER CYLINDER BUSHING/
PIN
② SLIDING SURFACE OF THRUST
RECEIVER
3. MAINTENANCE
9. WATER SEPARATOR with WATER
LEVEL SENSOR
10. IDLING
11. SHIFT CONTROL CABLE
12. THROTTLE CONTROL CABLE/
THROTTLE LINK
13. REMOTE CONTROL LEVER FRICTION
14. ALTERNATOR BELT
1. MAINTENANCE SCHEDULE
2. ENGINE OIL
3. OIL FILTER
4. GEAR CASE OIL
5. SPARK PLUGS
6. VALVE CLEARANCE
7. FUEL STRAINER (LOW PRESSURE
SIDE)
8. FUEL STRAINER (HIGH PRESSURE
SIDE)
1. MAINTENANCE SCHEDULE
REGULAR SERVICE PERIOD (1)
Item
Perform at every indicated month or
operating hour interval, whichever
comes first.
Engine oil
Gear case oil
Engine oil filter
Alternator belt
Throttle linkage
Idling speed
Valve clearance
Spark plug
Propeller and
cotter pin
Anode metal
Lubrication
Water separator
Fuel strainer
Fuel strainer
(High pressure type)
Thermostat
Fuel line
Battery and cable
connection
Bolt and nuts
Crankcase breather
tube
Cooling water
passages
Each
use
Check level
Change
Change
Replace
Check-adjust
Check-adjust
Check-adjust
Check-adjust
Check
Clean
Replace
○
Check
○
Check
Grease
Check
Check
Replace
○
After
use
Every
Every
Every
First
2 year
year
month 6 month
or
or
or
or
20 Hrs. 100 Hrs. 200 Hrs. 400 Hrs.
○
○
3-2
○
○
○
○
○
○
○
○
○
3-8
○
○ (2)
14-88
2-77
3-19
○ (2)
○
○
○
○
○
Check
Check
Replace
○
Check level-tightness
○
3-7
14-2
Replace
Every 2year (Replace if necessary)
3-15
3-18
8-3
5-104
–
○
Check-tightness
○
–
○
Check
Clean
3-4
3-3
3-28
3-26
3-22
3-9
○
○
○
○
Refer
to
page
○ (3)
–
–
(1) For professional commercial use, log hours of operation to determine proper maintenance intervals.
(2) Lubricate more frequently when used in salt water.
(3) When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.
3-1
2. ENGINE OIL
[1] DIPSTICK
Oil Level Inspection:
[2]
UPPER
LIMIT
Check the engine oil level with the engine stopped and the
outboard motor in the vertical position.
1) Remove the engine cover.
[3]
LOWER
LIMIT
2) Remove the dipstick and wipe it clean.
3) Insert the dipstick all the way in the oil level pipe, then pull
it out and read the oil level.
4) If the oil level is low, remove the oil filler cap and add the
recommended oil to reach the upper limit mark on the
dipstick.
5) Reinstall the oil filler cap and dipstick.
Oil Change:
Drain the used oil while the engine is warm. Warm oil drains
quickly and completely.
1) Remove the oil filler cap and the drain plug cover.
[1]
OIL FILLER
CAP
2) Attach the drain plug cover to the oil drain guide of the oil
case.
3) Place a suitable oil container next to the outboard motor,
and remove the oil drain plug bolt.
Please dispose of used motor oil in a manner that is
compatible with the environment. We suggest you take
used oil in a sealed container to your local recycling canter
or service station for reclamation. Do not throw it in the
trash, pour it on the ground, or down a drain.
CAUTION
[1]
DRAIN
PLUG
COVER
Used engine oil contains substances that have been
identified as carcinogenic.
If repeatedly left in contact with the skin for prolonged
periods, it may cause skin cancer.
Wash your hands thoroughly with soap and water as
soon as possible after contact with used engine oil.
4) Replace the 12 mm drain plug washer with a new one, and
reinstall the oil drain plug bolt. Tighten the oil drain plug
bolt to the specified torque.
TORQUE: 23 N.m (2.3 kgf.m, 17 lbf.ft)
5) Reinstall the drain plug cover.
3-2
[1] 12 mm
DRAIN PLUG
WASHER
[2] OIL DRAIN
PLUG BOLT
[3]
DRAIN
PLUG
GUIDE
6) Refill with the recommended engine oil to the upper limit
mark on the dipstick.
Engine oil
capacity
Without oil filter replacement:
6.5R (6.9 US qt, 5.7 Imp qt)
With oil filter replacement:
6.7R (7.1 US qt, 5.9 Imp qt)
Recommended
engine oil
SAE 10W-30
API Service classification SG/SH/SJ
[1] SAE Viscosity Grades
[2] AMBIENT TEMPERATURE
NOTICE
Using nondetergent oil can shorten the engine’s service life
and using 2-stroke oil can damage the engine.
[1] OIL FILTER
7) Install the engine cover (P. 4-2).
3. OIL FILTER
Replacement:
1) Drain the engine oil, then reinstall the oil drain plug bolt
and drain plug cover, as described in the oil change
procedure.
[2]
OIL FILTER
WRENCH
07HAA-PJ70101
2) Place a shop towel under the oil filter to absorb any spilled
oil, then remove the oil filter with an special tool.
TOOL:
Oil filter wrench
07HAA-PJ70101
3) Drain the used oil filter into a suitable container for oil
disposal (P. 3-2).
4) Clean the filter mounting base, and coat the seal of the new
oil filter with clean engine oil.
• Use only a genuine Honda oil filter or a filter of equivalent
quality specified for you model. Using the wrong Honda
filter, or a not-Honda filter which is not of equivalent
quality, may cause engine damage.
5) Screw on the new oil filter by hand, until the seal contacts
the filter mounting base, then use an special tool to tighten
the filter an additional 7/8 turn.
TOOL:
Oil filter wrench
07HAA-PJ70101
TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)
6) Refill the engine with the specified amount of the
recommended oil, as described in the oil change
procedure.
Reinstall the oil filter cap and dipstick.
7) Start the engine, and check the leaks.
8) Stop the engine, and check the oil level as described on
page 3-2. If necessary, add oil to the upper limit mark on the
dipstick.
9) Reinstall the engine cover.
3-3
[1] RUBBER SEAL
4. GEAR CASE OIL
Inspection:
1) Place the outboard motor on a level surface and position it
vertically.
2) Remove the oil level bolt and check whether the gear case
oil flows out of the gear case. If it flows out, be sure to catch
the oil in a suitable container.
Replace the O-ring on assembly.
3) If the oil does not flow out, add oil.
[1]
5.5 x 1.5 mm
O-RING
4) Coat a new O-ring with clean engine oil and install the Oring on the oil level bolt.
Set the oil level bolt on the gear case and tighten the bolt
to the specified torque.
[2] OIL LEVEL BOLT
TORQUE: 3.4 N.m (0.35 kgf.m, 2.5 lbf.ft)
Addition of gear oil:
[1] OIL LEVEL BOLT
1) Remove the oil drain bolt, and install the commercially
available gear oil pump in the oil drain bolt hole.
Replace the O-ring on assembly.
2) Remove the oil level bolt, and add the gear oil until it flows
out of the oil level bolt hole.
Replace the O-ring on assembly.
Gear oil capacity
0.98R (1.04 US qt, 0.86 Imp qt)
Recommended
gear oil
MARINE SAE 90 Hypoid gear oil API
Service classification (GL-4)
[2] OIL DRAIN
BOLT
3) Check for the metal particles on the magnet end of the oil
drain bolt.
[3] MAGNET
4) If there are metal particles on the magnet end of the oil
drain bolt, disassemble the gear case assembly and check
(See section 14).
5) After adding the gear oil, apply clean engine oil to the new
O-rings and install them on the oil drain bolt and the oil
level bolt.
Set the oil drain bolt and the oil level bolt on the gear case,
and tighten the bolts to the specified torque.
TORQUE: 3.4 N.m (0.35 kgf.m, 2.5 lbf.ft)
3-4
[2]
OIL DRAIN
BOLT
[4]
GEAR OIL PUMP
(Commercially
available)
Replacement:
[1] OIL LEVEL BOLT
1) Place the outboard motor on a level surface and tilt up the
outboard motor.
2) Remove the oil level bolt and the oil drain bolt, and drain
the old oil.
Replace the O-rings on assembly.
If there is water in the oil, the water will flow out first when
the oil drain bolt is removed, or the oil will be a milky color.
If water in the gear oil is detected, check the gaskets and
water seals for damage, and check the torque on the gear
case bolts.
3) Check for the metal particles on the magnet end of the oil
drain bolt (P. 3-4).
[2] OIL DRAIN
BOLT
4) If there are metal particles on the magnet end of the oil
drain bolt, disassemble the gear case assembly and check
(See section 14).
5) Install a commercially available gear oil pump in the oil
drain bolt hole, and add gear oil until it flows out of the oil
level bolt hole.
Gear oil capacity
0.98R (1.04 US qt, 0.86 Imp qt)
Recommended
gear oil
MARINE SAE 90 Hypoid gear oil API
Service classification (GL-4)
6) After adding the gear oil, apply clean engine oil to the new
O-rings and install them on the oil drain bolt and the oil
level bolt.
Set the oil drain bolt and the oil level bolt on the gear case,
and tighten the bolts to the specified torque.
[1]
5.5 x 1.5 mm
O-RING
[2]
OIL DRAIN BOLT
TORQUE: 3.4 N.m (0.35 kgf.m, 2.5 lbf.ft)
[1]
GEAR OIL PUMP
(Commercially
available)
3-5
5. SPARK PLUGS
[1]
SCREWDRIVER
Removal:
1) Remove the engine cover (P. 4-2).
[2] SLOT
2) Set a screwdriver in the slot in the two mud guard clips at
the top of the under cover grommet, and raise the mud
guard clips.
Remove the two mud guard clips.
3) Detach the upper part of the under cover grommet.
[3]
MUD GUARD
CLIP
[4]
MUD GUARD
CLIP (2)
[5]
UNDER COVER
GROMMET
4) Remove the two 6 x 25 mm socket bolts and remove the
PHC cover.
[1]
PHC COVER
[2] 6 x 25 mm SOCKET
BOLT (2)
3-6
5) Remove the 6 x 25 mm socket bolts and remove each
ignition coil from the corresponding spark plug.
[1]
No.1 IGNITION
COIL
Pull out each ignition coil halfway.
6) Disconnect the ignition coil 3P connector from each
ignition coil.
[2]
No.2 IGNITION
COIL
Remove each ignition coils.
NOTICE
• Do not pull out the ignition coils excessively.
[3]
No.3 IGNITION
COIL
• Do not drop the ignition coils and do not strike on the
ignition coils, either, during removal/installation of the
coils.
[4]
No.4 IGNITION
COIL
• Do not reuse the ignition coils when they are dropped.
7) Clean any dirt from around the spark plug bases.
[5] IGNITION COIL
[6]
6 x 25 mm
SOCKET
BOLT (2)
[7] IGNITION COIL
3P CONNECTOR
8) Remove the spark plugs using a spark plug wrench.
[1] SPARK PLUG
WRENCH
3-7
Inspection/Cleaning:
1) Visually inspect the spark plugs. Discard the plugs if the
insulators are cracked or chipped.
2) Remove carbon or other deposits with a plug cleaner.
1.0 – 1.1 mm
(0.039 – 0.043 in)
[1]
SEALING
WASHER
NOTICE
Do not spray the cleaner more than 20 seconds.
3) Measure the plug gap with a wire-type feeler gauge.
If the measurement is out of the specification, replace the
spark plug.
Spark plug gap
Recommended
spark plug
1.0 – 1.1 mm (0.039 – 0.043 in)
Service limit: 1.3 mm (0.051 in)
[3] Damaged
washer
[2] Cracked
insulation
IZFR6K11 (NGK)
SKJ20DR-M11 (DENSO)
4) Replace the spark plugs with the new ones if the center
electrode is rounded as shown.
NOTICE
[4]
Worn or
deformed
electrodes
[5]
Center
electrode
• These outboard motors are equipped with the iridium
spark plugs. Do not adjust the spark plug gap.
• After cleaning the spark plugs with a plug cleaner,
remove the sand thoroughly from the spark plugs.
• Never clean the spark plugs with a stiff wire brush. It can
damage the fine-grain film of the iridium chips of the
iridium spark plug.
5) Make sure each sealing washer is in good condition.
With each spark plug sealing washer attached, thread the
spark plugs in by hand to seat the sealing washers and
prevent crossthreading.
Then tighten with a plug wrench (an additional 1/2 turn if a
new plug) to compress the sealing washer. If you are
reusing a plug, tighten 1/8 – 1/4 turn after the plug seats.
TORQUE: 18 N.m (1.8 kgf.m, 13 lbf.ft)
[1]
Lip on reverse
side of grommet.
[2]
MUD GUARD
CLIPS
NOTICE
A loose spark plugs can become very hot and can damage
the engine. Overtightening the spark plugs can damage the
threads in the engine.
6) Install the ignition coils and tighten each with the 6 x 25
mm socket bolt securely (P. 3-7).
7) Connect the ignition coil 3P connector to each ignition coil
and install the PHC cover (P. 3-6 and 7).
8) Push in the two mud guard clips at the top of the under
cover grommet securely until they click.
9) Check that the lip at the reverse side of the under cover
grommet is engaged with the L./R. engine under covers
securely.
• Check that the under cover grommet adheres to the
engine under covers securely.
• If the projections on the reverse side of the under cover
grommet are out of position, set them on the under cover
grommet properly.
10) Install the engine cover (P. 4-2).
3-8
[4] UNDER COVER
GROMMET
[3] Projections on
reverse side of
grommet.
6. VALVE CLEARANCE
[1]
UNDER COVER
GROMMET
Inspection/Adjustment:
• Valve clearance inspection and adjustment must be
performed with the engine cold.
1) Remove the engine cover (P. 4-2).
2) Move the remote control lever to the “N” (Neutral)
position.
3) Set a screwdriver in the slot in the six mud guard clips, and
raise the mud guard clips (P. 3-6).
Remove the six mud guard clips.
4) Remove the under cover grommet.
5) Remove the PHC cover (P. 3-6).
Remove the four ignition coils and the four spark plugs (P.
3-7).
Remove the L./R. engine under covers (P. 4-9).
[2] MUD GUARD
CLIP (6)
6) Remove the two 6 x 22 mm flange bolts and remove the R.
side cover bracket from the engine assembly.
[1] R. SIDE COVER
BRACKET
6 x 22 (2)
7) Disconnect the breather tube and main wire harness from
the cylinder head cover.
Hold the main wire harness at the exhaust manifold side.
[1]
CYLINDER
HEAD
COVER
[2]
BREATHER
TUBE
3-9
[3]
MAIN
WIRE
HARNESS
8) Clamp the fuel tube B and D with the commercially
available tube clips as shown, and disconnect the fuel tube
B and D from the fuel pump (low pressure side).
[1] TUBE CLIP
(Commercially
available)
[2] FUEL TUBE B
WARNING
Gasoline is highly flammable and explosive.
You can be burned or seriously injured when handling
fuel.
• Keep heat, sparks and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
• Before disconnecting the fuel tubes, be sure to clamp the
fuel tubes with a tube clips to prevent the gasoline from
leaking.
[4] FUEL TUBE D
[3] FUEL PUMP
9) Disconnect the oil tube from the mounting case.
[1] OIL TUBE
[2] MOUNTING
CASE
10) Move the water relief tube A from your side of the
projection on the cylinder head cover to the other side.
[1] WATER RELIEF
TUBE A
[3]
CYLINDER HEAD
COVER
3-10
[2]
PROJECTION
11) Remove the six 6 mm hex. cap nuts and the six head cover washers, and remove the cylinder head cover.
[1] CYLINDER HEAD
COVER
[2]
HEAD COVER
WASHER (6)
[3]
6 mm HEX.
CAP NUT (6)
12) Release the pressure regulator control tube from the two 3.5 mm tube clips of the silencer duct assembly.
Remove the harness band clip, that clamps the main wire harness, from the silencer duct assembly.
13) Remove the breather tube from the 18.5 mm clamp and the guide of the silencer duct assembly.
[1]
SILENCER DUCT
ASSEMBLY
[2] 18.5 mm CLAMP
[3] BREATHER
TUBE
[4]
PRESSURE
REGULATOR
CONTROL TUBE
[8] GUIDE
[7]
MAIN WIRE
HARNESS
[5] 3.5 mm TUBE CLIP
3-11
[5] 3.5 mm TUBE CLIP
[6] HARNESS BAND CLIP
14) Remove the four 6 x 25 mm flange bolts and the four 6 mm
washers, and remove the silencer duct assembly.
[1]
6 mm
WASHER (4)
15) Attach the wrench to the 16 x 49 mm washer bolt on the
crankshaft pulley as shown.
Turn the crankshaft pulley clockwise.
16) Align the cutout in the crankshaft pulley with the “
on the chain case.
[1]
WRENCH
6 x 25 (4)
[2]
SILENCER DUCT
ASSEMBLY
[2] 16 x 49 mm
WASHER BOLT
” mark
• Do not turn the crankshaft pulley counterclockwise.
[3]
CRANKSHAFT
PULLEY
[3]
CRANKSHAFT
PULLEY
[4]
CUTOUT
[5] CHAIN
CASE
3-12
[6]
“ ” MARK
17) Holding the cutout in the crankshaft pulley aligned with the
“ ” mark on the chain case, check that the “ ” mark on
the intake camshaft sprocket is in alignment with the
“ ” mark on the exhaust camshaft sprocket. (The No.1
piston is at the top dead center of its compression stroke
this time.)
[1]
EXHAUST
CAMSHAFT
SPROCKET
[2] “ ” MARKS
[3]
INTAKE
CAMSHAFT
SPROCKET
• Perform this check on each cylinder with its piston at the
top dead center of its compression stroke (i.e. both the
intake and exhaust rocker arms are not lifted).
18) With the engine in the position described in step 17, check
the intake and exhaust valve clearances on the No.1
cylinder by inserting a feeler gauge between the
intake/exhaust side rocker arm valve adjusting screw and
the valve stem end.
IN
0.21 – 0.25 mm
(0.008 – 0.010 in)
EX
0.28 – 0.32 mm
(0.011 – 0.013 in)
Valve clearance
[6]
INTAKE
SIDE
[5]
EXHAUST
SIDE
No.1
No.1
No.2
No.2
No.3
No.3
No.4
No.4
[1]
VALVE ADJUSTING
LOCK NUT
[2] VALVE
ADJUSTING
SCREW
[3] FEELER GAUGE
19) If adjustment is necessary, loosen the valve adjusting lock
nut while holding the valve adjusting screw with a
screwdriver.
20) Insert a feeler gauge between the intake/exhaust side
rocker arm valve adjusting screw and the valve stem end.
21) Adjust the intake and exhaust valve clearances by turning
the valve adjusting screw.
22) After adjustment, secure the valve adjusting screw and
loosely tighten the lock nut.
23) Recheck the valve clearances again. Tighten the valve
adjusting lock nut to the specified torque.
TORQUE:
Intake side: 20 N.m (2.0 kgf.m, 14 lbf.ft)
Exhaust side: 14 N.m (1.4 kgf.m, 10 lbf.ft)
3-13
[3] FEELER GAUGE
[4] SCREWDRIVER
24) After adjusting the intake and exhaust valve clearances of
the No.1 cylinder, turn the crankshaft pulley clockwise by
increments of 180° and bring the piston of each cylinder at
the top dead center of its compression stroke.
Repeat the procedure from step 18 through step 23.
[5]
INTAKE
SIDE
[4]
EXHAUST
SIDE
No.1
No.1
No.2
No.2
[1] No.3 PISTON AT TOP DEAD CENTER OF
COMPRESSION STROKE:
[2] No.4 PISTON AT TOP DEAD CENTER OF
COMPRESSION STROKE:
No.3
No.4
No.3
No.4
[3] No.2 PISTON AT TOP DEAD CENTER OF
COMPRESSION STROKE:
3-14
25) After adjusting the valve clearances on each cylinder, install
the silencer duct assembly on the silencer case.
26) Set the four 6 x 25 mm flange bolts and the four 6 mm
washers, then tighten the four 6 x 25 mm flange bolts
securely.
[1]
SILENCER
DUCT
ASSEMBLY
6 x 25 (4)
[2]
6 mm
WASHER
(4)
27) Set the breather tube in the guide of the silencer duct
assembly and secure the tube with the 18.5 mm clamp.
[1] SILENCER DUCT
ASSEMBLY
28) Secure the pressure regulator control tube with the two 3.5
mm tube clips of the silencer duct assembly.
[2]
18.5 mm
CLAMP
Connect the pressure regulator control tube aligning the
marked part on the tube with the end of the 3.5 mm tube
clip (P. 2-70).
29) Set the main wire harness’ harness band clip on the
silencer duct assembly.
30) Install the cylinder head cover (P. 10-40).
[6]
GUIDE
[5]
3.5 mm TUBE
CLIP (2)
7. FUEL STRAINER (LOW PRESSURE
SIDE)
Inspection:
1) Remove the engine cover (P. 4-2).
2) Visually check the fuel strainer cup (low pressure side) for
water or foreign material in the cup. Check the fuel strainer
for contamination.
3) If there is water or foreign material in the fuel strainer cup,
or if the fuel strainer is contaminated, disassemble the
strainer and clean it (P. 3-16).
3-15
[4]
HARNESS
BAND CLIP
[3] PRESSURE
REGULATOR
CONTROL
TUBE
[1]
FUEL STRAINER
(LOW PRESSURE
SIDE)
Removal:
[1] FUEL TUBE E
WARNING
Gasoline is highly flammable and explosive.
You can be burned or seriously injured when handling fuel.
[2]
TUBE CLIPS
(Commercially
available)
• Keep heat, sparks and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
1) Clamp the fuel tube C and E securely with the two
commercially available tube clips.
[3] FUEL TUBE C
2) Remove the strainer suspension from the fuel strainer stay.
[1] FUEL STRAINER
STAY
3) Disconnect the fuel tube C and E from the fuel strainer (low
pressure side).
Remove the strainer suspension from the fuel strainer cup.
• Before disconnecting the fuel tubes, be sure to clamp the
fuel tubes with a tube clips to prevent the gasoline from
leaking.
[2] STRAINER
SUSPENSION
Disassembly/Cleaning:
1) Remove the three 5 x 12 mm screws from the fuel strainer
body, then remove the plate and the fuel strainer cup.
[1]
PLATE
[2] 5 x 12 mm
SCREW (3)
2) Clean the water or sediment in the cup, and if necessary,
replace the strainer.
3) Replace the O-ring with a new one on assembly.
Assembly:
1) Install a new fuel strainer on the fuel strainer body.
[6]
O-RING
2) Set a new O-ring on the fuel strainer cup.
Install the fuel strainer cup and the plate on the fuel strainer
body.
[3]
FUEL
STRAINER
CUP
3) Tighten the three 5 x 12 mm screws to the specified torque.
TORQUE: 3.4 N.m (0.35 kgf.m, 2.5 lbf.ft)
3-16
[5]
FUEL
STRAINER
[4]
FUEL
STRAINER
BODY
4) Install the strainer suspension on the fuel strainer cup so
that its projections are at the fuel strainer body side.
[1] FUEL STRAINER BODY
5) Install the fuel strainer (low pressure side) on the fuel
strainer stay securely.
[2] PROJECTIONS
[3] FUEL STRAINER
STAY
[4] STRAINER
SUSPENSION
6) Check that the center of the 5 x 12 mm screw at the fuel
tube C installation part is in line with the center of the
strainer suspension as shown.
[1] FUEL
STRAINER
STAY
[2] “
” MARK
[3]
FUEL TUBE E
7) Connect the fuel tube C to the “ ” mark side of the fuel
strainer. Connect the fuel tube E to the “ ” mark side of
the fuel strainer.
• After connecting the tubes, check for gasoline leakage.
8) Install the engine cover (P. 4-2).
[5] “
” MARK
[6] 5 x 12 mm SCREW
[4]
FUEL TUBE C
[7]
STRAINER
SUSPENSION
[8] Screw center must be in line
with the suspension center.
3-17
8. FUEL STRAINER (HIGH PRESSURE
SIDE)
• Disconnect the battery cable from the battery negative (-)
terminal before relieving the fuel pressure.
• Replace the sealing washers when the service check bolt is
loosened or removed.
• Catch the draining gasoline from the filter to avoid
contaminating the engine parts with the gasoline.
WARNING
Gasoline is highly flammable and explosive.
You can be burned or seriously injured when handling fuel.
• Keep heat, sparks and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
Replace the fuel filter (high pressure side) at the replacement
interval shown or in the following case.
• Regular replacement period of every 2 years or 400 operating
hours
• When the fuel pressure does mot reach 270 – 320 kPa (2.8 –
3.3 kgf/cm2, 40 – 47 psi) with the pressure regulator control
tube connected, be sure that the fuel pump unit (P. 5-107) and
the pressure regulator (P. 5-106) are normal, and replace the
fuel filter (high pressure side).
Replacement:
1) Remove the engine cover (P. 4-2).
Remove the L./R. engine under covers (P. 4-9).
[1]
STRAINER
2) Relieve the fuel pressure following the instruction of “How
to relieve fuel pressure” (P. 5-102).
3) Remove the three screw-washers from the strainer cover
while wrapping the strainer cover with a cloth or shop
towel.
Replace the O-ring on assembly.
4) Remove the strainer. Replace the fuel strainer if it is
contaminated or damaged.
Assembly:
1) Apply the engine oil to a new O-ring and install it on the
strainer cover.
2) Install the spring, strainer and washer in the case, then
install the strainer cover.
3) Tighten the three screw-washers to the specified torque.
TORQUE: 3.4 N.m (0.35 kgf.m, 2.5 lbf.ft)
[8]
5 mm
SCREWWASHER
(3)
[2] SPRING
[3]
WASHER
4) After tightening the screw-washers, check for gasoline
leakage.
5) Set a new sealing washer on the service check bolt, and
tighten the service check bolt to the specified torque.
TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)
6) Install the L./R. engine under covers (P. 4-14).
Install the engine cover (P. 4-2).
3-18
[4] O-RING
[7] SERVICE
CHECK
BOLT
[6] SEALING
WASHER
[5] STRAINER
COVER
9. WATER SEPARATOR with WATER
LEVEL SENSOR
[1]
WATER SEPARATOR
WARNING
Gasoline is highly flammable and explosive.
You can be burned or seriously injured when handling fuel.
• Keep heat, sparks and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
Inspection:
1) Remove the engine cover (P. 4-2).
[1] CONNECTOR
BRACKET A
[2] HARNESS
CLIP
2) Check the water separator for water accumulation or
sediment. If water or sediment is found, or the water filled
alert buzzer is sound, remove the water separator as
follows.
Removal/Cleaning:
[3]
WATER LEVEL
SENSOR
2P
CONNECTOR
• Turn the ignition switch to the OFF position, disconnect the
battery negative (-) cable, then positive (+) cable.
1) Open the harness clip. Remove the water level sensor 2P
connector from the connector bracket A.
Disconnect the water level sensor 2P connector.
2) Clamp the fuel tube A and C with the commercially
available tube clips securely.
[2] FUEL TUBE C
[1]
FUEL TUBE A
[3]
TUBE CLIPS
(Commercially
available)
[4] WATER SEPARATOR
3) Remove the strainer suspension from the fuel strainer stay.
4) Disconnect the fuel tube A and C from the water separator
with water level sensor.
[1]
FUEL STRAINER STAY
• Before disconnecting the fuel tubes, be sure to clamp the
fuel tubes with a tube clips to prevent the gasoline from
leaking.
Remove the strainer suspension from the water separator
cup.
[2] STRAINER
SUSPENSION
3-19
Disassembly:
1) Remove the three 5 x 12 mm screws from the water
separator body, then remove the plate and the water
separator cup.
[1]
5 x 12 mm
SCREW (3)
2) Clean the water separator cup. Replace the fuel strainer
with a new one if it is contaminated.
Replace the O-ring with a new one on assembly.
[2]
PLATE
[3]
WATER
SEPARATOR
CUP
[4]
O-RING
[5]
WATER
SEPARATOR
BODY
Water level sensor float check:
1) Check the float in the water separator cup for smooth
operation.
2) If it does not operate smoothly, replace the water separator
cup.
Water level sensor continuity check:
1) With the water separator cup removed, hold the cup
upright (i.e. as if it is mounted) and check for continuity
between the 2P connecter terminals. There must be no
continuity between the terminals.
2) With the water separator cup removed, hold the cup upside
down and check for continuity between the 2P connector
terminals. There must be continuity between the terminals.
[1] FLOAT
3) If there is any abnormality during the check, replace the
water separator cup.
Assembly:
1) Set a new O-ring on the water separator cup. Install the
water separator cup and the plate on the water separator
body.
2) Tighten the three 5 x 12 mm screws to the specified torque.
TORQUE: 3.4 N.m (0.35 kgf.m, 2.5 lbf.ft)
3-20
[2] NORMAL
(AS INSTALLED)
[3] UPSIDE DOWN
(INVERTED CUP)
3) Install the strainer suspension on the water separator cup
so that its projections are at the water separator body side.
4) Install the water separator with water level sensor on the
fuel strainer stay securely.
[1] WATER SEPARATOR
BODY
[2]
PROJECTIONS
[4] FUEL STRAINER
STAY
5) Check that the center of the 5 x 12 mm screw at the fuel
tube A installation part is in line with the center of the
strainer suspension as shown.
[1]
“ ” MARK
[3]
STRAINER
SUSPENSION
[2] FUEL TUBE C
[3]
FUEL STRAINER
STAY
6) Connect the fuel tube A to the “ ” mark side of the water
separator with water level sensor. Connect the fuel tube C
to the “ ” mark side of the water separator with water
level sensor.
• After connecting the tubes, check for gasoline leakage.
[5]
“ ” MARK
[4] FUEL TUBE A
[6] 5 x 12 mm SCREW
[7]
STRAINER
SUSPENSION
[8] Center of screw must be in
line with suspension center.
3-21
7) Connect the water level sensor 2P connector and install the
2P connector on the connector bracket A.
Route the water level sensor wire through the harness clip.
Clamp at the taped part of the water level sensor wire and
close the harness clip.
[1]
CONNECTOR
BRACKET A
[2] TAPED PART
8) Install the engine cover (P. 4-2).
[3] HARNESS
CLIP
[4] WATER LEVEL SENSOR
2P CONNECTOR
10. IDLING
Inspection:
[1]
ELECTRIC
PART COVER
Check the following before starting the idling inspection.
– Spark plug gap (These models are equipped with the iridium
spark plugs. If the spark plug gap is out of the specification,
replace the spark plug with a new one.) (P. 3-8).
– MIL must be OFF.
1) Place the outboard motor vertically (with the engine level
to the ground), and set the remote control lever in the “N”
(Neutral) position.
2) Remove the propeller. Set the outboard motor gear case in
a test tank filled with water.
Remove the engine cover (P. 4-2).
3) Remove the electric part cover.
[1] ENGINE SPEED CHECK
CONNECTOR [Blue 2P connector]
4) Install the commercially available digital tachometer
(KOWA: KEK-8-MT600) or the HDS (Honda Diagnostic
System).
How to connect the digital tachometer (KOWA: KEK-8MT600):
1) Disconnect the engine speed check connector (Blue
connector: 2P connector).
2) Connect the 2P connector of the cable that is included in
the digital tachometer kit (KOWA: KEK-8-MT600) to the
engine side 2P connector.
[2]
CABLE included in
digital tachometer
kit.
3-22
3) Connect the pin jack, that is the opposite side from the
cable 2P connector, to the digital tachometer.
[1]
PIN JACK
[2] DIGITAL TACHOMETER
(KOWA: KEK-8-MT600)
How to connect the HDS (Honda Diagnostic System):
1) Disconnect the data link connectors (Red connector: 4P
connector).
[1] DATA LINK CONNECTORS (DLC)
[RED: 4P CONNECTOR]
2) Connect the 4P connector that goes to the HDS to the
engine side 4P connector.
[2]
HDS 4P CONNECTOR
5) Start the engine and let it warm up sufficiently. Run the
engine under no load until the engine speed stabilizes, and
check the idling speed.
Specified idle speed
(At neutral)
750 ± 50 min–1 (rpm)
• If the idle speed is out of the specification, adjust the idle
(P. 5-94).
• When the idle speed is outside the specification or when
a problem symptom shown on the Idle Control System
Troubleshooting Guide (P. 5-93) appears, perform the
adjustment.
6) Install the engine cover (P. 4-2).
3-23
[1]
HDS (Honda
Diagnostic
System)
11. SHIFT CONTROL CABLE
[1] FLAT PART OF
DETENT ARM
Inspection:
[2] NEUTRAL SWITCH
END
1) Remove the engine cover (P. 4-2).
Remove the front separate cover (P. 4-7).
2) Move the remote control lever to the “N” (Neutral)
position.
Check that the detent arm roller sets in the groove in the
shift arm as shown.
Check that the center of the neutral switch end aligns with
the center of the flat part of the detent arm.
[3] Align.
3) If the center of the neutral switch end does not align with
the center of the flat part of the detent arm, check the
detent arm for deformation and damage.
Replace the detent arm with a new one if necessary (P. 1713).
If the detent arm roller is not in the groove in the shift arm,
adjust (P. 3-25).
[5]
SHIFT
ARM
GROOVE
[4] DETENT ARM
ROLLER
[4] DETENT ARM
ROLLER
[5]
SHIFT ARM
GROOVE
[1] FLAT PART OF
DETENT ARM
[3]
Align.
[2] NEUTRAL
SWITCH END
[4] DETENT ARM
ROLLER
3-24
Adjustment:
[1] SHIFT PIVOT
[2] LOCK NUT
1) Move the remote control lever to the “N” (Neutral)
position.
2) Loosen the shift pivot lock nut of the remote control cable
(shift side) and detach the shift pivot from the shift link pin.
3) Check that the detent arm roller sets in the groove in the
shift arm.
4) Turn the shift pivot right or left so that the shift pivot sets
on the shift link pin smoothly.
5) Set the shift pivot on the shift link pin. Move the remote
control lever back and forth several times to check that the
detent arm roller is in the groove in the shift arm securely.
[4] SHIFT LINK
PIN
[3] SHIFT ARM
[1] SHIFT PIVOT
Check that the center of the neutral switch end aligns with
the center of the flat part of the detent arm.
[2] LOCK NUT
Tighten the lock nut securely.
If the detent arm roller is not in the groove in the shift arm,
readjust.
6) After adjustment, install the front separate cover (P. 4-7).
Install the engine cover (P. 4-2).
[5]
GROOVE IN
SHIFT ARM
[6] FLAT PART OF
DETENT ARM
[7] Align.
[8] NEUTRAL
SWITCH END
[9]
DETENT ARM
ROLLER
3-25
12. THROTTLE CONTROL CABLE/
THROTTLE LINK
Inspection:
1) Remove the engine cover (P. 4-2).
Remove the front separate cover (P. 4-7).
2) Move the remote control lever to the “F” (Forward) full
open position.
NOTICE
[4] “N” (NEUTRAL)
[3] “F” (FORWARD)
[2]
REMOTE
CONTROL
LEVER
[1]
FULL
OPEN
POSITION
• If it is hard to move the remote control lever to the “F”
(Forward) position with the engine stopped, move the
lever while turning the propeller or propeller shaft.
[1] THROTTLE ARM
• Do not move the remote control lever with force, or
damage to the gearshift system can result.
[2] SHIFT LINK
BRACKET
3) With the remote control lever in the “F” (Forward) full open
position, check that the throttle arm is in contact with the
full open stopper of the shift link bracket.
[3]
FULL OPEN
STOPPER
4) With the throttle arm in the position described in step 3,
check for clearance between the throttle cam of the throttle
body and the full open side stopper. It must be 1 mm (0.04
in) or below.
[1] THROTTLE
CAM
[2]
STOPPER
(FULL
OPEN
SIDE)
[3] 1 mm (0.04 in) OR BELOW
5) Move the remote control lever to the “N” (Neutral) position
and check that the throttle cam of the throttle body is in the
full close position.
[3]
STOPPER
(FULL
CLOSE
SIDE)
Check the clearance between the throttle cam and the full
close side stopper. It must be 1 mm (0.04 in) or below.
6) If either of the above step 3, 4 or 5 is not satisfied, adjust as
follows (P. 3-27).
If step 3 is not satisfied: Go to <Throttle arm not in full open
position>.
If step 4 or 5 is not satisfied: Go to <Throttle cam not in full
open position>.
3-26
[1]
THROTTLE
CAM
[2] 1 mm (0.04 in) OR BELOW
Adjustment:
[1] LINK PIN
[2]
THROTTLE
ARM
<Throttle arm not in full open position>
1) Loosen the shift pivot lock nut of the remote control cable
(throttle side), and remove the shift pivot from the throttle
arm link pin.
2) Screw in the shift pivot a little until the throttle arm contacts
the full open stopper, and temporarily install the shift pivot
on the throttle arm.
[4]
SHIFT
PIVOT
[3] LOCK NUT
3) Move the remote control lever to the “F” (Forward) full
open position (P. 3-26).
4) Check that step 3, 4 and 5 under the section of Inspection
are satisfied (P. 3-26).
If not, perform the adjustment procedure from step 1.
If the throttle arm is in contact with the full open side
stopper but the step 4 or 5 is not satisfied, go to <Throttle
cam not in full open position>.
[1] SHIFT PIVOT
5) Move the remote control lever to the “N” (Neutral) and
tighten the shift pivot lock nut securely.
<Throttle cam not in full open position>
• Perform this adjustment with the remote control cable
(throttle side) installed on the throttle arm.
• Be sure that the throttle arm is in contact with the full open
side stopper.
1) Remove the throttle rod linkage pivot from the throttle
plate and loosen the linkage pivot lock nut.
2) With the throttle arm in contact with the full open side
stopper, turn the throttle rod linkage pivot right or left to
adjust the clearance between the throttle cam and the full
open side stopper. It must be 1 mm (0.04 in) or below.
[2] LOCK NUT
[1]
LINKAGE
PIVOT
3) Temporarily install the linkage pivot on the throttle plate.
4) Check that step 3, 4 and 5 under the section of Inspection
are satisfied (P. 3-26).
If step 3 is not satisfied, readjust following the procedure of
<Throttle arm not in full open position>.
If the throttle cam is in contact with the full open side
stopper but the step 5 is not satisfied, go to <Throttle cam
not in full open position>.
5) Tighten the linkage pivot lock nut securely.
3-27
[4] THROTTLE PLATE
[3]
THROTTLE
ROD
Check item:
[1] 5 x 16 mm
HEX. BOLT
<Side-mount remote control type only>
1) Remove the remote control box cover B and C (P. 16-2).
2) Move the remote control lever to the full open position and
be sure that the link joint arm is in contact with the 5 x 16
mm hex. bolt.
If not in contact, tighten the 5 x 16 mm hex. bolt unit it
contacts the link joint arm.
3) Install the remote control box cover B and C (P. 16-2).
[2] LINK JOINT ARM
13. REMOTE CONTROL LEVER
FRICTION
Inspection/Adjustment:
1) Check the remote control lever for smooth operation.
If the lever movement is too light or too heavy, adjust the
friction.
2) Adjust by turning the friction adjusting bolt right or left.
[1] FRICTION ADJUSTING BOLT
14. ALTERNATOR BELT
Inspection:
1) Remove the engine cover (P. 4-2).
Remove the silencer duct assembly (P. 3-11 and 12).
2) Check the alternator belt for wear and damage.
Replace the alternator belt if necessary (P. 3-29).
3) Check the alternator belt and the related parts for stain with
oil, etc. If stained, clean the stained parts and replace the
alternator belt.
4) Check the belt tension and belt deflection (P. 3-29).
[1] ALTERNATOR
BELT
3-28
a. Best tension check using belt tension gauge:
1) Set the special tool at the center between the alternator belt
pulleys, and measure the belt tension.
TOOL:
Belt tension gauge
07JGG-0010101
Used belt
329 – 490 N
(40 – 50 kgf, 88 – 110 lbf)
New belt
490 – 588 N
(50 – 60 kgf, 110 – 132 lbf)
Belt tension
[1]
BELT TENSION
GAUGE
07JGG-0010101
2) If the belt tension is out of the specification, adjust the belt
tension.
[1] BELT
DEFLECTION
b. Belt deflection inspection
1) Measure the belt deflection by pushing the alternator belt
at the center between the pulleys with 98 N (10 kgf, 22 lbf)
of force.
Used belt
10.6 – 11.1 mm
(0.42 – 0.44 in)
New belt
10.1 – 10.6 mm
(0.40 – 0.42 in)
Belt deflection
[2] When pushed with
98 N (10 kgf, 22 lbf)
of force.
2) If the belt deflection is out of the specification, adjust the
belt tension.
Belt Tension Adjustment:
10 x 80
1) If the belt tension or belt deflection is out of the
specification, loosen the 10 x 80 mm flange bolt and the 8
mm flange nut, and adjust the belt tension or deflection by
turning the special adjusting bolt right or left.
[1]
8 mm FLANGE
NUT
2) After adjustment, tighten the 8 mm flange nut and the 10 x
80 mm flange bolt in this order to the specified torque.
TORQUE:
8 mm flange nut: 26 N.m (2.7 kgf.m, 20 lbf.ft)
10 x 80 mm flange bolt: 44 N.m (4.5 kgf.m, 33 lbf.ft)
3) After tightening the bolt and nut to the specified torque,
check the alternator belt tension and deflection again.
If the measurement is still out of the specification, repeat
the step 1 and 2.
[3] ALTERNATOR
BELT
10 x 80
[2]
SPECIAL
ADJUSTING
BOLT
[1] 8 mm FLANGE
NUT
Replacement:
1) Loosen the 10 x 80 mm flange bolt and the 8 mm flange
nut.
2) Loosen the special adjusting bolt and move the alternator
assembly fully to the engine side.
[3] ALTERNATOR ASSEMBLY
3-29
[2]
SPECIAL
ADJUSTING
BOLT
3) Remove the alternator belt by removing it from the
alternator pulley first, then from the crankshaft pulley.
[1]
ALTERNATOR
BELT
• Do not contaminate the alternator belt with oil or grease.
• Do not bend the alternator belt. Store the belt by hanging
it on the wall.
Installation:
1) Install a new alternator belt on the crankshaft pulley first,
then install the other end of the belt on the alternator
pulley.
NOTICE
Do not turn the crankshaft pulley counterclockwise.
[2] CRANKSHAFT
PULLEY
[3] ALTERNATOR
PULLEY
2) Tighten the special adjusting bolt.
Tighten the 8 mm flange nut and the 10 x 80 mm flange bolt
in this order to the specified torque.
TORQUE:
8 mm flange nut: 26 N.m (2.7 kgf.m, 20 lbf.ft)
10 x 80 mm flange bolt: 44 N.m (4.5 kgf.m, 33 lbf.ft)
10 x 80
[1]
8 mm FLANGE
NUT
3) After tightening the nut and bolt to the specified torque,
check the belt tension and deflection (P. 3-29).
4) Install the silencer duct assembly (P. 3-11 and 12).
Install the engine cover (P. 4-2).
[3] ALTERNATOR
ASSEMBLY
3-30
[2] SPECIAL
ADJUSTING
BOLT
4. ENGINE COVER/COVER LOCK
1. ENGINE COVER
2. FRONT SEPARATE COVER
3. L./R. ENGINE UNDER COVERS
4.5 N.m (0.45 kgf.m,
3.3 lbf.ft)
4.5 N.m (0.45 kgf.m,
3.3 lbf.ft)
4-1
4. UNDER COVER FRONT BRACKET/
L./R. SIDE COVER BRACKETS
1. ENGINE COVER
a. REMOVAL/INSTALLATION
Remove the engine cover by pulling the cover lock lever toward you.
b. DISASSEMBLY/ASSEMBLY
[1] ENGINE COVER
[2] ENGINE COVER SEAL
ASSEMBLY:
Install the engine cover seal in
the direction shown.
[2]-1
INSIDE
[2]-2
OUTSIDE
[3]
COVER LOCK
LEVER
c. HOOK BRACKET ASSEMBLY REMOVAL
1) Remove the 6 x 20 mm socket bolt and the 6 x 16 mm
socket bolt, then remove the hook bracket assembly (Front
side hook bracket only).
[1]
6 x 20 mm SOCKET
BOLT
(2) [Rear L./R. sides only]
(1) [Front side only]
[2]
HOOK BRACKET
ASSEMBLY
Remove the two 6 x 20 mm socket bolts and remove the
hook bracket assembly (Rear L./R. side hook brackets only).
2) Remove the three 6.5 x 10 x 11.5 mm distance collars from
the engine cover (Front side hook bracket only).
Remove the four 6.5 x 10 x 11.5 mm distance collars from
the engine cover (Rear L./R. side hook brackets only).
[4]
6 x 16 mm
SOCKET BOLT
[Front side only]
4-2
[3]
6.5 x 10 x 11.5 mm
DISTANCE COLLAR
(4) [Rear L./R. sides only]
(3) [Front side only]
d. HOOK BRACKET DISASSEMBLY/ASSEMBLY
[4]
COVER LOCK
BOLT
FRONT SIDE:
[5] HOOK DAMPER
[2]
6 x 20 mm SOCKET
BOLT
[3]
6.5 x 10 x 11.5 mm
DISTANCE COLLAR (3)
[6] 12 mm WASHER
[7] LOCK ADJUSTING
SPRING
[8] HOOK BRACKET
[1]
6 x 16 mm SOCKET
BOLT
[9] 6 mm WASHER
[10] 6 mm HEX. NUT
L./R. SIDES:
[3] COVER LOCK BOLT
[4] HOOK DAMPER
[2]
6.5 x 10 x 11.5 mm
DISTANCE COLLAR (3)
[5] 12 mm WASHER
[6]
LOCK ADJUSTING
SPRING
[7] HOOK BRACKET
[1]
6 x 20 mm SOCKET
BOLT (2)
[8] 6 mm WASHER
[9] 6 mm HEX. NUT
4-3
e. HOOK BRACKET ASSEMBLY
[1]
COVER LOCK
BOLT
1) Apply grease to the cover lock bolt installation part of the
hook bracket.
2) Install the lock adjusting spring, 12 mm washer and the
hook damper on the hook bracket.
[2]
HOOK
DAMPER
3) Apply grease to the flanged part of the cover lock bolt.
Apply grease to the straight part under the flange of the
cover lock bolt, too. Install the cover lock bolt on the hook
bracket.
4) Position the 6 mm washer and 6 mm hex. nut on the cover
lock bolt and tighten the 6 mm hex. nut securely.
[3]
LOCK
ADJUSTING
SPRING
[7]
12 mm
WASHER
[4]
6 mm
WASHER
[6]
HOOK
BRACKET
[5]
6 mm HEX.
NUT
f. HOOK BRACKET ASSEMBLY INSTALLATION
1) Install the four 6.5 x 10 x 11.5 mm distance collars on the
engine cover (Rear L./R. side hook brackets only).
[1]
6 x 20 mm SOCKET BOLT
(2) [Rear L./R. sides only]
(1) [Front side only]
[2]
HOOK BRACKET
ASSEMBLY
Install the three 6.5 x 10 x 11.5 mm distance collars on the
engine cover (Front side hook bracket only).
2) Position the hook bracket assembly on the engine cover
and secure it with the two 6 x 20 mm socket bolts (Rear
L./R. side hook brackets only).
Position the hook bracket assembly on the engine cover
and secure it with the 6 x 20 mm socket bolt and the 6 x 16
mm socket bolt (Front side hook bracket only).
[4]
6 x 16 mm SOCKET
BOLT
[Front side only]
4-4
[3]
6.5 x 10 x 11.5 mm
DISTANCE COLLAR
(4) [Rear L./R. sides only]
(3) [Front side only]
g. ADJUSTMENT
• HOOK BRACKET
1) Install the engine cover on the outboard motor and lock it
securely.
2) Measure the clearance between the engine cover and the
L./R. engine under covers.
• Measure the clearance at the three points, i.e. at the front
and at the rear right and left sides.
3) Check that the measurement is within 17.5 – 18.5 mm (0.69
– 0.73 in) at each point.
4) If the measurement is out of the specification, adjust the
clearance.
17.5 – 18.5 mm
(0.69 – 0.73 in)
5) To adjust, remove the engine cover and set a wrench or
equivalent tool in the cutout in the tapered part of the cover
lock bolt. Loosen the 6 mm hex. nut of the hook bracket
assembly.
[1]
Set a wrench or
equivalent tool at
tapered part.
6) After assembly, loosely tighten the 6 mm hex. nut.
7) Install the engine cover on the outboard motor and lock it
securely. Measure the clearance between the engine cover
and the L./R. engine under covers again.
If the clearance is out of the specification, repeat step 5.
If the clearance is within the specification, remove the
engine cover and tighten the 6 mm hex. nut securely.
8) Install the engine cover (P. 4-2).
[2] 6 mm HEX. NUT
4-5
h. ENGINE COVER DISASSEMBLY
Remove the hook bracket assembly (P. 4-2).
[1]
ENGINE COVER
AIR GUIDE
[2]
4 x 10 mm SELFTAPPING SCREW (8)
[3] ENGINE COVER
i. ENGINE COVER ASSEMBLY
1) Clean the engine cover and engine cover air guide mating
surfaces.
2) Apply the sealant (Shin-Etsu Chemical KE45 or equivalent)
to the indicated position of the engine cover air guide.
3) Tighten the engine cover air guide with the eight 4 x 10 mm
self-tapping screws securely.
4) Install the hook bracket assembly (P. 4-4).
4-6
[1]
Apply the sealant.
(Shin-Etsu Chemical
KE45 or equivalent)
2. FRONT SEPARATE COVER
a. REMOVAL
1) Remove the engine cover (P. 4-2).
2) Loosen the undercase grommet band and remove it from the remote control cable grommet.
3) Remove the 6 x 17 mm special bolt and the three 6 x 25 mm screws, then detach the front separate cover.
4) Remove the front separate cover.
[2]
UNDERCASE
GROMMET BAND
[3]
6 x 17 mm SPECIAL
BOLT
[1]
FRONT SEPARATE
COVER
[4]
6 x 25 mm SCREW (3)
b. INSTALLATION
[1] <Rear side>
1) Install the front separate cover by aligning the recess at the
rear of the front separate cover (i.e. R. engine under cover
side) with the projection of the R. engine under cover.
2) Install by aligning the projection at the front (i.e. under
cover front bracket side) of the front separate cover with
the recess of the under cover front bracket.
[5]
PROJECTION
[4]
R. ENGINE
UNDER
COVER
[6] <Front side> [2] RECESS
[5]
PROJECTION
[3]
FRONT SEPARATE
COVER
4-7
[2]
RECESS
[3]
FRONT
SEPARATE
COVER
[7]
UNDER COVER
FRONT BRACKET
3) Loosely tighten the three 6 x 25 mm screws and one 6 x 17
mm special bolt.
• Check that the special bolt is not on the case but it is
tightened properly.
[2]
6 x 17 mm SPECIAL
BOLT
[1]
6 x 25 mm
SCREW (3)
4) Tighten the 6 x 25 mm screws and the 6 x 17 mm special
bolt securely in the numbered sequence shown in two or
three steps.
5) Install the undercase grommet band on the remote control
cable grommet and fasten the band securely.
①
②
Install the engine cover (P. 4-2).
④
③
[3] UNDERCASE
GROMMET BAND
4-8
3. L./R. ENGINE UNDER COVERS
a. REMOVAL
Remove the following parts.
– Engine cover (P. 4-2)
– Front separate cover (P. 4-7)
– Electric part cover (P. 3-22)
[1]
FLUSH PLUG
CAP
1) Remove the flush plug cap from the R. engine under cover.
2) Open the wire harness clip. Remove the power tilt switch
3P connector from the connector bracket B.
3) Disconnect the power tilt switch 3P connector.
[1]
CONNECTOR
BRACKET B
[3]
WIRE HARNESS
CLIP
4) Set a screwdriver in the slot in each mud guard clip as
shown and raise the mud guard clips.
Remove the six mud guard clips.
[2] POWER TILT SWITCH
3P CONNECTOR
[1]
SCREWDRIVER
[2]
SLOT
5) Remove the under cover grommet.
[3]
MUD GUARD
CLIP
[4]
MUD GUARD
CLIP (6)
[5]
UNDER COVER
GROMMET
4-9
6) Loosen the two 5 x 10 mm rivet screws and remove the two
14 mm clips.
[1] 14 mm CLIP (2)
[2]
5 x 10 mm RIVET
SCREW (2)
7) Remove the three 6 x 25 mm screws and the eleven 6 x 17 mm special bolts from the L./R. engine under covers.
[1]
L. ENGINE UNDER COVER
[4] 6 x 25 mm SCREWS
8) Detach the L. engine under cover from the projection of the
L. side cover bracket.
[2]
R. ENGINE UNDER COVER
[3] 6 x 17 mm SPECIAL
BOLT (11)
[1] L. ENGINE UNDER
COVER
[3]
L. SIDE COVER
BRACKET
4-10
[2] PROJECTION
9) Open the L. engine under cover and disconnect the 7 x 400
mm tube from the water check grommet.
[2]
7 x 400 mm
TUBE
[1]
WATER
CHECK
GROMMET
10) Detach the R. engine under cover from the projection of the
R. side cover bracket.
11) Remove the L./R. engine under covers.
[1] PROJECTION
[2]
R. ENGINE UNDER
COVER
[3] R. SIDE
COVER
BRACKET
[2]
R. ENGINE UNDER
COVER
[1] L. ENGINE UNDER
COVER
4-11
b. R. ENGINE UNDER COVER DISASSEMBLY
[1] 16 mm HEX. NUT
[6]
POWER TILT
SWITCH STAY
[5]
POWER TILT
SWITCH STAY
GROMMET
[2] WATER JOINT
CAP
[3] R. ENGINE UNDER
COVER
[4] POWER TILT SWITCH
c. INSPECTION
[1] UP (Up)
• POWER TILT SWITCH
Check for continuity between the terminals with the switch in
each position.
Lb
W/Bl
Lg
UP (Up)
DN (Down)
: Continuity
4-12
[2] DN (Down)
d. COMPONENTS DRAWING
[1]
6 x 25 mm SCREWS
4.5 N.m (0.45 kgf.m,
3.3 lbf.ft)
[3] 14 mm CLIP (2)
[2]
L. ENGINE
UNDER
COVER
[4]
7 x 400 mm TUBE
[5]
POWER TILT SWITCH
3P CONNECTOR
[6]
FLUSH PLUG CAP
[7] 6 x 17 mm SPECIAL
BOLT (11)
[13]
WATER CHECK
GROMMET
[10] 5 x 10 mm RIVET
SCREW (2)
[11] UNDER COVER
GROMMET
[12] MUD GUARD
CLIP (6)
4-13
[9]
R. ENGINE UNDER
COVER
[8] DRAIN PLUG
COVER
e. R. ENGINE UNDER COVER ASSEMBLY
1) Position the water joint cap on the R. engine under cover and tighten the 16 mm hex. nut securely. Note the
installation direction of the water joint cap.
2) Position the power tilt switch on the power tilt switch grommet with the “UP” mark on the power tilt switch facing
up.
3) Install the power tilt switch on the R. engine under cover and install the power tilt switch stay as shown.
Secure the power tilt switch stay with the locking lugs of the power tilt switch.
[1] 16 mm HEX. NUT
[7] POWER TILT
SWITCH STAY
[2]
WATER JOINT
CAP
[6] POWER TILT
SWITCH STAY
GROMMET
[5] POWER TILT
SWITCH
[4]
LOCKING
LUGS
[3]
R. ENGINE UNDER
COVER
f. INSTALLATION
[1]
7 x 400 mm
TUBE
1) If the water check grommet is not mounted on the L. engine
under cover, install it from the outside of the L. engine
under cover.
2) Connect the 7 x 400 mm tube to the water check grommet.
[2]
WATER
CHECK
GROMMET
3) Install the L. engine under cover aligning the bottom edge
of the L. engine under cover with the extension case as
shown.
[1]
L. ENGINE
UNDER
COVER
[2] Align.
[3] EXTENSION
CASE
4-14
4) Install the L. engine under cover aligning the hole in the L.
engine under cover with the projection on the L. side cover
bracket.
[1] L. ENGINE UNDER
COVER
[2] PROJECTION
[4]
HOLE
[3]
L. SIDE COVER
BRACKET
5) Check that the cover lock cable A is set on the L. engine
under cover as shown.
[1]
L. SIDE COVER
BRACKET
[4]
COVER LOCK
CABLE A
[2]
L. ENGINE
UNDER
COVER
[3] Cross section
viewed from
A-A side.
A
A
[2] L. ENGINE UNDER
COVER
6) Hold the power tilt switch wire above the R. engine under
cover.
7) Install the R. engine under cover aligning the bottom of the
R. engine under cover with the extension case as shown.
Note that the 8 x 300 mm tube with the flush plug cap is
outside the R. engine under cover this time.
[1] R. ENGINE
UNDER
COVER
[2] Align.
[3]
EXTENSION CASE
4-15
8) Align the projections at the front side (i.e. swivel case side)
of the L. engine under cover with the recess in the R. engine
under cover as shown.
[1] RECESS
[2]
R. ENGINE
UNDER
COVER
[4]
PROJECTIONS
[3]
L. ENGINE UNDER
COVER
9) With the R. engine under cover held in alignment with the
L. engine under cover described in step 7, install the R.
engine under cover by aligning the hole in the R. engine
under cover with the projection on the R. side cover
bracket.
[1] PROJECTION
[2] R. ENGINE UNDER
COVER
[3]
HOLE
[4] R. SIDE
COVER
BRACKET
10) Check that the cover lock cable B sets underside the R.
engine under cover as shown.
[1]
Cross-section
viewed from A-A
side.
[2]
R. ENGINE UNDER
COVER
A
[3] COVER LOCK
CABLE B
A
[3]
COVER LOCK
CABLE B
[2]
R. ENGINE UNDER
COVER
4-16
11) Install the L./R. engine under covers aligning the projection
on the rear (i.e. cylinder head cover side) of the L. engine
under cover with the recess in the R. engine under cover.
[1] L. ENGINE UNDER
COVER
Install the L./R. engine under covers, too, aligning the
projections at the upper part of the L. engine under cover
with the recess at the upper part of the R. engine under
cover.
[2] PROJECTION
[3]
RECESS
• Check that each alignment performed in step 4 through
step 11 is not out of alignment.
[4] R. ENGINE UNDER
COVER
[1]
L. ENGINE
UNDER
COVER
12) Loosely tighten the three 6 x 25 mm screws and the eleven
6 x 17 mm special bolts on the L./R. engine under covers.
• Check that the special bolts are not on the case but they
are tightened properly.
[2]
PROJECTIONS
[4]
R. ENGINE UNDER
COVER
13) Tighten the three 6 x 25 mm screws to the specified torque
and the eleven 6 x 17 mm special bolts to the standard
torque in the numbered sequence and in two or three steps
securely.
TORQUE:
6 x 25 mm screws: 4.5 N.m (0.45 kgf.m, 3.3 lbf.ft)
[3]
RECESS
STANDARD TORQUE:
6 x 17 mm special bolts: 4.2 N.m (0.42 kgf.m, 3.0 lbf.ft)
• Check that each alignment performed in step 4 through
step 11 is not out of alignment.
[1]
L. ENGINE UNDER COVER
⑥
[2]
R. ENGINE UNDER COVER
⑫
⑪
①
⑭
④
③
⑨
⑩
⑤
[3] 6 x 25 mm SCREWS
[4] 6 x 17 mm SPECIAL
BOLT (11)
4-17
⑦
⑬
②
⑧
14) Check that the end of each 14 mm clip aligns with the end
of the taped part of the power tilt motor wire as shown.
15) Tighten the two 5 x 10 mm rivet screws securely while
pushing the end of the two 14 mm clips against the
corresponding projection on the L. engine under cover.
[2] 5 x 10 mm
RIVET
SCREW (2)
[3]
POWER TILT
MOTOR WIRE
[4]
SPIRAL
TUBE
[1]
PROJECTIONS
Take care not to let the alignment points described in the
previous step come out of alignment.
[5] TAPING
[6] 14 mm
CLIP (2)
[5] TAPING
[7] 14 mm
CLIPS
[2]
5 x 10 mm RIVET
SCREW (2)
16) Insert the under cover grommet into the idle exhaust port
as shown.
[1]
IDLE EXHAUST PORT
17) Insert the four projections on the under cover grommet into
the holes in the engine under covers.
[2]
UNDER COVER
GROMMET
18) Aligning the holes in the under cover grommet with the
holes in the engine under cover, set the six mud guard clips
in the respective holes.
• Do not push in the head of the mud guard clips.
[6] HOLE (4)
[5] PROJECTION (4)
[3]
CLIP
HEAD
[4] MUD GUARD
CLIP (6)
4-18
19) Push in the head of the mud guard clips in the numbered
sequence securely.
[1] LIP on the reverse side
of the grommet.
20) Check that the lip on the reverse side of the under cover
grommet is set on the engine under cover.
⑤
⑥
①
②
• Check that the under cover grommet adheres to the
engine under cover securely.
③
21) Connect the power tilt switch 3P connector.
22) Install the power tilt switch 3P connector on the connector
bracket B.
Clamp the alternator fuse cable, PGM-FI main relay wire
and the power tilt switch wire with the wire harness clip.
[2] ALTERNATOR FUSE
CABLE
④
[3] CONNECTOR
BRACKET B
[1]
PGM-FI
MAIN RELAY
WIRE
[6]
WIRE
HARNESS
CLIP
[5]
POWER TILT
SWITCH WIRE
[4]
POWER TILT
SWITCH
3P CONNECTOR
23) Tighten the flush plug cap on the R. engine under cover.
24) Install the following parts.
– Electric part cover (P. 3-22)
– Front separate cover (P. 4-7)
– Engine cover (P. 4-2)
[1]
FLUSH PLUG
CAP
4-19
4. UNDER COVER FRONT BRACKET/
L./R. SIDE COVER BRACKETS
[1]
4 x 7 x 160 mm
VINYL TUBE
[2] COVER LOCK
CABLE A
[3]
LOCK
NUT
Remove the following pars.
– Engine cover (P. 4-2)
– Front separate cover (P. 4-7)
– L./R. engine under cover (P. 4-9)
– Remote control cable/grommet (P. 17-2)
a. UNDER COVER FRONT BRACKET
REMOVAL:
1) Remove the 4 x 7 x 160 mm vinyl tube and the 3.5 x 430
mm fuel tube from the under cover front bracket.
2) Loosen the cover lock cable A lock nut and remove the
cover lock cable A from the front lock.
3) Remove the trim angle sensor 3P connector and the power
tilt motor 2P connector from the connector bracket A.
[6]
FRONT
LOCK
[5] UNDER COVER
FRONT BRACKET
[1] POWER TILT MOTOR
2P CONNECTOR
Disconnect the trim angle sensor 3P connector and the
power tilt motor 2P connector.
[4] 3.5 x 430 mm
FUEL TUBE
[2] TRIM ANGLE
SENSOR
3P CONNECTOR
[3]
CONNECTOR
BRACKET A
4) Remove the undercase grommet C outside from the under
cover front bracket.
[1] WIRES
[2] TUBE
Pull out the tube and wires through the hole in the under
cover front bracket.
[5]
HOLE
[4]
UNDERCASE
GROMMET C
4-20
[3]
UNDER
COVER
FRONT
BRACKET
5) Remove the two 8 x 30 mm hex. bolts and the two 8 mm
washers, then remove the under cover front bracket.
[1]
UNDER COVER
FRONT BRACKET
[2] 8 mm WASHER (2)
[3] 8 x 30 mm
HEX. BOLT (2)
DISASSEMBLY:
1) Remove the 6 mm E-ring and the 8 mm washer from the lock front shaft.
2) Remove the lock front shaft from the under cover front bracket.
Remove the cover lock lever, two cover lock bushing As, 10 mm washer and the two 10 mm wave washers.
Check the cover lock bushing A for scores, scratches and other damage. Replace the cover lock bushing A with a new
one if necessary.
[8]
LOCK FRONT
SHAFT
[1]
UNDER COVER
FRONT BRACKET
[7]
COVER LOCK
BUSHING A (2)
[6]
10 mm WASHER
[2]
8 mm WASHER
[5]
10 mm WAVE
WASHER (2)
[4] COVER LOCK LEVER
4-21
[3] 6 mm E-RING
3) Remove the 6 mm E-ring from the cover open shaft.
Remove the cover lock bushing B in a manner of bringing
it to the lock lever return spring side.
[1]
COVER OPEN
SHAFT
[2]
UNDER
COVER
FRONT
BRACKET
With the return spring compressed with the bushing B,
hold the cover open shaft at a slightly inclined angle.
Remove the cover open shaft with care not to let its head
contact the under cover front bracket.
4) Remove the cover lock bushing B, 8 mm washer, and the
lock lever return spring from the cover open shaft.
Check the cover lock bushing B for scores, scratches and
other damage. Replace the cover lock bushing B with a new
one if necessary.
[4]
COVER LOCK
BUSHING B
[4]
COVER LOCK
BUSHING B
[3] HEAD
[5] 6 mm E-RING
[7]
LOCK
LEVER
RETURN
SPRING
[6] 8 mm WASHER
[1] COVER OPEN SHAFT
5) Remove the 6 mm E-ring, 8 mm washer and the cover lock
bushing A from the front lock.
[1] FRONT LOCK
Check the cover lock bushing A for scores, scratches and
other damage. Replace the cover lock bushing A with a new
one if necessary.
[2] 6 mm E-RING
[3]
8 mm WASHER
6) Lower the front lock and detach the hook of the cover lock
hook spring from the hole in the under cover front bracket.
[4]
COVER LOCK
BUSHING A
Remove the cover lock bushing from the under cover front
bracket and hold it at the front lock side.
7) Set the front lock in the position shown.
With the front lock set at a slightly inclined angle in the
position shown, remove the front lock from the under cover
front bracket.
[7]
BRACKET
CAP
Remove the cover lock bushing and the cover lock hook
spring from the front lock.
8) Remove the bracket cap.
[6]
COVER LOCK
BUSHING
[1] FRONT
LOCK
4-22
[5]
COVER LOCK
HOOK SPRING
COMPONENTS DRAWING:
[3]
6 mm E-RING (3)
[2]
UNDER COVER
FRONT BRACKET
[1]
LOCK FRONT SHAFT
[4] 8 mm WASHER (3)
[5]
COVER LOCK
BUSHING A (3)
[15] COVER LOCK
BUSHING B
[14] LOCK LEVER
RETURN SPRING
[13]
COVER OPEN
SHAFT
[12]
10 mm
WASHER
[11]
10 mm WAVE
WASHER (2)
[10]
COVER LOCK
LEVER
[9]
COVER LOCK
HOOK SPRING
[6]
BRACKET
CAP
[8] COVER LOCK
BUSHING
[7] FRONT LOCK
4-23
b. L. SIDE COVER BRACKET
REMOVAL:
[1]
COVER LOCK
CABLE A
1) Loosen the lock nuts on the cover lock cable A and B, and
disconnect the cover lock cable A and B from the side lock.
[2] LOCK NUT
[3]
COVER LOCK
CABLE B
[4] SIDE LOCK
[2] LOCK NUT
2) Remove the two 8 x 55 mm flange bolts and remove the
L. side cover bracket.
[1]
L. SIDE COVER
BRACKET
8 x 55 (2)
4-24
DISASSEMBLY:
1) Remove the 6 mm E-ring and the 8 mm washer from the
side lock.
2) Lower the side lock and detach the hook of the cover lock
hook spring from the hole in the L. side cover bracket.
[2] 6 mm E-RING
[1]
8 mm WASHER
[3]
COVER LOCK
BUSHING A (2)
Remove the side lock from the L. side cover bracket.
Remove the cover lock hook spring from the side lock.
3) Remove the two cover lock bushing As from the L. side
cover bracket.
Check the two cover lock bushing As for wear and damage
that are mounted on the side lock installation parts on the
L. side cover bracket.
Check the cover lock bushing A for scores, scratches and
other damage. Replace the cover lock bushing A with a new
one if necessary.
[5] COVER LOCK
HOOK SPRING
[6]
L. SIDE COVER
BRACKET
[4]
SIDE LOCK
COMPONENTS DRAWING:
[1] 8 mm WASHER
[2] 6 mm E-RING
[3]
COVER LOCK
CABLE B
[4]
L. SIDE COVER
BRACKET
[5]
COVER LOCK
BUSHING A (2)
[6]
COVER
LOCK HOOK
SPRING
[9] CABLE CLIP
4-25
[8]
COVER LOCK
CABLE A
8 x 55 (2)
[7] SIDE LOCK
c. R. SIDE COVER BRACKET
REMOVAL:
1) Loosen the lock nut on the cover lock cable B, and
disconnect the cover lock cable B from the side lock.
[1] LOCK NUT
[2] SIDE LOCK
[3] COVER LOCK
CABLE B
2) Remove the two 6 x 22 mm flange bolts and remove the R.
side cover bracket.
6 x 22 (2)
[1] R. SIDE COVER
BRACKET
4-26
DISASSEMBLY:
1) Remove the 6 mm E-ring and the 8 mm washer from the
side lock.
[2]
6 mm E-RING
[3] COVER LOCK
BUSHING A (2)
2) Lower the side lock and detach the hook of the cover lock
hook spring from the hole in the R. side cover bracket.
Remove the side lock from the R. side cover bracket.
[1]
8 mm WASHER
Remove the cover lock hook spring from the side lock.
3) Remove the two cover lock bushing As from the R. side
cover bracket.
[4]
COVER LOCK
HOOK SPRING
Check the cover lock bushing A for scores, scratches and
other damage. Replace the cover lock bushing A with a new
one if necessary.
[5]
R. SIDE COVER
BRACKET
COMPONENTS DRAWING:
[1] 6 mm E-RING
[2] 8 mm WASHER
[3] COVER LOCK
BUSHING A (2)
[4] R. SIDE COVER
BRACKET
6 x 22 (2)
[5] COVER LOCK
HOOK SPRING
[7]
COVER LOCK
CABLE B
4-27
[6] SIDE LOCK
d. R. SIDE COVER BRACKET/L. SIDE COVER
BRACKET/UNDER COVER FRONT BRACKET
ASSEMBLY
R. SIDE COVER BRACKET:
[2] 6 mm E-RING
[3] COVER LOCK
BUSHING A (2)
[1]
8 mm WASHER
1) Apply marine grease to the outer surface of the cover lock
bushing As, and install them on the R. side cover bracket.
2) Apply marine grease to the side lock shaft.
3) Install the cover lock hook spring on the side lock aligning
the hook of the spring with the hole in the side lock.
[7] (MARINE
GREASE)
[5]
HOLE
[4]
COVER LOCK
HOOK SPRING
Install the cover lock hook spring on the R. side cover
bracket aligning another hook of the spring with the hole in
the R. side cover bracket.
4) Install the 8 mm washer and the 6 mm E-ring on the side
lock.
[7] (MARINE
GREASE)
[5]
HOLE
[6] R. SIDE COVER
BRACKET
L. SIDE COVER BRACKET:
1) Apply marine grease to the cover lock bushing As and
install them on the L. side cover bracket.
[1] 8 mm
WASHER
[2] 6 mm E-RING
[3]
COVER LOCK
BUSHING A (2)
2) Apply marine grease to the side lock shaft.
3) Install the cover lock hook spring on the side lock aligning
the hook of the spring with the hole in the side lock.
[4]
HOLE
[7] (MARINE
GREASE)
Install the cover lock hook spring on the L. side cover
bracket aligning another hook of the spring with the hole in
the L. side cover bracket.
[5]
COVER
LOCK
HOOK
SPRING
4) Install the 8 mm washer and the 6 mm E-ring on the side
lock.
[4]
HOLE
[7] (MARINE
GREASE)
[8] L. SIDE COVER
BRACKET
4-28
[6] SIDE LOCK
UNDER COVER FRONT BRACKET:
1) Install the bracket cap.
2) Apply marine grease to the front lock shaft and the outer
surface of the cover lock bushing.
3) Apply marine grease to the outer surface of the cover lock
hook spring. Install the cover lock hook spring aligning its
hook with the hole in the front lock.
[1] COVER LOCK
BUSHING A
[4]
(MARINE
GREASE)
[9]
BRACKET CAP
4) Set the front lock in the position shown. Install the front
lock on the under cover front bracket at an inclined angle.
5) Install the cover lock hook spring on the under cover front
bracket aligning its hook with the hole in the under cover
front bracket.
[3]
8 mm WASHER
[2] 6 mm E-RING
[7]
HOLE
[8] COVER LOCK
BUSHING
[5]
COVER
LOCK
HOOK
SPRING
6) Apply marine grease to the outer surface of a cover lock
bushing A and install it on the under cover front bracket.
7) Install the 8 mm washer and the 6 mm E-ring on the front
lock.
[6]
FRONT
LOCK
[4] (MARINE
GREASE)
[7] HOLE
[6] FRONT LOCK
[10] UNDER COVER
FRONT BRACKET
[6]
FRONT
LOCK
8) Apply marine grease to the outer surface of the cover open
shaft, lock lever return spring, 8 mm washer and the cover
lock bushing B. Install the lock lever return spring, 8 mm
washer, and the cover lock bushing B on the cover open
shaft.
Hold the lock lever return spring compressed with the
cover lock bushing B.
[1]
UNDER
COVER
FRONT
BRACKET
9) Install the cover open shaft at an inclined angle in the under
cover front bracket.
[6]
COVER
OPEN
SHAFT
10) Install the cover lock bushing B in the under cover front
bracket.
[5] COVER LOCK
BUSHING B
11) Install the 6 mm E-ring on the cover open shaft.
[2] (MARINE GREASE)
4-29
[2] (MARINE
GREASE)
[3]
LOCK
LEVER
RETURN
SPRING
[4]
8 mm WASHER
12) Apply marine grease to the outer surface of the 10 mm washer, two 10 mm wave washers and the cover lock bushing
A and to the inner wall of the lock front shaft hole in the under cover front bracket.
13) Install the two cover lock bushing As, 10 mm washer and the two 10 mm wave washers on the cover lock lever as
shown. Install the cover lock lever on the under cover front bracket.
14) Install the lock front shaft.
Install the 8 mm washer and the 6 mm E-ring on the lock front shaft.
[1]
LOCK FRONT
SHAFT
[2]
UNDER COVER
FRONT BRACKET
[5] (MARINE GREASE)
[9] COVER LOCK
BUSHING A (2)
[3] 8 mm WASHER
[8] 10 mm WASHER
[7] 10 mm WAVE
WASHER (2)
[6] COVER LOCK LEVER
e. R. SIDE COVER BRACKET/L. SIDE COVER
BRACKET/UNDER COVER FRONT BRACKET
INSTALLATION
[5] (MARINE
GREASE)
[4] 6 mm E-RING
[1]
R. SIDE COVER
BRACKET
1) Install the R. side cover bracket with the two 6 x 22 mm
flange bolts.
6 x 22 (2)
2) Install the L. side cover bracket with the two 6 x 55 mm
flange bolts.
[1] L. SIDE COVER
BRACKET
8 x 55 (2)
4-30
3) Install the under cover front bracket securely with the two
8 x 30 mm hex. bolts and the two 8 mm washers.
[1]
UNDER COVER
FRONT BRACKET
[3]
8 x 30 mm
HEX. BOLT (2)
4) Pass the tube and the wires through the hole in the under
cover front bracket.
[1]
UNDER
COVER
FRONT
BRACKET
[5]
UNDERCASE
GROMMET C
5) Connect the trim angle sensor 3P connector and the power
tilt motor 2P connector. Install the power tilt motor 2P
connector on the lower side of the connector bracket A and
the trim angle sensor 3P connector on the upper side of the
connector bracket A.
[1]
TRIM ANGLE SENSOR
3P CONNECTOR
[2]
POWER TILT
MOTOR
2P CONNECTOR
[3]
CONNECTOR
BRACKET A
4-31
[2]
8 mm WASHER (2)
[2] WIRES
[3] TUBE
[4] HOLE
6) Check that the taped ends of the power tilt motor wire and
trim angle sensor wire are in alignment with the end of the
undercase grommet C. Install the undercase grommet C on
the under cover front bracket so they engage securely in
the groove of the undercase grommet C.
[2]
Wires and tube must not
interfere with the lock lever.
[1]
FRONT
LOCK
Move the front lock with a hand and check that the wires
and tube do not interfere with the front lock.
[3] TAPED PART
[7]
UNDERCASE
GROMMET C
[6]
SPEED
SENSOR
TUBE A
7) Adjust the length between the end of the cable outer and
the end of the nut of the cover lock cable A (longer one) so
that it is 20 mm (0.8 in) as shown.
8) Holding the nut in the position described in step 7, position
the inner cable end of the cover lock cable A on the front
lock and position the cable A nut on the under cover front
bracket.
Tighten the washer side lock nut securely.
• Check that the nut set in step 7 is not out of the position.
If it is, repeat the procedure from step 7.
9) Position the 4 x 7 x 160 mm vinyl tube and the 3.5 x 430 mm
fuel tube on the under cover front bracket.
[5] TRIM ANGLE
SENSOR WIRE
[4]
POWER
TILT
MOTOR
WIRE
20 mm (0.8 in)
[1]
UNDER COVER
FRONT
BRACKET SIDE
[2]
4 x 7 x 160 mm
VINYL TUBE
[3] COVER LOCK
CABLE A
[4]
LOCK
NUT
[5]
3.5 x 430 mm
FUEL TUBE
[6] FRONT LOCK
4-32
10) Adjust the length between the other end of the cable outer
and the end of the nut of the cover lock cable A so that it is
13 mm (0.5 in) as shown.
11) Holding the nut in the position described in step 10,
position the inner cable end of the cover lock cable A on the
side lock and position the cable A nut on the L. side cover
bracket.
Tighten the washer side lock nut securely.
• Check that the nut set in step 10 is not out of the position.
If it is, repeat the procedure from step 10.
12) Check for clearance between the end of the long hole in the
side lock and the inner cable end as shown. There must be
no clearance.
13 mm (0.5 in)
[2]
L. SIDE COVER
BRACKET SIDE
[1]
COVER LOCK
CABLE A
[4]
STOPPER
[3] LOCK
NUT
[5]
Contact.
If there is clearance, repeat the procedure from step 7.
Check that the side lock is in contact with the stopper of the
L. side cover bracket.
[7] No clearance.
[6] SIDE LOCK
13) Adjust the length between the end of the cable outer and
the end of the nut of the cover lock cable B (shorter one) so
that it is 13 mm (0.5 in) as shown.
14) Holding the nut in the position described in step 13,
position the inner cable end of the cover lock cable B on the
side lock and position the cable B nut on the L. side cover
bracket.
Tighten the washer side lock nut securely.
• Check that the nut set in step 13 is not out of the position.
If it is, repeat the procedure from step 13.
[1]
L. SIDE
COVER
BRACKET
SIDE
13 mm (0.5 in)
[2] COVER LOCK
CABLE B
[3] SIDE LOCK
[4] STOPPER
15) Check for clearance between the end of the long hole in the
side lock and the inner cable end as shown. There must be
no clearance.
[5]
Contact.
If there is clearance, repeat the procedure from step 7.
[6]
LOCK
NUT
Check that the side lock is in contact with the stopper of the
L. side cover bracket.
[7] No clearance.
[2] COVER
LOCK
CABLE B
4-33
16) Adjust the length between the other end of the cable outer
and the end of the nut of the cover lock cable B so that it is
13 mm (0.5 in) as shown.
17) Holding the nut in the position described in step 16,
position the inner cable end of the cover lock cable B on the
side lock and position the cable B nut on the R. side cover
bracket.
13 mm
(0.5 in)
Tighten the washer side lock nut securely.
• Check that the nut set in step 16 is not out of the position.
If it is, repeat the procedure from step 16.
[1]
COVER LOCK
CABLE B
[2]
R. SIDE
COVER
BRACKET
SIDE
[3] Contact.
[4]
STOPPER
18) Check for clearance between the end of the long hole in the
side lock and the inner cable end as shown. There must be
no clearance.
If there is clearance, repeat the procedure from step 7.
Check that the side lock is in contact with the stopper of the
R. side cover bracket.
[5] No clearance.
[7] LOCK NUT
19) After installing the cover lock cable A and B, operate the
cover lock lever and check the front lock and the L./R. side
locks for smooth operation.
20) Pull up the cover lock lever (i.e. release the cover lock).
Look down the cover lock bolt hole of each of the under
cover front bracket and the L./R. side cover brackets and
check that the front lock and the side lock do not appear.
[1] View of each bracket from the top:
[2] FRONT LOCK
or SIDE LOCK
21) If the front lock or side lock appears when looking down the
cover lock bolt hole, perform the following check.
<When L. side bracket side appears>
Loosen the lock nut at the cover lock cable A of the L. side
bracket, and adjust by turning the adjusting nut right or left.
<When R. side bracket side appears>
Loosen the lock nut at the cover lock cable B of the R. side
bracket, and adjust by turning the adjusting nut right or left.
[3]
COVER LOCK
BOLT HOLE
(The front lock
and side lock
must not appear
when viewing the
cover lock bolt
hole from the top
with the lever
pulled up.)
[4] L. SIDE COVER BRACKET SIDE:
[5] COVER LOCK
CABLE A
22) Install the following parts.
– Remote control cable/grommet (P. 17-5)
– L./R. engine under cover (P. 4-14)
– Front separate cover (P. 4-7)
– Engine cover (P. 4-2)
[7] ADJUSTING NUT
4-34
[6] SIDE LOCK
[6] LOCK NUT
5. PROGRAMMED FUEL INJECTION
1. SERVICE PRECAUTIONS
2. CIRCUIT DIAGRAM
3. VACUUM CONNECTIONS
4. PARTS LOCATION/ECM TERMINAL LAYOUT
5. TROUBLESHOOTING
6. TROUBLESHOOTING WITH HDS TESTER
7. TROUBLESHOOTING WITHOUT HDS
TESTER
8. IDLE CONTROL SYSTEM
9. FUEL SUPPLY SYSTEM
10. IAB (INTAKE AIR BYPASS) CONTROL
SYSTEM
11. VAPOR SEPARATOR/FUEL PUMP
(HIGH PRESSURE SIDE)
12. SILENCER CASE/THROTTLE BODY/
INTAKE MANIFOLD
13. FUEL INJECTOR/PRESSURE REGULATOR
14. FUEL PUMP (LOW PRESSURE SIDE)
5-1
BF135A•BF150A
15. FUEL STRAINER (LOW PRESSURE SIDE)/
WATER SEPARATOR
16. EOP (ENGINE OIL PRESSURE) SWITCH
(HIGH PRESSURE SIDE)
17. EOP (ENGINE OIL PRESSURE) SWITCH
(LOW PRESSURE SIDE)
18. ECT (ENGINE COOLANT TEMPERATURE)
SENSOR 1
19. ECT (ENGINE COOLANT TEMPERATURE)
SENSOR 2, 3, 4
20. BARO (BAROMETRIC PRESSURE)
SENSOR
21. KNOCK SENSOR
22. CMP (CAMSHAFT POSITION) SENSOR
23. CKP (CRANKSHAFT POSITION) SENSOR
24. VTEC SOLENOID VALVE (BF150A Only)
25. VAPOR CHAMBER/CHECK VALVE
26. EXHAUST MANIFOLD
SYSTEM DIAGRAM ...........................End of book
BF135A•BF150A
1. SERVICE PRECAUTIONS
• PGM-FI (PROGRAMMED FUEL INJECTION)
TROUBLESHOOTING
• Apply the recommended engine oil to the O-rings before
installation. Avoid using the vegetable oil and the alcoholic grease.
• First, check the MIL of the indicator.
• Be sure to turn the ignition switch OFF before disconnecting and connecting the ECM connector.
• After inspection and repair, clear the DTC (P. 5-14) or
reset the ECM memory (P. 5-57).
O-RING
INJECTOR
• CHECK AFTER OPERATION
PGM-FI MIL
• FUEL LINE SERVICE
• Do not smoke while working on the fuel system. Keep
open flame or sparks away from the work area.
• Disconnect the battery cable from the battery negative
(–) terminal.
• Before removing and installing the fuel line, relieve the
fuel pressure by loosening the service check bolt of the
high pressure side fuel strainer, as described in “How to
relieve fuel pressure” (P. 5-102).
SHOP TOWEL
SERVICE CHECK BOLT
12 N • m (1.2 kgf • m, 9 lbf • ft)
• Replace the sealing washers during reassembly.
• Replace the O-rings when the fuel line is removed/
installed or replaced.
• Check the parts for secure installation and the bolts,
screws and other fasteners for secure tightening.
• Connect the battery cable to the battery negative (–) terminal.
• FUEL LEAK CHECK
• Turn the ignition switch ON (but do not turn the starter)
after connecting the fuel lines. The fuel pump unit (high
pressure side) should operate for approximately 2 seconds and the fuel pressure in the high pressure side fuel
line should rise. Repeat this operation 2 or 3 times and
check for fuel leakage.
• WHEN THE BOAT IS EQUIPPED WITH RADIO
EQUIPMENT
• The ECM and its wires are designed to be unaffected by
radio waves. However, the ECM can malfunction when it
senses an extremely powerful electric wave. Note the following to avoid malfunction of the ECM.
• Install the antenna and the body of the radio equipment
at least 50 cm (20.0 in) away from the ECM, remote control cable A and the remote control box.
• Antenna wire must not be too long. Do not route the
antenna wire along the remote control cable A and other
cables/wires.
• Do not mount the radio equipment of large output power
on the boat. (The maximum output power of the radio
equipment should be 10W when mounted on a boat.)
• Install the D-GPS antenna and the body unit at least 3 m
(10 ft) away from the engine.
• Connect the D-GPS antenna ground wire to ground.
5-2
BF135A•BF150A
2. CIRCUIT DIAGRAM
To STARTER MOTOR
BATTERY
IGNITION SWITCH
PGM-FI MAIN RELAY
INJECTOR
IGNITION COIL
VTEC SOLENOID VALVE
IAC (IDLE AIR CONTROL) VALVE
KNOCK SENSOR
EOP (ENGINE OIL PRESSURE) SWITCH
(HIGH PRESSURE SIDE)
ECT (ENGINE COOLANT TEMPERATURE) SENSOR 4
5-3
ECT (ENGINE COOLANT TEMPERATURE) SENSOR 3
ECT (ENGINE COOLANT TEMPERATURE) SENSOR 2
IAT (INTAKE AIR TEMPERATURE) SENSOR
ECT (ENGINE COOLANT TEMPERATURE) SENSOR 1
TP (THROTTLE POSITION) SENSOR
BARO (BAROMETRIC PRESSURE) SENSOR
MAP (MANIFOLD ABSOLUTE PRESSURE) SENSOR
CKP (CRANKSHAFT POSITION) SENSOR
CMP (CAMSHAFT POSITION) SENSOR
FUEL PUMP (HIGH PRESSURE SIDE)
BF135A•BF150A
A/F (AIR FUEL RATIO) SENSOR
A/F (AIR FUEL RATIO) SENSOR RELAY
IAB (INTAKE AIR BYPASS) CONTROL VALVE
FUEL GAUGE
BUZZER
MIL
ACG INDICATOR LIGHT
IC REGULATOR (ALTERNATOR)
INDICATOR LIGHT
OVERHEAT INDICATOR LIGHT
OIL INDICATOR LIGHT
TACHOMETER PULSE CHECK CONNECTOR
TACHOMETER (OPTION)
DATA LINK CONNECTOR
EMERGENCY STOP SWITCH
TRIM METER (OPTION)
TRIM ANGLE SENSOR
EOP (ENGINE OIL PRESSURE) SWITCH
(LOW PRESSURE SIDE)
WATER LEVEL SWITCH
NEUTRAL SWITCH
5-4
BF135A•BF150A
3. VACUUM CONNECTIONS
To MOUNT
CASE
A
A
VAPOR SEPARATOR
FUEL PUMP
HIGH PRESSURE SIDE FUEL FILTER
VAPOR FILTER
SILENCER CASE
TP (THROTTLE POSITION) SENSOR
MAP (MANIFOLD ABSOLUTE PRESSURE)
SENSOR
IAC (IDLE AIR CONTROL) VALVE
VACUUM TANK
5-5
IAB (INTAKE AIR BYPASS) CONTROL SOLENOID
VALVE
DIAPHRAGM
INJECTOR
WATER SEPARATOR
FUEL STRAINER
BREATHER CHAMBER
FUEL PUMP (LOW PRESSURE SIDE)
PRESSURE REGULATOR
BF135A•BF150A
4. PARTS LOCATION/ECM TERMINAL LAYOUT
IAT (INTAKE AIR TEMPERATURE) SENSOR
BARO (BAROMETRIC PRESSURE) SENSOR
ECT (ENGINE COOLANT TEMPERATURE) SENSOR 2
INJECTOR
IAB (INTAKE AIR BYPASS) CONTROL SOLENOID
VALVE
KNOCK SENSOR
FUEL PUMP (HIGH PRESSURE SIDE)
WATER LEVEL SENSOR
TP (THROTTLE POSITION) SENSOR
MAP (MANIFOLD ABSOLUTE PRESSURE) SENSOR
IAC (IDLE AIR CONTROL) VALVE
5-6
BF135A•BF150A
A/F (AIR FUEL RATIO) SENSOR
VTEC SOLENOID VALVE
ECT (ENGINE COOLANT TEMPERATURE) SENSOR 4
CKP (CRANKSHAFT POSITION) SENSOR
ECT (ENGINE COOLANT TEMPERATURE) SENSOR 1
ECM (ENGINE CONTROL MODULE)
A/F (AIR FUEL RATIO) SENSOR RELAY
5-7
PGM-FI MAIN RELAY
EOP (ENGINE OIL PRESSURE) SWITCH
(HIGH PRESSURE SIDE)
EOP (ENGINE OIL PRESSURE) SWITCH
(LOW PRESSURE SIDE)
CMP (CAMSHAFT POSITION) SENSOR
ECT (ENGINE COOLANT TEMPERATURE) SENSOR 3
BF135A•BF150A
• ECM TERMINAL LAYOUT
ECM CONNECTOR A
HARNESS SIDE CONNECTOR
VIEWED FROM THE TERMINAL SIDE
Terminal
No.
Wire
color
Terminal
mark
1
G/W
LG2
Logic ground 2 (Common with B17)
2
G/R
SG2
Sensor ground 2
3
Not used
4
W/Bl
AFV1
A/F sensor (V)
Power source for the A/F sensor
5
W/Bu
PA
BARO sensor
At ignition switch ON: Approx. 3V
6
R/G
TOH3
ECT sensor 4
Detects cylinder block temperature.
7
Not used
8
Not used
9
Not used
10
Not used
Name
Content/Signal
11
Br/W
VCC2
Sensor power 2
At ignition switch ON: Approx. 5V
12
Lg/Bl
VCC3
Sensor power 3
At ignition switch ON: Approx. 5V
13
Lg/R
FLR2
Fuel pump relay 2
14
Bl/Y
AFC1
A/F sensor (C)
15
R/Bu
KS
Knock sensor
16
R
TOH2
ECT sensor 3
Detects exhaust port temperature.
17
Y/R
OPSH
EOP switch (High pressure side)
At switch ON: Approx. 0V
At switch OFF: Battery voltage
18
Not used
19
Br
EFD
Fuel filter water level switch
At switch ON (High water level): Approx. 0V
At switch OFF: Battery voltage
20
G/Y
VTS
VTEC solenoid valve
Power to drive solenoid valve:
High engine rpm (4,300 min-1/rpm or above): ON
21
G
FUP
Fuel gauge
Power to drive fuel gauge
22
Not used
23
Not used
24
Bl/R
EMS2
Emergency stop switch 2
At switch ON: Approx. 0V
At switch OFF: Battery voltage
25
G/O
LAFR
A/F sensor heater relay
Power to drive A/F sensor heater relay
26
Bl
SVS
IAB solenoid valve
Power to drive IAB solenoid valve
High engine rpm (4,300 min-1/rpm or above): ON
5-8
BF135A•BF150A
ECM CONNECTOR B
HARNESS SIDE CONNECTOR
VIEWED FROM THE TERMINAL SIDE
Terminal
No.
Wire
color
1
Not used
Terminal
mark
Name
Content/Signal
2
G
TDC
CMP sensor
CMP sensor signal
3
Bu
CRK
CKP sensor
CKP sensor signal
4
Br/Y
VCC1
Sensor power 1
Power for sensor (5V)
5
W/R
PB
MAP sensor
Detects vacuum at the intake manifold.
6
G/R
SG1
Sensor ground 1
7
R/Bl
THL
TP sensor
Detects throttle position.
8
R/W
TE
ECT sensor 1
Detects cylinder block engine temperature.
9
Not used
10
Lg/R
FLR1
Fuel pump relay 1
Power to drive fuel pump relay
11
R/Y
TA
IAT sensor
Detects intake air temperature.
12
R/Bl
TOH1
ECT sensor 2
Detects cylinder head temperature.
13
R/Bu
NTSW
Neutral switch
At switch ON (Neutral): Approx. 0V
At switch OFF: Battery voltage
14
P
OPSL
EOP switch (Low pressure side)
At switch ON: Approx. 0V
At switch OFF: Battery voltage
15
Bu
K-LINE
Communication signal
At ignition switch ON: Approx. 12V
16
Lg/W
SCS
Service check signal
17
G/Bl
LG1
Logic ground 1
18
Y/G
BUZZ
Buzzer
19
W/Bu
ACGL
Alternator indicator light
Inputs alternator indicator light ON signal.
20
Bl/R
EMS1
Emergency stop switch 1
At switch ON: Approx. 0V
21
Br
INJ1
No. 1 injector
Power to drive No. 1 injector
22
Bu
IGN1
No. 1 ignition coil
Outputs No. 1 ignition signal.
23
R
INJ2
No. 2 injector
Power to drive No. 2 injector
24
Bu/Bl
IGN2
No. 2 ignition coil
Outputs No. 2 ignition signal.
25
R/Bu
WARNL MIL
Power to turn MIL ON
26
G/W
EACVP
IAC valve (+)
Power to drive IAC valve (+)
Power to sound buzzer
At switch OFF: Battery voltage
27
Bu
INJ3
No. 3 injector
Power to drive No. 3 injector
28
W/G
IGN3
No. 3 ignition coil
Outputs No. 3 ignition signal
29
Y
INJ4
No. 4 injector
Power to drive No. 4 injector
30
Bu/R
IGN4
No. 4 ignition signal
Outputs No. 4 ignition signal
31
R
OHL
Overheat indicator light
Overheat indicator light ON line
32
Y
OPL
Oil pressure light
Oil indicator light ON line
33
Gr
TACHO
Tachometer pulse
34
Bl
EACVM IAC valve (–)
5-9
Drives tachometer.
Power to drive IAC valve (–)
BF135A•BF150A
ECM CONNECTOR C
HARNESS SIDE CONNECTOR
VIEWED FROM THE TERMINAL SIDE
Terminal
No.
Wire
color
Terminal
mark
1
Y/Bl
IGP1
ECM main power 1 (Common with C5)
2
G
PG1
Power ground 1 (Common with C6)
3
Bl/W
AFHT
A/F sensor heater
4
W
AFHT+
A/F sensor heater (+)
5
Y/Bl
IGP2
ECM main power 2 (Common with C1)
6
G/R
PG2
Power ground 2 (Common with C2)
Name
Content/Signal
At ignition switch ON: Battery voltage
At ignition switch ON: Battery voltage
5-10
BF135A•BF150A
5. TROUBLESHOOTING
The ECM (Engine Control Module) has the self-diagnosis
function which memorizes the failure code and turns the
MIL (Malfunction Indicator Light) ON when it detects an
abnormality with the input/output system.
• If the MIL does not come ON but the engine failure
(abnormality other than monitoring ECM) occurred,
detect the probable problem part by referring to the
Quick Reference Chart of Troubleshooting by System on
page 5-12, and troubleshoot accordingly.
• HOW TO CARRY OUT TROUBLESHOOTING
When the MIL comes ON or blinks or any abnormality
occurs during running, identify the problem detected by
ECM according to the following procedure, and troubleshoot accordingly.
To troubleshoot, connect the tester probe to a commercially available digital circuit tester. Note that the tester
probe must agree with the connector terminal of the digital circuit tester not to apply excessive force to the connector terminal.
1. Turn the ignition switch ON and check that the MIL
comes ON.
PGM-FI MIL
2. When the MIL is ON or blinking, check the DTC
(Diagnostic Trouble Code) using the HDS tester (P. 513).
Or, use the short connector to blink the MIL and troubleshoot the problem indicated by the number of blinks
of the MIL (P. 5-57).
5-11
3. Perform the troubleshooting by referring to the “Troubleshooting Guide by DTC” (P. 5-15) or “Troubleshooting Guide by No. of Blinks” (P. 5-59).
Check each connector and wire harness for secure
connection and damage before troubleshooting.
Repair the connector and wire harness if necessary.
4. After troubleshooting, perform repairs as needed and
perform the necessary work (P. 5-14 or 5-58).
BF135A•BF150A
• QUICK REFERENCE CHART OF TROUBLESHOOTING BY SYSTEM
When the MIL does not come ON but the engine becomes faulty, refer to the following troubleshooting chart and check
the parts in the numbered order shown on the chart.
Idle Control System
Check point
Idle
adjusting
screw
IAC
valve
Neutral
switch
Vacuum
pipe
Ref. page
5-94
5-95
17-13
5-5
Symptom
Engine does not start
2
1
Engine starts but stalls soon
1
2
3
Engine speed is higher than the specified idle speed
after warm up.
3
2
1
Engine speed is higher than the specified trolling speed
after warm up.
3
4
Engine speed is lower than the specified idle speed
after warm up.
2
1
3
Engine speed is lower than the specified trolling speed
after warm up.
2
1
3
Engine speed is not stable during idling and trolling.
2
1
1
2
4
3
Low Pressure Fuel Supply System
Check point
Low
pressure
fuel line
Water
separator
Low
pressure
fuel strainer
Low
pressure
fuel pump
Vapor
separator
Ref. page
5-142
5-111
Symptom
5-104
3-19
3-15
Engine does not start
3
1
2
4
Engine starts but stalls soon
3
1
2
4
1
2
1
2
Engine speed is not stable during idling and trolling,
or engine stalls.
Engine sometimes misfires or stalls soon
3
4
Engine stalls soon at hot restart of the engine.
1
High Pressure Fuel Supply System
Check point
High
pressure
fuel line
Ref. page
5-104
5-107
1
2
Engine starts but stalls soon
1
2
Engine speed is not stable during idling and trolling,
or engine stalls.
1
Symptom
Engine does not start
High
High
pressure
pressure
fuel pump fuel strainer
3-18
Fuel
injector
Pressure
regulator
5-105
5-106
3
3
2
Engine speed does not rise
1
3
Engine sometimes misfires or stalls soon
1
3
3
3
3
2
2
3
5-12
BF135A•BF150A
6. TROUBLESHOOTING WITH HDS
TESTER
• DTC (DIAGNOSTIC TROUBLE CODE) CHECK
1. Remove the engine cover and the electric part cover
(Section 4).
2. Disconnect the 4P (Red) connector and connect the
HDS pocket tester to the data link connector (DLC).
4P CONNECTOR
(RED)
• WHEN USING HDS POCKET TESTER DURING
CRUISING
1. Remove the engine cover and the electric part cover
(Section 4).
2. Remove the cap from the under cover front bracket.
Route the extension wire in the HDS pocket tester kit
through the front cover bracket.
• Set the grommet on the under cover front bracket
securely.
UNDER COVER
FRONT BRACKET
CAP
TESTER WIRE
DATA LINK
CONNECTOR (DLC)
3. Disconnect the red 4P connector from the DLC (Data
Link Connector) and secure the DLC wire as sown.
• Route the extension wire of the tester in the position
shown so that it does not interfere with the parts.
4. Connect the extension wire to the DLC.
DLC
CLAMP
HDS POCKET
TESTER
3. Turn the ignition switch ON and check the DTC shown
on the HDS pocket tester.
Refer to the HDS pocket tester's operation manual for
how to use the HDS pocket tester.
5-13
EXTENSION WIRE
OF TESTER
BF135A•BF150A
5. Secure the extension wire as shown with the band.
EXTENSION WIRE
OF TESTER
• TO CLEAR DTC
1. Remove the engine cover and the electric part cover.
2. Connect the HDS pocket tester to the data link connector (DLC).
3. Turn the ignition switch ON.
4. Clear the DTC using the HDS pocket tester.
Refer to the HDS pocket tester's operation manual for
how to use the HDS pocket tester.
• When abnormality remains in the system, the DTC
cannot be cleared as the ECM continues self-diagnosis.
WIRE BAND
6. Connect the extension wire to the HDS pocket tester.
7. Install the electric part cover and the engine cover in
the reverse order of removal.
• FINAL PROCEDURE
(AFTER TROUBLESHOOTING)
1. Clear the DTC.
2. Disconnect the HDS pocket tester wire from the data
link connector.
3. Install the cap on the under cover front bracket.
4. Install the electric part cover and the engine cover.
5-14
BF135A•BF150A
a. TROUBLESHOOTING GUIDE BY DTC
DTC
–
or
PGM-FI MIL
Detected unit
MIL does not
ECM
come ON/blinks
0-2,
Probable problem part
• Open circuit in MIL wire
• Open circuit in ECM ground wire or
poor grounding
0-8
• Faulty ECM
MIL stays ON
ECM
• Open circuit in ECM power supply line
or
• Short circuit in data link connector wire
0-2,
• Short circuit in MIL wire
0-5,
• Short circuit in sensor power supply line
0-8
• Faulty ECM
3-1
5-18
• Blown MIL bulb
0-5,
–
Ref. page
MIL stays ON
MAP sensor (Voltage too low)
• Short circuit in MAP sensor wire
5-21
5-28
• Faulty MAP sensor
• Faulty ECM
3-2
MIL stays ON
MAP sensor (Voltage too high)
• Open circuit in MAP sensor wire
5-29
• Faulty MAP sensor
• Faulty ECM
4-1
MIL stays ON
CKP sensor (No pulse)
• Open/short circuit in CKP sensor wire
5-30
• CKP sensor
• Faulty ECM
4-2
MIL stays ON
CKP sensor (Abnormal pulse)
• Faulty CKP sensor
5-32
• Faulty ECM
6-1
MIL stays ON
ECT sensor 1 (Voltage too low)
• Short circuit in ECT sensor 1
5-33
• Faulty ECT sensor 1
• Faulty ECM
6-2
MIL stays ON
ECT sensor 1 (Voltage too high)
• Open circuit in ECT sensor 1 wire
5-33
• Faulty ECT sensor 1
• Faulty ECM
7-1
MIL stays ON
TP sensor (Voltage too low)
• Open/short circuit in TP sensor wire
5-34
• Faulty TP sensor
• Faulty ECM
7-2
MIL stays ON
TP sensor (Voltage too high)
• Open circuit in TP sensor wire
5-35
• Faulty TP sensor
• Faulty ECM
8-1
MIL stays ON
CMP sensor (No pulse)
• Open/short circuit in CMP sensor
5-36
• Faulty DC1 sensor
• Faulty ECM
8-2
MIL stays ON
CMP sensor (Abnormal pulse)
• Open/short circuit in CMP sensor
• Faulty CMP sensor
• Faulty ECM
–: DTC does not appear.
5-15
5-37
BF135A•BF150A
DTC
PGM-FI MIL
Detected unit
10-1
MIL comes ON
IAT sensor (Voltage too low)
Probable problem part
• Short circuit in IAT sensor wire
Ref. page
5-38
• Faulty IAT sensor
• Faulty ECM
10-2
MIL comes ON
IAT sensor (Voltage too high)
• Open circuit in IAT sensor wire
5-38
• Faulty IAT sensor
• Faulty ECM
13-1
MIL comes ON
BARO sensor (Voltage too low)
• Short circuit in BARO sensor wire
5-39
• Faulty BARO sensor
• Faulty ECM
13-2
MIL comes ON
BARO sensor (Voltage too high)
• Open circuit in BARO sensor wire
5-40
• Faulty BARO sensor
• Faulty ECM
14-1
MIL comes ON
IAC valve (Abnormal current flow)
• Open/short circuit in IAC valve wire
5-41
• Faulty IAC valve
• Faulty ECM
21-1
MIL comes ON
VTEC solenoid valve
• Open/short circuit in VTEC solenoid valve
(Abnormal output)(BF150A only)
• Faulty VTEC solenoid valve
5-42
• Faulty ECM
23-1
MIL comes ON
Knock sensor (Abnormal detection)
• Open/short circuit in knock sensor wire
5-43
• Faulty knock sensor
• Faulty ECM
41-3
MIL comes ON
A/F sensor heater
(Abnormal current flow)
• Open/short circuit in A/F sensor heater wire
5-44
• Faulty A/F sensor heater
• Faulty ECM
41-4
MIL comes ON
A/F sensor heater
• Open/short circuit in A/F sensor heater wire
(Abnormal current flow)
• Faulty A/F sensor heater
5-46
• Faulty ECM
48-5
MIL comes ON
A/F sensor heater
• Open circuit in A/F sensor heater wire
(Abnormal current flow)
• Faulty A/F sensor
5-49
• Faulty ECM
48-6
MIL comes ON
A/F sensor heater
• Short circuit in A/F sensor wire C line
(Abnormal current flow)
• Faulty A/F sensor
5-50
• Faulty ECM
48-7
MIL comes ON
A/F sensor heater
(Abnormal current flow)
• Short circuit in A/F sensor wire V line
5-50
• Faulty A/F sensor
• Faulty ECM
5-16
BF135A•BF150A
DTC
PGM-FI MIL
140-1
MIL comes ON
Detected unit
ECT sensor 2 (Voltage too low)
Probable problem part
• Short circuit in ECT sensor 2 wire
Ref. page
5-51
• Faulty ECT sensor 2
• Faulty ECM
140-2
MIL comes ON
ECT sensor 2 (Voltage too high)
• Open circuit in ECT sensor 2 wire
5-51
• Faulty ECT sensor 2
• Faulty ECM
141-1
MIL comes ON
ECT sensor 3 (Voltage too low)
• Short circuit in ECT sensor 3 wire
5-52
• Faulty ECT sensor 3
• Faulty ECM
141-2
MIL comes ON
ECT sensor 3 (Voltage too high)
• Open circuit in ECT sensor 3 wire
5-53
• Faulty ECT sensor 3
• Faulty ECM
142-1
143-1
MIL comes ON
MIL comes ON
EOP switch
• Open/short circuit in EOP switch wire
(Abnormal signal)
• Faulty ECM
ECT sensor 4 (Voltage too low)
• Short circuit in ECT sensor 4 wire
5-54
5-55
• Faulty ECT sensor 3
• Faulty ECM
143-2
MIL comes ON
ECT sensor 4 (Voltage too high)
• Open circuit in ECT sensor 4 wire
5-56
• Faulty ECT sensor 4
• Faulty ECM
When multiple DTC’s main codes are indicated:
DTC
main
codes
PGM-FI MIL
7, 13
MIL comes ON
Detected unit
Probable problem part
• Open circuit in VCC line
(power source for sensor)
6,7
MIL comes ON
10,13
48,140
141,143
5-17
• Open circuit in SG (sensor ground) line
Ref. page
BF135A•BF150A
b. TROUBLESHOOTING
• MIL Does Not Come ON
1. Fuse check
-1. Turn the ignition switch ON and check that the warning
buzzer sounds twice.
Does the buzzer sound twice?
YES – Perform “6. Alternator indicator light check”
NO – Go to the step 2.
2. Main power line check
-1. Disconnect the remote control harness 14P connector.
-2. Measure the voltage between the No. 3 (White/Black)
terminal of the main harness side 14P connector and
the engine ground.
• Note that voltage is constantly applied to the
White/Black terminal. Take care not to short-circuit
the terminal.
MAIN HARNESS SIDE
14P CONNECTOR
BLACK/WHITE
-2. Check the No. 4 (15A) fuse.
Is the fuse normal?
YES – Go to the step 3.
NO – Repair open in the wire between the No. 4
fuse and the ECM, and between the No. 4
fuse and the injector. After repair, replace the
No. 4 fuse.
-3. Check the No. 7 (30A) fuse.
Is the fuse normal?
YES – Go to the step 4.
NO – Repair short in the wire between the PGM-FI
main relay and the fuse box, and between the
PGM-FI main relay and the starter magnetic
switch. After repair, replace the No. 7 fuse.
VIEWED FROM THE
TERMINAL SIDE
Is there the battery voltage?
YES – Go to the step 3.
NO – Repair open in the main harness.
-3. Turn the ignition switch ON. Check for continuity
between the No. 1 (White/Black) terminal and the No.
2 (Black/Yellow) terminal of the remote control box harness side 14P connector.
-4. Check the No. 3 (30A) fuse.
Is the fuse normal?
YES – Perform “2. Main power line check”.
NO – Repair short in the wire between the fuse box
and the ignition switch, between the fuse box
and the alternator, and between the fuse box
and the power trim/tilt switch or power tilt
switch. After repair, replace the No. 3 fuse.
REMOTE CONTROL
HARNESS SIDE 14P
CONNECTOR
BLACK/YELLOW
WHITE/BLACK
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Perform “3. IGP power line check”.
NO – Go to the step 4.
-4. Check the ignition switch (P. 16-9).
Is the ignition switch normal?
YES – Repair open in the remote control box harness.
NO – The ignition switch is faulty.
5-18
BF135A•BF150A
3. IGP power line check
-1. Turn the ignition switch OFF. Disconnect the PGM-FI
main relay 6P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 2 (Black/Yellow) terminal of the PGMFI main relay harness side 6P connector and the
engine ground.
4. ECM power line check
-1. Turn the ignition switch OFF and disconnect the fuse
box 3P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 3 (Yellow/Black) terminal of the fuse
box side 3P connector and the engine ground.
PGM-FI MAIN RELAY HARNESS
SIDE 6P CONNECTOR
FUSE BOX SIDE 3P CONNECTOR
BLACK/YELLOW
YELLOW/BLACK
VIEWED FROM THE
TERMINAL SIDE
Is there the battery voltage?
YES – Go to the step 3.
NO – Repair open in the main harness.
-3. Turn the ignition switch OFF. Check for continuity
between the No. 6 (Black) terminal of the PGM-FI main
relay 6P connector and the engine ground.
PGM-FI MAIN RELAY HARNESS
SIDE 6P CONNECTOR
BLACK
VIEWED FROM THE
TERMINAL SIDE
Is there the battery voltage?
YES – Go to the step 3.
NO – The PGM-FI main relay is faulty, or the fuse
box is faulty.
-3. Turn the ignition switch OFF and disconnect the ECM
connector C.
-4. Check for the continuity between the No. 2 (Yellow/
Black) terminal of the fuse box harness side 3P connector and the respective terminals of the No. 1
(Yellow/Black) and No. 5 (Yellow/Black) terminals of
the ECM connector C.
ECM CONNECTOR C
IGP2
(YELLOW/BLACK)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Perform “4. ECM power line check”.
NO – Repair open in the main harness (Black).
IGP1
(YELLOW/BLACK)
FUSE BOX HARNESS
SIDE 3P CONNECTOR
YELLOW/BLACK
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Perform “5. MIL power line check”.
NO – Repair open in the wire of the main harness.
5-19
BF135A•BF150A
5. MIL power line check
-1. Turn the ignition switch OFF and disconnect the fuse
box 3P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 2 (Yellow/Red) terminal of the fuse
box side 3P connector and the engine ground
6. Alternator indicator light check
-1. Turn the ignition switch ON and check the alternator
indicator light.
FUSE BOX SIDE 3P CONNECTOR
7. MIL line check
-1. Turn the ignition switch OFF and disconnect the ECM
connector B.
-2. Disconnect the MIL 6P connector.
-3. Check for continuity between the No. 25 (Red/Blue)
terminal of the ECM harness side connector B and the
No. 4 (Red/Blue) terminal of the MIL harness side 6P
connector.
YELLOW/RED
VIEWED FROM THE
TERMINAL SIDE
Is there the battery voltage?
YES – Go to the step 3.
NO – The PGM-FI main relay is faulty.
-3. Turn the ignition switch OFF and connect the fuse box
3P connector.
-4. Disconnect the MIL 6P connector.
-5. Turn the ignition switch ON. Measure the voltage
between the No. 6 (Yellow/Black) terminal of the MIL
6P harness side connector and the engine ground.
MIL HARNESS SIDE
6P CONNECTOR
YELLOW/BLACK
Does the alternator indicator light come ON?
YES – Perform “8. Function test”.
NO – Replace the MIL.
MIL HARNESS SIDE
6P CONNECTOR
ECM CONNECTOR B
WARNL
(RED/BLUE)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Go to the step 4.
NO – Repair open in the main harness.
-4. Check for continuity between the No. 4 (Yellow/ Black)
terminal and the No. 6 (Red/Blue) terminal of the MIL
6P connector.
MIL 6P CONNECTOR
VIEWED FROM THE
TERMINAL SIDE
Is there the battery voltage?
YES – Perform “6. Alternator indicator light check”.
NO – Repair open in the main wire harness.
YELLOW/BLACK
RED/BLUE
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Substitute a known-good ECM and recheck.
NO – MIL is faulty or open circuit in the MIL harness
wire.
5-20
BF135A•BF150A
8. Function test
-1. Turn the ignition switch OFF and connect the HDS
pocket tester.
-2. Turn the ignition switch ON and perform the function
test. (See the HDS pocket tester's operation manual for
the test procedure.)
Does the MIL blink?
YES – Substitute a known-good ECM and recheck.
NO – Check the MIL.
If the MIL is normal, repair the main wire harness (open in the Red/Blue wire between the
MIL and ECM).
• MIL Comes ON but DTC Code
Does Not Appear
1. ECM power line check
-1. Turn the ignition switch OFF and disconnect the ECM
connector C.
-2. Turn the ignition switch ON. Measure the voltage
between the respective terminals of the No. 2
(Yellow/Black) and No. 6 (Yellow/Black) terminals of the
ECM connector C and the engine ground.
ECM CONNECTOR C
IGP2
(YELLOW/BLACK)
IGP1
(YELLOW/BLACK)
VIEWED FROM THE
TERMINAL SIDE
Is there the battery voltage?
YES – Perform “2. Data link connector check”.
NO – Repair open in the main harness.
2. Data link connector check
-1. Turn the ignition switch OFF and disconnect the HDS
pocket tester.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 4 (Yellow/Red) terminal of the data
link connector and the engine ground.
DATA LINK CONNECTOR
YELLOW/RED
VIEWED FROM THE
TERMINAL SIDE
Is there the battery voltage?
YES – Go to the step 3.
NO – Repair open in the main harness.
5-21
BF135A•BF150A
-3. Turn the ignition switch OFF and disconnect the ECM
connector B.
-4. Check for the continuity between the No. 3 (Light
green/White) terminal of the data link connector and
the engine ground.
DATA LINK CONNECTOR
Is there the continuity?
YES – Perform “3. DTC recheck”.
NO – Repair open in the main harness.
3. DTC recheck
-1. Turn the ignition switch OFF and connect the HDS
pocket tester.
-2. Turn the ignition switch ON and check the DTC with
the HDS pocket tester.
LIGHT GREEN/WHITE
Is the main code 0 (either of 0-2, 0-5 or 0-8)?
YES – Substitute a known-good ECM and recheck.
NO – Troubleshoot the problem of the DTC.
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the main harness.
NO – Go to the step 5.
-5. Check for the continuity between the No. 3 (Light
green/White) terminal of the data link connector and
the No. 16 (Light green/White) terminal of the ECM
harness side connector B.
ECM CONNECTOR B
DATA LINK
CONNECTOR
VIEWED FROM THE
TERMINAL SIDE
SCS
(LIGHT GREEN/
WHITE)
Is there the continuity?
YES – Go to the step 6.
NO – Repair open in the main harness.
-6. Check for the continuity between the service check
connector No. 1 (Black) terminal and the engine
ground.
DATA LINK
CONNECTOR
GND
(BLACK)
VIEWED FROM THE
TERMINAL SIDE
5-22
BF135A•BF150A
• Alert System Initial Operation Is
Faulty
1. Function test
-1. Turn the ignition switch OFF and connect the HDS
pocket tester.
-2. Turn the ignition switch ON and test the buzzer using
the HDS pocket tester.
Does the buzzer sound?
YES – Go to the step 3.
NO – Perform “2. Buzzer line check”.
2. Buzzer line check
-1. Turn the ignition switch OFF and disconnect the
Yellow/Green terminal from the buzzer.
-2. Connect the Yellow/Green terminal of the buzzer to the
Black terminal with a jumper wire to short.
-3. Turn the ignition switch ON and check that the buzzer
sounds.
Does the buzzer sound?
YES – Repair open in the wire harness (wire
between the buzzer and ECM).
NO – Go to the step 4.
-3. Test the MIL using the HDS pocket tester.
-4. Perform the unit check of the buzzer.
Does the MIL blink?
YES – Go to the step 4.
NO – Perform “3. MIL line check”.
Is the buzzer normal?
YES – Go to the step 5.
NO – The buzzer is faulty.
-4. Test the overheat indicator light using the HDS pocket
tester.
Does the overheat indicator light blink?
YES – Go to the step 5.
NO – Perform “4. Overheat indicator line check”.
-5. Test the oil pressure indicator light using the HDS
pocket tester.
Does the oil pressure indicator light blink?
YES – End of the test
NO – Perform “5. Oil pressure indicator line check”.
-5. Perform the unit check of the ignition switch (P. 16-9).
Is the ignition switch normal?
YES – Go to the step 6.
NO – The ignition switch is faulty.
-6. Disconnect the remote control box harness side 14P
connector.
-7. Turn the ignition switch ON. Check for the continuity
between the No. 1 (White/Black) and the No. 2
(Black/Yellow) terminals of the remote control box harness side 14P connector.
REMOTE CONTROL BOX
HARNESS SIDE 14P
CONNECTOR
BLACK/YELLOW
WHITE/BLACK
VIEWED FROM THE
TERMINAL SIDE
Is there continuity?
YES – Repair open in the main harness.
NO – Repair open in the remote control box harness.
5-23
BF135A•BF150A
3. MIL line check
-1. Turn the ignition switch OFF and disconnect the MIL
6P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 2 (Yellow/Red) terminal of the MIL 6P
main harness side connector and the engine ground.
MIL HARNESS SIDE 6P
CONNECTOR
-5. Check for continuity between the No. 4 (Yellow/ Black)
terminal and the No. 6 (Red/Blue) terminal of the MIL
6P connector.
MIL 6P CONNECTOR
YELLOW/BLACK
RED/BLUE
YELLOW/RED
VIEWED FROM THE
TERMINAL SIDE
VIEWED FROM THE
TERMINAL SIDE
Is there the battery voltage?
YES – Go to the step 3.
NO – Repair open in the main wire harness.
Is there the continuity?
YES – Substitute a known-good ECM and recheck.
NO – The MIL is faulty or repair open in the MIL harness.
-3. Turn the ignition switch OFF and disconnect the ECM
connector B.
-4. Check for the continuity between the No. 25 (Red/Blue)
terminal of the ECM harness side connector B and the
No. 4 (Red/Blue) terminal of the MIL main harness side
6P connector.
MIL HARNESS SIDE
6P CONNECTOR
ECM CONNECTOR B
WHITE/BLACK
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Go to the step 5.
NO – Repair open in the main harness.
5-24
BF135A•BF150A
4. Overheat indicator line check
-1. Turn the ignition switch OFF. Disconnect the Red terminal of the indicator light and connect the Black terminal to short.
-2. Turn the ignition switch ON and check the overheat
indicator light.
Does the overheat indicator light come ON?
YES – Repair open in the wire harness (between the
ECM and the indicator light).
NO – Go to the step 3.
-3. Turn the ignition switch OFF and connect the indicator
light Red terminal.
-4. Disconnect the remote control harness 14P connector.
-5. Check for the continuity between the No. 7 (Red) terminal and the No. 2 (Black/Yellow) terminal of the
remote control harness side 14P connector.
-3. Turn the ignition switch OFF and connect the indicator
light Yellow terminal.
-4. Disconnect the remote control harness 14P connector.
-5. Check for the continuity between the No. 6 (Yellow) and
the No. 2 (Black/Yellow) terminals of the remote control
harness side 14P connector.
REMOTE CONTROL
HARNESS SIDE 14P
CONNECTOR
BLACK/YELLOW
YELLOW
VIEWED FROM THE
TERMINAL SIDE
REMOTE CONTROL
HARNESS SIDE 14P
CONNECTOR
Is there the continuity?
YES – Repair open in the main harness.
NO – The indicator light is faulty or repair open in
the remote control harness wire.
BLACK/YELLOW
RED
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair open in the wire of the main harness.
NO – The indicator light is faulty or repair open in
the remote control harness.
5. Oil pressure indicator line check
-1. Turn the ignition switch OFF. Disconnect the Yellow terminal of the indicator light and connect the Black terminal to short.
-2. Turn the ignition switch ON and check the oil pressure
indicator light.
Does the oil pressure indicator light come ON?
YES – Go to the step 3.
NO – Repair open in the wire harness (between the
ECM and the indicator light).
5-25
BF135A•BF150A
• Neutral Switch Malfunction
• Before following test, perform the neutral position check.
Engine speed does not increase in gears (BF150A only).
1. Switch condition check with the HDS pocket tester
-1. Turn the ignition switch OFF and connect the HDS
pocket tester.
-2. Turn the ignition switch ON and check the neutral
switch condition using the HDS pocket tester.
Does the switch position agree with the indication of
the tester?
YES – Substitute a known-good ECM and recheck.
NO – Perform “2. Neutral switch line check”.
2. Neutral switch line check
-1. Turn the neutral switch OFF and disconnect the neutral
switch 2P connector.
-2. Check for the continuity between the No. 1 (Black/Blue)
terminal of the neutral switch harness side 2P connector and the engine ground.
NEUTRAL SWITCH HARNESS
SIDE 2P CONNECTOR
BLACK/BLUE
-4. Disconnect the ECM connector B.
-5. Check for the continuity between the No. 13
(Black/Blue) terminal of the ECM harness side connector B and the No. 1 (Black/Blue) terminal of the
neutral switch harness side 2P connector.
ECM CONNECTOR B
NEUTRAL SWITCH
HARNESS SIDE 2P
CONNECTOR
NTSW
(BLACK/BLUE)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Perform “3. Neutral switch check”.
NO – Repair open in the main harness.
3. Neutral switch check
-1. Turn the ignition switch OFF and disconnect the neutral switch 2P connector.
-2. Check for the continuity between the No. 1 (Black) terminal and the No. 2 (Black/Blue) terminal of the neutral
switch side 2P connector.
NEUTRAL SWITCH SIDE 2P
CONNECTOR
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire of the main harness.
NO – Go to the step 3.
-3. Check for the continuity between the No. 2 (Black) terminal of the neutral switch harness side 2P connector
and the engine ground.
NEUTRAL SWITCH HARNESS
SIDE 2P CONNECTOR
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity with the gear in Neutral and
no continuity with the gear in other than Neutral?
YES – Substitute a known-good ECM and recheck.
NO – The neutral switch is faulty.
BLACK
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Go to the step 4.
NO – Repair open in the main wire harness.
5-26
BF135A•BF150A
• Tachometer Malfunction
1. Engine speed check using the HDS pocket tester.
-1. Turn the ignition switch OFF and connect the HDS
pocket tester.
-2. Start the engine and check the engine speed with the
HDS pocket tester.
-4. Check for the continuity between the No. 12 (Gray) terminal of the main harness side 14P connector and the
No. 33 (Gray) terminal of the ECM harness side connector B.
MAIN HARNESS SIDE
14P CONNECTOR
ECM CONNECTOR B
Do the tachometer and tester readings agree?
YES – Normal (Temporary problem has been
removed.)
NO – Perform “2. Tachometer power line check”.
*Tolerance of genuine Honda tachometer:
At 2,000 rpm:±160 rpm
At 4,000 rpm:+200 rpm
–150 rpm
At 6,000 rpm:+200 rpm
–150 rpm
2. Tachometer power line check
-1. Turn the ignition switch OFF and disconnect the
Yellow/Black and the Black terminals of the tachometer.
-2. Turn the ignition switch ON and measure the voltage
between the meter harness side Yellow/Black and the
Black terminals.
Is there the battery voltage?
YES – Perform “3. Tachometer pulse line check”.
NO – Repair open in the wire of the meter harness.
3. Tachometer pulse line check
-1. Turn the ignition switch OFF and disconnect the ECM
connector B.
-2. Disconnect the remote control harness 14P connector.
-3. Check for the continuity between the No. 12 (Gray) terminal of the main harness side 14P connector and the
engine ground.
MAIN HARNESS SIDE
14P CONNECTOR
GRAY
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the main harness.
NO – Go to the step 4.
5-27
TACHO
(GRAY)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Check for open in the remote control harness
and meter harness wires. If the harnesses are
normal, substitute a known-good ECM and
recheck.
NO – Repair open in the wire of the main harness.
BF135A•BF150A
• ECM Troubleshooting
• MAP Sensor Troubleshooting
DTC 0-2, 0-5, 0-8: Inside of ECM is faulty
DTC 3-1: MAP sensor voltage is low
1. Symptom reproduction test
-1. Connect the HDS pocket tester.
-2. Turn the ignition switch ON and wait for 1 second or
more.
-3. Clear the DTC once.
-4. Start the engine and check the DTC again.
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Turn the ignition switch ON.
-3. Check the MAP sensor voltage using the HDS pocket
tester.
Does the DTC 0-2, 0-5, and/or 0-8 appear?
YES – Substitute a known-good ECM and recheck.
NO – Temporary failure inside ECM (Disappeared)
Is the measured voltage 0.22 to 3.15V?
YES – Temporary failure (Disappeared)
NO – Perform “2. MAP sensor signal line short-circuit test”.
2. MAP sensor signal line short-circuit test
-1. Turn the ignition switch OFF and disconnect the MAP
sensor 3P connector.
-2. Disconnect the ECM connector A.
-3. Check for the continuity between the No. 2 (White/Red)
terminal of the MAP sensor harness side 3P connector and the body ground.
MAP SENSOR HARNESS
SIDE 3P CONNECTOR
PB (WHITE/RED)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the MAP
sensor and ECM.
NO – Perform “3. MAP sensor check”.
3. MAP sensor check
-1. Connect the ECM connector A and the MAP sensor
3P connector.
-2. Turn the ignition switch ON and read the MAP sensor
voltage using the HDS pocket tester.
Is the voltage 2.76 – 2.96V?
YES – Substitute a known-good ECM and recheck.
NO – Replace the MAP sensor.
5-28
BF135A•BF150A
DTC 3-2: MAP sensor voltage is high
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Turn the ignition switch ON.
-3. Check PB voltage using the HDS pocket tester.
Is the measured voltage 0.22 – 3.15V?
YES – Temporary failure (Disappeared)
NO – Perform “2. MAP sensor power line check”.
2. MAP sensor power line check
-1. Turn the ignition switch OFF and disconnect the MAP
sensor 3P connector.
-2. Turn the ignition switch ON.
-3. Measure the voltage between the No. 3 (Brown/Yellow)
terminal and the No. 1 (Green/Red) terminal of the
MAP sensor harness side 3P connector.
MAP SENSOR HARNESS
SIDE 3P CONNECTOR
SG1
(GREEN/RED)
VCC1
(BROWN/YELLOW)
VIEWED FROM THE
TERMINAL SIDE
Is the measured voltage 4.75 – 5.25V?
YES – Perform “5. MAP sensor signal line open circuit check”.
NO – Perform “3. MAP sensor power line open circuit check”.
3. MAP sensor power line open circuit check
-1. Turn the ignition switch OFF and disconnect the ECM
connector B.
-2. Check for the continuity between the No. 3
(Brown/Yellow) terminal of the MAP sensor harness
side 3P connector and the No. 4 (Brown/Yellow) terminal of the ECM harness side connector B.
MAP SENSOR
HARNESS SIDE
3P CONNECTOR
5-29
4. MAP sensor ground line open circuit check
-1. Check for the continuity between the No. 1
(Green/Red) terminal of the MAP sensor harness side
3P connector and the body ground.
MAP SENSOR HARNESS
SIDE 3P CONNECTOR
SG1
(GREEN/RED)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Perform “5. MAP sensor signal line open circuit check”.
NO – Repair open in the wire between the MAP
sensor and the ECM.
5. MAP sensor signal line open circuit check
-1. Connect the ECM connector A.
-2. Turn the ignition switch ON.
-3. Measure the voltage between the No. 2 (White/Red)
terminal and the No. 1 (Green/Red) terminal of the
MAP sensor harness side 3P connector.
MAP SENSOR HARNESS
SIDE 3P CONNECTOR
SG1
(GREEN/RED)
PB
(WHITE/RED)
VIEWED FROM THE
TERMINAL SIDE
ECM CONNECTOR B
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Perform “4. MAP sensor ground line open circuit check”.
NO – Repair open in the wire between the MAP
sensor and the ECM.
VCC1
(BROWN/YELLOW)
Is the measured voltage 4.75 – 5.25V?
YES – Perform “7. MAP sensor check”.
NO – Perform “6. MAP sensor signal line open circuit check”.
BF135A•BF150A
6. MAP sensor signal line open circuit check
-1. Turn the ignition switch OFF and disconnect the ECM
connector B.
-2. Check for the continuity between the No. 2 (White/Red)
terminal of the MAP sensor harness side 3P connector and the No. 5 (White/Red) terminal of the ECM connector B.
ECM CONNECTOR B
MAP SENSOR
HARNESS SIDE
3P CONNECTOR
PB
(WHITE/RED)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Perform “7. MAP sensor check”.
NO – Repair open in the wire between the MAP
sensor and ECM.
7. MAP sensor check
-1. Connect the ECM connector B and the MAP sensor
3P connector.
-2. Turn the ignition switch ON and read the PB voltage
using the HDS pocket tester.
Is the voltage 2.76 – 2.96V?
YES – Substitute a known-good ECM and recheck.
NO – Replace the MAP sensor.
• CKP Sensor Troubleshooting
DTC 4-1: No CKP pulse
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Start the engine and let it run at idling under no load.
-3. Check the DTC using the HDS pocket tester.
Does the DTC 4-1 appear?
YES – Perform “2. CKP sensor power line check”.
NO – Temporary failure (Disappeared)
2. CKP sensor power line check
-1. Turn the ignition switch OFF and disconnect the CKP
sensor 3P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 1 (Yellow/Black) terminal and the No.
2 (Green/Red) terminal of the CKP sensor harness
side connector.
CKP SENSOR HARNESS
SIDE 3P CONNECTOR
IGP
(YELLOW/BLACK)
LG1
(GREEN/RED)
VIEWED FROM THE
TERMINAL SIDE
Is there the battery voltage?
YES – Perform “4. CKP sensor signal line open circuit check”.
NO – Perform “3. CKP sensor power line open circuit check”.
5-30
BF135A•BF150A
3. CKP sensor power line open circuit check
-1. Turn the ignition switch ON and measure the voltage
between the No. 1 (Yellow/Black) terminal of the CKP
sensor harness side 3P connector and the engine
ground.
CKP SENSOR HARNESS
SIDE 3P CONNECTOR
IGP
(YELLOW/BLACK)
5. CKP sensor signal line short circuit check
-1. Turn the ignition switch OFF. Check for continuity
between the No. 3 (Blue) terminal of the CKP sensor
harness side 3P connector and the engine ground.
CKP SENSOR HARNESS
SIDE 3P CONNECTOR
CRK (Bu)
VIEWED FROM THE
TERMINAL SIDE
Is there the battery voltage?
YES – Repair open in the CKP sensor ground line.
NO – Repair open in the wire between the No. 4
fuse and the CKP sensor.
4. CKP sensor signal line open circuit check
-1. Turn the ignition switch ON and measure the voltage
between the No. 3 (Blue) terminal of the CKP sensor
harness side 3P connector and the engine ground.
CKP SENSOR HARNESS
SIDE 3P CONNECTOR
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Perform “6. CKP sensor ground line short circuit check”.
NO – Repair open in the wire between the CKP
sensor and the ECM.
6. CKP sensor ground line open circuit check
-1. Turn the ignition switch OFF. Check for continuity
between the No. 2 (Green/Black) terminal of the CKP
sensor harness side 3P connector and the engine
ground.
CKP SENSOR HARNESS
SIDE 3P CONNECTOR
CRK (BLUE)
LG1 (GREEN/BLACK)
VIEWED FROM THE
TERMINAL SIDE
Is the measured voltage 4.75 – 5.25V?
YES – Perform “5. CKP sensor signal line short circuit check”.
NO – Repair open in the wire between the CKP
sensor and the ECM.
5-31
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Perform “7. CKP sensor check”.
NO – Repair open in the wire between the CKP
sensor and the ECM.
BF135A•BF150A
7. CKP sensor check
-1. Connect the HDS pocket tester and clear the DTC
once.
-2. Start the engine and let it run at idling under no load.
Check the DTC with the HDS pocket tester.
Does the DTC 4-1 appear?
YES – Replace the CKP sensor and recheck. If the
DTC 4-1 appears again, substitute a knowngood ECM and recheck.
NO – End of the check
DTC 4-2: CKP pulse is abnormal
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Start the engine and let it run at idling under no load.
-3. Check the DTC with the HDS pocket tester.
Does the DTC 4-2 appear?
YES – Check the crank pulse plate for deformation
and damage. Replace the crank pulse plate
with a new one if it is deformed or damaged,
and check again. If abnormal, replace the
CKP sensor and check. If the DTC 4-2 still
appears, replace the ECM.
NO – Temporary failure (Disappeared)
5-32
BF135A•BF150A
• ECT Sensor 1 Troubleshooting
DTC 6-2: ECT sensor 1 voltage is high
DTC 6-1: ECT sensor 1 voltage is low
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Turn the ignition switch ON.
-3. Measure the ECT sensor 1 voltage using the HDS
pocket tester.
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Turn the ignition switch ON.
-3. Check the ECT sensor 1 voltage using the HDS pocket tester.
Is the measurement 0.23 – 3.15V?
YES – Temporary failure (Disappeared)
NO – Perform “2. ECT sensor 1 line short circuit
check”.
2. ECT sensor 1 line short circuit check
-1. Turn the ignition switch OFF and disconnect the ECM
connector B.
-2. Check for the continuity between the No. 2 (Red/White)
terminal of the ECT sensor 1 harness side 2P connector and the body ground.
ECT SENSOR 1 HARNESS
SIDE 2P CONNECTOR
Is the measurement 0.23 – 3.15V?
YES – Temporary failure (Disappeared)
NO – Go to the step 2.
2. ECT sensor 1 line check
-1. Turn the ignition switch OFF and disconnect the ECT
sensor 1 connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 2 (Red/White) and the No. 1
(Green/Red) terminals of the ECT sensor 1 harness
side 2P connector.
ECT SENSOR 1 HARNESS
SIDE 2P CONNECTOR
SG2
(GREEN/RED)
TE (RED/WHITE)
TE (RED/WHITE)
VIEWED FROM THE
TERMINAL SIDE
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the ECM
and the ECT sensor 1.
NO – Perform “3. ECT sensor 1 check”.
3. ECT sensor 1 check
-1. Turn the ignition switch OFF and connect the HDS
pocket tester.
-2. Turn the ignition switch ON. Check the engine coolant
temperature with the HDS pocket tester.
Is the engine coolant temperature normal?
YES – Substitute a known–good ECM and recheck.
NO – Replace the ECT sensor 1 and recheck.
Is the measurement 4.30 – 5.25V?
YES – Perform “4. ECT sensor 1 check”.
NO – Perform “3. ECT sensor 1 signal line open circuit check”.
3. ECT sensor 1 line open circuit check
-1. Turn the ignition switch ON. Measure the voltage
between the No. 2 (Red/White) terminal of the ECT
sensor 1 harness side 2P connector and the engine
ground.
ECT SENSOR 1 HARNESS
SIDE 2P CONNECTOR
TE (RED/WHIT)
VIEWED FROM THE
TERMINAL SIDE
5-33
BF135A•BF150A
Is the measurement 4.30 – 5.25V?
YES – Repair open in the sensor ground line.
NO – Repair open in the wire between the ECM
and the ECT sensor 1.
4. ECT sensor 1 check
-1. Turn the ignition switch OFF and connect the HDS
pocket tester.
-2. Turn the ignition switch ON and check the engine
coolant temperature with the HDS pocket tester.
Is the engine coolant temperature normal?
YES – Substitute a known-good ECM and recheck.
NO – Replace the ECT sensor 1 and recheck.
• TP Sensor Troubleshooting
DTC 7-1: TP sensor voltage is low
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Turn the ignition switch ON.
-3. Measure the TP sensor voltage using the HDS pocket
tester.
Is the measurement 0.08 – 4.92V?
YES – Temporary failure (Disappeared)
NO – Perform “2. TP sensor signal line short circuit
check”.
2. TP sensor signal line short circuit check
-1. Turn the ignition switch OFF and disconnect the TP
sensor connector.
-2. Disconnect the ECM connector B.
-3. Check for continuity between the No. 2 (Red/Black) terminal of the TP sensor harness side 3P connector and
the engine ground.
TP SENSOR HARNESS
SIDE 3P CONNECTOR
THL (RED/BLACK)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the TP sensor and the ECM.
NO – Perform “3. TP sensor check”.
3. TP sensor check
-1. Connect the ECM connector B and the TP sensor 3P
connector.
-2. Turn the ignition switch ON and measure the TP sensor voltage using the HDS pocket tester.
Is the measurement voltage 4.49 – 4.85V at full
open throttle and 0.44 – 0.56V at full close throttle?
YES – Substitute a known-good ECM and recheck.
NO – Replace the TP sensor.
5-34
BF135A•BF150A
DTC 7-2: TP sensor voltage is high
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Turn the ignition switch ON.
-3. Measure the TP sensor voltage with the HDS pocket
tester.
Is the measurement 0.08 – 4.92V?
YES – Temporary failure (Disappeared)
NO – Perform “2. TP sensor power line check”.
2. TP sensor power line check
-1. Turn the ignition switch OFF and disconnect the TP
sensor 3P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 3 (Brown/White) and the No. 1
(Green/Red) terminals of the TP sensor harness side
3P connector.
TP SENSOR HARNESS
SIDE 3P CONNECTOR
SG2
(GREEN/RED)
VCC2
(BROWN/WHITE)
VIEWED FROM THE
TERMINAL SIDE
Is the measurement 4.75 – 5.25V?
YES – Perform “4. TP sensor signal line open circuit
check”.
NO – Perform “3. TP sensor power line open circuit
check”.
3. TP sensor power line open circuit check
-1. Turn the ignition switch ON. Measure the voltage
between the No. 3 (Brown/White) terminal of the TP
sensor harness side 3P connector and the engine
ground.
TP SENSOR HARNESS
SIDE 3P CONNECTOR
VCC2
(BROWN/WHITE)
VIEWED FROM THE
TERMINAL SIDE
Is the measurement 4.75 – 5.25V?
YES – Repair open in the wire between the TP sensor and the engine ground.
NO – Repair open in the wire between the TP sensor and the ECM.
4. TP sensor signal line open circuit check
-1. Turn the ignition switch ON. Measure the voltage
between the No. 2 (Red/Black) terminal of the TP sensor harness side 3P connector and the engine ground.
TP SENSOR HARNESS
SIDE 3P CONNECTOR
TH (RED/BLACK)
VIEWED FROM THE
TERMINAL SIDE
Is the measurement 4.75 – 5.25V?
YES – Perform “5. TP sensor check”.
NO – Repair open in the TP sensor and the ECM.
5-35
BF135A•BF150A
5. TP sensor check
-1. Turn the ignition switch OFF and connect the TP sensor 3P connector.
-2. Measure the TP sensor voltage using the HDS pocket
tester.
Is the measurement voltage 4.49 – 4.85V at full
open throttle and 0.44 – 0.56V at full close throttle?
YES – Substitute a known-good ECM and recheck.
NO – Replace the TP sensor.
• CMP Sensor Troubleshooting
DTC 8-1: No CMP sensor pulse
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Start the engine and let it run at idling under no load.
-3. Check the DTC using the HDS pocket tester.
Does the DTC 8-1 appear?
YES – Check the pulse plate. If it is normal, perform
“2. CMP sensor power line check”. If it is
abnormal, replace the pulse plate and
recheck.
NO – Temporary failure (Disappeared)
2. CMP sensor power line check
-1. Turn the ignition switch OFF and disconnect the CMP
sensor 3P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 1 (Yellow/Black) terminal and the No.
2 (Green/Red) terminal of the CMP sensor harness
side 3P connector.
CMP SENSOR HARNESS
SIDE 3P CONNECTOR
IGP
(YELLOW/BLACK)
LG1 (GREEN/RED)
VIEWED FROM THE
TERMINAL SIDE
Is there the battery voltage?
YES – Perform “4. CMP sensor signal line open circuit check”.
NO – Perform “3. CMP sensor power line open circuit check”.
5-36
BF135A•BF150A
3. CMP sensor power line open circuit check
-1. Turn the ignition switch ON. Measure the voltage
between the No. 1 (Yellow/Black) terminal of the CMP
sensor harness side 3P connector and the engine
ground.
CMP SENSOR HARNESS
SIDE 3P CONNECTOR
IGP
(YELLOW/BLACK)
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Start the engine and let it run at idling under no load.
-3. Check the DTC using the HDS pocket tester.
Does the DTC 8-2 appear?
YES – Replace the CMP sensor and recheck. If the
DTC 8-2 appears again, substitute a knowngood ECM and recheck.
NO – Temporary failure (Disappeared)
VIEWED FROM THE
TERMINAL SIDE
Is there the battery voltage?
YES – Repair open in the CMP sensor ground line.
NO – Repair open in the wire between the No. 4
fuse and the CMP sensor.
4. CMP sensor signal line open circuit check
-1. Turn the ignition switch ON. Measure the voltage
between the No. 3 (Green) terminal of the CMP sensor
harness side 3P connector and the engine ground.
CMP SENSOR HARNESS
SIDE 3P CONNECTOR
TDC (GREEN)
VIEWED FROM THE
TERMINAL SIDE
Is the measurement voltage 4.75 – 5.25V?
YES – Perform “5. CMP sensor check”.
NO – Repair open in the wire between the CMP
sensor and the ECM.
5. CMP sensor check
-1. Connect the HDS pocket tester and clear the DTC
once.
-2. Start the engine and let it run at idling under no load.
Check the DTC using the HDS pocket tester.
Does the DTC 8-1 appear?
YES – Replace the CMP sensor and recheck. If the
DTC 8-1 appears again, substitute a knowngood ECM and recheck.
NO – End of the check
5-37
DTC 8-2: CMP sensor pulse is abnormal
BF135A•BF150A
• IAT Sensor Troubleshooting
DTC 10-2: IAT sensor voltage is high
DTC 10-1: IAT sensor voltage is low
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Turn the ignition switch ON.
-3. Measure the IAT sensor (TA) voltage using the HDS
pocket tester.
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Turn the ignition switch ON.
-3. Measure the IAT sensor (TA) voltage using the HDS
pocket tester.
Is the measurement voltage 0.08 – 4.92V?
YES – Temporary failure (Disappeared)
NO – Perform “2. IAT sensor line short circuit
check”.
2. IAT sensor line short circuit check
-1. Turn the ignition switch OFF and disconnect the ECM
connector B.
-2. Check for the continuity between the No. 2
(Red/Yellow) terminal of the IAT sensor harness side
2P connector and the body ground.
Is the measured voltage 0.08 – 4.92V?
YES – Temporary failure (Disappeared)
NO – Perform “2. IAT sensor signal line open circuit
check”.
2. IAT sensor signal line open circuit check
-1. Turn the ignition switch OFF and disconnect the IAT
sensor 2P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 2 (Red/Yellow) terminal of the IAT
sensor harness side 2P connector and the engine
ground.
IAT SENSOR HARNESS
SIDE 2P CONNECTOR
IAT SENSOR HARNESS
SIDE 2P CONNECTOR
TA (RED/YELLOW)
TA (RED/YELLOW)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the ECM
and the IAT sensor.
NO – Perform “3. IAT sensor check”.
3. IAT sensor check
-1. Turn the ignition switch OFF and connect the HDS
pocket tester.
-2. Turn the ignition switch ON and check the intake air
temperature using the HDS pocket tester.
Does the measurement correspond to the ambient
temperature?
YES – Substitute a known-good ECM and recheck.
NO – Replace the IAT sensor with a new one and
recheck.
VIEWED FROM THE
TERMINAL SIDE
Is the measured voltage 4.75 – 5.25V?
YES – Perform “3. IAT sensor ground line open circuit check”.
NO – Repair open in the wire between the IAT sensor and the ECM.
3. IAT sensor ground line open circuit check
-1. Turn the ignition switch OFF.
-2. Check for the continuity between the No. 1
(Green/Red) terminal of the IAT sensor harness side
2P connector and the body ground.
IAT SENSOR HARNESS
SIDE 2P CONNECTOR
SG2 (GREEN/RED)
VIEWED FROM THE
TERMINAL SIDE
5-38
BF135A•BF150A
Is there the continuity?
YES – Perform “4. IAT sensor check”.
NO – Repair open in the wire between the IAT sensor and the engine ground.
4. IAT sensor check
-1. Turn the ignition switch OFF and connect the HDS
pocket tester.
-2. Turn the ignition switch ON and check the intake air
temperature using the HDS pocket tester.
Does the measurement correspond to the ambient
temperature?
YES – Substitute a known–good ECM and recheck.
NO – Substitute a known–good IAT sensor and
recheck.
• BARO Sensor Troubleshooting
DTC 13-1: BARO sensor voltage is low
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Turn the ignition switch ON.
-3. Measure the BARO sensor (PA) voltage using the
HDS pocket tester.
Is the measurement voltage 1.58 – 4.49V?
YES – Temporary failure (Disappeared)
NO – Perform “2. BARO sensor signal line short circuit check”.
2. BARO sensor signal line short circuit check
-1. Turn the ignition switch OFF and disconnect the ECM
connector B.
-2. Check for the continuity between the No. 2
(White/Blue) terminal of the BARO sensor harness
side 3P connector and the body ground.
BARO SENSOR HARNESS
SIDE 3P CONNECTOR
PA (WHITE/BLUE)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the ECM
and the BARO sensor.
NO – Perform “3. BARO sensor check”.
3. BARO sensor check
-1. Turn the ignition switch OFF and connect the BARO
sensor connector and the ECM connector B.
-2. Turn the ignition switch ON. Measure the BARO sensor voltage using the HDS pocket tester.
Is the measurement voltage 2.76 – 2.96V?
YES – Substitute a known-good ECM and recheck.
NO – Replace the BARO sensor and recheck.
5-39
BF135A•BF150A
DTC 13-2: BARO sensor voltage is high
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Turn the ignition switch ON.
-3. Measure the BARO sensor (PA) voltage using the
HDS pocket tester.
Is the measurement voltage 1.58 – 4.49V?
YES – Temporary failure (Disappeared)
NO – Perform “2. BARO sensor power line check”.
2. BARO sensor power line check
-1. Turn the ignition switch OFF and disconnect the BARO
sensor 3P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 3 (Brown/White) and the No. 1
(Green/Red) terminals of the BARO sensor harness
side 3P connector.
BARO SENSOR HARNESS
SIDE 3P CONNECTOR
SG2
(GREEN/RED)
VCC2
(BROWN/WHITE)
VIEWED FROM THE
TERMINAL SIDE
Is the measurement voltage 4.75 – 5.25V?
YES – Perform “4. BARO sensor signal line open circuit check”.
NO – Perform “3. BARO sensor power line open circuit check”.
Is the measured voltage 4.75 – 5.25V?
YES – Repair open in the wire between the BARO
sensor and the engine ground.
NO – Repair open in the wire between the BARO
sensor and the ECM.
4. BARO sensor signal line open circuit check
-1. Turn the ignition switch ON. Measure the voltage
between the No. 2 (White/Blue) terminal of the BARO
sensor harness side 3P connector and the engine
ground.
BARO SENSOR HARNESS
SIDE 3P CONNECTOR
PA (WHITE/BLUE)
VIEWED FROM THE
TERMINAL SIDE
Is the measured voltage 4.75 – 5.25V?
YES – Perform “5. BARO sensor check”.
NO – Repair open in the wire between the BARO
sensor and the ECM.
5. BARO sensor check
-1. Turn the ignition switch OFF and connect the BARO
sensor connector.
-2. Turn the ignition switch ON and measure the BARO
sensor voltage using the HDS pocket tester.
Is the measured voltage 2.76 – 2.96V?
YES – Substitute a known-good ECM and recheck.
NO – Replace the BARO sensor and recheck.
3. BARO sensor power line open circuit check
-1. Turn the ignition switch ON. Measure the voltage
between the No. 3 (Brown/White) terminal of the
BARO sensor harness side 3P connector and the
engine ground.
BARO SENSOR HARNESS
SIDE 3P CONNECTOR
VCC2 (BROWN/WHITE)
VIEWED FROM THE
TERMINAL SIDE
5-40
BF135A•BF150A
• IAC Valve Troubleshooting
DTC 14-1: IAC valve current is abnormal
-2. Check for the continuity between the IAC valve No. 2
terminal and the body ground.
IAC VALVE SIDE 2P
CONNECTOR
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Start the engine and let it run at idling under no load.
-3. Measure the engine speed using the HDS pocket
tester.
Is the engine speed 650 min-1 (rpm) or above?
YES – Temporary failure (Disappeared)
NO – Perform “2. IAC valve open circuit check”.
2. IAC valve open circuit check
-1. Turn the ignition switch OFF and disconnect the IAC
valve 2P connector.
-2. Measure the resistance between the No. 1 and No. 2
terminals of the IAC valve.
IAC VALVE SIDE 2P
CONNECTOR
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Replace the IAC valve.
NO – Perform “4. IAC valve line open circuit check”.
4. IAC valve line open circuit check
-1. Connect the IAC valve 2P connector.
-2. Disconnect the ECM connector B.
-3. Measure the resistance between the No. 26
(Green/White) and the No. 34 (Black) terminals of the
ECM connector B.
ECM CONNECTOR B
VIEWED FROM THE
TERMINAL SIDE
EACVP
(GREEN/WHITE)
EACVM
(BLACK)
Is the measured resistance 8 – 12 ?
YES – Perform “3. IAC valve short circuit check”.
NO – Replace the IAC valve.
3. IAC valve short circuit check
-1. Check for the continuity between the IAC valve No. 1
terminal and the body ground.
IAC VALVE SIDE 2P
CONNECTOR
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Replace the IAC valve.
NO – Go to the step 2.
5-41
VIEWED FROM THE
TERMINAL SIDE
Is the measured resistance 10 – 13 ?
YES – Perform “5. IAC valve line short circuit check”.
NO – Repair open in the wire between the ECM
and the IAC valve.
BF135A•BF150A
5. IAC valve line short circuit check
-1. Check for the continuity between the No. 26
(Green/White) terminal of the ECM connector B and
the engine ground, and between the No. 34 (Black) terminal of the ECM connector B and the engine ground.
ECM CONNECTOR B
EACVM
(BLACK)
EACVP
(GREEN/WHITE)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the ECM
and the IAC valve.
NO – Substitute a known-good ECM and recheck.
• VTEC Solenoid Valve Troubleshooting
DTC 21-1: VTEC solenoid valve output is abnormal
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Start the engine and warm it up for 5 minutes by running the engine at 3,000 min-1 (rpm) under no load.
-3. Disconnect the neutral switch 2P connector.
-4. Increase the engine speed gradually and run the
engine at 4,500 min-1 (rpm) for a few seconds.
-5. Check the DTC again using the HDS pocket tester.
Does the DTC 21-1 appear?
YES – Perform “2. Spool solenoid valve check”.
NO – Temporary failure (Disappeared)
2. Spool solenoid valve check
-1. Turn the ignition switch OFF and disconnect the spool
solenoid valve connector.
-2. Measure the resistance between the spool solenoid
valve side 1P connector (Green/White) terminal and
the body ground.
SOLENOID VALVE SIDE
1P CONNECTOR
VIEWED FROM THE
TERMINAL SIDE
Is the measured resistance 12 – 18 ?
YES – Perform “3. VTEC signal line short circuit
check”.
NO – Replace the spool solenoid valve.
5-42
BF135A•BF150A
3. VTEC signal line short circuit check
-1. Disconnect the ECM connector A.
-2. Check for the continuity between the No. 20
(Green/Yellow) terminal of the ECM connector A and
the body ground.
ECM CONNECTOR A
VTS (GREEN/YELLOW)
• Knock Sensor Troubleshooting
DTC 23-1: Knock sensor detects failure
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Start the engine and warm it up for 5 minutes or more
by running the engine at 5,000 min-1 (rpm) or more
under no load.
-3. Check the DTC again with the HDS pocket tester.
Does the DTC 23-1 appear?
YES – Perform “2. Knock sensor signal line open circuit check”.
NO – Temporary failure (Disappeared)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the ECM
and the spool solenoid valve.
NO – Perform “4. VTEC signal line open circuit
check”.
4. VTEC signal line open circuit check
-1. Check for the continuity between the spool solenoid
valve harness side connector terminal and the No. 20
(Green/Yellow) terminal of the ECM connector A.
SPOOL SOLENOID
VALVE HARNESS
SIDE CONNECTOR
2. Knock sensor signal line open circuit check
-1. Turn the ignition switch OFF. Disconnect the knock
sensor connector and the ECM connector A.
-2. Check for the continuity between the (Red/Blue) terminal of the knock sensor harness side connector and
the No. 15 (Red/Blue) terminal of the ECM connector
A.
ECM CONNECTOR A
KNOCK SENSOR
HARNESS SIDE 1P
CONNECTOR
KS
(RED/BLUE)
ECM CONNECTOR A
VTS (GREEN/YELLOW)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Substitute a known-good ECM and recheck.
NO – Repair open in the wire between the ECM
and the spool solenoid valve.
5-43
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Perform “3. Knock sensor signal line short circuit check”.
NO – Repair open in the wire between the knock
sensor and the ECM.
BF135A•BF150A
3. Knock sensor signal line short circuit test
-1. Check for the continuity between the No. 15 (Red/Blue)
terminal of the ECM connector A and the body ground.
ECM CONNECTOR A
KS (RED/BLUE)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the ECM
and the spool solenoid valve.
NO – Substitute a known-good ECM and recheck.
• A/F Heater Troubleshooting
DTC 41-3: A/F heater is abnormal
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Start the engine and warm it up 5 minutes or more by
running the engine at 3,000 min-1 (rpm) under no load.
-3. Check the DTC again using the HDS pocket tester.
Does the DTC 41-3 appear?
YES – Perform “2. A/F heater relay check”.
NO – Temporary failure (Disappeared)
2. A/F heater relay check
-1. Turn the ignition switch OFF and disconnect the A/F
sensor 4P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 3 (White) terminal of the A/F sensor
harness side 4P connector and the engine ground.
A/F SENSOR HARNESS
SIDE 4P CONNECTOR
AFHT+ (WHITE)
VIEWED FROM THE TERMINAL SIDE
Is there the battery voltage?
YES – Perform “3. A/F sensor heater check”.
NO – Go to the step 3.
-3. Turn the ignition switch OFF and disconnect the A/F
heater relay 4P connector.
-4. Measure the voltage between the No. 1 (White/ Green)
terminal of the A/F heater relay harness side 4P connector and the engine ground.
• Note that the battery voltage is constantly applied to
the White/Green terminal. Take care not to short-circuit the terminal.
A/F HEATER RELAY HARNESS
SIDE 4P CONNECTOR
+B (WHITE/GREEN)
VIEWED FROM THE
TERMINAL SIDE
5-44
BF135A•BF150A
Is there the battery voltage?
YES – Go to the step 5.
NO – Blown No. 1 fuse, or repair open in the wire
between the A/F heater relay and the No. 1
fuse.
-5. Turn the ignition switch ON. Measure the voltage
between the No. 3 (White) terminal of the A/F heater
relay harness side 4P connector and the engine
ground.
A/F HEATER RELAY HARNESS
SIDE 4P CONNECTOR
-9. Check for the continuity between the No. 3 (White) terminal of the A/F heater relay harness side 4P connector and the No. 3 (White) terminal of the A/F sensor
harness side 4P connector.
A/F SENSOR HARNESS
SIDE 4P CONNECTOR
A/F HEATER RELAY
HARNESS SIDE
4P CONNECTOR
AFHT+ (WHITE)
AFHT+ (WHITE)
VIEWED FROM THE
TERMINAL SIDE
AFHT+ (WHITE)
VIEWED FROM THE
TERMINAL SIDE
Is there the battery voltage?
YES – Go to the step 6.
NO – Repair open in the wire between the A/F
heater relay and the No. 5 fuse.
Is there the continuity?
YES – Perform “3. A/F sensor heater check”.
NO – Repair open in the wire between the A/F
heater relay and the A/F sensor.
3. A/F sensor heater check
-1. Turn the ignition switch OFF and disconnect the A/F
sensor 4P connector.
-2. Measure the resistance between the No. 3 (Black) and
the No. 4 (Black) terminals of the A/F sensor side 4P
connector.
-6. Check the A/F heater relay (P. 18-20).
Is the A/F heater relay normal?
YES – Go to the step 7.
NO – Replace the A/F heater relay.
-7. Turn the ignition switch OFF and disconnect the ECM
connector A.
-8. Check for the continuity between the No. 4 (Green/
Orange) terminal of the A/F heater relay harness side
4P connector and the No. 25 (Green/Orange) terminal
of the ECM connector A.
AFHT (BLACK)
AFHT+ (BLACK)
VIEWED FROM THE
TERMINAL SIDE
ECM CONNECTOR A
A/F HEATER RELAY
HARNESS SIDE
4P CONNECTOR
Is the resistance 2 – 3 (at room temperature)?
YES – Perform “4. Heater line short circuit check”.
NO – Replace the A/F sensor.
AFHT(GREEN/ORANGE)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Go to the step 9.
NO – Repair open in the wire between the A/F
heater relay and the ECM.
5-45
A/F SENSOR SIDE 4P
CONNECTOR
BF135A•BF150A
4. Heater line short circuit check
-1. Turn the ignition switch OFF and disconnect the ECM
connector C.
-2. Check for the continuity between the No. 3
(Black/White) terminal of the ECM connector C and
the engine ground, and between the No. 4 (White) terminal of the ECM connector C and the engine ground.
ECM CONNECTOR C
AFHT
(BLACK/WHITE)
AFHT+ (WHITE)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the A/F sensor and the ECM.
NO – Perform “5. Heater line open circuit check”.
5. Heater line open circuit check
-1. Turn the ignition switch OFF and connect the A/F sensor 4P connector.
-2. Measure the resistance between the No. 3
(Black/White) and the No. 4 (White) terminals of the
ECM connector C.
DTC 41-4: A/F sensor heater is abnormal
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Start the engine and warm it up for 5 minutes or more
by running the engine at 3,000 min-1 (rpm) under no
load.
-3. Check the DTC again using the HDS pocket tester.
Does the DTC 41-4 appear?
YES – Perform “2. A/F heater relay check”.
NO – Temporary failure (Disappeared)
2. A/F heater relay check
-1. Turn the ignition switch OFF and disconnect the A/F
sensor 4P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 3 (White) terminal of the A/F sensor
harness side 4P connector and the engine ground.
A/F SENSOR HARNESS
SIDE 4P CONNECTOR
AFHT+
(WHITE)
VIEWED FROM THE
TERMINAL SIDE
ECM CONNECTOR C
AFHT+ (WHITE)
AFHT
(BLACK/WHITE)
VIEWED FROM THE
TERMINAL SIDE
Is the resistance 2 – 3 (at room temperature)?
YES – Replace the A/F sensor and recheck. If it is
still abnormal, substitute a known-good ECM
and recheck.
NO – Repair open in the wire between the A/F sensor and the ECM.
Is there the battery voltage?
YES – Perform “3. A/F heater harness check”.
NO – Go to the step 3.
-3. Turn the ignition switch OFF and disconnect the A/F
heater relay 4P connector.
-4. Measure the voltage between the No. 1 (White/ Green)
terminal of the A/F heater relay harness side 4P connector and the engine ground.
• Note that the battery voltage is constantly applied
to the White/Green terminal. Take care not to
short-circuit the terminal.
A/F HEATER RELAY HARNESS
SIDE 4P CONNECTOR
+B (WHITE/GREEN)
VIEWED FROM THE
TERMINAL SIDE
5-46
BF135A•BF150A
Is there the battery voltage?
YES – Go to the step 5.
NO – Blown No. 1 fuse, or repair open in the wire
between the A/F heater relay and the No. 1
fuse.
-5. Turn the ignition switch ON. Measure the voltage
between the No. 3 (White) terminal of the A/F heater
relay harness side 4P connector and the engine
ground.
A/F HEATER RELAY HARNESS
SIDE 4P CONNECTOR
A/F SENSOR
HARNESS SIDE
4P CONNECTOR
AFHT+
(WHITE)
A/F HEATER RELAY
HARNESS SIDE
4P CONNECTOR
AFHT+
(WHITE)
VIEWED FROM THE
TERMINAL SIDE
AFHT+ (WHITE)
VIEWED FROM THE
TERMINAL SIDE
Is there the battery voltage?
YES – Go to the step 6.
NO – Repair open in the wire between the A/F
heater relay and the No. 5 fuse.
-6. Check the A/F heater relay (single unit check) (P. 1824).
Is the A/F heater relay normal?
YES – Go to the step 7.
NO – Replace the A/F heater relay.
-7. Turn the ignition switch OFF and disconnect the ECM
connector A.
-8. Check for continuity between the No. 4 (Green/
Orange) terminal of the A/F heater relay harness side
4P connector and the No. 25 (Green/Orange) terminal
of the ECM connector A.
A/F HEATER RELAY
HARNESS SIDE
4P CONNECTOR
ECM CONNECTOR A
AFHT(GREEN/ORANGE)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Go to the step 9.
NO – Repair open in the wire between the A/F
heater relay and the ECM.
5-47
-9. Check for the continuity between the No. 3 (White) terminal of the A/F heater relay harness side 4P connector and the No. 3 (White) terminal of the A/F sensor
harness side 4P connector.
Is there the continuity?
YES – Perform “3. A/F heater check”.
NO – Repair open in the wire between the A/F
heater relay and the A/F sensor.
3. A/F heater check
-1. Turn the ignition switch OFF and disconnect the A/F
sensor 4P connector.
-2. Measure the resistance between the No. 3 (Black) and
the No. 4 (Black) terminals of the A/F sensor side 4P
connector.
A/F SENSOR SIDE
4P CONNECTOR
AFHT (BLACK)
AFHT+ (BLACK)
VIEWED FROM THE
TERMINAL SIDE
Is the measured resistance 2 – 3 (at room temperature)?
YES – Perform “4. Heater line short circuit check”.
NO – Replace the A/F sensor.
BF135A•BF150A
4. Heater line short circuit check
-1. Turn the ignition switch OFF and disconnect the ECM
connector C.
-2. Check for the continuity between the No. 3
(Black/White) terminal of the ECM connector C and
the engine ground, and between the No. 4 (White) terminal of the ECM connector C and the engine ground.
ECM CONNECTOR C
AFHT+
(WHITE)
AFHT
(BLACK/WHITE)
-3. Check for the continuity between the No. 3 (Black/
White) terminal of the ECM connector C and the
respective terminals of the No. 1 (White/Black) and the
No. 2 (Black/Yellow) terminals of the A/F sensor harness side 4P connector.
A/F SENSOR
HARNESS SIDE
4P CONNECTOR
AFV1
(WHITE/
BLACK)
ECM CONNECTOR C
AFC1
(BLACK/
YELLOW)
AFHT
(BLACK/ WHITE)
VIEWED FROM THE
TERMINAL SIDE
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the A/F sensor and the ECM.
NO – Perform “5. Heater line open circuit check”.
5. Heater line open circuit check
-1. Turn the ignition switch OFF and connect the A/F sensor 4P connector.
-2. Measure the resistance between the No. 3 (Black/
White) terminal and the No. 4 (White) terminal of the
ECM connector C.
ECM CONNECTOR C
AFHT
(BLACK/WHITE)
AFHT+ (WHITE)
VIEWED FROM THE
TERMINAL SIDE
Is the resistance 2 – 3 (at room temperature)?
YES – Perform “6. Sensor line short circuit check”.
NO – Repair open in the wire between the A/F sensor and the ECM.
Is there the continuity?
YES – Repair short in the wire between the A/F sensor and the ECM.
NO – Go to the step 4.
-4. Check for continuity between the No. 4 (White) terminal of the ECM connector C and the respective terminals of the No. 1 (White/Black) and the No. 2
(Black/Yellow) terminals of the A/F sensor harness
side 4P connector.
A/F SENSOR
HARNESS SIDE
4P CONNECTOR
ECM CONNECTOR C
AFHT+
(WHITE)
AFV1
(WHITE/
BLACK)
AFC1
(BLACK/
YELLOW)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the A/F sensor and the ECM.
NO – Replace the A/F sensor and recheck. If it is
still abnormal, substitute a known-good ECM
and recheck.
6. Sensor line short circuit check
-1. Disconnect the ECM connector B.
-2. Disconnect the A/F sensor 4P connector.
5-48
BF135A•BF150A
• A/F Sensor Troubleshooting
DTC 48-5: A/F sensor current is abnormal
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Start the engine and warm it up for 5 minutes or more
by running the engine at 3,000 min-1 (rpm) under no
load.
-3. Check the DTC again using the HDS pocket tester.
Does the DTC 48-5 appear?
YES – Perform “2. A/F sensor line open circuit
check”.
NO – Temporary failure (Disappears)
2. A/F sensor line open circuit check
-1. Turn the ignition switch OFF. Disconnect the A/F sensor connector and the ECM connector A.
-2. Check for the continuity between the No. 1
(White/Black) terminal of the A/F sensor harness side
4P connector and the No. 4 (White/Black) terminal of
the ECM connector A.
ECM CONNECTOR A
A/F SENSOR
HARNESS SIDE
4P CONNECTOR
AFV1
(WHITE/BLACK)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Go to the step 3.
NO – Repair open in the wire between the A/F sensor and the ECM.
5-49
-3. Check for the continuity between the No. 2
(Black/Yellow) terminal of the A/F sensor harness side
4P connector and the No. 14 (Black/Yellow) terminal of
the ECM connector A.
ECM CONNECTOR A
A/F SENSOR
HARNESS SIDE
4P CONNECTOR
AFC1
(BLACK/
YELLOW)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Replace the A/F sensor and recheck. If there
is abnormality, substitute a known-good ECM
and recheck.
NO – Repair open in the wire between the A/F sensor and the ECM.
BF135A•BF150A
DTC 48-6: A/F sensor V current is abnormal
DTC 48-7: A/F sensor C current is abnormal
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Start the engine and warm it up 5 minutes or more by
running the engine at 3,000 min-1 (rpm) under no load.
-3. Check the DTC again using the HDS pocket tester.
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Start the engine and warm it up for 5 minutes or more
by running the engine at 3,000 min-1 (rpm) under no
load.
-3. Check the DTC again using the HDS pocket tester.
Does the DTC 48-6 appear?
YES – Perform “2. A/F sensor line short circuit
check”.
NO – Temporary failure (Disappeared)
2. A/F sensor line (V line) short circuit check
-1. Turn the ignition switch OFF. Disconnect the A/F sensor connector and the ECM connector A.
-2. Check for the continuity between the No. 1
(White/Black) terminal of the A/F sensor harness side
4P connector and the engine ground.
A/F SENSOR HARNESS
SIDE 4P CONNECTOR
AFV1
(WHITE/BLACK)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the A/F sensor and the ECM.
NO – Replace the A/F sensor and recheck. If there
is any abnormality, substitute a known-good
ECM and recheck.
Does the DTC 48-7 appear?
YES – Perform “2. A/F sensor line short circuit
check”.
NO – Temporary failure (Disappeared)
2. A/F sensor line (C line) short circuit check
-1. Turn the ignition switch OFF. Disconnect the A/F sensor connector and the ECM connector A.
-2. Check for the continuity between the No. 2
(Black/Yellow) terminal of the A/F sensor harness
side 4P connector and the engine ground.
A/F SENSOR HARNESS SIDE
4P CONNECTOR
AFC1
(BLACK/YELLOW)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the A/F sensor and the ECM.
NO – Replace the A/F sensor and recheck. If it is
abnormal, substitute a known-good ECM and
recheck.
5-50
BF135A•BF150A
• ECT Sensor 2 Troubleshooting
DTC 140-2: ECT sensor 2 voltage is high
DTC 140-1: ECT sensor 2 voltage is low
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Turn the ignition switch ON.
-3. Measure the ECT sensor 2 voltage using the HDS
pocket tester.
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Turn the ignition switch ON.
-3. Measure the ECT sensor 2 voltage using the HDS
pocket tester.
Is the measured voltage 0.08 – 4.99V?
YES – Temporary failure (Disappeared)
NO – Perform “2. ECT sensor 2 signal line short circuit check”.
2. ECT sensor 2 signal line short circuit check
-1. Turn the ignition switch OFF. Disconnect the ECT sensor 2 connector and the ECM connector B.
-2. Check for the continuity between the No. 2 (Red/Black)
terminal of the ECT sensor 2 harness side 2P connector and the body ground.
ECT SENSOR 2 HARNESS SIDE
2P CONNECTOR
Is the measured voltage 0.08 – 4.99V?
YES – Temporary failure (Disappeared)
NO – Perform “2. ECT sensor 2 signal line open circuit check”.
2. ECT sensor 2 signal line open circuit check
-1. Turn the ignition switch OFF and disconnect the 2P
connector from the ECT sensor 2.
-2. Turn the ignition switch ON.
-3. Measure the voltage between the No. 2 (Red/Black)
terminal of the ECT sensor 2 harness side 2P connector and the engine ground.
ECT SENSOR 2 HARNESS SIDE
2P CONNECTOR
TOH1 (RED/BLACK)
TOH1 (RED/BLACK)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the ECT
sensor 2 and the ECM.
NO – Perform “3. ECT sensor 2 check”.
3. ECT sensor 2 check
-1. Turn the ignition switch OFF and connect the ECT sensor 2 2P connector.
-2. Turn the ignition switch ON and measure the ECT sensor 2 temperature using the HDS pocket tester.
Does the measurement correspond to the engine
coolant temperature?
YES – Substitute a known-good ECM and recheck.
NO – Replace the ECT sensor 2.
5-51
VIEWED FROM THE
TERMINAL SIDE
Is the measured voltage 4.75 – 5.25V?
YES – Perform “3. ECT sensor 2 ground line open
circuit check”.
NO – Repair open in the wire between the ECT
sensor 2 and the ECM.
BF135A•BF150A
3. ECT sensor 2 ground line open circuit check
-1. Connect the ECM connector B.
-2. Check for the continuity between the No. 1 (Green/
Red) terminal of the ECT sensor 2 harness side 2P
connector and the body ground.
ECT SENSOR 2 HARNESS SIDE
2P CONNECTOR
SG2
(GREEN/RED)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Perform “4. ECT sensor 2 check”.
NO – Repair open in the wire between the ECT
sensor 2 and the engine ground.
4. ECT sensor 2 check
-1. Turn the ignition switch OFF and connect all the connectors.
-2. Turn the ignition switch ON. Measure the ECT sensor
2 temperature using the HDS pocket tester.
Does the measurement correspond to the engine
coolant temperature?
YES – Substitute a known-good ECM and recheck.
NO – Replace the ECT sensor 2.
• ECT Sensor 3 Troubleshooting
DTC 141-1: ECT sensor 3 voltage is low
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Turn the ignition switch ON.
-3. Measure the ECT sensor 3 voltage using the HDS
pocket tester.
Is the measured voltage 0.08 – 4.99V?
YES – Temporary failure (Disappeared)
NO – Perform “2. ECT sensor 3 signal line short circuit check”.
2. ECT sensor 3 signal line short circuit check
-1. Turn the ignition switch OFF. Disconnect the ECT sensor 3 connector and the ECM connector B.
-2. Check for the continuity between the No. 2 terminal
(Red) of the ECT sensor 3 harness side 2P connector
and the body ground.
ECT SENSOR 3 HARNESS SIDE
2P CONNECTOR
TOH2 (RED)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the ECT
sensor 3 and the ECM.
NO – Perform “3. ECT sensor 3 check”.
3. ECT sensor 3 check
-1. Turn the ignition switch OFF and connect the ECT sensor 3 2P connector.
-2. Turn the ignition switch ON and measure the ECT sensor 3 temperature using the HDS pocket tester.
Does the measurement agree with the engine
coolant temperature?
YES – Substitute a known-good ECM and recheck.
NO – Replace the ECT sensor 3.
5-52
BF135A•BF150A
DTC 141-2: ECT sensor 3 voltage is high
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Turn the ignition switch ON.
-3. Measure the ECT sensor 3 voltage using the HDS
pocket tester.
Is the measured voltage 0.08 – 4.99V?
YES – Temporary failure (Disappeared)
NO – Perform “2. ECT sensor 3 signal line open circuit check”.
2. ECT sensor 3 signal line open circuit check
-1. Turn the ignition switch OFF and disconnect the 2P
connector from the ECT sensor 3.
-2. Turn the ignition switch ON.
-3. Measure the voltage between the No. 2 (Red) terminal
of the ECT sensor 3 harness side 2P connector and
the engine ground.
ECT SENSOR 3 HARNESS SIDE
2P CONNECTOR
TOH2 (RED)
VIEWED FROM THE
TERMINAL SIDE
Is the measured voltage 4.75 – 5.25V?
YES – Perform “3. ECT sensor 3 ground line open
circuit check”.
NO – Repair open in the wire between the ECT
sensor 3 and the ECM.
5-53
3. ECT sensor 3 ground line open circuit check
-1. Connect the ECM connector B.
-2. Check for continuity between the No. 1 (Green/Red)
terminal of the ECT sensor 3 harness side 2P connector and the body ground.
ECT SENSOR 3 HARNESS SIDE
2P CONNECTOR
SG2
(GREEN/RED)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Perform “4. ECT sensor 3 check”.
NO – Repair open in the wire between the ECT
sensor 3 and the engine ground.
4. ECT sensor 3 check
-1. Turn the ignition switch OFF and connect all the connectors.
-2. Turn the ignition switch ON and measure the ECT sensor 3 temperature using the HDS pocket tester.
Does the measurement agree with the engine
coolant temperature?
YES – When the DTC appears again, substitute a
known-good ECM and recheck.
NO – Replace the ECT sensor 3.
BF135A•BF150A
• EOP switch (High pressure side)
Troubleshooting
DTC 142-1: EOP switch signal is abnormal
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Turn the ignition switch ON.
-3. Check the EOP switch signal using the HDS pocket
tester.
Is there the OFF signal?
YES – Temporary failure (Disappeared)
NO – Perform “2. EOP switch signal line open circuit
check”.
2. EOP switch signal line open circuit check
-1. Turn the ignition switch OFF and disconnect the EOP
switch 2P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 1 (Yellow/Red) terminal of the EOP
switch harness side 2P connector and the body
ground.
EOP SWITCH
HARNESS SIDE 2P CONNECTOR
OPSH
(YELLOW/RED)
3. EOP switch signal line short circuit check
-1. Turn the ignition switch OFF. Disconnect the EOP
switch 2P connector and the ECM connector A.
-2. Check for the continuity between the No. 1
(Yellow/Red) terminal of the EOP switch harness side
2P connector and the body ground.
EOP SWITCH
HARNESS SIDE 2P CONNECTOR
OPSH
(YELLOW/RED)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the EOP
switch and the ECM.
NO – Perform “4. EOP switch ground line open circuit check”.
4. EOP switch ground line open circuit check
-1. Check for the continuity between the No. 2
(Green/Red) terminal of the EOP switch harness side
2P connector and the body ground.
EOP SWITCH
HARNESS SIDE 2P CONNECTOR
VIEWED FROM THE
TERMINAL SIDE
Is there the battery voltage?
YES – Perform “3. EOP switch signal line short circuit
check”.
NO – Repair open in the wire between the EOP
switch and the ECM.
SG2
(GREEN/RED)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Perform “5. EOP switch check”.
NO – Repair open in the wire between the EOP
switch and the ECM.
5-54
BF135A•BF150A
5. EOP switch check
-1. Turn the ignition switch OFF and connect all the connectors.
-2. Turn the ignition switch ON and check the EOP switch
using the HDS pocket tester.
Does the tester shows the switch OFF?
YES – If the DTC appears again, substitute a knowngood ECM and recheck.
NO – Replace the EOP switch.
• ECT Sensor 4 Troubleshooting
DTC 143-1: ECT sensor 4 voltage is low
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Turn the ignition switch ON.
-3. Measure the ECT sensor 4 voltage using the HDS
pocket tester.
Is the measured voltage 0.08 – 4.99V?
YES – Temporary failure (Disappeared)
NO – Perform “2. ECT sensor 4 signal line short circuit check”.
2. ECT sensor 4 signal line short circuit check
-1. Turn the ignition switch OFF. Disconnect the ECT sensor 4 connector and the ECM connector B.
-2. Check for the continuity between the No. 2
(Red/Green) terminal of the ECT sensor 4 harness
side connector and the body ground.
ECT SENSOR 4 HARNESS
SIDE 2P CONNECTOR
TOH3
(RED/GREEN)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the ECT
sensor 4 and the ECM.
NO – Perform “3. ECT sensor 4 check”.
3. ECT sensor 4 check
-1. Turn the ignition switch OFF and connect the ECT sensor 4 2P connector.
-2. Turn the ignition switch ON. Measure the ECT sensor
4 temperature using the HDS pocket tester.
Does the measurement correspond to the engine
coolant temperature?
YES – If the DTC appears again, substitute a knowngood ECM and recheck.
NO – Replace the ECT sensor 4.
5-55
BF135A•BF150A
DTC 143-2: ECT sensor 4 voltage is high
1. Symptom reproduction test
-1. Connect the HDS pocket tester and clear the DTC
once. If the DTC can not be cleared, go on the troubleshooting.
-2. Turn the ignition switch ON.
-3. Measure the ECT sensor 4 voltage using the HDS
pocket tester.
Is the measured voltage 0.08 – 4.99V?
YES – Temporary failure (Disappeared)
NO – Perform “2. ECT sensor 4 signal line open circuit check”.
2. ECT sensor 4 signal line open circuit check
-1. Turn the ignition switch OFF and disconnect the 2P
connector from the ECT sensor 4.
-2. Turn the ignition switch ON.
-3. Measure the voltage between the No. 2 (Red/Green)
terminal of the ECT sensor 4 harness side 2P connector and the engine ground.
ECT SENSOR 4 HARNESS
SIDE 2P CONNECTOR
TOH3
(RED/GREEN)
VIEWED FROM THE
TERMINAL SIDE
3. ECT sensor 4 ground line open circuit check
-1. Connect the ECM connector B.
-2. Check for the continuity between the No. 1
(Green/Red) terminal of the ECT sensor 4 harness
side 2P connector and the body ground.
ECT SENSOR 4 HARNESS SIDE
2P CONNECTOR
SG2
(GREEN/RED)
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Perform “4. ECT sensor 4 check”.
NO – Repair open in the wire between the ECT
sensor 4 and the engine ground.
4. ECT sensor 4 check
-1. Turn the ignition switch OFF and connect all the connectors.
-2. Turn the ignition switch ON and measure the ECT sensor 4 temperature using the HDS pocket tester.
Does the measurement correspond to the engine
coolant temperature?
YES – When the DTC appears again, substitute a
known-good ECM and recheck.
NO – Replace the ECT sensor 4.
Is the measured voltage 4.75 – 5.25V?
YES – Perform “3. ECT sensor 4 ground line open
circuit check”.
NO – Repair open in the wire between the ECT
sensor 4 and the ECM.
5-56
BF135A•BF150A
7. TROUBLESHOOTING WITHOUT
HDS TESTER
• Check of Number of Blinks of MIL
1. Remove the engine cover and the electric part cover
(Section 4).
2. Disconnect the red 4P connector and connect (shortcircuit) the SCS short connector to the DLC (Data Link
Connector).
4P CONNECTOR
(RED)
• ECM Reset Procedure
1. Turn the ignition switch OFF.
2. Short-circuit the 4P (Red) data link connector located
inside the electric part cover using the special tool
(SCS short connector).
3. Turn the ignition switch ON.
4. Turn the emergency stop switch ON (push) and OFF
(release). Repeat this procedure five times. (Repeat
turning the switch ON for 0.5 sec. or more and turning
it OFF for 0.1 sec. or more.)
5. Check that the buzzer sounds twice.
• The MIL should stay ON.
6. Turn the ignition switch OFF. (ECM reset procedure
completes.)
• Perform the step 4 through the step 6 within 20 seconds.
0.5 sec. or more
SCS SHORT CONNECTOR
070PZ-ZY30100
DLC (DATA LINK
CONNECTOR)
3. Check the number of blinks of the MIL.
Count the number of blinks when the MIL starts blinking. The diagnostic trouble code (DTC) is indicated
repeatedly. The number of long blinks equals the first
digit and the number of short blinks equals the second digit of the DTC.
When multiple problems occur simultaneously, the
MIL repeatedly indicates them by blinking separate
codes, one after another.
Separate problems:
See DTC 1.
See DTC 3.
See DTC 14.
Multiple problems:
See DTC 1
and 3.
See DTC 3
and 4.
See DTC 1
and 14
5-57
ON
(Push)
OFF
(Release)
0.1 sec. or more
Within 20 sec.
BUZZER
IGNITION
SWITCH ON
ON
OFF
IGNITION
SWITCH OFF
BF135A•BF150A
• Final Procedure (After Troubleshooting)
• Connecting Test Harness
1. Disconnect the SCS short connector from the data link
connector.
• Note that the MIL stays ON while the SCS short connector is connected to the data link connector.
Use the test harness (special tool) and a commercially
available digital circuit tester for troubleshooting.
Disconnect the test harness sensor connector if the
instruction tells to do so for troubleshooting.
2. Be sure to reset the ECM after troubleshooting.
The MIL can come ON or blink when the ECM detected poor or loose contact of a connector. If it is hard to
identify the problem part by following the troubleshooting flow chart, check the three connectors of the ECM
and the connector of the probable faulty part, and
clean or repair the connector(s) if necessary.
ECM
TEST HARNESS
070PZ-ZY60100
TEST HARNESS SENSOR CONNECTOR
If the problem cannot be identified by the above procedure, check by following the troubleshooting for the
fuel supply system (P. 5-96).
A CONNECTOR
CONNECTOR
A
C CONNECTOR
CONNECTOR C
(26P)
(6P)
B CONNECTOR
CONNECTOR
B
DIGITAL CIRCUIT
(34P)
TESTER
(Commercially available)
5-58
BF135A•BF150A
a. TROUBLESHOOTING GUIDE
MIL
Detected unit
Probable problem part
Ref. page
No. of blinks
MIL
MIL does
not come
ON
OFF
ECM
• Open circuit in MIL wire
• Blown MIL bulb
• Open circuit or poor grounding of ECM
ground wire
• Faulty ECM
5-61
Stays ON
ON
ECM
• Open circuit in ECM power supply line
• Short circuit in data link connector wire
• Short circuit in MIL wire
• Short circuit in sensor power supply line
• Faulty ECM
5-64
3
ON
MAP (Sensor voltage)
• Open or short circuit in MAP sensor line
• Faulty MAP sensor
• Faulty ECM
5-71
4
ON
CKP sensor (Pulse)
• Open or short circuit in CKP sensor wire
• Faulty CKP sensor
• Faulty ECM
5-72
6
ON
ECT sensor 1 (Sensor voltage)
• Open or short circuit in ECT sensor 1 wire
• Faulty ECT sensor 1
• Faulty ECM
5-74
7
ON
TP sensor (Sensor voltage)
• Open or short circuit in TP sensor wire
• Faulty TP sensor
• Faulty ECM
5-75
8
ON
CMP sensor (Pulse)
• Open or short circuit in CMP sensor
• Faulty CMP sensor
• Faulty ECM
5-77
10
ON
IAT sensor (Sensor voltage)
• Open or short circuit in IAT sensor wire
• Faulty IAT sensor
• Faulty ECM
5-78
13
ON
BARO sensor (Sensor voltage)
• Short circuit in BARO sensor
• Faulty BARO sensor
• Faulty ECM
5-80
14
ON
IAC valve (Input/output current)
• Open or short circuit in IAC valve wire
• Faulty IAC valve
• Faulty ECM
5-81
21
ON
VTEC solenoid
(Output current)
(BF150A only)
• Open circuit or short circuit in VTEC solenoid wire
• Faulty VTEC solenoid
• Faulty ECM
5-82
23
ON
Knock sensor (Sensor voltage)
• Open circuit or short circuit in knock
sensor wire
• Faulty knock sensor
• Faulty ECM
5-83
5-59
BF135A•BF150A
MIL
Detected unit
Probable problem part
Ref. page
ECT sensor 2 (Low voltage)
• Open or short circuit in the ECT sensor 2 wire
• Faulty ECT sensor 2
• Faulty ECM
5-84
ON
ECT sensor 3 (Low voltage)
• Open or short circuit in the ECT sensor 3 wire
• Faulty ECT sensor 3
• Faulty ECM
5-86
26
ON
EOP switch (Current)
• Open or short circuit in the EOP switch wire
• Faulty ECM
5-87
27
ON
ECT sensor 4
(Sensor voltage)
• Open or short circuit in the ECT sensor 4 wire
• Faulty ECT sensor 4
• Faulty ECM
5-89
41
ON
A/F sensor heater (Current)
• Open or short circuit in the A/F sensor
heater wire
• Faulty A/F sensor heater
• Faulty ECM
5-90
48
ON
A/F sensor (Current)
• Open or short circuit in the A/F sensor wire
• Faulty A/F sensor
• Faulty ECM
5-92
No. of blinks
MIL
24
ON
25
When multiple DTC’s main codes appear:
MIL
Detected unit
Probable problem part
Ref. page
No. of blinks
MIL
7, 13
ON
ECM (Sensor voltage)
• Open circuit in the VCC (sensor power
supply) line
--
6, 7
10, 13
24, 25
27, 48
ON
ECM (Sensor voltage)
• Open circuit in the SG (sensor ground) line
--
5-60
BF135A•BF150A
b. TROUBLESHOOTING
• MIL Does Not Come On
1. Fuse check
-1. Turn the ignition switch ON and check that the warning
buzzer sounds twice.
Does the buzzer sound twice?
YES – Perform "6. Alternator indictor light check".
NO – Go to the step 2.
2. Main power supply line check
-1. Disconnect the remote control harness 14P connector.
-2. Measure the voltage between the No. 3 (White/ Black)
terminal of the main harness side 14P connector and
the engine ground.
• Note that the battery voltage is constantly applied to
the White/Black terminal. Take care not to short-circuit the terminal.
MAIN HARNESS SIDE
14P CONNECTOR
WHITE/BLACK
-2. Check the No. 4 (15A) fuse.
Is the fuse normal?
YES – Go to the step 3.
NO – Repair short in the wire between the No. 4
fuse and the ECM, and between the No. 4
fuse and the injector. After repair, replace the
No. 4 fuse.
-3. Check the No. 7 (30A) fuse.
Is the fuse normal?
YES – Go to the step 4.
NO – Repair short in the wire between the PGM-FI
main relay and fuse box, and between the
PGM-FI main relay and starter magnetic
switch. After repair, replace the No. 7 fuse.
VIEWED FROM THE TERMINAL SIDE
Is there the battery voltage?
YES – Go to the step 3.
NO – Repair open in the main harness wire.
-3. Turn the ignition switch ON. Check for the continuity
between the No. 1 (White/Black) and the No. 2
(Black/Yellow) terminals of the remote control box harness side 14P connector.
REMOTE CONTROL
HARNESS SIDE 14P
CONNECTOR
-4. Check the No. 3 (10A) fuse.
Is the fuse normal?
YES – Perform "2. Main power supply line check".
NO – Repair short in the wire between the fuse box
and ignition switch, between the fuse box and
alternator, between the fuse box and power
trim/tilt switch or the power tilt switch. After
repair, replace the No. 3 fuse.
BLACK/YELLOW
WHITE/BLACK
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Perform "3. IGP power supply line check".
NO – Go to the step 4.
-4. Check the ignition switch (P. 16-9).
Is the ignition switch normal?
YES – Repair open in the remote control box harness.
NO – The ignition switch is faulty.
5-61
BF135A•BF150A
3. IGP power supply line check
-1. Turn the ignition switch OFF and disconnect the PGMFI main relay 6P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 2 (Black/Yellow) terminal of the PGMFI main relay harness side 6P connector and the
engine ground.
PGM-FI MAIN RELAY
HARNESS SIDE 6P
CONNECTOR
4. ECM power supply line check
-1. Turn the ignition switch OFF and disconnect the fuse
box 3P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 3 (Yellow/Black) terminal of the fuse
box side 3P connector and the engine ground.
FUSE BOX SIDE 3P
CONNECTOR
BLACK/YELLOW
YELLOW/BLACK
VIEWED FROM THE TERMINAL SIDE
VIEWED FROM THE TERMINAL SIDE
Is there the battery voltage?
YES – Go to the step 3.
NO – Repair open in the main harness wire.
-3. Turn the ignition switch OFF. Check for the continuity
between the No. 6 (Black) terminal of the PGM-FI main
relay 6P connector and the engine ground.
PGM-FI MAIN RELAY
HARNESS SIDE 6P
CONNECTOR
BLACK
Is there the battery voltage?
YES – Go to the step 3.
NO – PGM-FI main relay is faulty, or fuse box is
faulty.
-3. Turn the ignition switch OFF and disconnect the ECM
connector C.
-4. Check for the continuity between the No.2
(Yellow/Black) terminal of the fuse box harness side 3P
connector and the respective terminals of the No. 1
(Yellow/Black) and the No. 5 (Yellow/Black) terminals of
the ECM connector C.
ECM CONNECTOR C
FUSE BOX HARNESS
SIDE 3P CONNECTOR
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Perform “4. ECM power supply line check”.
NO – Repair open in the main harness (Black) wire.
YELLOW/BLACK
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Perform “5. MIL power supply line check”.
NO – Repair open in the main harness wire.
5-62
BF135A•BF150A
5. MIL power supply line check
-1. Turn the ignition switch OFF and disconnect the fuse
box 3P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 2 (Yellow/Red) terminal of the fuse
box side 3P connector and the engine ground.
FUSE BOX SIDE 3P
CONNECTOR
YELLOW/RED
VIEWED FROM THE TERMINAL SIDE
Is there the battery voltage?
YES – Go to the step 3.
NO – PGM-FI main relay is faulty.
-3. Turn the ignition switch OFF and connect the fuse box
3P connector.
-4. Disconnect the MIL 6P connector.
-5. Turn the ignition switch ON. Measure the voltage
between the No. 6 (Yellow/Red) terminal of the MIL
harness side 6P connector and the engine ground.
MIL HARNESS SIDE
6P CONNECTOR
YELLOW/RED
VIEWED FROM THE TERMINAL SIDE
Is there the battery voltage?
YES – Perform “6. Alternator indicator light check”.
NO – Repair open in the main wire harness.
5-63
6. Alternator indicator light check
-1. Turn the ignition switch ON and check the alternator
indicator light.
Does the alternator indicator light come ON?
YES – Perform “7. MIL ON line check”.
NO – Replace the MIL.
7. MIL ON line check
-1. Turn the ignition switch OFF and connect the test harness.
-2. Connect the test harness B-25 terminal to the engine
ground to short-circuit. Turn the ignition switch ON and
check the MIL.
B-25
Does the MIL come ON?
YES – Substitute a known-good ECM and recheck.
NO – Repair open in the main harness wire
between the MIL and the ECM.
BF135A•BF150A
• MIL ON but MIL Does Not Blink
With SCS Circuit Shorted
1. Engine start check
-1. Disconnect the SCS short connector and start the
engine.
Does the engine start?
YES – Perform “2. Data link connector line check”.
NO – Perform “3. Sensor check”.
-6. Connect the SCS short connector to the data link connector to short-circuit.
-7. Measure the voltage between the test harness B-16
terminal (+) and A-1 (–) terminal, and between the B16 terminal (+) and B-17 terminal (–).
B-16
A-1
B-17
2. Data link connector line check
-1. Turn the ignition switch OFF and connect the test harness (P. 5-58).
-2. Disconnect the test harness sensor connector.
-3. Turn the ignition switch ON. Measure the voltage
between the test harness B-16 terminal (+) and A-1
terminal (–), and between the B-16 terminal (+) and B17 terminal (–).
A-1
B-16
Is the measured voltage 4.30 – 5.25V?
YES – Go to the step 8.
NO – Go to the step 10.
-8. Disconnect the SCS short connector.
-9. Turn the ignition switch OFF. Check for the continuity
between the data link connector No. 1 (Black) terminal
and the engine ground.
DATA LINK CONNECTOR
B-17
Is the measured voltage 4.30 – 5.25V?
YES – Go to the step 4.
NO – Substitute a known-good ECM and recheck.
-4. Turn the ignition switch OFF and connect the test harness.
-5. Turn the ignition switch ON. Measure the voltage
between the test harness B-16 terminal (+) and A-1
terminal (–), and between the B-16 terminal (+) and B17 terminal (–).
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Repair open in the main harness between the
data link connector and the ECM.
NO – Repair open in the main harness between the
data link connector and the engine ground.
B-16
A-1
B-17
Is the measured voltage 4.30 – 5.25V?
YES – Repair open in the wire harness between the
ECM and the data link connector.
NO – Go to the step 6.
-10. Disconnect the SCS short connector from the data link
connector.
-11. Turn the ignition switch OFF and disconnect the ECM
connector A.
-12. Turn the ignition switch ON and check that the MIL
comes ON.
Does the MIL come ON?
YES – Repair short in the main harness (Red/Blue)
between the MIL and the ECM.
NO – Substitute a known-good ECM and recheck.
5-64
BF135A•BF150A
3. Sensor check
-1. Turn the ignition switch ON.
-2. Disconnect the MAP sensor 3P connector and check
the MIL.
-9. With the ECU connector A disconnected, check for the
continuity between the test harness A-12 terminal and
the engine ground.
A-12
Does the MIL go OFF?
YES – Replace the MAP sensor.
NO – Go to the step 3.
-3. Connect the MAP sensor 3P connector.
-4. Disconnect the TP sensor 3P connector and check the
MIL.
Does the MIL go OFF?
YES – Replace the TP sensor.
NO – Go to the step 5.
-5. Connect the TP sensor 3P connector.
-6. Disconnect the BARO sensor 3P connector and check
the MIL.
Does the MIL go OFF?
YES – Replace the BARO sensor.
NO – Go to the step 7.
-7. Turn the ignition switch OFF and connect the test harness.
-8. Check for the continuity between the test harness B-4
terminal and the engine ground with the ECM connector A disconnected.
B-4
Is there the continuity?
YES – Repair open in the wire between the ECM
and the BARO sensor.
NO – Perform “4. ECM main power supply line
check”.
4. ECM main power supply line check
-1. Connect the ECM connector A.
-2. Check for the continuity between the test harness C-1
terminal and the respective terminals of A-1 and B-17
terminals.
Measure the voltage between the test harness C-5 terminal and the respective terminals of A-1 and B-17 terminals.
A-1
C-1
C-5
B-17
Is there the continuity?
YES – Repair open in the main harness between the
ECM and the MAP sensor.
NO – Go to the step 9.
5-65
Is there the continuity?
YES – Substitute a known-good ECM and recheck.
NO – Check the PGM-FI main relay harness (P. 597).
BF135A•BF150A
• Alert System Initial Operation Is Faulty
1. Wire harness short-circuit check
-1. Turn the ignition switch OFF and connect the test harness.
-2. Disconnect the ECM connector A, B and C from the
ECM.
-3. Turn the ignition switch ON and check whether the
buzzer sounds.
Does the buzzer sound?
YES – Repair short in the wire between the buzzer
and the ECM.
NO – Go to the step 4.
-4. Check the oil pressure indicator light.
Does the oil pressure indicator light come ON?
YES – Go to the step 5.
NO – Repair short in the wire between the oil pressure indicator light and the ECM.
-5. Check the overheat indicator light.
Does the overheat indicator light come ON?
YES – Repair short in the wire between the overheat
indicator light and the ECM.
NO – Go to the step 6.
-6. Check the MIL.
-3. Turn the ignition switch OFF and disconnect the
Yellow/Green terminal from the buzzer.
-4. Connect the Yellow/Green terminal of the buzzer to the
Black terminal with a jumper wire to short-circuit.
-5. Turn the ignition switch ON and check whether the
buzzer sounds.
Does the buzzer sound?
YES – Repair open in the wire between the buzzer
and the ECM.
NO – Go to the step 6.
-6. Check the buzzer (single unit check).
Is the buzzer normal?
YES – Go to the step 7.
NO – The buzzer is faulty.
-7. Check the ignition switch (single unit check) (P. 16-9).
Is the ignition switch normal?
YES – Go to the step 8.
NO – The ignition switch is faulty.
-8. Disconnect the remote control box harness side 14P
connector.
-9. Turn the ignition switch ON. Check for the continuity
between the No. 1 (White/Black) and the No. 2
(Black/Yellow) terminals of the remote control box harness side 14P connector.
REMOTE CONTROL
HARNESS SIDE 14P
CONNECTOR
Does the MIL come ON?
YES – Repair short in the wire between the MIL and
the ECM.
NO – Perform "2. Buzzer line check".
BLACK/YELLOW
2. Buzzer line check
-1. Connect the test harness B-18 terminal to the engine
ground to short-circuit.
-2. Turn the ignition switch ON and check that the buzzer
sounds.
WHITE/BLACK
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Repair open in the main harness.
NO – Repair open in the remote control box harness.
B-18
Does the buzzer sound?
YES – Perform “3. Overheat indicator line check”.
NO – Go to the step 3.
5-66
BF135A•BF150A
3. Overheat indicator line check
-1. Connect the test harness B-31 terminal to the engine
ground to short-circuit.
-2. Turn the ignition switch ON and check that the overheat indicator light comes ON.
4. Oil pressure indicator line check
-1. Connect the test harness B-32 terminal to the engine
ground to short-circuit.
-2. Turn the ignition switch ON and check the oil pressure
indicator light.
B-31
B-32
Does the overheat indicator light come ON?
YES – Perform "4. Oil pressure indicator line check".
NO – Go to the step 3.
Does the oil pressure indicator light come ON?
YES – Go to the step 3.
NO – Perform "5. MIL line check".
-3. Turn the ignition switch OFF. Disconnect the indicator
light Red terminal and connect it to the Black terminal
with a jumper wire to short-circuit.
-4. Turn the ignition switch ON and check the overheat
indicator light.
-3. Turn the ignition switch OFF. Disconnect the indicator
light Yellow terminal and connect it to the Black terminal with a jumper wire to short-circuit.
-4. Turn the ignition switch ON and check the oil pressure
indicator light.
Does the overheat indicator light come ON?
YES – Repair open in the wire between the ECM
and the indicator light.
NO – Go to the step 5.
Does the oil pressure indicator light come ON?
YES – Go to the step 5.
NO – Repair open in the wire between the ECM
and the indicator light.
-5. Turn the ignition switch OFF and connect the indicator
light Red terminal.
-6. Disconnect the remote control harness 14P connector.
-7. Check for the continuity between the No. 7 (Red) and
the No. 2 (Black/Yellow) terminals of the remote control
harness side 14P connector.
-5. Turn the ignition switch OFF and connect the indicator
light Yellow terminal.
-6. Disconnect the remote control harness 14P connector.
-7. Check for the continuity between the No. 6 (Yellow) and
the No. 2 (Black/Yellow) terminals of the remote control
harness side 14P connector.
REMOTE CONTROL
HARNESS SIDE 14P
CONNECTOR
BLACK/YELLOW
RED
REMOTE CONTROL
HARNESS SIDE 14P
CONNECTOR
BLACK/YELLOW
YELLOW
VIEWED FROM THE TERMINAL SIDE
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Repair open in the main harness.
NO – The indicator light is faulty, or repair open in
the remote control harness.
5-67
Is there the continuity?
YES – Repair open in the main harness.
NO – The indicator light is faulty, or repair open in
the remote control harness.
BF135A•BF150A
5. MIL line check
-1. Disconnect the ECM connector B and connect the test
harness B-25 terminal to the engine ground to shortcircuit.
-2. Turn the ignition switch ON and check the MIL.
B-25
6. Alternator indicator line check
-1. Turn the ignition switch OFF and disconnect the alternator 4P connector.
-2. Check for the continuity between the test harness B-19
terminal and the engine ground.
B-19
Does the MIL come ON?
YES – Go to the step 3.
NO – Perform “6. Alternator indicator line check”.
-3. Turn the ignition switch ON and measure the voltage
between the test harness B-25 terminal and the
engine ground.
Is there the continuity?
YES – Repair short in the wire between the ECM
and the alternator.
NO – Go to the step 3.
-3. Check for the continuity between the No. 1
(White/Blue) terminal of the alternator harness side 4P
connector and the test harness B-19 terminal.
ALTERNATOR HARNESS
SIDE 4P CONNECTOR
ACG
(WHITE/BLUE)
B-25
B-19
Is there the battery voltage?
YES – Repair open in the main harness between the
ECM and the MIL.
NO – Go to the step 4.
-4. Turn the ignition switch OFF and disconnect the MIL
6P connector.
-5. Turn the ignition switch ON. Measure the No. 2
(Yellow/Red) terminal of the MIL 6P main harness side
connector and the engine ground.
MIL HARNESS SIDE
6P CONNECTOR
YELLOW/RED
B-19
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Substitute a known-good ECM and recheck.
NO – Repair open in the wire between the ECM
and the alternator.
7. Water level sensor line check
-1. Disconnect the water separator water level sensor 4P
connector.
-2. Check for the continuity between the test harness A-19
terminal and the engine ground.
VIEWED FROM THE TERMINAL SIDE
Is there the battery voltage?
YES – Check the MIL. If it is normal, replace the MIL
harness.
NO – Perform the troubleshooting of “MIL does not
come ON” (P. 5-61).
A-19
Is there the continuity?
YES – Repair short in the main harness between the
water level sensor and the ECM.
NO – Go to the step 3.
5-68
BF135A•BF150A
-3. Check for the continuity between the No. 1 (Brown) terminal of the water separator water level sensor harness side connector and the test harness A-19 terminal.
WATER LEVEL SENSOR HARNESS SIDE
2P CONNECTOR
9. EOP switch (high pressure side) line check
-1. Disconnect the high pressure side EOP switch 2P connector.
-2. Check for the continuity between the test harness A-17
terminal and the engine ground.
A-17
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Perform "8. EOP switch (low pressure side)
line check".
NO – Repair open in the main harness between the
water level sensor and the ECM.
8. EOP switch (low pressure side) line check
-1. Disconnect the low pressure side EOP switch wire.
-2. Check for the continuity between the test harness B-14
terminal and the engine ground.
B-14
Is there the continuity?
YES – Repair short in the main harness between the
high pressure side EOP switch and the ECM.
NO – Go to the step 3.
-3. Check for the continuity between the test harness A-17
terminal and the No. 1 (Yellow/Red) terminal of the
EOP switch harness side 2P connector.
EOP SWITCH
(HIGH PRESSURE SIDE)
HARNESS SIDE
2P CONNECTOR
OPSH
(YELLOW/RED)
A-17
Is there the continuity?
YES – Repair short in the main harness between the
low pressure side EOP switch and the ECM.
NO – Go to the step 3.
-3. Check for the continuity between the test harness B-14
terminal and the EOP switch harness side (Pink) terminal.
EOP SWITCH HARNESS
SIDE TERMINAL
B-14
PINK
Is there the continuity?
YES – Perform “9. EOP switch (high pressure side)
line check”.
NO – Repair open in the main harness between the
low pressure side EOP switch and the ECM.
5-69
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Connect each connector and recheck. If
there is any abnormality, substitute a knowngood ECM and recheck.
NO – Repair open in the main harness between the
high pressure side EOP switch and the ECM.
BF135A•BF150A
• Neutral Switch Malfunction
• Tachometer Malfunction
Engine speed does not increase in gear (BF150A only)
Tachometer does not function so that it corresponds to the engine speed.
Perform neutral switch inspection (P. 17-13) and neutral
position adjustment (P. 3-25) before troubleshooting.
1. Neutral switch line check
-1. Start the engine and warm it up with the gear in neutral.
-2. Disconnect the neutral switch 3P connector. Raise the
engine speed slowly and check that the engine speed
changes when it reaches approx. 4,500 rpm.
Does the engine speed change (Does VTEC function)?
YES – Replace the neutral switch.
NO – Go to the step 3.
-3. Stop the engine and connect the test harness.
Disconnect the ECM connector A, B and C.
-4. With the neutral switch 2P connector disconnected,
check for the continuity between the test harness B-13
terminal and the engine ground.
1. Tachometer power supply check
-1. Turn the ignition switch OFF and disconnect the
tachometer’s connecting terminal.
-2. Turn the ignition switch ON and measure the voltage
between the harness side Black/Yellow terminal and
the Black terminal.
Is there the battery voltage?
YES – Perform “2. Tachometer pulse line check”.
NO – Repair open in the meter harness.
2. Tachometer pulse line check
-1. Turn the ignition switch OFF and connect the test harness.
Disconnect the ECM connector A, B and C.
-2. Check for the continuity between the test harness B-33
terminal and the engine ground.
B-13
B-33
Is there the continuity?
YES – Repair short in the main harness between the
ECM and the neutral switch.
NO – Substitute a known-good ECM and recheck.
Is there the continuity?
YES – Repair short in the main harness between the
tachometer and the ECM.
NO – Go to the step 3.
-3. Check for the continuity between the test harness B-33
terminal and the meter harness Gray terminal.
METER HARNESS
TERMINAL
B-33
GRAY
Is there the continuity?
YES – Substitute a known-good ECM and recheck.
NO – Repair open in the main harness between the
tachometer and the ECM.
5-70
BF135A•BF150A
• MAP Sensor Troubleshooting
MIL blinks 3 times.
1. Symptom reproduction test
-1. Reset the ECM.
-2. Turn the ignition switch OFF and connect the test harness. Hold the sensor connector connected.
-3. Turn the ignition switch ON.
-4. Measure the voltage between the test harness B-5 terminal (+) and the B-6 terminal (–).
3. MAP sensor signal line open circuit check
-1. Connect the ECM connector A.
-2. Turn the ignition switch ON.
-3. Measure the voltage between the No. 2 (White/Red)
terminal of the MAP sensor harness side 3P connector and the engine ground.
MAP SENSOR HARNESS
SIDE 3P CONNECTOR
PB (WHITE/RED)
B-5
B-6
VIEWED FROM THE TERMINAL SIDE
Is the measured voltage 0.22 – 3.15V?
YES – Temporary failure (Disappeared)
NO – Perform "2. MAP sensor signal line short circuit check".
2. MAP sensor signal line short circuit check
-1. Turn the ignition switch OFF and disconnect the MAP
sensor 3P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 3 (Brown/Yellow) terminal of the MAP
sensor harness side 3P connector and the engine
ground.
Is the measurement 4.75 – 5.25V?
YES – Perform "4. MAP sensor signal line short circuit check".
NO – Repair open in the wire between the ECM
and the MAP sensor.
4. MAP sensor signal line short circuit check
-1. Check for the continuity between the No. 2 (White/
Red) terminal of the MAP sensor harness side 3P connector and the body ground.
MAP SENSOR HARNESS
SIDE 3P CONNECTOR
MAP SENSOR HARNESS
SIDE 3P CONNECTOR
VCC1
(BROWN/YELLOW)
PB (WHITE/RED)
VIEWED FROM THE TERMINAL SIDE
VIEWED FROM THE TERMINAL SIDE
Is the measured voltage 4.75 – 5.25V?
YES – Perform "3. MAP sensor signal line open circuit check".
NO – Repair open in the wire between the ECM
and the MAP sensor.
5-71
Is there the continuity?
YES – Repair short in the wire between the MAP
sensor and the ECM.
NO – Perform “5. MAP sensor ground line open circuit check”.
BF135A•BF150A
5. MAP sensor ground line open circuit check
-1. Check for the continuity between the No. 1 (Green/
Red) terminal of the MAP sensor harness side 3P connector and the body ground.
MAP SENSOR HARNESS
SIDE 3P CONNECTOR
MIL blinks 4 times.
1. Symptom reproduction test
-1. Reset the ECM.
-2. Start the engine and let it run at idling under no load.
-3. Check the MIL.
Does the MIL come ON?
YES – Perform "2. CKP sensor power supply line
open circuit check".
NO – Temporary failure (Disappeared)
SG1 (GREEN/RED)
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Perform “6. MAP sensor check”.
NO – Repair open in the wire between the MAP
sensor and the ECM.
6. MAP sensor check
-1. Connect the MAP sensor 3P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the test harness B-5 terminal (+) and the B-6
terminal (–).
B-5
• CKP Sensor Troubleshooting
2. CKP sensor power supply line open circuit check
-1. Turn the ignition switch OFF and disconnect the CKP
sensor 3P connector.
-2. Turn the ignition switch ON and measure the voltage
between the No. 1 (Yellow/Black) terminal of the CKP
sensor harness side 3P connector and the engine
ground.
CKP SENSOR HARNESS
SIDE 3P CONNECTOR
IGP
(YELLOW/BLACK)
B-6
VIEWED FROM THE TERMINAL SIDE
Is the measurement 2.76 – 2.96V?
YES – Substitute a known-good ECM and recheck.
NO – Replace the MAP sensor.
Is there the battery voltage?
YES – Perform "3. CKP sensor signal line open circuit check".
NO – Repair open in the wire between the ECM
and CKP sensor.
3. CKP sensor signal line open circuit check
-1. Turn the ignition switch ON. Measure the voltage
between the No. 3 (Blue) terminal of the CKP sensor
harness side 3P connector and the engine ground.
CKP SENSOR HARNESS
SIDE 3P CONNECTOR
CRK (BLUE)
VIEWED FROM THE TERMINAL SIDE
5-72
BF135A•BF150A
Is the measured voltage 4.75 – 5.25V?
YES – Perform "4. CKP sensor signal line short circuit check".
NO – Repair open in the wire between the CKP
sensor and the ECM.
4. CKP sensor signal line short circuit check
-1. Turn the ignition switch OFF. Check for the continuity
between the No. 3 (Blue) terminal of the CKP sensor
harness side 3P connector and the engine ground.
CKP SENSOR HARNESS
SIDE 3P CONNECTOR
CRK (BLUE)
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Perform "5. CKP sensor ground line open circuit check".
NO – Repair open in the wire between the CKP
sensor and the ECM.
5. CKP sensor ground line open circuit check
-1. Check for the continuity between the No. 2 (Green/
Black) terminal of the CKP sensor harness side 3P
connector and the engine ground.
CKP SENSOR HARNESS
SIDE 3P CONNECTOR
LG1
(GREEN/BLACK)
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Perform "6. CKP sensor check".
NO – Repair open in the wire between the CKP
sensor and the ECM.
5-73
6. CKP sensor check
-1. Reset the ECM.
-2. Start the engine and let it run at idling under no load.
Check the MIL.
Does the MIL come ON?
YES – Replace the CKP sensor and recheck. If the
MIL comes ON again, substitute a knowngood ECM and recheck.
NO – End of the check.
BF135A•BF150A
• ECT Sensor 1 Troubleshooting
MIL comes ON 6 times.
1. Symptom reproduction test
-1. Reset the ECM.
-2. Turn the ignition switch OFF and connect the test harness.
• Hold the sensor connector connected.
-3. Turn the ignition switch ON.
-4. Measure the voltage between the test harness B-8 terminal (+) and the A-2 terminal (–).
A-2
3. ECT sensor 1 line short circuit check
-1. Turn the ignition switch OFF and disconnect the ECM
connector B.
-2. Check for the continuity between the No. 2 (Red/White)
terminal of the ECT sensor 1 harness side 2P connector and the body ground.
ECT SENSOR 1 HARNESS SIDE
2P CONNECTOR
TE (RED/WHITE)
B-8
VIEWED FROM THE TERMINAL SIDE
Is the measured voltage 0.22 – 3.15V?
YES – Temporary failure (Disappeared)
NO – Perform "2. ECT sensor 1 signal line open circuit check".
Is there the continuity?
YES – Repair short in the wire between the ECM
and the ECT sensor 1.
NO – Perform "4. ECT sensor 1 ground line short
circuit check".
2. ECT sensor 1 signal line open circuit check
-1. Turn the ignition switch ON. Measure the voltage
between the No. 2 (Red/White) terminal of the ECT
sensor 1 harness side 2P connector and the engine
ground.
4. ECT sensor 1 ground line short circuit check
-1. Turn the ignition switch OFF. Check for the continuity
between the No. 1 (Green/Red) terminal of the ECT
sensor 1 harness side 2P connector and the engine
ground.
ECT SENSOR 1 HARNESS SIDE
2P CONNECTOR
TE (RED/WHITE)
VIEWED FROM THE TERMINAL SIDE
Is the measured voltage 4.30 – 5.25V?
YES – Perform "3. ECT sensor 1 line short circuit
check".
NO – Repair open in the wire between the ECM
and ECT sensor 1.
ECT SENSOR 1 HARNESS SIDE
2P CONNECTOR
SG2 (GREEN/RED)
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Perform the 5. ECT sensor 1 check.
NO – Repair open in the wire between the ECM
and the ECT sensor.
5-74
BF135A•BF150A
5. ECT sensor 1 check
-1. Turn the ignition switch OFF and disconnect the 2P
connector of the ECT sensor 1.
-2. Measure the resistance between the No. 1 and the No.
2 terminals of the ECT sensor 1 side 2P connector.
ECT SENSOR 1 SIDE
2P CONNECTOR
VIEWED FROM THE TERMINAL SIDE
• TP Sensor Troubleshooting
MIL blinks 7 times.
1. Symptom reproduction test
-1. Reset the ECM.
-2. Turn the ignition switch OFF and connect the test harness.
Hold the sensor connector connected.
-3. Turn the ignition switch ON.
-4. Measure the voltage between the B-7 terminal (+) and
the A-2 terminal (–) of the test harness.
A-2
B-7
RESISTANCE
Is the measured voltage 0.08 – 4.92V?
YES – Temporary failure (Disappeared)
NO – Perform "2.TP sensor power supply line open
circuit check".
ENGINE COOLANT TEMPERATURE
Is there the resistance corresponding to the engine
coolant temperature?
YES – Substitute a known-good ECM and recheck.
NO – Replace the ECT sensor 1.
2. TP sensor power supply line open circuit check
-1. Turn the ignition switch ON. Measure the voltage
between the No. 3 (Brown/White) terminal of the TP
sensor harness side 3P connector and the engine
ground.
TP SENSOR HARNESS SIDE
3P CONNECTOR
VCC2
(BROWN/WHITE)
VIEWED FROM THE TERMINAL SIDE
Is the measured voltage 4.75 – 5.25V?
YES – Perform "3. TP sensor signal line open circuit
check".
NO – Repair open in the wire between the TP sensor and the ECM.
5-75
BF135A•BF150A
3. TP sensor signal line open circuit check
-1. Turn the ignition switch OFF and disconnect the TP
sensor connector.
-2. Measure the voltage between the No. 2 (Red/Black)
terminal of the TP sensor harness side 3P connector
and the engine ground.
5. TP sensor ground line open circuit check
-1. Turn the ignition switch OFF and disconnect the TP
sensor 3P connector.
-2. Check for the continuity between the No. 1 (Green/
Red) terminal of the TP sensor harness side 3P connector and the engine ground.
TP SENSOR HARNESS SIDE
3P CONNECTOR
TP SENSOR HARNESS SIDE
3P CONNECTOR
SG2 (GREEN/RED)
THL (RED/BLACK)
VIEWED FROM THE TERMINAL SIDE
Is the measured voltage 4.75 – 5.25V?
YES – Perform "4. TP sensor signal line short circuit
check".
NO – Repair open in the wire between the TP sensor and the ECM.
4. TP sensor signal line short circuit check
-1. Turn the ignition switch OFF and disconnect the TP
sensor connector.
-2. Check for the continuity between the No. 2 (Red/
Black) terminal of the TP sensor harness side 3P connector and the engine ground.
TP SENSOR HARNESS SIDE
3P CONNECTOR
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Perform "6. TP sensor check".
NO – Repair open in the wire between the TP sensor and the engine ground.
6. TP sensor check
-1. Turn the ignition switch OFF and connect the TP sensor 3P connector.
-2. Measure the voltage between the B-7 terminal and the
A-2 terminal of the test harness.
A-2
B-7
THL (RED/BLACK)
VIEWED FROM THE TERMINAL SIDE
Is the voltage 4.49 – 4.85V when the throttle is fully
open and 0.44 – 0.56V when the throttle is fully
closed?
YES – Substitute a known-good ECM and recheck.
NO – Replace the TP sensor.
Is there the continuity?
YES – Repair short in the wire between the TP sensor and the ECM.
NO – Perform "5.TP sensor ground line open circuit
check".
5-76
BF135A•BF150A
• CMP Sensor Troubleshooting
MIL blinks 8 times.
1. Symptom reproduction test
-1. Reset the ECM.
-2. Start the engine and let it run at idling under no load.
-3. Check the MIL.
Does the MIL come ON?
YES – Check the pulse plate. If it is normal, perform
"2. CMP sensor power supply line open circuit
check". If it is abnormal, replace the pulse
plate and recheck.
NO – Temporary failure (Disappeared)
2. CMP sensor power supply line open circuit check
-1. Turn the ignition switch ON. Measure the voltage
between the No. 1 (Yellow/Black) terminal of the CMP
sensor harness side 3P connector and the engine
ground.
CMP SENSOR HARNESS SIDE
3P CONNECTOR
IGP
(YELLOW/BLACK)
Is the voltage 4.75 – 5.25V?
YES – Perform "4. CMP sensor signal line short circuit check".
NO – Repair open in the wire between the CMP
sensor and the ECM.
4. CMP sensor signal line short circuit check
-1. Turn the ignition switch OFF and disconnect the CMP
sensor 3P connector.
-2. Check for the continuity between the No. 3 (Green) terminal of the CMP sensor harness side 3P connector
and the engine ground.
CMP SENSOR HARNESS SIDE
3P CONNECTOR
TDC (GREEN)
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the CMP
sensor and the ECM.
NO – Perform "5. CMP sensor ground line open circuit check".
VIEWED FROM THE TERMINAL SIDE
Is there the battery voltage?
YES – Perform "3. CMP sensor signal line open circuit check".
NO – Repair open in the wire between the No. 4
fuse and the CMP sensor.
3. CMP sensor signal line open circuit check
-1. Turn the ignition switch ON. Measure the voltage
between the No. 3 (Green) terminal of the CMP sensor
harness side 3P connector and the engine ground.
5. CMP sensor ground line open circuit check
-1. Turn the ignition switch OFF and disconnect the CMP
sensor 3P connector.
-2. Check for the continuity between the No. 2 (Green/
Black) terminal of the CMP sensor harness side 3P
connector and the engine ground.
CMP SENSOR HARNESS SIDE
3P CONNECTOR
LG1
(GREEN/BLACK)
CMP SENSOR HARNESS SIDE
3P CONNECTOR
TDC (GREEN)
VIEWED FROM THE TERMINAL SIDE
5-77
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Perform “6. CMP sensor check”.
NO – Repair open in the wire between the CMP
sensor and the engine ground.
BF135A•BF150A
6. CMP sensor check
-1. Reset the ECM.
-2. Start the engine and let it run at idling under no load.
Check the MIL.
Does the MIL come ON?
YES – Replace the CMP sensor and recheck. If the
MIL comes ON again, substitute a knowngood ECM and recheck.
NO – End of the check
• IAT Sensor Troubleshooting
MIL blinks 10 times.
1. Symptom reproduction check
-1. Reset the ECM.
-2. Turn the ignition switch OFF and connect the test harness.
• Hold the sensor connector connected.
-3. Turn the ignition switch ON.
-4. Measure the voltage between the B-11 terminal (+)
and the A-2 terminal (-) of the test harness.
A-2
B-11
Is the voltage 0.08 – 4.92V?
YES – Temporary failure (Disappeared)
NO – Perform "2. IAT sensor signal line open circuit
check".
2. IAT sensor signal line open circuit check
-1. Turn the ignition switch OFF and disconnect the IAT
sensor 2P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 2 (Red/Yellow) terminal of the IAT
sensor harness side 2P connector and the engine
ground.
IAT SENSOR HARNESS SIDE
2P CONNECTOR
TA (RED/YELLOW)
VIEWED FROM THE TERMINAL SIDE
Is the voltage 4.75 – 5.25V?
YES – Perform “3. IAT sensor signal line short circuit
check”.
NO – Repair open in the wire between the IAT sensor and the ECM.
5-78
BF135A•BF150A
3. IAT sensor signal line short circuit check
-1. Turn the ignition switch OFF and disconnect the ECM
connector B.
-2. Check for the continuity between the No. 2 (Red/
Yellow) terminal of the IAT sensor harness side 2P
connector and the body ground.
5. IAT sensor check
-1. Turn the ignition switch OFF and disconnect the IAT
sensor 2P connector.
-2. Measure the resistance between the No. 1 and the No.
2 terminals of the IAT sensor side 2P connector.
IAT SENSOR HARNESS SIDE
2P CONNECTOR
IAT SENSOR SIDE
2P CONNECTOR
TA (RED/YELLOW)
VIEWED FROM THE TERMINAL SIDE
4. IAT sensor ground line short circuit check
-1. Turn the ignition switch OFF.
-2. Check for the continuity between the No. 1 (Green/
Red) terminal of the IAT sensor harness side 2P connector and the body ground.
IAT SENSOR HARNESS SIDE
2P CONNECTOR
SG2 (GREEN/RED)
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Perform "5. IAT sensor check".
NO – Repair open in the wire between the IAT sensor and the engine ground.
5-79
RESISTANCE
Is there the continuity?
YES – Repair short in the wire between the IAT sensor and the ECM.
NO – Perform "4. IAT sensor ground line short circuit check".
VIEWED FROM THE TERMINAL SIDE
INTAKE AIR TEMPERATURE
Is there the resistance corresponding to the ambient
temperature?
YES – Substitute a known-good ECM and recheck.
NO – Replace the IAT sensor and recheck.
BF135A•BF150A
• BARO Sensor Troubleshooting
MIL blinks 13 times.
1. Symptom reproduction test
-1. Reset the ECM.
-2. Turn the ignition switch OFF and connect the test harness.
• Hold the sensor connector connected.
-3. Turn the ignition switch ON.
-4. Measure the voltage between the A-5 terminal (+) and
the A-2 terminal (–) of the test harness.
3. BARO sensor signal line open circuit check
-1. Turn the ignition switch ON. Measure the voltage
between the No. 2 (White/Blue) terminal of the BARO
sensor harness side 3P connector and the body
ground.
BARO SENSOR HARNESS SIDE
3P CONNECTOR
PA (WHITE/BLUE)
A-5
VIEWED FROM THE TERMINAL SIDE
A-2
Is there 1.58 – 4.49V?
YES – Temporary failure (Disappeared)
NO – Perform "2. BARO sensor power supply line
open circuit check".
2. BARO sensor power supply line open circuit check
-1. Turn the ignition switch OFF and disconnect the BARO
sensor 3P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No. 3 (Brown/White) terminal of the
BARO sensor harness side 3P connector and the
body ground.
Is the voltage 4.75 – 5.25V?
YES – Perform “4. BARO sensor signal line short circuit check”.
NO – Repair open in the wire between the BARO
sensor and the ECM.
4. BARO sensor signal line short circuit check
-1. Turn the ignition switch OFF and disconnect the ECM
connector B.
-2. Check for the continuity between the No. 2
(White/Blue) terminal of the BARO sensor harness
side 3P connector and the body ground.
BARO SENSOR HARNESS SIDE
3P CONNECTOR
BARO SENSOR HARNESS SIDE
3P CONNECTOR
VCC2
(BROWN/WHITE)
PA (WHITE/BLUE)
VIEWED FROM THE TERMINAL SIDE
VIEWED FROM THE TERMINAL SIDE
Is the voltage 4.75 – 5.25V?
YES – Perform "3. BARO sensor signal line open circuit check".
NO – Repair open in the wire between the BARO
sensor and the ECM.
Is there the continuity?
YES – Repair short in the wire between the ECM
and the BARO sensor.
NO – Perform "5. BARO sensor ground line open
circuit check".
5-80
BF135A•BF150A
5. BARO sensor ground line open circuit check
-1. Turn the ignition switch ON. Measure the voltage
between the No. 1 (Green/Red) terminal of the BARO
sensor harness side 3P connector and the engine
ground.
BARO SENSOR HARNESS SIDE
3P CONNECTOR
SG2
(GREEN/RED)
• IAC Valve Troubleshooting
MIL blinks 14 times
1. Symptom reproduction test
-1. Reset the ECM.
-2. Turn the ignition switch OFF and connect the test harness.
• Hold the sensor connector connected.
-3. Start the engine. Check the engine speed during
idling.
Is the engine speed 650 rpm or above?
YES – Temporary failure (Disappeared)
NO – Perform "2. IAC valve open circuit check".
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Perform "6. BARO sensor check".
NO – Repair open in the wire between the BARO
sensor and the engine ground.
6. BARO sensor check
-1. Turn the ignition switch ON.
-2. Measure the voltage between the A-5 terminal (+) and
the A-2 terminal (–) of the test harness.
A-5
2. IAC valve open circuit check
-1. Turn the ignition switch OFF and disconnect the IAC
valve 2P connector.
-2. Measure the resistance between the IAC valve No. 1
and the No. 2 terminals.
IAC VALVE SIDE
2P CONNECTOR
VIEWED FROM THE TERMINAL SIDE
A-2
Is the resistance 8 – 12 ?
YES – Perform "3. IAC valve short circuit check".
NO – Replace the IAC valve.
Is the measurement 2.76 – 2.96V?
YES – Substitute a known-good ECM and recheck.
NO – Replace the BARO sensor and recheck.
3. IAC valve short circuit check
-1. Check for the continuity between the IAC valve No. 1
terminal and the body ground.
IAC VALVE SIDE
2P CONNECTOR
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Replace the IAC valve.
NO – Go to the step 2.
5-81
BF135A•BF150A
-2. Check for the continuity between the IAC valve No. 2
terminal and the body ground.
IAC VALVE SIDE
2P CONNECTOR
• VTEC Solenoid Valve Troubleshooting
MIL blinks 21 times
1. Spool solenoid valve check
-1. Turn the ignition switch OFF and disconnect the spool
solenoid valve connector.
-2. Measure the resistance between the spool solenoid
valve side 1P connector terminal (Green/White) and
the body ground.
VIEWED FROM THE TERMINAL SIDE
SPOOL SOLENOID VALVE
SIDE 1P CONNECTOR
Is there the continuity?
YES – Replace the IAC valve.
NO – Perform "4. IAC valve line open circuit check".
4. IAC valve line open circuit check
-1. Connect the IAC valve 2P connector.
-2. Disconnect the ECM connector B.
-3. Measure the resistance between the test harness B-26
terminal and the B-34 terminal.
B-26
B-34
Is the resistance 10 – 13 ?
YES – Perform "5. IAC valve line short circuit check".
NO – Check for open in the wire between the ECM
and the IAC valve.
5. IAC valve line short circuit check
-1. Check for the continuity between the test harness B-26
terminal and the engine ground, and between the B-34
terminal and the engine ground.
B-26
B-34
VIEWED FROM THE TERMINAL SIDE
Is the measured resistance 12 – 18 ?
YES – Perform "2. VTEC signal line short circuit
check".
NO – Replace the spool solenoid valve.
2. VTEC signal line short circuit check
-1. Turn the ignition switch OFF and connect the test harness.
Hold the ECM connector A disconnected.
-2. Check for the continuity between the test harness A-20
terminal and the engine ground.
A-20
Is there the continuity?
YES – Repair short in the wire between the ECM
and the spool solenoid valve.
NO – Perform “3. VTEC signal line open circuit
check”.
Is there the continuity?
YES – Repair short in the wire between the ECM
and the IAC valve.
NO – Substitute a known-good ECM and recheck.
5-82
BF135A•BF150A
3. VTEC signal line open circuit check
-1. Check for the continuity between the spool solenoid
valve harness side connector terminal and A-20 terminal of the test harness.
SPOOL SOLENOID VALVE
SIDE CONNECTOR
A-20
• KNOCK Sensor Troubleshooting
MIL blinks 23 times
1. Symptom reproduction test
-1. Reset the ECM.
-2. Turn the ignition switch OFF and connect the test harness.
• Hold the sensor connector connected.
-3. Start the engine and let it warm up by running the
engine at 5,000 min-1 (rpm) or more for 5 minutes or
more under no load.
-4. Check the MIL.
Is there the continuity?
YES – Perform "4. Symptom reproduction test".
NO – Repair open in the wire between the ECM
and the spool solenoid valve.
Does the MIL come ON?
YES – Perform "2. Knock sensor signal line open circuit check".
NO – Temporary failure (Disappeared)
4. Symptom reproduction test
-1. Disconnect the test harness and connect each connector securely.
-2. Reset the ECM.
-3. Start the engine and let it warm up by running the
engine at 3,000 min-1 (rpm) for 5 minutes under no
load.
-4. Disconnect the neutral switch 2P connector.
-5. Increase the engine speed gradually until it reaches
4,500 min-1 (rpm), and run the engine for a few seconds.
-6. If there is any abnormality, substitute a known-good
ECM and recheck.
2. Knock sensor signal line open circuit check
-1. Turn the ignition switch OFF and disconnect the knock
sensor 1P connector.
-2. Check for the continuity between the knock sensor harness side connector (Red/Blue) terminal and the test
harness A-15 terminal.
A-15
Is there the continuity?
YES – Perform "3. Knock sensor signal line short circuit check".
NO – Repair open in the wire between knock sensor and the ECM.
5-83
BF135A•BF150A
3. Knock sensor signal line short circuit check
-1. Check for the continuity between the test harness A-15
terminal and the engine ground.
A-15
• ECT Sensor 2 Troubleshooting
MIL blinks 24 times
1. Symptom reproduction test
-1. Reset the ECM.
-2. Turn the ignition switch OFF and connect the test harness.
• Hold the sensor connector connected.
-3. Turn the ignition switch ON.
-4. Measure the voltage between the test harness B-12
terminal (+) and the A-2 terminal (–).
A-2
B-12
Is there the continuity?
YES – Repair short in the wire between the ECM
and the spool solenoid valve.
NO – Substitute a known-good ECM and recheck.
Is the voltage 0.08 – 4.99V?
YES – Temporary failure (Disappeared)
NO – Perform "2. ECT sensor 2 signal line open circuit check".
2. ECT sensor 2 signal line open circuit check
-1. Turn the ignition switch OFF. Disconnect the 2P connector from the ECT sensor 2.
-2. Turn the ignition switch ON.
-3. Measure the voltage between the No. 2 (Red/Black)
terminal of the ECT sensor 2 harness side 2P connector and the engine ground.
ECT SENSOR 2 HARNESS SIDE
2P CONNECTOR
TOH1 (RED/BLACK)
VIEWED FROM THE TERMINAL SIDE
Is the voltage 4.75 – 5.25V?
YES – Perform "3. ECT sensor 2 ground line short
circuit check".
NO – Repair open in the wire between the ECT
sensor 2 and the ECM.
5-84
BF135A•BF150A
3. ECT sensor 2 ground line short circuit check
-1. Turn the ignition switch OFF. Disconnect the ECT sensor 2 connector and the ECM connector B.
-2. Check for the continuity between the No. 2 (Red/
Black) terminal of the ECT sensor 2 harness side 2P
connector and the body ground.
5. ECT sensor 2 check
-1. Turn the ignition switch OFF and disconnect the 2P
connector of the ECT sensor 2 .
-2. Measure the resistance between the No. 1 and the No.
2 terminals of the ECT sensor 2 side 2P connector.
ECT SENSOR 2 SIDE
2P CONNECTOR
ECT SENSOR 2 HARNESS SIDE
2P CONNECTOR
TOH1 (RED/BLACK)
Is there the continuity?
YES – Repair short in the wire between the ECT
sensor 2 and the engine ground.
NO – Perform “4. ECT sensor 2 ground line open
circuit check”.
4. ECT sensor 2 ground line open circuit check
-1. Reset the ECM connector B.
-2. Check for the continuity between the No. 1 (Green/
Red) terminal of the ECT sensor 2 harness side 2P
connector and the body ground.
VIEWED FROM THE TERMINAL SIDE
RESISTANCE
VIEWED FROM THE TERMINAL SIDE
ENGINE COOLANT TEMPERATURE
ECT SENSOR 2 HARNESS SIDE
2P CONNECTOR
SG2 (GREEN/RED)
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Perform "5. ECT sensor 2 check".
NO – Repair open in the wire between the ECT
sensor 2 and the engine ground.
5-85
Is there the resistance corresponding to the engine
coolant temperature?
YES – Substitute a known-good ECM and recheck.
NO – Replace the ECT sensor 2.
BF135A•BF150A
• ECT Sensor 3 Troubleshooting
MIL blinks 25 times
1. Symptom reproduction test
-1. Reset the ECM.
-2. Turn the ignition switch OFF and connect the test harness.
• Hold the sensor connector connected.
-3. Turn the ignition switch ON.
-4. Measure the voltage between the test harness A-16
terminal (+) and the A-2 terminal (–).
3. ECT sensor 3 signal line short circuit check
-1. Turn the ignition switch OFF. Disconnect the ECT sensor 3 connector and the ECM connector B.
-2. Check for the continuity between the No. 2 (Red) terminal of the ECT sensor 3 harness side 2P connector
and the body ground.
ECT SENSOR 3 HARNESS SIDE
2P CONNECTOR
TOH2 (RED)
A-2
VIEWED FROM THE TERMINAL SIDE
A-16
Is the voltage 0.08 – 4.99V?
YES – Temporary failure (Disappeared)
NO – Perform "2. ECT sensor 3 signal line open circuit check".
2. ECT sensor 3 signal line open circuit check
-1. Turn the ignition switch OFF. Disconnect the 2P connector from the ECT sensor 3.
-2. Turn the ignition switch ON.
-3. Measure the voltage between the No. 2 (Red) terminal
of the ECT sensor 3 harness side 2P connector and
the engine ground.
ECT SENSOR 3 HARNESS SIDE
2P CONNECTOR
Is there the continuity?
YES – Repair short in the wire between the ECT
sensor 3 and the engine ground.
NO – Perform "4. ECT sensor 3 ground line open
circuit check".
4. ECT sensor 3 ground line open circuit check
-1. Connect the ECM connector B.
-2. Check for the continuity between the No. 1 (Green/
Red) terminal of the ECT sensor 3 harness side 2P
connector and the body ground.
ECT SENSOR 3 HARNESS SIDE
2P CONNECTOR
SG2 (GREEN/RED)
TOH2 (RED)
VIEWED FROM THE TERMINAL SIDE
VIEWED FROM THE TERMINAL SIDE
Is the voltage 4.75 – 5.25V?
YES – Perform "3. ECT sensor 3 signal line short circuit check".
NO – Repair open in the wire between the ECT
sensor 3 and the ECM.
Is there the continuity?
YES – Perform "5. ECT sensor 3 check".
NO – Repair open in the wire between the ECT
sensor 3 and the engine ground.
5-86
BF135A•BF150A
5. ECT sensor 3 check
-1. Turn the ignition switch OFF and disconnect the ECT
sensor 3 2P connector.
-2. Measure the resistance between the No.1 and No.2
terminals of the ECT sensor 3 side 2P connector.
ECT SENSOR 3 SIDE
2P CONNECTOR
VIEWED FROM THE TERMINAL SIDE
• EOP switch (High Pressure Side)
Troubleshooting
MIL blinks 26 times
1. Symptom reproduction test
-1. Reset the ECM.
-2. Turn the ignition switch OFF and connect the test harness.
• Hold the sensor connector connected.
-3. Turn the ignition switch ON.
-4. Measure the voltage between the test harness A-17
terminal (+) and A-2 terminal (–).
A-2
RESISTANCE
A-17
Is the voltage 0V (OFF signal)?
YES – Temporary failure (Disappeared)
NO – Perform "2. EOP switch signal line open circuit check".
ENGINE COOLANT TEMPERATURE
Is there the resistance corresponding to the engine
coolant temperature?
YES – Substitute a known-good ECM and recheck.
NO – Replace the ECT sensor 3.
2. EOP switch signal line open circuit check
-1. Turn the ignition switch OFF and disconnect the EOP
switch 2P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No.1 (Yellow/Red) terminal of the EOP
switch harness side 2P connector and the body
ground.
EOP SWITCH HARNESS SIDE 2P
CONNECTOR
OPSH (YELLOW/RED)
VIEWED FROM THE TERMINAL SIDE
Is there the battery voltage?
YES – Perform “3. EOP switch signal line short circuit
check”.
NO – Repair open in the wire between the EOP
switch and the ECM.
5-87
BF135A•BF150A
3. EOP switch signal line short circuit check
-1. Turn the ignition switch OFF. Disconnect the EOP
switch 2P connector and the ECM connector A.
-2. Check for the continuity between the No.1 (Yellow/
Red) terminal of the EOP switch harness side 2P connector and the body ground.
EOP SWITCH HARNESS SIDE 2P
CONNECTOR
OPSHH
(YELLOW/RED)
VIEWED FROM THE TERMINAL SIDE
5. EOP switch check
-1. Turn the ignition switch OFF and connect each connector.
-2. Turn the ignition switch ON and measure the voltage
between the test harness A-17 terminal (+) and the A2 terminal.
A-2
A-17
Is the voltage 0V (switch OFF)?
YES – Substitute a known-good ECM and recheck.
NO – Replace the EOP switch (high pressure side).
Is there the continuity?
YES – Repair short in the wire between the EOP
switch and the ECM.
NO – Perform “4. EOP switch ground line open circuit check”.
4. EOP switch ground line open circuit check
-1. Check for the continuity between the No.2 (Green/
Red) terminal of the EOP switch harness side 2P connector and the body ground.
EOP SWITCH HARNESS SIDE 2P
CONNECTOR
SG2 (GREEN/RED)
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Perform "5. EOP switch check".
NO – Repair open in the wire between the EOP
switch and the ECM.
5-88
BF135A•BF150A
• ECT Sensor 4 Troubleshooting
MIL blinks 27 times
1. Symptom reproduction test
-1. Reset the ECM.
-2. Turn the ignition switch OFF and connect the test harness.
• Hold the sensor connector connected.
-3. Turn the ignition switch ON.
-4. Measure the voltage between the test harness A-6 terminal (+) and the A-2 terminal (–).
A-2
3. ECT sensor 4 signal line short circuit check
-1. Turn the ignition switch OFF. Disconnect the ECT sensor 4 connector and the ECM connector B.
-2. Check for the continuity between the No.2 (Red/
Green) terminal of the ECT sensor 4 harness side 2P
connector and the body ground.
ECT SENSOR 4 HARNESS SIDE
2P CONNECTOR
TOH3 (RED/GREEN)
A-6
VIEWED FROM THE TERMINAL SIDE
Is the voltage 0.08 – 4.99V?
YES – Temporary failure (Disappeared)
NO – Perform "2. ECT sensor 4 signal line open circuit check".
2. ECT sensor 4 signal line open circuit check
-1. Turn the ignition switch OFF and disconnect the 2P
connector from the ECT sensor 4.
-2. Turn the ignition switch ON.
-3. Measure the voltage between the No.2 (Red/Green)
terminal of the ECT sensor 4 harness side 2P connector and the engine ground.
ECT SENSOR 4 HARNESS
SIDE 2P CONNECTOR
Is there the continuity?
YES – Repair short in the wire between the ECT
sensor 4 and the engine ground.
NO – Perform “4. ECT sensor 4 ground line open
circuit check”.
4. ECT sensor 4 ground line open circuit check
-1. Connect the ECM connector B.
-2. Check for the continuity between the No.1 (Green/
Red) terminal of the ECT sensor 4 harness side 2P
connector and the body ground.
ECT SENSOR 4 HARNESS SIDE
2P CONNECTOR
SG2 (GREEN/RED)
TOH3 (RED/GREEN)
VIEWED FROM THE TERMINAL SIDE
VIEWED FROM THE TERMINAL SIDE
Is the voltage 4.75 – 5.25V?
YES – Perform "3. ECT sensor 4 signal line short circuit check".
NO – Repair open in the wire between the ECT
sensor 4 and the ECM.
5-89
Is there the continuity?
YES – Perform "5. ECT sensor 4 check".
NO – Repair open in the wire between the ECT
sensor 4 and the engine ground.
BF135A•BF150A
5. ECT sensor 4 check
-1. Turn the ignition switch OFF and disconnect the ECT
sensor 4 2P connector.
-2. Measure the voltage between the No.1 and No.2 terminals of the ECT sensor 4 side 2P connector.
ECT SENSOR 4 SIDE
2P CONNECTOR
• A/F Sensor Heater Troubleshooting
MIL blinks 41 times
1. Symptom reproduction test
-1. Reset the ECM.
-2. Start the engine and run it at 3,000 rpm for 5 minutes
or more to warm up.
-3. Check the MIL.
Does the MIL come ON?
YES – Perform "2. A/F relay check".
NO – Temporary failure (Disappeared)
RESISTANCE
VIEWED FROM THE TERMINAL SIDE
2. A/F relay check
-1. Turn the ignition switch OFF and connect the test harness.
Hold the sensor connector connected.
-2. Disconnect the A/F sensor 4P connector.
-3. Turn the ignition switch ON. Measure the voltage
between the test harness C-4 terminal and the engine
ground.
C-4
ENGINE COOLANT TEMPERATURE
Is there the resistance corresponding to the engine
coolant temperature?
YES – Substitute a known-good ECM and recheck.
NO – Replace the ECT sensor 4.
Is there the battery voltage?
YES – Perform "4. A/F heater check".
NO – Check the A/F relay and replace if necessary.
If it is normal, go to the step 4.
-4. Turn the ignition switch OFF and disconnect the A/F
relay 4P connector.
-5. Measure the voltage between the No.1 (White/ Green)
terminal of the A/F relay harness side 4P connector
and the engine ground.
• Note that the battery voltage is constantly applied to
the White/Green terminal. Take care not to short-circuit the terminal.
A/F RELAY HARNESS SIDE
4P CONNECTOR
+B
(WHITE/GREEN)
VIEWED FROM THE TERMINAL SIDE
5-90
BF135A•BF150A
Is there the battery voltage?
YES – Go to the step 6.
NO – Blown No.1 (30A) fuse, or repair open in the
wire between the A/F relay and the No.1
(10A) fuse.
-6. Turn the ignition switch ON. Measure the voltage
between the No.2 (Yellow/Red) terminal of the A/F
relay harness side 4P connector and the engine
ground.
A/F RELAY HARNESS SIDE
4P CONNECTOR
IGP
(YELLOW/RED)
4. A/F heater check
-1. Turn the ignition witch OFF and disconnect the A/F
sensor 4P connector.
-2. Measure the resistance between the No.3 (Black) and
No.4 (Black) terminals of the A/F sensor’s sensor side
4P connector.
A/F SENSOR SIDE
4P CONNECTOR
AFHT (BLACK)
AFHT+ (BLACK)
VIEWED FROM THE TERMINAL SIDE
Is the resistance 2 – 3 ?
YES – Perform “5. Heater line short circuit check”.
NO – Replace the A/F sensor.
VIEWED FROM THE TERMINAL SIDE
Is there the battery voltage?
YES – Perform "3. A/F relay drive line check".
NO – Blown No.5 (10A) fuse, or repair open in the
wire between the A/F relay and the No.5 fuse.
3. A/F relay drive line check
-1. Turn the ignition switch OFF and connect the A/F relay
connector.
-2. Disconnect the ECM connector A.
-3. Turn the ignition switch ON and measure the voltage
between the test harness A-25 and the engine ground.
A-25
Is there the battery voltage?
YES – Substitute a known-good ECM and recheck.
NO – Repair open in the A/F relay and the ECM.
5-91
5. Heater line short circuit check
-1. Turn the ignition switch OFF and disconnect the ECM
connector C.
-2. Check for the continuity between the test harness C-3
terminal and the engine ground, and between the C-4
terminal and the engine ground.
C-3
C-4
Is there the continuity?
YES – Repair short in the wire between the A/F sensor and the ECM.
NO – Perform “6. Heater line open circuit check”.
BF135A•BF150A
6. Heater line open circuit check
-1. Connect the No.3 (Black/White) and the No.4 (White)
terminals of the A/F sensor harness side 4P connector
respectively to the engine ground with the jumper
wires.
-2. Check for the continuity between the test harness C-3
terminal and the engine ground, and between the C-4
terminal and the engine ground.
C-3
C-4
• A/F Sensor Troubleshooting
MIL blinks 48 times
1. Symptom reproduction test
-1. Reset the ECM.
-2. Start the engine and let it warm up by running the
engine at 3,000 rpm for 5 minutes or more under no
load. Run the engine at idling for an additional one
minute under no load.
-3. Check the MIL.
Does the MIL come ON?
YES – Perform "2. A/F sensor line open circuit
check".
NO – Temporary failure (Disappeared)
Is there the continuity?
YES – Perform "7. Sensor line short circuit check".
NO – Repair open in the wire between the A/F sensor and the ECM.
7. Sensor line short circuit check
-1. Disconnect the ECM connector B.
-2. Disconnect the A/F sensor 4P connector.
-3. Check for the continuity between the test harness C-3
terminal and the respective terminals of A-4 and A-14
terminals, and between the C-4 terminal and the
respective terminals of A-4 and A-14 terminals.
2. A/F sensor line open circuit check
-1. Turn the ignition switch OFF. Disconnect the A/F sensor connector and the ECM connector A.
-2. Connect the No.1 (White/Black) terminal of the A/F
sensor harness side 4P connector to the engine
ground to short using a jumper wire.
-3. Check for the continuity between the test harness A-4
terminal and the engine ground.
A-4
A-4
C-3
C-4
A-14
Is there the continuity?
YES – Repair short in the wire between the A/F sensor and the ECM.
NO – Replace the A/F sensor and recheck. If it is
still abnormal, substitute a known-good ECM
and recheck.
Is there the continuity?
YES – Go to the step 4.
NO – Repair open in the wire between the A/F sensor and the ECM.
-4. Connect the No.2 (Black/Yellow) terminal of the A/F
sensor harness side 4P connector to the engine
ground to short using a jumper wire.
-5. Check for continuity between the test harness A-14 terminal and the engine ground.
A-14
Is there the continuity?
YES – Perform "3. A/F sensor line short circuit
check".
NO – Repair open in the wire between the A/F sensor and the ECM.
5-92
BF135A•BF150A
3. A/F sensor line short circuit check
-1. Turn the ignition switch OFF. Disconnect the A/F sensor connector and the ECM connector A.
-2. Check for the continuity between the test harness A-4
terminal and the engine ground.
A-4
8. IDLE CONTROL SYSTEM
• Troubleshooting
When the MIL does not come ON but an engine failure of
either of the following symptoms occurs at the engine start
or during idling, inspect the system(s) and part(s) in the
numbered sequence.
• Hard to start
1. Vacuum line
2. IAC valve (P. 5-95)
Is there the continuity?
YES – Repair short in the wire between the A/F sensor and the ECM.
NO – Go to the step 3.
-3. Check for the continuity between the test harness A-14
terminal and the engine ground.
A-14
Is there the continuity?
YES – Repair short in the wire between the A/F sensor and the ECM.
NO – Replace the A/F sensor and recheck. If there
is any abnormality, substitute a known-good
ECM and recheck.
• Engine starts but stalls soon.
1. Idle adjusting screw (P. 5-94)
2. IAC valve (P. 5-95)
3. Vacuum line
• Engine speed is higher than the specified
idle speed after warming up.
1. Vacuum line
2. IAC valve (P. 5-95)
3. Idle adjusting screw (P. 5-94)
• Engine speed is higher than the specified
trolling speed after warming up.
1.
2.
3.
4.
Neutral switch (P. 17-13)
Vacuum line
Idle adjusting screw (P. 5-94)
IAC valve (P. 5-95)
• Engine speed is lower than the specified
idling or trolling speed after warming up.
1. IAC valve (P. 5-95)
2. Idle adjusting screw (P. 5-94)
3. Vacuum line
• Engine speed is not stable during idling and
trolling.
1.
2.
3.
4.
5-93
IAC valve (P. 5-95)
Idle adjusting screw (P. 5-94)
Vacuum line
Neutral switch (P. 17-13)
BF135A•BF150A
• Idle Adjusting Screw Adjustment
Check the following before adjustment.
• Idle speed inspection (P. 3-22)
• Spark plug (P. 3-6)
• MIL is OFF. (If it is ON, troubleshoot according to the
chart on P. 5-15 or 5-59.)
6) Adjust the idle speed by turning the adjusting screw.
• If adjustment cannot be made, check each vacuum
tube for disconnection and collapse, then check and
clean the throttle body (P. 5-95).
ADJUSTING SCREW
1) Remove the propeller. Set the outboard motor in a test
tank filled with water.
• Fill the tank with water above the gear case.
2) Connect the HDS tester (P. 5-13).
• If you do not have the HDS tester, connect a digital
tachometer (P. 3-22).
3) Set the SCS mode using the HDS tester.
• If you do not have the HDS tester, disconnect the red
4P connector and connect (short-circuit) the SCS
short connector to the DLC . (P. 5-57).
4) Start the engine and let it warm up with the gear in
neutral.
5) Disconnect the IAC valve 2P connector and check the
idle speed.
Specified idle speed
575 ± 30 min-1 (rpm)
2P CONNECTOR
7) After adjustment, connect the IAC valve 2P connector
and clear the DTC (P. 5-14) or reset the ECM (P. 5-57).
8) Run the engine at idling for 5 minutes or more, then
check the idle speed again.
Specified idle speed
750 ± 50 min-1 (rpm)
9) If the idle speed is out of the specification, repeat the
procedure from step 5) through step 8). If the idle
speed is still out of the specification, replace the IAC
valve. If the specified idle speed cannot be obtained
yet, replace the ECM with a new one and recheck.
10) After adjustment, apply the paint (Nippon Paint
Unipack #200 or equivalent) to the head of the adjusting screw.
ADJUSTING SCREW
IAC VALVE
Apply paint here.
5-94
BF135A•BF150A
• Throttle Body Inspection/Cleaning
1) Remove the engine cover.
2) Remove the intake air silencer (P. 5-128).
3) Turn the throttle cam and check the throttle valve for
smooth movement and the throttle valve shaft for play.
4) Check that there is no gap between the throttle shaft
stopper and the throttle stop screw.
• The throttle stop screw cannot be adjusted. If it is
faulty, replace the throttle body.
7) After cleaning, install the throttle rod and the silencer
chamber (P. 5-135).
8) After assembly, check the idle speed and adjust if necessary (P. 5-94).
• IAC Valve Replacement
1) Remove the engine cover.
THROTTLE STOP SCREW
2) Turn the ignition switch OFF and disconnect the IAC
valve 2P connector.
3) Remove
IAC
VALVE the two 8 x 45 mm flange bolts and remove
the IAC valve and IAC valve gasket.
2P CONNECTOR
THROTTLE BODY
5) Check the throttle valve and bore for contamination.
Clean if necessary.
NOTICE
IAC VALVE GASKET
• Do not spray the carburetor cleaner directly to the
throttle body.
• Use the genuine Honda carburetor cleaner.
• Do not wipe the throttle valve where is coated with
the molybdenum (i.e. both ends of the throttle valve).
6) Wipe the inner wall of the throttle bore and both ends
of the throttle valve with a shop towel or equivalent
material sprayed with the carburetor cleaner.
3) Apply the engine oil to the new IAC valve gasket and
install it.
4) Install the IAC valve and tighten the 8 x 45 mm flange
bolts securely.
5) Connect the IAC valve 2P connector securely.
Clean.
Coated with molybdenum
5-95
6) Start the engine and let it warm up. Running the
engine at idling, check the IAC valve for proper operation (idle speed inspection; see P. 3-22).
BF135A•BF150A
9. FUEL SUPPLY SYSTEM
High pressure fuel supply system
• Troubleshooting
• Hard to start
When the MIL does not come ON but an engine failure of
either of the following symptoms occurs at the engine start
or during idling, inspect the system(s) and part(s) in the
numbered sequence.
1. Fuel line (high pressure side) (P. 5-104)
2. Fuel pump (high pressure side) (P. 5-107)
3. Fuel injector (P. 5-105)
Low pressure fuel supply system
• Engine starts but stalls soon.
• Hard to start
1. Fuel line (high pressure side) (P. 5-104)
2. Fuel injector (P. 5-105)
3. Pressure regulator (P. 5-106)
1.
2.
3.
4.
Water separator (P. 3-19)
Fuel strainer (low pressure side) (P. 3-15)
Fuel line (low pressure side) (P. 5-104)
Vapor separator (P. 5-111 thru. 5-127)
• Engine starts but stalls soon.
1.
2.
3.
4.
Water separator (P. 3-19)
Fuel strainer (low pressure side) (P. 3-15)
Fuel line (low pressure side) (P. 5-104)
Vapor separator (P. 5-111 thru. 5-127)
• Engine speed is not stable during idling and
trolling, or engine stalls.
1. Water separator (P. 3-19)
2. Fuel strainer (low pressure side) (P. 3-15)
• Engine speed is not stable during idling and
trolling, or engine stalls.
1. Fuel line (high pressure side) (P. 5-104)
2. Fuel injector (P. 5-105)
3. Pressure regulator (P. 5-106)
• Engine speed does not increase
1.
2.
3.
4.
5.
Fuel line (high pressure side) (P. 5-104)
Pressure regulator (P. 5-106)
Fuel pump (high pressure side) (P. 5-107)
Fuel strainer (high pressure side) (P. 3-18)
Fuel injector (P. 5-105)
• Engine sometimes misfires or tends to stall.
• Engine sometimes misfires or tends to stall.
1.
2.
3.
4.
Water separator (P. 3-19)
Fuel strainer (low pressure side) (P. 3-15)
Fuel line (low pressure side) (P. 5-104)
Fuel pump (low pressure side) (P. 5-142)
1.
2.
3.
4.
Water separator (P. 3-19)
Fuel injector (P. 5-105)
Fuel pump (high pressure side) (P. 5-107)
Pressure regulator (P. 5-106)
• Engine tends to stall at hot restart of the
engine.
1. Vapor separator (P. 5-111 thru. 5-127)
5-96
BF135A•BF150A
• PGM-FI Main Relay Harness Inspection
Check with test harness:
1. Turn the ignition switch OFF and disconnect each connector from the PGM-FI main relay.
5. Turn the ignition switch ON. Measure the voltage
between the No.2 (Black/Yellow) terminal of the PGMFI main relay harness side 6P connector and the
engine ground.
PGM-FI MAN RELAY HARNESS
SIDE 6P CONNECTOR
2. Connect the test harness.
• Disconnect the connector A, B and C from the ECM.
3. Check for the continuity between the No.6 (Black) terminal of the harness side 6P connector and the engine
ground.
HARNESS SIDE 6P
CONNECTOR
BLACK
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the PGM-FI
main relay and the engine ground.
NO – Go to the step 4.
4. Measure the voltage between the No.3 (White/Yellow)
terminal of the fuse box side 4P connector and the
engine ground.
FUSE BOX SIDE
4P CONNECTOR
WHITE/YELLOW
VIEWED FROM THE TERMINAL SIDE
Is there the battery voltage?
YES – Go to the step 5.
NO – Blown No.7 (30A) fuse, or open in the wire
between the fuse box and the PGM-FI main
relay.
BLACK/YELLOW
VIEWED FROM THE TERMINAL SIDE
Is there the battery voltage?
YES – Go to the step 6.
NO – Blown No.3 (10A) fuse, or faulty ignition
switch, or open in the wire between the PGMFI main relay and the ignition switch.
6. Measure the voltage between the No.2 (White/Yellow)
terminal of the harness side 2P connector and the
engine ground.
PGM-FI MAIN RELAY HARNESS
SIDE 2P CONNECTOR
WHITE/YELLOW
VIEWED FROM THE TERMINAL SIDE
Is there the battery voltage?
YES – Go to the step 7.
NO – Blown No.3 (10A) fuse, or faulty ignition
switch, or open in the wire between the PGMFI main relay and the ignition switch.
7. Check for the continuity between the No.4 (White/
Black) terminal of the fuse box side 4P connector and
the respective terminals of the C-1 and C-5 terminals
of the test harness.
FUSE BOX SIDE 4P
CONNECTOR
C-1
WHITE/BLACK
C-5
VIEWED FROM THE TERMINAL SIDE
5-97
BF135A•BF150A
Is there the continuity?
YES – Go to the step 8.
NO – Blown No.4 (15A) fuse, or open in the wire
between the PGM-FI main relay and the No.4
(15A) fuse, or open in the wire between the
No.4 (15A) fuse and the ECM.
8. Check for the continuity between the NO.3 (Light
green/Red) terminal of the fuse box side 6P connector
and the respective terminals of the test harness A-13
and B-10 terminals.
Check without test harness:
1. Turn the ignition switch OFF and disconnect each connector from the PGM-FI main relay.
2. Disconnect the ECM connectors A, B, and C.
3. Check for the continuity between the No.6 (Black) terminal of the harness side 6P connector and the engine
ground.
PGM-FI MAIN RELAY HARNESS
SIDE 6P CONNECTOR
BLACK
FUSE BOX SIDE
6P CONNECTOR
A-13
LIGHT GREEN/
RED
VIEWED FROM THE TERMINAL SIDE
B-10
VIEWED FROM THE
TERMINAL SIDE
Is there the continuity?
YES – Go to the step 9.
NO – Repair open in the wire between the PGM-FI
main relay and the ECM.
9. Turn the ignition switch ON. Measure the voltage
between the test harness C-1 terminal (+) and the C2/C-6 terminals (–), and between the C-5 terminal (+)
and the C-2/C-6 (–) terminals.
Is there the continuity?
YES – Repair short in the wire between the PGM-FI
main relay and the engine ground.
NO – Go to the step 4.
4. Measure the voltage between the No.3 (White/Yellow)
terminal of the fuse box side 4P connector and the
engine ground.
FUSE BOX SIDE
4P CONNECTOR
WHITE/YELLOW
VIEWED FROM THE TERMINAL SIDE
C-2
C-2
C-1
C-6
C-5
C-6
Is there the battery voltage?
YES – Go to the step 5.
NO – Blown No.7 (30A) fuse, or open in the wire
between the fuse box and the PGM-FI main
relay.
5. Turn the ignition switch ON. Measure the voltage
between the No.2 (Black/Yellow) terminal of the harness side 6P connector and the engine ground.
Is there the battery voltage?
YES – End of the check (Good)
NO – Replace the PGM-FI main relay.
HARNESS SIDE
6P CONNECTOR
BLACK/YELLOW
VIEWED FROM THE TERMINAL SIDE
5-98
BF135A•BF150A
Is there the battery voltage?
YES – Go to the step 6.
NO – Blown No.3 (10A) fuse, or faulty ignition
switch, or open in the wire between the PGMFI main relay and the ignition switch.
6. Measure the voltage between the No.2 (White/Yellow)
terminal of the harness side 2P connector and the
engine ground.
HARNESS SIDE
2P CONNECTOR
8. Check for the continuity between the terminals of the
fuse box harness side 6P connector and ECM connectors A and B:
Fuse Box
6P connector
ECM connector A
No.13 (Light green/Red)
No.3 (Light green/Red)
Fuse Box
6P connector
ECM connector B
No.10 (Light green/Red)
No.3 (Light green/Red)
FUSE BOX
HARNESS SIDE
6P CONNECTOR
ECM CONNECTOR A
FLR2
(LIGHT GREEN/RED)
WHITE/YELLOW
LIGHT GREEN/
RED
VIEWED FROM THE TERMINAL SIDE
Is there the battery voltage?
YES – Go to the step 7.
NO – Blown No.3 (10A) fuse, or faulty ignition
switch, or open in the wire between the PGMFI main relay and the ignition switch.
FLR1
(LIGHT GREEN/RED)
ECM CONNECTOR B
7. Check for the continuity between the fuse box side 4P
connector and ECM connector terminals:
Fuse Box
4P connector
ECM connector C
No.1 (Yellow/Black)
No.4 (White/ Black)
No.5 (Yellow/Black)
No.4 (White/ Black)
ECM CONNECTOR C
FUSE BOX SIDE 4P
CONNECTOR
WHITE/BLACK
IGP2
(YELLOW/BLACK)
IGP2
(YELLOW/BLACK)
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Go to the step 9.
NO – Repair open in the wire between the PGM-FI
main relay and the ECM.
9. Turn the ignition switch ON. Measure the voltage
between the terminals of the ECM connector C:
No.1 (Yellow/Black) (
No.1 (Yellow/Black) (
No.5 (Yellow/Black) (
No.5 (Yellow/Black) (
)
)
)
)
No. 2 (Green) ( )
No. 6 (Green/red) ( )
No. 2 (Green) ( )
No. 6 (Green/Red) ( )
ECM CONNECTOR A
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Go to the step 8.
NO – Blown No.4 (15A) fuse, or open in the wire
between the PGM-FI main relay and the No.4
(15A) fuse, or open in the wire between the
No.4 (15A) fuse and the ECM.
5-99
VIEWED FROM THE TERMINAL SIDE
Is there the battery voltage?
YES – End of the check (Good)
NO – Replace the PGM-FI main relay.
BF135A•BF150A
• Injector Harness Inspection
Check with test harness:
1. Turn the ignition switch OFF and disconnect each 2P
connector from the respective injectors.
Is there the continuity?
YES – Repair open in the wire between the ECM
and the injector
NO – Go to the step 5.
5. Connect each injector 2P connector.
2. Connect the test harness.
• Disconnect the connector A, B, and C from the ECM.
3. Check for the continuity between the test harness and
each injector harness side 2P connector:
No.2 (Brown) of the No.1 injector
B-21
B-23
No.2 (Red) of the No.2 injector
B-27
No.2 (Blue) of the No.3 injector
B-29
No.2 (Yellow) of the No.4 injector
6. Turn the ignition switch ON. Check for the voltage
between the test harness and engine ground:
B-21 terminal and the engine ground
B-23 terminal and the engine ground
B-27 terminal and the engine ground
B-29 terminal and the engine ground
B-21
B-21
BROWN
RED
No. 1
No. 2
YELLOW
BLUE
No. 4
No. 3
B-27
B-29
B-29
B-27
B-23
B-23
INJECTOR HARNESS
SIDE 2P CONNECTORS
Is there the battery voltage?
YES – End of the check (Good)
NO – Check the injector (P. 5-105). If it is normal,
repair open in the wire between the No.4
(15A) fuse and the injector.
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Go to the step 4.
NO – Repair open in the wire between the injector
and ECM.
4. Check for the continuity between the test harness and
engine ground:
B-21 terminal and the engine ground,
B-23 terminal and the engine ground
B-27 terminal and the engine ground
B-29 terminal and the engine ground.
B-21
B-23
B-27
B-29
5-100
BF135A•BF150A
Check without test harness:
1. Turn the ignition switch OFF and disconnect the 2P
connector from the respective injectors.
2. Disconnect the ECM connector B and C.
Is there the continuity?
YES – Repair open in the wire between the ECM
and the injector.
NO – Go to the step 5.
5. Connect the injector 2P connector.
3. Check for the continuity between the ECM connector B
and each injector harness side 2P connector:
ECM connector B
Injector
No.21 (Brown)
No.2 (Brown) of the No.1 injector
No.23 (Red)
No.2 (Red) of the No.2 injector
No.27 (Blue)
No.2 (Blue) of the No.3 injector
No.29 (Yellow)
No.2 (Yellow) of the No.4 injector
6. Turn the ignition switch ON. Measure the voltage
between the No.1 (Yellow/Black) terminal of each
injector harness side terminal and the engine ground.
INJECTOR HARNESS
SIDE 2P CONNECTOR
YELLOW/BLACK
ECM CONNECTOR B
VIEWED FROM THE TERMINAL SIDE
BROWN
RED
No. 1
No. 2
BLUE YELLOW
No. 3
No. 4
INJECTOR HARNESS
SIDE 2P CONNECTORS
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Go to the step 4.
NO – Repair open in the wire between the injector
and the ECM.
4. Check for the continuity between the injector harness
side 2P connector terminal and engine ground:
No.2 (Brown) of No.1 injector and engine ground.
No.2 (Red) of No.2 injector and engine ground.
No.2 (Blue) of the No.3 injector and engine ground.
No.2 (Yellow) of the No.4 injector and engine ground
INJECTOR HARNESS
SIDE 2P CONNECTORS
No. 1
BROWN
No. 2
RED
No. 4
No. 3
BLUE
VIEWED FROM THE TERMINAL SIDE
5-101
YELLOW
Is there the battery voltage?
YES – End of the check (Good)
NO – Check the injector (P. 5-105). If it is normal,
repair open in the wire between the No.4
(15A) fuse and the injector.
BF135A•BF150A
• How To Relive Fuel Pressure
SHOP
TOWEL
Gasoline is highly flammable and explosive.
You can be burned or seriously injured when handling fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
• Disconnect the battery cable from the battery negative (-) terminal before relieving the fuel pressure.
• Replace the sealing washer when the service check bolt is
loosened or removed.
1) Remove the engine cover (P. 4-2).
2) Set an offset wrench on the 6 mm service check bolt of the
vapor separator. Place a shop towel or equivalent material
over the service check bolt.
3) Loosen the service check bolt approximately one turn slowly to relieve the fuel pressure.
4) After relieving the fuel pressure, remove the service check
bolt and replace the 6 mm sealing washer with a new one.
5) Tighten the service check bolt to the specified torque.
TORQUE: 12 N • m (1.2 kgf • m, 9 lbf • ft)
SERVICE
CHECK BOLT
SERVICE
CHECK BOLT
SEALING WASHER
Do not reuse.
• Fuel Pressure Measurement
1) Relieve the fuel pressure according to “How to relive fuel
pressure” explained above.
2) Remove the service check bolt and set the special tool (fuel
pressure gauge set) in the threaded bolt hole.
FUEL PRESSURE GAUGE SET
07406-0040002
5-102
BF135A•BF150A
3) Disconnect the pressure regulator control tube from the
pressure regulator, and clamp the vacuum tube.
4) Remove the propeller. Set the outboard motor gear case in
a test tank filled with water. Start the engine and measure
the fuel pressure at idling.
Standard fuel pressure
(At idle speed of
650 ± 50 min-1 /rpm)
PRESSURE REGULATOR
CONTROL TUBE
TUBE CLAMP
(Commercially available)
270 – 320 kPa
(2.8 – 3.3 kgf/cm2,
39.8 – 46.9 psi)
5) When the fuel pressure is outside the specified standard
pressure, check the following.
When fuel pressure is higher than standard pressure:
• Check the pressure regulator return hose for kinking, collapse or restrictions.
• Check the pressure regulator for proper operation
(Inspection: P. 5-106).
When the fuel pressure is lower than the standard
pressure:
PRESSURE REGULATOR
SERVICE CHECK BOLT
12 N·m (1.2 kgf·m,
9 lbf·ft)
• Check the pressure regulator for proper operation
(Inspection: P. 5-106).
• Check the high pressure side fuel strainer for clogging
(Replacement: P.3-18).
• Check the high pressure side fuel pump for proper operation (Inspection: P. 5-107).
6) After check, replace the sealing washer with a new one and
tighten the service check bolt to the specified torque.
TORQUE: 12 N • m (1.2 kgf • m, 9 lbf • ft)
SEALING WASHER
Do not reuse.
7) Connect the vacuum tube to the pressure regulator.
5-103
BF135A•BF150A
• Fuel Line Inspection
Gasoline is highly flammable and explosive.
You can be burned or seriously injured when handling fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
1) Check the fuel pipe, fuel hose, pressure regulator return
hose and the fuel tube for damage, gasoline leakage, rust
and other abnormalities.
Check that the hoses and tubes are not interfering with the
neighboring pars.
2) Replace the hose or tube if there is damage, gasoline leakage, rust, etc.
Note the following on replacement.
• Relieve the fuel pressure according to "How to relive fuel
pressure" (P. 5-102), then replace the fuel pipe, hoses and
tube.
• Replace the O-rings with the new ones. Apply the engine
oil to the O-rings before installation.
FUEL TUBES
PRESSURE REGULATOR
RETURN HOSE
FUEL PIPE
FUEL HOSE
(HIGH PRESSURE SIDE)
FUEL TUBES
FUEL TUBES
5-104
BF135A•BF150A
• Fuel Injector Inspection
When the engine is hard to start:
1) Disconnect the fuel injector connector and measure the
resistance between the terminals.
2) If the fuel injector is normal, check the following
• No.7 (10A) fuse
• No.4 (15A) fuse
• Open or short circuit in the injector harness (between
ECM, injectors and No.4 fuse) (P. 5-100).
When the engine starts:
1) Start the engine and warm it up.
2) With the engine running at idling, disconnect the fuel injector connector of each cylinder and check the idle speed
change and idling stability.
• The fuel injector is normal when the idling condition
changes.
• If the idling condition does not change when the fuel injector connector is disconnected, replace the fuel injector of
the cylinder and recheck the idling condition.
3) With the engine running at idling, check for the operation
sound of the fuel injectors using a sound scope (or with a
screwdriver or equivalent if a sound scope is not available).
• If there is no operation sound, replace the fuel injector
with a new one and recheck.
4) If no abnormality is detected, replace the ECM.
5-105
BF135A•BF150A
• Pressure Regulator Inspection
Gasoline is highly flammable and explosive.
You can be burned or seriously injured when handling fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
• If the fuel pressure is lower than the specified standard pressure, check the high pressure side fuel pump (P. 5-107), then
check the pressure regulator.
1) Check that the pressure regulator control tube is not bent,
disconnected and damaged.
2) Remove the service check bolt. Set the special tool (fuel
pressure gauge set) in the threaded bolt hole.
FUEL PRESSURE GAUGE
SET 07406-0040002
3) Remove the propeller. Set the gear case in a test tank filled
with water and start the engine.
4) With the engine idling, disconnect the pressure regulator
control tube from the pressure regulator and clamp it.
PRESSURE REGULATOR
CONTROL TUBE
TUBE CLAMP
(Commercially available)
5) Check the fuel pressure. It should be higher than the pressure measured with the vacuum tube connected.
Standard fuel pressure
(At idle speed of
650 ± 50 min-1 /rpm)
270 – 320 kPa
(2.8 – 3.3 kgf/cm2,
40 – 47 psi)
6) When the fuel pressure does not rise, connect the vacuum
tube to the pressure regulator. Pinch the pressure regulator return hose that goes from the pressure regulator to the
vapor separator a couple of times lightly, and measure the
fuel pressure again.
NOTICE
Protect the pressure regulator return hose by winding a
shop towel or equivalent material around the hose, and
lightly pinch the hose with the pliers.
PRESSURE REGULATOR
SHOP
TOWEL
PRESSURE REGULATOR
RETURN HOSE
7) If the measurement is outside the specified standard pressure, replace the pressure regulator (P. 5-136).
PLIERS
5-106
BF135A•BF150A
• Fuel Pump (High pressure side) Inspection
FUEL PUMP 2P
CONNECTOR
Gasoline is highly flammable and explosive.
You can be burned or seriously injured when handling fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
• Turn the ignition switch OFF before disconnecting and connecting the connectors.
• Use a known-good battery.
CONNECTOR BRACKET
1) Remove the engine cover (P. 4-2).
2) Turn the ignition switch ON. Check that the fuel pump operation sound can be heard for approximately 2 seconds.
Is there the fuel pump operation sound?
YES – Check the gasoline discharge volume.
NO – Go to the step 3.
BLACK
ENGINE
GROUND
3) Remove the high pressure side fuel pump 2P connector
from the connector bracket, and disconnect the connector.
4) Measure the voltage between the Black terminal of the harness side connector and the body ground.
Is there the continuity?
YES – Check the gasoline discharge volume.
NO – Go to the step 5.
5) Attach the positive (+) tester lead to the Blue/Yellow (+) terminal and the negative (–) tester lead to the Black (–) terminal of the harness side connector. Turn the ignition
switch ON and be sure that there is battery voltage for
approximately 2 seconds.
Is there the battery voltage?
YES – Check the gasoline discharge volume (P. 5-108).
NO – Check the PGM-FI main relay harness (P. 5-97).
FUEL PUMP HARNESS
SIDE 2P CONNECTOR
BLUE/
YELLOW (+)
FUEL PUMP HARNESS
SIDE 2P CONNECTOR
5-107
BLACK (–)
BF135A•BF150A
• Discharge Volume Check
PRESSURE REGULATOR
Gasoline is highly flammable and explosive.
You can be burned or seriously injured when handling fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
• Use a known-good battery for discharge volume check.
1) Turn the ignition switch OFF.
2) Disconnect the pressure regulator return hose from the
pressure regulator, and connect a hose that is equivalent to
the pressure regulator return hose to the pressure regulator.
PRESSURE REGULATOR
RETURN HOSE
PRESSURE REGULATOR
3) Turn the ignition switch ON. Operate the fuel pump for
approximately 2 seconds and measure the gasoline discharge volume.
Standard discharge volume
45 cc (4.75 cu in)
or more
4) If gasoline is not discharged or the discharge volume is too
small, check the following and replace the fuel pump (P. 5121).
• Clogged high pressure side fuel filter
• Clogged high pressure side fuel hose/pipe
• Faulty pressure regulator
5) If the high pressure side fuel pump is normal, connect the
2P connector. Set the connector on the connector bracket.
FUEL PUMP 2P CONNECTOR
CONNECTOR BRACKET
5-108
BF135A•BF150A
10. IAB (Intale Air Bypass)
CONTROL SYSTEM
• IAB Control Valve Inspection
1. Vacuum line check
-1. Check the vacuum tubes between the shutter valve
diaphragm and IAB control valve, and between the
solenoid valve and intake manifold.
SHUTTER VALVE DIAPHRAGM
3. IAB control valve check
-1. Connect the vacuum tubes.
-2. Disconnect the IAB control valve 2P connector while
running the engine at idling.
-3. Check the vacuum tube located above the IAB control
valve for vacuum.
Is there the vacuum?
YES – Perform "4. Ground line short circuit check".
NO – Replace the IAB control valve.
4. Ground line short circuit check
-1. Turn the ignition switch OFF. Disconnect the ECM connector A and the IAB control valve 2P connector.
-2. Check for the continuity between the No.2 (Black) terminal of the IAB control valve harness side 2P connector and the engine ground.
IAB CONTROL VALVE HARNESS
SIDE 2P CONNECTOR
BLACK
INTAKE MANIFOLD
VACUUM TUBE
Are the tubes disconnected, torn or clogged?
YES – Replace the vacuum tubes.
NO – Perform "2. Operation check at idling".
2. Operation check at idling
-1. Start the engine and let it warm up. Run the engine at
idling.
-2. Disconnect the vacuum tube from the shutter valve
diaphragm, and check the vacuum.
Is there the vacuum?
YES – Perform “5. Operation check at engine stop
and at high engine speed”.
NO – Go to the step 3.
-3. Disconnect the vacuum tube underside the IAB control
valve, and check the vacuum.
Is there the vacuum?
YES – Perform "3. IAB control valve check".
NO - • Faulty vacuum chamber
• Faulty check valve
5-109
VIEWED FROM THE TERMINAL SIDE
Is there the continuity?
YES – Repair short in the wire between the ECM
and the IAB control valve.
NO – Substitute a known-good ECM and recheck.
5. Operation check at engine stop and at high engine
speed
-1. Start the engine and run it at idling. Stop the engine
and check the shutter valve diaphragm side vacuum
tube for the vacuum.
Is the vacuum removed?
YES – Perform shutter valve diaphragm check (P. 5110).
NO – Perform "6. Signal line open circuit check".
BF135A•BF150A
6. Signal line open circuit check
-1. Turn the ignition switch OFF and disconnect the IAB
control valve 2P connector.
-2. Turn the ignition switch ON. Measure the voltage
between the No.1 (Yellow/Black) terminal of the IAB
control valve harness side 2P connector and the
engine ground.
IAB CONTROL VALVE HARNESS
SIDE 2P CONNECTOR
YELLOW/BLACK
VIEWED FROM THE TERMINAL SIDE
Is there the battery voltage?
YES – Perform "7. IAB control valve check”.
NO – Repair open in the wire between the ECM
and the IAB control valve
• Shutter Valve Diaphragm Inspection
NOTICE
• Do not try to adjust the full close stop screw.
• Note that the shutter valve diaphragm must not be disassembled. If replacement is necessary, replace as an
assembly of the intake manifold assembly.
1) Check the following.
• Check the shutter valve shaft for play and the stuck
shaft.
• Check the shutter valve for smooth movement from
the full open to the full close positions.
• Check there is no clearance between the full close
screw and the full close stopper when the shutter
valve is in the full close position.
• Move the shutter valve to the full open position and
check that the shutter valve contacts the full open
stopper.
SHUTTER VALVE DIAPHRAGM
7. IAB control valve check
-1. Turn the ignition switch OFF. Disconnect the IAB control valve 2P connector.
-2. Measure the resistance between the IAB control valve
side 2P connector terminals.
Is the resistance 37 – 44 ?
YES – Substitute a known-good ECM and recheck.
NO – Replace the IAB control valve.
FULL OPEN STOPPER
STOP SCREW
2) If there is any abnormality, clean the shutter valve
diaphragm with a contact cleaner and recheck.
If it is still abnormal, replace the intake manifold
assembly.
5-110
BF135A•BF150A
11. VAPOR SEPARATOR/FUEL PUMP
(HIGH PRESSURE SIDE)
a. REMOVAL
Gasoline is highly flammable and explosive.
You can be burned or seriously injured when handling fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
• Relieve the fuel pressure before removing the vapor separator.
• Disconnect the battery cable from the battery negative (–)
terminal before relieving the fuel pressure.
• Replace the sealing washer with a new one whenever the
service check bolt was loosened or removed.
1) Remove the engine cover and the L. engine under cover.
2) Relieve the fuel pressure (P. 5-102).
[2] HARNESS
BAND CLIP
[3] FUEL PUMP 2P
CONNECTOR
[1] CLAMPS
[4]
CONNECTOR
BRACKET
[6]
FUEL TUBE
[5] COVER LOCK CABLE
3) Remove the high pressure side fuel pump 2P connector
from the connector bracket and disconnect the connector.
[1] JOINT PIPE
4) Remove the harness band clip from the connector bracket.
5) Unclamp the cover lock cable and the fuel tube.
6) Remove the 6 x 25 mm flange bolt and disconnect the high
pressure side fuel hose. Remove the joint pipe and the Oring.
• Replace the O-ring with a new one.
7) Disconnect the air vent tube and the pressure regulator
return hose from the vapor separator.
[3]
FUEL HOSE
(HIGH
PRESSURE SIDE)
6 x 25
[1]
PRESSURE
REGULATOR
RETURN
HOSE
[3]
VAPOR
SEPARATOR
5-111
[2]
O-RING (2)
Do not reuse.
[2] AIR VENT
TUBE
BF135A•BF150A
8) Disconnect the fuel tube B from the low pressure side fuel
pump.
[1] FUEL TUBE B
9) Disconnect the water tube from the crankcase.
[1] WATER TUBE
10) Remove the two 8 x 35 mm flange bolts, two 8 mm washers, and one 8 x 30 mm flange bolt. Remove the vapor separator assembly.
[1]
VAPOR SEPARATOR
ASSEMBLY
[2]
8 mm WASHER (2)
8 x 35 (2)
8 x 30
5-112
BF135A•BF150A
b. DISASSEMBLY
1) Disconnect the 4.5 x 55 mm fuel tube.
2) Remove the 8 x 35 mm flange bolt and the 8 mm washer.
Remove the vapor separator stay.
3) Remove the collar and the vapor separator grommet.
[1] COLLAR
[7]
VAPOR SEPARATOR
STAY
[2]
8 mm WASHER
[6]
3.5 x 420 mm
DRAIN TUBE
8 x 35
[5]
TUBE CLIP B8 (2)
[4]
4.5 x 55 mm
FUEL TUBE
[3]
VAPOR SEPARATOR
GROMMET
4) Remove the 6 x 25 mm flange bolt and remove the high
pressure side fuel hose.
5) Remove the collar and the O-rings.
Replace the O-rings on assembly.
6) Remove the three 5 mm screws and remove the strainer
cover, O-ring, fuel strainer and the spring.
[3]
FUEL STRAINER
(HIGH PRESSURE SIDE)
[1] FUEL HOSE
(HIGH PRESSURE
SIDE )
6 x 25
[2]
STRAINER COVER
[9]
COLLAR
[5]
O-RING (2)
Do not reuse.
[8] 5 mm SCREW (3)
[7] SERVICE CHECK
BOLT
5-113
[5]
O-RING
[6]
SEALING WASHER
Do not reuse.
Do not reuse.
[4] FILTER SPRING
BF135A•BF150A
7) Remove the four 5 mm screw-washers. Remove the connector bracket and pump cover.
8) Remove the O-ring from the pump cover and discard it.
Replace the O-ring with a new one on assembly.
9) Remove the pump holder.
10) Remove the 4 mm screw and 4 mm washer, then remove
the pump harness assembly.
[2]
4 mm SCREW
[3]
4 mm WASHER
[4]
PUMP HARNESS
ASSEMBLY
[1]
5 mm SCREWWASHER (4)
[8]
PUMP COVER
[7]
PUMP HOLDER
[6]
O-RING
Do not reuse.
5-114
[5]
CONNECTOR
BRACKET
BF135A•BF150A
11) Remove the O-ring and the seal ring.
Replace the O-ring with a new one on assembly.
12) Remove the plate and the insulator.
13) Remove the high pressure side fuel pump, pump holder and
the O-ring.
Replace the O-ring with a new one on assembly.
[1]
O-RING
[2] INSULATOR
[3] PLATE
Do not reuse.
[6]
SEAL RING
[5]
FUEL PUMP
(HIGH PRESSURE
SIDE)
[4]
PUMP HOLDER
[1]
O-RING
Do not reuse.
14) Remove the four 6 x 25 mm flange bolts. Remove the fuel
pump case and the two O-rings.
Replace the O-rings with the new ones on assembly.
[1]
O-RING
Do not reuse.
[2] FUEL PUMP CASE
6 x 25 (4)
5-115
BF135A•BF150A
15) Remove the eight 5 mm screw-washers and the eight 6 mm
washers. Remove the water jacket cover and the cover gasket.
Replace the cover gasket with a new one on assembly.
[1]
COVER GASKET
Do not reuse.
[2]
5 mm COLLAR (8)
[3]
5 mm WASHER (8)
[9]
TUBE CLIP
[8]
7 x 400 mm
WATER TUBE
[7]
7.3 x 350 mm
WATER TUBE
[6]
TUBE CLIP B12
16) Remove the six 5 mm screw-washers. Remove the vapor
separator cover and the cover gasket.
Replace the cover gasket with a new one on assembly.
17) Remove the two screws. Then, remove the float, float pin
and the float valve.
18) Remove the two 6 x 16 mm flange bolts and remove the
vapor separator stay.
[5]
WATER JACKET COVER
[4]
5 mm SCREWWASHER (8)
[1]
5 mm SCREWWASHER (6)
[2]
VAPOR
SEPARATOR
COVER
[3]
COVER GASKET
6 x 16 (2)
Do not reuse.
[4]
FLOAT VALVE
[5]
FLOAT PIN
[10]
COLLAR (2)
[9]
VAPOR SEPARATOR
GROMMET (2)
[6]
SCREW (2)
[8]
VAPOR SEPARATOR
STAY
[7]
VAPOR SEPARATOR
CHAMBER
5-116
BF135A•BF150A
c. INSPECTION
FLOAT HEIGHT
• Check the float height by installing the float properly.
1) Place the vapor separator cover as shown. Measure the
distance between the float and vapor separator cover (i.e.
float height).
• Set the special tool at right angles to the float chamber
mating surface and measure at the highest position of
the float.
Float height
31 ± 2.5 mm (1.22 ± 0.10 in)
2) If the float height is out of the specification, check the float
valve and valve seat for wear and damage.
[1]
FLOAT LEVEL GAUGE
07401-0010000
3) If the float valve and valve seat are normal, adjust the float
height by gently bending the brass float tab taking care not
to damage the float.
• FLOAT
Check the float for damage and deformation, and check for the
gasoline in the float. Check the float for smooth movement.
[2]
FLOAT TAB
• FLOAT VALVE/VALVE SEAT
Check the float valve head and the float valve seat for scores,
scratches, wear and damage.
[1] VALVE SEAT
[2]
Good
[4] FLOAT VALVE
5-117
[3]
Replace.
BF135A•BF150A
d. ASSEMBLY
• Vapor Separator Chamber
[2]
5 mm SCREW-WASHER (6)
3.4 N • m (0.35 kgf • m, 2.5 lbf • ft)
[3]
VAPOR SEPARATOR
COVER
[1]
COVER GASKET
Do not reuse.
6 x 16 (2)
12 N • m (1.2 kgf • m, 9 lbf • ft)
[4]
FLOAT VALVE
COLLAR (2)
[5]
FLOAT PIN
[6]
SCREW (2)
2.1 N • m (0.21 kgf • m, 1.5 lbf • ft)
[7]
COVER GASKET
Do not reuse.
[18]
VAPOR SEPARATOR
GROMMET (2)
[17]
VAPOR SEPARATOR
STAY
[8]
5 mm COLLAR (8)
[9]
5 mm
WASHER (8)
[16]
VAPOR SEPARATOR
CHAMBER
[15] TUBE CLIP
[14]
7 x 400 mm
WATER TUBE
[13]
7.3 x 350 mm
WATER TUBE
[12]
TUBE CLIP B12
[11]
WATER JACKET COVER
5-118
[10]
5 mm SCREWWASHER (8)
3.4 N • m (0.35 kgf • m,
2.5 lbf • ft)
BF135A•BF150A
1) Install the float valve and float pin to the float.
[2]
FLOAT PIN
[1] SCREW (2)
2) Set the float assembly on the vapor separator cover and
tighten the two screws to the specified torque.
TORQUE: 2.1 N • m (0.21 kgf • m, 1.5 lbf • ft)
[3]
FLOAT
[4]
FLOAT VALVE
[5]
VAPOR
SEPARATOR
COVER
3) Install the vapor separator grommets on the vapor separator
stay.
[1]
COLLAR (2)
4) Install the vapor separator stay on the vapor separator
chamber and tighten the two 6 x 16 mm flange bolts to the
specified torque.
TORQUE: 12 N • m (1.2 kgf • m, 9 lbf • ft)
6 x 16 (2)
[2]
VAPOR SEPARATOR
GROMMET (2)
5) Install the collars on the vapor separator grommet.
[3]
VAPOR SEPARATOR
STAY
6) Apply a thin coat of the engine oil to the new cover gasket
and install the gasket in the groove in the vapor separator
chamber securely.
7) Install the vapor separator cover and tighten the 5 mm
screw-washers to the specified torque.
TORQUE: 3.4 N • m (0.35 kgf • m, 2.5 lbf • ft)
[1]
5 mm SCREWWASHER (6)
[2]
VAPOR
SEPARATOR
COVER
[3]
COVER GASKET
Do not reuse.
[4]
VAPOR
SEPARATOR
CHAMBER
5-119
BF135A•BF150A
8) Apply a thin coat of the engine oil to a new cover gasket and
install it on the water jacket cover.
[1]
COVER GASKET
Do not reuse.
[2]
WATER JACKET
COVER
9) Set the eight collars on the water jacket cover and install the
water jacket cover on the vapor separator chamber.
[3]
5 mm
COLLAR (8)
10) Set the eight 5 mm washers and the eight 5 mm screwwashers, then tighten the screws to the specified torque.
TORQUE: 3.4 N • m (0.35 kgf • m, 2.5 lbf • ft)
11) Connect the 7 x 400 mm water tube to the upper tube joint
of the water jacket cover, and secure the connection of the
tube with the tube clip.
12) Connect the 7.3 x 350 mm water tube to the lower tube joint
of the water jacket cover, and secure the connection of the
tube with the tube clip B12.
[6]
TUBE CLIP
[9]
7.3 x 350 mm
WATER TUBE
[7]
TUBE CLIP
B12
[8]
7 x 400 mm
WATER TUBE
5-120
[5]
5 mm
WASHER (8)
[4]
5 mm SCREWWASHER (8)
BF135A•BF150A
• Fuel Pump (High Pressure Side)
[2]
5 mm SCREW-WASHER (4)
3.4 N·m (0.35 kgf·m, 2.4 lbf·ft)
[1]
FUEL HOSE
(HIGH PRESSURE
SIDE)
[7]
4 mm SCREW
[3]
FUEL STRAINER
(HIGH PRESSURE SIDE)
[8]
4 mm WASHER
[9]
PUMP HARNESS
ASSEMBLY
[10]
CONNECTOR
BRACKET
[6]
PUMP COVER
6 x 25
[5]
FILTER SPRING
[4]
STRAINER
COVER
[17]
O-RING (2)
[11]
O-RING
Do not reuse.
Do not reuse.
[12] TERMINAL HOLDER
[25]
COLLAR
[11]
O-RING
Do not reuse.
[30]
5 mm SCREW (3)
3.4 N·m (0.35 kgf·m,
2.4 lbf·ft)
[29] SEAL RING
[14] INSULATOR
[15] FUEL PUMP
(HIGH PRESSURE SIDE)
[28]
SEALING WASHER
[27]
SERVICE CHECK BOLT
12 N·m (1.2 kgf·m,
9 lbf·ft)
[24] VAPOR SEPARATOR
STAY
[23]
DRAIN SCREW
[13] PLATE
Do not reuse.
[16] PUMP HOLDER
[11]
O-RING
Do not reuse.
[25]
COLLAR
[26]
VAPOR
SEPARATOR
GROMMET
[11]
O-RING
Do not reuse.
[17]
O-RING (2)
[22]
3.5 x 420 mm
DRAIN TUBE
[21]
TUBE CLIP B8 (2)
Do not reuse.
[20]
4.5 x 55 mm
FUEL TUBE
6 x 25 (4)
12 N·m (1.2 kgf·m,
9 lbf·ft)
5-121
8 x 25
24 N·m (2.4 kgf·m,
17 lbf·ft)
[18] 8 mm WASHER
[19] FUEL PUMP CASE
BF135A•BF150A
1) Apply a thin coat of the engine oil to the new O-rings and set
them on the vapor separator chamber.
2) Install the pump case with care not to allow the O-rings to
come out of position.
[1]
O-RING (2)
Do not reuse.
3) Tighten the 6 x 25 mm flange bolts.
TORQUE: 12 N • m (1.2 kgf • m, 9 lbf • ft)
6 x 25 (4)
4) Apply a thin coat of the engine oil to the new O-ring and set
it on the pump holder.
[2]
FUEL PUMP CASE
[1]
PUMP HOLDER
5) Install the pump holder on the pump case. Be sure to install
it in the direction shown.
6) Install the high pressure side fuel pump on the pump case.
• Install by aligning the projection on the pump with the
hole in the pump holder.
[1]
HIGH PRESSURE
SIDE FUEL PUMP
[2]
PUMP HOLDER
5-122
BF135A•BF150A
7) Install the pump harness assembly on the pump cover, and
secure the pump harness assembly with the 4 mm screw.
TORQUE: 2.1 N • m (0.21 kgf • m, 1.5 lbf • ft)
8) Set the terminal holder on the pump cover and route each
wire as shown.
• Align the bosses on the terminal holder with the holes in
the pump cover.
[1] 4 mm SCREW
[2] 4 mm WASHER
[4]
PUMP HARNESS
ASSEMBLY
[3]
PUMP COVER
[1] TERMINAL HOLDER
9) Set the terminals in the positions shown.
[2] TERMINALS
[4]
BLUE/
YELLOW
WIRE
10) Apply a thin coat of engine oil to the new O-ring and install
them on the oil case.
11) Set the seal ring at the discharge port of the pump.
[1]
BLACK WIRE
TERMINAL
[5]
O-RINGS
Do not reuse.
12) Apply a thin coat of the engine oil to the new O-ring and set
it at the discharge port of the pump.
13) Connect the pump harness assembly terminals to the pump
terminals as shown.
• Connect the Blue/Yellow wire terminal to the positive (+)
terminal of the pump and the Black wire terminal to the
negative (–) terminal of the pump.
5-123
[3]
BLACK
WIRE
[2]
BLUE/
YELLOW
WIRE
TERMINAL
[4]
SEAL RING
[3]
POSITIVE (+)
TERMINAL
BF135A•BF150A
14) Tighten the four 5 mm screw-washers securely.
• Install the connector bracket in the position shown and
secure with the two 5 mm screw-washers.
TORQUE: 3.4 N • m (0.35 kgf • m, 2.4 lbf • ft)
[1] 5 mm SCREW-WASHER (4)
[2]
CONNECTOR
BRACKET
3.4 N·m (0.35 kgf·m, 2.4 lbf·ft)
[3]
PUMP COVER
15) Apply the engine to the new O-ring and install it on the
strainer cover.
16) Install the spring and the fuel strainer, and install the strainer
cover.
• Install the fuel strainer in the direction shown.
[3] FUEL STRAINER SET
[1]
STRAINER
COVER
[2]
SEAL
17) Tighten the 5 mm washer screws securely.
TORQUE: 3.4 N • m (0.35 kgf • m, 2.4 lbf • ft)
[4] FILTER
SPRING
[5] O-RING
Do not reuse.
[6] 5 mm SCREW (3)
18) Apply the engine oil to the new O-rings and install them on
the collar.
6 x 25
[1] FUEL HOSE
(HIGH PRESSURE
SIDE)
[2] O-RING (2)
19) Install the collar on the strainer cover.
Do not reuse.
20) Set the fuel hose and secure it by tightening the 6 x 25 mm
flange bolt.
21) Using a new sealing washer, tighten the service check bolt
to the specified torque.
TORQUE: 12 N • m (1.2 kgf • m, 9 lbf • ft)
[5]
COLLAR
[4]
SERVICE
CHECK BOLT
[3] SEALING WASHER
Do not reuse.
5-124
BF135A•BF150A
e. INSTALLATION
1) Install the vapor separator grommet and the collar on the
fuel pump case.
2) Loosely tighten the vapor separator stay with the 8 mm
washer and the 8 x 35 mm flange bolt.
Tighten the 8 x 35 mm flange bolt, after installing the
vapor separator assembly on the engine.
3) Connect the 4.5 x 55 mm fuel tube and secure it with the
tube clip B8.
4) Connect the 3.5 x 420 mm drain tube to the vapor separator
stay.
5) Set the vapor separator assembly on the engine, and loosely tighten it with the two 8 mm washers, two 8 x 35 mm
flange bolts and the one 8 x 30 mm flange bolt.
Align the projection of the vapor separator stay with the
hole in the engine.
[1]
VAPOR
SEPARATOR
STAY
[2]
COLLAR
[3]
VAPOR
SEPARATOR
GROMMET
8 x 35
[7]
3.5 x 420 mm
DRAIN TUBE
[5]
4.5 x 55 mm
FUEL TUBE
[6]
TUBE CLIP B8 (2)
[4]
8 mm
WASHER
6) Tighten the three 8 x 35 mm flange bolts and one 8 x 30
mm flange bolt to the specified torque.
TORQUE: 26 N • m (2.7 kgf • m, 20 lbf • ft)
[8]
VAPOR SEPARATOR
ASSEMBLY
[1]
VAPOR
SEPARATOR
STAY
[11] HOLE
8 x 30
8 x 35 (2)
[9] 8 mm WASHER (2)
[10] PROJECTION
5-125
8 x 35 (2)
BF135A•BF150A
7) Connect the 7.3 x 350 mm water tube to the cylinder block
and secure it with the tube clip.
[1] TUBE CLIP
[2] 7.3 x 350 mm WATER TUBE
8) Connect the fuel tube B to the vapor separator and secure it
with the tube clip B12.
[1] TUBE CLIP B12
[2] FUEL TUBE B
9) Connect the pressure regulator return hose to the vapor
separator, and secure it with the tube clamp D10.5.
10) Connect the air vent tube to the vapor separator.
[2]
AIR VENT
TUBE
[1]
PRESSURE
REGULATOR
RETURN
HOSE
[3]
VAPOR
SEPARATOR
[4]
TUBE
CLAMP
D10.5
11) Apply the engine oil to the new O-ring and install it on the
joint pipe.
[1]
JOINT PIPE
12) Set the joint pipe in the fuel tube and install the fuel hose.
13) Tighten the 6 x 25 mm flange bolt to the specified torque.
[3]
FUEL HOSE
(HIGH PRESSURE SIDE
5-126
6 x 25
[2]
O-RING (2)
Do not reuse.
BF135A•BF150A
14) Connect the fuel pump 2P connector and set the connector
on the connector bracket.
[1]
HARNESS
BAND CLIP
15) Install the harness band clip on the connector bracket in the
position shown in the drawing.
[2]
CLAMPS
[3]
FUEL PUMP 2P
CONNECTOR
16) Secure the cover lock cable and the fuel hose with the
clamps.
[6]
FUEL TUBE
[4]
CONNECTOR
BRACKET
[5] COVER LOCK CABLE
17) After assembly, check each fuel tube and clamp and check
that they are not interfering with the neighboring parts.
[1]
PRESSURE REGULATOR RETURN HOSE
18) Turn the ignition switch ON. Check that the fuel pump turns
for 2 seconds and that there is no fuel/water leakage.
[2]
FUEL HOSE
(HIGH PRESSURE
SIDE)
[4]
FUEL TUBE B
[3] WATER TUBE
5-127
BF135A•BF150A
12. SILENCER CASE/THROTTLE
BODY/INTAKE MANIFOLD
[1] HARNESS
BAND CLIP
a. SILENCER CASE REMOVAL
1) Remove the engine cover.
2) Disconnect the IAT sensor 2P connector and remove the
harness band clip from the silencer case.
3) Loosen the air flow tube clamp.
[3] IAT SENSOR 2P
CONNECTOR
4) Disconnect the crankcase breather tube from the silencer
case.
[1] SILENCER
CASE
5) Remove the three 6 x 25 mm flange bolts and the three 6
mm washers. Remove the silencer case.
[2] AIR FLOW
TUBE CLAMP
6 x 25 (3)
[2] 6 mm WASHER (3)
• SILENCER CASE DISASSEMBLY/ASSEMBLY
[1] SENSOR GROMMET
[2] SILENCER CASE
ASSEMBLY:
Install in the direction
shown.
[3]
SILENCER DUCT
GROMMET
[4]
COLLAR (3)
[5]
GROMMET (3)
[10]
IAT SENSOR
[6] AIR FLOW
TUBE SPRING
[9] AIR FLOW TUBE
ASSEMBLY:
Install the air flow tube deep on
the silencer duct until it contacts
the projection on the silencer duct.
[7] AIR FLOW
TUBE CLAMP
[8] VINYL TUBE
[9]-1 PROJECTION
5-128
BF135A•BF150A
b. THROTTLE BODY/INTAKE MANIFOLD
REMOVAL
[1]
MAP SENSOR 3P
CONNECTOR
1) Remove the silencer case (P. 5-128).
2) Disconnect the MAP sensor 3P connector and remove the
harness band clip.
[2]
HARNESS
BAND CLIP
3) Remove the water level sensor connector from the the harness clip bracket E.
[1]
TP SENSOR 3P
CONNECTOR
4) Disconnect the TP sensor 3P connector and remove the
harness band clip from the harness clip bracket E.
[4]
HARNESS
BAND CLIP
5) Remove the throttle rod.
• Do not loosen the pivot lock nut.
[2]
WATER LEVEL
SENSOR
CONNECTOR
[3] HARNESS CLIP BRACKET E
[1]
THROTTLE
ROD
6) Remove one 8 x 60 mm flange bolt and remove the throttle
body.
7) Remove the throttle body gasket.
• Replace the throttle body gasket with a new one.
• The intake manifold assembly can be removed by skipping the steps 6 and 7 (i.e. with the throttle body mounted).
8) Disconnect the IAB control valve 2P connector.
5-129
[2]
THROTTLE BODY
[1]
IAB CONTROL
VALVE 2P
CONNECTOR
BF135A•BF150A
9) Disconnect the pressure regulator vacuum tube from the
intake manifold joint.
[1]
PRESSURE
REGULATOR
VACUUM
TUBE
[2]
INTAKE MANIFOLD
JOINT
10) Remove the two 8 x 55 mm flange bolts and remove the L.
side cover bracket.
• The L. side cover bracket can be removed without disconnecting the cover lock cable.
[1]
L. SIDE COVER BRACKET
8 x 55 (2)
11) Remove the five 8 x 35 mm flange bolts, two 8 mm washers
and the two 8 mm flange nuts. Remove the intake manifold
assembly.
[1] 8 mm WASHER
8 x 35 (5)
[3]
INTAKE MANIFOLD
ASSEMBLY
[2]
8 mm FLANGE
NUT (2)
5-130
BF135A•BF150A
c. INTAKE MANIFOLD DISASSEMBLY/ASSEMBLY
[2] SOLENOID VALVE TUBE
[1]
INTAKE MANIFOLD GASKET (4)
ASSEMBLY:
• Do not reuse.
• Install by aligning the projection
on the gasket with the groove in
the intake manifold.
[1]-1
PROJECTION
ASSEMBLY:
Connect the solenoid valve tube to the top of the
intake air cut-off solenoid valve, and the
diaphragm tube to the lower joint of the intake air
cut-off solenoid valve.
[2]-1
DIAPHRAGM
TUBE
[2]-2
SOLENOID
[2]-3 UP VALVE TUBE
8 x 60 (4)
22 N·m (2.2 kgf·m,
16 lbf·ft)
[3]
DIAPHRAGM TUBE
[1]-2
GROOVE
[4]
INTAKE AIR CUT-OFF
SOLENOID VALVE
[12]
COLLAR (2)
5 x 12
[11]
GROMMET (2)
[10]
THROTTLE BODY
[9]
THROTTLE BODY GASKET
[5]
SHUTTER VALVE DIAPHRAGM
Do not reuse.
INSPECTION: P. 5-110
Do not disassemble the
shutter valve diaphragm.
Replace as an assembly
of the intake manifold
assembly.
[8]
IAC VALVE GASKET
Do not reuse.
[6]
INTAKE MANIFOLD
ASSEMBLY
[7] IAC VALVE
8 x 45 (2)
22 N·m (2.2 kgf·m, 16 lbf·ft)
5-131
BF135A•BF150A
d. THROTTLE BODY DISASSEMBLY/REASSEMBLY
[1] MAP SENSOR
ASSEMBLY:
Apply the engine oil to the new
O-ring and install it on the MAP
sensor. Install aligning the
cutout in the set plate with the
lib of the sensor as shown.
[2]
5 x 18 mm SCREW
[1]-1
MAP
SENSOR
[3]
SET PLATE
[1]-2
SET
PLATE
[5] O-RING
Do not reuse.
[4]
HARNESS CLIP BRACKET E
ASSEMBLY:
Install the bracket aligning
the cutout in the bracket
with the stopper pin.
[6] IDLE ADJUSTING SCREW
ADJUSTMENT: P. 5-93
[5] O-RING
[4]-1
HARNESS CLIP
BRACKET E
Do not reuse.
[4]-2 STOPPER PIN
e. INTAKE MANIFOLD INSTALLATION
1) Install the new intake manifold gasket on the intake manifold
assembly.
• Install aligning the projection on the gasket with the
groove in the intake manifold.
2) Install the intake manifold assembly on the engine.
• Take care not to pinch the pressure regulator return hose
and the air vent tube at the top of the intake manifold.
5-132
[2] INTAKE MANIFOLD GASKET
[1]
PROJECTION
[3]
AIR VENT TUBE
[6]
GROOVE
[5]
TOP OF INTAKE
MANIFOLD
[4]
PRESSURE REGULATOR
RETURN HOSE
BF135A•BF150A
3) Set the five 8 x 35 mm flange bolts, two 8 mm washers and
the two 8 mm flange nuts.
[1] 8 mm FLANGE NUT (2)
4) Tighten the 8 x 35 mm flange bolts and the 8 mm flange
nuts in the numbered sequence in two or three steps to the
specified torque.
TORQUE: 26 N • m (2.7 kgf • m, 20 lbf • ft)
[2] 8 x 35 (2)
and 8 mm WASHER (2)
5) Install the new throttle body gasket on the intake manifold.
8 x 60 (4)
8 x 35 (3)
[1] THROTTLE BODY GASKET
6) Install the throttle body and tighten the 8 x 60 mm flange
bolts in the numbered sequence in two or three steps
securely.
TORQUE: 22 N • m (2.2 kgf • m, 16 lbf • ft)
[2] THROTTLE BODY
7) Install the throttle rod. Note the throttle rod installation direction. Don't loosen the lock nut of the throttle rod
8) Connect the IAB control valve 2P connector.
5-133
[1] THROTTLE ROD
[1]
IAB CONTROL VALVE
2P CONNECTOR
BF135A•BF150A
9) Connect the vacuum tube to the pressure regulator.
[1]
PRESSURE
REGULATOR
VACUUM
TUBE
[2]
INTAKE MANIFOLD
JOINT
10) Install the L. side cover bracket assembly and tighten the
two 8 x 55 mm flange bolts securely.
[1]
L. SIDE COVER BRACKET
8 x 55 (2)
11) Connect the MAP sensor 3P connector and set the harness
band clip in the hole in the sensor set plate.
[1]
MAP SENSOR 3P
CONNECTOR
[2]
HARNESS
BAND CLIP
12) Connect the TP sensor 3P connector and set the harness
band clip in the hole in the harness clip bracket E.
[1]
TP SENSOR 3P
CONNECTOR
13) Install the water level sensor connector on the harness clip
bracket E.
[4]
HARNESS
BAND CLIP
5-134
[2]
WATER LEVEL
SENSOR
CONNECTOR
[3]
HARNESS CLIP BRACKET E
BF135A•BF150A
f. SILENCER CASE INSTALLATION
1) Install the silencer case and tighten the three 6 x 25 mm
flange bolts and the three 6 mm washers.
• Check that the wire harnesses are not pinched.
• Set the main harness in the groove in the left lower section of the silencer case.
[2] CRANKCASE BREATHER TUBE
[1] SILENCER CASE
6 x 25 (3)
2) Tighten the three 6 x 25 mm flange bolts securely.
3) Connect the crankcase breather tube.
[3] 6 mm WASHER (3)
[5] WIRE HARNESS
[4] SILENCER CASE
4) Fasten the air flow tube clamp securely.
[1] HARNESS
BAND CLIP
5) Connect the IAT sensor 2P connector and secure the harness band clip in the hole in the silencer case.
[3] IAT SENSOR 2P
CONNECTOR
5-135
[2] AIR FLOW
TUBE CLAMP
BF135A•BF150A
13. FUEL INJECTOR/PRESSURE
REGULATOR
a. FUEL LINE ASSEMBLY REMOVAL
Gasoline is highly flammable and explosive.
You can be burned or seriously injured when handling fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
• Relieve the fuel pressure before removing the fuel injectors.
• Disconnect the battery cable from the battery negative (–)
terminal before relieving the fuel pressure.
• Replace the sealing washer with a new one when the service check bolt had been loosened or removed.
[1]
L. SIDE COVER BRACKET
1) Remove the engine cover and the L. engine under cover.
2) Relieve the fuel pressure according to “HOW TO RELIEVE
FUEL PRESSURE” (P. 5-102).
8 x 55 (2)
3) Remove the two 8 x 55 mm flange bolts and move the L.
side cover bracket out of position.
4) Remove the three main harness clips from the respective
clip brackets.
[1] HOSE CLIP
5) Disconnect the connector from each injector.
6) Remove the hose clip. Clamp the pressure regulator return
hose and the main wire harness.
[2]
CLIP
[5]
CLIP BRACKET
[4]
INJECTOR 2P
CONNECTOR
5-136
[3]
MAIN WIRE
HARNESS
BF135A•BF150A
7) Disconnect the pressure regulator control tube and the pressure regulator return hose from the pressure regulator.
[1]
TUBE CLAMP
D10.7
[2] PRESSURE REGULATOR
CONTROL TUBE
[3]
PRESSURE
REGULATOR
8) Remove the pressure regulator. Remove the joint pipe and
the O-rings.
• Replace the O-rings on assembly.
[6]
PRESSURE
REGULATOR
RETURN
HOSE
[5] JOINT PIPE
[4] O-RING (2)
Do not reuse.
9) Remove the 6 x 25 mm flange bolt and remove the fuel
hose (high pressure side).
[1]
JOINT PIPE
10) Remove the joint pipe and the O-rings.
• Replace the O-rings on assembly.
[3]
FUEL HOSE
(HIGH PRESSURE
SIDE)
[2] O-RING (2)
Do not reuse.
6 x 25
11) Release the fuel tube (2 places) and the air vent tube (2
places) from the 14 mm fuel tube clips.
[1] AIR VENT TUBE
[2]
FUEL LINE
ASSEMBLY
12) Remove the two 6 mm flange nuts and remove the fuel line
assembly.
[5] FUEL TUBE
[4]
14 mm FUEL
TUBE CLIP
[3] 8 mm FLANGE NUT (2)
5-137
BF135A•BF150A
b. FUEL TUBE ASSEMBLY DISASSEMBLY/ASSEMBLY
• Replace the O-rings with the new ones and apply the engine oil to the new O-rings before installation.
[1]
7.85 x 3.53 mm O-RING (4)
6 x 10 (4)
[2]
INJECTOR CLIP (4)
Do not reuse.
[3]
14 mm FUEL
TUBE CLIP (4)
[7]
INJECTOR (4)
[4]
CLIP BRACKET (4)
[6]
7.47 x 3.6 mm O-RING (4)
Do not reuse.
6 x 14 (4)
[5]
FUEL TUBE
• INJECTOR INSTALLATION
• Apply the engine oil to the new O-rings and install them on
the respective injectors.
• Install the injectors aligning the projection with the groove in
the fuel line.
[1]
INJECTOR
[2]
PROJECTION
[3]
INJECTOR
CLIP (4)
5-138
BF135A•BF150A
c. INJECTOR BASE REMOVAL/INSTALLATION
1) Remove the fuel injectors (P. 5-136).
2) Remove the silencer case (P. 5-128) and remove the intake manifold (P. 5-129).
3) Remove the five 8 x 25 mm flange bolts and the two 8 mm flange nuts, then remove the injector base and the injector
base gasket.
4) Install the removed parts in the reverse order of removal.
• Replace the injector base gasket on assembly.
• Tighten the 8 x 25 mm flange bolts and the 8 mm flange nuts to the specified torque in the numbered sequence in
a criss-cross pattern in two or three steps.
TORQUE: 24 N • m (2.4 kgf • m, 18 lbf • ft)
[1] INJECTOR BASE GASKET
Do not reuse.
[2]
INJECTOR BASE
[3]
8 mm FLANGE NUT (2)
24 N·m (2.4 kgf·m, 18 lbf·ft)
8 x 25 (5)
24 N·m (2.4 kgf·m, 18 lbf·ft)
5-139
BF135A•BF150A
d. FUEL TUBE ASSEMBLY INSTALLATION
[1]
AIR VENT TUBE
1) Apply the engine oil to the O-rings on the injectors. Install
the fuel line assembly and tighten the 8 mm flange nuts
securely.
• Replace the O-rings on assembly.
[2]
STUD BOLT (2)
22 N·m (2.2 kgf·m,
16 lbf·ft)
2) Set the air vent tube (2 places) and the fuel tube (2 places)
on the 14 mm fuel tube clip.
[6] FUEL TUBE
[5] FUEL LINE
ASSEMBLY
[4] 14 mm FUEL
TUBE CLIP
[3]
8 mm FLANGE NUT (2)
3) Apply the engine oil to the O-rings and install them on the
joint pipe.
4) Install the joint pipe on the fuel line.
5) Install the pressure regulator and tighten the joint nut to the
specified torque.
• Install the pressure regulator in the direction shown.
TORQUE: 27 N • m (2.8 kgf • m, 20 lbf • ft)
6) Connect the pressure regulator return hose and secure it
with the tube clamp D10.7.
[1]
PRESSURE
REGULATOR
RETURN HOSE
[2] PRESSURE REGULATOR
CONTROL TUBE
[3]
PRESSURE
REGULATOR
[6]
TUBE
CLAMP
D10.7
[4] O-RING (2)
[5]
JOINT PIPE
[3]
PRESSURE
REGULATOR
7) Connect the pressure regulator control tube.
10
5-140
Do not reuse.
BF135A•BF150A
8) Apply the engine oil to the O-rings and install them on the
joint pipe.
[1] COLLAR
9) Install the joint pipe on the fuel line.
10) Connect the fuel hose (high pressure side) and tighten the 6
x 25 mm flange bolt securely.
[3]
FUEL HOSE
(HIGH PRESSURE
SIDE)
11) Connect the 2P connector to each injector.
[2] O-RING (2)
Do not reuse.
6 x 25
[1]
HOSE CLIP
12) Set the three clips of the main harness on the clip brackets.
13) Clamp the pressure regulator return hose and the main wire
harness with the hose clip.
[2]
CLIP
[5]
CLIP BRACKET
[4]
INJECTOR 2P
CONNECTOR
5-141
[3]
MAIN WIRE
HARNESS
BF135A•BF150A
14. FUEL PUMP (LOW PRESSURE SIDE)
[1]
L. SIDE COVER
BRACKET
Gasoline is highly flammable and explosive.
You can be burned or seriously injured when handling fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
8 x 55 (2)
a. REMOVAL
1) Remove the engine cover and the L. engine under cover .
2) Remove the two 8 x 55 mm flange bolts and move the L.
side cover bracket a side.
[1]
TUBE CLAMP
(Commercially
available)
[2] FUEL TUBE B
[3]
FUEL
PUMP
3) Clamp the fuel tubes with a commercially available tube
clamps, then disconnect the fuel tubes from the fuel pump.
[4]
FUEL TUBE D
4) Remove the two 6 x 27 mm flange bolts and remove the fuel
pump.
[1]
FUEL PUMP
5) Remove the O-rings from the fuel pump.
• Replace the O-rings with the new ones on assembly.
6 x 27 (2)
[2] O-RING (2)
Do not reuse.
b. INSPECTION
[1] PLUNGER
Push the plunger to check for smooth operation.
Replace the plunger if it is faulty.
5-142
BF135A•BF150A
c. INSTALLATION
[3]
FUEL TUBE B
[2]
TUBE CLIP B11 (2)
[1]
SENSOR HOSE CLIP
[4] 33.2 x 2.4 mm O-RING
Do not reuse.
[9] FUEL TUBE E
6 x 27 (2)
[8] TUBE JOINT
[7] TUBE CLIP B12 (2)
[5] FUEL PUMP
12 N·m (1.2 kgf·m, 9 lbf·ft)
[6] FUEL TUBE D
1) Apply the engine oil to the new O-ring and install it on the
fuel pump.
[1]
" " MARK
2) Install the fuel pump with the " " mark facing up and tighten
the two 6 x 27 mm flange bolts to the specified torque.
TORQUE: 12 N • m (1.2 kgf • m, 9 lbf • ft)
[2]
FUEL PUMP
3) Connect the fuel tube B and D and secure them respectively
with the tube clip B1s.
4) Install the L. side cover bracket and tighten the 8 x 55 mm
flange bolt securely.
[1]
FUEL TUBE B
[2]
TUBE CLIP
B1 (2)
5) After assembly, start the engine and check for the gasoline
leakage from the low pressure side fuel pump.
[3]
FUEL TUBE D
5-143
6 x 27 (2)
BF135A•BF150A
15. FUEL STRAINER (LOW PRESSURE SIDE)/WATER SEPARATOR
Gasoline is highly flammable and explosive.
You can be burned or seriously injured when handling fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
a. REMOVAL/INSTALLATION
1) Remove the engine cover and the L. engine under cover .
2) Pinch the fuel tube A with the commercially available tube clip and disconnect the fuel tube A from the water separator.
3) Remove the water level sensor 2P connector from the connector bracket and disconnect the connector.
4) Pinch the fuel tube E with the commercially available tube clip and disconnect the fuel tube E from the fuel strainer (low
pressure side).
5) Disconnect the fuel tube C from the water separator and fuel strainer.
6) Remove the fuel strainer and water separator.
7) Remove the 6 x 14 mm flange bolts and fuel strainer stay.
• Installation is the reverse order of removal.
[4]
[2] FUEL STRAINER STAY
[3]
FUEL STRAINER
(LOW PRESSURE SIDE)
TUBE CLIP
B12 (4)
[5]
FUEL TUBE E
[1] CONNECTOR BRACKET
6 X 14 (2)
[6]
FUEL TUBE C
[11]
2P CONNECTOR
[10] HARNESS CLIP
[9] STRAINER SUSPENSION (2)
INSTALLATION:
Align the screw of the tube joint side
with the center of the strainer suspension as shown.
[9]-1
STRAINER
SUSPENSION
[7]
FUEL TUBE A
[9]-2
SCREW
5-144
[8]
WATER SEPARATOR
BF135A•BF150A
b. DISASSEMBLY/REASSEMBLY
• WATER SEPARATOR
[1]
WATER SEPARATOR CUP/
WATER LEVEL SWITCH
[2]
WATER SEPARATOR BODY
INSPECTION: P. 3-20
[6]
SET PLATE
[3]
BAFFLE PLATE
[4]
O-RING
[5]
5 x 12 mm
SCREW (3)
• FUEL STRAINER (LOW PRESSURE SIDE)
[2]
FUEL STRAINER BODY
[1]
FUEL STRAINER
(LOW PRESSURE SIDE)
[6]
SET PLATE
[3]
O-RING
[5]
5 x 12 mm
SCREW (3)
5-145
[4]
STRAINER CUP
BF135A•BF150A
16. EOP (ENGINE OIL PRESSURE)
SWITCH (HIGH PRESSURE SIDE)
a. INSPECTION
1) Disconnect the high pressure side EOP switch 2P connector.
2) Check for the continuity between the switch side 2P connector terminals.
• The high pressure side EOP switch is normal if there is
continuity.
• Replace the high pressure side EOP switch if there is no
continuity.
[1]
EOP SWITCH 2P
CONNECTOR
[1]
13 x 1.5 mm
O-RING
b. REPLACEMENT
Do not reuse.
1) Disconnect the high pressure side EOP switch 2P connector.
2) Remove the EOP switch and the O-ring.
• Replace the O-ring on assembly.
3) Apply the engine oil to the new O-ring and install it on the
switch.
[3]
EOP SWITCH
[2]
EOP SWITCH 2P
CONNECTOR
4) Tighten the EOP switch to the specified torque.
TORQUE: 22 N • m (2.2 kgf • m, 16 lbf • ft)
5) After installation, connect the switch connector.
17. EOP (ENGINE OIL PRESSURE)
SWITCH (LOW PRESSURE SIDE)
a. INSPECTION
1) Disconnect the low pressure side EOP switch terminal.
2) Check for the continuity between the switch terminal and the
engine ground.
• The low pressure side EOP switch is normal if there is
continuity.
• Replace the low pressure side EOP switch if there is no
continuity.
[1]
EOP SWITCH
5-146
BF135A•BF150A
b. REPLACEMENT
1) Disconnect the low pressure side EOP switch terminal.
2) Remove the EOP switch.
3) Clean the EOP switch installation section in the crankcase.
4) Apply the liquid gasket (ThreeBond® #1215 or equivalent) to
the indicated area of the threads of the new EOP switch.
[1] EOP SWITCH
5) Install and tighten the EOP switch to the specified torque.
TORQUE: 8 N • m (0.8 kgf • m, 6 lbf • ft)
NOTICE
• Be sure to use the torque wrench to tighten the EOP
switch.
• Do not exceed the specified torque when tightening the
EOP switch. Overtightening will damage the cylinder
block.
6) Connect the EOP switch terminal.
18. ECT (ENGINE COOLANT
TEMPERATURE) SENSOR 1
[1]
LIQUID GASKET
APPLICATION AREA
[1]
13 x 1.5 mm O-RING
Do not reuse.
[2]
ECT SENSOR 1
CONNECTOR
a. REPLACEMENT
1) Disconnect the 2P connector of ECT sensor 1.
2) Remove the ECT sensor 1 and the O-ring.
• Replace the O-ring on assembly.
3) Apply the engine oil to the new O-ring and install it on the
ECT sensor 1.
4) Tighten the ECT sensor 1 to the specified torque.
TORQUE: 12 N • m (1.2 kgf • m, 9 lbf • ft)
5) Connect the ECT sensor 1 connector.
5-147
[3]
ECT SENSOR 1
BF135A•BF150A
19. ECT (ENGINE COOLANT
TEMPERATURE) SENSOR 2, 3, 4
[1]
ECT SENSOR 2
2P CONNECTOR
[2] O-RING
Do not reuse.
a. REPLACEMENT
1) Disconnect the ECT sensor 2P connector.
2) Remove the ECT sensor and the O-ring.
• Replace the O-ring with a new one on assembly.
3) Apply the engine oil to the new O-ring and install it on the
ECT sensor.
[3] ECT SENSOR 2
4) Tighten the overheat sensor to the specified torque.
TORQUE: 12 N • m (1.2 kgf • m, 9 lbf • ft)
[4]
ECT SENSOR 3
2P CONNECTOR OF
5) After installation, connect the ECT sensor 2P connector.
[2] O-RING
Do not reuse.
[5] ECT SENSOR 3
[2] O-RING
Do not reuse.
[7] ECT
SENSOR 4
2P CONNECTOR
5-148
[6] ECT SENSOR 4
BF135A•BF150A
20. BARO (BAROMETRIC PRESSURE)
SENSOR
[1]
5 x 18 mm
WASHER BOLT
[2]
BARO SENSOR
3P CONNECTOR
a. REPLACEMENT
1) Disconnect the BARO sensor 3P connector.
2) Remove the 5 x 18 mm washer bolt and remove the BARO
sensor.
[3]
BARO
SENSOR
3) Install the BARO sensor and tighten the 5 x 18 mm washer
bolt securely.
4) After installation, connect the BARO sensor 3P connector.
21. KNOCK SENSOR
[1]
KNOCK SENSOR
a. REPLACEMENT
1) Disconnect the knock sensor 1P connector.
2) Remove the knock sensor.
3) Tighten the knock sensor to the specified torque.
TORQUE: 31 N • m (3.1 kgf • m, 22 lbf • ft)
[2]
KNOCK SENSOR
1P CONNECTOR
4) After installation, connect the knock sensor 1P connector.
22. CMP (CAMSHAFT POSITION)
SENSOR
[1] 15.2 x 1.9 mm O-RING
Do not reuse.
a. REPLACEMENT
1) Remove the R./L. side covers.
2) Disconnect the CMP sensor 3P connector.
3) Remove the 6 x 16 mm flange bolt and remove the CMP
sensor and the O-ring.
• Replace the O-ring on assembly.
4) Apply the engine oil to the new O-ring and install it on the
CMP sensor.
5) Tighten the 6 x 16 mm flange bolt.
6) After installation, connect the CMP sensor 3P connector.
7) Install the removed parts in the reverse order of removal.
5-149
[3]
CMP SENSOR
3P CONNECTOR
[2]
CMP SENSOR
6 x 16
BF135A•BF150A
23. CKP (CRANKSHAFT POSITION)
SENSOR
[1] O-RING
Do not reuse.
a. REPLACEMENT
1) Remove the silencer case (P. 5-128).
2) Disconnect the CKP sensor 3P connector.
3) Remove the 6 x 16 mm flange bolt, and remove the CKP
sensor and the O-ring.
• Replace the O-ring on assembly.
4) Apply the engine oil to the new O-ring and install it on the
CKP sensor.
[2] CKP SENSOR
[3]
CKP SENSOR 3P
CONNECTOR
6 x 16
5) Tighten the 6 x 16 mm flange bolt securely.
6) After installing the CKP sensor, connect the CKP sensor 3P
connector.
7) Install the removed parts in the reverse order of removal.
24. VTEC SOLENOID VALVE (BF150A Only)
a. REPLACEMENT
[1]
VTEC SOLENOID VALVE
1P CONNECTOR
[2]
HARNESS
BAND CLIP
BRACKET C
1) Disconnect the VTEC solenoid valve 1P connector and disconnect the connector from the harness band clip bracket C.
2) Remove the three 6 x 55 mm flange bolts. Remove the
VTEC solenoid valve assembly, gasket and the filter.
• Replace the gasket and filter as an assembly of the
VTEC solenoid valve assembly.
3) Install the new gasket and filter on the VTEC solenoid valve.
[3] FILTER
Do not reuse.
[5] GASKET
Do not reuse.
4) Install the VTEC solenoid valve assembly and tighten the 6 x
55 mm flange bolts securely.
5) Connect the VTEC solenoid valve 3P connector and set it
on the harness band clip bracket C.
[4]
VTEC SOLENOID
VALVE ASSEMBLY
6 x 16
5-150
BF135A•BF150A
25. VAPOR CHAMBER/CHECK VALVE
a. DISASSEMBLY/ASSEMBLY
1) Remove the intake manifold (P. 5-129).
[1]
CRANKCASE
BREATHER TUBE
[4] CHECK VALVE
[3]
VACUUM TUBE D
[2]
T-JOINT
ASSEMBLY:
Install with the "
" mark
toward the vacuum tube C side.
[4]-1
VACUUM
TUBE C
SIDE
[5]
VACUUM TUBE C
[6]
AIR VENT TUBE B
[13]
PRESSURE
REGULATOR
CONTROL
TUBE
[7]
AIR VENT TUBE A
[8]
PRESSURE REGULATOR
RETURN HOSE
[9]
SUSPENSION
[12]
VAPOR CHAMBER
[10]
AIR VENT TUBE E
[11]
TUBE CLIP
5-151
BF135A•BF150A
26. EXHAUST MANIFOLD
a. REMOVAL
1) Remove the engine cover and the L./R. engine under covers
(P. 4-2 and 4-9).
2) Disconnect the following water hoses.
• Water relief tube A/B
• 7 x 90 mm tube
• 7 x 75 mm tube
• 7 x 120 mm tube
• Water tube E
[1] WATER RELIEF TUBE A
[2]
7 x 120 mm
TUBE
[3]
7 x 90 mm
TUBE
[4]
7 x 75 mm
TUBE
[5]
WATER
TUBE E
[6] WATER RELIEF TUBE B
3) BF135A: Disconnect the A/F sensor connector and remove
the connector from the harness band clip bracket.
BF150A: Disconnect the A/F sensor and VTEC solenoid
valve connectors, and remove the connectors from the harness band clip bracket.
[1]
CONNECTOR
BRACKET
4) Remove the harness band clip from the connector bracket.
5) Remove the three 6 x 14 mm flange bolts and remove the
connector bracket.
[2]
A/F SENSOR
CONNECTOR
[3]
VTEC SOLENOID VALVE
CONNECTOR (BF150A only)
5-152
6 x 14 (3)
BF135A•BF150A
6) Disconnect the ECT sensor 3 connector.
[1]
ECT SENSOR 3
CONNECTOR
7) Remove the 6 x 55 mm flange bolts and remove the valve
assembly (BF135A) or the VTEC solenoid valve assembly
(BF150A).
[1]
VTEC SOLENOID VALVE
ASSEMBLY (BF150A)
or
VALVE ASSEMBLY (BF135A)
8) Remove the 6 x 22 mm flange bolts and remove the R. side
cover bracket.
[1] R. SIDE COVER BRACKET
6 x 22 (3)
5-153
6 x 55 (3)
BF135A•BF150A
9) Remove the two 10 x 75 mm flange bolts and the three 10 x
45 mm flange bolts. Remove the exhaust manifold and the
exhaust manifold gasket.
• Replace the gasket on assembly.
[1] GASKET
Do not reuse.
10 x 45 (3)
10) Remove the O-ring from the exhaust manifold.
• Replace the O-ring on assembly.
[4] EXHAUST MANIFOLD
ASSEMBLY
[3] 79.9 x 3.1 mm
O-RING
Do not reuse.
10 x 75 (3)
[2] 76.4 x 3.1 mm
O-RING
Do not reuse.
b. DISASSEMBLY/ASSEMBLY
[1]
EXHAUST MANIFOLD
COVER GASKET (2)
Do not reuse.
[2]
EXHAUST MANIFOLD
COVER (2)
6 x 14
[3]
WATER
TUBE
CLAMP
BRACKET
6 x 22 (4)
[9] 6 x 18 mm SCREW (2)
[8] ANODE METAL (2)
Replace with new one
if excessively deteriorated.
[6] A/F SENSOR
DISASSEMBLY/ASSEMBLY:
Remove/install the A/F sensor
using the special tool.
TORQUE:
3.4 N·m (0.35 kgf·m, 2.4 lbf·ft)
[7] EXHAUST
MANIFOLD
[4] O-RING
Do not reuse.
[5]-1
SENSOR SOCKET WRENCH,
22 x 150 mm
07906-PD10000
[5] ECT SENSOR 3
12 N·m (1.2 kgf·m, 9 lbf·ft)
5-154
BF135A•BF150A
c. INSTALLATION
6 x 14 (3)
[1]
CONNECTOR
BRACKET
6 x 55 (3)
[2]
VTEC SOLENOID
VALVE ASSEMBLY
10 x 45 (3)
10 x 75 (2)
[6] GASKET
Do not reuse.
[5]
EXHAUST MANIFOLD
ASSEMBLY
1) Apply the engine oil to the O-rings and install them on the
exhaust manifold assembly.
[4] 79.9 x 3.1 mm
O-RING
Do not reuse.
[3] 76.4 x 3.1 mm
O-RING
Do not reuse.
[1]
EXHAUST MANIFOLD
ASSEMBLY
2) Set the exhaust manifold assembly on the exhaust manifold
guide.
3) Set the new gasket. Align the holes located at the lower left
side, and loosely tighten the 10 x 75 mm flange bolt as
shown.
4) Align the bolt holes by turning the gasket in the direction
shown with the arrow. Take care not to damage the gasket.
[2] GASKET
10 x 75
5-155
BF135A•BF150A
5) Tighten the two 10 x 75 mm flange bolts and the three 10 x
45 mm flange bolts to the specified torque in the numbered
sequence in two or three steps.
10 x 45 (3)
TORQUE: 39 N • m (4.0 kgf • m, 29 lbf • ft)
10 x 75 (2)
6) Install the R. side cover bracket and tighten the 6 x 22 mm
flange bolts securely.
[1] R. SIDE COVER BRACKET
6 x 22 (2)
7) Connect the 2P connector to the ECT sensor 3.
[2]
2P CONNECTOR
5-156
[1]
ECT SENSOR 3
BF135A•BF150A
8) Install the VTEC spool valve assembly (BF150A) or valve
assembly (BF135A) and tighten the 6 x 55 mm flange bolts
securely.
• Do not allow the gasket and filter to come out of position.
[1] FILTER
[2] GASKET
[1]
VTEC SPOOL VALVE
ASSEMBLY (BF150A) or
VALVE ASSEMBLY
(BF135A)
9) Install the harness band clip bracket C and tighten the three
6 x 14 mm flange bolts securely.
6 x 55 (3)
[1]
HARNESS BAND
CLIP BRACKET C
10) BF135A: Connect the A/F sensor connector and set the
connector on the harness band clip bracket C.
BF150A: Connect the A/F sensor and the VTEC solenoid
valve connectors and set the connectors on the harness
band clip bracket C.
11) Set the harness band clip on the harness band clip bracket
C.
[2]
A/F SENSOR
CONNECTOR
[3]
VTEC SOLENOID VALVE
CONNECTOR (BF150A only)
5-157
6 x 14 (3)
BF135A•BF150A
12) Connect the following water hoses.
• Water relief tube A/B
• 7 x 90 mm tube
• 7 x 75 mm tube
• 7 x 120 mm tube
• Water tube E
[1]
WATER RELIEF TUBE A
[2]
7 x 120 mm
TUBE
[3]
7 x 90 mm
TUBE
[4]
7 x 75 mm
TUBE
[5]
WATER
TUBE E
[6] WATER RELIEF TUBE B
5-158
6. ALTERNATOR
1. SILENCER DUCT
2. ALTERNATOR
110 N.m (11.2 kgf.m, 81 lbf.ft)
26 N.m (2.7 kgf.m,
20 lbf.ft)
44 N.m (4.5 kgf.m,
33 lbf.ft)
8 N.m (0.8 kgf.m,
5.8 lbf.ft)
6-1
1. SILENCER DUCT
a. REMOVAL
1) Remove the engine cover (P. 4-2).
Release the pressure regulator control tube from the two
3.5 mm tube clips of the silencer duct assembly.
[2] SILENCER DUCT
ASSEMBLY
[3]
18.5 mm CLAMP
[4]
PRESSURE
REGULATOR
CONTROL
TUBE
[1]
BREATHER
TUBE
Remove the harness band clip, that secures the main wire
harness, from the silencer duct assembly.
2) Release the breather tube from the 18.5 mm clamp and the
guide of the silencer duct assembly.
[8]
GUIDE
[7] 3.5 mm TUBE
CLIP (2)
[5] MAIN WIRE
HARNESS
[6] HARNESS
BAND CLIP
3) Remove the four 6 x 25 mm flange bolts and the four 6 mm
washers, then remove the silencer duct assembly.
6-2
[1]
6 mm
WASHER
(4)
6 x 25 (4)
[2] SILENCER DUCT
ASSEMBLY
b. DISASSEMBLY
Remove the eight 5 x 12 mm self-tapping screws and remove the silencer duct A.
c. COMPONENTS DRAWING
[2] 18.5 mm CLAMP
[1]
5 x 12 mm SELF-TAPPING
SCREW (8)
[3] SILENCER DUCT A
6 x 25 (4)
[4] SILENCER DUCT B
[11]
6 mm WASHER (4)
[5]
DUCT GROMMET (4)
[6]
DUCT COLLAR (4)
[10]
3.5 mm TUBE
CLIP (2)
[9]
BREATHER TUBE
[8]
PRESSURE REGULATOR
CONTROL TUBE
[7] HARNESS
BAND CLIP
d. ASSEMBLY
Install the silencer duct A on the silencer duct B and tighten the eight 5 x 12 mm self-tapping screws securely.
6-3
e. INSTALLATION
1) Install the silencer duct assembly on the silencer case.
[1]
6 mm
WASHER (4)
6 x 25 (4)
[2]
SILENCER DUCT
ASSEMBLY
2) Set the four 6 mm washers and the four 6 x 25 mm flange
bolts, then tighten the four 6 x 25 mm flange bolts securely.
3) Set the breather tube in the 18.5 mm clamp and the guide
of the silencer duct assembly.
4) Secure the pressure regulator control tube with the two 3.5
mm tube clips of the silencer duct assembly.
Connect the pressure regulator control tube aligning the
marked part on the tube with the end of the 3.5 mm tube
clip (P. 2-71).
[2] SILENCER
DUCT
ASSEMBLY
[1]
BREATHER
TUBE
[3]
18.5 mm CLAMP
[4]
PRESSURE
REGULATOR
CONTROL
TUBE
5) Install the main wire harness’ harness band clip on the
silencer duct assembly.
6) Install the engine cover (P. 4-2).
[8]
GUIDE
[7]
3.5 mm TUBE
CLIP (2)
[5] MAIN WIRE
HARNESS
[6] HARNESS
BAND CLIP
6-4
2. ALTERNATOR
a. ALTERNATOR ASSEMBLY INSPECTION
(With the alternator assembly mounted on the
outboard motor)
NOTICE
Do not disconnect the battery terminals while the alternator is
running.
• Alternator assembly inspection must be made with the
assembly mounted on the outboard motor.
• Replace the IC regulator when the battery voltage exceeds 16V.
• Before disconnecting the alternator fuse cable, be sure to
disconnect the battery negative (-) terminal.
Check the following before starting the alternator assembly
inspection.
[1]
ALTERNATOR
INDICATOR
LIGHT
– Battery condition and cable connection
– Alternator belt for looseness, cut and/or fraying (P. 3-28)
– Alternator 4P connector and alternator fuse cable for
connection
– Blown 90A fuse and 10A fuse
– Open or short circuit in each harness and cable
[1] ALTERNATOR 4P CONNECTOR
1) Turn the ignition switch to the “ON” position and check that
the alternator indictor light comes ON.
2) If the alternator indicator light does not come ON,
disconnect the alternator 4P connector and short-circuit the
white/blue terminal of the harness side connector to the
ground.
3) If the indicator light still does not come ON, check the
following.
[2] ALTERNATOR
– Indicator light (P. 16-9)
– Main wire harness for open circuit
[1] ALTERNATOR
4P CONNECTOR
4) Start the engine and check that the alternator indicator light
goes OFF.
– The alternator is normal when the light goes OFF.
– If the indicator light is still ON, check each part of the
alternator (P. 6-14) and repeat the above steps 2 and 3.
• When the alert system functions while the alternator is in
operation, the warning buzzer sounds intermittently.
6-5
[3] Harness side connector
viewed from front side
[2]
(White/
Blue)
b. REMOVAL
Remove the following pars.
– Engine cover (P. 4-2)
– Silencer duct (P. 6-2)
[1] ALTERNATOR
4P CONNECTOR
1) Disconnect the battery negative (-) cable from the battery
negative terminal.
Disconnect the alternator 4P connector.
Disconnect the alternator fuse cable from the alternator
assembly.
[3]
ALTERNATOR B TERMINAL
WASHER-NUT
2) Loosen the 10 x 80 mm flange bolt and the 8 mm flange
nut.
3) Loosen the special adjusting bolt and move the alternator
assembly to the engine side as full as it goes.
10 x 80
[3]
ALTERNATOR
ASSEMBLY
4) Detach the alternator belt from the alternator pulley first,
then from the crankshaft pulley.
[2]
ALTERNATOR
FUSE CABLE
[1] 8 mm
FLANGE
NUT
[2] SPECIAL
ADJUSTING
BOLT
[1] ALTERNATOR
BELT
Remove the alternator belt.
• Do not contaminate the alternator belt with oil and grease
after removal.
[2] CRANKSHAFT
PULLEY
• Do not bend the alternator belt. Store the belt by hanging
it on the wall.
[3] ALTERNATOR
PULLEY
6-6
5) Remove the 10 x 80 mm flange bolt. Pull the alternator assembly toward you.
Remove the 8 mm flange nut and remove the alternator assembly from the tensioner bolt.
[2]
8 mm FLANGE
NUT
[1] ALTERNATOR ASSEMBLY
10 x 80
[3] TENSIONER BOLT
c. ALTERNATOR BRACKET DISASSEMBLY
1) Remove the four 8 x 28 mm flange bolts and remove the alternator bracket.
2) Remove the special adjusting bolt and remove the tensioner bolt.
3) Remove the 6 x 16 mm flange bolt and remove the alternator stay.
4) Remove the two 8 x 20 mm flange bolts and remove the engine hanger B.
8 x 20 (2)
[1] ENGINE HANGER B
[2] ALTERNATOR
BRACKET
[3] ALTERNATOR
STAY
6 x 16
8 x 28 (4)
[5] TENSIONER BOLT
6-7
[4]
SPECIAL ADJUSTING
BOLT
d. ALTERNATOR ASSEMBLY/ALTERNATOR BRACKET COMPONENTS DRAWING
[4]
ALTERNATOR
BELT
[1]
CRANKSHAFT
PULLEY
10 x 80
44 N.m (4.5 kgf.m,
33 lbf.ft)
[5]
8 mm FLANGE NUT
26 N.m (2.7 kgf.m,
20 lbf.ft)
[3] ALTERNATOR
ASSEMBLY
8 x 20 (2)
[2]
ALTERNATOR
4P CONNECTOR
[6]
ALTERNATOR FUSE CABLE
[12]
ENGINE HANGER B
[7]
ALTERNATOR B TERMINAL
WASHER-NUT
8 N.m (0.8 kgf.m, 5.8 lbf.ft)
[11]
ALTERNATOR
BRACKET
8 x 28 (4)
6 x 16
[10] TENSIONER
BOLT
[9] ALTERNATOR
STAY
6-8
[8]
SPECIAL ADJUSTING
BOLT
e. ALTERNATOR ASSEMBLY DISASSEMBLY
1) Loosen the pulley lock nut using a 22 mm offset wrench
and a 10 mm offset wrench.
[2]
22 mm OFFSET
WRENCH
[3]
PULLEY
LOCK
NUT
2) Remove the pulley lock nut and the alternator pulley.
[1]
10 mm OFFSET
WRENCH
[3]
PULLEY LOCK
NUT
[4]
ALTERNATOR
PULLEY
3) Remove the 6 mm hex. nut from the insulator bushing and
remove the insulator bushing.
[1] REAR END COVER
BOLT (3)
4) Remove the three rear end cover bolts and the rear end
cover.
[2]
REAR END
COVER
[3]
INSULATOR
BUSHING
[4]
6 mm HEX.
NUT
6-9
5) Remove the two 4 x 6 mm screws from the brush holder
assembly and remove the brush holder assembly.
Remove the brush holder insulator from the brush holder
assembly.
[1]
BRUSH HOLDER
INSULATOR
[2]
4 x 6 mm
SCREW (2)
[3]
BRUSH
HOLDER
ASSEMBLY
6) Remove the two 4 x 25 mm screw-washers and the 4 x 6
mm screw from the IC regulator, then remove the IC
regulator.
[2]
4 x 25 mm SCREWWASHER (4)
[1]
IC REGULATOR
6-10
[3] 4 x 6 mm SCREW
7) Remove the four 4 x 6 mm screws from the rectifier
assembly.
[1] WIRE (Straighten.)
8) Straighten the four wires as shown and remove the rectifier
assembly.
NOTICE
Replace the stator with a new one if a wire broke near the
small hole in the rectifier assembly.
[2]
4 x 6 mm
SCREW (4)
[3]
RECTIFIER
ASSEMBLY
9) Remove the two 5 mm hex. nuts and the two rear housing
bolts.
Remove the rear housing.
[1]
5 mm HEX.
NUT (2)
[2]
REAR HOUSING
BOLT (2)
10) Remove the wave washer.
[4]
WAVE
WASHER
6-11
[3]
REAR
HOUSING
11) Remove the rotor from the stator (drive end housing).
[1]
BEARING
COVER
Remove the bearing cover from the rotor shaft.
[2]
STATOR
[DRIVE END
HOUSING]
[3] ROTOR
12) Check the rear bearing for abnormal sound and play before
removal. Replace the rear bearing with a new one if there
is abnormal sound or play.
13) Using a commercially available bearing puller as shown,
remove the rear bearing and washer.
Replace the rear bearing with new one on assembly.
[1]
BEARING
PULLER
(Commercially
available)
NOTICE
Install a commercially available bearing puller with care not
to damage the rotor fins.
[2] REAR
BEARING
[3]
WASHER
[2] REAR BEARING
6-12
14) Remove the four screws and the retainer plate.
[2] SCREW (4)
Remove the two stud bolts from the stator [drive end
housing].
[1]
RETAINER
PLATE
[4]
STATOR
[DRIVE END
HOUSING]
[3]
STUD
BOLT (2)
15) Check the front bearing for abnormal sound or play before
removal.
Replace the front bearing if necessary.
[1]
DRIVER
07749-0010000
16) Holding the stator [drive end housing] by attaching the
wood blocks to both sides of the stator [drive end housing]
as shown, remove the front bearing from the stator using
the special tools.
Replace the front bearing with a new one on assembly.
TOOLS:
Driver
Attachment, 24 x 26 mm
Pilot, 15 mm
[2] FRONT
BEARING
07749-0010000
07746-0010700
07746-0040300
[4] ATTACHMENT,
24 x 26 mm
07746-0010700
6-13
[3]
PILOT, 15 mm
07746-0040300
f. INSPECTION (Unit inspection)
• BRUSH HOLDER ASSEMBLY
Measure the brush length.
If the measurement is less than the service limit, replace the
brush holder assembly.
STANDARD
SERVICE LIMIT
10.5 mm (0.41 in)
8.4 mm (0.33 in)
• RECTIFIER ASSEMBLY
[1] E (GROUND)
• Inspect the rectifier assembly by removing it from the
outboard motor.
Check for continuity between the B terminal and the respective
P terminals (P1, P2, P3 and P4), and between the E terminal and
the respective P terminals (P1, P2, P3 and P4).
Note to check for continuity in two directions by reversing the
polarities.
P'1
B
P4
P1
There should be continuity only in one direction.
Replace the rectifier assembly as necessary.
P2
P3
[2] Circuit diagram:
B
P'1
P1
P2
P3
P4
[1]
E (GROUND)
• ROTOR
1) Check to be sure that there is continuity between the slip
rings.
[1] SLIP
RINGS
[2] ROTOR SHAFT
2) Check to see that there is no continuity between a slip ring
and the rotor, and between a slip ring and the rotor shaft.
3) Measure the slip ring O.D.
STANDARD
SERVICE LIMIT
14.4 mm (0.57 in)
14.0 mm (0.55 in)
4) If the measurement is less than the service limit, replace
the rotor.
6-14
[3]
ROTOR
• STATOR [DRIVE END HOUSING]
Inspect the stator by removing it from the outboard motor.
[1] WIRES
[1] WIRES
1) Check to see that there is continuity between the wires.
2) Check to see that there is no continuity between each wire
and the stator core.
[2] STATOR CORE
6-15
g. COMPONENTS DRAWING
[2]
INSULATOR
BUSHING
[1] 6 mm HEX. NUT
[3]
4 x 25 mm SCREWWASHER (2)
[4]
4 x 6 mm
SCREW (7)
[5] BRUSH HOLDER
INSULATOR
[23]
RECTIFIER
ASSEMBLY
[6] REAR END
COVER BOLT (3)
[24] IC REGULATOR
[22] ROTOR
[7]
REAR END
COVER
[25] BRUSH
HOLDER
ASSEMBLY
[21] REAR BEARING
[8] REAR HOUSING
[19] WAVE
WASHER
[9]
REAR
HOUSING
BOLT (2)
[20] WASHER
[17]
PULLEY LOCK NUT
110 N.m (11.2 kgf.m,
81 lbf.ft)
[18] BEARING
COVER
[10] 5 mm HEX. NUT
[11]
FRONT BEARING
[16]
ALTERNATOR
PULLEY
[15] STATOR
[DRIVE END
HOUSING]
6-16
[12] SCREW (4)
[14] STUD
BOLT (2)
[13] RETAINER PLATE
h. ALTERNATOR ASSEMBLY ASSEMBLY
1) Tighten the two stud bolts on the stator.
[1]
DRIVER
07749-0010000
2) Apply grease to the outer surface of a new front bearing.
Drive the front bearing into the stator using the special
tools as shown.
TOOLS:
Driver
Attachment, 37 x 40 mm
Pilot, 15 mm
07749-0010000
07746-0010200
07746-0040300
[3] ATTACHMENT,
37 x 40 mm
07746-0010200
3) Install the retainer plate with the projections toward the
front bearing and tighten it with the four screws.
[1]
RETAINER
PLATE
[5]
PROJECTIONS
[2]
PILOT, 15 mm
07746-0040300
[2] SCREW (4)
[3]
STATOR
[DRIVE END
HOUSING]
[4] STUD
BOLTS (2)
6-17
4) Position a washer on the rotor shaft.
Apply grease to the inner wall of the new rear bearing and
install it on the rotor shaft.
[1]
REAR
BEARING
[3]
ROTOR
SHAFT
5) Attach the special tool to the front bearing side of the rotor
shaft, and position the rotor on the hydraulic press.
TOOL:
Attachment, 52 x 55 mm
07746-0010400
[1]
FRONT
BEARING
SIDE
[3] ATTACHMENT,
52 x 55 mm
07746-0010400
6) Attach the special tool to the rear bearing side and install
the rear bearing on the rotor using the hydraulic press.
TOOLS:
Attachment, 52 x 55 mm
Driver, 22 mm I.D.
Attachment,15 mm I.D.
07746-0010400
07746-0020100
07746-0020200
[1]
DRIVER,
22 mm I.D.
07746-0020100
[2]
ATTACHMENT,
15 mm I.D.
07746-0020200
[3]
REAR BEARING
6-18
[2]
WASHER
[2]
ROTOR
SHAFT
7) Check the rotor slip rings for contamination with grease.
[1]
BEARING
COVER
If it is contaminated with grease, wipe it off thoroughly with
a clean cloth.
Install the rotor on the stator [drive end housing].
[2]
SLIP RINGS
Install a bearing cover on the rotor shaft.
[3]
STATOR
[DRIVE END
HOUSING]
[4]
ROTOR
8) Apply grease to the surface of the rear bearing and install
the wave washer.
9) Pass the wire through the respective four holes in the rear
housing.
[1] HOLES
(Four places)
[3]
5 mm HEX.
NUT (2)
Install the rear housing on the stator [drive end housing]
and tighten the two 5 mm hex. nuts and the rear housing
bolts securely.
• Install the rear housing aligning the outer side of the
wave washer with the outer side of the bearing.
[4]
REAR
HOUSING
[6]
WAVE
WASHER
6-19
[2]
REAR HOUSING
BOLT (2)
[5]
WIRES
10) Pass the four wires through the four holes at the projection
on the reverse side of the rectifier assembly.
11) Bend each wire to the rectifier assembly side.
[1]
WIRE (Bend along
the hole.)
Bend each wire along the respective screw holes.
12) Tighten the four 4 x 6 mm screws securely.
NOTICE
Replace the stator with a new one if a wire broke near the
hole in the rectifier assembly.
[2]
4 x 6 mm
SCREW (4)
[3]
RECTIFIER
ASSEMBLY
13) Assemble the brush holder insulator with the brush holder
assembly.
14) Position the brush holder assembly on the IC regulator and
loosely tighten the 4 x 6 mm screw.
[1]
BRUSH HOLDER
INSULATOR
• Loosely tighten the 4 x 6 mm screw so that the brush
holder does not move.
[2]
4 x 6 mm SCREW
(Loosely tighten so
the brush holder
does not move.)
[3]
BRUSH HOLDER
ASSEMBLY
[4]
IC REGULATOR
6-20
15) Tighten the two 4 x 25 mm screw-washers and the two 4 x
6 mm screws securely while pushing the brush of the IC
regulator/brush holder assembly, assembled in step 14,
lightly against the rotor shaft slip rings.
Tighten the 4 x 6 mm screw securely that has been
tightened loosely in step 14.
NOTICE
[1] 4 x 6 mm SCREW (2)
[3]
IC REGULATOR/BRUSH
HOLDER ASSEMBLY
Take care not to damage the rotor shaft slip rings with the
brush during installation.
[4]
SLIP
RINGS
16) Install the rear end cover and tighten the three rear end
cover bolts securely.
17) Install the insulator bushing and tighten the 6 mm hex. nut
securely.
[1] REAR END
COVER
BOLT (3)
[2] REAR END
COVER
[3]
INSULATOR
BUSHING
[4]
6 mm HEX. NUT
6-21
[2]
4 x 25 mm SCREWWASHER (2)
18) Position the alternator pulley on the rotor shaft and tighten
the pulley lock nut.
19) Tighten the pulley lock nut to the specified torque using a
10 mm offset wrench and a torque wrench.
[1]
ALTERNATOR
PULLEY
[2]
PULLEY LOCK
NUT
TORQUE: 110 N.m (11.2 kgf.m, 81 lbf.ft)
[5]
TORQUE
WRENCH
[3] PULLEY LOCK
NUT
[4]
10 mm
OFFSET
WRENCH
i. ALTERNATOR BRACKET ASSEMBLY
1) Tighten the alternator bracket with the four 8 x 28 mm
flange bolts securely.
2) Tighten the 6 x 16 mm flange bolt securely while pushing
the alternator stay against the projection on the alternator
bracket.
3) Position the special adjusting bolt on the tensioner bolt.
4) Install the engine hanger B with the two 8 x 20 mm flange
bolts.
8 x 20 (2)
[1]
ENGINE
HANGER B
[2]
ALTERNATOR
BRACKET
[3]
PROJECTION
[4]
ALTERNATOR
STAY
6 x 16
8 x 28 (4)
[6] TENSIONER BOLT
6-22
[5]
SPECIAL ADJUSTING
BOLT
j. INSTALLATION
1) Position the alternator assembly over the tensioner bolt and loosely tighten the 8 mm flange nut.
2) Position the alternator assembly between the projections of the alternator bracket and loosely tighten the 10 x 80 mm
flange bolt.
[1] ALTERNATOR
ASSEMBLY
10 x 80
[2]
8 mm FLANGE
NUT
[4]
Between the
projections
[3] TENSIONER BOLT
3) Install the alternator belt on the crankshaft pulley first, then
on the alternator pulley.
[1] ALTERNATOR
BELT
NOTICE
Do nut turn the crankshaft pulley counterclockwise.
[2] CRANKSHAFT
PULLEY
[3] ALTERNATOR
PULLEY
6-23
4) Tighten the special adjusting bolt.
Inspect and adjust the alternator belt (P. 3-29).
[1] 8 mm FLANGE
NUT
10 x 80
5) After adjustment, tighten the 8 mm flange nut and 10 x 80
mm flange bolt in this order to the specified torque.
TORQUE:
8 mm flange nut: 26 N.m (2.7 kgf.m, 20 lbf.ft)
10 x 80 mm flange bolt: 44 N.m (4.5 kgf.m, 33lbf.ft)
6) After tightening the nut and the bolt to the specified torque,
check the alternator belt tension and deflection (P. 3-29).
[2] SPECIAL
ADJUSTING
BOLT
[3]
ALTERNATOR ASSEMBLY
7) Connect the alternator 4P connector to the alternator
assembly.
[1] ALTERNATOR 4P CONNECTOR
8) Connect the alternator fuse cable to the alternator
assembly and loosely tighten the alternator B terminal
washer-nut.
9) Tighten the alternator B terminal washer-nut to the
specified torque so that the alternator fuse cable is
connected at 60˚ from the horizontal line as shown.
TORQUE: 8 N.m (0.8 kgf.m, 5.8 lbf.ft)
10) Install the following parts.
– Silencer duct (P. 6-4)
– Engine cover (P. 4-2)
[2]
ALTERNATOR
B TERMINAL
WASHER-NUT
[3] ALTERNATOR
FUSE CABLE
[2]
ALTERNATOR B TERMINAL
WASHER-NUT
60°
[3] ALTERNATOR
FUSE CABLE
6-24
7. ENGINE REMOVAL/INSTALLATION
1. REMOVAL
2. INSTALLATION
26 N.m (2.7 kgf.m,
20 lbf.ft)
44 N.m (4.5 kgf.m,
33 lbf.ft)
44 N.m (4.5 kgf.m,
33 lbf.ft)
64 N.m (6.5 kgf.m,
47 lbf.ft)
26 N.m (2.7 kgf.m,
20 lbf.ft)
64 N.m (6.5 kgf.m,
47 lbf.ft)
64 N.m (6.5 kgf.m,
47 lbf.ft)
44 N.m (4.5 kgf.m,
33 lbf.ft)
44 N.m (4.5 kgf.m,
33 lbf.ft)
7-1
26 N.m (2.7 kgf.m,
20 lbf.ft)
1. REMOVAL
Remove the following pars.
– Engine cover (P. 4-2).
– L./R. engine under covers (P. 4-9).
– Under cover front bracket/L./R. side cover brackets (P. 4-20).
– Vapor separator (P. 5-111).
– Gear case assembly (P. 14-3 and 42).
1) Hook the hoist hooks on the three engine hangers and
secure the engine not to fall down.
Remove the following parts.
– Extension case/lower rubber mount (P. 14-89).
– Oil case (P. 14-94).
2) Be sure that the engine is held vertically and remove the
following parts.
– Starter motor (P. 18-1).
– Starter cable (P. 18-15).
– Shift link bracket/neutral switch (P. 17-11).
[1]
ENGINE HANGER (3)
3) Remove the two 6 x 20 mm flange bolts and remove the
seal holder assembly from the engine assembly.
4) Disconnect the air vent tube A and the oil tube from the
mounting case.
7-2
6 x 20
[1]
SEAL HOLDER
ASSEBLY
[1]
AIR VENT TUBE A
[2]
OIL TUBE
5) Remove the four 8 x 30 mm flange bolts that secure the
exhaust guide from the underside of the mounting case.
6) Disconnect the water relief tube C from the relief valve
cover (P. 8-6).
[1]
EXHAUST
GUIDE
8 x 30 (4)
7) Remove the two 10 mm cap nuts and the 10 x 70 mm flange
bolt from the engine assembly.
8) Remove the two 8 x 55 mm flange bolts and the 12 x 83
mm flange bolt.
7-3
10 x 70
[1]
10 mm CAP NUTS
12 x 83
8 x 55
9) Remove the following bolts and washers from the underside of the mounting case.
• 8 x 100 mm flange bolt (1)
• 10 x 80 mm flange bolt (1)
• 10 x 110 mm flange bolts (2)
• 12 x 70 mm hex. bolt (1)
• 12 x 130 mm hex. bolts (2)
• 12 mm washers (3)
10) Lift up the engine assembly slowly and remove it from the mounting case.
NOTICE
• Be sure that the hoist hooks are set on the three engine
hangers securely.
• Lift up the engine assembly while holding the engine
vertically.
11) Remove the two dowel pins, mounting case gasket, exhaust guide gasket and the oil pump rubber.
[1]
ENGINE ASSEMBLY
[9]
MOUNTING
CASE GASKET
[2]
10 x 16 mm
DOWEL PIN
[8]
OIL PUMP RUBBER
[3]
EXHAUST GUIDE
GASKET
[7]
14 x 20 mm
DOWEL PIN
[4]
12 mm WASHER (3)
[6]
12 x 70 mm
HEX. BOLT
[5]
12 x 130 mm
HEX. BOLT (2)
10 x 80
10 x 110 (2)
7-4
8 x 100
COMPONENTS DRAWING
10 x 70
44 N.m (4.5 kgf.m, 33 lbf.ft)
[1]
10 mm CAP NUT (2)
44 N.m (4.5 kgf.m, 33 lbf.ft)
[2]
ENGINE ASSEMBLY
8 x 55 (2)
26 N.m (2.7 kgf.m,
20 lbf.ft)
12 x 83
64 N.m (6.5 kgf.m,
47 lbf.ft)
[11]
OIL PUMP RUBBER
[3]
10 x 16 mm
DOWEL PIN
[10]
14 x 20 mm
DOWEL PIN
[4]
EXHAUST
GUIDE GASKET
[9]
MOUNTING CASE
GASKET
[5]
MOUNTING CASE
8 x 30 (4)
26 N.m (2.7 kgf.m, 20 lbf.ft)
[8]
12 x 70 mm HEX. BOLT
64 N.m (6.5 kgf.m, 47 lbf.ft)
[6]
12 mm WASHER (3)
[7]
12 x 130 mm HEX. BOLT (2)
64 N.m (6.5 kgf.m, 47 lbf.ft)
10 x 80
44 N.m (4.5 kgf.m, 33 lbf.ft)
10 x 110 (2)
44 N.m (4.5 kgf.m, 33 lbf.ft)
7-5
8 x 100
26 N.m (2.7 kgf.m, 20 lbf.ft)
2. INSTALLATION
[1]
SHIFT SHAFT B
1) Align the punch mark on the shift shaft A with the punch
mark on the shift shaft B before installing the engine
assembly.
[2] ALIGNMENT
MARKS
NOTICE
• Be sure to align the punch marks securely before
installing the engine assembly. Install the engine
assembly with care not to let the punch marks come out
of alignment.
• Note that the proper shifting cannot be made unless the
punch marks are in proper alignment.
[3]
SHIFT
SHAFT A
2) Disconnect the water relief tube B and the 7 x 40 mm tube
from the exhaust guide (P. 8-5, 6).
[1]
EXHAUST GUIDE
3) Remove the exhaust guide from the exhaust manifold of
the engine assembly.
4) Apply grease to the exhaust manifold of the engine
assembly and to the sealing surface of the exhaust guide.
5) Install the exhaust guide gasket and the exhaust guide on
the mounting case, and loosely tightem the four 8 x 30 mm
flange bolts.
8 x 30 (4)
[2]
EXHAUST GUIDE
GASKET
6) Install the 10 x 16 mm dowel pin, 14 x 20 mm dowel pin,
mounting case gasket and the oil pump rubber on the
mounting case.
7) Lower the engine assembly slowly while aligning the two
10 x 55 mm stud bolts and the shift shaft B with the
respective installation holes in the engine assembly.
NOTICE
• Take care not to ruin the stepped part of the shift shaft B
and the threaded part of the 10 x 55 mm stud bolts.
• Do not allow the alignment marks on the shift shaft A and
B come out of alignment. If they came out of alignment,
perform the Shift Shaft A/B Alignment procedure
explained for engine installation (P. 17-22).
• Lower the engine assembly slowly while holding the
engine vertically.
7-6
[1]
SHIFT SHAFT B
[2]
10 x 55 STUD BOLTS
8) Lower the engine assembly slowly onto the mounting case
while aliging the exhaust manifold of the engine assembly
with the exhaust guide.
[1]
EXHAUST
MANIFOLD
9) Connect the water relief tube B and the 7 x 40 mm tube,
disconnected in step 2, to the exhaut guide (P. 8-7, 9).
NOTICE
Lower the engine assembly onto the mounting case slowly
while holding the engine vertically.
[2]
EXAUST GUIDE
10) Tighten the four 8 x 30 mm flange bolts in the numbered
sequence in two or three steps from the underside of the
mounting case. Tighten to the specified torque.
TORQUE: 26 N.m (2.7 kgf.m, 20 lbf.ft)
②
④
③
①
11) Loosely tighten each bolt and washer at the designated
places from the underside of the mounting case. Then,
tighten them to the specified torque in the numbered
sequence in two or three steps.
TORQUE:
12 x 70 mm hex. bolt,
12 x 130 mm hex. bolt: 64 N.m (6.5 kgf.m, 47 lbf.ft)
10 x 80 mm flange bolt,
10 x 110 mm flange bolt: 44 N.m (4.5 kgf.m, 33 lbf.ft)
8 x 100 mm flange bolt: 26 N.m (2.7 kgf.m, 20 lbf.ft)
Tightening
②
①
⑦
⑤
Part name
Q' ty
①, ②
12 x 130 mm hex. bolt, 12 mm washer
2
③
12 x 70 mm hex. bolt, 12 mm washer
1
④, ⑤
10 x 110 mm flange bolt
2
⑥
10 x 80 mm flange bolt
1
⑦
8 x 100 mm flange bolt
1
point
7-7
⑥
③
④
12) Loosely tighten the bolts and nuts at the designated places
from the top of the engine assembly. Tighten the bolts and
nuts to the specified torque in the numbered sequence in
two or three steps.
TORQUE:
12 x 83 mm flange bolt: 64 N.m (6.5 kgf.m, 47 lbf.ft)
10 x 70 mm flange bolt: 44 N.m (4.5 kgf.m, 33 lbf.ft)
8 x 55 mm flange bolt: 26 N.m (2.7 kgf.m, 20 lbf.ft)
10 mm cap nut: 44 N.m (4.5 kgf.m, 33 lbf.ft)
8 x 55
12 x 83
①
⑥
⑤
13) Connect the water relief tube C to the relief valve cover (P.
8-7).
[1]
10 mm CAP NUTS
④
14) Connect the air vent tube A and the oil tube to the
mounting case.
15) Tape around the stepped part of the shift shaft B to protect
it.
16) Install the seal holder assembly on the engine assembly
and tighten the two 6 x 20 mm flange bolts (P. 17-23).
Set the starter cable and the alternator fuse cable in the
cable bracket A (P. 17-23).
17) Install the following parts.
– Shift link bracket/neutral switch (P. 17-17)
– Starter cable (P. 18-17)
– Starter motor (P. 18-14)
– Oil case (P. 14-95)
– Extension case/lower rubber mount (P. 14-91)
– Gear case assembly (P. 14-5 and 44)
– Vapor separator (P. 5-125)
– Under cover front bracket/L./R. side cover brackets (P. 430)
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)
7-8
[1]
AIR VENT TUBE A
6 x 20 (2)
③
10 x 70
②
[2]
OIL TUBE
[1] SEAL HOLDER
ASSEMBLY
[2]
TAPE
[3]
SHIFT
SHAFT B
8. THERMOSTAT/RELIEF VALVE/
FLUSH VALVE
1. THERMOSTAT
2. WATER RELIEF TUBE/RELIEF VALVE
12 N.m (1.2 kgf.m, 9 lbf.ft)
12 N.m (1.2 kgf.m, 9 lbf.ft)
8-1
3. FLUSH VALVE
1. THERMOSTAT
a. DISASSEMBLY
1) Remove the engine cover (P. 4-2).
2) Disconnect the water relief tube A from the thermostat cover.
Do not reuse the thermostat cover O-ring. Replace it with a new one on reassembly.
3) Remove the thermostat.
4) Disconnect the 2P connectors from the ECT sensor 2 and 4, and remove the ECT sensor 2 and 4.
Do not reuse the 9.5 x 1.9 mm O-rings. Replace them with the new ones on reassembly.
5) Release the breather tube from the 18.5 mm clamp of the harness clip bracket B.
6) Remove the two 6 x 14 mm flange bolts from the harness clip bracket B. With the harness clip bracket B raised a little,
remove the harness band clip and the wire harness clip from the harness clip bracket B.
[1]
THERMOSTAT COVER
[14]
THERMOSTAT
COVER O-RING
[3]
WATER RELIEF
TUBE A
6 x 22 (3)
[2]
TUBE CLAMP D25.0
[4]
HARNESS CLIP
BRACKET B
[13]
THERMOSTAT
(60˚C: For cylinder block)
6 x 14 (2)
[12]
ECT SENSOR 4
[11]
9.5 x 1.9 mm
O-RING (2)
[10]
THERMOSTAT
(50˚C: For cylinder head)
[5]
18.5 mm CLAMP
[9]
ECT SENSOR 2
[8]
BREATHER TUBE
8-2
[7]
WIRE HARNESS CLIP
[6]
HARNESS BAND CLIP
b. INSPECTION
• THERMOSTAT
[1]
THERMOMETER
1) Immerse the thermostat in water.
2) Heat the water and observe the operation of the thermostat
as the water temperature increases.
3) Measure the water temperature when the thermostat starts
to open.
[2]
THERMOSTAT
• Don't let the thermometer or the thermostat touch the
container; this may cause a false reading.
Thermostat for cylinder head:
Start opening
48 – 52˚C (118 – 126˚F)
Fully open
60˚C (140 ˚F)
Thermostat for cylinder block:
Start opening
58 – 62˚C (136 – 144˚F)
Fully open
70˚C (158˚F)
4) Measure the lift height when the thermostat is fully open.
Thermostat for cylinder head:
Lift height
More than 3.0 mm (0.12 in)
Thermostat for cylinder block:
Lift height
More than 3.0 mm (0.12 in)
c. THERMOSTAT IDENTIFICATION
[1] <Thermostat for cylinder head>
NOTICE
There are two types of thermostat; one for the cylinder head
and the other for the cylinder block. Do not confuse them on
assembly.
Thermostat for cylinder head:
The thermostat for the cylinder head can be identified with the
purple paint (or two grooves) on the thermostat.
[3]
PURPLE PAINT
Thermostat for cylinder block:
The thermostat for the cylinder block can be identified with no
paint (or three grooves) on the thermostat.
8-3
[1] <Thermostat for cylinder block>
[2] GROOVES
(3 places)
[2]
GROOVES
(2 places)
d. ASSEMBLY
1) Check the thermostats for the identification mark and install each of them in the proper position (P. 8-3).
Install the thermostat for the cylinder head in the ECT sensor 2 installation hole side, and install the thermostat for
the cylinder block in the ECTsensor 4 installation hole side.
2) Install a new thermostat cover O-ring on the thermostat cover, and tighten the thermostat cover with the three 6 x 22
mm flange bolts securely.
3) Set the tube clamp D25.0 on the water relief tube A, and insert the water relief tube A into the thermostat cover
securely.
4) Position the tube clamp D25.0 so that its lugs are toward the direction shown.
5) Install a new 9.5 x 1.9 mm O-ring on the ECT sensor 2 and 4 respectively. Apply a liquid sealant (ThreeBond® #1201
or #1215 or equivalent) to the threads and seat of each sensor.
6) Install the ECT sensor 2 and 4, and tighten them to the specified torque.
TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)
7) Set the 18.5 mm clamp, harness band clip and the wire harness clip on the harness clip bracket B, and tighten the
two 6 x 14 mm flange bolts.
8) Install the engine cover (P. 4-2).
[1]
THERMOSTAT COVER
[3]
WATER RELIEF TUBE A
6 x 22 (3)
[2]
TUBE CLAMP D25.0
[14]
THERMOSTAT
COVER O-RING
Do not reuse.
[4]
HARNESS CLIP
BRACKET B
[13]
THERMOSTAT
(60˚C: For cylinder block)
[12]
ECT SENSOR 4
12 N.m (1.2 kgf.m, 9 lbf.ft)
6 x 14 (2)
[11]
9.5 x 1.9 mm
O-RING (2)
Do not reuse.
[10]
THERMOSTAT
(50˚C: For cylinder head)
[5]
18.5 mm CLAMP
[9]
ECT SENSOR 2
12 N.m (1.2 kgf.m, 9 lbf.ft)
[8]
BREATHER TUBE
8-4
[7]
WIRE HARNESS CLIP
[6]
HARNESS BAND CLIP
2. WATER RELIEF TUBE/RELIEF VALVE
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under covers (P. 4-9)
a. REMOVAL OF WATER RELIEF TUBE ASSEMBLY
1) Disconnect the water relief tube A from the thermostat cover.
Remove the water tube clamp from the water relief tube A and the main wire harness.
2) Disconnect the 7 x 90 mm tube, 7 x 120 mm tube and the water tube E from the engine side.
Disconnect the water relief tube B from the water tube clamp B.
3) Disconnect the water relief tube B from the exhaust guide.
b. DISASSEMBLY OF WATER RELIEF TUBE ASSEMBLY
1)
2)
3)
4)
Disconnect the water relief tube A and B from the 4-way joint.
Disconnect the 7 x 90 mm tube and the 7 x 120 mm tube from the fuel tube joint.
Disconnect the fuel tube joint from the 7 x 75 mm tube.
Disconnect the 7 x 75 mm tube and the water tube E from the 4-way joint.
[1]
TUBE CLAMP D25.0 (4)
[2]
TUBE CLAMP D10.5 (8)
[14]
WATER RELIEF
TUBE A
[13]
WATER TUBE CLAMP
[12]
7 x 90 mm TUBE
[11]
FUEL TUBE JOINT
[10]
7 x 75 mm TUBE
[9]
4-WAY JOINT
[8]
7 x 120 mm
TUBE
[7]
WATER TUBE E
[6]
WATER RELIEF TUBE B
[4]
EXHAUST GUIDE
[5]
WATER TUBE CLAMP B
8-5
[3]
THERMOSTAT
COVER
c. WATER RELIEF TUBE C/RELIEF VALVE DISASSEMBLY
1) Disconnect the 7 x 160 mm tube, 7 x 40 mm tube and the water relief tube C from the engine side.
2) Disconnect each tube from the T-joint.
3) Remove the two 6 x 22 mm flange bolts and remove the relief valve cover and the relief valve.
Do not reuse the relief valve cover O-ring. Replace it with a new one on assembly.
[1]
TUBE CLAMP D10.5 (6)
[8]
7 x 160 mm TUBE
6 x 22 (2)
[2]
WATER RELIEF TUBE C
[7]
RELIEF VALVE COVER
[6]
T-JOINT
[5]
7 x 40 mm TUBE
[4]
RELIEF VALVE
COVER O-RING
[3]
RELIEF VALVE
d. INSPECTION
• RELIEF VALVE
[1]
RELIEF VALVE
1) Check the rubber part of the relief valve for deterioration
and cracks. Replace the relief valve with a new one if
necessary.
2) Check the operation of the relief valve spring and replace
the relief valve with a new one if necessary.
[3]
RUBBER PART
8-6
[2]
RELIEF VALVE
SPRING
e. WATER RELIEF TUBE C/RELIEF VALVE
ASSEMBLY
NOTICE
Check the tubes for deterioration and cracks before assembly.
Replace if necessary.
1) Install the relief valve on the mount case noting the
installation direction as shown.
2) Set a new relief valve cover O-ring on the relief valve cover,
and install the relief valve cover with the two 6 x 22 mm
flange bolts.
3) Connect the 7 x 160 mm tube, 7 x 40 mm tube and the
water relief tube C to the T-joint, and clamp each tube with
the tube clamp D10.5.
4) Set the tube clamp D10.5 on the side of each tube where is
opposite to the other end connected to the T-joint, and
connect each tube to the engine side.
Clamp each tube with the tube clamp D10.5.
[1] RELIEF VALVE COVER SIDE
[2]
RELIEF VALVE
[3]
MOUNTING CASE SIDE
[1]
TUBE CLAMP D10.5 (6)
6 x 22 (2)
[8]
7 x 160 mm TUBE
[2]
WATER RELIEF
TUBE C
[7]
RELIEF VALVE COVER
[6]
T-JOINT
[5]
7 x 40 mm TUBE
[4]
RELIEF VALVE
COVER O-RING
8-7
[3]
RELIEF VALVE
f. ASSEMBLY OF WATER RELIEF TUBE ASSEMBLY
[1]
WATER RELIEF
TUBE A SIDE
NOTICE
Check the tubes for deterioration and cracks before assembly.
Replace if necessary.
1) Note the connection position of each tube to the 4-way joint
as shown.
[2]
4-WAY JOINT
2) Connect the water relief tube B to the 4-way joint so that its
installation angle is approximately 33˚ as shown.
[3]
WATER RELIEF
TUBE B SIDE
[4]
4-WAY JOINT
[5]
APPROX. 33˚
[6]
WATER RELIEF
TUBE B
3) Connect the water relief tube A to the 4-way joint so that its
installation angle is approximately 90˚ as shown.
[1]
4-WAY JOINT
[3]
APPROX. 90˚
4) Set the tube clamp D25.0s on the water relief tube A and B.
5) Set the tube clamp D25.0s in the position 8 mm from the
end of each tube as shown.
[1] TUBE CLAMP
D25.0 (2)
[2]
WATER RELIEF
TUBE A
[2]
WATER RELIEF
TUBE A
8 mm
(0.3 in)
[3]
4-WAY JOINT
8 mm
(0.3 in)
8-8
[4]
WATER RELIEF
TUBE B
6)
7)
8)
9)
Connect the 7 x 75 mm tube and the water tube E to the 4-way joint.
Connect the 7 x 75 mm tube to the fuel tube joint.
Connect the 7 x 90 mm tube and the 7 x 120 mm tube to the fuel tube joint.
Connect the 7 x 120 mm tube with the lugs of the tube clamp D10.5s toward down.
g. INSTALLATION OF WATER RELIEF TUBE ASSEMBLY
1) Connect the water relief tube B to the exhaust guide.
Clamp the water relief tube B with the water tube clamp B.
2) Connect the water relief tube A to the thermostat cover and set the tube clamp D25.0 with its lugs toward the direction
shown (i.e. toward the intake manifold side).
Clamp the water relief tube A and the main wire harness with the water tube clamp.
3) Connect the 7 x 90 mm tube and the water tube E to the engine side.
4) Connect the 7 x 120 mm tube to the engine side and set the tube clamp D10.5s with the lugs toward down.
5) Install the following parts.
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)
NOTICE
Start the engine after connecting the tubes. Check that the
water does not leak from each joint.
[1]
TUBE CLAMP D25.0 (4)
[2]
TUBE CLAMP D10.5 (8)
[14]
WATER RELIEF
TUBE A
[13]
WATER TUBE CLAMP
[12]
7 x 90 mm TUBE
[11]
FUEL TUBE JOINT
[10]
7 x 75 mm TUBE
[9]
4-WAY JOINT
[8]
7 x 120 mm
TUBE
[7]
WATER TUBE E
[6]
WATER RELIEF TUBE B
[4]
EXHAUST GUIDE
[5]
WATER TUBE CLAMP B
8-9
[3]
THERMOSTAT
COVER
3. FLUSH VALVE
a. DISASSEMBLY
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under cover (P. 4-9)
1) Disconnect the 7 x 200 mm tube from the mount case.
2) Disconnect the 8 x 300 mm tube from the flush valve cover.
Remove the water seal, water hose joint A and the flush plug cap from the 8 x 300 mm tube.
3) Remove the 6 x 16 mm flange bolt, then remove the flush valve cover, flush valve and the flush valve spring.
Do not reuse the 16 mm O-ring on the flush valve cover. Replace with a new one on assembly.
[1]
TUBE CLAMP D10.5 (2)
[2]
7 x 200 mm TUBE
[3]
MOUNT CASE
[4]
FLUSH VALVE
SPRING
[5]
FLUSH VALVE
[12]
8 x 300 mm TUBE
[6]
16 mm O-RING
[7]
FLUSH VALVE
COVER
6 x 16
[11]
FLUSH PLUG CAP
8-10
[10]
WATER HOSE
JOINT A
[9]
WATER SEAL
[8]
13 mm TUBE CLIP B1 (2)
b. INSPECTION
• FLUSH VALVE
Check the flush valve gasket for deterioration and cracks, and
replace the flush valve if necessary.
[1]
FLUSH VALVE
GASKET
c. ASSEMBLY
[2]
FLUSH VALVE COVER SIDE
NOTICE
Check each tube for deterioration and cracks before assembly.
Replace the tubes if necessary.
1) Install a new 16 mm O-ring on the flush valve cover.
2) Install the flush valve spring and the flush valve on the flush valve cover. Note the installation direction of the flush
valve.
3) Tighten the flush valve cover with the 6 x 16 mm flange bolt securely.
4) Install the tube clip B12.5s, flush plug cap, water hose joint A and the water seal on the 8 x 300 mm tube. Connect
the 8 x 300 mm tube to the flush valve cover and clamp the tube with the tube clip B12.5s.
5) Connect the 7 x 200 mm tube to the mount case.
6) Install the following parts.
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)
[1]
TUBE CLAMP D10.5 (2)
[2]
7 x 200 mm TUBE
[3]
MOUNT CASE
[4]
FLUSH VALVE
SPRING
[5]
FLUSH VALVE
[12]
8 x 300 mm TUBE
[6]
16 mm O-RING
[7]
FLUSH VALVE
COVER
6 x 16
[11]
FLUSH PLUG CAP
8-11
[10]
WATER HOSE
JOINT A
[9]
WATER SEAL
[8]
13 mm TUBE CLIP B1 (2)
9. CRANKSHAFT PULLEY/CAM CHAIN
1. DISASSEMBLY
2. ASSEMBLY
245 N.m (25.0 kgf.m, 181 lbf.ft)
12 N.m (1.2 kgf.m, 9 lbf.ft)
12 N.m (1.2 kgf.m, 9 lbf.ft)
12 N.m (1.2 kgf.m, 9 lbf.ft)
12 N.m (1.2 kgf.m, 9 lbf.ft)
12 N.m (1.2 kgf.m, 9 lbf.ft)
12 N.m (1.2 kgf.m, 9 lbf.ft)
22 N.m (2.2 kgf.m, 16 lbf.ft)
22 N.m (2.2 kgf.m, 16 lbf.ft)
12 N.m (1.2 kgf.m, 9 lbf.ft)
9-1
1. DISASSEMBLY
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under cover (P. 4-9)
– Silencer duct (P. 6-2)
– Alternator belt (P. 3-29)
– Thermostat (P. 8-2)
– Cylinder head cover (P. 10-2)
[1]
HARNESS CLIP
BRACKET C
Put the No.1 piston at the top dead center of its compression
stroke before disassembly (P. 3-12 and 13).
6 x 14 (3)
[2]
HARNESS
BAND CLIP
(3)
1) Detach the A/F sensor 4P connector and the VTEC solenoid
valve 1P connector [BF150A only] from the harness clip
bracket C. Disconnect the connectors.
2) Remove the three harness band clips from the harness clip
bracket C.
3) Remove the three 6 x 14 mm flange bolts from the harness
clip bracket C and remove the harness clip bracket C.
[4]
A/F SENSOR
4P CONNECTOR
4) Remove the two 8 x 20 mm flange bolts from the engine
hanger B and remove the engine hanger B.
[1]
ENGINE HANGER B
[3] VTEC SOLENOID
VALVE
1P CONNECTOR
[BF150A only]
8 x 20 (2)
5) Remove the main wire harness from the recesses of the
chain case.
[2] MAIN WIRE
HARNESS
[3]
RECESSES OF
CHAIN CASE
9-2
6) Disconnect the CKP sensor 3P connector from the CKP
sensor.
[1] CKP SENSOR
3P CONNECTOR
[2] CKP SENSOR
7) Loosen the 16 x 49 mm bolt-washer using the special tools
as shown.
TOOLS:
Handle
Pulley holder attachment, HEX 50 mm
Socket wrench, 19 mm
07JAB-001020B
07JAB-0010400
07JAA-001020A
[1]
PULLEY HOLDER
ATTACHMENT,
HEX 50 mm
07JAB-0010400
[2] HANDLE
07JAB-001020B
[3]
SOCKET WRENCH,
19 mm
07JAA-001020A
8) Remove the 16 x 49 mm bolt-washer and remove the
crankshaft pulley and the 4.5 x 21 mm key.
[1]
16 x 49 mm
BOLT-WASHER
[3]
4.5 x 21 mm
KEY
9-3
[2]
CRANKSHAFT
PULLEY
9) Remove all bolts securing the chain case.
• 10 x 43 mm flange bolts (3)
• 6 x 38 mm (SH) flange bolt (1)
• 6 x 28 mm flange bolts (10)
• 6 x 31 mm special bolts (2)
• 6 x 25 mm flange bolts (3)
[1]
6 x 37 (SH BOLT)
6 x 28 (10)
10) Remove the chain case gasket and the chain case O-ring
from the chain case.
Replace the chain case gasket and the chain case O-ring
with new ones on assembly.
[4] CHAIN CASE
GASKET
10 x 43 (3)
[2]
6 x 31 mm
SPECIAL
BOLT (2)
[5] CHAIN CASE
O-RING
[3]
CHAIN CASE
6 x 25 (3)
11) Pushing the cam chain tensioner arm toward the cam chain
tensioner, align the hole in the lock with the hole in the cam
chain and insert the pin of 1.5 mm in O.D. into the hole.
[1] CAM CHAIN
TENSIONER ARM
[2] Push.
NOTICE
Do not remove the pin of 1.5 mm in O.D. from the cam
chain tensioner before installing the cam chain tensioner.
[3] CAM CHAIN
TENSIONER
[4]
O.D. 1.5 mm PIN
[5]
Align hole in lock
with hole in cam
chain.
9-4
12) Remove the two 6 x 30 mm flange bolts and remove the
cam chain tensioner while pushing the cam chain tensioner
arm toward the cam chain (direction of arrow).
6 x 30 (2)
[1] CAM CHAIN
TENSIONER
[2]
CAM CHAIN
TENSIONER ARM
13) Remove the tensioner pivot bolt and the cam chain
tensioner arm.
14) Remove the three 6 x 20 mm flange bolts and remove the
cam chain guide.
[1]
TENSIONER
PIVOT BOLT
[2] CAM CHAIN
GUIDE
6 x 20 (3)
[3] CAM CHAIN
TENSIONER ARM
15) Remove the two 8 x 110 mm flange bolts and remove the
cam chain guide B.
8 x 110 (2)
[1] CAM CHAIN
GUIDE B
9-5
16) Remove the crank pulser plate from the crankshaft.
[1] CRANKSHAFT
[2]
CRANK PULSER
PLATE
17) Remove the cam chain.
NOTICE
Keep the cam chin away from any magnetic parts and
devices after removal.
9-6
[1]
CAM CHAIN
CHAIN CASE DISASSEMBLY:
1) Check the 43 x 58 x 7 mm oil seal for cut and other damage and replace if necessary.
Remove the 43 x 58 x 7 mm oil seal using a commercially available oil seal remover.
Replace the 43 x 58 x 7 mm oil seal with a new one on assembly.
2) Remove the CKP sensor and the chain case cover from the chain case.
Replace the CKP sensor at the 15 x 1.9 mm O-ring with a new one on assembly.
6 x 14 (3)
[2]
CHAIN CASE COVER
[1] CHAIN CASE
[3]
43 x 58 x 7 mm
OIL SEAL
[5] CKP SENSOR
6 x 16
[4] 15 x 1.9 mm O-RING
9-7
COMPONENTS DRAWING:
[2] 16 x 49 mm BOLT-WASHER
245 N.m (25.0 kgf.m, 181 lbf.ft)
[3] CRANKSHAFT PULLEY
[1] 6 x 38 (SH BOLT)
12 N.m (1.2 kgf.m, 9 lbf.ft)
10 x 43 (3)
6 x 28 (10)
12 N.m (1.2 kgf.m, 9 lbf.ft)
[4]
6 x 31 mm SPECIAL BOLT (2)
12 N.m (1.2 kgf.m, 9 lbf.ft)
[20]
CKP SENSOR
6 x 14 (3)
12 N.m (1.2 kgf.m, 9 lbf.ft)
[5]
43 x 58 x 7 mm OIL SEAL
[19]
CHAIN CASE COVER
[6] CHAIN CASE
6 x 30 (2)
12 N.m (1.2 kgf.m, 9 lbf.ft)
[7] 15 x 1.9 mm O-RING
6 x 16
[18] CAM CHAIN TENSIONER
6 x 20 (3)
12 N.m (1.2 kgf.m, 9 lbf.ft)
[17]
TENSIONER PIVOT BOLT
22 N.m (2.2 kgf.m, 16 lbf.ft)
[16] CAM CHAIN
TENSIONER ARM
[8]
CAM CHAIN GUIDE
[15] CAM CHAIN
[9]
CRANK PULSER
PLATE
8 x 110 (2)
22 N.m (2.2 kgf.m, 16 lbf.ft)
[14]
CAM CHAIN GUIDE B
6 x 25 (3)
12 N.m (1.2 kgf.m, 9 lbf.ft)
[13]
CHAIN CASE GASKET
9-8
[12]
CHAIN CASE
O-RING
[11]
4.5 x 21 mm KEY
[10] CRANKSHAFT
2. ASSEMBLY
[1] <Oil seal installation direction>
CHAIN CASE ASSEMBLY:
1) Apply soapy water to the outer surface of a new 43 x 58 x
7 mm oil seal.
[2] (Apply grease
to the lip.)
Using the special tools, drive in the 43 x 58 x 7 mm oil seal
until it seats on the chain case as shown.
After installation, apply grease to the oil seal lip.
TOOLS:
Driver
Attachment, 52 x 55 mm
07749-0010000
07746-0010400
[3] OIL SEAL
[4]
DRIVER
07749-0010000
[5]
ATTACHMENT,
52 x 55 mm
07746-0010400
[3] OIL SEAL
2) Remove the old liquid gasket, oil and contamination from
the chain case cover and the chain case mating surfaces.
3) Apply a bead [ø2.0 – 3.0 mm (ø0.08 – 0.12 in)] of the liquid
gasket (ThreeBond® #1280B or equivalent) to the indicated
area of the chain case cover.
NOTICE
Assemble the chain case cover within 5 minutes after
application of the liquid gasket. If it has been left for 5
minutes or longer, remove the old liquid gasket and apply
the liquid gasket again before assembly.
[1] Apply a bead of liquid
gasket as shown.
9-9
4) Install the chain case by tightening the three 6 x 14 mm flange bolts to the specified torque.
TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)
5) Position a new 15 x 1.9 mm O-ring on the CKP sensor and apply engine oil to the O-ring.
Install the CKP sensor by tightening the 6 x 16 mm flange bolt securely.
6 x 14 (3)
12 N.m (1.2 kgf.m, 9 lbf.ft)
[2]
CHAIN CASE COVER
[1] CHAIN CASE
[3] (Apply grease
to the lip.)
[4]
43 x 58 x 7 mm
OIL SEAL
6 x 16
[6] CKP SENSOR
9-10
[5] 15 x 1.9 mm O-RING
CAM CHAIN/CRANKSHAFT PULLEY ASSEMBLY:
[1] CRANKSHAFT
SPROCKET
NOTICE
[2] “
” MARKS
Keep the cam chain away from any magnetic parts and
devices.
1) Align the “ ” mark on the crankshaft sprocket with the “
mark on the cylinder block.
”
[3] CYLINDER BLOCK
2) Install the cam chain guide and tighten the three 6 x 20 mm
flange bolts to the specified torque.
TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)
3) Install the cam chain tensioner arm and tighten the
tensioner pivot bolt to the specified torque.
[1]
TENSIONER
PIVOT BOLT
[2]
CAM CHAIN
GUIDE
TORQUE: 22 N.m (2.2 kgf.m, 16 lbf.ft)
6 x 20 (3)
[3] CAM CHAIN
TENSIONER ARM
9-11
4) Install the cam chain aligning the color plate (one) with the
“ ” mark (or punch mark) on the crankshaft sprocket as
shown.
5) Holding the hexagonal part of both the intake and exhaust
camshafts with the wrench or equivalent tool as shown,
align the “ ” mark on the exhaust camshaft sprocket with
the “ ” mark on the intake camshaft sprocket. (The No.1
piston is at the top dead center of its compression stroke.)
[1] CAM CHAIN
[2] “ ” MARK
(or punch mark)
[3] COLLAR PLATE
(1 place)
[1] <INTAKE SIDE>
[2] <EXHAUST SIDE>
[3] HEXAGONAL PART
6) Check that the punch mark on the intake camshaft sprocket
and the punch mark on the exhaust camshaft sprocket are
in the position shown.
7) Holding the No.1 cylinder at the top dead center of its
compression stroke and the punch marks in alignment as
described in step 5, align each punch mark on the intake
and exhaust camshaft sprockets with the mid point of the
corresponding color plates (2 places) of the cam chain, and
install the cam chain.
[4] PUNCH MARKS
NOTICE
• Turn the intake camshaft and the exhaust camshaft while
holding the hexagonal part of the intake and exhaust
camshafts with the wrench or equivalent tool and thereby
aligning the alignment marks on both the intake and
exhaust camshaft sprockets.
• Install the cam chain aligning the mid point of the two
color plates with the punch mark on the intake/exhaust
camshaft sprockets.
• Check that the color plate (one) of the crankshaft sprocket
is not out of alignment.
• After installing the cam chain, check that the crankshaft
sprocket and the camshaft sprocket are in alignment with
the No.1 piston at the top dead center of its compression
stroke.
[5]
EXHAUST
CAMSHAFT
SPROCKET
[7] INTAKE
CAMSHAFT
SPROCKET
[8] COLOR PLATES (2 places)
[9]
CAM CHAIN
9-12
[6] “ ” MARKS
[4] PUNCH MARKS
8) Pushing the cam chain tensioner arm toward the cam
chain, install the cam chain tensioner by aligning the
cutouts of the cam chain tensioner with the recess in the
cam chain tensioner arm. Tighten the two 6 x 30 mm flange
bolts to the specified torque.
6 x 30 (2)
[1] 1.5 mm PIN
TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)
[2]
CAM CHAIN
TENSIONER
Remove the 1.5 mm pin.
[3]
CAM CHAIN
TENSIONER
ARM
[4]
RECESS
[5]
CUTOUTS
9) Wipe up oil, etc. from the crankshaft outer surface with a
clean shop towel.
Install the crankshaft pulser plate on the crankshaft with the
“OUT-SIDE” mark facing out.
[1]
“OUT-SIDE” MARK
[2]
CRANK PULSER
PLATE
[3] CRANKSHAFT
(Wipe up oil, etc. from crankshaft
surface with a clean shop towel.)
9-13
10) Install the cam chain guide B and tighten the two 8 x 110
mm flange bolts to the specified torque.
TORQUE: 22 N.m (2.2 kgf.m, 16 lbf.ft)
8 x 110 (2)
[1] CAM CHAIN
GUIDE B
11) Install the new chain case gasket on the chain case.
[1] CHAIN CASE
GASKET
[2] CHAIN CASE
9-14
12) Install the new chain case O-ring on the chain case.
[1]
CHAIN CASE
O-RING
[2] CHAIN CASE
13) Remove the old liquid gasket, oil and the contamination
from the cylinder block/cylinder head and chain case
mating surfaces.
14) Apply a bead [ø2.0 – 3.0 mm (ø0.08 – 0.12 in)] of the liquid
gasket (ThreeBond® #1280B or equivalent) to the indicated
areas of the chain case.
[1]
Apply bar [2.5 mm
(0.10 in) thick] of the
liquid gasket here
again; i.e. to the bead
of the liquid gasket
applied before.
Apply bead [2.5 mm (0.10 in) thick] of the liquid gasket
again to the part “A” shown in the drawing; i.e. apply to the
bead of the liquid gasket applied before.
NOTICE
[2] PART “A”
Assemble the chain case within 5 minutes after applying
the liquid gasket. If it has been left for 5 minutes or longer,
remove the old liquid gasket and apply the liquid gasket
again before assembly.
[2] PART “A”
[3]
Apply a bead of
liquid gasket.
[3]
Apply a bead of
liquid gasket
9-15
15) Install the chain case on the cylinder block aligning the end
of the chain case at the crankcase side.
16) Loosely tighten the two 6 x 31 mm special bolts in the
positions shown.
[1]
6 x 38
(SH BOLT)
10 x 43 (3)
6 x 28 (10)
[2]
6 x 31 mm
SPECIAL BOLTS
17) Loosely tighten all the chain case bolts but the two 6 x 31
mm special bolts, and tighten them to the specified torque
in two or three steps in a criss-cross pattern. (Tighten the
three 10 x 43 mm flange bolts to the standard torque.)
TORQUE:
6 x 38 mm (SH) flange bolt (1)/
6 x 28 mm flange bolts (10)/
6 x 31 mm special bolts (2)/
6 x 25 mm flange bolts (3): 12 N.m (1.2 kgf.m, 9 lbf.ft)
STANDARD TORQUE:
10 x 43 mm flange bolts (3): 39 N.m (40 kgf.m, 29 lbf.ft)
NOTICE
• Do not touch the surfaces coated with the liquid gasket.
[3] CHAIN CASE
• Take care not to slide the chain case during installation as
it makes the thickness of the liquid gasket uneven.
• Take care not to let the chain case gasket and O-ring come
out of position.
6 x 25 (3)
[3] CHAIN CASE
[4] CYLINDER BLOCK
[5] CRANKCASE
9-16
18) Wipe up oil thoroughly from the threaded part of the
crankshaft where the 16 x 49 mm bolt-washer is tightened,
and from the crankshaft pulley and the 16 x 49 mm boltwasher with a clean shop towel.
19) Wipe up oil from the boss on the side of the crankshaft
pulley with a clean shop towel sprayed with the degreasing
cleaning agent.
: [1] Wipe up contamination.
: [2] Apply engine oil.
: [3] Degrease with degreasing cleaning agent.
[4] 16 x 49 mm
BOLT-WASHER
20) Apply the engine oil to the threads and the seating surface
of the 16 x 49 mm bolt-washer.
[5]
CRANKSHAFT
PULLEY
[6] CRANKSHAFT
21) Position the 4.5 x 21 mm key and the crankshaft pulley on
the crankshaft, then loosely tighten the 16 x 49 mm boltwasher.
[1]
16 x 49 mm
BOLT-WASHER
[3]
4.5 x 21 mm
KEY
9-17
[2]
CRANKSHAFT
PULLEY
22) Tighten the 16 x 49 mm bolt-washer to the specified torque
using the special tools as shown.
TOOLS:
Handle
Pulley holder attachment, HEX 50 mm
Socket wrench, 19 mm
[1] HANDLE
07JAB-001020B
07JAB-001020B
07JAB-0010400
07JAA-001020A
TORQUE: 245 N.m (25.0 kgf.m, 181 lbf.ft)
[2] SOCKET WRENCH,
19 mm
07JAA-001020A
[3] PULLEY HOLDER
ATTACHMENT,
HEX 50 mm
07JAB-0010400
23) Connect the CKP sensor 3P connector to the CKP sensor.
[1]
CKP SENSOR
3P CONNECTOR
[2] CKP SENSOR
9-18
24) Position the main wire harness in the recesses of the chain
case.
[1] ENGINE HANGER B
8 x 20 (2)
25) Tighten the engine hanger B with the two 8 x 20 mm flange
bolts.
[2]
MAIN WIRE
HARNESS
[3]
RECESSES OF
CHAIN CASE
26) Position the three harness band clips on the harness clip
bracket C.
Tighten the harness clip bracket C with the three 6 x 14 mm
flange bolts securely.
[1]
HARNESS CLIP
BRACKET C
6 x 14 (3)
27) Connect the A/F sensor 4P connector and the VTEC
solenoid valve 1P connector [BF150A only], and install
them on the harness clip bracket C.
28) Install the following parts.
– Cylinder head cover (P. 10-40)
– Thermostat (P. 8-4)
– Alternator belt (P. 3-30)
– Silencer duct (P. 6-4)
– L./R. engine under cover (P. 4-14)
– Engine cover (P. 4-2)
[2]
HARNESS
BAND CLIP
(3)
[4]
A/F SENSOR
4P CONNECTOR
9-19
[3] VTEC SOLENOID
VALVE
1P CONNECTOR
[BF150A only]
10. CYLINDER HEAD/VALVE
1. CYLINDER HEAD COVER REMOVAL
2. CYLINDER HEAD COVER
DISASSEMBLY
3. CAMSHAFT/ROCKER ARM
DISASSEMBLY
4. CAMSHAFT/ROCKER ARM
INSPECTION
5. CYLINDER HEAD ASSEMBLY
REMOVAL
6. CYLINDER HEAD ASSEMBLY
DISASSEMBLY
7. CYLINDER HEAD ASSEMBLY
INSPECTION
8. VALVE GUIDE REPLACEMENT
9. VALVE SEAT RECONDITIONING
10. CLYLINDER HEAD ASSEMBLY
ASSEMBLY
11. CYLINDER HEAD ASSEMBLY
INSTALLATION
12. CAMSHAFT/ROCKER ARM
ASSEMBLY
13. CYLINDER HEAD COVER ASSEMBLY
14. CYLINDER HEAD COVER
INSTALLATION
12 N.m (1.2 kgf.m, 9 lbf.ft)
[1]
Used bolt:
39 N.m (4.0 kgf.m, 29 lbf.ft) + 90˚ + 90˚
New bolt:
39 N.m (4.0 kgf.m, 29 lbf.ft) + 90˚ + 90˚ + 98˚
113 N.m (11.5 kgf.m, 83 lbf.ft)
72 N.m (7.3 kgf.m, 53 lbf.ft)
22 N.m (2.2 kgf.m, 16 lbf.ft)
12 N.m (1.2 kgf.m, 9 lbf.ft)
22 N.m (2.2 kgf.m, 16 lbf.ft)
39 N.m {4.0 kgf.m,
29 lbf.ft)
12 N.m (1.2 kgf.m, 9 lbf.ft)
10-1
22 N.m (2.2 kgf.m, 16 lbf.ft)
1. CYLINDER HEAD COVER REMOVAL
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under covers (P. 4-9)
– Ignition coil/spark plug (P. 3-6)
1) Disconnect the breather tube and the main wire harness
from the cylinder head cover.
[2]
MAIN WIRE
HARNESS
[1]
BREATHER
TUBE
2) Remove the two 6 x 22 mm flange bolts, then remove the
R. side cover bracket assembly from the engine assembly.
[1]
R. SIDE COVER
BRACKET ASSEMBLY
6 x 22 (2)
3) Disconnect the fuel tube B and the fuel tube D from the fuel
pump (low pressure side).
NOTICE
[1] TUBE CLIPS
(Commercially
available)
[2]
FUEL
TUBE B
Before disconnecting the fuel tube B and the fuel tube D,
clamp the fuel tubes with the tube clips to prevent gasoline
leakage.
[4]
FUEL TUBE D
10-2
[3] FUEL PUMP
(Low pressure
side)
4) Disconnect the oil tube from the mounting case.
[1]
OIL TUBE
[2]
MOUNTING CASE
5) Move the water relief tube A from your side of the
projection on the cylinder head cover to the other side.
[1]
WATER RELIEF
TUBE A
[2]
PROJECTION
[3]
CYLINDER
HEAD
COVER
6) Remove the six 6 mm hex. cap nuts and the six head cover
washers, then remove the cylinder head cover.
[1]
CYLINDER HEAD
COVER
[2]
HEAD COVER
WASHER (6)
10-3
[3]
6 mm HEX. CAP
NUT
2. CYLINDER HEAD COVER DISASSEMBLY
[1]
HEAD COVER GASKET
INSPECTION:
Check for damage and
deterioration. Replace if
necessary.
[2]
CYLINDER HEAD COVER
[3]
HEAD COVER WASHER (6)
[4]
6 mm HEX. CAP NUT (6)
12 N.m (1.2 kgf.m, 9 lbf.ft)
[5]
PHC COVER
[11]
SPARK PLUG TUBE SEAL (4)
INSPECTION:
Check the seal lip for a
break or other damage.
Replace if necessary.
[9]
TUBE CLIP
D32.5
[10]
OIL TUBE
10-4
[8]
IGNITION COIL (4)
[7]
6 x 25 mm SOCKET
BOLT (4)
[6]
6 x 25 mm SOCKET
BOLT (2)
3. CAMSHAFT/ROCKER ARM
DISASSEMBLY
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under covers (P. 4-9)
– Ignition coil/spark plug (P. 3-6)
– Cylinder head cover (P. 10- 2)
1) Move the remote control lever to the “N” (Neutral)
position.
2) Turn the crankshaft pulley clockwise until it sets the No.1
piston at the top dead center of its compression stroke (P.
3-12).
Remove the following parts.
– Crankshaft pulley/cam chain (P. 9-2)
3) Disconnect the CMP sensor 3P connector. Remove the
harness band clip from the clip bracket F.
[1]
CLIP
BRACKET F
[2]
HARNESS
BAND CLIP
[3]
CMP SENSOR 3P
CONNECTOR
4) Remove the 6 x 16 mm flange bolts from the No.5 rocker
shaft holder, then remove the CMP sensor and the CMP
hole plug.
5) Remove the 15.2 x 1.9 mm O-rings from the CMP sensor
and the CMP hole plug.
Replace the O-rings with the new ones on assembly.
6 x 16 (2)
6) Secure the hex. part of the intake camshaft with a wrench
or equivalent tool.
10-5
[1]
CMP HOLE PLUG
[2]
CMP SENSOR
[1]
INTAKE CAMSHAFT
7) Using a hex. wrench, loosen the 14 mm sealing bolt that
tightens the camshaft collar.
[1]
CAMSHAFT COLLAR
[2]
14 mm SEALING BOLT
8) Remove the VTC flange bolt from the intake camshaft
sprocket. Remove the intake camshaft sprocket from the
intake camshaft.
[2]
INTAKE CAMSHAFT
SPROCKET
[1]
VTC FLANGE
BOLT
9) Secure the hex. part of the exhaust camshaft with a wrench
or equivalent tool.
10-6
[3]
INTAKE
CAMSHAFT
[1]
EXHAUST CAMSHAFT
10) Using a hex. wrench, loosen the 14 mm sealing bolt that
tightens the CMP pulse plate.
[1]
CMP PULSE PLATE
[2]
14 mm SEALING BOLT
11) Remove the 10 x 32 mm flange bolt from the exhaust
camshaft sprocket, then remove the exhaust camshaft
sprocket from the exhaust camshaft.
10 x 32
[1]
EXHAUST
CAMSHAFT
12) Loosen the rocker arm’s lock nut, then loosen the valve
adjusting screw fully.
[2]
VALVE ADJUSTING
SCREW
[1]
VALVE ADJUSTING
LOCK NUT
10-7
[2]
EXHAUST
CAMSHAFT
SPROCKET
13) Loosen the camshaft holder bolts in the numbered
sequence in two or three steps.
5
4
7
6
e
w
t
r
a
p
d
s
1
u
y
o
14) Remove the following bolts.
• Head cover bolts (6)
• 8 x 110 mm flange bolts (2)
• 8 x 90 mm flange bolts (12)
• 6 x 32 mm flange bolt (1)
• 6 x 20 mm flange bolts (2)
i
9
8
q
0
3
15) Remove the cam chain guide B, camshaft holder and the
intake and exhaust camshafts.
Remove the 10 dowel pins.
2
[1]
INTAKE CAMSHAFT
[2]
EXHAUST CAMSHAFT
[3]
CAM CHAIN
GUIDE B
8 x 110 (2)
[4]
HEAD CAVER
BOLT (6)
8 x 90 (12)
6 x 20 (2)
6 x 32
[6]
10 x 16 mm
DOWEL PIN (10)
10-8
[5]
CAMSHAFT
HOLDER (4)
16) Remove the 14 mm sealing bolts from the intake/exhaust
camshafts, then remove the camshaft collar and the CMP
pulse plate.
[1] EXHAUST
CAMSHAFT
[2]
CMP
PULSE
PLATE
[3] CAMSHAFT
COLLAR
[5]
INTAKE
CAMSHAFT
17) Insert the bolts into the rocker shaft holders and remove
the rocker arm assembly from the cylinder head assembly.
[1]
ROCKER ARM
ASSEMBLY
[3]
10 x 16 mm
DOWEL PIN (10)
10-9
[4]
14 mm SEALING
BOLT (2)
[2]
BOLT (4)
COMPONENTS DRAWING
[3]
VTC FLANGE BOLT
113 N.m (11.5 kgf.m, 83 lbf.ft)
[1]
10 x 16 mm
DOWEL PIN (10)
[4] INTAKE CAMSHAFT
SPROCKET
[2]
ROCKER ARM
ASSEMBLY
10 x 32
72 N.m (7.3 kgf.m,
53 lbf.ft)
[5]
EXHAUST
CAMSHAFT
SPROCKET
[6]
EXHAUST
CAMSHAFT
[7]
INTAKE
CAMSHAFT
[8]
CMP PULSE PLATE
[22] 15.2 x 1.9 mm O-RING (2)
[9]
14 mm SEALING BOLT (2)
39 N.m (4.0 kgf.m,
29 lbf.ft)
[21] CMP HOLE PLUG
6 x 16 (2)
6 x 14
[20]
No.1 CAMSHAFT
HOLDER
[12] CMP SENSOR
[18]
No.3 CAMSHAFT
HOLDER
[16]
10 x 16 mm
DOWEL PIN (10)
10-10
6 x 20 (2)
12 N.m (1.2 kgf.m, 9 lbf.ft)
[11] CLIP BRACKET F
[19]
No.2 CAMSHAFT
HOLDER
[17]
No.4 CAMSHAFT
HOLDER
[10]
CAMSHAFT COLLAR
[14]
CAM CHAIN
GUIDE B
8 x110 (2)
22 N.m (2.2 kgf.m,
16 lbf.ft)
8 x 90 (12)
22 N.m (2.2 kgf.m,
16 lbf.ft)
6 x 32
12 N.m (1.2 kgf.m,
9 lbf.ft)
[15]
No.5 CAMSHAFT
HOLDER
[13]
HEAD COVER
BOLT (6)
22 N.m (2.2 kgf.m,
16 lbf.ft)
DISASSEMBLY OF ROCKER ARM ASSEMBLY
BF150A:
NOTICE
• Note the location of each part before disassembly. Do not
confuse the parts and install them in their original positions.
• Check the camshaft contact surface of each rocker arm for
wear or damage.
• Insert the bolts in the rocker shaft holders before removing or
installing the rocker arm assembly from/on the cylinder head.
Apply molybdenum disulfide oil to the outer surface of the intake/exhaust rocker shafts on assembly.
[1] MOLYBDENUM
DISULFIDE OIL
[2]
INTAKE ROCKER
ARM ASSEMBLY
[3]
EXHAUST
ROCKER ARM
[1] MOLYBDENUM
DISULFIDE OIL
[4]
No.1 ROCKER SHAFT HOLDER
[5]
No.2 ROCKER SHAFT HOLDER
[6]
No.3 ROCKER SHAFT HOLDER
[7]
No.4 ROCKER SHAFT HOLDER
[11]
INTAKE ROCKER
SHAFT
[8]
EXHAUST ROCKER
SHAFT
[10]
RUBBER BAND
10-11
[9]
No.5 ROCKER SHAFT HOLDER
BF135A:
NOTICE
• Note the location of each part before disassembly. Do not
confuse the parts and install them in their original positions.
• Check the camshaft contact surface of each rocker arm for
wear or damage.
• Insert the bolts in the rocker shaft holders before removing or
installing the rocker arm assembly from/on the cylinder head.
Apply molybdenum disulfide oil to the outer surface of the intake/exhaust rocker shafts on assembly.
[1] MOLYBDENUM
DISULFIDE OIL
[2]
INTAKE ROCKER
ARM ASSEMBLY
[3]
EXHAUST
ROCKER ARM
[1] MOLYBDENUM
DISULFIDE OIL
[4]
No.1 ROCKER SHAFT HOLDER
[5]
No.2 ROCKER SHAFT HOLDER
[6]
No.3 ROCKER SHAFT HOLDER
[7]
No.4 ROCKER SHAFT HOLDER
[11]
INTAKE ROCKER
SHAFT
[10]
RUBBER BAND
10-12
[8]
EXHAUST ROCKER
SHAFT
[9]
No.5 ROCKER SHAFT HOLDER
4. CAMSHAFT/ROCKER ARM
INSPECTION
[1] INTAKE CAMSHAFT:
<BF150A>
<BF135A>
[2] PRI [3] MID [4] SEC
[4] SEC [2] PRI
• CAM HEIGHT
Clean the camshaft and check the cam surface for wear and
damage.
STANDARD
IN: PRI/SEC
32.626 – 32.931 mm
(1.2845 – 1.2965 in)
IN: MID
35.369 – 35.654 mm
(1.3925 – 1.4037 in)
EX
33.927 – 34.212 mm
(1.3357 – 1.3469 in)
SERVICE LIMIT
[5] CAM CHAIN
[6] EXHAUST CAMSHAFT:
PRI: Primary MID: Mid SEC: Secondary
[5] CAM CHAIN
• CAMSHAFT JOURNAL O.D.
Clean the camshaft and check the journals for wear and
damage.
STANDARD
No.1
28.955 – 28.970 mm
(1.1400 – 1.1405 in)
No.2 – No.5
28.925 – 28.940 mm
(1.1388 – 1.1394 in)
SERVICE LIMIT
• CAMSHAFT JOURNAL I.D.
STANDARD
No.1 – No.5
10-13
29.000 – 29.024 mm
(1.1417 – 1.1427 in)
[5] CAM CHAIN
SERVICE LIMIT
• CAMSHAFT OIL CLEARANCE
1) Clean the camshaft and check the journals for wear and
damage.
2) Clean the rocker shaft holder bearings and the camshaft
holder bearings. Install the rocker shaft holders and the
camshaft on the cylinder head assembly.
[1]
PLASTIGAUGE
3) Set a plastigauge on each journal as shown.
NOTICE
• Set a plastigauge in the axial direction on each journal.
• Do not turn the camshaft during the check.
4) Install the camshaft holder on the rocker shaft holder and
tighten the bolts to the specified torque (P. 10-35).
TORQUE:
Head cover bolt,
8 x 90 mm flange bolt,
8 x 110 mm flange bolt: 22 N.m (2.2 kgf.m, 16 lbf.ft)
6 x 20 mm flange bolt,
6 x 32 mm flange bolt: 12 N.m (1.2 kgf.m, 9 lbf.ft)
5) Remove the camshaft holder. Measure the width of the
pressed part of the plastigauge using a scale printed on the
bag of the plastigauge.
NOTICE
Measure the widest width on the plastigauge.
STANDARD
SERVICE LIMIT
No.1
0.030 – 0.069 mm
(0.0012 – 0.0027 in)
0.15 mm
(0.006 in)
No.2 – No.5
0.060 – 0.099 mm
(0.0024 – 0.0039 in)
0.15 mm
(0.006 in)
[1]
SCALE
6) If the measurement exceeds the service limit, replace the
camshaft holder, rocker shaft holder and the cylinder head
as a set. Recheck the camshaft oil clearance.
If the measurement still exceeds the service limit, replace
the camshaft.
[2]
PLASTIGAUGE
10-14
• CAMSHAFT AXIAL CLEARANCE
1) Install the rocker shaft holder, camshaft and the camshaft
holder, and tighten the bolts to the specified torque (P. 1035).
2) Put the camshaft at the top dead center of the compression
stroke of the No.1 piston (with the dowel pin at your side).
Install the dial indicator.
3) Check the camshaft axial play by pushing and pulling the
camshaft of the opposite side from the indicator.
STANDARD
SERVICE LIMIT
0.05 – 0.20 mm
(0.002 – 0.008 in)
0.4 mm
(0.02 in)
4) If the measurement exceeds the service limit, replace the
camshaft holder, rocker shaft holder and the cylinder head
as a set, and recheck.
If the measurement still exceeds the service limit, replace
the camshaft.
• CAMSHAFT RUNOUT
1) Place the V blocks or equivalent under the journal at both
ends of the camshaft
2) Install the dial indicator and measure the camshaft runout
by turning the camshaft.
STANDARD
SERVICE LIMIT
0.03 mm (0.001 in) Max.
0.4 mm (0.02 in)
3) Replace the camshaft if the measurement exceeds the
service limit.
• ROCKER SHAFT O.D.
STANDARD
IN/EX
SERVICE LIMIT
16.983 – 16.994 mm
(0.6686 – 0.6690 in)
NOTICE
Measure the rocker shaft O.D. at the sliding part of the rocker
arm.
10-15
[1]
Dowel pin is at your side.
• ROCKER ARM I.D.
STANDARD
IN
17.019 – 17.035 mm
(0.6700 – 0.6707 in)
EX
17.012 – 17.039 mm
(0.6698 – 0.6708 in)
SERVICE LIMIT
• ROCKER ARM-TO-ROCKER SHAFT CLEARANCE
STANDARD
SERVICE LIMIT
IN
0.025 – 0.052 mm
(0.0010 – 0.0020 in)
0.08 mm
(0.003 in)
EX
0.018 – 0.056 mm
(0.0007 – 0.0022 in)
0.08 mm
(0.003 in)
If the measurement exceeds the service limit, replace the
rocker arm as an assembly and recheck.
If the measurement still exceeds the service limit, replace the
rocker shaft.
[1] MID ROCKER ARM
• VTEC ROCKER ARM ASEMBLY INSPECTION
(BF150A only)
Check of stuck rocker arm assembly at high lift side:
1) Remove the cylinder head cover (P. 10-2).
2) Put the No.1 piston at the top dead center of the
compression stroke (P. 3-12).
3) Move the secondary rocker arm of the No.1 cylinder up and
down with a finger. Check that the secondary rocker arm
moves independent from the mid rocker arm.
NOTICE
• If it does not, remove and disassemble the rocker arm
assembly to check (P. 10-18).
• If the rocker arm assembly is not normal, replace the
rocker arm as an assembly.
4) Repeat the step 2 and 3 on each cylinder to put the piston
of each cylinder at the top dead center of its compression
stroke. Check the secondary rocker arm.
5) Install the cylinder head cover (P. 10-40).
Check of stuck rocker arm assembly at low lift side:
NOTICE
• Before performing inspection with the special tool(s), check
that the secondary rocker arm moves independently. (See
Check of stuck rocker arm assembly at high lift side.)
• Check with the special tool(s) can be made on the following
conditions.
– At cylinder head disassembly
– Engine power drops significantly at high rpm but the cause
of the problem cannot be identified by following the
troubleshooting chart.
1) Start the engine and let it warm up for five minutes.
2) Remove the cylinder head cover (P. 10-2).
3) Check the valve clearance (P. 3-9).
10-16
[2]
SECONDARY
ROCKER ARM
NOTICE
• Check that the following conditions are met before using the
air supply (special tool). The following conditions are
essential for use of the air supply, as the specified air
pressure of 290 kPa (3.0 kgf/cm2, 43 psi) must be maintained
at the gauge of the tool. Stop using the other air tools unless
the specified air pressure is maintained.
– Check whether the air compressor tank is under the
specified air pressure and the tank gauge shows the value
of the set pressure.
– Connect the air supply to the air intake port located close to
the compressor.
– Check as quickly as possible (within 6 seconds), or the air
pressure drops possibly marking it hard to switch the valve
timing to the high lift side.
• Check on each cylinder with the piston at the top dead center
of its compression stroke.
• Oil can spurt out when the air pressure is applied. Adjust the
air pressure with the regulator valve (special tool) and
increase the air pressure gradually.
[1]
AIR SUPPLY
07LAJ-PR30102
[2]
AIR JOINT ADAPTER
07ZAJ-PNA0300
4) Remove the 10 mm sealing bolt from the No.1 camshaft
holder and install the air stopper (special tool).
5) Remove the two mounting bolts of the No.2 and No.3
camshaft holders (intake side), and install the special tool
as shown.
TOOLS:
Air supply
VTEC air adapter
VTEC air stopper
Air joint adapter
07LAJ-PR30102
07ZAJ-PNA0101
07ZAJ-PNA0200
07ZAJ-PNA0300
[3]
10 mmSEALING
BOLT
NOTICE
Install the VTEC air adapter (special tool) and tighten it by
hand.
6) Apply the specified air pressure and check that the valve
timing switched to the high lift side.
[5]
VTEC AIR ADAPTR
07ZAJ-PNA0101
[4]
VTEC AIR STOPPER
07ZAJ-PNA0200
Air pressure: 290 kPa (3.0 kgf/cm2, 43 psi)
7) Check that the three intake rocker arms are interconnected
by applying the specified amount of air pressure. Move the
secondary rocker arm up and down with a finger and check
that both the mid rocker arm and the primary rocker arm
move up and down, too.
8) If there is abnormality in the rocker arm movement, replace
the intake rocker arm as an assembly.
9) Remove the VTEC air adapter (special tool) and tighten the
camshaft holder mounting bolts to the specified torque.
[2] MID ROCKER ARM
[1]
PRIMARY
ROCKER
ARM
TORQUE: 22 N.m (2.2 kgf.m, 16 lbf.ft)
10) Remove the air stopper (special tool) from the No.1
camshaft holder, and tighten the 10 mm sealing bolt to the
specified torque.
TORQUE: 20 N.m (2.0 kgf.m, 14 lbf.ft)
11) Install the cylinder head cover (P. 10-40).
12) Check that the MIL does not come ON.
10-17
[3]
SECONDARY
ROCKER ARM
• VTEC ROCKER ARM/ROCKER ARM INSPECTION
BF150A:
1) Disassemble the rocker arm assembly. Check that the
rocker arm pistons move smoothly.
[1]
ROCKER ARM
PISTONS
NOTICE
• Remove the pistons from the primary rocker arm by
applying low air pressure to the rocker arm. Take care not
to apply excessive air pressure as the pistons can jump
out of the rocker arm.
• After removing the rocker arm assembly, tie the assembly
with a rubber band or equivalent to prevent each
component of the assembly from missing. Note to
remove the rubber band after installation.
2) If the pistons do not move smoothly, replace the rocker arm
as an assembly.
3) Apply the engine oil to the rocker arm pistons on assembly.
10-18
BF135A:
[1]
ROCKER ARM
PISTONS
5. CYLINDER HEAD ASSEMBLY
REMOVAL
NOTICE
②
①
• Removal of the cylinder head assembly must be made when
the engine is cold (38˚C or below).
• Take care not to damage (scores or scratches) the gasket
mating surfaces with the cylinder head and the cylinder
block.
• Do not bend the cylinder head gaskets as they are the metal
gaskets.
• Keep the cam chain away from the magnetic parts.
⑥
⑤
⑩
⑨
⑦
⑧
③
④
Remove the following pars.
– Engine cover (P. 4-2)
– L./R. engine under covers (P. 4-9)
– Ignition coil/spark plug (P. 3-6)
– L./R. side cover brackets (P. 4-24)
– Cylinder head cover (P. 10-2)
1) Move the remote control lever to the “N” (Neutral)
position.
2) Turn the crankshaft pulley clockwise until it puts the No.1
piston at the top dead center of its compression stroke (P.
3-12).
Remove the following pars.
– Crankshaft pulley/cam chain (P. 9-2)
– Camshaft/rocker arm (P. 10-5)
– Throttle body/intake manifold (P. 5-129)
– Fuel line assembly (P. 5-136)
– Injector base (P. 5-139)
– Exhaust manifold (P. 5-152)
3) Loosen the 11 x 155 mm bolt washers in the numbered
sequence shown in two or three steps.
4) Remove the ten 11 x 155 mm bolt washers from the
cylinder head assembly.
[1]
CYLINDER HEAD
GASKET
5) Remove the cylinder head assembly. Remove the cylinder
head gasket and the two dowel pins.
Replace the cylinder head gasket with a new one on
assembly.
[2]
14 x 20 mm
DOWEL PIN (2)
[3]
CYLINDER HEAD
ASSEMBLY
10-19
6. CYLINDER HEAD ASSEMBLY
DISASSEMBLY
[1] PLASTIC HAMMER
[2]
SOCKET
NOTICE
Mark each removed parts and store them securely classifying
them into the groups of the intake side and the exhaust side of
each cylinder. Install each part in the original position on
assembly.
1) Use the socket that matches the diameter of the valve
spring retainer. Attach the socket to the retainer and lightly
tap on the socket to separate the valve keepers from the
retainer.
NOTICE
• Tap at right angles with each valve stem head. Take care
not to bend the valves.
• Support the cylinder head with a suitable material to
prevent damage to the valve.
2) Change the attachment of the special tool as shown.
TOOLS:
Valve spring compressor
Valve spring compressor attachment
[2]
VALVE SPRING
COMPRESSOR
07757-0010000
[1]
VALVE SPRING
COMPRESSOR
ATTACHMENT
07757-PJ10100
07757-0010000
07757-PJ10100
[3]
ADAPTER
3) Compress the valve springs using the special tools as
shown.
TOOLS:
Valve spring compressor
Valve spring compressor attachment
07757-0010000
07757-PJ10100
NOTICE
[1]
VALVE SPRING
COMPRESSOR
ATTACHMENT,
07757-PJ10100
• Take care not to let the special tools contact the cylinder
head.
• Do not compress the valve springs more than necessary
as it causes weak valve spring.
[2]
VALVE SPRING
COMPRESSOR
07757-0010000
10-20
4) Remove the valve keeper from the groove in the valve
stem.
5) Remove the remaining valve keepers.
6) Remove the valve spring retainer, valve spring, valve, valve
spring seat and the valve stem seal.
Check the valve for chipping and excessive carbon
deposits. Clean the valve if necessary.
Replace the valve stem seal on assembly.
[1]
VALVE KEEPER (2)
[1]
VALVE SPRING
RETAINER
[2]
VALVE SPRING
[3]
VALVE STEM SEAL
[4]
VALVE SPRING
SEAT
[5]
VALVE
10-21
COMPONENTS DRAWING
[1]
14 x 20 mm
DOWEL PIN (2)
[2]
CYLINDER HEAD
GASKET
[3]
VTC HOLE PLUG
[19]
VTC FILTER
6 x 20
[4]
CYLINDER HEAD
[5]
EXHAUST VALVE GUIDE (8)
[6]
VALVE STEM SEAL B (8)
[7]
EXHAUST VALVE
SPRING (8)
[18]
VTC STRAINER
6 x 20 (2)
[17]
INTAKE VALVE (8)
[16]
EXHAUST VALVE (8)
[8]
LOST MOTION (8)
[15] INTAKE VALVE GUIDE (8)
[14] VALVE SPRING SEAT (16)
[13] VALVE STEM SEAL A (8)
[12] INTAKE VALVE
SPRING (8)
[11] VALVE SPRING
RETAINER (16)
10-22
[10]
VALVE
KEEPER (32)
[9]
11 x 155 mm BOLT-WASHER (10)
Used bolt:
39 N.m (4.0 kgf.m, 29 lbf.ft) + 90˚ + 90˚
New bolt:
39 N.m (4.0 kgf.m, 29 lbf.ft) + 90˚ + 90˚ + 98˚
7. CYLINDER HEAD ASSEMBLY
INSPECTION
• VALVE SPRING FREE LENGTH
Measure the free length of the valve springs.
STANDARD
SERVICE LIMIT
49.64 mm
(1.954 in)
IN/EX
• VALVE FACE/VALVE STEM O.D.
<Valve face>
Inspect each valve face for pitting or wear irregularities. Inspect
each valve face for even seat. Replace the valve if necessary.
<Valve stem>
1) Check each valve for bend, seizure or damage.
2) Insert each valve into the corresponding valve guide to
check the operation.
3) Measure the valve stem O.D. at the sliding surface of the
valve guide.
STANDARD
SERVICE LIMIT
IN
5.475 – 5.485 mm
(0.2156 – 0.2159 in)
5.445 mm
(0.2144 in)
EX
5.450 – 5.460 mm
(0.2146 – 0.2150 in)
5.420 mm
(0.2134 in)
[1]
VALVE FACE
• VALVE LENGTH/VALVE O.D.
STANDARD
OVERALL
LENGTH
VALVE
O.D.
IN
108.7 – 109.5 mm
(4.28 – 4.31 in)
EX
108.3 – 109.1 mm
(4.26 – 4.30 in)
IN
34.85 – 35.15 mm
(1.372 – 1.384 in)
EX
29.85 – 30.15 mm
(1.175 – 1.187 in)
[1]
OVERALL LENGTH
SERVICE LIMIT
[2]
VALVE
O.D.
• VALVE GUIDE I.D.
Using the valve guide reamer, 5.525 mm (special tool), ream
the valve guides to remove any carbon deposits before
measuring. Measure and record each valve guide I.D.
NOTICE
Turn the valve guide reamer, 5.525 mm (special tool) clockwise
and never turn it counterclockwise. Continue to turn the
reamer as you lift it from the valve guide.
IN/EX
10-23
STANDARD
SERVICE LIMIT
5.51 – 5.53 mm
(0.217 – 0.218 in)
5.55 mm
(0.219 in)
[1]
VALVE GUIDE
REAMER, 5.525 mm
07HAH-PJ70100
• VALVE STEM-TO-VALVE GUIDE CLEARANCE
STANDARD
SERVICE LIMIT
IN
0.030 – 0.055 mm
(0.0012 – 0.0022 in)
0.08 mm
(0.003 in)
EX
0.055 – 0.080 mm
(0.0022 – 0.0031 in)
0.11 mm
(0.004 in)
If the stem-to-guide clearance exceeds the service limit,
replace the valve and the valve guide as a set (P. 10-26).
NOTICE
Recondition the valve seat whenever replacing the valve guide
(P. 10-28).
• VALVE SEAT WIDTH
IN/EX
STANDARD
SERVICE LIMIT
1.25 – 1.55 mm
(0.049 – 0.061 in)
2.0 mm
(0.08 in)
If the valve seat width is under the standard, or over the service
limit, or if the valve seat is too high/low, recondition the valve
seat (P. 10-28).
[1] VALVE SEAT
TOO LOW
[3] VALVE SEAT
TOO HIGH
[2]
SEAT
WIDTH
• VALVE INTALLATION HEIGHT
STANDARD
IN/EX
10-24
44.0 – 44.6 mm
(1.73 – 1.76 in)
SERVICE LIMIT
[1]
INTALLATION HEIGHT
• CYLINDER HEAD WARPAGE
1) Remove the carbon deposits from the combustion
chamber. Clean off any gasket material from the cylinder
head surface.
[1]
MEASUREMENT POINT
2) Check the spark plug holes and valve areas for cracks.
3) Check the cylinder head for warpage using a straight edge
and a feeler gauge.
SERVICE LIMIT
0.05 mm (0.002 in) Min.
NOTICE
Take care not to damage (scores, scratches, etc.) the
cylinder head at the mating surface with the gasket.
[2]
STRAIGHT EDGE
4) If the measurement exceeds the service limit, recondition.
NOTICE
Reconditioning must be made within the standard value of
the cylinder head height.
[3]
FEELER GAUGE
• CYLINDER HEAD HEIGHT
STANDARD
SERVICE LIMIT
103.95 – 104.05 mm
(4.093 – 4.096 in)
[1]
CYLINDER
HEAD HEIGHT
Cylinder head reconditioning procedure:
Apply Prussian Blue compound to the level block to identify the
warpage, and using a fine oil stone, grind the cylinder head in
the figure of “8” with the warped part being the center of the
ground part. Or use the lapping machine to recondition the
cylinder head.
• 11 x 155 mm BOLT-WASHER (CYLINDER HEAD
BOLT) O.D.
1) Measure the bolt O.D. at two points as shown.
SERVICE LIMIT
10.6 mm (0.42 in)
2) If the measurement is below the service limit, replace the
bolt.
10-25
50 mm (2.0 in)
45 mm
(1.8 in)
8. VALVE GUIDE REPLACEMENT
1) Chill the replacement valve guides in the freezer section of
a refrigerator for about an hour.
2) Drive the valve guide out of the combustion chamber side
using a special tools.
TOOL:
Valve guide driver, 5.5 mm
[1]
VALVE GUIDE
DRIVER, 5.5 mm
07742-0010100
07742-0010100
CAUTION
When driving the valve guides out, be careful not to
damage head.
3) Remove the new valve guides from the refrigerator one at
a time as needed.
[1]
VALVE GUIDE
4) Install the new valve guides from the valve spring side of
the cylinder head. Drive each valve guide as shown.
Valve guide
projection height
IN
15.2 – 16.2 mm
(0.60 – 0.64 in)
EX
15.5 – 16.5 mm
(0.61 – 0.65 in)
[2] PROJECTION
HEIGHT
5) After installation, inspect the valve guide for damage.
Replace any damaged valve guide.
• VALVE GUIDE REAMING
For best results, be sure the cylinder head is at room
temperature before reaming valve guides.
1) Coat the reamer and valve guide with cutting oil.
2) Rotate the reamer clockwise through the valve guide for
the full length of the reamer.
3) Continue to rotate the reamer clockwise while removing it
from the valve guide.
TOOL:
Valve guide reamer, 5.525 mm
10-26
07HAH-PJ70100
[1]
VALVE GUIDE
REAMER, 5.525 mm
07HAH-PJ70100
4) Thoroughly clean the cylinder head to remove any cutting
residue.
5) Check the valve guide bore; it should be straight, round and
centered in the valve guide, insert the valve and check
operation. If the valve does not operate smoothly, the guide
may have been bent during installation. Replace the valve
guide if it is bent or damaged.
6) Check the Valve Stem-to-Valve Guide Clearance (P. 10-24).
10-27
9. VALVE SEAT RECONDITIONING
1) Thoroughly clean the combustion chambers and valve
seats to remove carbon deposits. Apply a light coat of
Prussian Blue compound or erasable felt-tipped marker ink
to the valve faces.
2) Insert the valves, and then lift them and snap them closed
against their seats several times. Be sure the valve does not
rotate on the seat. The transfered marking compound will
show any area of the seat that is not concentric.
3) Using a 45˚ cutter, remove enough material to produce a
smooth and concentric seat. Follow the Valve Seat Cutter
Manufacturer's Instructions.
Turn the cutter clockwise, never counterclockwise.
Continue to turn the cutter as you lift it from the valve seat.
TOOLS:
Cutter holder, 5.5 mm
Valve seat cutter, 45˚ 35 mm
Valve seat cutter, 45˚ 33 mm
Valve seat cutter, 32˚ 38.5 mm
Valve seat cutter, 32˚ 33 mm
Valve seat cutter, 60˚ 30 mm
Valve seat cutter, 60˚ 37.5 mm
07781-0010101
07780-0010400
07780-0010800
07780-0012400
07780-0012900
07780-0014000
07780-0014100
[1]
VALVE FACE
[1] VALVE SEAT CUTER
45˚
[2]
IN, 35 mm: 07780-0010400
EX, 33 mm: 07780-0010800
60˚
[3]
IN, 37.5 mm: 07780-0014100
EX, 30 mm: 07780-0014000
32˚
[4]
IN, 38.5 mm: 07780-0012400
EX, 33 mm: 07780-0012900
[5]
CUTTER HOLDER,
5.5 mm
07781-0010101
4) Use the 30˚ – 32˚ and 60˚ cutters to narrow and adjust the
valve seat so that it contacts the middle of the valve face.
The 30˚ – 32˚ cutter removes material from the top edge.
The 60˚ cutter removes material from the bottom edge. Be
sure that the width of the finished valve seat is within
specification.
[2] OLD SEAT
WIDTH
[1]
CONTACT
TOO HIGH
30˚ – 32˚
[2] OLD SEAT
WIDTH
[3]
CONTACT
TOO LOW
60˚
10-28
• VALVE SEAT WIDTH
IN/EX
STANDARD
SERVICE LIMIT
1.25 – 1.55 mm
(0.049 – 0.061 in)
2.0 mm
(0.08 in)
5) Make a light pass with the 45˚ cutter to remove any possible
burrs at the edges of the seat.
1.25 – 1.55 mm
(0.049 – 0.061 in)
6) After resurfacing the seats, inspect for even valve seating.
Apply Prussian Blue compound or erasable felt-tipped
marker ink to the valve faces. Insert the valves, and then lift
them and snap them closed against their seats several
times. Be sure the valve does not rotate on teh seat. The
seating surface, as shown by the transferred marking
compound, should have good contact all the way around.
7) Lap the valves into their seats, using a hand valve lapper
and lapping compound (commercially available).
NOTICE
To avoid severe engine damage, be sure to remove all
lapping compound from the cylinder head before
assembly.
8) Check valve clearance after assembly.
10-29
[1]
VALVE LAPPER
(Commercially
available)
10. CYLINDER HEAD ASSEMBLY
ASSEMBLY
1) Apply molybdenum disulfide oil to the valve stem sliding
surface and insert the valve into the valve guide.
Check that the valve moves up and down smoothly.
[1]
VALVE SPRING
SEAT
[2]
MOLYBDENUM
DISULFIDE OIL
NOTICE
Do not confuse the intake valve and the exhaust valve on
assembly.
2) Install the valve spring seat.
[3]
VALVE
3) Apply engine oil to the inner wall of a new valve stem seal.
Set the valve stem seal in the special tool, and push it
straight into the valve guide by hand.
TOOL:
Stem seal driver
[1] SPRING (WHITE)
[2] SPRING (BLACK)
07PAD-0010000
NOTICE
Note that the valve stem seal A (intake side) has the white
spring and the valve stem seal B (exhaust side) has the
black spring. Do not confuse them on assembly.
[4] VALVE STEM
SEAL A
(INTAKE SIDE)
[5]
VALVE STEM
SEAL
[6]
STEM SEAL
DRIVER
07PAD-0010000
10-30
[3] VALVE STEM
SEAL B
(EXHAUST SIDE)
4) Install the valve spring and the valve spring retainer.
NOTICE
[1]
VALVE SPRING
Do not confuse the intake valve spring and the exhaust
valve spring.
<Identification>
The intake side can be identified with the pink paint on the
spring. The exhaust side can be identified with the gray
paint.
<Installation direction>
Install the intake and the exhaust valve springs with the
paint mark side toward the valve spring retainer.
[1] LOCATION OF VALVE
SPRING PAINT:
[2]
VALVE SPRING
RETAINER
[2]
PAINT
[1]
VALVE SPRING COMPRESSOR
ATTACHMENT
07757-PJ10100
5) Using the same special tool as that used during
disassembly, compress the valve springs and set the valve
keepers in the groove in the respective valve stems
securely.
TOOLS:
Valve spring compressor
Valve spring compressor attachment
07757-0010000
07757-PJ10100
[3]
VALVE
KEEPER (2)
[2]
VALVE SPRING
COMPRESSOR
07757-0010000
NOTICE
• Take care not to let the special tools contact the cylinder
head.
• Do not compress the valve springs more than necessary
as it causes weak valve spring.
• The valve keepers can be installed in the groove in the
valve stem by applying a small mount of grease to the
valve keepers and adhering them to the groove in the
valve stem.
6) Tap on the valve stem head lightly with a plastic hammer
two or three times and set the valve stem and keepers in
the proper position securely.
NOTICE
• Tap at right angles with each valve stem head. Take care
not to bend the valve.
• Support the cylinder head with a suitable material to
prevent damage to the valve.
10-31
[1]
PLASTIC
HAMMER
11. CYLINDER HEAD ASSEMBLY
INSTALLATION
[1]
PROJECTION
NOTICE
[2]
CYLINDER
HEAD
GASKET
• Do not let any foreign material enter the gap between the
gasket, cylinder head and the cylinder block.
• Take care not to damage (scores, scratches, etc.) the cylinder
head and the cylinder block at the mating surface with the
gasket.
• Do not bend the cylinder head gaskets as they are the metal
gaskets.
• Keep the cam chain away from the magnetic parts.
1) Clean the cylinder head and cylinder block mounting
surfaces.
2) Install the two dowel pins on the cylinder block.
Install a new cylinder head gasket on the cylinder block by
setting the projection of the cylinder head gasket in the
position shown.
[3] 14 x 20 mm
DOWEL PIN (2)
[1] CRANKSHAFT
SPROCKET
3) Align the “ ” mark on the crankshaft sprocket with the
“ ” mark on the cylinder block.
[2] “
4) Align the dowel pins on the cylinder block with the dowel
pin installation positions of the cylinder head assembly as
shown, and install the cylinder head assembly on the
cylinder block.
10-32
” MARKS
[1]
CYLINDER HEAD
ASSEMBLY
5) Apply engine oil to the threads and the washer seat of the
ten 11 x 155 mm bolt-washers, and loosely tighten them on
the cylinder head assembly.
[1]
11 x 155 mm
BOLT-WASHER (10)
6) Tighten the 11 x 155 mm bolt-washers to the specified
torque in the numbered sequence in two or three steps.
After tightening to the specified torque, tighten each bolt in
the numbered sequence twice in increments of 90˚.
When a bolt is replaced with a new one, tighten
additionally to 98˚.
TORQUE:
Used bolt: 39 N.m (4.0 kgf.m, 29 lbf.ft) + 90˚ + 90˚
New bolt: 39 N.m (4.0 kgf.m, 29 lbf.ft) + 90˚ + 90˚ + 98˚
7) Install the following parts.
– Exhaust manifold (P. 5-155)
– Injector base (P. 5-139)
– Fuel line assembly (P. 5-140)
– Throttle body/intake manifold (P. 5-132)
– Camshaft/rocker arm (P. 10-34)
– Crankshaft pulley/cam chain (P. 9-11)
– Cylinder head cover (P. 10-40)
– L./R. side cover brackets (P. 4-30)
– Ignition coil/spark plug (P. 3-8)
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)
10-33
⑨
⑩
⑤
⑥
①
②
④
③
⑧
⑦
12. CAMSHAFT/ROCKER ARM
ASSEMBLY
[1]
Apply a bead
of the liquid
gasket.
1) Degrease the cylinder head mating surface of the No.5
rocker shaft holder with the degreasing cleaning agent.
2) Apply a bead [ø2.0 – 3.0 mm (ø0.08 – 0.12 in)] of the liquid
gasket (ThreeBond® #1280B or equivalent) to the indicated
area of the No.5 rocker shaft holder.
NOTICE
• Assemble the No.5 rocker shaft holder within 5 minutes
after application of the liquid gasket. If it has been left for
5 minutes or longer, remove the old liquid gasket and
apply the liquid gasket again.
• Do not pour the engine oil in the oil tank at least 30
minutes after assembly.
[1]
ROCKER ARM
ASSEMBLY
3) Set the ten dowel pins on the cylinder head assembly.
4) Insert the bolts into each of the rocker shaft holders and
install the rocker arm assembly on the cylinder head
assembly.
[3]
10 x 16 mm
DOWEL PIN (10)
5) Apply engine oil to the threads and seat of the 14 mm
sealing bolts.
Install the camshaft collar on the intake camshaft and the
CMP pulse plate on the exhaust camshaft, then tighten the
14 mm sealing bolts to the specified torque.
[1]
CAMSHAFT
COLLAR
[2]
BOLT (4)
[2] EXHAUST
CAMSHAFT
[3]
CMP PULSE
PLATE
TORQUE: 39 N.m (4.0 kgf.m, 29 lbf.ft)
NOTICE
• Tighten the bolt while holding the hex. part of the
camshaft with a wrench or equivalent tool.
• Do not damage (scores, scratches, etc.) the cams and
journals of the camshaft journal.
10-34
[5]
INTAKE
CAMSHAFT
[4]
14 mm SEALING
BOLT (2)
6) Apply molybdenum disulfide oil to the journals and cam surfaces of the camshafts.
7) Install the intake/exhaust camshafts, ten dowel pins, camshaft holders and the cam chain guide B.
NOTICE
Install the camshafts with the No.1 piston at the top dead
center of the compression stroke (i.e. dowel pin at your
side).
8) Apply engine oil to the threads and seat of each bolt and loosely tighten to the designated position respectively.
[1]
INTAKE CAMSHAFT
[2]
EXHAUST CAMSHAFT
[3]
CAM CHAIN GUIDE B
8 x 110 (2)
[4]
HEAD COVER
BOLT (6)
8 x 90 (12)
6 x 20 (2)
[7]
MOLYBDENUM
DISULFIDE OIL
[6]
10 x 16 mm
DOWEL PIN (10) [5]
CAMSHAFT
HOLDER
6 x 32
9) Tighten each bolt to the specified torque in the numbered
sequence in two or three steps.
TORQUE:
Head cover bolt,
8 x 90 mm flange bolt,
8 x 110 mm flange bolt: 22 N.m (2.2 kgf.m, 16 lbf.ft)
6 x 20 mm flange bolt,
6 x 32 mm flange bolt: 12 N.m (1.2 kgf.m, 9 lbf.ft)
o u
i
p
q 9
0
w
a
3 1
2
4
7 5
6
8
t e
r
y
d
10-35
s
10) Secure the hex. part of the exhaust camshaft with a wrench
or equivalent tool.
11) Install the exhaust camshaft sprocket on the exhaust
camshaft by aligning the concave in the exhaust camshaft
sprocket with the dowel pin on the exhaust camshaft.
Tighten the 10 x 32 mm flange bolt on the exhaust camshaft
to the specified torque.
[1]
EXHAUST CAMSHAFT
[1]
EXHAUST CAMSHAFT
SPROCKET
[2]
CONCAVE
[3]
EXHAUST
CAMSHAFT
TORQUE: 72 N.m (7.3 kgf.m, 53 lbf.ft)
[4]
DOWEL PIN
12) Secure the hex. part of the intake camshaft with a wrench
or equivalent tool.
10-36
[1]
INTAKE CAMSHAFT
13) Install the intake camshaft sprocket on the intake camshaft
by aligning the concave in the intake camshaft sprocket
with the dowel pin on the intake camshaft.
Tighten the VTEC flange bolt on the intake camshaft to the
specified torque.
[1]
INTAKE CAMSHAFT
SPROCKET
[2]
CONCAVE [3]
INTAKE
CAMSHAFT
TORQUE: 113 N.m (11.5 kgf.m, 83 lbf.ft)
[4] DOWEL PIN
14) Apply engine oil to the outer surface of the new 15.2 x 1.9
mm O-rings, and install the O-rings on the CMP sensor and
CMP hole plug.
15) Install the CMP sensor (exhaust side) and the CMP hole
plug (intake side) in the CMP sensor holes in the No.5
rocker shaft holder. Tighten the CMP sensor and CMP hole
plug with the 6 x 16 mm flange bolts respectively.
6 x 16 (2)
[1]
CMP HOLE PLUG
[2]
CMP SENSOR
16) Connect the CMP sensor 3P connector and set the harness
band clip on the clip bracket F.
17) Install the crankshaft pulley/cam chain (P. 9-11) and adjust
the valve clearance (P. 3-9).
18) Install the following parts.
– Cylinder head cover (P. 10-40)
– Ignition coil/spark plug (P. 3-8)
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)
[1]
CLIP
BRACKET F
[2]
HARNESS BAND
CLIP
10-37
[3]
CMP SENSOR 3P
CONNECTOR
13. CYLINDER HEAD COVER
ASSEMBLY
[1] <Spark plug tube seal
installation direction>
1) Install the spark plug tube seals on the cylinder head cover
noting the installation direction of the seal.
[2]
SPARK PLUG TUBE
SEAL (4)
2) Clean the groove of the cylinder head cover and clean the
head cover gasket.
[1]
HEAD COVER
GASKET
3) Install the head cover gasket on the cylinder head cover.
[2]
CYLINDER HEAD
COVER
10-38
[3]
CYLINDER HEAD
COVER
4) Connect the oil tube to the cylinder head cover by aligning
the projection on the oil tube with the projection on the
cylinder head cover.
Check that the oil tube is inserted in the cylinder head cover
securely.
[1]
CYLINDER HEAD
COVER
5) Set the tube clip D32.5 with the lugs in the position shown.
[2]
PROJECTIONS
[3]
TUBE CLIP
D32.5
[5]
LUGS
10-39
[4]
OIL TUBE
14. CYLINDER HEAD COVER
INSTALLATION
1) Thoroughly clean the cylinder head/cylinder head cover
mating surfaces using a degreasing cleaning agent.
2) Apply a bead [ø2.0 – 3.0 mm (ø0.08 – 0.12 in)] of the liquid
gasket (ThreeBond® #1280B or equivalent) to the cylinder
head/chain case mating surfaces and to the No.5 rocker
shaft holder as shown.
[1]
Apply a bead
of liquid
gasket.
NOTICE
• Assemble the cylinder head cover within 5 minutes after
application of the liquid gasket. If it has been left for 5
minutes or longer, remove the old liquid gasket and apply
the liquid gasket again.
• Do not pour the engine oil in the oil tank at least 30
minutes after assembly.
3) Apply soapy water to the spark plug tube seal lip of the
cylinder head cover.
4) Install the cylinder head cover on the cylinder head by
aligning the spark plug tube with the spark plug tube seal.
NOTICE
• Check the spark plug tube seals for breakage and fatigue
when installing the cylinder head cover.
• After installation, check that the spark plug tube seals are
not turned up but they are set properly.
• Wipe up the oozing soapy water.
[1]
Apply soapy water
to the lip.
[2]
SPARK PLUG
TUBE SEAL (4)
5) After installation, swing the cylinder head cover lightly to
make the head cover gasket fit on the cylinder head cover.
6) Install the six head cover washers and loosely tighten the
six 6 mm hex. cap nuts.
[3]
SPARK PLUG
TUBE (4)
[4]
CYLINDER HEAD COVER
[5]
HEAD COVER WASHER (6)
[6]
6 mm HEX. CAP
NUT (6)
10-40
7) Tighten the 6 mm hex. cap nuts to the specified torque in
the numbered sequence in two or three steps.
TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)
③
④
①
②
⑤
⑥
8) Move the water relief tube A from the other side of the
projection on the cylinder head cover to your side.
[1]
WATER RELIEF
TUBE A
[2]
PROJECTION
[3]
CYLINDER HEAD COVER
9) Connect the fuel tube B and D to the fuel pump (low
pressure side).
[1] TUBE CLIPS
(Commercially
available)
[4]
FUEL TUBE D
10-41
[2]
FUEL
TUBE B
[3]
FUEL PUMP
(Low pressure
side)
10) Connect the oil tube to the mounting case.
After connection, check that the oil tube is inserted in the
mounting case securely.
[1]
OIL TUBE
[2]
MOUNTING CASE
11) Install the R. side cover bracket assembly on the engine
assembly and tighten the two 6 x 22 mm flange bolts.
[1]
R. SIDE COVER
BRACKET ASSEMBLY
6 x 22 (2)
12) Connect the breather tube and the main wire harness to the
cylinder head cover.
[1]
PROJECTION
NOTICE
Route the main wire harness so it sets on the projections on
the cylinder head cover securely.
13) Install the following parts.
– Ignition coil/spark plug (P. 3-8)
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)
[2]
MAIN WIRE
HARNESS
[3]
BREATHER
TUBE
10-42
[2]
MAIN WIRE
HARNESS
11. OIL PUMP/FLYWHEEL
1. EOP SWITCH/OIL FILTER
FLANGE
2. OIL PUMP
3. FLYWHEEL
12 N.m (1.2 kgf.m, 9 lbf.ft)
8 N.m (0.8 kgf.m, 5.8 lbf.ft)
12 N.m (1.2 kgf.m, 9 lbf.ft)
22 N.m (2.2 kgf.m, 16 lbf.ft)
118 N.m (12.0 kgf.m, 87 lbf.ft)
39 N.m (4.0 kgf.m,
29 lbf.ft)
32 N.m (3.3 kgf.m, 24 lbf.ft)
11-1
1. EOP SWITCH/OIL FILTER FLANGE
a. DISASSEMBLY
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under covers (P. 4-9)
1) Drain the engine oil (P. 3-2) and remove the oil filter using
the special tool as shown.
TOOL:
Oil filter wrench
07HAA-PJ70101
2) Remove the EOP switch (low pressure side).
3) Disconnect the water tube E and 7 x 160 mm tube from the
oil filter flange.
4) Remove the oil filter flange.
5) Disconnect the ECT sensor 2P connector and the EOP
switch (high pressure side) 2P connector.
Remove the ECT sensor and the EOP switch (high pressure
side).
[1]
13 x 1.5 mm O-RING
Do not reuse.
[2]
9.5 x 1.9 mm O-RING
Do not reuse.
[1]
OIL FILTER
WRENCH
07HAA-PJ70101
[3]
ECT SENSOR
12 N.m (1.2 kgf.m, 9 lbf.ft)
[4]
TUBE CLAMP D10.5 (2)
[5]
EOP SWITCH
(LOW PRESSURE SIDE)
8 N.m (0.8 kgf.m, 5.8 lbf.ft)
6 x 25 (4)
[6]
OIL FILTER
12 N.m (1.2 kgf.m,
9 lbf.ft)
[7]
OIL FILTER FLANGE
[11]
EOP SWITCH
(HIGH PRESSURE SIDE)
[10]
22 N.m (2.2 kgf.m,
WATER TUBE E
16 lbf.ft)
INSPECTION:
Check the tube for
deterioration. Replace
the tube if necessary.
11-2
6 x 20
[9]
22.5 x 24 mm
O-RING (2)
Do not reuse.
[8]
7 x 160 mm TUBE
INSPECTION:
Check the tube for deterioration.
Replace the tube if necessary.
b. INSPECTION
Check for continuity between the terminal and body.
If there is no continuity, replace the EOP switch
c. ASSEMBLY
1) Apply engine oil to a new 13 x 1.5 mm O-ring and install it
on the ECT sensor.
2) Tighten the ECT sensor to the specified torque and connect
the ECT sensor 2P connector.
TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)
[1]
9.5 x 1.9 mm O-RING
[2]
ECT SENSOR
3) Apply engine oil to the 9.5 x 1.9 mm O-ring and install it on
the EOP switch (high pressure side).
4) Tighten the EOP switch (high pressure side) to the specified
torque and connect the EOP switch (high pressure side) 2P
connector.
TORQUE: 22 N.m (2.2 kgf.m, 16 lbf.ft)
[4]
13 x 1.5 mm O-RING
11-3
[3]
EOP SWITCH
(High pressure side)
5) Apply engine oil to a new 22.5 x 24 mm O-ring and install it on the oil filter flange.
6) Install the oil filter flange and tighten the 6 x 20 mm flange bolt and the four 6 x 25 mm flange bolts securely.
7) Connect the water tube E and the 7 x 160 mm tube to the oil filter flange, and clamp the tube with the tube clamp
D10.5 securely.
[1]
WATER TUBE E
[2]
TUBE CLAMP D10.5 (2)
6 x 25 (4)
[3]
OIL FILTER FLANGE
6 x 20
[5]
22.5 x 24 mm O-RING (2)
[4]
7 x 160 mm TUBE
8) Apply engine oil to the O-ring that is set in the new oil filter.
[1]
O-RING
9) Clean the oil filter mounting part of the engine side oil filter
flange and apply engine oil to the stud.
Tighten the oil filter by hand.
[1]
OIL FILTER
11-4
10) Then, tighten it to the specified torque using the same
special tool as that used during disassembly.
TOOL:
Oil filter wrench
07HAA-PJ70101
TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)
[1]
OIL FILTER
WRENCH
07HAA-PJ70101
11) Before installing the EOP switch (low pressure side), clean
the switch and apply the liquid gasket (ThreeBond® #1215
or equivalent) to the area shown.
NOTICE
Take care not to put the liquid gasket on the switch end and
the oil passage.
[1]
APPLICATION
AREA
12) Tighten the EOP switch (low pressure side) to the specified
torque using the torque wrench.
TORQUE: 8 N.m (0.8 kgf.m, 5.8 lbf.ft)
[1]
EOP SWITCH
TERMINAL
NOTICE
Use the torque wrench to tighten the EOP switch (low
pressure side). Do not overtighten the EOP switch as it can
damage the oil filter flange.
13) Connect the EOP switch terminal to the EOP switch (low
pressure side).
14) Add the specified amount of the engine oil (P. 3-2).
After adding the oil, check each joint for oil leakage.
15) Install the following parts.
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)
[2]
EOP SWITCH
(LOW PRESSURE SIDE)
11-5
2. OIL PUMP
a. REMOVAL
1) Remove the engine from the outboard motor (P. 7-2).
2) Remove the five 8 x 32 mm flange bolts. Remove the oil pump body assembly, oil pump body gasket, 14 x 20 mm
dowel pin and the 10 x 16 mm dowel pin.
Replace the oil pump body gasket with a new one on assembly.
[2]
14 x 20 mm
DOWEL PIN
[1]
OIL PUMP BODY
ASSEMBLY
[3]
10 x 16 mm
DOWEL PIN
[4]
OIL PUMP BODY
GASKET
8 x 32 (5)
11-6
b. DISASSEMBLY
[1]
31 x 46 x 7 mm OIL SEAL
[2]
6 x 16 mm FLAT
SCREW (9)
INSPECTION:
• Check the oil seal lip for
breakage or other damage.
Replace if necessary.
• Do not reuse. Replace on
assembly.
[3]
OIL PUMP COVER
[11]
INNER ROTOR
[4]
5 x 8 mm DOWEL PIN (2)
[10]
OUTER ROTOR
[5]
OIL PUMP BODY
[6]
RELIEF VALVE
[7]
18 mm SEALING BOLT
39 N.m (4.0 kgf.m, 29 lbf.ft)
[9]
46 x 60 x 9 mm OIL SEAL
INSPECTION:
• Check the oil seal lip for
breakage or other damage.
Replace if necessary.
• Do not reuse. Replace on
assembly.
11-7
[8]
RELIEF VALVE
SPRING
c. INSPECTION
• OIL PUMP BODY I.D.
STANDARD
SERVICE LIMIT
84.000 – 84.030 mm
(3.3071 – 3.3083 in)
• OIL PUMP BODY DEPTH
STANDARD
SERVICE LIMIT
9.520 – 9.550 mm
(0.3748 – 0.3760 in)
• OUTER ROTOR HEIGHT
STANDARD
9.480 – 9.500 mm
(0.3732 – 0.3740 in)
11-8
SERVICE LIMIT
• INNER ROTOR-TO-OUTER ROTOR CLEARANCE
STANDARD
SERVICE LIMIT
0.04 – 0.16 mm
(0.002 – 0.006 in)
0.20 mm
(0.008 in)
• OUTER ROTOR-TO-PUMP BODY CLEARANCE
STANDARD
SERVICE LIMIT
0.02 – 0.07 mm
(0.001 – 0.003 in)
0.12 mm
(0.005 in)
• OUTER ROTOR-TO-OIL PUMP BODY SIDE
CLEARANCE
STANDARD
SERVICE LIMIT
0.14 – 0.19 mm
(0.006 – 0.007 in)
0.20 mm
(0.008 in)
11-9
d. ASSEMBLY
[1]
OIL PUMP BODY
1) Apply thread locking agent to the threads of the 18 mm
sealing bolt.
2) Check the relief valve surface for scores, scratches and
other damage. Apply engine oil to the relief valve and the
relief valve spring.
3) Install the relief valve and the relief valve spring in the oil
pump body, and tighten the 18 mm sealing bolt to the
specified torque.
TORQUE: 39 N.m (4.0 kgf.m, 29 lbf.ft)
[4]
RELIEF
VALVE
4) Clean the inner rotor and the outer rotor thoroughly. Apply
engine oil to the inner and outer rotors and install them on
the oil pump body.
Note to install the rotors in the same direction as the
direction of the rotors noted on disassembly.
[1]
OIL PUMP
COVER
[4]
5 x 8 mm
DOWEL PIN (2)
11-10
[2]
18 mm SEALING
BOLT
[2]
INNER ROTOR
[1]
OIL PUMP
BODY
5) Install the two dowel pins and the oil pump cover on the oil
pump body and tighten the nine 6 x 16 mm flat screws.
Check that the rotors move smoothly.
[3]
RELIEF VALVE
SPRING
[3]
OUTER ROTOR
[2] 6 x 16 mm FLAT
SCREW (9)
[3]
OIL PUMP
BODY
6) Apply soapy water to the outer surface of each new oil seal.
7) Using the special tools, drive the 46 x 60 x 9 mm oil seal into the oil pump body and the 31 x 46 x 7 mm oil seal into
the oil pump cover so they set in the respective position of the dimensions shown.
– Install the 46 x 60 x 9 mm oil seal so that the distance from the oil pump body end to the oil seal surface is 27.4 –
28.0 mm (1.08 – 1.10 in) (dimension A).
– Install the 31 x 46 x 7 mm oil seal so that the distance from the oil pump body end to the oil seal surface is 63.9 –
64.5 mm (2.52 – 2.54 in) (dimension B) with the oil pump cover installed with the flat screws.
TOOLS:
Driver
Oil seal driver attachment, 72 mm
Oil seal driver
07749-0010000
07947-6340201
07947-SB00100
8) After installing the oil seals, apply grease to each oil seal lip.
[1] 46 x 60 x 9 mm [2] <Oil seal installation
OIL SEAL
direction>
[9]
OIL SEAL DRIVER
ATTACHMENT, 72 mm
07947-6340201
[5] 31 x 46 x 7 mm
OIL SEAL
[2] <Oil seal installation
direction>
[3] (Apply grease
to the lip.)
[3] (Apply grease
to the lip.)
[4]
DRIVER
07749-0010000
[4]
DRIVER
07749-0010000
[8]
OIL PUMP BODY
[7]
OIL SEAL DRIVER
07947-SB00100
[6]
OIL PUMP COVER
[10] DIMENSION B
[11] DIMENSION A
e. INSTALLATION
1) Install the 14 x 20 mm dowel pin, 10 x 16 mm dowel pin,
and the new oil pump body gasket on the engine side.
Install the oil pump body and tighten the five 8 x 32 mm
flange bolts.
[1]
OIL PUMP
BODY
ASSEMBLY
[2]
14 x 20 mm
DOWEL PIN
2) Install the engine on the outboard motor (P. 7-6).
[3]
10 x 16 mm
DOWEL PIN
8 x 32 (5)
11-11
[4]
OIL PUMP
BODY GASKET
3. FLYWHEEL
a. REMOVAL
1) Remove the engine from the outboard motor (P. 7-2).
2) Remove the oil pump body assembly (P. 11-6).
3) Set the special tool on the starter motor mounting part and
temporarily tighten the special tool using the 10 mm bolts,
10 mm washers and the 10 mm nuts.
[1]
10 mm BOLT (2)
NOTICE
• Do not damage the mating surface of the oil pump body
gasket on the cylinder block.
• Check that the special tool is set on the ring gear securely.
TOOL:
Ring gear holder
[3]
10 mm NUT (2)
[2]
RING GEAR HOLDER
070PB-ZY60100
070PB-ZY60100
4) Remove the eight 8 mm special bolts and the flywheel
boss.
[1]
FLYWHEEL BOSS
[2]
8 mm SPECIAL
BOLT (8)
5) Remove the eight 12 mm bolts and the flywheel.
6) Remove the special tool.
[1]
12 mm BOLT (8)
[2]
FLYWHEEL
11-12
b. COMPONENTS DRAWING
[4]
14 x 20 mm
DOWEL PIN
[3]
FLYWHEEL
[2]
12 mm BOLT (8)
118 N.m (12.0 kgf.m, 87 lbf.ft)
[1]
FLYWHEEL BOSS
[5]
10 x 16 mm DOWEL PIN
[8]
8 mm SPECIAL BOLT (8)
32 N.m (3.3 kgf.m, 24 lbf.ft)
8 x 32 (5)
[6]
OIL PUMP BODY
GASKET
[7]
OIL PUMP BODY ASSEMBLY
11-13
c. INSPECTION
[1]
FLYWHEEL
Check the ring gear for wear and damage. If it is worn or
damaged, check the starter motor pinion gear.
[2]
RING GEAR
d. INSTALLATION
1) Clean the crankshaft and flywheel mating surfaces
thoroughly with the degreasing cleaning agent.
⑦
①
2) Apply engine oil to the threads and seating surface of the
12 mm bolts.
④
⑤
3) Install the flywheel on the crankshaft and loosely tighten
the eight 12 mm bolts. Install the special tool, that had been
used for removal, on the starter motor mounting part (P. 1112).
⑥
③
4) Tighten the 12 mm bolts to the specified torque in the
numbered sequence in two or three steps.
②
⑧
TORQUE: 118 N.m (12.0 kgf.m, 87 lbf.ft)
5) Clean the flywheel and flywheel boss mating surfaces
thoroughly with the degreasing cleaning agent.
6) Apply engine oil to the threads and seating surface of the 8
mm special bolts.
7) Install the flywheel boss on the flywheel and loosely
tighten the eight 8 mm special bolts.
8) Tighten the 8 mm special bolts to the specified torque in the
numbered sequence in two to three steps.
TORQUE: 32 N.m (3.3 kgf.m, 24 lbf.ft)
①
⑦
⑤
④
③
NOTICE
Be sure to clean the mating surfaces of the crankshaft,
flywheel and the flywheel boss thoroughly with the
degreasing cleaning agent.
9) Remove the special tool.
10) Install the oil pump body assembly (P. 11-11).
11) Install the engine on the outboard motor (P. 7-6).
11-14
⑥
⑧
②
12. CRANKCASE/BALANCER
1. CRANKCASE/BALANCER CASE
ASSEMBLY REMOVAL
2. BALANCER CASE ASSEMBLY
DISASSEMBLY
3. INSPECTION
4. BALANCER CASE ASSEMBLY
ASSEMBLY
5. CRANKCASE/BALANCER CASE
ASSEMBLY INSTALLATION
12 N.m (1.2 kgf.m, 9 lbf.ft)
44 N.m (4.5 kgf.m, 33 lbf.ft)
22 N.m (2.2 kgf.m, 16 lbf.ft)
22 N.m (2.2 kgf.m, 16 lbf.ft)
44 N.m (4.5 kgf.m, 33 lbf.ft)
12 N.m (1.2 kgf.m, 9 lbf.ft)
12-1
1. CRANKCASE/BALANCER CASE
ASSEMBLY REMOVAL
6 x 25 (15)
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under covers (P. 4-9)
– Silencer case (P. 5-128)
– Throttle body/intake manifold (P. 5-129)
– Silencer duct (P. 6-2)
– Electric parts/main harness (P. 18-1, 15, 19 and 27)
1) Move the remote control lever to the “N” (Neutral)
position.
2) Turn the crankshaft pulley clockwise until it sets the No.1
piston at the top dead center of its compression stroke (P.
3-12).
Remove the following parts.
– Crankshaft pulley/cam chain (P. 9-2)
3) Remove the engine from the outboard motor (P. 7-2).
4) Remove the fifteen 6 x 25 mm flange bolts from the
crankcase.
5) Insert the screwdriver into the recesses of the crankcase
and raise the crankcase little by little.
NOTICE
Take care not to damage the crankcase and lower block
mating surfaces.
[1]
RECESS
6) Remove the crankcase and the two dowel pins from the
lower block.
[1]
RECESS
[1]
CRANKCASE
[2]
13 x 20 mm
DOWEL PIN (2)
12-2
7) Remove the two chain guide bolts and remove the balancer
chain guide.
Remove the three 6 x 14 mm flange bolts and remove the
balancer chain tensioner.
8) Hold the rear balancer shaft by inserting the special tool
into the maintenance hole in the front balancer.
Remove the 10 x 30 mm bolt-washer and remove the
crankshaft sprocket, driven sprocket and the balancer
chain.
TOOL:
Pin driver, 6.0 mm
6 x 14 (3)
[1]
BALANCER CHAIN
TENSIONER
[2]
CHAIN GUIDE
BOLT (2)
[3]
BALANCER
CHAIN GUIDE
07744-0010500
NOTICE
Check that the special tool is inserted in the balancer case
assembly securely.
[1]
PIN DRIVER, 6.0 mm
07744-0010500
[1]
DRIVEN SPROCKET
[2]
MAINTENANCE HOLE
[3]
REAR BALANCER SHAFT
[2]
10 x 30 mm
BOLT-WASHER
[4]
BALANCER CHAIN
[3]
CRANKSHAFT
SPROCKET
9) Remove the special tool from the balancer case assenbly.
10) Remove the two 10 x 105 mm flange bolts, 8 x 75 mm
flange bolt and the 8 x 50 mm flange bolt. Remove the
balancer case assembly and the two dowel pins.
10 x 105 (2)
8 x 50
8 x 75
[1]
BALANCER CASE
ASSEMBLY
[3]
12 x 16 mm
DOWEL PIN
12-3
[2]
18 x 13 mm
DOWEL PIN
COMPONENTS DRAWING
6 x 25 (15)
12 N.m (1.2 kgf.m, 9 lbf.ft)
6 x 14
[2]
CABLE
BRACKET B
[1]
CRANKCASE
[16]
26 x 2.7 mm O-RING
Do not reuse.
[15]
OIL CAP
10 x 105 (2)
44 N.m (4.5 kgf.m,
33 lbf.ft)
8 x 20 (2)
8 x 50
22 N.m (2.2 kgf.m,
16 lbf.ft)
[14]
ENGINE HANGER
8 x 75
22 N.m (2.2 kgf.m, 16 lbf.ft)
[3]
BALANCER CASE
ASSEMBLY
[13]
BALANCER CHAIN TENSIONER
6 x 14 (3)
[4]
13 x 20 mm
DOWEL PIN (2)
[12]
DRIVEN SPROCKET
[11]
BALANCER CHAIN
[10]
12 x 16 mm
DOWEL PIN
[5]
18 x 13 mm
DOWEL PIN
[9]
10 x 30 mm BOLT-WASHER
44 N.m (4.5 kgf.m, 33 lbf.ft)
[6]
BALANCER CHAIN GUIDE
[8]
CRANKSHAFT
SPROCKET
12-4
[7]
CHAIN GUIDE BOLT (2)
12 N.m (1.2 kgf.m, 9 lbf.ft)
2. BALANCER CASE ASSEMBLY DISASSEMBLY
6 x 32 (3)
12 N.m (1.2 kgf.m,
9 lbf.ft)
6 x 25 (2)
12 N.m (1.2 kgf.m,
9 lbf.ft)
8 x 55 (3)
27 N.m (2.8 kgf.m, 20 lbf.ft)
[1]
REAR BALANCER
HOLDER
[7]
REAR BALANCER
SHAFT
[2]
BALANCER SHAFT
BEARING (4)
INSPECTION:
Check the bearings for damage
and replace if necessary.
After replacing the bearing,
check the oil clearance (P. 12-6).
[6]
8 x 10 mm
DOWEL PIN (2)
[3]
12 x 16 mm
DOWEL PIN (2)
[5]
FRONT BALANCER
SHAFT
[4]
FRONT BALANCER
HOLDER
12-5
3. INSPECTION
• BALANCER SHAFT JOURNAL O.D.
Measure the O.D. of the balancer shaft No.1 journal.
STANDARD
SERVICE LIMIT
Front
19.938 – 19.950 mm
(0.7850 – 0.7854 in)
19.92 mm
(0.784 in)
Rear
23.938 – 23.950 mm
(0.9424 – 0.9429 in)
23.92 mm
(0.942 in)
If the measurement exceeds the service limit, replace the
balancer shaft.
• BALANCER SHAFT AXIAL FREE PLAY
1) Assemble the balancer case assembly (P. 12-7).
2) Measure the balancer shaft axial play with the dial indicator
by moving the balancer shaft back and force.
STANDARD
SERVICE LIMIT
0.060 – 0.140 mm
(0.0024 – 0.0055 in)
0.15 mm
(0.006 in)
3) If the measurement exceeds the service limit, replace the
balancer case assembly.
• BALANCER SHAFT OIL CLEARANCE
1) Clean the balancer shaft No.2 journal and the balancer
holder bearing. Check the journal and the bearing for
damage and wear.
2) Assemble the balancer case assembly (P. 12-7).
3) Remove the rear balancer holder. Set a plastigauge on the
balancer shaft No.2 journal as shown.
[1]
PLASTIGAUGE
NOTICE
• Set the plastigauge in the axial direction on the balancer
shaft No.2 journal.
• Do not turn the balancer shaft while checking oil
clearance.
4) Reinstall the rear balancer holder and tighten the bolts to
the specified torque (P. 12-7).
5) Remove the rear balancer holder. Measure the width of the
pressed part of the plastigauge using the scale printed on
the bag of the plastigauge.
[1]
PLASTIGAUGE
NOTICE
Measure the widest width on the plastigauge.
STANDARD
SERVICE LIMIT
0.060 – 0.120 mm
(0.0024 – 0.0047 in)
0.15 mm
(0.006 in)
6) If the measurement exceeds the service limit, replace the
balancer shaft bearing and recheck the oil clearance.
If the measurement still exceeds the service limit, replace
the balancer shaft.
12-6
[2]
SCALE
4. BALANCER CASE ASSEMBLY
ASSEMBLY
[1]
BALANCER SHAFT
BEARING
[2]
PROJECTION
1) Install the four balancer shaft bearings on the front/rear
balancer holders by aligning the projection on each
balancer shaft bearing with the concave at the
corresponding bearing installation part of the front/rear
balancer shaft.
[3]
CONCAVE
2) Apply molybdenum disulfide oil to each journal of the
balancer shaft.
3) Install the front and rear balancer shafts on the front
balancer holder while aligning the alignment marks on
each of the front and rear balancer shaft gears as shown.
[1]
FRONT
BALANCER
SHAFT
[2]
REAR BALANCER
SHAFT
[3]
MOLYBDENUM
DISULFIDE OIL
[4] ALIGNMENT
MARKS
[5] FRONT BALANCER
HOLDER
4) Apply engine oil to the threads and seat of the 8 x 55 mm
flange bolts.
5) Install the four dowel pins and the rear balancer holder on
the front balancer holder. Tighten the bolts to the specified
torque.
TORQUE:
8 x 55 mm flange bolt: 27 N.m (2.8 kgf.m, 20 lbf.ft)
6 x 32 mm flange bolt,
6 x 25 mm flange bolt: 12 N.m (1.2 kgf.m, 9 lbf.ft)
12-7
[1]
REAR
BALANCER
HOLDER
6 x 32 (3)
8 x 55 (3)
6 x 25 (2)
[3]
8 x 10 mm
DOWEL PIN
(2)
[2]
12 x 16 mm
DOWEL PIN
(2)
5. CRANKCASE/BALANCER CASE
ASSEMBLY INSTALLATION
10 x 105 (2)
8 x 50
8 x 75
1) Apply engine oil to the threads and seat of each bolt.
[1]
BALANCER CASE
ASSEMBLY
2) Install the balancer case assembly and the two dowel pins
on the lower block and tighten the bolts to the specified
torque.
TORQUE:
10 x 105 mm flange bolt: 44 N.m (4.5 kgf.m, 33 lbf.ft)
8 x 75 mm flange bolt,
8 x 50 mm flange bolt: 22 N.m (2.2 kgf.m, 16 lbf.ft)
[2]
18 x 13 mm
DOWEL PIN
[3]
12 x 16 mm
DOWEL PIN
3) Install the crankshaft sprocket on the crankshaft aligning
the projection on the crankshaft sprocket with the concave
in the crankshaft.
After installation, check that the “ ” mark on the
crankshaft sprocket aligns with the “ ” mark on the
cylinder block.
[1]
CRANKSHAFT
SPROCKET
[2]
CRANKSHAFT
NOTICE
The No.1 piston is at the top dead center of its compression
stroke when the “ ” mark on the crankshaft sprocket
aligns with the “ ” mark on the cylinder block.
[4]
PROJECTION
[3] CONCAVE
[5]
“ ” MARK
12-8
4) Align the alignment mark on the front balancer holder with
the projection on the rear balancer shaft.
[1]
REAR BALANCER
SHAFT
[2]
PROJECTION
5) Hold the rear balancer shaft by inserting the special tool
into the maintenance hole in the front balancer.
TOOL:
Pin driver, 6.0 mm
07744-0010500
[1]
PIN DRIVER, 6.0 mm
07744-0010500
[3]
ALIGNMENT
MARK
[2] MAINTENANCE
HOLE
NOTICE
Check that the special tool is inserted in the balancer case
assembly securely.
[3]
REAR BALANCER SHAFT
6) Install the balancer chain on the crankshaft sprocket while
aligning the “ ” mark on the crankshaft sprocket with the
color plate (1 place) of the balancer chain.
[1]
CRANKSHAFT
SPROCKET
[4]
COLOR PLATE (1 place)
7) Install the driven sprocket on the balancer chain while
aligning the alignment mark on the driven sprocket with
the color plates (2 places) of the balancer chain.
[2]
BALANCER
CHAIN
[3] “
” MARK
[1]
COLOR PLATE
(2 places)
[4]
ALIGNMENT
MARK
[3]
BALANCER
CHAIN
12-9
[2]
DRIVEN
SPROCKET
8) Install the driven sprocket together with the balancer chain
on the rear balancer shaft by aligning the concave in the
driven sprocket with the projection on the rear balancer
shaft.
TORQUE: 44 N.m (4.5 kgf.m, 33 lbf.ft)
[2] CONCAVE
[3] PROJECTION
[1]
10 x 30 mm
BOLT-WASHER
After installation, remove the special tool from the balancer
case assembly.
[5] DRIVEN
SPROCKET
[4]
REAR BALANCER
SHAFT
9) Install the balancer chain guide on the lower block and
tighten the two chain guide bolts to the specified torque.
TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)
[1]
CHAIN GUIDE
BOLT (2)
[2]
BALANCER CHAIN
GUIDE
10) Pushing the balancer chain tensioner against the balancer
chain, install the balancer chain tensioner on the balancer
holder. Tighten the three 6 x 14 mm flange bolts.
[1] BALANCER CHAIN
TENSIONER
6 x 14 (3)
12-10
After replacing the balancer chain tensioner with new one:
11) Install the set clip, that came together with the new
balancer chain tensioner, on the balancer chain tensioner.
[1]
BALANCER CHAIN
TENSIONER
[2]
SET CLIP
12) Install the balancer chain tensioner assembled in step 10 on
the rear balancer holder and tighten the three 6 x 14 mm
flange bolts.
After installation, remove the set clip from the balancer
chain tensioner.
[1]
BALANCER CHAIN
TENSIONER
6 x 14 (3)
13) Install the crankshaft pulley/cam chain (P. 9-11).
NOTICE
• Do not apply the liquid gasket to the chain case and
crankcase mating surfaces.
• Do not tighten the three bolts of the chain case/crankcase
mating side and do not install the crankshaft pulley.
14) Clean the crankcase and lower block mating surfaces
thoroughly with the degreasing cleaning agent.
15) Apply a bead [ø2.0 – 3.0 mm (ø0.08 – 0.12 in)] of the liquid
gasket (ThreeBond® #1280B or equivalent) to the indicated
area of the crankcase.
NOTICE
• Assemble the crankcase within 5 minutes after applying
the liquid gasket. If it has been left for 5 minutes or longer,
remove the old liquid gasket and apply the liquid gasket
again.
• Do not pour the engine oil in the oil tank at least 30
minutes after assembly.
12-11
[1]
Apply a bead of
liquid gasket.
16) Apply engine oil to the threads and seat of the 6 x 25 mm
flange bolts
6 x 25 (18)
17) Install the two dowel pins and crankcase on the lower block
and loosely tighten the 6 x 25 mm flange bolts.
[1]
CRANKCASE
[2] 13 x 20 mm
DOWEL PIN (2)
18) Tighten the 6 x 25 mm flange bolts to the specified torque
in the numbered sequence in two to three steps.
⑬
⑫
TORQUE: 12 N.m (1.2 kgf.m, 9 lbf.ft)
⑭
19) Install the engine on the outboard motor (P. 7-6).
20) Install the following parts.
– Crankshaft pulley (P. 9-17)
– Electric parts/main wire harness (P. 18-14, 17, 19 and 27)
– Silencer duct (P. 6-4)
– Throttle body/intake manifold (P. 5-132)
– Silencer case (P. 5-135)
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)
⑨
⑧
④
⑤
①
②
③
⑥
⑦
⑩
⑪
⑰
⑱
⑯
12-12
⑮
13. CYLINDER BLOCK/CRANKSHAFT/
PISTON
1. DISASSEMBLY
2. INSPECTION
3. BEARING SELECTION
4. ASSEMBLY
26 N.m (2.7 kgf.m,
20 lbf.ft)
20 N.m (2.0 kgf.m,
14 lbf.ft) + 90˚
29 N.m (3.0 kgf.m,
22 lbf.ft) + 56˚
13-1
26 N.m (2.7 kgf.m,
20 lbf.ft)
1. DISASSEMBLY
a. LOWER BLOCK/CRANKSHAFT/CYLINDER
BLOCK
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under covers (P. 4-9)
– Cylinder head assembly (P. 10-19)
– Engine assembly (P. 7-2)
– Oil pump (P. 11-6)
– Flywheel (P. 11-12)
– Crankcase/balancer case assembly (P. 12-2)
1) Loosen the bolts in the numbered sequence in two or three
steps.
2) Remove the four 8 x 50 mm flange bolts and ten 8 x 35 mm
flange bolts from the lower block.
②
①
⑥
⑤
⑩
⑨
⑭
⑬
⑪
⑫
⑦
⑧
③
④
3) Loosen the ten 11 x 95 mm washer bolts in the numbered
sequence in two or three steps.
4) Remove the ten 11 x 95 mm washer bolts from the lower
block.
②
①
⑥
⑤
⑩
⑨
⑦
⑧
③
④
[1]
RECESS
[1]
RECESS
5) Insert the screwdriver into the recesses of the lower block
and raise the lower block little by little.
13-2
6) Remove the lower block, 80 x 98 x 10 mm oil seal and the
eleven dowel pins from the cylinder block.
Replace the oil seal on assembly.
[1]
LOWER BLOCK
[2] 80 x 98 x 10 mm
OIL SEAL
[4]
13 x 14 mm
DOWEL PIN (10)
[3]
18 x 22 mm
DOWEL PIN
7) Check the lower main bearings for damage (scores,
scratches, etc.) and replace if necessary.
8) Remove the five lower main bearings from the lower block.
[1]
LOWER BLOCK
ORIFICE
NOTICE
Store the removed lower main bearings separately for each
journal.
9) Remove the lower block orifice from the lower block and
check the lower block orifice for blockage.
If it is clogged, clean it with a cleaning solvent and remove
the blockage by blowing the oil passage with the
compressed air.
If the blockage cannot be removed by blowing with the
compressed air, replace the lower block orifice with a new
one.
[2]
LOWER BLOCK
[3]
LOWER MAIN
BEARING (5)
NOTICE
Remove the blockage with care not to damage the oil
passage of the lower block orifice.
10) Check that the piston is at the bottom dead center of its
stroke. If not, move the piston to the bottom dead center by
turning the crankshaft.
11) Remove the connecting rod bolts, then remove the
connecting rod cap, connecting rod bearing and the two
dowel pins.
NOTICE
Store the removed connecting rod cap, connecting rod
bearing and the dowel pins classifying them into each
cylinder.
13-3
[1]
CONNECTING
ROD CAP
[4]
10 x 12 mm
DOWEL PIN (2)
[2]
CONNECTING
ROD BOLT (2)
[3]
CONNECTING
ROD BEARING
12) Remove the crankshaft from the cylinder block with care
not to damage (scores, scratches, etc.) the journals.
Remove the two thrust washers.
[1]
CRANKSHAFT
[2]
UPPER MAIN
BEARING (5)
13) Before removing the upper main bearings, check each
bearing for damage (scores, scratches, etc.) and replace if
necessary.
14) Remove the five upper main bearings from the cylinder
block.
[3]
THRUTST
WASHER (2)
NOTICE
Store the upper main bearings separately for each journal.
15) Remove the oil jet orifice and the 6.5 x 1.5 mm O-ring from
the cylinder block, and check the oil jet orifice for blockage.
If it is clogged, clean it with a cleaning solvent and remove
the blockage by blowing the oil passage with the
compressed air.
If the blockage cannot be removed by blowing with the
compressed air, replace the oil jet orifice with a new one.
NOTICE
Remove the blockage with care not to damage the oil
passage of the oil jet orifice.
[4] 6.5 x 1.5 mm O-RING
[5]
OIL JET ORIFICE
16) Remove the oil jet bolt from the No.1/No.2 cylinder of the
cylinder block and remove the oil jet body.
[1]
OIL JET BOLT
[2]
OIL JET
BODY
17) Remove the piston assembly from the cylinder by pushing
the piston assembly with the handle of a hammer as
shown.
NOTICE
• Before removing the piston assembly, remove the carbon
deposits from the cylinder with care not to damage
(scores, scratches, etc.) the piston.
• Do not damage the cylinder with the connecting rod.
• Store the removed piston assembly components
separately for each cylinder.
13-4
[1]
PISTON ASSEMBLY
[2]
CYLINDER BLOCK
b. PISTON ASSEMBLY
1) Remove the connecting rod bearing and the piston ring
from the piston assembly.
[1]
CONNECTING
ROD BEARING
[2]
PISTON RING
NOTICE
• Do not apply excessive force to the piston ring as it can
break the piston ring. Handle the piston ring with care.
• Store the removed connecting rod bearing and the piston
ring separately for each piston.
[3]
PISTON RING
PLIERS
(Commercially
available)
2) Apply oil to the piston pin clip. Align the piston pin clip end
gap with the cutout in the piston pin hole.
[1]
PISTON PIN
CLIP
NOTICE
Do not damage the piston pin clip installation groove.
[2]
CUTOUT
3) Remove the piston pin clips from the cut out at both sides
of the piston.
NOTICE
Remove the piston pin clips with care not to let them jump
out of position.
4) Warm up the piston assembly to approximately 70˚C
(158˚F) and remove the piston pin.
CAUTION
Take care not to get your hand, etc. burned during
disassembly.
13-5
[1]
PISTON PIN
CLIP
c. COMPONENTS DRAWING
8 x 50 (4)
26 N.m (2.7 kgf.m, 20 lbf.ft)
8 x 35 (10)
26 N.m (2.7 kgf.m, 20 lbf.ft)
[1]
11 x 95 mm BOLT-WASHER (10)
29 N.m (3.0 kgf.m, 22 lbf.ft) + 56˚
[2]
LOWER MAIN BEARING (5)
[3]
CRANKSHAFT
[4]
80 x 98 x 10 mm
OIL SEAL
[18]
LOWER BLOCK
ORIFICE
10 N.m (1.0 kgf.m,
7 lbf.ft)
[5]
UPPER MAIN
BEARING (5)
[17]
LOWER BLOCK
[6]
THRUST WASHER (2)
[16]
18 x 22 mm
DOWEL PIN
[7]
OIL JET BOLT (2)
16 N.m (1.6 kgf.m, 12 lbf.ft)
[8]
8 x 10 mm
BOLT-WASHER (2)
[15]
8 mm
BOLT CAP
[9]
OIL JET BODY (2)
[14]
13 x 14 mm
DOWEL PIN (10)
8 x 20 (2)
[12]
OIL JET ORIFICE
[13]
ENGINE HANGER
13-6
[11]
6.5 x 1.5 mm
O-RING
[10]
CYLINDER BLOCK
[1]
TOP RING
[14]
SECOND RING
[2]
PISTON RING
[3]
PISTON PIN
CLIP (2)
[13]
SIDE RAIL (2)
[4]
PISTON
[12]
OIL RING
[11]
SPACER
[5]
CONNECTING ROD
[10]
PISTON PIN
[6]
10 x 12 mm
DOWEL PIN (2)
[9]
CONNECTING ROD
BEARING (2)
[7]
CONNECTING
ROD CAP
[8]
CONNECTING ROD BOLT (2)
20 N.m (2.0 kgf.m, 14 lbf.ft) + 90˚
13-7
2. INSPECTION
[1]
O.D.
• PISTON SKIRT O.D.
1) Check the piston outer surface for damage (scores,
scratches, etc.). Check the piston for warpage and cracks.
11 mm
(0.4 in)
2) Measure and record the piston O.D. at a point 11 mm from
the bottom, and 90˚ to the piston pin bore.
STANDARD
SERVICE LIMIT
A
86.98 – 86.99 mm
(3.4244 – 3.4248 in)
86.93 mm
(3.4224 in)
B
86.97 – 86.98 mm
(3.4240 – 3.4244 in)
86.92 mm
(3.4220 in)
90˚
• CYLNDER SLEEVE I.D.
[1]
TOP
1) Check the inner wall of the cylinder for damage (scores,
scratches, etc.).
2) Measure and record the cylinder I.D. at three levels in both
X and Y axis. Take the maximum reading to determine the
cylinder I.D.
STANDARD
SERVICE LIMIT
A or l
87.01 – 87.02 mm
(3.4256 – 3.4260 in)
87.07 mm
(3.4279 in)
B or ll
87.00 – 87.01 mm
(3.4252 – 3.4256 in)
87.07 mm
(3.4279 in)
• PISTON-TO-CYLINDER CLEARANCE
STANDARD
SERVICE LIMIT
0.02 – 0.04 mm
(0.001 – 0.002 in)
0.05 mm
(0.002 in)
[2]
MIDDLE
[5]
NO.1 CYLINDER
[3]
BOTTOM
[4]
NO.4 CYLINDER
[1]
TOP
X
Y
• CYLINDER SLEEVE I.D. GAP BETWEEN TOP AND
BOTTOM
Determine the gap of the cylinder sleeve I.D. between the top
and the bottom measurements.
SERVICE LIMIT
13-8
0.05 mm (0.002 in)
[2]
MIDDLE
[3]
BOTTOM
• PISTON RING THICKNESS
1) Check the piston ring for damage (scores, scratches, etc.).
2) Measure the piston ring thickness.
STANDARD
TOP
1.170 – 1.185 mm
(0.0461 – 0.0467 in)
SECOND
1.175 – 1.190 mm
(0.0463 – 0.0469 in)
SERVICE LIMIT
The oil rings are the combination rings. Replace the top
ring, second ring and the oil rings as a set when either top
or second ring needs replacement.
• PISTON RING GROOVE WIDTH
1) Check the piston ring grooves for uneven wear, damage
and clogged oil hole.
2) Measure the piston ring groove width.
STANDARD
SERVICE LIMIT
TOP
1.23 – 1.24 mm
(0.0484 – 0.0488 in)
1.25 mm
(0.0492 in)
SECOND
1.24 – 1.25 mm
(0.0488 – 0.0492 in)
1.25 mm
(0.0492 in)
OIL
2.005 – 2.025 mm
(0.0789 – 0.0797 in)
2.05 mm
(0.081 in)
[1]
TOP
[2]
SECOND
[3]
OIL
• PISTON RING SIDE CLEARANCE
Set the piston ring on the piston properly so it is almost flush
with the piston outer surface. Measure the piston ring side
clearance.
STANDARD
SERVICE LIMIT
TOP
0.045 – 0.070 mm
(0.0018 – 0.0028 in)
0.13 mm
(0.005 in)
SECOND
0.040 – 0.065 mm
(0.0016 – 0.0026 in)
0.13 mm
(0.005 in)
The oil rings are the combination rings. Replace the top ring,
second ring and the oil rings as a set when either top or second
ring needs replacement.
• PISTON RING END GAP
Use the piston to push the piston ring into the cylinder and
position it horizontally at 15 to 20 mm from the bottom of the
cylinder.
STANDARD
SERVICE LIMIT
TOP
0.20 – 0.35 mm
(0.008 – 0.014 in)
0.6 mm
(0.02 in)
SECOND
0.50 – 0.65 mm
(0.020 – 0.026 in)
0.75 mm
(0.030 in)
OIL
0.20 – 0.70 mm
(0.008 – 0.028 in)
0.8 mm
(0.031 in)
If the end gap is larger than the service limit, install a new
piston ring and recheck. Check the cylinder sleeve I.D. (P. 13-8).
13-9
[1]
PISTON RING
[2]
END GAP
15 – 20 mm
(0.6 – 0.8 in)
• PISTON PIN BORE I.D.
STANDARD
SERVICE LIMIT
21.960 – 21.963 mm
(0.8646 – 0.8647 in)
• PISTON PIN O.D.
STANDARD
SERVICE LIMIT
21.961 – 21.965 mm
(0.8646 – 0.8648 in)
21.953 mm
(0.8643 in)
• PISTON PIN-TO-PIN BORE CLEARANCE
1) Set the cylinder gauge at the piston pin O.D. and zero the
cylinder gauge.
2) Insert the cylinder gauge in the piston pin bore and
measure the piston pin-to-pin bore clearance.
STANDARD
SERVICE LIMIT
–0.005 – +0.002 mm
(–0.0002 – +0.0001 in)
0.005 mm
(0.0002 in)
• CONNECTING ROD SMALL END I.D.
STANDARD
SERVICE LIMIT
23.969 – 23.982 mm
(0.9437 – 0.9442 in)
• CONNECTING ROD SMALL END-TO-PISTON PIN
CLEARANCE
STANDARD
SERVICE LIMIT
0.005 – 0.015 mm
(0.0002 – 0.0006 in)
0.02 mm
(0.001 in)
13-10
• CONNECTING ROD BIG END AXIAL CLEARANCE
STANDARD
SERVICE LIMIT
0.15 – 0.35 mm
(0.006 – 0.014 in)
0.4 mm
(0.02 in)
• CRANKSHAFT MAIN JOURNAL O.D.
STANDARD
SERVICE LIMIT
No.1, 2, 4, 5,
54.984 – 54.992 mm
(2.1647 – 2.1650 in)
No.3
54.976 – 55.000 mm
(2.1644 – 2.1654 in)
[2]
NO.4 MAIN
JOURNAL
[1]
NO.2 MAIN
JOURNAL
[5]
NO.1 MAIN
JOURNAL
[4]
NO.3 MAIN
JOURNAL
[3]
NO.5 MAIN
JOURNAL
• CRANK PIN JOURNAL O.D.
STANDARD
SERVICE LIMIT
[1]
CRANK PINS
47.976 – 48.000 mm
(1.8888 – 1.8898 in)
• CRANKSHAFT JOURNAL (MAIN, PIN)
ROUNDNESS
Measure the crankshaft main journal O.D. and the crank pin
O.D. in the A and B directions. Calculate the gap between the
measurements to determine the roundness.
STANDARD
SERVICE LIMIT
0.005 mm (0.0002 in) Max.
0.010 mm (0.0004 in)
[2]
[1]
ROUNDNESS (Measure at ROUNDNESS: B
the center of the journal.)
A
• CRANKSHAFT JOURNAL (MAIN, PIN)
CILINDRICITY
Measure the crankshaft main journal O.D. and the crank pin
O.D. at the points A and B. Calculate the gap between the
measurements to determine the cylindricity.
STANDARD
SERVICE LIMIT
0.005 mm (0.0002 in) Max.
0.010 mm (0.0004 in)
13-11
[3]
CYLINDRICITY:
A
[4]
CYLINDRICITY (Measure at
both ends of the journal.)
B
• CRANKSHAFT AXIAL CLEARANCE
Install the dial indicator as shown. Measure the crankshaft axial
play by moving the crankshaft back and forth with a
screwdriver.
STANDARD
SERVICE LIMIT
0.10 – 0.35 mm
(0.004 – 0.014 in)
0.45 mm
(0.018 in)
If the measurement exceeds the service limit, check the thrust
washer and the cylinder block thrust surface. Replace the
thrust washer and recheck.
If the measurement still exceeds the service limit, replace the
crankshaft.
• THRUST METAL SIDE CLEARANCE
Measure the clearance between the No.4 main journal thrust
washer and the crankshaft.
STANDARD
SERVICE LIMIT
0.10 – 0.35 mm
(0.004 – 0.014 in)
0.45 mm
(0.018 in)
If the measurement exceeds the service limit, check the thrust
washer and the cylinder block thrust surface. Replace the
thrust washer and recheck.
If the measurement still exceeds the service limit, replace the
crankshaft.
• CRANKSHAFT RUNOUT
1) Install the No.1 and No.5 upper main bearings on the
cylinder block.
[1]
CRANKSHAFT
[2]
NO.5 UPPER
MAIN BEARING
2) Install the crankshaft on the cylinder block.
3) Set the dial indicator on the crankshaft. Measure the
crankshaft runout by turning the crankshaft.
STANDARD
SERVICE LIMIT
0.03 mm (0.001 in) Max.
0.04 mm (0.002 in)
[3]
CYLINDER
BLOCK
4) If the measurement exceeds the service limit, replace the
crankshaft.
[4]
NO.1 UPPER MAIN
BEARING
13-12
• CYLINDER HEAD SURFACE WARPAGE
1) Take care not to damage (score, scratches, etc.) the mating
surface with the gasket.
2) Measure the surface warpage using a straight edge and a
feeler gauge as shown.
STANDARD
SERVICE LIMIT
0.07 mm (0.003 in) Max.
0.10 mm (0.004 in)
• CONNECTING ROD BEARING OIL CLEARANCE
1) Clean the crank pin and the connecting rod bearing. Check
the crank pin and the bearing for damage and wear.
2) Install the crankshaft on the cylinder block. Install the
connecting rod cap on the connecting rod and tighten the
connecting rod bolts to the specified torque (P. 13-22).
3) Remove the connecting rod cap. Set a plastigauge on the
crank pin.
[1]
PLASTIGAUGE
NOTICE
• Set the plastigauge in the axial direction.
• Tighten the connecting rod bolts with care not to turn the
crankshaft and connecting rod.
4) Reinstall the connecting rod cap and tighten the connecting
rod bolts to the specified torque (P. 13-22).
5) Remove the connecting rod cap. Measure the pressured
width of the plastigauge using the scale printed on the bag
of the plastigauge.
[1] PLASTIGAUGE
NOTICE
Measure the widest width on the plastigauge.
STANDARD
SERVICE LIMIT
0.032 – 0.066 mm
(0.0013 – 0.0026 in)
0.077 mm
(0.0030 in)
6) If the measurement exceeds the service limit, check the
connecting rod big end I.D. and the crank pin O.D. If they
are OK, replace with the undersize bearing by referring to
the connecting rod bearing selection table (P. 13-16), and
measure the oil clearance again.
13-13
[2] SCALE
• CRANKSHAFT MAIN BEARING OIL CLEARANCE
1) Clean the crankshaft main journals and the main bearings.
Check the journals and the bearings for damage and wear.
2) Install the upper main bearings and the crankshaft on the
cylinder block. Install the lower main bearings and the
lower block and tighten the bolts to the specified torque (P.
13-24).
3) Remove the lower block and the lower main bearings. Set
the plastigauge on each main journal of the crankshaft as
shown.
[1]
PLASTIGAUGE
NOTICE
• Set the plastgauges in the axial direction.
• Do not turn the crankshaft during this check.
4) Reinstall the lower main bearings and the lower block.
Tighten the bolts to the specified torque (P. 13-24).
[1] PLASTIGAUGE
5) Remove the lower block and the lower main bearings.
Measure the pressured width of the plastigauge using the
scale printed on the bag of the plastigauge.
NOTICE
Measure the widest width on the plastigauge.
STANDARD
SERVICE LIMIT
No.1, 2, 4, 5
0.017 – 0.041 mm
(0.0007 – 0.0016 in)
0.05 mm
(0.002 in)
No.3
0.025 – 0.049 mm
(0.0010 – 0.0019 in)
0.055 mm
(0.0022 in)
[2]
SCALE
6) If the measurement exceeds the service limit, check the
lower block and the cylinder block main bearing I.D. and
the crankshaft main journal O.D. If they are OK, replace
with the undersize bearing by referring to the connecting
rod bearing selection table (P. 13-18), and measure the oil
clearance again.
• CONNECTING ROD BOLT
1) Measure the O.D. of each connecting rod bolt at two points
as shown, and calculate the gap between the
measurements.
STANDARD
0 – 0.1 mm (0 – 0.004 in)
2) If the gap exceeds the standard value, replace the
connecting rod bolt.
NOTICE
Measure the O.D. on each of the connecting rod bolt.
13-14
35 mm (1.4 in)
20 mm (0.8 in)
3. BEARING SELECTION
a. CONNECTING ROD BEARING
NOTICE
• When replacing the connecting rod bearing, check the crank
pin code letter and the connecting rod code number, and
select the correct bearing by referring to the bearing selection
table.
• If the code letters and/or numbers are not clear, clean the
areas with a cleaning solvent and check again. Do not scrub
with a stiff brush or driver to clean.
1) Check the connecting rod code numbers and record them.
NOTICE
The connecting rod code numbers are for the No.1 and the
subsequent number journals when viewed from the
crankshaft pulley side.
Connecting rod big end I.D.: 51 mm (2.0 in)
Code No.
Tolerance
1 or l
±0.000 – +0.006 mm (±0.0000 – +0.0002 in)
2 or ll
+0.006 – +0.012 mm (+0.0002 – +0.0005 in)
3 or lll
+0.012 – +0.018 mm (+0.0005 – +0.0007 in)
4 or llll
+0.018 – +0.024 mm (+0.0007 – +0.0009 in)
[1]
CONNECTING ROD
CODE NUMBER
2) Check the crank pin code letters and record them.
[1] CRANK PIN
CODE LETTER
NOTICE
The crank pin code letters are for the No.1 and the
subsequent number journals when viewed from the right
side of the position shown or from the crankshaft pulley
side.
3) Select the correct bearing by referring to the crank pin code
letter and the connecting rod code number.
[2]
No.1
[3]
No.2
[4]
No.3
[5]
No.4
[1] CRANK PIN
CODE LETTER
[5]
No.4
13-15
[2]
No.1
Connecting rod bearing selection table:
Crank pin
code letter
Connecting rod code number
1 or l
2 or ll
3 or lll
4 or llll
Bearing identification color
A
Red
Pink
Pink/
Yellow
Yellow
B
Pink
Yellow
Yellow/
Green
Green
C
Yellow
Green
Green/
Brown
Brown
D
Green
Brown
Brown/
Black
Black
Selection table:
Connecting rod bearing center thickness: 1.5 mm (0.06 in)
Mark I.D. color
Tolerance
G
Red
–0.008 – –0.005 mm (–0.0003 – –0.0002 in)
F
Pink
–0.005 – –0.002 mm (–0.0002 – –0.0001 in)
E
Yellow
–0.002 – +0.001 mm (–0.0001 – +0.00004 in)
D
Green
+0.001 – +0.004 mm (+0.00004 – +0.0002 in)
C
Brown
+0.004 – +0.007 mm (+0.0002 – +0.0003 in)
B
Black
+0.007 – +0.010 mm (+0.0003 – +0.0004 in)
A
Blue
+0.010 – +0.013 mm (+0.0004 – +0.0005 in)
The connecting rod bearings are available in blue, black,
brown, green, yellow, pink and red of the size identification
color in this order in increments of 0.003 mm (0.0001 in).
4) Note that the oil clearance is set taking the enlarged
amount of the housing caused by crash into consideration.
The bearings are selected so that the oil clearance is 0.032
– 0.066 mm (0.0013 – 0.0026 in).
5) Check the oil clearance after installing the selected bearing
(P. 13-13).
6) Align the projection on the bearing with the cutout in the
connecting rod or cap, and install with care not to damage
the sliding surface.
NOTICE
• Do not determine the bearing simply by referring to the
selection table, but check the oil clearance.
• If the selection table shows two identification colors, use
a pair of the bearing of each color for the upper and lower
bearings.
13-16
[1]
PROJECTION
[2]
IDENTIFICATION
COLOR
b. CRANKSHAFT MAIN BEARING
NOTICE
• When replacing the main bearing, check the crankshaft main
journal code number and the cylinder block I.D. code letter or
number, and select the correct bearing by referring to the
bearing selection table.
• If the code letter and/or number is not clear, clean the area
with a cleaning solvent and check again. Do not scrub with a
stiff wire brush or driver to clean.
1) Check the cylinder block I.D. code letters or numbers and
record them.
NOTICE
The cylinder block I.D. code letters or numbers are for the
No.1 and the subsequent number journals when viewed
from the left side.
[1]
CYLINDER BLOCK I.D.
CODE LETTER OR
NUMBER
Cylinder block I.D.: 59 mm (2.3 in)
Code No.
Tolerance
1 or A or l
±0.000 – +0.006 mm (±0.0000 – +0.0002 in)
2 or B or ll
+0.006 – +0.012 mm (+0.0002 – +0.0005 in)
3 or C or lll
+0.012 – +0.018 mm (+0.0005 – +0.0007 in)
4 or D or llll
+0.018 – +0.024 mm (+0.0007 – +0.0009 in)
[2]
NO.1 MAIN
JOURNAL
2) Check the crankshaft main journal code numbers and
record them.
[3]
NO.5 MAIN
JOURNAL
[1] CRANKSHAFT
MAIN JOURNAL
CODE NUMBER
NOTICE
The crankshaft main journal code numbers are for the No.1
and the subsequent number journals when viewed from
the right side of the position shown or from the crankshaft
pulley side.
3) Select the correct bearing by referring to the cylinder block
I.D. code letter or number and the crankshaft main journal
code number.
[2]
[3]
No.1 No.2
[4]
No.3
[5]
No.4
[6]
No.5
[1] CRANKSHAFT
MAIN JOURNAL
CODE NUMBER
[6]
No.5
13-17
[2]
No.1
Crankshaft main bearing selection table:
Cylinder block I.D. code letter or number
Crankshaft
main journal 1 or A or l 2 or B or ll 3 or C or lll 4 or D or llll
code number
Bearing identification color
1
Pink
Pink/
Yellow
Yellow
Green
2
Pink/
Yellow
Yellow
Green
Green/
Brown
3
Yellow
Green
Green/
Brown
Brown
4
Green
Green/
Brown
Brown
Black
5
Green/
Brown
Brown
Black
Black/
Blue
6
Brown
Black
Black/
Blue
Blue
Selection table:
Main bearing center thickness: 2.0 mm (0.08 in)
Mark I.D. color
Tolerance
F
Pink
–0.006 – –0.003 mm (–0.0002 – –0.0001 in)
E
Yellow
–0.003 – ±0.000 mm (–0.0001 – ±0.0000 in)
D
Green
±0.000 – +0.003 mm (±0.0000 – +0.0001 in)
C
Brown
+0.003 – +0.006 mm (+0.0001 – +0.0002 in)
B
Black
+0.006 – +0.009 mm (+0.0002 – +0.0004 in)
A
Blue
+0.009 – +0.012 mm (+0.0004 – +0.0005 in)
The main bearings are available in blue, black, brown, green,
yellow and pink of the size identification color in this order in
increments of 0.003 mm (0.0001 in).
4) Note that the oil clearance is set taking the enlarged
amount of the housing caused by crash into consideration.
The bearings are selected so that the oil clearance for the
No.1, 2, 4 and 5 journals is in the range of 0.017 – 0.041 mm
(0.0007 – 0.0016 in), and the oil clearance for the No.3
journal is in the range of 0.025 – 0.049 mm (0.0010 – 0.0019
in).
5) Check the oil clearance after installing the selected bearing
(P. 13-14).
6) Align the projection of the bearing with the cutout in the
cylinder block or lower block, and install with care not to
damage the sliding surface.
NOTICE
• Do not determine the bearing simply by referring to the
selection table, but check the oil clearance.
• If the selection table shows two identification colors, use
a pair of the bearing of each color for the upper and lower
bearings.
13-18
[1]
PROJECTION
[2]
IDENTIFICATION
COLOR
4. ASSEMBLY
a. PISTON ASSEMBLY
1) Install the piston pin clip only on one side of the piston.
NOTICE
Take care not to let the piston pin clip jump out of position.
[1]
PISTON PIN
CLIP
2) Warm up the piston to approximately 70˚C (158˚F).
CAUTION
Take care not to get your hand, etc. burned during
assembly.
3) Apply molybdenum disulfide oil to the outer surface of the
piston pin, inner wall of the piston pin hole in the piston
and to the inner wall of the connecting rod small end.
Install the connecting rod on the piston and install the
piston pin.
NOTICE
Install the piston pin so that the “
” mark on the piston
head points to the model mark on the connecting rod.
[1]
“
” MARK
[2]
MODEL MARK
4) Install the piston pin clip on the opposite side from where
the piston pin clip was installed in step 3.
NOTICE
Take care not to let the piston pin clip jump out of position.
[3]
MOLYBDENUM
DISULFIDE OIL
[4]
PISTON PIN
5) Install the connecting rod bearing on the connecting rod by
aligning the projection on the bearing with the concave in
the connecting rod.
[5]
PISTON PIN
CLIP
[6]
CONNECTING
ROD BEARING
[8]
PISTON
13-19
[7]
CONNECTING
ROD
6) Install the piston rings in the ring grooves in the piston with
the marker marks on the top ring and the second ring
facing up.
Install the side rail (top side) by aligning the lug of the side
rail (top side) with the positioning groove in the ring
groove.
[1]
TOP RING
[2]
SECOND RING
[3]
SIDE RAIL
(TOP SIDE)
NOTICE
• Clean the ring grooves thoroughly before installing the
piston rings.
• Install the piston rings with care not to break the piston
rings. Take care not to score or scratch the piston.
• Do not confuse the top ring and the second ring. The top
ring is glossy while the second ring can be identified with
the dark color.
• To install the oil rings, install the spacer first, then install
the side rails.
• Be sure that the lug of the side rail (top side) sets in the
positioning groove securely.
[4]
OIL RINGS
[6]
SPACER
[5]
SIDE RAIL
(SKIRT SIDE)
[7]
GROOVE
[8]
LUG
[1] DIMENSIONS OF PISTON RING:
B
A
[2] TOP RING
A: 3.1 mm
B: 1.2 mm
SECOND RING
A: 3.4 mm
B: 1.2 mm
7) After installing the piston rings, check for smooth
movement of each ring. [Except side rail (top side)]
8) Stagger the piston ring end gaps as shown.
NOTICE
Do not align with the piston pin and avoid the direction that
makes a right angle with the piston pin.
[9]
PISTON
[3]
SIDE RAIL
(TOP SIDE)
[1] TOP RING
[2] SECOND RING
[3] SIDE RAIL
(TOP SIDE)
[4] SPACER
[5] SIDE RAIL
(SKIRT SIDE)
[7] APPROX. 10˚
[8]
[6]
[9]
APPROX. 15˚ SPACER RING
SIDE RAIL
END GAP
END GAP
(TOP SIDE)
[8] APPROX. 15˚
[FIXED
[10] SIDE RAIL
POSITION]
END GAP
[11]
(SKIRT SIDE)
APPROX.120˚
[11]
APPROX. 120˚
[12]
PISTON
PIN
[14]
TOP RING END GAP
13-20
[13] SECOND RING
END GAP
b. LOWER BLOCK/CRANKSHAFT/CYLINDER
BLOCK
1) Apply molybdenum disulfide oil to the piston skirt and the
inner wall of the cylinder sleeve.
2) Using the handle of a hammer, drive the piston slowly into
the cylinder block with the “
” mark on the piston toward
the cam chain side.
[1]
“
” MARK
[2] MOLYBDENUM
DISULFIDE OIL
[3]
PISTON RING
COMPRESSOR
(Commercially
available)
[2]
MOLYBDENUM
DISULFIDE OIL
3) Apply engine oil to the threads and seat of the oil jet bolts.
4) Install the oil jet body on each of the No.1 and No.2 cylinder
and tighten the oil jet bolts to the specified torque.
[1]
OIL JET BOLT
TORQUE: 16 N.m (1.6 kgf.m, 12 lbf.ft)
[2]
OIL JET
BODY
5) Apply engine oil to the new 6.5 x 1.5 mm O-ring and install
it on the oil jet orifice.
Install the oil jet orifice on the cylinder block.
[1]
CYLINDER
BLOCK
[2]
6.5 x 1.5 mm
O-RING
[3]
OIL JET ORIFICE
13-21
6) Install the upper main bearings on the cylinder block
aligning the projection on the upper main bearing with the
concave in the cylinder block.
[1] PROJECTION
[2]
UPPER MAIN
BEARING
7) Apply molybdenum disulfide oil to the crankshaft main
journal, crank pin and the thrust washer mating surfaces.
8) Put the No.2 and No.3 pistons at the bottom dead center of
their stroke. Install the crankshaft on the cylinder block
while aligning it with the No.2 and No.3 connecting rods.
NOTICE
[3]
CONCAVE
Install the crankshaft with care not to damage the journals.
[4]
MOLYBDENUM
DISULFIDE OIL
[5]
CRANKSHAFT
[7]
CYLINDER
BLOCK
9) Install the connecting rod bearing on the connecting rod
cap aligning the projection on the connecting rod bearing
with the concave in the connecting rod cap.
[1]
CONNECTING ROD
BEARING
10) Install the two dowel pins on the connecting rod cap.
[3]
CONNECTING
ROD CAP
13-22
[6]
UPPER MAIN
BEARING (5)
[2]
10 x 12 mm
DOWEL PIN (2)
11) Apply engine oil to the threads and seat of the connecting
rod bolts.
Install the connecting rod cap assembly on the connecting
rod and tighten the two connecting rod bolts to the
specified torque.
After tightening to the specified torque, tighten the bolts to
an additional 90˚.
[1]
CONNECTING ROD
CAP ASSEMBLY
[2]
CONNECTING
ROD BOLT (2)
TORQUE: 20 N.m (2.0 kgf.m) + 90˚
NOTICE
• Install the connecting rod cap assembly aligning the code
number with the number on the counter part.
• Check that the piston is at the bottom dead center of its
stroke before tightening the bolts. It not, turn the
crankshaft to bring the piston at the bottom dead center.
12) Apply engine oil to the thrust washers and install them on
the cylinder block No.4 journal.
[3]
CODE
NUMBER
[1]
THRUST WASHER (2)
NOTICE
Install the thrust washers with the grooved side toward the
crankshaft.
[2]
GROOVES
13) Install the lower main bearings on the cylinder block
aligning the projection on the lower main bearing with the
concave in the lower block.
14) Apply engine oil to the threads of the lower block orifice.
Tighten the lower block orifice on the lower block to the
specified torque.
[1]
LOWER BLOCK
ORIFICE
TORQUE: 10 N.m (1.0 kgf.m, 7 lbf.ft)
[2] LOWER
BLOCK
[3]
LOWER MAIN
BEARING (5)
13-23
15) Clean the cylinder block and lower block mating surfaces
thoroughly with the degreasing cleaning agent.
16) Apply a bead [ø2.0 – 3.0 mm (ø0.08 – 0.12 in.)] of the liquid
gasket (ThreeBond® #1280B or equivalent) to the indicated
area of the cylinder block.
[1]
Apply a bead of
liquid gasket.
NOTICE
• Assemble the lower block within 5 minutes after applying
the liquid gasket. If it has been left for 5 minutes or longer,
remove the old liquid gasket and apply the liquid gasket
again.
• Do not pour the engine oil in the oil tank at least 30
minutes after assembly.
17) Install the eleven dowel pins and the lower block on the
cylinder block.
[1]
LOWER BLOCK
[2]
13 x 14 mm
DOWEL PIN (10)
[3]
18 x 22 mm
DOWEL PIN
13-24
18) Apply engine oil to the threads and the seating face of the
washer of the 11 x 95 mm bolt-washers.
19) Loosely tighten the ten 11 x 95 mm bolt-washers on the
lower block, then tighten the bolt-washers in the numbered
sequence in two or three steps to the specified torque.
After tightening to the specified torque, tighten the boltwashers to an additional 56˚ in the numbered order.
⑨
⑩
⑤
⑥
①
②
④
③
⑧
⑦
TORQUE: 29 N.m (3.0 kgf.m, 22 lbf.ft) + 56˚
20) Apply engine oil to the threads and seating face of both the
8 x 50 mm flange bolts and the 8 x 35 mm flange bolts.
21) Loosely tighten the four 8 x 50 mm flange bolts and ten 8 x
35 mm flange bolts on the lower block. Tighten them to the
specified torque in the numbered sequence in two or three
steps.
⑬
⑭
⑨
⑩
⑤
⑥
①
②
④
③
TORQUE: 26 N.m (2.7 kgf.m, 20 lbf.ft)
⑧
⑦
⑫
13-25
⑪
22) Apply soapy water to the outer surface of the new 80 x 98
x 10 mm oil seal. Apply engine oil to the oil seal lip.
23) Using the special tools as shown, install the 80 x 98 x 10
mm oil seal on the crankshaft.
Drive in the oil seal so its upper side is 0.2 – 1.2 mm (0.01 –
0.05 in) deep from the surface.
TOOLS:
Driver
Oil seal driver attachment, 96
[2]
OIL SEAL DRIVER
ATTACHMENT,96
07ZAD-PNA0100
[1]
DRIVER
07749-0010000
07749-0010000
07ZAD-PNA0100
NOTICE
Drive in the oil seal with the part number on the oil seal
toward out.
24) Install the following pars.
– Crankcase/balancer case assembly (P. 12-8)
– Flywheel (P. 11-14)
– Oil pump (P. 11-11)
– Engine assembly (P. 7-6)
– Cylinder head assembly (P. 10-32)
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)
[3]
OIL SEAL INSTALLATION DEPTH:
[4] CRANKSHAFT
0.2 – 1.2 mm
(0.01 – 0.05 in)
[5]
80 x 98 x 10 mm
OIL SEAL
13-26
14. PROPELLER/GEAR CASE/EXTENSION
CASE/OIL CASE
1. PROPELLER
2. GEAR CASE ASSEMBLY [*1]
3. WATER PUMP/SHIFT ROD [*1]
4. PROPELLER SHAFT HOLDER
ASSEMBLY [*1]
5. PROPELLER SHAFT/PROPELLER
SHAFT HOLDER [*1]
6. VERTICAL SHAFT/BEVEL GEAR [*1]
7. SHIM SELECTION [*1]
8. SHIM POSITION [*1]
9. BACKLASH ADJUSTMENT [*1]
10. GEAR CASE ASSEMBLY [*2]
11. WATER PUMP/SHIFT ROD [*2]
[*1]: LC, XC, LD and XD types
12. PROPELLER SHAFT HOLDER
ASSEMBLY [*2]
13. PROPELLER SHAFT/PROPELLER
SHAFT HOLDER [*2]
14. VERTICAL SHAFT/BEVEL GEAR [*2]
15. SHIM SELECTION [*2]
16. SHIM POSITION [*2]
17. BACKLASH ADJUSTMENT [*2]
18. ANODE METAL/WATER SCREEN
19. EXTENSION CASE/LOWER RUBBER
MOUNT
20. OIL CASE
[*2]: XCC, LCD and XCD types
83 N.m
(8.5 kgf.m,
61 lbf.ft)
34 N.m (3.5 kgf.m, 25 lbf.ft)
39 N.m (4.0 kgf.m, 29 lbf.ft)
34 N.m (3.5 kgf.m, 25 lbf.ft)
14-1
[1]
1 N.m (0.1 kgf.m, 0.7 lbf.ft)
Max. torque:
44 N.m (4.5 kgf.m, 33 lbf.ft)
34 N.m (3.5 kgf.m, 25 lbf.ft)
1. PROPELLER
a. REMOVAL/INSTALLATION
[1]
18 mm CASTLE NUT
INSTALLATION:
TORQUE:
1 N.m (0.1 kgf.m, 0.7 lbf.ft)
If the split pin cannot be set by tightening to
the specified torque, tighten the castle nut
additionally until the split pin can be set.
MAX. TORQUE:
44 N.m (4.5 kgf.m, 33 lbf.ft)
[2]
3-BLADE PROPELLER
[5]
PROPELLER THRUST WASHER
INSTALLATION:
Install the propeller thrust washer as
shown.
[5]-1
GEAR CASE
SIDE
[5]-2
PROPELLER
SIDE
[4]
PROPELLER WASHER
[3]
3 mm SPLIT PIN
INSTALLATION:
• Replace with a new one on
assembly.
• Be sure to use the genuine
part (stainless steel) and
bend the pin ends as shown
to stake the nut.
[3]-1
3 mm SPLIT PIN
14-2
2. GEAR CASE ASSEMBLY [*1]
[1]
SPEED SENSOR
TUBE B
a. REMOVAL
1) Place the remote control lever in the “N” (Neutral) position.
2) Tilt up the outboard motor to the uppermost position.
3) Disconnect the speed sensor tube B and the speed sensor
tube C.
[2]
SPEED SENSOR
TUBE C
4) Remove the 10 x 32 mm hex. bolt and the 10 mm washer.
Remove the trim tab from the gear case assembly.
[1]
TRIM TAB
[3]
10 mm WASHER
5) Remove the seven 10 x 40 mm hex. bolts and the seven 10
mm washers, then remove the gear case assembly from
the outboard motor.
Remove the two dowel pins.
[2]
10 x 32 mm
HEX. BOLT
[1]
6 x 10 mm
DOWEL PIN (2)
6) After removing the gear case assembly, lower the outboard
motor to the lowermost position.
[2]
10 mm
WASHER (7)
[4]
GEAR CASE
ASSEMBLY
[3]
10 x 40 mm
HEX. BOLT (7)
14-3
7) Remove the shift rod A from the shift shaft A.
[2]
SHIFT
ROD A
[1]
SHIFT
SHAFT A
b. COMPONENTS DRAWING
[1]
SHIFT ROD A
[9]
VERTICAL SHAFT
[8]
6 x 10 mm
DOWEL PIN (2)
[2]
10 mm WASHER (7)
[7]
GEAR CASE
ASSEMBLY
[3]
10 x 40 mm HEX. BOLT (7)
34 N.m (3.5 kgf.m, 25 lbf.ft)
[4]
TRIM TAB
[6]
10 mm WASHER
14-4
[5]
10 x 32 mm HEX. BOLT
c. INSTALLATION
1) Place the remote control lever in the “N” (Neutral) position.
[1]
CUTOUT
2) Check that the shift rod of the gear case is in the “N”
(Neutral) position.
To check:
Check whether the cutout of the shift rod spline faces in the
direction shown. [It indicates that the shift rod is in the “N”
(Neutral) position.]
3) If the cutout of the spline is not in the direction shown,
protect the spline with a shop towel or equivalent material
and turn the shift rod right and left with a wrench until the
cutout faces toward the specified direction.
[3]
SHIFT ROD
[2] CRUISING
DIRECTION
[2]
SHIFT ROD
[1]
SHOP TOWEL
4) Tilt up the outboard motor to the uppermost position.
5) Apply grease to the spline of the shift rod A.
6) Install the shift rod A by aligning the projection of the shift
shaft A with the cutout in the spline of the shift rod A. Check
that the cutout in the spline of the shift rod A is toward the
cruising direction.
[3]
CUTOUT
[1]
SHIFT SHAFT A
[2]
PROJECTION
[4] CRUISING
DIRECTION
[4]
CRUISING DIRECTION
[5]
SHIFT ROD A
14-5
7) Apply grease to the vertical shaft spline and the shift rod
spline.
Apply grease to the water tube insertion part and to the
inner wall of the water tube seal ring of the impeller
housing.
Apply grease to the inner wall of the vertical shaft bushing
[XC and XD types only] (P. 14-90).
[1]
WATER TUBE
[3]
WATER TUBE
SEAL RING
8) Install the two dowel pins. Aligning the water tube with the
water tube seal ring of the impeller housing, install the
vertical shaft and the crankshaft. Install the shift rod and
shift rod A, too, by aligning the splines.
9) Install the gear case assembly on the outboard motor.
Loosely tighten the seven 10 mm washers and the seven 10
x 40 mm hex. bolts.
[2]
VERTICAL
SHAFT
[4]
6 x 10 mm
DOWEL PIN (2)
[7]
10 mm
WASHER (7)
[6]
10 x 40 mm
HEX. BOLT (7)
10) Connect the speed sensor tube B and the speed sensor
tube C.
[5]
GEAR CASE
ASSEMBLY
[1] SPEED SENSOR
TUBE B
11) Lower the outboard motor to the lowermost position and
tighten the seven 10 x 40 mm hex. bolts to the specified
torque.
TORQUE: 34 N.m (3.5 kgf.m, 25 lbf.ft)
[2]
SPEED SENSOR
TUBE C
12) Position the trim tab on the gear case assembly.
[1] TRIM TAB
[2] “
” MARKS
13) Install the trim tab on the gear case assembly aligning the
“ ” mark on the trim tab with the “ ” mark on the gear
case. Tighten the 10 mm washer and the 10 x 32 mm hex.
bolt.
[3]
10 x 32 mm
HEX. BOLT
14) After installing the gear case assembly, adjust the shift
control cable (P. 3-25).
[4]
10 mm WASHER
14-6
3. WATER PUMP/SHIFT ROD [*1]
[1]
WATER TUBE
SEAL RING
a. DISASSEMBLY
Remove the following parts.
– Propeller (P. 14-2)
– Gear case assembly (P. 14-3)
1) Remove the speed sensor tube C.
2) Remove the water tube seal ring from the impeller housing.
[2]
8 x 40 mm
HEX. BOLT (4)
[3]
8 mm
WASHER (4)
[8]
IMPELLER
HOUSING
[7]
VERTICAL
SHAFT
3) Remove the four 8 x 40 mm hex. bolts and the four 8 mm
washers from the impeller housing. Remove the impeller
housing.
Remove the four distance collars from the impeller
housing.
[4]
DISTANCE
COLLAR (4)
4) Remove the woodruff key from the vertical shaft.
[5]
WOODRUFF
KEY
[6]
SPEED SENSOR
TUBE C
5) Remove the impeller cover, impeller gasket, two dowel
pins, gear case grommet and the rubber setting plate.
[1]
IMPELLER COVER
NOTICE
Replace the impeller gasket with a new one on assembly.
[5]
IMPELLER
GASKET
[4]
6 x 10 mm
DOWEL PIN (2)
14-7
[2]
GEAR CASE
GROMMET
[3]
RUBBER SETTING
PLATE
6) Check the pump impeller for cracks, wear or damage from
overheating, and replace if necessary.
7) Remove the pump impeller, pump liner and the water
pump O-ring from the impeller housing.
Replace the O-ring with a new one on assembly.
[1]
IMPELLER
HOUSING
[4]
WATER PUMP
O-RING
8) Remove the two 6 x 20 mm flange bolts and remove the
water seal housing.
[1]
WATER SEAL
HOUSING
[2]
PUMP LINER
[3]
PUMP IMPELLER
6 x 20 (2)
9) Remove the 58.5 x 3.5 mm O-ring from the water seal
housing.
Replace the O-ring with a new one on assembly.
[2]
58.5 x 3.5 mm
O-RING
10) Before removing the 23 x 36 x 6 mm water seal, check the
water seal lip for cut. Replace if necessary.
11) Remove the two 23 x 36 x 6 mm water seals from the water
seal housing using a commercially available oil seal
remover.
Replace the water seals with the new ones on assembly.
14-8
[1]
WATER SEAL
HOUSING
[2]
23 x 36 x 6 mm
WATER SEALS
12) Remove the 6 x 12 mm hex. bolt and the pivot washer.
Remove the shift rod holder and the shift rod assembly.
[1]
SHIFT ROD
HOLDER
[2]
SHIFT ROD
ASSEMBLY
[3]
6 x 12 mm
HEX. BOLT
[4]
PIVOT
WASHER
13) Remove the shift rod spring, 12 mm washer and the 10 mm
E-ring from the shift rod.
[2]
SHIFT ROD SPRING
[3]
12 mm
WASHER
[1]
10 mm
E-RING
[4]
SHIFT ROD
14) Check the 12 x 21 x 6 mm water seal lip for cut and replace
if necessary.
[1]
12 x 21 x 6 mm
WATER SEALS
15) Remove the two 12 x 21 x 6 mm water seals from the shift
rod holder using a commercially available oil seal remover.
[2]
SHIFT ROD HOLDER
16) Remove the 55.6 x 3.5 mm O-ring from the shift rod holder.
NOTICE
• Replace the 12 x 21 x 6 mm water seals with the new ones
on assembly.
• Replace the 55.6 x 3.5 mm O-ring with a new one on
assembly.
14-9
[3]
55.6 x 3.5 mm
O-RING
b. COMPONENTS DRAWING
[2]
WATER TUBE SEAL RING
[1]
IMPELLER HOUSING
[3]
8 x 40 mm HEX. BOLT (4)
19.7 N.m (2.0 kgf.m, 14 lbf.ft)
[4]
8 mm
WASHER (4)
[5]
DISTANCE
COLLAR (4)
6 x 20 (2)
[16]
WATER SEAL
HOUSING
[6]
WATER PUMP
O-RING
[7]
PUMP LINER
[15]
58.5 x 3.5 mm
O-RING
[14]
23 x 36 x 6 mm
WATER SEAL (2)
[8]
PUMP IMPELLER
[9]
WOODRUFF KEY
[10]
IMPELLER COVER
[11]
IMPELLER GASKET
[12]
VERTICAL SHAFT
[13]
6 x 10 mm
DOWEL PIN (2)
14-10
[1]
12 x 21 x 6 mm
WATER SEAL (2)
[2]
SHIFT ROD
HOLDER
[15]
55.6 x 3.5 mm
O-RING
[14]
SHIFT ROD SPRING
[13]
12 mm WASHER
[12]
10 mm E-RING
[10]
TUBE JOINT
[3]
GEAR CASE
GROMMET
[11]
SHIFT ROD
[9]
SPEED SENSOR
TUBE C
[8]
SENSOR NIPPLE
[7]
6 x 12 mm
HEX. BOLT
[6]
PIVOT WASHER
[4]
RUBBER SETTING
PLATE
[5]
WIRE BAND (2)
Do not reuse.
14-11
c. ASSEMBLY
[1] <Water seal installation
direction>
1) Apply soapy water to the circumference of the 12 x 21 x 6
mm water seals.
2) Drive the 12 x 21 x 6 mm water seals one by one in the shift
rod holder using the special tools. Note the installation
direction of the water seals.
Be sure to apply grease to the water seal mating surfaces
before installation.
TOOLS:
Driver
Oil seal driver attachment, 21 mm
[2]
12 x 21 x 6 mm
WATER SEALS
07749-0010000
07947-ZV00100
3) After installing the water seals, apply grease to the water
seal lips.
[3]
(Apply grease to the
water seal mating
surfaces and the lips.)
[4]
DRIVER
07749-0010000
[6]
SHIFT ROD
HOLDER
4) Position the 10 mm E-ring, 12 mm washer and the shift rod
spring on the shift rod.
[5]
OIL SEAL DRIVER
ATTACHMENT,
21 mm
07947-ZV00100
[2]
SHIFT ROD SPRING
[1]
10 mm
E-RING
[3]
12 mm
WASHER
[4]
SHIFT ROD
14-12
5) Install the shift rod by aligning the shift cam of the shift rod
with the groove in the shift slider so that the cutout of the
shift rod spline faces in the cruising direction.
[1] CUTOUT
[2] No mark in the shift
rod end.
NOTICE
• Check that there is no marking in the shift rod end.
• If the shift cam is in alignment with the groove in the shift
slider but the cutout of the spline is not in the cruising
direction, see the step 3 on page 14-5 and adjust
accordingly.
[4]
CRUISING
DIRECTION
[3]
SHIFT ROD
[1]
[4]
<LC, XC, LD and XD types> <XCC, LCD and XCD types>
[3]
SHIFT ROD
[2]
NO MARK
[3]
SHIFT ROD
[5]
MARK
[3]
SHIFT ROD
[5]
SHIFT CAM
[6]
GROOVE IN SHIFT
SLIDER
6) Apply grease to the circumference of the new 55.6 x 3.5
mm O-ring and install it on the shift rod holder.
[2] SHIFT ROD
HOLDER
[1]
55.6 x 3.5 mm
O-RING
7) Install the shift rod holder aligning the projection with the
concave in the gear case and tighten with the pivot washer
and the 6 x 12 mm hex. bolt.
After installation, check that the cutout of the shift rod
spline faces in the cruising direction.
[1]
SHIFT ROD
HOLDER
[2] PROJECTION
[3] 6 x 12 mm
HEX. BOLT
[4] PIVOT
WASHER
[5]
CONCAVE
14-13
8) Apply soapy water to the circumference of the 23 x 36 x 6
mm water seals.
[1] 23 x 36 x 6 mm
WATER SEALS
[2] <Water seal installation
direction>
9) Drive the 23 x 36 x 6 mm water seals one by one in the
water seal housing using the special tools. Note the
installation direction of the water seals.
Be sure to apply grease to the water seal mating surfaces
before installation.
TOOLS:
Driver
Attachment, 32 x 35 mm
07749-0010000
07746-0010100
10) After installing the water seals, apply grease to the water
seal lips.
[4]
DRIVER
07749-0010000
[6]
WATER SEAL
HOUSING
11) Apply grease to the circumference of the new 58.5 x 3.5
mm O-ring and position it on the water seal housing.
12) Install the water seal housing so that the concave faces in
the cruising direction, and tighten it with the two 6 x 20 mm
flange bolts.
[1]
WATER SEAL
HOUSING
[3]
(Apply grease to the
water seal mating
surfaces and the lips.)
[5]
ATTACHMENT,
32 x 35 mm
07746-0010100
6 x 20
[4]
VERTICAL
SHAFT
[2]
CONCAVE
[3]
58.5 x 3.5 mm
O-RING
14-14
13) Apply grease to the inner wall of the water pump liner.
Install the pump impeller in the water pump liner with the
woodruff key installation groove facing up and the pump
impeller fins in the direction shown.
Be sure to align the hole in the pump liner with the hole in
the pump impeller.
[1]
(Apply grease
to the inside.)
[2] WOODRUFF KEY
INSTALLATION GROOVE
[3]
[2] WOODRUFF KEY
PUMP
INSTALLATION
IMPELLER
GROOVE
[4]
WATER PUMP LINER
14) Install the water pump liner in the impeller housing by
aligning the two projections on the pump liner with the two
grooves inside the impeller housing.
Be sure that the part “A” of the water pump liner is in
alignment with the part “B” of the impeller housing, too.
[2]
[1]
PROJECTIONS
“A” POINT
[3] CONCAVES
15) Apply grease to the circumference of the new water pump
O-ring and install it on the impeller housing.
[6]
WATER PUMP
LINER
16) Install the rubber setting plate, gear case grommet, two
dowel pins, new impeller gasket and the impeller cover.
[1]
IMPELLER
GASKET
[5]
IMPELLER
HOUSING
[4]
“B” POINT
[2]
IMPELLER
COVER
[3]
GEAR CASE
GROMMET
[5]
6 x 10 mm
DOWEL PIN (2)
[4]
RUBBER SETTING
PLATE
14-15
17) Install the woodruff key in the groove in the vertical shaft.
Align the groove in the pump impeller with the woodruff
key and install the impeller housing by turning it clockwise.
[2]
WOODRUFF KEY
NOTICE
• Turn the impeller housing clockwise when it is turned
with the pump impeller mounted.
• After installing the impeller housing, check that the
impeller cover and the impeller gasket are set in the
proper position.
[1]
VERTICAL
SHAFT
[5]
GROOVE
[4]
IMPELLER
HOUSING
[3]
GROOVE IN
PUMP IMPELLER
18) Install the four distance collars on the impeller housing,
and tighten the four 8 mm washers and the four 8 x 40 mm
hex. bolts to the specified torque.
TORQUE: 19.7 N.m (2.0 kgf.m, 14 lbf.ft)
19) Apply grease to the inner wall of the water tube seal ring.
Install the water tube seal ring aligning the projection with
the hole in the housing.
[1]
SPEED SENSOR
TUBE C
[2] WATER TUBE
SEAL RING
[3]
8 x 40 mm
HEX. BOLT (4)
20) Install the speed sensor tube C.
[4]
8 mm WASHER (4)
21) Install the following parts.
– Gear case assembly (P. 14-5)
– Propeller (14-2)
[5]
DISTANCE
COLLAR (4)
[6]
IMPELLER
HOUSING
14-16
4. PROPELLER SHAFT HOLDER
ASSEMBLY [*1]
[2] PROPELLER SHAFT
HOLDER ASSEMBLY
a. REMOVAL/INSTALLATION
Remove the following parts.
– Propeller (P. 14-2)
– Gear case assembly (P. 14-3)
– Water pump/shift rod (P. 14-7)
1) Remove the two 10 mm washers and the two 10 x 40 mm
flange bolts.
2) Insert a screwdriver or equivalent tool into the recess in the
propeller shaft holder and remove the propeller shaft
holder assembly from the gear case.
[1]
RECESS
Installation is the reverse order of removal.
[2]
PROPELLER SHAFT
HOLDER ASSEMBLY
[3]
10 mm WASHER (2)
[1]
GEAR CASE ASSEMBLY
10 x 40 (2)
34 N.m (3.5 kgf.m, 25 lbf.ft)
14-17
5. PROPELLER SHAFT/PROPELLER
SHAFT HOLDER [*1]
[1]
8 x 47 mm
SHIFTER PIN
[2]
CLUTCH
SHIFTER
a. DISASSEMBLY
Remove the following parts.
– Propeller (P. 14-2)
– Gear case assembly (P. 14-3)
– Water pump/shift rod (P. 14-7)
– Propeller shaft holder assembly (P. 14-17)
1) Remove the cross pin ring and the 8 x 47 mm shifter pin,
then remove the clutch shifter.
[3]
CROSS PIN
RING
2) Remove the shift slider assembly and the two #7 steel balls
from the propeller shaft. Take care not to lose the steel
balls.
[2]
SHIFT SLIDER
ASSEMBLY
[1]
PROPELLER
SHAFT
[3]
#7 STEEL
BALL (2)
3) Remove the 14 mm circlip from the shift slider assembly.
[1]
SHIFT SLIDER
ASSEMBLY
[2]
14 mm CIRCLIP
14-18
4) Remove the 3 x 12.8 mm roller from the shift slider
assembly using a commercially available pin driver.
[1]
3 x 12.8 mm
ROLLER
[2]
SHIFT SLIDER
ASSEMBLY
5) Remove the shift plate from the shift slider, then remove
the two shift springs and the two #9 steel balls.
NOTICE
Take care not to let the shift springs and the #9 steel balls
pop out of the shift slider during removal of the shift plate.
[2]
#9 STEEL BALLS
[1]
SHIFT SLIDER
[3]
SHIFT PLATE
[4]
SHIFT SPRINGS
6) Remove the reverse bevel gear/bearing assembly and the
propeller shaft from the propeller shaft holder using the
hydraulic press as shown.
[1]
PROPELLER
SHAFT HOLDER
[3]
HYDRAULIC
PRESS TABLE
[4]
REVERSE BEVEL
GEAR/BEARING
ASSEMBLY
14-19
[2]
PROPELLER
SHAFT
7) Before removing the bearing, check the bearing for
abnormal sound and play. Replace if necessary.
8) Install a commercially available universal bearing puller
between the reverse bevel gear and the bearing.
9) Remove the bearing from the reverse bevel gear using the
special tools as shown.
Replace the bearing with a new one on assembly.
TOOLS:
Driver
Attachment, 27.2
Pilot, 35 mm
07749-0010000
07747-0010300
07746-0040800
[1]
DRIVER
07749-0010000
[5]
UNIVERSAL
BEARING PULLER
(Commercially
available)
[4]
PILOT, 35 mm
07746-0040800
10) Check the thrust bearing for abnormal sound and play.
Replace if necessary.
11) Remove the thrust bearing, thrust bearing washer and the
105 x 3.1 mm O-ring from the propeller shaft holder.
Replace the O-ring with a new one on assembly.
[2]
ATTACHMENT, 27.2
07747-0010300
[1]
PROPELLER
SHAFT HOLDER
[3]
50 x 90 x 20 mm
RADIAL BALL
BEARING
[2] 105 x 3.1 mm
O-RING
[3]
THRUST
BEARING
[4]
THRUST BEARING
WASHER
12) Before removing the 30 x 45 x 7 mm water seals, check the
water seal lips for cut and other damage. Replace the water
seals if necessary.
[1]
30 x 45 x 7 mm
WATER SEALS
13) Remove the two 30 x 45 x 7 mm water seals from the
propeller shaft holder using a commercially available oil
seal remover.
Replace the water seals with the new ones on assembly.
[2]
PROPELLER
SHAFT HOLDER
14-20
14) Check the needle bearing for abnormal sound and play
before removal. Replace the needle bearing if necessary.
15) Remove the needle bearing from the propeller shaft holder
using the special tools as shown.
Replace the needle bearing with a new one on assembly.
TOOLS:
Remover weight
Remover handle
Bearing remover, 30 mm
[1]
REMOVER WEIGHT
07741-0010201
[2]
REMOVER HANDLE
07936-3710100
07741-0010201
07936-3710100
07936-8890300
[4]
PROPELLER
SHAFT HOLDER
b. INSPECTION
• CLUTCH SHIFTER
[3]
BEARING REMOVER,
30 mm
07936-8890300
[1] CLUTCH PARTS
Check the clutch part of the forward and reverse sides for wear
and damage.
• PROPELLER SHAFT O.D.
STANDARD
SERVICE LIMIT
At forward
bevel gear
24.987 – 25.000 mm
(0.9837 – 0.9843 in)
24.966 mm
(0.9829 in)
At needle
bearing
30.007 – 30.020 mm
(1.1814 – 1.1819 in)
29.990 mm
(1.1807 in)
[1]
AT FORWARD
BEVEL GEAR
[2]
AT NEEDLE
BEARING
14-21
c. COMPONENTS DRAWING
[6]
3 x 12.8 mm
ROLLER
[3]
CROSS PIN RING
[2]
8 x 47 mm
SHIFTER PIN
[7]
14 mm CIRCLIP
[9]
SHIFT SPRING (2)
[4]
SHIFT
SLIDER
[10]
SHIFT PLATE
[1]
CLUTCH SHIFTER
[8]
#9 STEEL BALLS
[5]
#7 STEEL
BALL (2)
[19]
PROPELLER SHAFT
[11]
REVERSE
BEVEL GEAR
[12]
50 x 90 x 20 mm
RADIAL BALL
BEARING
[13]
THRUST
BEARING
[14]
THRUST BEARING
WASHER
[15]
105 x 3.1 mm
O-RING
[17]
30 x 37 x 26 mm
NEEDLE BEARING
[18]
30 x 45 x 7 mm
WATER SEAL (2)
14-22
[16]
PROPELLER
SHAFT HOLDER
d. ASSEMBLY
1) Apply gear oil to the circumference of the new needle
bearing.
2) Install the needle bearing on the propeller shaft holder
using the special tools and the hydraulic press.
TOOLS:
Attachment, 62 x 68 mm
Outer driver attachment, 30 x 37
[1]
ATTACHMENT,
62 x 68 mm
07746-0010500
[2]
OUTER DRIVER
ATTACHMENT,
30 x 37
070PD-ZY60200
07746-0010500
070PD-ZY60200
NOTICE
Install the needle bearing with the stamped side toward the
special tools.
[4]
PROPELLER
SHAFT HOLDER
3) Apply soapy water to the circumference of the new 30 x 45
x 7 mm water seals.
[1] 30 x 45 x 7 mm
WATER SEALS
[3]
30 x 37 x 26 mm
NEEDLE BEARING
[2] <Water seal installation
direction>
4) Drive the 30 x 45 x 7 mm water seals one by one into the
propeller shaft holder using the special tool. Note the
installation direction of the water seals.
Apply grease to the water seal mating surfaces before
installation.
TOOL:
Oil seal driver
07947-SB00100
[4]
OIL SEAL DRIVER
07947-SB00100
5) After installation of the water seals, apply grease to the
water seal lips.
[5]
PROPELLER
SHAFT HOLDER
14-23
[3]
(Apply grease to the
water seal mating
surfaces and the lips.)
6) Apply gear oil to the circumference of the new bearing.
7) Install the bearing on the revere bevel gear using the
special tools and the hydraulic press.
TOOLS:
Driver
Attachment, 62 x 68 mm
Pilot, 35 mm
07749-0010000
07746-0010500
07746-0040800
NOTICE
[1]
DRIVER
07749-0010000
[5]
REVERSE BEVEL
GEAR
Install the bearing holding the inner part of the bearing.
[2]
ATTACHMENT,
62 x 68 mm
07746-0010500
[3]
PILOT, 35 mm
07746-0040800
[4]
50 x 90 x 20 mm
RADIAL BALL
BEARING
8) Apply gear oil to the circumference of the thrust bearing.
9) Soak the propeller shaft holder in the container filled with
oil with the reverse bevel gear/bearing assembly
installation side toward down.
10) Heat the oil to 80 – 90˚C (176 – 194˚F).
11) Check that there is no groove at the spline of the propeller
installation side of the propeller shaft.
[1]
THERMOMETER
[2]
PROPELLER
SHAFT
HOLDER
[1]
[4]
<LC, XC, LD and XD types> <XCC, LCD and XCD types>
[2] No groove
[5] Groove
[3]
Heat the oil to 80 – 90˚C
(176 – 194˚F).
[3]
PROPELLER SHAFT
[3]
PROPELLER SHAFT
12) After the entire of the propeller shaft holder becomes hot,
remove the holder from the container, and install the thrust
bearing washer, thrust bearing, propeller shaft and the
reverse bevel gear/bearing assembly in this order quickly
on the propeller shaft holder.
Note to install the thrust bearing water with the chamfered
side toward the holder.
NOTICE
[4]
REVERSE BEVEL
GEAR/BEARING
ASSEMBLY
[5]
PROPELLER
SHAFT
[8]
THRUST
BEARING
• Do not heat the oil above 90˚C (194˚F).
• The entire holder becomes hot. Be sure to wear the
gloves during the operation.
[6]
THRUST
BEARING
WASHER
13) Apply grease to the circumference of the new 105 x 3.1 mm
O-ring and install it on the propeller shaft holder.
NOTICE
Wait until the propeller shaft holder cools down before
installing the O-ring.
14-24
[7]
CHAMFER
[2]
PROPELLER
SHAFT HOLDER
14) Install the shift spring, two #9 steel balls, shift spring and
the shift plate in this order in the shift slider.
15) Install the 3 x 12.8 mm roller while aligning the hole in the
shift slider with the hole in the shift plate, then install the 14
mm circlip.
[2]
3 x 12.8 mm
ROLLER
[3]
SHIFT SPRINGS
[1]
SHIFT SLIDER
[4]
SHIFT PLATE
[6]
14 mm CIRCLIP
16) Set the #7 steel balls in the steel ball installation holes in
the shift slider assembly, then push the shift slider
assembly slowly into the propeller shaft.
NOTICE
[1]
PROPELLER
SHAFT
[5]
#9 STEEL BALLS
[2]
SHIFT SLIDER
ASSEMBLY
Push the shift slider assembly into the propeller shaft with
care not to allow the #7 steel balls to pop out.
[3]
#7 STEEL BALL (2)
17) With the “F” mark on the clutch shifter toward the forward
bevel gear (i.e. toward front), assemble the clutch shifter
with the propeller shaft while aligning the 8 x 47 mm shifter
pin installation hole with the long hole in the propeller
shaft.
[1]
“F” MARK
[3]
FORWARD BEVEL
GEAR SIDE
[2]
REVERSE BEVEL
GEAR SIDE
[4]
SHIFTER PIN
INSTALLATION HOLE
[5]
LONG HOLE IN
PROPELLER SHAFT
[7]
CLUTCH SHIFTER
[6]
PROPELLER SHAFT
14-25
18) Install the 8 x 47 mm shifter pin while aligning the hole in
the clutch shifter with the hole in the shift slider.
[2]
8 x 47 mm
SHIFTER PIN
[1]
HOLE IN SHIFT
SLIDER
[3]
SHIFT SLIDER
[5]
HOLE IN CLUTCH
SHIFTER
[4]
CLUTCH SHIFTER
19) Install the cross pin ring on the clutch shifter.
[2]
CROSS PIN RING
NOTICE
Check that the coils of the cross pin ring do not overlap
each other.
20) Check that the #7 steel balls are set in the groove in the
propeller shaft securely as shown.
Check procedure:
• Be sure that the clutch shifter is not at the reverse bevel
gear installation side.
If it is at the reverse bevel gear installation side, pull up
the shift slider assembly slowly.
• Be sure that the #7 steel balls cannot be checked through
the gap between the propeller shaft and shift slider.
If the steel balls can be checked, push in the shift slider
assembly slowly again.
21) Install the following parts.
– Propeller shaft holder assembly (P. 14-17)
– Water pump/shift rod (P. 14-12)
– Gear case assembly (P. 14-5)
– Propeller (P. 14-2)
14-26
[1]
CLUTCH SHIFTER
[1]
CLUTCH SHIFTER
[2]
GROOVE
[5]
#7 STEEL BALL (2)
[3]
PROPELLER
SHAFT
[4]
SHIFT SLIDER
6. VERTICAL SHAFT/BEVEL GEAR [*1]
[1]
VERTICAL SHAFT
a. DISASSEMBLY
Remove the following parts.
– Propeller (P. 14-2)
– Gear case assembly (P. 14-3)
– Water pump/shift rod (P. 14-7)
– Propeller shaft holder assembly (P. 14-17)
1) Attach the special tool to the end (crankshaft installation
side) of the vertical shaft.
TOOL:
Vertical shaft holder
07SPB-ZW10200
[2]
VERTICAL SHAFT
HOLDER
07SPB-ZW10200
[3]
PINION GEAR
NUT
2) Place a shop towel or equivalent material as shown to
protect the gear case.
3) Holding the special tool, remove the pinion gear nut and
the pinion gear.
[5]
GEAR CASE
[4]
SHOP TOWEL
4) Remove the 64 mm lock nut using the special tool as
shown.
TOOL:
Lock nut wrench, 30/64 mm
07916-MB00002
[1]
LOCK NUT WRENCH,
30/64 mm
07916-MB00002
5) Remove the vertical shaft assembly.
NOTICE
Take care not to drop the needle bearing (roller) when
removing the vertical shaft assembly.
6) Check the needle bearing for abnormal sound and play. If
there is abnormal sound and play, replace the roller and the
outer race as a set.
7) Remove the needle bearing (roller).
8) Check the taper bearing (inner race) of the forward bevel
gear/taper bearing assembly for noise, play and other
abnormality. Replace together with the outer race as a set
if necessary.
9) Remove the forward bevel gear/taper bearing assembly.
14-27
[1] FORWARD
BEVEL
GEAR/TAPER
BEARING
ASSEMBLY
[2]
NEEDLE
BEARING
(ROLLER)
10) Check the taper bearing (outer race) for damage before
removing it. Replace together with the inner race as a set if
necessary.
11) Remove the taper bearing (outer race) using the special
tools as shown.
TOOLS:
Remover weight
Remover handle
Bearing race puller
[1]
REMOVER
WEIGHT
07741-0010201
[2]
BEARING RACE
PULLER
070PC-ZY3A100
[3]
FORWARD
BEVEL
GEAR SHIM
07741-0010201
07936-3710100
070PC-ZY3A100
12) Remove the forward bevel gear shim from the gear case.
Replace the forward bevel gear shim with a new one on
assembly.
[5]
REMOVER HANDLE
07936-3710100
[4]
50 x 90 x 28 mm
TAPER BEARING
(OUTER RACE)
13) Remove the oil slinger from the vertical shaft by expanding
the cut in the oil slinger with a screwdriver.
[1]
OIL SLINGER
[2]
VERTICAL SHAFT
14) Check the taper roller bearing for noise, play and other
abnormality before removing it. Replace the inner race and
the outer race as a set if necessary.
15) Set a commercially available universal bearing puller on
the taper roller bearing (inner race), and install the vertical
shaft on the hydraulic press with the crankshaft installation
side toward up.
16) Remove the taper roller bearing from the vertical shaft
using the hydraulic press.
17) Remove the pinion gear shim from the vertical shaft.
Replace the pinion gear shim with a new one on assembly.
14-28
[2]
VERTICAL SHAFT
[1]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
[3]
UNIVERSAL
BEARING PULLER
(Commercially
available)
18) Check the needle bearing (outer race) in the gear case for
damage before removing it. Replace the needle bearing
(outer race) if necessary.
19) Attach the special tools to the needle bearing (outer race)
and place a shop towel or equivalent material under the
needle bearing (outer race) as shown.
TOOLS:
Driver handle, 15 x 280 mm
Bearing driver attachment, 37 mm
Pilot, 35 mm
[1]
DRIVER HANDLE,
15 x 280 mm
07949-3710001
07949-3710001
07ZMD-MBW0200
07746-0040800
[2]
BEARING DRIVER
ATTACHMENT,
37 mm
07ZMD-MBW0200
20) Remove the needle bearing (outer race) from the gear case
using the special tools.
NOTICE
• Remove the needle bearing (outer race) with care not to
damage the gear case.
• Replace the needle bearing (outer race) and the roller as
a set on assembly.
[6]
NEEDLE BEARING
(OUTER RACE)
[5]
PILOT, 35 mm
07746-0040800
b. INSPECTION
• VERTICAL SHAFT O.D.
At needle
bearing
STANDARD
SERVICE LIMIT
28.556 – 28.575 mm
(1.1242 – 1.1250 in)
28.545 mm
(1.1238 in)
[1]
AT NEEDLE
BEARING
14-29
[3]
GEAR CASE
[4]
SHOP TOWEL
c. COMPONENTS DRAWING
[1]
VERTICAL SHAFT
[2]
64 mm LOCK NUT
123 N.m (12.5 kgf.m, 90 lbf.ft)
[3]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
(INNER RACE)
[4]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
(OUTER RACE)
[3]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
(INNER RACE)
[16]
OIL SLINGER
[5]
PINION GEAR
SHIM
*1
[15]
GEAR CASE
[6]
FORWARD BEVEL
GEAR
[7]
50 x 90 x 28 mm
TAPER BEARING
(INNER RACE)
[8]
NEEDLE BEARING
(OUTER RACE)
[9]
NEEDLE BEARING
(ROLLER)
[13]
FORWARD BEVEL
GEAR SHIM
[14]
*1: Replace the inner race and the outer race as a set
after removing the taper bearing (inner race) from
the forward bevel gear.
14-30
[12]
50 x 90 x 28 mm
TAPER BEARING
(OUTER RACE)
[10]
PINION GEAR
[11]
PINION GEAR NUT
142 N.m (14.5 kgf.m, 105 lbf.ft)
d. ASSEMBLY
NOTICE
Measure the bearing height from the end of the taper bearing
outer race to the end of the inner race and record the
measurement before installing the 50 x 90 x 28 mm taper
bearing on the forward bevel gear (P. 14-39).
1) Apply gear oil to the inner wall and the roller of the new
taper bearing (inner race).
2) Position a wood block or equivalent material underside the
forward bevel gear.
3) Install the taper bearing on the forward bevel gear using
the special tools and the hydraulic press.
TOOLS:
Driver
Oil seal driver, 52 x 55 mm
07749-0010000
07NAD-P200100
or 07NAD-P20A100
[1]
DRIVER
07749-0010000
[5]
50 x 90 x 28 mm
TAPER BEARING
(INNER RACE)
[4]
WOOD BLOCK
4) Install the new forward bevel gear shim in the gear case.
5) Apply gear oil to the circumference of the taper bearing
(outer race).
6) Install the taper bearing (outer race) in the gear case using
the special tools as shown.
TOOLS:
Driver handle, 480 mm
Taper vearing installer attachment
[2]
OIL SEAL DRIVER,
52 x 55 mm
07NAD-P200100 or
07NAD-P20A100
[3]
FORWARD
BEVEL GEAR
[1]
DRIVER HANDLE,
480 mm
070GD-0010100
[2]
FORWARD
BEVEL GEAR
SHIM
070GD-0010100
070PF-ZY60100
NOTICE
Install the taper bearing (outer race) with the larger
diameter side toward the forward bevel gear.
7) Install the forward bevel gear/taper bearing assembly in the
gear case.
[4]
TAPER BEARING
INSTALLER ATTACHMENT
070PF-ZY60100
8) Install the pinion gear on the vertical shaft and loosely
tighten the pinion gear nut by hand.
9) Apply gear oil to the inner wall of the inner race, roller and
the circumference of the outer race of the taper roller
bearings. Assemble the inner races and outer race.
10) Install the pinion gear shim, taper roller bearing and the
special tool on the vertical shaft.
TOOL:
Driver shaft, B
14-31
07964-MB00200
[3]
50 x 90 x 28 mm
TAPER BEARING
(OUTER RACE)
[2]
VERTICALL
SHAFT
[1]
DRIVER SHAFT, B
07964-MB00200
[3]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
11) Position the vertical shaft on the hydraulic press with the
pinion gear side facing up.
12) Install the taper roller bearing on the vertical shaft using the
hydraulic press.
NOTICE
• Check that the ends of the special tool are set on the taper
roller bearing inner race and on the hydraulic press table
securely.
• Do not ruin the threads at the end of the vertical shaft
(pinion gear nut installation part).
13) Remove the pinion gear nut and the pinion gear from the
vertical shaft.
[2]
PINION GEAR
NUT
[1]
VERTICAL
SHAFT
[3]
PINION
GEAR
[4]
PINION GEAR
SHIM
[8]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
[5]
Set securely.
[7]
DRIVER SHAFT, B
07964-MB00200
[6] HYDRAULIC
PRESS TABLE
14) Install the oil slinger on the vertical shaft aligning the
projection on the inside of the oil slinger with the concave
of the pinion gear installation side of the vertical shaft.
[1]
VERTICAL
SHAFT
[2] PROJECTION
[3]
CONCAVE
[4]
OIL SLINGER
15) Attach the special tool to the new needle bearing as shown.
Install the needle bearing with the stamped side of the
needle bearing (outer race) toward the special tool.
TOOL:
Oil seal driver attachment, 27.5 x 44 mm
14-32
07948-9540000
[1]
OIL SEAL DRIVER
ATTACHMENT,
27.5 x 44 mm
07948-9540000
[2]
NEEDLE
BEARING
16) Install the needle bearing in the gear case using the special
tools.
TOOLS:
Shaft installer, 15 x 370 mm
07VMF-KZ30200
Attachment, 78 x 90 mm
07GAD-SD40101
Oil seal driver attachment, 27.5 x 44 mm 07948-9540000
[1]
SHAFT INSTALLER,
15 x 370 mm
07VMF-KZ30200
17) After installation, check that the bottom surface of the
needle bearing is flush with the bottom of the gear case.
Apply grease to the needle bearing roller.
[2]
ATTACHMENT,
78 x 90 mm
07GAD-SD40101
[6]
NEEDLE
BEARING
[5]
(Apply grease
to the roller.)
[4]
OIL SEAL DRIVER
ATTACHMENT,
27.5 x 44 mm
07948-9540000
18) Install the vertical shaft assembly taking care not to bring
the needle bearing roller out of position.
19) Apply the thread locking agent to the threads and seat of
the 64 mm lock nut, and tighten the lock nut using the
special tool.
TOOL:
Lock nut wrench, 30/64 mm
TORQUE: 123 N.m (12.5 kgf.m, 90 lbf.ft)
14-33
07916-MB00002
[1]
LOCK NUT WRENCH,
30/64 mm
07916-MB00002
[3]
GEAR CASE
20) Wipe the tapered part of the vertical shaft and pinion gear
with a shop towel and a degreasing cleaning solvent.
[1]
VERTICAL SHAFT
21) Attach the special tool to the end (crankshaft installation
side) of the vertical shaft as shown.
TOOL:
Vertical shaft holder
07SPB-ZW10200
22) Place a shop towel in the gear case as shown to protect the
gear case.
23) Apply gear oil to the threads and seat of the pinion gear
nut.
[2]
VERTICAL SHAFT
HOLDER
07SPB-ZW10200
[3]
PINION GEAR
NUT
[5]
GEAR CASE
[4]
SHOP TOWEL
24) Install the pinion gear on the vertical shaft. Holding the
special tool in the position, tighten the pinion gear nut to
the specified torque.
TORQUE: 142 N.m (14.5 kgf.m, 105 lbf.ft)
NOTICE
Check that the forward bevel gear/taper bearing assembly
is set properly.
25) Install the following parts.
– Propeller shaft holder assembly (P. 14-17)
– Water pump/shift rod (P. 14-12)
– Gear case assembly (P. 14-5)
– Propeller (P. 14-2)
14-34
7. SHIM SELECTION [*1]
[1]
PINION GEAR
NUT
NOTICE
[2]
VERTICAL
SHAFT
Adjust the shim thickness after replacing the gear case, vertical
shaft, bearing, taper bearing and the taper roller bearing.
a. PINION GEAR SHIM
Remove the taper roller bearing if it is mounted on the vertical
shaft (P. 14-28).
1) Wipe the tapered part of the vertical shaft and pinion gear
with a shop towel and a degreasing cleaning solvent.
2) Install the pinion gear on the vertical shaft and tighten the
pinion gear nut to the specified torque.
[4]
PINION GEAR
[3]
TAPERED PARTS
TORQUE: 142 N.m (14.5 kgf.m, 105 lbf.ft)
NOTICE
• Do not install the vertical shaft in the gear case.
• We recommend that you attach the special tool (vertical
shaft holder) at the end of the vertical shaft to facilitate
tightening of the pinion gear nut to the specified torque
(P. 14-34).
3) Do not confuse the pinion gear side and the taper roller
bearing side of the special tool.
Do not score and scratch the opposite side (measurement
side) from the side where the tool number is stamped.
TOOL:
Gauge adapter, 110 mm
[1]
GAUGE ADAPTER,
110 mm
070PJ-ZY30100
[2]
TAPER ROLLER
BEARING SIDE
[3]
PINION GEAR
SIDE
070PJ-ZY30100
4) Holding the special tool with the side of the stamped tool
number facing the opposite side from the pinion gear, be
sure that the tool of the pinion gear nut side is not set on
the nut.
Tighten the bolts by hand while pushing both tools toward
the pinion gear side.
NOTICE
• Do not tighten the bolts with a tool.
• There must be no wobbling in the special tool. It must
securely set on the pinion gear.
5) Set both tools on both sides of the flange of the vertical
shaft with the side of the special tool stamped with the tool
number and the tapered part facing the opposite side from
the pinion gear as shown. Tighten the bolts by hand.
[1]
Tool must not
get on the nut.
[2]
PINION
GEAR
[3] MEASUREMENT
SURFACES
[6]
BOLT (2)
[5]
PINION GEAR
NUT
[4]
TOOL NO.
STAMPED
SURFACE
[1]
MEASUREMENT
SURFACE
NOTICE
[2]
TOOL NO.
STAMPED
SURFACE
• Do not tighten the bolts with a tool.
• There must be no wobbling in the special tool. It must
securely set on the pinion gear.
[3]
TAPERED
SURFACE
[4] BOLTS
14-35
6) Hold the vertical shaft upright (with the pinion gear toward
up) and secure the vertical shaft.
[1]
DEPTH GAUGE
(Commercially
available)
7) Set the commercially available depth gauge at the gauge
adapter of the pinion gear side as shown. Measure the
vertical shaft length (distance D) and record it.
[2]
PINION GEAR
[3]
GAUGE ADAPTER,
110 mm
070PJ-ZY30100
8) Assemble the outer race and the inner race of the 30 x 62 x
40 mm taper roller bearing, and turn the outer race two or
three turns.
9) Measure the bearing height from the outer race end to the
inner race end as shown, and record the measurement.
10) Measure the height of the taper roller bearing outer race
and record it.
14-36
[1] OUTER RACE
[2]
INNER RACE
[1] OUTER RACE
11) Calculate the gap (distance E) between the outer race and
inner race using the measurements obtained in step 9 and
10 and the following formula.
Formula:
Bearing height – Outer race height = Gap (distance E)
Example:
When, bearing height from the outer race end to the inner
race end is 34.9 mm (1.37 in),
And, outer race height is 29.7 mm (1.17 in):
34.9 – 29.7 = 5.2
Therefore, the gap (distance E) is 5.2 mm (0.20 in).
12) Determine the calculation value using the vertical shaft
length (distance D) obtained in step 7 and the gap (distance
E) obtained in step 11 and the following formula.
Formula:
Vertical shaft length (distance D) + Gap (distance E) – 147.2
= Calculation value
Example:
When, vertical shaft length (distance D) is 141.8 mm (5.58
in),
And, gap (distance E) is 5.2 mm (0.20 in):
141.8 + 5.2 – 147.2= –0.20
Therefore, the calculation value is –0.20 mm (–0.008 in).
[1]
GEAR CASE
13) Cross reference the calculation value and the engagement
mark located on the trim tab installation part of the gear
case, and select the shim of the appropriate thickness from
the shim selection table accordingly.
• Shim type table
[1] Shim type
[2] Thickness
[3] Pinion gear shim A
0.10 mm (0.004 in)
[4] Pinion gear shim B
0.15 mm (0.006 in)
[5] Pinion gear shim C
0.30 mm (0.012 in)
[6] Pinion gear shim D
0.50 mm (0.020 in)
14-37
[2]
ENGAGEMENT
MARK
• Pinion gear shim selection table
[3] Unit: mm (in)
[2] Calculation value
[1] Engagement
mark on the
gear case
+0.41 (+0.0161) +0.35 (+0.014) +0.30 (+0.0118) +0.25 (+0.010) +0.20 (+0.008) +0.15 (+0.006) +0.10 (+0.004)
–
–
–
–
–
–
–
+0.35 (+0.014) +0.30 (+0.0118) +0.25 (+0.010) +0.20 (+0.008) +0.15 (+0.006) +0.10 (+0.004) +0.05 (+0.002)
F
0.30 (0.0118)
0.35 (0.014)
0.40 (0.0157)
0.45 (0.018)
0.50 (0.020)
0.55 (0.022)
0.60 (0.024)
E
0.25 (0.010)
0.30 (0.0118)
0.35 (0.014)
0.40 (0.0157)
0.45 (0.018)
0.50 (0.020)
0.55 (0.022)
D
0.20 (0.008)
0.25 (0.010)
0.30 (0.0118)
0.35 (0.014)
0.40 (0.0157)
0.45 (0.018)
0.50 (0.020)
C
0.15 (0.006)
0.20 (0.008)
0.25 (0.010)
0.30 (0.0118)
0.35 (0.014)
0.40 (0.0157)
0.45 (0.018)
B
0.10 (0.004)
0.15 (0.006)
0.20 (0.008)
0.25 (0.010)
0.30 (0.0118)
0.35 (0.014)
0.40 (0.0157)
0.10 (0.004)
0.15 (0.006)
0.20 (0.008)
0.25 (0.010)
0.30 (0.0118)
0.35 (0.014)
A
[3] Unit: mm (in)
[2] Calculation value
[1] Engagement
mark on the
gear case
+0.05 (+0.002) ±0 (±0.000) –0.05 (–0.002) –0.10 (–0.004) –0.15 (–0.006) –0.20 (–0.008) –0.25 (–0.010)
–
–
–
–
–
–
–
±0 (±0.000) –0.05 (–0.002) –0.10 (–0.004) –0.15 (–0.006) –0.20 (–0.008) –0.25 (–0.010) –0.31 (–0.0122)
F
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
0.85 (0.033)
0.90 (0.035)
0.95 (0.037)
E
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
0.85 (0.033)
0.90 (0.035)
D
0.55 (0.022)
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
0.85 (0.033)
C
0.50 (0.020)
0.55 (0.022)
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
B
0.45 (0.018)
0.50 (0.020)
0.55 (0.022)
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
A
0.40 (0.0157)
0.45 (0.018)
0.50 (0.020)
0.55 (0.022)
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
• How to read shim selection table
When the engagement mark on the gear case is E and the calculation value is –0.20 mm (–0.008 in) or more, the shim
thickness is 0.80 mm (0.031 in).
When the calculation value is less than –0.20 mm (–0.008 in), the shim thickness is 0.85 mm (0.033 in). (See Shim
selection table above.)
[3] Unit: mm (in)
[2] Calculation value
[1] Engagement
mark on the
gear case
+0.05 (+0.002) ±0 (±0.000) –0.05 (–0.002) –0.10 (–0.004) –0.15 (–0.006) –0.20 (–0.008) –0.25 (–0.010)
–
–
–
–
–
–
–
±0 (±0.000) –0.05 (–0.002) –0.10 (–0.004) –0.15 (–0.006) –0.20 (–0.008) –0.25 (–0.010) –0.31 (–0.0122)
F
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
0.85 (0.033)
0.90 (0.035)
0.95 (0.037)
E
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
0.85 (0.033)
0.90 (0.035)
D
0.55 (0.022)
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
0.85 (0.033)
C
0.50 (0.020)
0.55 (0.022)
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
B
0.45 (0.018)
0.50 (0.020)
0.55 (0.022)
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
A
0.40 (0.0157)
0.45 (0.018)
0.50 (0.020)
0.55 (0.022)
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
• Shim combination
To obtain 0.75 mm (0.030 in) of shim thickness, combine three gear shim As and one gear shim B and one gear shim C,
or combine one gear shim A, one gear shim B and one gear shim D by referring to the shim type table.
14-38
b. FORWARD BEVEL GEAR SHIM
[1]
OUTER RACE
1) Assemble the outer race and the inner race of the new 50 x
90 x 28 mm taper bearing, and turn the outer race two or
three turns.
2) Measure the bearing height (distance F) from the outer race
end to the inner race end as shown, and record the
measurement.
[2]
INNER RACE
3) Determine the calculation value using the bearing height
(distance F) and the following formula.
Formula:
Bearing height (distance F) – 28 = Calculation value
Example:
When bearing height (distance F) is 28.05 mm (1.104 in):
28.05 – 28 = 0.05
Therefore, the calculation value is 0.05 mm (0.002 in).
4) Cross reference the calculation value and the engagement
mark located on the trim tab installation part of the gear
case, and select the shim of the appropriate thickness from
the shim selection table accordingly.
[1]
GEAR CASE
• Shim type table
[1] Shim type
[2] Thickness
[3] Forward bevel gear shim A
0.10 mm (0.004 in)
[4] Forward bevel gear shim B
0.15 mm (0.006 in)
[5] Forward bevel gear shim C
0.30 mm (0.012 in)
[6] Forward bevel gear shim D
0.50 mm (0.020 in)
• Pinion gear shim selection table
[3] Unit: mm (in)
[1] Engagement
mark on the
gear case
[2] Calculation value
+0.10 (+0.004)
–
+0.05 (+0.002)
+0.05 (+0.002)
–
±0 (±0.000)
1
0.40 (0.016)
0.45 (0.018)
2
0.35 (0.014)
0.40 (0.016)
3
0.30 (0.012)
0.35 (0.014)
4
0.25 (0.010)
0.30 (0.012)
5
0.20 (0.008)
0.25 (0.010)
6
0.15 (0.006)
0.20 (0.008)
Refer to page 14-38 for the information on how to read the
shim selection table and shim combination.
14-39
[2]
EMGAGEMENT
MARK
8. SHIM POSITION [*1]
[1]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
(INNER RACE)
[11]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
(OUTER RACE)
[10]
PINION GEAR SHIM
SELECTION: P. 14-35
[9]
VERTICAL SHAFT
[8]
PINION GEAR
[7]
PINION GEAR NUT
142 N.m (14.5 kgf.m, 105 lbf.ft)
[2]
50 x 90 x 28 mm
TAPER BEARING
(INNER RACE)
[3]
FORWARD BEVEL
GEAR SHIM
SELECTION: P. 14-39
ADJUSTMENT: P. 14-41
[6]
REVERSE BEVEL
GEAR
14-40
[5]
FORWARD BEVEL
GEAR
[4]
50 x 90 x 28 mm
TAPER BEARING
(OUTER RACE)
9. BACKLASH ADJUSTMENT [*1]
a. FORWARD BEVEL GEAR BACKLASH
Backlash adjustment must be made after adjustment of each
gear shim (P. 14-35).
Install the parts except the water pump in the gear case (P. 1412, 17 and 31).
1) Hold the propeller shaft securely with the special tool as
shown, and tighten the puller bolt to the specified torque.
TOOLS:
Puller jaws
Puller bolt
07SPC-ZW0010Z
07SPC-ZW0011Z
[1]
PULLER BOLT
07SPC-ZW0011Z
[2]
PULLER JAWS
07SPC-ZW0010Z
TORQUE: 5 N.m (0.5 kgf.m, 3.6 lbf.ft)
Turn the vertical shaft five to ten turns clockwise to fit the
bevel gear bearing.
[1]
BACKLASH
INDICATOR
ATTACHMENT
07SPK-ZW10100
2) Attach the special tool to the vertical shaft as shown, and
adjust the dial indicator so its needle is at the line “2” of the
special tool (backlash indicator tool).
TOOLS:
Backlash indicator tool
Backlash indicator attachment
90˚
90˚
90˚
90˚
[2]
BACKLASH
INDICATOR TOOL
07SPJ-ZW0030Z
07SPJ-ZW0030Z
07SPK-ZW10100
3) Turn the vertical shaft lightly right and left and record the
dial indicator reading.
Measure the backlash at the four points (by turning the
vertical shaft 90˚) in the same manner.
NOTICE
Do not turn the propeller shaft when turning the vertical
shaft.
4) Obtain the forward bevel gear backlash using the dial
indicator runout and the following formula.
Formula:
Dial indicator runout ÷ 0.86 = Backlash
Example:
When dial indicator runout is 0.195 mm (0.0077 in):
0.195 ÷ 0.86 = 0.23
Therefore, the backlash is 0.23 mm (0.009 in).
Standard value
0.10 – 0.30 mm
(0.004 – 0.012 in)
5) If the backlash is too large, increase the forward bevel gear
shim thickness and recheck the backlash.
If the backlash it too small, reduce the forward bevel gear
shim thickness and recheck the backlash.
NOTICE
Use the special tool when 50 x 90 x 28 mm taper bearing
outer race is removed to adjust the backlash again (P. 1428).
14-41
[4]
VERTICAL
SHAFT
[3]
DIAL INDICATOR
Adjust the dial indicator needle at
line “2” of the backlash indicator
tool.
10. GEAR CASE ASSEMBLY [*2]
[1]
SPEED SENSOR
TUBE B
a. REMOVAL
1) Place the remote control lever in the “N” (Neutral) position.
2) Tilt up the outboard motor to the uppermost position.
3) Disconnect the speed sensor tube B and the speed sensor
tube C.
[2]
SPEED SENSOR
TUBE C
4) Remove the 10 x 32 mm hex. bolt and the 10 mm washer.
Remove the gear case cover from the gear case assembly.
[1]
GEAR CASE
COVER
[3]
10 mm WASHER
5) Remove the seven 10 x 40 mm hex. bolts and the seven 10
mm washers, then remove the gear case assembly from
the outboard motor.
[2]
10 x 32 mm
HEX. BOLT
[1]
6 x 10 mm
DOWEL PIN (2)
6) After removing the gear case assembly, lower the outboard
motor to the lowermost position.
[2]
10 mm
WASHER (7)
[4]
GEAR CASE
ASSEMBLY
[3]
10 x 40 mm
HEX. BOLT (7)
14-42
7) Remove the shift rod A from the shift shaft A.
[2]
SHIFT
ROD A
[1]
SHIFT
SHAFT A
b. COMPONENTS DRAWING
[1]
SHIFT ROD A
[9]
VERTICAL SHAFT
[8]
6 x 10 mm
DOWEL PIN (2)
[2]
10 mm WASHER (7)
[7]
GEAR CASE
ASSEMBLY
[3]
10 x 40 mm HEX. BOLT (7)
34 N.m (3.5 kgf.m, 25 lbf.ft)
[4]
GEAR CASE COVER
[6]
10 mm WASHER
14-43
[5]
10 x 32 mm HEX. BOLT
c. INSTALLATION
1) Place the remote control lever in the “N” (Neutral) position.
[1]
CUTOUT
2) Check that the shift rod of the gear case is in the “N”
(Neutral) position.
To check:
Check whether the cutout of the shift rod spline faces in the
direction shown. [It indicates that the shift rod is in the “N”
(Neutral) position.]
3) If the cutout of the spline is not in the direction shown,
protect the spline with a shop towel or equivalent material
and turn the shift rod right and left with a wrench until the
cutout faces toward the specified direction.
[3]
SHIFT ROD
[2] CRUISING
DIRECTION
[2]
SHIFT ROD
[1]
SHOP TOWEL
4) Tilt up the outboard motor to the uppermost position.
5) Apply grease to the spline of the shift rod A.
6) Install the shift rod A by aligning the projection of the shift
shaft A with the cutout in the spline of the shift rod A. Check
that the cutout in the spline of the shift rod A is toward the
cruising direction.
[1]
SHIFT SHAFT A
[2]
PROJECTION
[3]
CUTOUT
[4] CRUISING
DIRECTION
[4]
CRUISING
DIRECTION
[5]
SHIFT ROD A
14-44
7) Apply grease to the vertical shaft spline and the shift rod
spline.
Apply grease to the water tube insertion part and to the
inner wall of the water tube seal ring of the impeller
housing.
Apply grease to the inner wall of the vertical shaft bushing
[XCC and XCD types only] (P. 14-90).
[3]
WATER TUBE
SEAL RING
8) Install the two dowel pins. Aligning the water tube with the
water tube seal ring of the impeller housing, install the
vertical shaft and the crankshaft. Install the shift rod and
shift rod A, too, by aligning the splines.
9) Install the gear case assembly on the outboard motor.
Loosely tighten the seven 10 mm washers and the seven 10
x 40 mm hex. bolts.
[2]
VERTICAL
SHAFT
[1]
WATER TUBE
[4]
6 x 10 mm
DOWEL PIN (2)
[7]
10 mm
WASHER (7)
[6]
10 x 40 mm
HEX. BOLT (7)
[5]
GEAR CASE
ASSEMBLY
10) Connect the speed sensor tube B and the speed sensor
tube C.
[1] SPEED SENSOR
TUBE B
11) Lower the outboard motor to the lowermost position and
tighten the seven 10 x 40 mm hex. bolts to the specified
torque.
TORQUE: 34 N.m (3.5 kgf.m, 25 lbf.ft)
[2]
SPEED SENSOR
TUBE C
12) Position the gear case cover on the gear case assembly.
[1] GEAR CASE COVER
[2] “
” MARKS
13) Install the gear case cover aligning the “ ” mark on the
gear case cover with the “ ” mark on the gear case.
Tighten the 10 mm washer and the 10 x 32 mm hex. bolt.
14) After installing the gear case assembly, adjust the shift
control cable (P. 3-25).
[3]
10 x 32 mm
HEX. BOLT
[4]
10 mm WASHER
14-45
11. WATER PUMP/SHIFT ROD [*2]
[1]
WATER TUBE
SEAL RING
a. DISASSEMBLY
Remove the following parts.
– Propeller (P. 14-2)
– Gear case assembly (P. 14-42)
1) Remove the speed sensor tube C.
2) Remove the water tube seal ring from the impeller housing.
[8]
IMPELLER
HOUSING
[2]
8 x 40 mm
HEX. BOLT (4)
[3]
8 mm
WASHER (4)
[7]
VERTICAL
SHAFT
3) Remove the four 8 x 40 mm hex. bolts and the four 8 mm
washers from the impeller housing. Remove the impeller
housing.
Remove the four distance collars from the impeller
housing.
[4]
DISTANCE
COLLAR (4)
4) Remove the woodruff key from the vertical shaft.
[5] WOODRUFF
KEY
[6]
SPEED SENSOR
TUBE C
5) Remove the impeller cover, impeller gasket, two dowel
pins, gear case grommet and the rubber setting plate.
[1]
IMPELLER COVER
NOTICE
Replace the impeller gasket with a new one on assembly.
[5]
IMPELLER
GASKET
[4]
6 x 10 mm
DOWEL PIN (2)
14-46
[2]
GEAR CASE
GROMMET
[3] RUBBER SETTING
PLATE
6) Check the pump impeller for cracks, wear or damage from
overheating, and replace if necessary.
7) Remove the pump impeller, pump liner and the water
pump O-ring from the impeller housing.
Replace the O-ring with a new one on assembly.
[1]
IMPELLER
HOUSING
[4]
WATER PUMP
O-RING
8) Remove the two 6 x 20 mm flange bolts and remove the
water seal housing.
[1]
WATER SEAL
HOUSING
[2]
PUMP LINER
[3]
PUMP IMPELLER
6 x 20 (2)
9) Remove the 58.5 x 3.5 mm O-ring from the water seal
housing.
Replace the O-ring with a new one on assembly.
[2]
58.5 x 3.5 mm
O-RING
10) Before removing the 23 x 36 x 6 mm water seal, check the
water seal lip for cut. Replace if necessary,
11) Remove the two 23 x 36 x 6 mm water seals from the water
seal housing using a commercially available oil seal
remover.
Replace the water seals with the new ones on assembly.
14-47
[1] WATER SEAL
HOUSING
[2]
23 x 36 x 6 mm
WATER SEAL
12) Remove the 6 x 12 mm hex. bolt and the pivot washer.
Remove the shift rod holder and the shift rod assembly.
[1]
SHIFT ROD
HOLDER
[2]
SHIFT ROD
ASSEMBLY
[3]
6 x 12 mm
HEX. BOLT
[4]
PIVOT
WASHER
13) Remove the shift rod spring, 12 mm washer and the 10 mm
E-ring from the shift rod.
[2]
SHIFT ROD SPRING
[1]
10 mm
E-RING
[3]
12 mm
WASHER
[4]
SHIFT ROD
14) Check the 12 x 21 x 6 mm water seal lip for cut and replace
if necessary.
[1] 12 x 21 x 6 mm
WATER SEAL
15) Remove the two 12 x 21 x 6 mm water seals from the shift
rod holder using a commercially available oil seal remover.
[2]
SHIFT ROD
HOLDER
16) Remove the 55.6 x 3.5 mm O-ring from the shift rod holder.
NOTICE
• Replace the 12 x 21 x 6 mm water seals with the new ones
on assembly.
• Replace the 55.6 x 3.5 mm O-ring with a new one on
assembly.
14-48
[3]
55.6 x 3.5 mm
O-RING
b. COMPONENTS DRAWING
[2]
WATER TUBE
SEAL RING
[3]
8 x 40 mm HEX. BOLT (4)
19.7 N.m (2.0 kgf.m, 14 lbf.ft)
[4]
8 mm
WASHER (4)
[1]
IMPELLER HOUSING
[5]
DISTANCE
COLLAR (4)
6 x 20 (2)
[16]
WATER SEAL
HOUSING
[6]
WATER PUMP
O-RING
[7]
PUMP LINER
[15]
58.5 x 3.5 mm
O-RING
[14]
23 x 36 x 6 mm
WATER SEAL (2)
[8]
PUMP IMPELLER
[9]
WOODRUFF KEY
[10]
IMPELLER COVER
[11]
IMPELLER GASKET
[12]
VERTICAL SHAFT
[13]
6 x 10 mm
DOWEL PIN (2)
14-49
[1]
12 x 21 x 6 mm
WATER SEAL (2)
[2]
SHIFT ROD
HOLDER
[15]
55.6 x 3.5 mm O-RING
[14]
SHIFT ROD SPRING
[13]
12 mm WASHER
[12]
10 mm E-RING
[10]
TUBE JOINT
[3]
GEAR CASE
GROMMET
[11]
SHIFT ROD
[9]
SPEED SENSOR
TUBE C
[8]
SENSOR NIPPLE
[7]
6 x 12 mm
HEX. BOLT
[6]
PIVOT WASHER
[4]
RUBBER SETTING
PLATE
[5]
WIRE BAND (2)
Do not reuse.
14-50
c. ASSEMBLY
[1] <Water seal
installation direction>
1) Apply soapy water to the circumference of the 12 x 21 x 6
mm water seals.
2) Drive the 12 x 21 x 6 mm water seals one by one in the shift
rod holder using the special tools. Note the installation
direction of the water seals.
Be sure to apply grease to the water seal mating surfaces
before installation.
TOOLS:
Driver
Oil seal driver attachment, 21 mm
[2]
12 x 21 x 6 mm
WATER SEALS
07749-0010000
07947-ZV00100
3) After installing the water seals, apply grease to the water
seal lips.
[3]
(Apply grease to
the seal mating
surfaces and lips.)
[4]
DRIVER
07749-0010000
[5]
OIL SEAL DRIVER
ATTACHMENT,
21 mm
07947-ZV00100
[6]
SHIFT ROD
HOLDER
4) Position the 10 mm E-ring, 12 mm washer and the shift rod
spring on the shift rod.
[2]
SHIFT ROD SPRING
[3]
12 mm
WASHER
[1]
10 mm
E-RING
[4]
SHIFT ROD
14-51
5) Install the shift rod by aligning the shift cam of the shift rod
with the groove in the shift slider so that the cutout of the
shift rod spline faces in the cruising direction.
[1] CUTOUT
[2] Mark in the shift
rod end.
NOTICE
• Check for marking in the end of the shift rod.
• If the shift cam is in alignment with the groove in the shift
slider but the cutout of the spline is not in the cruising
direction, see the step 3 on page 14-44 and adjust
accordingly.
[4]
CRUISING
DIRECTION
[3]
SHIFT ROD
[1]
[4]
<LC, XC, LD and XD types> <XCC, LCD and XCD types>
[3]
SHIFT ROD
[5] MARK
[2] NO MARK
[3]
SHIFT ROD
[3]
SHIFT ROD
[5]
CAM
[6]
GROOVE IN SHIFT SLIDER
6) Apply grease to the circumference of the new 55.6 x 3.5
mm O-ring and install it on the shift rod holder.
[2] SHIFT ROD
HOLDR
[1]
55.6 x 3.5 mm
O-RING
7) Install the shift rod holder aligning the projection with the
concave in the gear case and tighten it with the pivot
washer and the 6 x 12 mm hex. bolt.
After installation, check that the cutout of the shift rod
spline faces in the cruising direction.
[1]
SHIFT ROD
HOLDER
[2] PROJECTION
[3] 6 x 12 mm
HEX. BOLT
[4] PIVOT
WASHER
[5]
CONCAVE
14-52
8) Apply soapy water to the circumference of the 23 x 36 x 6
mm water seals.
[1] 23 x 36 x 6 mm
WATER SEALS
[2] <Water seal installation
direction>
9) Drive the 23 x 36 x 6 mm water seals one by one in the
water seal housing using the special tools. Note the
installation direction of the water seals.
Be sure to apply grease to the water seal mating surfaces
before installation.
TOOLS:
Driver
Attachment, 32 x 35 mm
07749-0010000
07746-0010100
10) After installing the water seals, apply grease to the water
seal lips.
[4]
DRIVER
07749-0010000
[6]
WATER SEAL
HOUSING
11) Apply grease to the circumference of the new 58.5 x 3.5
mm O-ring and position it on the water seal housing.
12) Install the water seal housing so that the concave faces in
the cruising direction, and tighten it with the two 6 x 20 mm
flange bolts.
[1]
WATER SEAL
HOUSING
[3]
(Apply grease to
the seal mating
surfaces and lips.)
[5]
ATTACHMENT,
32 x 35 mm
07746-0010100
6 x 20
[4]
VERTICAL
SHAFT
[2]
CONCAVE
[3]
58.5 x 3.5 mm
O-RING
14-53
13) Apply grease to the inner wall of the water pump liner.
Install the pump impeller in the water pump liner with the
woodruff key installation groove facing up and the pump
impeller fins in the direction shown.
Be sure to align the hole in the pump liner with the hole in
the pump impeller.
[1]
(Apply grease
to the inside.)
[2] WOODRUFF KEY
INSTALLATION GROOVE
[3]
[2] WOODRUFF KEY
PUMP
INSTALLATION
IMPELLER
GROOVE
[4]
WATER PUMP LINER
14) Install the water pump liner in the impeller housing by
aligning the two projections on the pump liner with the two
grooves inside the impeller housing.
[2]
PROJECTIONS
[1]
“A” POINT
[3] CONCAVES
15) Be sure that the part “A” of the water pump liner is in
alignment with the part “B” of the impeller housing, too.
[6]
WATER PUMP
LINER
[5]
IMPELLER
HOUSING
[4]
“B” POINT
16) Install the rubber setting plate, gear case grommet, two
dowel pins, new impeller gasket and the impeller cover.
[1]
IMPELLER
GASKET
[2]
IMPELLER COVER
[3]
GEAR CASE
GROMMET
[5]
6 x 10 mm
DOWEL PIN (2)
[4]
RUBBER SETTING
PLATE
14-54
17) Install the woodruff key in the groove in the vertical shaft.
Align the groove in the pump impeller with the woodruff
key and install the impeller housing by turning it clockwise.
[2]
WOODRUFF KEY
NOTICE
• Turn the impeller housing clockwise when it is turned
with the pump impeller mounted.
• After installing the impeller housing, check that the
impeller gasket is set in the proper position.
[1]
VERTICAL SHAFT
[5]
GROOVE
[4]
IMPELLER
HOUSING
[3]
GROOVE IN PUMP
IMPELLER
18) Improve the four distance collars on the impeller housing,
and tighten the four 8 mm washers and the four 8 x 40 mm
hex. bolts to the specified torque.
TORQUE: 19.7 N.m (2.0 kgf.m, 14 lbf.ft)
19) Apply grease to the inner wall of the water tube seal ring.
Install the water tube seal ring aligning the projection with
the hole in the housing.
20) Install the speed sensor tube C assembly (5 x 270 mm
tube).
21) Install the following parts.
– Gear case assembly (P. 14-44)
– Propeller (P. 14-2)
[1]
SPEED SENSOR
TUBE C ASSEMBLY
(5 x 270 mm TUBE)
[2]
WATER TUBE
SEAL RING
[3]
8 x 40 mm
HEX. BOLT (4)
[4]
8 mm WASHER (4)
[5]
DISTANCE
COLLAR (4)
[6]
IMPELLER HOUSING
14-55
12. PROPELLER SHAFT HOLDER
ASSEMBLY [*2]
[2] PROPELLER
SHAFT HOLDER
ASSEMBLY
a. REMOVAL/INSTALLATION
Remove the following parts.
– Propeller (P. 14-2)
– Gear case assembly (P. 14-42)
– Water pump/shift rod (P. 14-46)
1) Remove the two 10 mm washers and the two 10 x 40 mm
flange bolts.
2) Insert a screwdriver or equivalent tool into the recess in the
propeller shaft holder and remove the propeller shaft
holder assembly from the gear case.
[1]
RECESSE
Installation is the reverse order of removal.
[2]
PROPELLER
SHAFT HOLDER
ASSEMBLY
[3]
10 mm WASHER (2)
[1]
GEAR CASE ASSEMBLY
10 x 40 (2)
34 N.m (3.5 kgf.m, 25 lbf.ft)
14-56
13. PROPELLER SHAFT/PROPELLER
SHAFT HOLDER [*2]
[1]
8 x 47 mm
SHIFTER PIN
[2]
CLUTCH SHIFTER
a. DISASSEMBLY
Remove the following parts.
– Propeller (P. 14-2)
– Gear case assembly (P. 14-42)
– Water pump/shift rod (P. 14-46)
– Propeller shaft holder assembly (P. 14-56)
1) Remove the cross pin ring and the 8 x 47 mm shifter pin,
then remove the clutch shifter.
[3]
CROSS PIN
RING
2) Remove the shift slider assembly and the two #7 steel balls
from the propeller shaft. Take care not to lose the steel
balls.
[2]
SHIFT SLIDER
ASSEMBLY
[1]
PROPELLER
SHAFT
[3]
#7 STEEL BALL (2)
3) Remove the 14 mm circlip from the shift slider assembly.
[1]
SHIFT SLIDER
ASSEMBY
[2]
14 mm CIRCLIP
14-57
4) Remove the 3 x 12.8 mm roller from the shift slider
assembly using a commercially available pin driver.
[1]
3 x 12.8 mm ROLLER
[2]
SHIFT SLIDER
ASSEMBLY
5) Remove the shift plate from the shift slider, then remove
the two shift springs and the two #9 steel balls.
NOTICE
[2]
#9 STEEL BALLS
Take care not to let the shift springs and the #9 steel balls
pop out of the shift slider during removal of the shift plate.
[1]
SHIFT SLIDER
[4]
SHIFT SPRINGS
[3]
SHIFT PLATE
6) Prepare the fixing tool of the dimensions shown.
60 mm
(2.4 in)
ø10 (0.4 in)
300 mm
(11.8 in)
30 mm
(1.2 in)
69.5 mm
(2.74 in)
69.5 mm
(2.74 in)
14-58
ø35 (1.4 in)
ø10
(0.4 in)
7) Position the propeller shaft holder assembly on the fixing
tool and secure the holder assembly with the bolt.
8) Hold the fixing tool with a vise.
9) Loosen the bearing holder using the special tool as shown.
TOOL:
Pin spanner wrench, 110 mm
[1]
PIN SPANNER
WRENCH, 110 mm
07WAA-S1G0100
07WAA-S1G0100
10) Remove the bearing holder assembly from the propeller
shaft holder.
NOTICE
Avoid holding the propeller shaft holder directly in a vise.
Use the fixing tool to hold it in a vise.
[3]
FIXING TOOL
11) Before removing the taper bearing (inner race), check the
inner race for abnormal sound and play. If there is any
abnormal sound or play in the inner race, replace the inner
race and the outer race as a set.
12) Attach a commercially available universal bearing puller
between the bearing holder and the forward bevel gear.
13) Remove the forward bevel gear from the taper bearing
(inner race) using the special tools and the hydraulic press.
TOOLS:
Driver
Attachment, 27.2
Pilot, 35 mm
07749-0010000
07747-0010300
07746-0040800
[1]
DRIVER
07749-0010000
[7]
50 x 90 x 28 mm
TAPER BEARING
(INNER RACE)
[6]
BEARING
HOLDER
[5]
FORWARD BEVEL
GEAR
14-59
[2]
PROPELLER
SHAFT HOLDER
ASSEMBLY
[2]
ATTACHMENT,
27.2
07747-0010300
[3]
UNIVERSAL
BEARING PULLER
(Commercially
available)
[4]
PILOT, 35 mm
07746-0040800
14) Before removing the taper bearing (outer race), check the
outer race for damage. Replace the inner race and the outer
race as a set if necessary.
15) Remove the taper bearing (outer race) from the bearing
holder using the special tools and the hydraulic press.
TOOLS:
Driver
Taper vearing driver attachment
[1]
TAPER BEARING
DRIVER
ATTACHMENT
070PD-ZY60100
[2]
DRIVER
07749-0010000
07749-0010000
070PD-ZY60100
16) Remove the shim from the bearing holder.
Replace the shim with a new one on assembly.
17) Remove the thrust bearing washer and the propeller shaft
from the propeller shaft holder.
[3]
BEARING
HOLDER
[1]
PROPELLER
SHAFT HOLDER
[2]
THRUST BEARING
WASHER
[3]
PROPELLER SHAFT
18) Check the thrust bearing for abnormal sound and play.
Replace if necessary.
19) Remove the thrust bearing, thrust bearing washer, shim
and the 105 x 3.1 mm O-ring from the propeller shaft
holder.
[1]
PROPELLER
SHAFT HOLDER
NOTICE
[2]
THRUST BEARING
WASHER
[3] THRUST
BEARING
• Replace the shim with a new one on assembly.
• Replace the 105 x 3.1 mm O-ring with a new one on
assembly.
[4]
THRUST SHIM
[5]
105 x 3.1 mm O-RING
20) Before removing the 30 x 45 x 7 mm water seals, check the
water seal lips for cut and replace if necessary.
21) Remove the two 30 x 45 x 7 mm water seals from the
propeller shaft holder using a commercially available oil
seal remover.
Replace the water seals with the new ones on assembly.
[1]
30 x 45 x 7 mm
WATER SEALS
[2]
PROPELLER
SHAFT HOLDER
14-60
22) Check the needle bearing for abnormal sound and play
before removal. Replace the needle bearing if necessary.
23) Remove the needle bearing from the propeller shaft using
the special tools as shown.
Replace the needle bearing with a new one on assembly.
TOOLS:
Remover weight
Remover handle
Bearing remover, 30 mm
[1]
REMOVER WEIGHT
07741-0010201
[2]
REMOVER HANDLE
07936-3710100
07741-0010201
07936-3710100
07936-8890300
[4]
PROPELLER
SHAFT HOLDER
b. INSPECTION
• CLUTCH SHIFTER
[3]
BEARING REMOVER,
30 mm
07936-8890300
[1] CLUTCH PARTS
Check the clutch part of the forward and reverse sides for wear
and damage
• PROPELLER SHAFT O.D.
STANDARD
SERVICE LIMIT
At reverse
bevel gear
24.987 – 25.000 mm
(0.9837 – 0.9843 in)
24.966 mm
(0.9829 in)
At needle
bearing
30.007 – 30.020 mm
(1.1814 – 1.1819 in)
29.990 mm
(1.1807 in)
[1]
AT REVERSE
BEVEL GEAR
[2] AT NEEDLE
BEARING
14-61
c. COMPONENTS DRAWING
[4] CROSS
PIN RING
[3]
8 x 47 mm
SHIFTER PIN
[1]
FORWARD
BEVEL GEAR
[7]
3 x 12.8 mm
ROLLER
[8]
14 mm CIRCLIP
[10]
SHIFT SPRING (2)
[5]
SHIFT
SLIDER
[2]
CLUTCH
SHIFTER
[11]
SHIFT PLATE
[9]
#9 STEEL BALLS
[6]
#7 STEEL BALL (2)
[12]
FORWARD BEVEL
GEAR SHIM
[13]
THRUST BEARING
WASHER
[24]
PROPELLER SHAFT
[23]
50 x 90 x 28 mm
TAPER BEARING
(INNER RACE)
[15]
50 x 90 x 28 mm
TAPER BEARING
(OUTER RACE)
[14]
BEARING HOLDER
191 N.m (19.5 kgf.m,
141 lbf.ft)
[16] THRUST
BEARING
[17]
THRUST BEARING
WASHER
[18]
THRUST SHIM
[19]
105 x 3.1 mm O-RING
[20]
PROPELLER SHAFT HOLDER
[22]
30 x 45 x 7 mm
WATER SEAL (2)
14-62
[21]
30 x 37 x 26 mm
NEEDLE BEARING
d. ASSEMBLY
1) Apply gear oil to the circumference of the new needle
bearing.
2) Install the needle bearing on the propeller shaft holder
using the special tools and the hydraulic press.
TOOLS:
Attachment, 62 x 68 mm
Outer driver attachment, 30 x 37
[1]
ATTACHMENT,
62 x 68 mm
07746-0010500
[2]
OUTER DRIVER
ATTACHMENT,
30 x 37
070PD-ZY60200
07746-0010500
070PD-ZY60200
NOTICE
Install the needle bearing with the stamped side toward the
special tools.
[4]
PROPELLER
SHAFT HOLDER
3) Apply soapy water to the circumference of the new 30 x 45
x 7 mm water seals.
[3]
30 x 37 x 26 mm
NEEDLE
BEARING
[1] 30 x 45 x 7 mm
WATER SEALS
[2] <Water seal installation
direction>
[4]
OIL SEAL DRIVER
07947-SB00100
[3]
(Apply grease to
the seal mating
surfaces and lips.)
4) Drive the 30 x 45 x 7 mm water seals one by one into the
propeller shaft holder using the special tool. Note the
installation direction of the water seals.
Apply grease to the water seal mating surfaces before
installation.
TOOL:
Oil seal driver
07947-SB00100
5) After installation of the water seals, apply grease to the
water seal lips.
[5]
PROPELLER
SHAFT HOLDER
14-63
6) Apply gear oil to the circumference of the new 105 x 3.1
mm O-ring and install it on the propeller shaft holder.
[2]
THRUST
BEARING
7) Install the new thrust shim on the propeller shaft holder.
8) Install the thrust bearing washer with the chamfered side
toward the thrust shim.
9) Apply gear oil to the circumference of the thrust bearing
and install it on the thrust bearing washer.
10) Check that there is the groove at the spline of the propeller
installation side of the propeller shaft.
[1]
[4]
<LC, XC, LD and XD types> <XCC, LCD and XCD types>
[2] No groove
[5] Groove
[1]
CHAMFER
[3]
THRUST BEARING
WASHER
[6]
THRUST SHIM
[5]
105 x 3.1 mm
O-RING
[4] PROPELLER
SHAFT HOLDER
[2] THRUST BEARING
WASHER
[1]
PROPELLER
SHAFT HOLDER
[3]
PROPELLER SHAFT
[3]
PROPELLER SHAFT
[3]
CHAMFER
11) Install the propeller shaft and the thrust bearing washer on
the propeller shaft holder.
Install the thrust bearing washer with the chamfered side
toward the flange of the propeller shaft.
[4]
PROPELLER SHAFT
12) Install the new shim on the bearing holder.
13) Apply gear oil to the circumference of the taper bearing
(outer race) and install it on the bearing holder.
NOTICE
Install the taper bearing (outer race) with the smaller
diameter side toward the shim.
[1]
FORWARD BEVEL
GEAR SHIM
[3]
BEARING
HOLDER
[2]
50 x 90 x 28 mm
TAPER BEARING
(OUTER RACE)
14) Install the taper bearing (outer race) on the bearing holder
using the special tools and the hydraulic press as shown.
TOOLS:
Driver
Taper bearing inataller attachment
14-64
07749-0010000
070PF-ZY60100
[1]
DRIVER
07749-0010000
[4]
50 x 90 x 28 mm
TAPER BEARING
(OUTER RACE)
[2]
TAPER BEARING
INSTALLER
ATTACHMENT
070PF-ZY60100
[3]
BEARING
HOLDER
15) Place the wood block under the forward bevel geaar.
16) Place the bearing holder assembly on the forward bevel
gear.
17) Apply gear oil to the inner wall of the taper bearing inner
race and position it in the forward bevel gear.
[2]
ATTACHMENT,
62 x 68 mm
07746-0010500
[1]
DRIVER
07749-0010000
18) Install the taper bearing inner race on the forward bevel
gear using the special tools and hydraulic press.
TOOLS:
Driver
Attachment, 62 x 68 mm
07749-0010000
07746-0010500
[6]
50 x 90 x 28 mm
TAPER BEARING
(INNER RACE)
NOTICE
Install by applying gear oil between the inner and outer
races of the taper bearing.
[5]
BEARING
HOLDER
ASSEMBLY
[4]
FORWARD
BEVEL GEAR
[3]
WOOD BLOCK
19) Apply gear oil to the threads and seat of the bearing holder
assembly.
20) Position the bearing holder assembly on the propeller
shaft.
Loosely tighten the bearing holder assembly by hands
against the propeller shaft holder.
[1]
BEARING
HOLDER
ASSEMBLY
[2]
PIN SPANNER
WRENCH, 110 mm
07WAA-S1G0100
21) Attach the fixing tool, that had been used during propeller
shaft/propeller shaft holder removal, on the propeller shaft
holder assembly and secure with the bolt.
22) Tighten the bearing holder to the specified torque using the
special tool as shown.
TOOL:
Pin spanner wrench, 110 mm
07WAA-S1G0100
TORQUE: 191 N.m (19.5 kgf.m, 141 lbf.ft)
NOTICE
Avoid holding the propeller shaft holder directly in a vise.
Use the fixing tool to hold it in a vise.
[4]
FIXING TOOL
14-65
[3]
PROPELLER SHAFT
HOLDER ASSEMBLY
23) Install the shift spring, two #9 steel balls, shift spring and
the shift plate in this order in the shift slider.
24) Install the 3 x 12.8 mm roller aligning the hole in the shift
slider with the hole in the shift plate, then install the 14 mm
circlip.
[2]
3 x 12.8 mm
ROLLER
[3]
SHIFT SPRINGS
[1]
SHIFT
SLIDER
[4]
SHIFT PLATE
[6]
14 mm CIRCLIP
25) Set the #7 steel balls in the steel ball installation holes in
the shift slider assembly, and push the shift slider assembly
slowly into the propeller shaft.
NOTICE
[5]
#9 STEEL BALLS
[2] SHIFT SLIDER
ASSEMBLY
[1]
PROPELLER
SHAFT
Push the shift slider assembly into the propeller shaft with
care not to allow the #7 steel balls to pop out.
[3]
#7 STEEL BALL (2)
26) With the “F” mark on the clutch shifter toward the reverse
bevel gear (i.e. toward front), assemble the clutch shifter
with the propeller shaft while aligning the 8 x 47 mm shifter
pin installation hole with the long hole in the propeller
shaft.
[1] “F” MARK
[2] FORWARD BEVEL
GEAR SIDE
[3]
REVERSE BEVEL
[4] SHIFTER PIN
GEAR SIDE
INSTALLATION HOLE
[5]
LONG HOLE IN
PROPELLER SHAFT
[7]
CLUTCH SHIFTER
[6]
PROPELLER SHAFT
14-66
27) Install the 8 x 47 mm shifter pin while aligning the hole in
the clutch shifter with the hole in the shift slider.
[2]
8 x 47 mm
SHIFTER PIN
[1]
HOLE IN SHIFT
SLIDER
[3]
SHIFT SLIDER
[5]
HOLE IN CLUTCH
SHIFTER
[4]
CLUTCH SHIFTER
28) Install the cross pin ring on the clutch shifter.
[2]
CROSS PIN RING
NOTICE
Check that the coils of the cross pin ring do not overlap
each other.
29) Check that the #7 steel balls are set in the groove in the
propeller shaft securely as shown.
Check procedure:
• Be sure that the clutch shifter is not at the forward bevel
gear installation side.
If it is at the forward bevel gear installation side, pull up
the shift slider assembly slowly.
• Be sure that the #7 steel balls cannot be checked through
the gap between the propeller shaft and shift slider.
If the steel balls can be checked, push in the shift slider
assembly slowly again.
30) Install the following parts.
– Propeller shaft holder assembly (P. 14-56)
– Water pump/shift rod (P. 14-51)
– Gear case assembly (P. 14-44)
– Propeller (P. 14-2)
14-67
[1]
CLUTCH SHIFTER
[1]
CLUTCH SHIFTER
[2]
GROOVE
[5]
#7 STEEL BALL (2)
[3]
PROPELLER
SHAFT
[4]
SHIFT SLIDER
14. VERTICAL SHAFT/BEVEL
GEAR [*2]
[1]
VERTICAL SHAFT
a. DISASSEMBLY
Remove the following pars.
– Propeller (P. 14-2)
– Gear case assembly (P. 14-42)
– Water pump/shift rod (P. 14-46)
– Propeller shaft holder assembly (P. 14-56)
1) Attach the special tool to the end (crankshaft installation
side) of the vertical shaft.
TOOL:
Vertical shaft holder
07SPB-ZW10200
2) Place a shop towel or equivalent material as shown to
protect the gear case.
[2]
VERTICAL SHAFT
HOLDER
07SPB-ZW10200
3) Holding the special tool, remove the pinion gear nut and
the pinion gear.
[5]
GEAR CASE
[3]
PINION GEAR
NUT
[4]
SHOP TOWEL
4) Remove the 64 mm lock nut using the special tool as
shown.
TOOL:
Lock nut wrench, 30/64 mm
07916-MB00002
5) Remove the vertical shaft assembly.
NOTICE
Take care not to drop the needle bearing (roller) when
removing the vertical shaft assembly.
14-68
[1]
LOCK NUT WRENCH,
30/64 mm
07916-MB00002
6) Check the needle bearing for abnormal sound and play.
Replace the roller and the outer race as a set if necessary.
7) Remove the needle bearing (roller).
[1]
NEEDLED BEARING
(ROLLER)
8) Replace the puller jaws of the special tool as shown.
TOOLS:
Bearing race puller
Puller jaws, 25 mm
[1]
PULLER JAWS, 25 mm
07WPC-ZW50100
(Replacement tool)
070PC-ZY3A100
07WPC-ZW50100
[2]
BEARING RACE
PULLER
070PC-ZY3A100
[3]
Removed tool
9) Remove the reverse bevel gear using the special tools with
the new puller jaws replaced in step 8 as shown.
TOOLS:
Remover weight
Remover handle
Bearing race puller
Puller jaws, 25 mm
07741-0010201
07936-3710100
070PC-ZY3A100
07WPC-ZW50100
[1]
REMOVER
WEIGHT
07741-0010201
[2]
BEARING RACE
PULLER
070PC-ZY3A100
[5]
REMOVER HANDLE
07936-3710100
14-69
[3]
REVERSE
BEVEL GEAR
[4]
PULLER JAWS, 25 mm
07WPC-ZW50100
10) Check the bearing for abnormal noise and play before
removal. Replace if necessary.
11) Remove the 50 x 90 x 20 mm radial ball bearing using the
special tools as shown.
TOOLS:
Remover weight
Remover handle
Bearing race puller
Puller jaws, 25 mm
[1]
REMOVER
WEIGHT
07741-0010201
[3]
50 x 90 x 20 mm
[2]
BEARING RACE RADIAL BALL
BEARING
PULLER
070PC-ZY3A100
[6]
REMOVER
HANDLE
07936-3710100
[4]
[5]
REVERSE
PULLER JAWS,
BEVEL
25 mm
GEAR SHIM
07WPC-ZW50100
07741-0010201
07936-3710100
070PC-ZY3A100
07WPC-ZW50100
12) Remove the reverse bevel gear shim from the gear case.
NOTICE
• Replace the 50 x 90 x 20 mm radial ball bearing with a
new one on assembly.
• Replace the reverse bevel gear shim on assembly.
13) Remove the oil slinger from the vertical shaft expanding
the cut in the oil slinger using a screwdriver.
[1]
OIL SLINGER
[2]
VERTICAL SHAFT
14) Check the taper roller bearing for noise, play and other
abnormality before removing it. Replace the inner race and
the outer race as a set if necessary.
15) Position a commercially available universal bearing puller
on the taper roller bearing (inner race), and position the
vertical shaft on the hydraulic press with the crankshaft
installation side toward up.
16) Remove the taper roller bearing from the vertical shaft
using the hydraulic press.
17) Remove the shim from the vertical shaft.
Replace the shim with a new one on assembly.
14-70
[2]
VERTICAL
SHAFT
[1]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
[3]
UNIVERSAL
BEARING PULLER
(Commercially
available)
18) Check the needle bearing (outer race) for damage before
removal. Replace if necessary.
19) Position the special tools on the needle bearing (outer race)
and the shop towel under the needle bearing (outer race) as
shown.
TOOLS:
Driver handle, 15 x 280 mm
Bearing driver attachment, 37 mm
Pilot, 35 mm
[1]
DRIVER HANDLE,
15 x 280 mm
07949-3710001
07949-3710001
07ZMD-MBW0200
07746-0040800
[2]
BEARING DRIVER
ATTACHMENT,
37 mm
07ZMD-MBW0200
20) Remove the needle bearing (outer race) from the gear case
using the special tools.
NOTICE
• Remove the needle bearing (outer race) with care not to
damage the gear case.
• Replace the needle bearing (outer race) and the roller as
a set on assembly.
[6]
NEEDLE BEARING
(OUTER RACE)
[5]
PILOT, 35 mm
07746-0040800
b. INSPECTION
• VERTICAL SHAFT O.D.
At needle
bearing
STANDARD
SERVICE LIMIT
28.556 – 28.575 mm
(1.1242 – 1.1250 in)
28.545 mm
(1.1238 in)
[1]
AT NEEDLE
BEARING
14-71
[3]
GEAR CASE
[4]
SHOP TOWEL
c. COMPONENTS DRAWING
[1]
VERTICAL SHAFT
[2]
64 mm LOCK NUT
123 N.m (12.5 kgf.m, 90 lbf.ft)
[3]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
(INNER RACE)
[4]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
(OUTER RACE)
[3]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
(INNER RACE)
[14]
OIL SLINGER
[5]
PINION GEAR SHIM
[6]
REVERSE BEVEL
GEAR
[13]
GEAR CASE
[7]
NEEDLE BEARING
(OUTER RACE)
[8]
NEEDLE BEARING
(ROLLER)
[9]
PINION GEAR
[12]
REVERSE BEVEL
GEAR SHIM
14-72
[11]
50 x 90 x 20 mm
RADIAL BALL
BEARING
[10]
PINION GEAR NUT
142 N.m (14.5 kgf.m, 105 lbf.ft)
d. ASSEMBLY
1) Apply gear oil to the circumference of the new bearing.
2) Place a wood block under the reverse bevel gear.
3) Install the bearing on the reverse bevel gear using the
special tool and the hydraulic press.
TOOL:
Oil seal driver, 65 mm
07JAD-PL90100
or 07JAD-PL9A100
[1]
OIL SEAL DRIVER,
65 mm
07JAD-PL90100 or
07JAD-PL9A100
[2]
50 x 90 x 20 mm
RADIAL BALL
BEARING
[4]
REVERSE BEVEL
GEAR
[3]
WOOD BLOCK
4) Soak the gear case in the container filled with oil with the
bearing installation side toward down.
[1]
THEMOMETER
[2]
GEAR CASE
5) Heat the oil to 80 – 90˚C (176 – 194˚F).
6) After the entire of the bearing installation side of the gear
case becomes hot, remove the gear case from the
container and install the bevel gear shim and the reverse
bevel gear/bearing assembly on the gear case quickly.
NOTICE
• Do not heat the oil above 90˚C (194˚F).
• The entire gear case becomes hot. Be sure to wear the
gloves during the operation.
• Do not apply the force of 8,829 N (900 kgf, 1984 lbf) or
above during installation.
[3]
Heat the oil to 80 – 90˚C
(176 – 194˚F).
[4]
REVERSE BEVEL
GEAR SHIM
[6]
GEAR CASE
14-73
[5]
REVERSE BEVEL
GEAR/BEARING
ASSEMBLY
7) Position the pinion gear on the vertical shaft and loosely
tighten the pinion gear nut by hand.
[2]
VERTICAL
SHAFT
8) Apply gear oil to the inner wall of the inner race, roller and
the circumference of the outer race of the taper roller
bearings. Assemble the inner race and the outer race.
9) Position the shim, taper roller bearing and the special tool
on the vertical shaft.
TOOL:
Driver shaft, B
[1]
DRIVER SHAFT, B
07964-MB00200
07964-MB00200
[3]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
10) Position the vertical shaft on the hydraulic press with the
pinion gear toward up as shown.
[2]
PINION GEAR
NUT
11) Install the taper roller bearing on the vertical shaft using the
hydraulic press.
NOTICE
• Check that the ends of the special tool are set on the taper
roller bearing inner race and the hydraulic press table
securely.
• Do not ruin the threads at the end of the vertical shaft
(pinion gear nut installation part).
12) Remove the pinion gear nut and the pinion gear from the
vertical shaft.
[1]
VERTICAL
SHAFT
[8]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
[3]
PINION
GEAR
[4]
PINION GEAR
SHIM
[5]
Set securely.
[7]
DRIVER SHAFT, B
07964-MB00200
[6] HYDRAULIC
PRESS TABLE
14-74
13) Install the oil slinger on the vertical shaft aligning the
projection on the inside of the oil slinger with the recess of
the pinion gear installation side of the vertical shaft.
[2] PROJECTION
[1]
VERTICAL SHAFT
[3]
CONCAVE
[4]
OIL SLINGER
14) Attach the special tool to the new needle bearing as shown.
Install the needle bearing with the stamped side of the
needle bearing (outer race) toward the special tool.
TOOL:
Oil seal driver attachment, 27.5 x 44 mm
07948-9540000
[1]
OIL SEAL DRIVER
ATTACHMENT,
27.5 x 44 mm
07948-9540000
[2]
NEEDLE
BEARING
15) Install the needle bearing in the gear case using the special
tools.
TOOLS:
Shaft installer, 15 x 370 mm
07VMF-KZ30200
Attachment, 78 x 90 mm
07GAD-SD40101
Oil seal driver attachment, 27.5 x 44 mm 07948-9540000
[1]
SHAFT INSTALLER,
15 x 370 mm
07VMF-KZ30200
[2]
ATTACHMENT,
78 x 90 mm
07GAD-SD40101
16) After installation, check that the bottom surface of the
needle bearing is flush with the bottom of the gear case.
Apply grease to the needle bearing roller.
[6]
(Apply grease
to the roller.)
[5]
NEEDLE
BEARING
[4]
OIL SEAL DRIVER
ATTACHMENT,
27.5 x 44 mm
07948-9540000
14-75
[3]
GEAR CASE
17) Install the vertical shaft assembly with care not to let the
needle bearing roller come out of position.
18) Apply gear oil to the threads and seat of the 64 mm lock
nut, and tighten the lock nut using the special tool.
TOOL:
Lock nut wrench, 30/64 mm
[1]
LOCK NUT WRENCH,
30/64 mm
07916-MB00002
07916-MB00002
TORQUE: 123 N.m (12.5 kgf.m, 90 lbf.ft)
19) Wipe the tapered part of the vertical shaft and pinion gear
with a shop towel and a degreasing cleaning solvent.
[1]
VERTICAL SHAFT
20) Attach the special tool to the end (crankshaft installation
side) of the vertical shaft as shown.
TOOL:
Vertical shaft holder
07SPB-ZW10200
21) Place a shop towel in the gear case as shown to protect the
gear case.
22) Apply gear oil to the threads and seat of the pinion gear
nut.
[2]
VERTICAL SHAFT
HOLDER
07SPB-ZW10200
[3]
PINION GEAR
NUT
23) Tighten the pinion gear nut to the specified torque while
installing the pinion gear on the vertical shaft and holding
the special tool in position.
TORQUE: 142 N.m (14.5 kgf.m, 105 lbf.ft)
NOTICE
Check that the forward bevel gear/taper bearing assembly
is set properly.
24) Install the following parts.
– Propeller shaft holder assembly (P. 14-56)
– Water pump/shift rod (P. 14-51)
– Gear case assembly (P. 14-44)
– Propeller (P. 14-2)
14-76
[5]
GEAR CASE
[4]
SHOP TOWEL
15. SHIM SELECTION [*2]
[1]
PINION GEAR NUT
NOTICE
[2]
VERTICAL
SHAFT
Adjust the shim thickness after replacing the gear case, vertical
shaft, bearing, taper bearing and the taper roller bearing.
a. PINION GEAR SHIM
Remove the 30 x 62 x 40 mm taper roller bearing if it is
mounted on the vertical shaft (P. 14-70).
1) Wipe the tapered part of the vertical shaft and the pinion
gear with a shop towel and a degreasing cleaning solvent.
2) Install the pinion gear on the vertical shaft and tighten the
pinion gear nut to the specified torque.
[4]
PINION GEAR
[3]
TAPERED PARTS
TORQUE: 142 N.m (14.5 kgf.m, 105 lbf.ft)
NOTICE
• Do not install the vertical shaft in the gear case.
• We recommend that you attach the special tool (vertical
shaft holder) at the end of the vertical shaft to facilitate
tightening of the pinion gear nut to the specified torque
(P. 14-76).
3) Do not confuse the pinion gear side and the taper roller
bearing side of the special tool.
Do not score and scratch the opposite side (measurement
side) from the side where the tool number is stamped.
TOOL:
Gauge adapter, 110 mm
[1]
GAUGE ADAPTER,
110 mm
070PJ-ZY30100
[3]
PINION GEAR
SIDE
070PJ-ZY30100
4) Holding the special tool with the side of the stamped tool
number facing the opposite side from the pinion gear, be
sure that the tool of the pinion gear nut side is not set on
the nut.
Tighten the bolts by hand while pushing both tools toward
the pinion gear side.
NOTICE
• Do not tighten the bolts with a tool.
• There must be no wobbling in the special tool. It must
securely set on the pinion gear.
5) Set both tools on both sides of the flange of the vertical
shaft with the side of the special tool, where is stamped
with the tool number, and the tapered part facing the
opposite side from the pinion gear as shown. Tighten the
bolts by hand.
[1]
Tool must not
get on the nut.
[2]
PINION
GEAR
[3] MEASUREMENT
SURFACES
[6]
BOLT (2)
[5]
PINION GEAR
NUT
[4]
TOOL NO.
STAMPED
SURFACE
[1] MEASUREMENT SURFACE
[2]
TOOL NO.
STAMPED
SURFACE
NOTICE
• Do not tighten the bolts with a tool.
• There must be no wobbling in the special tool. It must
securely set on the pinion gear.
[4]
BOLTS
14-77
[2]
TAPER ROLLER
BEARING SIDE
[3]
TAPERED
SURFACE
6) Hold the vertical shaft upright (with the pinion gear toward
up) and secure the vertical shaft.
[1]
DEPTH GAUGE
(Commercially available)
7) Set the commercially available depth gauge at the gauge
adapter of the pinion gear side as shown. Measure the
vertical shaft length (distance D) and record it.
[2]
PINION GEAR
[3]
GAUGE ADAPTER,
110 mm
070PJ-ZY30100
8) Assemble the outer race and the inner race of the 30 x 62 x
40 mm taper roller bearing, and turn the outer race two or
three turns.
9) Measure the bearing height from the outer race end to the
inner race end as shown, and record the measurement.
10) Measure the height of the taper roller bearing outer race
and record it.
14-78
[1] OUTER RACE
[2]
INNER RACE
[1] OUTER RACE
11) Calculate the gap (distance E) between the outer race and
inner race using the measurements obtained in step 9 and
10 and the following formula.
Formula:
Bearing height – Outer race height = Gap (distance E)
Example:
When, bearing height from the outer race end to the inner
race end is 34.9 mm (1.37 in),
And, outer race height is 29.7 mm (1.17 in):
34.9 – 29.7 = 5.2
Therefore, the gap (distance E) is 5.2 mm (0.20 in).
12) Determine the calculation value using the vertical shaft
length (distance D) obtained in step 7 and the gap (distance
E) obtained in step 11 and the following formula.
Formula:
Vertical shaft length (distance D) + Gap (distance E) – 147.2
= Calculation value
Example:
When, vertical shaft length (distance D) is 141.8 mm (5.58
in),
And, gap (distance E) is 5.2 mm (0.20 in):
141.8 + 5.2 – 147.2 = –0.20
Therefore, the calculation value is –0.20 mm (–0.008 in).
[1]
GEAR CASE
13) Cross reference the calculation value and the engagement
mark located on the trim tab installation part of the gear
case, and select the shim of the appropriate thickness from
the shim selection table accordingly.
• Shim type table
[1] Shim type
[2] Thickness
[3] Pinion gear shim A
0.10 mm (0.004 in)
[4] Pinion gear shim B
0.15 mm (0.006 in)
[5] Pinion gear shim C
0.30 mm (0.012 in)
[6] Pinion gear shim D
0.50 mm (0.020 in)
14-79
[2]
ENGAGEMENT
MARK
• Pinion gear shim selection table
[3] Unit: mm (in)
[2] Calculation value
[1] Engagement
mark on the
gear case
+0.41 (+0.0161) +0.35 (+0.014) +0.30 (+0.0118) +0.25 (+0.010) +0.20 (+0.008) +0.15 (+0.006) +0.10 (+0.004)
–
–
–
–
–
–
–
+0.35 (+0.014) +0.30 (+0.0118) +0.25 (+0.010) +0.20 (+0.008) +0.15 (+0.006) +0.10 (+0.004) +0.05 (+0.002)
F
0.30 (0.0118)
0.35 (0.014)
0.40 (0.0157)
0.45 (0.018)
0.50 (0.020)
0.55 (0.022)
0.60 (0.024)
E
0.25 (0.010)
0.30 (0.0118)
0.35 (0.014)
0.40 (0.0157)
0.45 (0.018)
0.50 (0.020)
0.55 (0.022)
D
0.20 (0.008)
0.25 (0.010)
0.30 (0.0118)
0.35 (0.014)
0.40 (0.0157)
0.45 (0.018)
0.50 (0.020)
C
0.15 (0.006)
0.20 (0.008)
0.25 (0.010)
0.30 (0.0118)
0.35 (0.014)
0.40 (0.0157)
0.45 (0.018)
B
0.10 (0.004)
0.15 (0.006)
0.20 (0.008)
0.25 (0.010)
0.30 (0.0118)
0.35 (0.014)
0.40 (0.0157)
0.10 (0.004)
0.15 (0.006)
0.20 (0.008)
0.25 (0.010)
0.30 (0.0118)
0.35 (0.014)
A
[3] Unit: mm (in)
[2] Calculation value
[1] Engagement
mark on the
gear case
+0.05 (+0.002) ±0 (±0.000) –0.05 (–0.002) –0.10 (–0.004) –0.15 (–0.006) –0.20 (–0.008) –0.25 (–0.010)
–
–
–
–
–
–
–
±0 (±0.000) –0.05 (–0.002) –0.10 (–0.004) –0.15 (–0.006) –0.20 (–0.008) –0.25 (–0.010) –0.31 (–0.0122)
F
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
0.85 (0.033)
0.90 (0.035)
0.95 (0.037)
E
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
0.85 (0.033)
0.90 (0.035)
D
0.55 (0.022)
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
0.85 (0.033)
C
0.50 (0.020)
0.55 (0.022)
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
B
0.45 (0.018)
0.50 (0.020)
0.55 (0.022)
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
A
0.40 (0.0157)
0.45 (0.018)
0.50 (0.020)
0.55 (0.022)
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
• How to read shim selection table
When the engagement mark on the gear case is E and the calculation value is –0.20 mm (–0.008 in) or more, the shim
thickness is 0.80 mm (0.031 in).
When the calculation value is less than –0.20 mm (–0.008 in), the shim thickness is 0.85 mm (0.033 in). (See Shim
selection table above.)
[3] Unit: mm (in)
[2] Calculation value
[1] Engagement
mark on the
gear case
+0.05 (+0.002) ±0 (±0.000) –0.05 (–0.002) –0.10 (–0.004) –0.15 (–0.006) –0.20 (–0.008) –0.25 (–0.010)
–
–
–
–
–
–
–
±0 (±0.000) –0.05 (–0.002) –0.10 (–0.004) –0.15 (–0.006) –0.20 (–0.008) –0.25 (–0.010) –0.31 (–0.0122)
F
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
0.85 (0.033)
0.90 (0.035)
0.95 (0.037)
E
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
0.85 (0.033)
0.90 (0.035)
D
0.55 (0.022)
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
0.85 (0.033)
C
0.50 (0.020)
0.55 (0.022)
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
0.80 (0.031)
B
0.45 (0.018)
0.50 (0.020)
0.55 (0.022)
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
A
0.40 (0.0157)
0.45 (0.018)
0.50 (0.020)
0.55 (0.022)
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
• Shim combination
To obtain 0.75 mm (0.030 in) of shim thickness, combine three gear shim As and one gear shim B and one gear shim C,
or combine one gear shim A, one gear shim B and one gear shim D by referring to the shim type table.
14-80
b. FORWARD BEVEL GEAR SHIM
[1]
OUTER RACE
1) Assemble the outer race and the inner race of the 50 x 90 x
28 mm taper bearing, and turn the outer race two or three
turns.
2) Measure the bearing height (distance F) from the outer race
end to the inner race end as shown, and record the
measurement.
[2]
INNER RACE
3) Measure the inner race height (distance K) as shown, and
record the measurement.
4) Determine the calculation value using the bearing height
(distance F), inner race height (distance K) and the
following formula.
Formula:
Bearing height (distance F) – Inner race height (distance K)
= Calculation value
Example:
When, bearing height (distance F) is 28.05 mm (1.104 in),
And, inner race height (distance K) is 28.00 mm (1.102 in):
28.05 – 28.00 = 0.05
Therefore, the calculation value is 0.05 mm (0.002 in).
5) Check the calculation value and select the shim of the
appropriate thickness from the shim selection table
accordingly.
• Shim type table
[1] Shim type
[2] Thickness
[3] Forward bevel gear shim A
0.10 mm (0.004 in)
[4] Forward bevel gear shim B
0.15 mm (0.006 in)
[5] Forward bevel gear shim C
0.30 mm (0.012 in)
[6] Forward bevel gear shim D
0.50 mm (0.020 in)
• Forward bevel gear shim selection table [3] Unit: mm (in)
[1] Calculation value
[2] Shim thickness
+0.15 – +0.10 (+0.006 – +0.004)
0.35 (0.014)
+0.10 – +0.05 (+0.004 – +0.002)
0.40 (0.016)
+0.05 – ±0 (+0.002 – ±0.000)
0.45 (0.018)
Refer to page 14-80 for information on shim combination.
14-81
[1]
50 x 90 x 28 mm
TAPER BEARING
(INNER RACE)
c. REVERSE BEVEL GEAR SHIM
1) Measure the bearing height (distance H) of the new 50 x 90
x 20 mm radial ball bearing as shown, and record the
measurement.
2) Determine the calculation value using the bearing height
(distance H) and the following formula.
Formula:
Bearing height (distance H) – 20 = Calculation value
Example:
When, bearing height (distance H) is 19.95 mm (0.785 in):
19.95 – 20 = –0.05
Therefore, the calculation value is –0.05 mm (–0.002 in).
3) Cross reference the calculation value and the engagement
mark located on the trim tab installation part of the gear
case, and select the shim of the appropriate thickness from
the shim selection table accordingly.
[1]
GEAR CASE
• Shim type table
[1] Shim type
[2] Thickness
[3] Forward bevel gear shim A
0.10 mm (0.004 in)
[4] Forward bevel gear shim B
0.15 mm (0.006 in)
[5] Forward bevel gear shim C
0.30 mm (0.012 in)
[6] Forward bevel gear shim D
0.50 mm (0.020 in)
• Reverse bevel gear shim selection table [3] Unit: mm (in)
[1] Engagement
mark on the
gear case
[2] Calculation value
±0 (±0.000)
–
–0.05 (–0.002)
–0.05 (–0.002)
–
–0.12 (–0.005)
1
0.60 (0.024)
0.65 (0.026)
2
0.55 (0.022)
0.60 (0.024)
3
0.50 (0.020)
0.55 (0.022)
4
0.45 (0.018)
0.50 (0.020)
5
0.40 (0.016)
0.45 (0.018)
6
0.35 (0.014)
0.40 (0.016)
Refer to page 14-80 for the information on how to read the
shim selection table and shim combination.
14-82
[2]
ENGAGEMENT
MARK
d. THRUST SHIM
[1]
OUTER RACE
1) Assemble the outer race and inner race of the 50 x 90 x 28
mm taper bearing, and turn the outer race two or three
turns.
2) Measure the bearing height (distance F) from the outer race
end to the inner race end as shown, and record the
measurement.
[2]
INNER RACE
3) Measure the inner race height (distance K) as shown, and
record the measurement.
4) Determine the calculation value using the bearing height
(distance F), inner race height (distance K) and the
following formula.
Formula:
Bearing height (distance F) – Inner race height (distance K)
= Calculation value
Example:
When, bearing height (distance F) is 28.05 mm (1.104 in),
And, inner race height (distance K) is 28.00 mm (1.102 in):
28.05 – 28.00 = 0.05
Therefore, the calculation value is 0.05 mm (0.002 in).
5) Check the calculation value and the bearing height, and
select the shim of the appropriate thickness from the shim
selection table accordingly.
• Shim type table
[1] Shim type
[2] Thickness
[3] Thrust shim A
0.10 mm (0.004 in)
[4] Thrust shim B
0.15 mm (0.006 in)
[5] Thrust shim C
0.30 mm (0.012 in)
[6] Thrust shim D
0.50 mm (0.020 in)
• Thrust shim selection table
[3] Unit: mm (in)
[2] Calculation value
[1] Bearing height
+0.15 (+0.006) +0.10 (+0.004) +0.05 (+0.002)
–
–
–
+0.10 (+0.004) +0.05 (+0.002) ±0 (±0.000)
28.00
(1.102)
–
28.05
(1.104)
0.65 (0.026)
0.70 (0.028)
0.75 (0.030)
28.05
(1.104)
–
28.10
(1.106)
0.60 (0.024)
0.65 (0.026)
0.70 (0.028)
Refer to page 14-80 for the information on how to read the
shim selection table and shim combination.
14-83
[1]
50 x 90 x 28 mm
TAPER BEARING
(INNER RACE)
16. SHIM POSITION [*2]
[1]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
(INNER RACE)
[14]
30 x 62 x 40 mm
TAPER ROLLER
BEARING
(OUTER RACE)
[13]
PINION GEAR SHIM
SELECTION: P. 14-77
[12]
VERTICAL SHAFT
[11]
PINION GEAR
[10]
PINION GEAR NUT
142 N.m (14.5 kgf.m, 105 lbf.ft)
[2]
50 x 90 x 20 mm
RADIAL BALL
BEARING
[9]
THRUST SHIM
[3]
REVERSE BEVEL
GEAR SHIM
SELECTION: P. 14-83
ADJUSTMENT: P. 14-87
[8]
50 x 90 x 28 mm
TAPER BEARING
(INNER RACE)
[7]
50 x 90 x 28 mm
TAPER BEARING
(OUTER RACE)
14-84
[5] FORWARD
BEVEL GEAR
SELECTION: P. 14-82
ADJUSTMENT: P. 14-86
[4]
[6]
REVERSE BEVEL GEAR
FORWARD BEVEL
GEAR SHIM
SELECTION: P. 14-81
ADJUSTMENT: P. 14-85
17. BACKLASH ADJUSTMENT [*2]
a. FORWARD BEVEL GEAR BACKLASH
Backlash adjustment must be made after adjustment of each
gear shim (P. 14-77).
Install the parts except the water pump in the gear case (P. 1451, 56 and 73).
1) Hold the propeller shaft securely with the special tool as
shown, and tighten the puller bolt to the specified torque.
TOOLS:
Puller jaws
Puller bolt
07SPC-ZW0010Z
07SPC-ZW0011Z
[1]
PULLER BOLT
07SPC-ZW0011Z
[2]
PULLER JAWS
07SPC-ZW0010Z
TORQUE: 5 N.m (0.5 kgf.m, 3.6 lbf.ft)
Turn the vertical shaft five to ten turns clockwise to fit the
bevel gear bearing.
[1]
BACKLASH
INDICATOR
ATTACHMENT
07SPK-ZW10100
2) Attach the special tool to the vertical shaft as shown, and
adjust the dial indicator so its needle is at the line “2” of the
special tool (backlash indicator tool).
TOOLS:
Backlash indicator tool
Backlash indicator attachment
90˚
90˚
90˚
90˚
[2]
BACKLASH
INDICATOR TOOL
07SPJ-ZW0030Z
07SPJ-ZW0030Z
07SPK-ZW10100
3) Turn the vertical shaft lightly right and left and record the
dial indicator reading.
Measure the backlash at the four points (by turning the
vertical shaft 90˚) in the same manner.
NOTICE
Do not turn the propeller shaft when turning the vertical
shaft.
4) Obtain the forward bevel gear backlash using the dial
indicator runout and the following formula.
Formula:
Dial indicator runout ÷ 0.86 = Backlash
Example:
When dial indicator runout is 0.195 mm (0.0077 in):
0.195 ÷ 0.86 = 0.23
Therefore, the backlash is 0.23 mm (0.009 in).
Standard value
0.10 – 0.30 mm
(0.004 – 0.012 in)
5) If the backlash is too large, reduce the forward bevel gear
shim thickness and recheck the backlash.
If the backlash is too small, increase the forward bevel gear
shim thickness and recheck the backlash.
NOTICE
Use the special tool when 50 x 90 x 28 mm taper bearing
outer race is removed to adjust the backlash again (P. 1460).
14-85
[4]
VERTICAL
SHAFT
[3]
DIAL INDICATOR
Adjust the dial indicator needle at
line “2” of the backlash indicator
tool.
b. REVERSE BEVEL GEAR BACKLASH
1) Turn the vertical shaft five to ten turns clockwise for snug
seat of the bevel gear taper roller bearing.
2) Using the wrench, turn the shift rod in the direction shown
with the arrow and fix the propeller shaft.
NOTICE
If it is hard to fix the propeller shaft, turn the propeller shaft
to change the phase of the shaft and fix it.
3) Attach the special tool to the vertical shaft as shown, and
adjust the dial indicator so its needle is at the line “2” of the
special tool (backlash indicator tool).
TOOLS:
Backlash indicator tool
Backlash indicator attachment
[1]
BACKLASH
INDICATOR
ATTACHMENT
07SPK-ZW10100
07SPJ-ZW0030Z
07SPK-ZW10100
4) Turn the vertical shaft lightly right and left and record the
dial indicator reading.
Measure the backlash at the four points (by turning the
vertical shaft 90˚) in the same manner.
90˚
90˚
90˚
90˚
[2]
BACKLASH
INDICATOR TOOL
07SPJ-ZW0030Z
NOTICE
Do not turn the propeller shaft when turning the vertical
shaft.
5) Obtain the reverse bevel gear backlash using the dial
indicator runout and the following formula.
Formula:
Dial indicator runout ÷ 0.86 = Backlash
Example:
When dial indicator runout is 0.195 mm (0.0077 in):
0.195 ÷ 0.86 = 0.23
Therefore, the backlash is 0.23 mm (0.009 in).
Standard value
0.10 – 0.35 mm
(0.004 – 0.014 in)
6) If the backlash is too large, increase the reverse bevel gear
shim thickness and recheck the backlash.
If the backlash is too small, reduce the reverse bevel gear
shim thickness and recheck the backlash.
NOTICE
Use the special tool when 50 x 90 x 20 mm radial ball
bearing is removed to adjust the backlash again (P. 14-69).
7) Adjust the thrust clearance after replacement of the
forward bevel gear shim (P. 14-87).
14-86
[4]
VERTICAL
SHAFT
[3]
DIAL INDICATOR
Adjust the dial indicator needle at
line “2” of the backlash indicator
tool.
c. THRUST CLEARANCE ADJUSTMENT
Adjust the thrust clearance after replacement of the forward
bevel gear shim.
1) Check that the bearing holder assembly is securely
tightened to the specified torque on the propeller shaft
holder (P. 14-65).
Check that the clutch shifter and the shift slider are not
installed (P. 14-57).
[1]
DIAL INDICATOR
[2]
PROPELLER SHAFT
HOLDER ASSEMBLY
2) Fix the propeller shaft holder assembly on the fixing tool
securely using the bolt as shown (P. 14-59).
3) Set the dial indicator perpendicularly so that its tip contacts
the end of the propeller shaft.
4) Move the propeller shaft up and down and read the runout
of the dial indicator. It must be within the specified range.
Standard value
0.2 – 0.4 mm
(0.01 – 0.02 in)
5) If the thrust clearance exceeds the specification, increase
the thrust shim thickness and recheck the thrust clearance.
If the thrust clearance is less than the specification, reduce
the thrust shim thickness and recheck the thrust clearance.
14-87
[3]
FIXING TOOL
18. ANODE METAL/WATER SCREEN
a. REMOVAL/INSTALLATION
Anode metal/water screen removal/installation can be made with the gear case mounted on the outboard motor.
[3]
ANODE METAL (2)
[1]
5 x 50 mm OVAL SCREW
1 N.m (0.1 kgf.m, 0.7 lbf.ft)
INSPECTION:
Replace the anode metal if
it is corroded excessively.
[2]
6 x 50 mm HEX. BOLT
[4]
5.5 x 1.5 mm O-RING
Do not reuse.
[5]
OIL LEVEL BOLT
3.4 N.m (0.35 kgf.m, 2.5 lbf.ft)
[6]
5 mm SELFLOCKING NUT
[11]
L. WATER SCREEN
[8]
6 mm SELFLOCKING NUT
INSPECTION:
Check for the clogged
water through hole
before installation.
[7]
R. WATER SCREEN
[4]
5.5 x 1.5 mm O-RING
Do not reuse.
[10]
GEAR CASE ASSEMBLY
14-88
INSPECTION:
Check for the clogged
water through hole
before installation.
[9]
OIL DRAIN BOLT
3.4 N.m (0.35 kgf.m, 2.5 lbf.ft)
19. EXTENSION CASE/LOWER
RUBBER MOUNT
[1]
LOWER MOUNT
HOUSING
6 x 12
a. DISASSEMBY
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under cover (P. 4-9)
– Gear case assembly (P. 14-3 and 42)
1) Tilt up the outboard motor and hold it in the position by
hooking the hoist hook on each of the three engine
hangers.
2) Remove the three 8 x 30 mm hex. bolts and the three 8 mm
washers, then remove the lower mount housing from the
extension case.
3) Remove the 6 x 12 mm flange bolt from the extension case
and disconnect the ground cable.
4) Holding the 12 mm self-locking nut with a wrench, remove
the 12 x 225 mm hex. bolt, 12 mm self-locking nut and the
two 12 mm washers.
5) Remove the lower rubber mount and the lower mount
collar from the extension case.
[4]
[3] 8 mm
8 x 30 mm
WASHER (3)
HEX. BOLT (3)
[2]
GROUND
CABLE
[1]
12 x 225 mm
HEX. BOLT
[2]
LOWER MOUNT
COLLAR
[3]
[4]
LOWER RUBBER 12 mm
MOUNT
WASHER (2)
[5]
12 mm SELFLOCKING NUT
6) Remove the eight 10 x 40 mm flange bolts and remove the
extension case from the outboard motor.
Remove the two dowel pins.
NOTICE
Remove the extension case with care not to drop it.
7) Remove the under cover seal B and the extension case
grommet from the extension case.
8) Remove the circlip, and then remove the 26 mm washer
and the vertical shaft bushing from the extension case (XC,
XCC, XD and XCD types only).
[1]
XC, XCC, XD and XCD types only
[1]
UNDER COVER
SEAL B
[2]
EXTENSION
CASE GROMMET
[3]
6 x 10 mm
DOWEL PIN (2)
[2]
EXTENSION CASE
[3]
VERTICAL SHAFT
BUSHING
[4]
26 mm WASHER
[5]
CIRCLIP
14-89
10 x 40 (8)
[4]
EXTENSION CASE
9) Remove the 6 x 12 mm flange bolt, and remove the water
tube setting plate, water tube and the water tube grommet.
[1]
WATER TUBE
GROMMET
[2]
WATER TUBE
SETTING PLATE
6 x 12
[3]
WATER TUBE
b. COMPONENTS DRAWING
[1]
12 x 225 mm HEX. BOLT (2)
83 N.m (8.5 kgf.m, 61 lbf.ft)
[2]
WATER TUBE
GROMMET
[19]
WATER TUBE
[3]
UNDER COVER
SEAL B
[4]
LOWER MOUNT
COLLAR (2)
[5]
LOWER RUBBER
MOUNT (2)
[6]
12 mm
WASHER (4)
[8]
6 x 10 mm
DOWEL PIN (2)
[18]
EXTENSION CASE
GROMMET
[7]
12 mm SELFLOCKING NUT
(2)
6 x 12
[17]
WATER TUBE
SETTING PLATE
[16]
8 x 30 mm
HEX. BOLT (6)
[14]
LOWER MOUNT
HOUSING (2)
[15]
8 mm
WASHER (6)
14-90
[13]
EXTENSION
CASE
[12]
VERTICAL SHAFT
BUSHING
[11]
[9]
10 x 40 (8)
26 mm
CIRCLIP
39 N.m (4.0 kgf.m, 29 lbf.ft) WASHER
[10]
XC, XCC, XD and XCD types only
c. ASSEMBLY
1) Apply grease to the circumference of the water tube
grommet and install it on the water tube.
2) Connect the water tube to the oil case noting the
installation direction as shown.
3) Install the water tube set plate aligning the stopper hole of
the water tube set plate with the projection on the oil case,
and then tighten the 6 x 12 mm flange bolt.
[1]
PROJECTION
[2]
STOPPER
HOLE
[5]
WATER TUBE
GROMMET
[3]
WATER TUBE
6 x 12 SETTING PLATE
[4]
WATER TUBE
4) Install the under cover seal B, extension case grommet and
the two dowel pins on the extension case.
NOTICE
[1]
EXTENSION CASE
GROMMET
[2]
UNDER COVER
SEAL B
Install the under cover seal B underside the projections of
the extension case securely.
5) Apply grease to the inner wall of the vertical shaft bushing.
Install the vertical shaft bushing, 26 mm washer and the
circlip in the extension case (XC, XCC, XD and XCD types
only).
[3] 6 x 10 mm
DOWEL PIN (2)
[1] XC, XCC, XD and XCD types only
[2]
EXTENSION CASE
[3]
VERTICAL SHAFT
BUSHING
[4]
EXTENSION CASE
[4]
26 mmWASHER
[5]
CIRCLIP
[5]
PROJECTION
[2]
UNDER COVER
SEAL B
14-91
6) Clean the extension case and oil case mating surfaces with
a degreasing cleaning solvent and a shop towel.
7) Apply sealant to the entire sealing surface of the oil case
side of the extension case (ThreeBond® #5222B or
equivalent).
[1]
EXTENSION CASE
[2]
Sealant (ThreeBond®
#5222B) application
area
8) Apply grease to the water tube end. Install the extension
case on the outboard motor aligning the water tube with
the extension case grommet.
[1]
WATER TUBE
9) Tighten the eight 10 x 40 mm flange bolts to the specified
torque.
TORQUE: 39 N.m (4.0 kgf.m, 29 lbf.ft)
10 x 40 (8)
[3]
EXTENSION
CASE
14-92
[2]
EXTENSION CASE
GROMMET
10) Install the lower mount collar and the lower rubber mount
on the extension case.
[1]
12 x 225 mm HEX. BOLT
NOTICE
• Install the lower mount collar with the smaller diameter
side toward the lower rubber mount.
• Install the lower rubber mount with the “OUT” mark
toward out.
11) Install the 12 x 225 mm hex. bolt, two 12 mm washers and
the 12 mm self-locking nut. Holding the 12 mm self-locking
nut with a wrench, tighten the 12 x 225 mm hex. bolt to the
specified torque.
TORQUE: 83 N.m (8.5 kgf.m, 61 lbf.ft)
[6]
LOWER MOUNT
COLLAR
[2]
12 mm SELFLOCKING NUT
[5]
“OUT” MARK
[4]
LOWER RUBBER
MOUNT
[3]
12 mm
WASHER (2)
12) Connect the ground cable with the 6 x 12 mm flange bolt.
13) Install the lower mount housing on the extension case, and
tighten the three 8 mm washers and the three 8 x 30 mm
hex. bolts.
[1]
LOWR MOUNT
HOUSING
14) Remove the hoist hooks from the engine hangers and
lower the outboard motor to the lowermost position.
6 x 12
15) Install the following pars.
– Gear case assembly (P. 14-5 and 44)
– L./R. engine under cover (P. 4-14)
– Engine cover (P. 4-2)
[2]
GROUND CABLE
[4]
8 x 30 mm
HEX. BOLT (3)
14-93
[3]
8 mm WASHER (3)
20. OIL CASE
a. REMOVAL
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under cover (P. 4-9)
– Gear case assembly (P. 14-3 and 42)
– Extension case/lower rubber mount (P. 14-89)
1) Drain the engine oil from the oil case (P. 3-2).
2) Remove the sixteen 10 x 40 mm flange bolts and remove the oil case from the mount case.
[1]
OIL LEVEL PIPE
6 x 12
[2]
OIL LEVEL GAUGE
[3]
11.5 x 3.5 mm O-RING
Do not reuse.
[10]
OIL PAN GASKET
[4]
6 x 10 mm DOWEL PIN (2)
[5]
20.6 x 2.6 mm O-RING
Do not reuse.
6 x 18 (2)
[9]
OIL CASE
[6]
OIL STRAINER
[7]
OIL DRAIN PLUG BOLT
23 N.m (2.3 kgf.m, 17 lbf.ft)
10 x 40 (16)
34 N.m (3.5 kgf.m, 25 lbf.ft)
14-94
[8]
12 mm DRAIN
PLUG WASHER
Do not reuse.
b. INSTALLATION
1) Clean the oil case and mount case mating surfaces and the
both sides of the oil pan gasket with a cleaning solvent and
a shop towel.
2) Apply bead [ø1.0 – 5.0 mm (ø0.04 – 0.20 in)] of the liquid
gasket (ThreeBond® #1211 or equivalent) to the indicated
area of the oil pan gasket.
[2]
OIL PAN GASKET
[1]
Liquid gasket
application area
NOTICE
• Assemble within 90 minutes after application of the liquid
gasket. If the parts have been left unassembled for 90
minutes, remove the old gasket and apply a new gasket
again.
• Do not fill in the oil case with the engine oil for 15 minutes
after assembly.
[3]
LIQUID GASKET
(Apply to both sides.)
[4]
OIL PAN GASKE
3) Apply engine oil to the circumference of the new 20.6 x 2.6
mm O-ring, and install it on the oil strainer.
[1]
MOUNT CASE
4) Install the oil pan gasket on the mount case. Install the oil
strainer and tighten the two 6 x 18 mm flange bolts.
[4]
OIL PAN GASKET
[2]
20.6 x 2.6 mm
O-RING
6 x 8 (2)
[3]
OIL STRAINER
14-95
5) Apply the engine oil to the threads and seat of the sixteen
10 x 40 mm flange bolts.
Install the two dowel pins and the oil case on the mount
case, then loosely tighten the sixteen 10 x 40 mm flange
bolts.
[2]
OIL LEVEL GAUGE
6 x 12
[1]
OIL LEVEL PIPE
6) Apply engine oil to the new 11.5 x 3.5 mm O-ring, and
install it on the oil level pipe.
7) Install the oil level pipe on the mount case and tighten the
6 x 12 mm flange bolts.
Install the oil level gauge.
[3]
11.5 x 3.5 mm
O-RING
[4]
6 x 10 mm
DOWEL PIN (2)
[5]
OIL CASE
10 x 40 (16)
8) Tighten the 10 x 40 mm flange bolts to the specified torque
in the numbered sequence in two or three steps.
TORQUE: 34 N.m (3.5 kgf.m, 25 lbf.ft)
9) Tighten the 12 mm drain plug washer and the oil drain plug
bolt on the oil case. Tighten them to the specified torque
and add the engine oil.
TORQUE: 23 N.m (2.3 kgf.m, 17 lbf.ft)
⑫
⑥
⑪
⑩
⑬
⑤
④
⑭
①
10) Install the following parts.
– Extension case/lower rubber mount (P. 14-91)
– Gear case assembly (P. 14-5 and 44)
– L./R. engine under cover (P. 4-14)
– Engine cover (P. 4-2)
②
⑨
③
⑧
⑯
⑦
14-96
⑮
15. MOUNTING CASE/STERN BRACKET/SWIVEL
CASE/POWER TRIM/TILT ASSEMBLY
1. MOUNTING CASE
2. STERN BRACKET/SWIVEL CASE
REMOVAL/INSTALLATION
3. STERN BRACKET/SWIVEL
CASE/POWER TRIM/TILT ASSEMBLY
4. POWER TRIM/TILT ASSEMBLY
5. AIR BLEEDING
6. BLOW PRESSURE INSPECTION
7. POWER TILT MOTOR ASSEMBLY
83 N.m (8.5 kgf.m,
61 lbf.ft)
34 N.m (3.5 kgf.m,
25 lbf.ft)
34 N.m (3.5 kgf.m,
25 lbf.ft)
34 N.m (3.5 kgf.m,
25 lbf.ft)
15-1
1. MOUNTING CASE
a. REMOVAL
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under covers (P. 4-9)
– Under cover front bracket (P. 4-20)
– Water relief tube C (P. 8-6)
– Engine assembly (P. 7-2)
Remove the two 12 mm self-locking nuts and remove the mounting case assembly.
[2]
MOUNTING CASE
ASSEMBLY
[1]
12 mm SELF-LOCKING
NUT (2)
15-2
b. MOUNTING CASE DISASSEMBLY
1) Remove the under cover seal A and the mounting case rubber seal from the mounting case.
Remove the shift shaft B and the shift shaft washer.
2) Remove the three 6 x 25 mm flange bolts and remove the idle exhaust port and the idle exhaust port gasket.
Replace the gasket with a new one on assembly.
3) Check the 22 x 35 x 7 mm water seal lips for cut and replace if necessary before removal.
Remove the two 22 x 35 x 7 mm water seals using a commercially available oil seal remover. Replace the oil seals
with the new ones on assembly.
4) Remove the 12 mm E-ring from the shift shaft A and remove the 14 mm washer and the shift shaft A.
Check the 14 x 26 x 8 mm water seal lip for cut and replace if necessary before removal. Remove the 14 x 26 x 8 mm
water seal using a commercially available oil seal remover. Replace with a new one on assembly.
5) Remove the two 12 x 145 mm stud bolts from the upper rubber mount.
6) Remove the six 8 x 35 mm flange bolts and remove the upper mount holder, upper mount holder gasket and the
upper rubber mount. Replace the gasket with a new one on assembly.
Check the upper rubber mount for deterioration and cracks. Replace with a new one if necessary.
[5] 22 x 35 x 7 mm
WATER SEAL (2)
[4] SHIFT SHAFT B
[3] SHIFT SHAFT A
[2] 20 x 28 x 13 mm
NEEDLE BEARING
8 x 35 (6)
[6] UPPER MOUNT
HOLDER
[7] UPPER MOUNT
HOLDER GASKET
[8] UPPER RUBBER
MOUNT
6 x 25 (3)
[1] SHIFT SHAFT
WASHER
[9] IDLE EXHAUST
PORT
[17]
14 x 26 x 8 mm
WATER SEAL
[10] IDLE EXHAUST
PORT GASKET
[16] 14 mm WASHER
[15] 12 mm E-RING
[11] MOUNTING
CASE
[12] UNDER COVER
SEAL A
[14] 12 x 145 mm
STUD BOLT (2)
15-3
[13] MOUNTING CASE
RUBBER SEAL
c. 20 x 28 x 13 mm NEEDLE BEARING REMOVAL
1) Remove all parts from the mounting case.
[1] 20 x 28 x 13 mm
NEEDLE BEARING
2) Warm up the 20 x 28 x 13 mm needle bearing of the
mounting case and remove the needle bearing.
Replace the 20 x 28 x 13 mm needle bearing with a new one
on assembly.
NOTICE
Take care not to get burned during operation.
[2] MOUNTING CASE
d. 20 x 28 x 13 mm NEEDLE BEARING
INSTALLATION
1) Apply engine oil to the circumference of the new 20 x 28 x
13 mm needle bearing.
2) Install the 20 x 28 x 13 mm needle bearing in the mounting
case using the special tools and the hydraulic press as
shown.
TOOLS:
Driver
Attachment, 28 x 30 mm
Pilot, 20 mm
07749-0010000
07946-1870100
07746-0040500
[1]
DRIVER
07749-0010000
[2]
ATTACHMENT,
28 x 30 mm
07946-1870100
[3]
PILOT, 20 mm
07746-0040500
e. MOUNTING CASE ASSEMBLY
1) Install the upper rubber mount in the mounting case with
the “UP” mark on the upper rubber mount toward up and
the white paint mark toward the opposite side from the
water seal installation part.
[1] UPPER RUBBER
MOUNT
[2]
“UP” MARK
[3] WHITE
PAINT
MARK
Note the installation direction of the upper rubber mount.
[4] WATER SEAL INSTALLATION PART
15-4
2) Install the new upper mount holder gasket and the upper
mount holder on the upper rubber mount with the cutouts
in the upper mount holder gasket and in the upper mount
holder toward the opposite side from the water seal
installation part.
8 x 35 (6)
[1]
UPPER
MOUNT
HOLDER
Note the installation direction.
3) Tighten the upper rubber mount securely with the six 8 x 35
mm flange bolts.
[4]
WATER SEAL
INSTALLATION
PART
4) Tighten the two 12 x 145 mm stud bolts on the upper
rubber mount securely with the longer threads of the stud
bolts toward the upper rubber mount side.
[2] CUTOUTS
[3] UPPER MOUNT
HOLDER GASKET
[1] UPPER RUBBER
MOUNT
[2] 12 x 145 mm
STUD BOLT (2)
[3] <12 x 145 mm STUD BOLT>
[4] SHORT
15-5
[5] LONG
[6]
UPPER
RUBBER
MOUNT
SIDE
5) Apply grease to the circumference and the mating surfaces
of the two new 22 x 35 x 7 mm water seals.
6) Install the 22 x 35 x 7 mm water seals one by one in the
mounting case using the special tools as shown. Note the
installation direction of the water seals.
[1] <Water seal
installation direction>
[3]
DRIVER
07749-0010000
7) After installing the water seals, apply 2 – 4 g (0.07 – 0.14 oz)
of grease to the lip and the area around the lip of the water
seals.
[2]
(Apply grease to the
circumference and mating
surfaces of the seals.)
• Note the installation direction of the water seals.
TOOLS:
Driver
Attachment, 32 x 35 mm
Pilot, 22 mm
07749-0010000
07746-0010100
07746-0041000
[4] ATTACHMENT,
32 x 35 mm
07746-0010100
[5]
PILOT, 22 mm
07746-0041000
8) Apply grease to the circumference of the new 14 x 26 x 8
mm water seal.
9) Install the water seal with the special tools as shown. Note
the installation direction.
[1] <Water seal installation
direction>
[3]
DRIVER
07749-0010000
10) After installing the water seal, apply 2 – 4 g (0.07 – 0.14 oz)
of grease to the lip and the area around the lip of the water
seal.
• Note the installation direction of the water seal.
TOOLS:
Driver
Attachment, 24 x 26 mm
Pilot, 12 mm
[2] (Apply grease to the
circumference and
the lip of the seal.)
07749-0010000
07746-0010700
07746-0040100
[4]
ATTACHMENT,
24 x 26 mm
07746-0010700
[5]
14 x 26 x 8 mm
WATER SEAL
[6] PILOT, 12 mm
07746-0040100
15-6
11) Apply grease to the shift shaft A installation part in the
mounting case.
12) Set the shift shaft A on the mounting case and install the 14
mm washer and the 12 mm E-ring on the shift shaft A.
[1] SHIFT
SHAFT A
[2] 14 mm
WASHER
[3] 12 mm
E-RING
13) Install the shift shaft washer on the mounting case.
14) Apply grease to the shift shaft B installation part in the
mounting case.
[1]
SHIFT
SHAFT B
Install the shift shaft B on the mounting case aligning the
punch mark on the shift shaft B with the punch mark on the
shift shaft A as shown.
[2]
SHIFT SHAFT
WASHER
[3]
SHIFT SHAFT A
[1]
SHIFT SHAFT B
[4] PUNCH MARKS
15-7
15) Clean the mounting case/idle exhaust port mating surfaces
and the both sides of the idle exhaust port gasket
thoroughly with a degreasing cleaning solvent and shop
towel.
16) Apply a bead [ø1.0 – 5.0 mm (ø0.04 –0.20 in)] of the liquid
gasket (ThreeBond® #1211 or equivalent) to the indicated
area of the both sides of the idle exhaust port gasket.
[2] LIQUID GASKET
(Apply to both sides.)
[1]
LIQUID GASKET
APPLICATION
AREA
[3] GASKET
NOTICE
• Install the idle exhaust gasket within 90 minutes after
application of the liquid gasket.
[4]
IDLE EXHAUST
PORT GASKET
• If it has been left for 90 minutes or longer, remove the old
gasket and apply a liquid gasket again before installation.
6 x 25 (3)
17) Install the idle exhaust port gasket on the mounting case
and tighten the three 6 x 25 mm flange bolts securely.
[5]
IDLE EXHAUST
PORT
[4]
IDLE EXHAUST
PORT GASKET
18) Install the mounting case rubber seal on the mounting case
with the cut side to your side.
19) Install the under cover seal A on the mounting case (P. 153).
[1]
MOUNTING CASE
RUBBER SEAL
15-8
[2] Install with
the cut side
to your side.
f. INSTALLATION
1) Set the mounting case assembly on the mount frame and tighten the two 12 mm self-locking nut to the specified
torque.
TORQUE: 83 N.m (8.5 kgf.m, 61 lbf.ft)
2) Remove the following parts.
– Engine assembly (P. 7-6)
– Water relief tube C (P. 8-7)
– Under cover front bracket (P. 4-31)
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)
[2]
MOUNTING CASE
ASSEMBLY
[1]
12 mm SELF-LOCKING
NUT (2)
83 N.m (8.5 kgf.m,
61 lbf.ft)
15-9
2. STERN BRACKET/SWIVEL CASE
REMOVAL/INSTALLATION
[1] POWER TILT MOTOR
2P CONNECTOR
[2] TRIM ANGLE
SENSOR
3P CONNECTOR
a. REMOVAL
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under covers (P. 4-9)
– Gear case assembly (P. 14-3 and 42)
– Remote control cable/grommet (P. 17-2)
– Starter cable (P. 18-15)
1) Place the outboard on a level surface (i.e. outboard motor
in the vertical position).
2) Remove the trim angle sensor 3P connector and the power
tilt motor 2P connector from the connector bracket A.
[3]
CONNECTOR
BRACKET A
Disconnect the trim angle sensor 3P connector and the
power tilt motor 2P connector.
3) Remove the undercase grommet C outside the under cover
front bracket.
[1] UNDER COVER
FRONT BRACKET
Pull off the tube and wires through the hole in the under
cover front bracket.
[5]
HOLE
[2]
WIRES
[3]
TUBE
[4]
UNDERCASE
GROMMET C
4) Hook the hoist hook on each of the three engine hangers.
[2] HOIST CHAIN
Remove the following part.
– Lower rubber mount (P. 14-89)
NOTICE
Check that the outboard motor is not lifted off.
15-10
[1] ENGINE
HANGER B
[3]
ENGINE
HANGER (2)
5) Swing the outboard motor right and left and remove the
two 12 mm self-locking nuts.
6) Check that the engine assembly/mounting case mating
surfaces are level to the ground.
Holding the outboard motor with the hoist, remove the
stern bracket/swivel case assembly mounted on the
outboard motor stand from the outboard motor.
If it is hard to remove the stern bracket/swivel case
assembly, remove by raising and lowering the outboard
motor slowly with the hoist.
NOTICE
• Do not raise the outboard motor stand off the ground
while raising the outboard motor with the hoist.
[1] 12 mm SELFLOCKING NUT
• Remove the stern bracket/swivel case assembly with care
not to damage the threads of the two 12 x 145 mm stud
bolts.
7) After removing the stern bracket/swivel case assembly,
lower the outboard motor slowly.
Store the outboard motor with the extension case set on
the ground.
NOTICE
• If it is necessary to store the outboard motor by laying it
on its side, install the L./R. engine under covers (P. 4-14),
drain the engine oil (P. 3-2) and drain the gasoline from
the vapor separator.
• Then, lay the outboard motor on a urethane foam sheet
or blanket with the intake manifold toward down.
[1]
12 mm SELF-LOCKING
NUT (2)
[2]
STERN BRACKET/SWIVEL
CASE ASSEMBLY
15-11
[1]
12 mm SELFLOCKING NUT
b. INSTALLATION
1) Lift up the outboard motor until the 12 x 145 mm stud bolts are flush with the holes in the mount frame of the stern
bracket/swivel case assembly.
2) Holding the outboard motor with the hoist, move the stern bracket/swivel case assembly, that are attached to the
outboard motor stand, slowly toward the outboard motor.
Insert the 12 x 145 mm stud bolts into the mount frame and tighten the two 12 mm self-locking nuts to the specified
torque.
TORQUE: 83 N.m (8.5 kgf.m, 61 lbf.ft)
[1]
12 mm SELF-LOCKING
NUT (2)
83 N.m (8.5 kgf.m,
61 lbf.ft)
[2] STERN BRACKET/SWIVEL
CASE ASSEMBLY
3) Install the lower rubber mount (P. 14-93).
[2] HOIST CHAIN
4) Detach the hoist hooks from the three engine hangers.
[1] ENGINE
HANGER B
15-12
[3]
ENGINE
HANGER (2)
5) Pass the tube and wires through the hole in the under cover
front bracket.
[1] UNDER COVER
FRONT BRACKET
[2]
WIRES
Check that the taped ends of the power tilt motor wire and
trim angle sensor wire are in alignment with the end of the
undercase grommet C.
[3]
TUBE
Install the undercase grommet C on the under cover front
bracket so they engage securely in the groove of the
undercase grommet C.
Move the front lock with a hand and check that the wires
and tube do not interfere with the front lock.
[5]
HOLE
[4] UNDERCASE
GROMMET C
[7] Wires and tube must
not interfere with the
lock lever.
[6]
FRONT LOCK
[8]
TAPED
PARTS
[4]
UNDERCASE
GROMMET C
[11] SPEED
SENSOR
TUBE A
6) Connect the trim angle sensor 3P connector and the power
tilt motor 2P connector.
[10]
TRIM ANGLE
SENSOR WIRE
[1] POWER TILT MOTOR
2P CONNECTOR
[9] POWER
TILT
MOTOR
WIRE
[2] TRIM ANGLE
SENSOR
3P CONNECTOR
Install the power tilt motor 2P connector on the lower side
of the connector bracket A and the trim angle sensor 3P
connector on the upper side of the connector bracket A.
7) Install the following parts.
– Starter cable (P. 18-17)
– Remote control cable/grommet (P. 17-5)
– Gear case assembly (P. 14-5 and 44)
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)
[3]
CONNECTOR
BRACKET A
15-13
3. STERN BRACKET/SWIVEL CASE/
POWER TRIM/TILT ASSEMBLY
a. STERN BRACKET/SWIVEL CASE/POWER TRIM/
TILT ASSEMBLY REMOVAL
Remove the following parts.
– Engine cover (P. 4-2)
– L./R. engine under covers (P. 4-9)
– Gear case assembly (P. 14-3 and 42)
– Stern bracket/swivel case (P. 15-10)
1) Loosen the manual valve fully and set the swivel case
assembly in the uppermost position.
After raising the swivel case assembly to the uppermost
position, secure it in the position with the tilt stopper.
Tighten the manual valve.
2) Open the wire harness clip and release the trim angle
sensor wire, power tilt motor wire and the speed sensor
tube A.
[1] MANUAL VALVE
[1] WIRE HARNESS
CLIP
Remove the spiral tube from the trim angle sensor wire,
power tilt motor wire and the speed sensor tube A.
[2]
SPIRAL TUBE
[3] WIRE/TUBE
3) Remove the wire band from the undercase grommet C and
release the trim angle sensor wire, power tilt motor wire
and the speed sensor tube A.
[1] WIRE BAND
Replace the tie wire with a new one on assembly.
[2] UNDERCASE
GROMMET C
15-14
4) Open the two wire bands that secure the speed sensor tube
A and B and disconnect the speed sensor tube A and B
from the joint A.
[1] SPEED SENSOR
TUBE A
Replace the wire bands with the new ones on assembly.
Check the speed sensor tube A for deterioration and cracks.
Replace if necessary.
[4]
WIRE
BAND (2)
[2] SPEED SENSOR
TUBE B
[3] JOINT A
5) Remove the motor wire bushing from the L. stern bracket.
[1]
L. STERN
BRACKET
[2]
MOTOR WIRE
BUSHING
6) Remove the two 6 x 25 mm hex. bolts and the two 6 mm
washers, and remove the anode metal.
Check the anode metal for corrosion. If it is corroded
excessively, replace with a new one.
[2]
6 mm
WASHER (2)
[1] ANODE METAL
15-15
[3] 6 x 25 mm
HEX. BOLT (2)
7) Remove the speed sensor tube plates that secure the speed
sensor tube B.
Remove the speed sensor tube B.
Check the speed sensor tube B for deterioration and cracks.
Replace if necessary.
[1] SPEED SENSOR
TUBE B
[2] 6 x 8 mm
SCREW (2)
[3] SPEED SENSOR
TUBE PLATE (2)
8) Remove the 10 mm self-locking nut and 10 mm washer,
and remove the 10 x 235 mm hex. bolt.
[1]
10 mm SELF-LOCKING
NUT
[2] 10 mm
WASHER
[3] 10 x 235 mm
HEX. BOLT
15-16
9) Remove the 15 mm E-ring from the upper cylinder pin. Remove the upper cylinder pin and the piston rod of the
power trim/tilt assembly from the swivel case assembly.
Check the upper cylinder bushing mounted on the piston rod of the power trim/tilt assembly. If it is damaged, replace
with a new one.
10) Remove the upper cylinder bushing.
Replace with a new one on assembly.
[3]
SWIVEL CASE
ASSEMBLY
[2] UPPER CYLINDER PIN
[1] 15 mm E-RING (2)
[5] UPPER CYLINDER
BUSHING (2)
[4] PISTON ROD
11) Remove the two 6 x 20 mm hex. bolts and the two 6 mm
washers from the trim angle sensor, and remove the trim
angle sensor.
[1]
TRIM ANGLE
SENSOR
[3]
6 mm WASHER (2)
15-17
[2]
6 x 20 mm HEX.
BOLT (2)
12) Remove the tilting bolt cap and loosen the 25 x 2.0 mm selflocking nut or the 7/8-14 UNF self-locking nut.
[1] TILTING BOLT
CAP
13) Holding the power trim/tilt assembly with the hands,
extend the L./R. stern brackets to the right and left and
remove the lower cylinder collar and the two 32 mm wave
washers.
14) Pull off the wires and tube through the hole in the L. stern
bracket and remove the power trim/tilt assembly.
Check the lower cylinder bushings mounted on the power
trim/tilt assembly for damage. Replace the bushings with
the new ones if necessary.
[3]
25 x 2.0 mm SELFLOCKING NUT
[2] 7/8-14 UNF SELFLOCKING NUT
15) Remove the lower cylinder bushings.
Replace the lower cylinder bushings with the new ones on
assembly.
NOTICE
• Do not push in the piston rod after removing the power
trim/tilt assembly.
If the piston rod is pushed down, extend the piston rod
fully and hold it in the position.
• Store the power trim/tilt assembly vertically with the
upper cylinder pin installation part facing up after
removal. Never store the power trim/tilt assembly by
laying it on its side or with the lower cylinder collar
installation part facing up.
[1] R. STERN
BRACKET
• If it is hard to remove the lower cylinder collar, loosen the
25 x 2.0 mm self-locking nut again.
[2] LOWER
CYLINDER
COLLAR
[7]
UPPER CYLINDER
PIN INSTALLATION
PART
[6]
L. STERN
BRACKET
[8]
LOWER CYLINDER
PIN INSTALLATION
PART
15-18
[5]
32 mm WAVE
WASHER (2)
[3] POWER TRIM/TILT
ASSEMBLY
[4] LOWER CYLINDER
BUSHING (2)
16) Remove the 25 x 2.0 mm self-locking nut or 7/8-14 UNF self-locking nut from the tilting shaft.
Replace the 25 x 2.0 mm self-locking nut or 7/8-14 UNF self-locking nut with a new one on assembly.
17) Remove the tilting shaft and remove the L./R. stern brackets, two 26 mm wave washers and the swivel case assembly.
Check the swivel case bushing that is mounted on the swivel case assembly.
Replace the swivel case bushing if it is damaged.
18) Remove the swivel case bushing.
Replace the swivel case bushing with a new one on assembly.
19) Remove the 15.54 x 2.26 mm O-ring from the tilting shaft.
Replace the O-ring with a new one on assembly.
Remove the wire harness clip from the L. stern bracket.
[1] SWIVEL CASE ASSEMBLY
[2]
7/8-14 UNF SELFLOCKING NUT
[11] SWIVEL CASE
BUSHING
[3] TILTING BOLT
CAP
[10] 26 mm WAVE
WASHER (2)
[4] TILTING SHAFT
[9]
25 x 2.0 mm SELFLOCKING NUT
[5] 15.54 x 2.26 mm
O-RING
[8] WIRE HARNESS
CLIP
[6] R. STERN
BRACKET
[7] L. STERN
BRACKET
b. INSPECTION
[1] TRIM ANGLE SENSOR
3P CONNECTOR
• TRIM ANGLE SENSOR
Attach the tester leads to the trim angle sensor connector and
measure the resistance.
Resistance between
Light green/black and Black
4–6Ω
Resistance between
Yellow/blue and Black
2.7 – 4.3 kΩ
15-19
c. COMPONENTS DRAWING
[1] TILTING BOLT
CAP
[16]
SPEED SENSOR
TUBE PLATE (2)
[15] 6 x 8 mm SCREW (2)
[2]
SPEED SENSOR
TUBE B
[14] WIRE HARNESS
CLIP
[3] 10 mm
WASHER
[13]
SPEED SENSOR
TUBE A
[12]
WIRE BAND (2)
[11] JOINT A
[4]
10 mm SELF-LOCKING
NUT
34 N.m (3.5 kgf.m,
25 lbf.ft)
[10] SPEED SENSOR
TUBE B
[5] MOTOR WIRE
BUSHING
[9] 10 x 235 mm
HEX. BOLT
[8] 6 mm WASHER (2)
15-20
[6] ANODE METAL
[7] 6 x 25 mm
HEX. BOLT (2)
[3]
15 mm E-RING (2)
[2] SWIVEL CASE
ASSEMBLY
[4] SWIVEL CASE
BUSHING (2)
[1] UPPER CYLINDER
PIN
[5]
TILTING
SHAFT
[6]
7/8-14 UNF SELFLOCKING NUT
34 N.m (3.5 kgf.m,
25 lbf.ft)
[19] 6 x 20 mm
HEX. NUT (2)
[18] 6 mm WASHER (2)
[17] TRIM ANGLE
SENSOR
[7]
15.54 x 2.26 mm
O-RING
[16] 25 x 2.5 mm SELFLOCKING NUT
34 N.m (3.5 kgf.m,
25 lbf.ft)
[8]
26 mm WAVE
WASHER (2)
[9]
R. STERN
BRACKET
[10] UPPER CYLINDER
BUSHING (2)
[15] L. STERN
BRACKET
[11] LOWER CYLINDER
COLLAR
[13]
LOWER CYLINDER
BUSHING (2)
[14] 32 mm WAVE
WASHER (2)
15-21
[12] POWER TRIM/TILT
ASSEMBLY
d. SWIVEL CASE ASSEMBLY DISASSEMBLY
1) Remove the 6 x 8 mm screw and the ground cable.
[1] 6 x 8 mm
SCREW
Remove the 39 mm external circlip.
[3]
39 mm
EXTERNAL
CIRCLIP
2) Put a mark on the mount frame so it aligns with the
“ ”mark on the lower mount center housing.
[1] “
[2]
GROUND
CABLE
” MARK
[4] LOWER MOUNT
CENTER HOUSING
3) Remove the lower mount center housing using a hydraulic
press and the special tools as shown.
TOOLS:
Driver
Attachment, 32 x 35 mm
Pilot, 30 mm
07749-0010000
07746-0010100
07746-0040700
[2] MOUNT
FRAME
[3] MARK
[2]
PRESS
[1]
DRIVER
07749-0010000
[5]
ATTACHMENT,
32 x 35 mm
07746-0010100
[3]
PILOT, 30 mm
07746-0040700
[4] LOWER MOUNT
CENTER HOUSING
15-22
4) Remove the mount frame and the 34 mm thrust washer
from the swivel case.
[1]
MOUNT FRAME
Remove the 40 mm wave washer.
[2]
SWIVEL CASE
[4]
34 mm THRUST
WASHER
5) Check the 39.5 x 52 x 6 mm oil seal lip for cut and replace
if necessary before removing the oil seal.
[1] SWIVEL CASE
LINER (2)
Remove the 39.5 x 52 x 6 mm oil seal from the swivel case
using a commercially available oil seal remover.
Replace the oil seal with a new one on assembly.
6) Remove the two swivel case liners from the swivel case.
[2]
SWIVEL
CASE
[3]
39.5 x 52 x 6 mm
OIL SEAL
15-23
[3]
40 mm WAVE
WASHER
7) Remove the three grease fittings from the swivel case.
[2] SWIVEL CASE
8) Remove the two 10 mm self-locking nuts and the two 10
mm washers, then remove the two thrust receivers.
[3] 10 mm
SELFLOCKING
NUT (2)
[1] GREASE
FITTING (3)
[4] 10 mm
WASHER
(2)
[5]
THRUST
RECEIVER (2)
9) Remove the 6 x 14 mm hex. bolt, and remove the detent
assisted spring and the detent spring.
10) Using a commercially available 2.5 mm pin driver, drive out
the 2.5 x 20 mm spring pin to the position where it does not
interfere with the swivel case as shown.
[1]
2.5 mm PIN
DRIVER
(Commercially
available)
Remove the driven-out 2.5 x 20 mm spring pin using the
cutting pliers or equivalent tool.
Remove the spring pin on the other side in the same
manner.
11) Remove the two tilt stoppers and the tilting bracket.
Check the tilt arm bushings mounted on the swivel case.
Replace them with the new ones if they are damaged.
12) Remove the tilt arm bushings.
Replace the tilt arm bushings with the new ones on
assembly.
[2]
2.5 x 20 mm
SPRING PIN
(2)
[3]
DETENT
SPRING
[4]
2.5 x 20 mm
HEX. BOLT
[5]
DETENT ASSISTED
SPRING
[2] 2.5 x 20 mm
SPRING PIN (2)
[9]
SWIVEL
CASE
[6]
TILTING
BRACKET
[8] TILT ARM
BUSHING (2)
15-24
[7]
TILT STOPPER (2)
e. COMPONENTS DRAWING
[2] 6 x 14 mm
HEX. BOLT
[3]
DETENT ASSISTED
SPRING
[1] DETENT
SPRING
[4]
SWIVEL CASE
LINER (2)
[5] 2.5 x 20 mm
SPRING PIN (2)
[6] TILTING
BRACKET
[21]
GREASE FITTING (3)
3 N.m (0.3 kgf.m,
2.2 lbf.ft)
[7]
TILT
STOPPER (2)
[8] TILT ARM
BUSHING (2)
[20]
MOUNT FRAME
[9] 10 mm SELFLOCKING NUT (2)
[10] 10 mm
WASHER (2)
[19]
34 mm THRUST
WASHER
[11] SWIVEL CASE
[18] THRUST
RECEIVER (2)
[17] 39.5 x 52 x 6 mm
OIL SEAL
[12]
LOWER MOUNT
CENTER HOUSING
[13]
6 x 8 mm
SCREW
[16] 40 mm WAVE
WASHER
[15] 39 mm EXTERNAL
CIRCLIP
15-25
[14] GROUND CABLE
f. SWIVEL CASE ASSEMBLY ASSEMBLY
1) Apply grease to the circumference of the new tilt stopper
bushings and install them on the swivel case.
[1]
2.5 mm PIN
DRIVER
(Commercially
available)
[2] PROJECTION
2) Install the two tilt stoppers and the tilting bracket on the
swivel case.
Install the tilt stopper in the position shown.
Check that the projection on the tilting bracket is in the
position shown.
[4]
2.5 x 20 mm
SPRING PIN
(2)
3) Drive the 2.5 x 20 mm spring pins into the tilting bracket
using a commercially available 2.5 mm pin driver as
shown.
Check that 1 – 2 mm (0.04 – 0.08 in) of the spring pin end is
out of the tilting bracket at the opposite side from the
driving side.
• Do not drive in the spring pins excessively. The tilt
stopper cannot operate properly if the extrusion length of
the pin is more than 1 – 2 mm (0.04 – 0.08 in).
4) Apply grease to the cam of the tilting bracket.
[5]
DETENT
SPRING
[3] DRIVE-IN
DIRECTION
[6]
6 x 14 mm
HEX. BOLT
[11]
SWIVEL
CASE
5) Apply grease to the detent spring roller. Secure the detent
spring and the detent assisted spring with the 6 x 14 mm
hex. bolt.
[10] TILT ARM
BUSHING (2)
6) Install the two thrust receivers on the swivel case, then
install the two 10 mm washers and the two 10 mm selflocking nuts.
7) Set the three grease fittings on the swivel case, and tighten
them to the specified torque.
[7]
DETENT ASSISTED
SPRING
[4] 2.5 x 20 mm
SPRING PIN
(2)
[8] TILTING
BRACKET
[9]
TILT
STOPPER
(2)
[2] SWIVEL CASE
Tighten the 10 mm self-locking nuts securely.
Apply grease to the sliding surface of the thrust receiver.
1 – 2 mm
(0.04 – 0.08 in)
[1]
GREASE
FITTING (3)
[3] 10 mm
SELFLOCKING
NUT (2)
TORQUE: 3 N.m (0.3 kgf.m, 2.2 lbf.ft)
[4] 10 mm
WASHER
(2)
[5]
THRUST
RECEIVER (2)
15-26
8) Apply grease to the outer surface of the swivel case liner.
Install the swivel case liner aligning the projection on the
swivel case liner with the concave in the swivel case.
9) Apply grease the circumference of the new 39.5 x 52 x 6
mm oil seal and install it in the bottom of the swivel case.
[4] SWIVEL
CASE
LINER
[3] PROJECTION
[2]
SWIVEL CASE
[1]
CONCAVE
Note the installation direction of the oil seal.
Apply grease to the oil seal lip.
[2]
SWIVEL
CASE
[1]
CONCAVE
[4] SWIVEL CASE
LINER
[3]
PROJECTION
[5]
39.5 x 52 x 6 mm
OIL SEAL
10) Apply grease to the surface of the 34 mm thrust washer and
install it on the mount frame.
[1] MOUNT FRAME
Apply grease to the entire surface of the mount frame shaft
and install the mount frame on the swivel case.
[2] SWIVEL CASE
• Install the mount frame with care not to push the swivel
case liner out of the swivel case.
11) Apply grease to the surface of the 40 mm wave washer and
install it on the mount frame.
[4]
34 mm
THRUST
WASHER
15-27
[3] 40 mm WAVE
WASHER
12) Apply grease to the spline of the lower mount center
housing.
[1] “
” MARK
Install the lower mount center housing on the mount frame
aligning the “ ” mark on the lower center housing with
the mark on the mount frame that had been put during
disassembly.
[4] LOWER MOUNT
CENTER HOUSING
13) Position the swivel case/mount frame on the hydraulic
press as shown.
14) Position the special tool on the lower mount center housing
as shown.
Press fit the lower mount center housing until it contacts
the swivel case (i.e. hydraulic pressure of the hydraulic
press rises slightly).
TOOL:
Driver, 40 mm I.D.
15-28
07746-0030100
[1]
DRIVER, 40 mm I.D.
07746-0030100
[2]
LOWER MOUNT
CENTER HOUSING
[2] MOUNT
FRAME
[3] MARK
15) Remove the swivel case assembly and the special tool from
the hydraulic press.
[1] 39 mm EXTERNAL
CIRCLIP
[2]
PART “A”
16) Check that the mount frame turns smoothly.
Check that the 39 mm external circlip sets in position
smoothly.
<Mount frame turns smoothly and circlip can be installed>
Install the 39 mm external circlip and apply grease to the
part “A” shown in the drawing.
[4] PRESS
<Circlip can be installed but the mount frame does not turn
smoothly>
(1) Attach the special tools to the lower mount center
housing.
TOOLS:
Driver
Attachment, 32 x 35 mm
Pilot, 30 mm
07749-0010000
07746-0010100
07746-0040700
(2) Tighten the puller bolt and align the surface of the lower
mount center housing with the circlip installation
groove in the mount frame.
Remove the puller and the special tool.
[3]
DRIVER
07749-0010000
[5]
ATTACHMENT,
32 x 35 mm
07746-0010100
[7]
PILOT, 30 mm
07746-0040700
(3) Install the 39 mm external circlip and apply grease to the
part “A” shown in the drawing.
[6] LOWER MOUNT
CENTER HOUSING
[8] CIRCLIP INSTALLATION
GROOVE
[9]
ENLARGED VIEW
OF MOUNT FRAME
17) Tighten the 6 x 8 mm screw while pushing the ground cable
against the projection of the lower mount center housing.
[1] Push against
the projection.
[2] 6 x 8 mm SCREW
18) After assembling the swivel case, fill the grease fittings
with the grease using a grease gun.
[4]
GROUND
CABLE
15-29
[3]
LOWER MOUNT
CENTER HOUSING
g. STERN BRACKET/SWIVEL CASE/POWER TRIM/
TILT ASSEMBLY INSTALLATION
• Check that the piston rod of the power trim/tilt assembly is in
the fully extended position.
[1]
SWIVEL
CASE
BUSHING
(2)
[2] SWIVEL CASE
ASSEMBLY
1) Apply grease to the inner wall and circumference of the
new swivel case bushings. Install the new swivel case
bushings on the swivel case.
[3]
TILTING SHAFT
[4]
TILTING
BOLT CAP
2) Apply grease to the new 15.54 x 2.26 mm O-ring and install
it in the groove in the tilting shaft.
Apply grease to the threads and bearing of the tilting shaft.
Apply grease to the shaft installation parts of the swivel
case assembly and of the L./R. stern brackets.
[5] 7/8-14 UNF
SELF-LOCKING
NUT
3) Tighten the new 25 x 2.5 mm self-locking nut or the 7/8-14
UNF self-locking nut on the threads at either the right or left
end of the tilting shaft.
4) Apply grease to the entire surface of the 26 mm wave
washer. Install the stern bracket and the 26 mm wave
washer on the end of the tilting shaft where the self-locking
nut has been mounted.
• When the 7/8-14 UNF self-locking nut has been tightened
on the tilting shaft, insert the tilting shaft into the R. stern
bracket.
5) Pass the tilting shaft through the swivel case assembly and
install the 26 mm wave washer and the stern bracket.
[6]
15.54 x 2.26 mm
O-RING
[11]
WIRE
HARNESS
CLIP
[10]
L. STERN BRACKET
[7] R. STERN
BRACKET
[8] 26 mm WAVE
WASHER (2)
[9] 25 x 2.0 mm SELFLOCKING NUT
6) Loosely tighten the new 25 x 2.0 mm self-locking nut or the
7/8-24 UNF self-locking nut on the tilting shaft. Move the
L./R. stern brackets to the self-locking nut side.
Raise the swivel case assembly to the uppermost position
and hold it in the position with the tilt stopper.
Install the wire harness clip on the L. stern bracket.
7) Apply grease to the inner wall and circumference of the
new lower cylinder bushings and install them on the power
trim/tilt assembly.
[1] POWER TRIM/TILT
ASSEMBLY
Apply grease to the circumference of the lower cylinder
collar and install it in the power trim/tilt assembly.
[2]
LOWER CYLINDER
COLLAR
Apply grease to the entire surface of the 26 mm wave
washers and install them on the power trim/tilt assembly.
8) Pass the trim angle sensor wire, power tilt motor wire and
the speed sensor tube B through the hole in the L. stern
bracket.
9) Install the lower cylinder collar, that has been mounted in
the power trim/tilt assembly, on the L./R. stern brackets.
[4]
LOWER CYLINDER
BUSHING (2)
15-30
[3]
32 mm WAVE
WASHER (2)
10) Tighten the 25 x 2.0 mm self-locking nut or the 7/8-14 UNF
self-locking nut to the specified torque.
[1]
TILTING BOLT CAP
TORQUE: 34 N.m (3.5 kgf.m, 25 lbf.ft)
Tighten the 25 x 2.0 mm self-locking nut or the 7/8-14 UNF
self-locking nut of the other side to the specified torque.
TORQUE: 34 N.m (3.5 kgf.m, 25 lbf.ft)
Tighten the tilting bolt cap on the 7/8-14 UNF self-locking
nut.
[3] 25 x 2.0 mm SELFLOCKING NUT
[2] 7/8-14 UNF SELFLOCKING NUT
11) Set the two 6 x 20 mm hex. bolts and the two 6 mm
washers on the trim angle sensor.
Tighten the two 6 x 20 mm hex. bolts securely.
[1]
TRIM ANGLE
SENSOR
12) Pass the trim angle sensor wire, power tilt motor wire and
the speed sensor tube B through the motor wire bushing.
Install the motor wire bushing in the L. stern bracket
aligning the projection on the motor wire bushing with the
concave in the L. stern bracket.
• Check that the speed sensor tube B is at the rear side in
the motor wire bushing, compared with the position of
the trim angle sensor wire and the power tilt motor wire,
by viewing the L. stern bracket from the reverse side.
[5] <Viewing L. stern bracket from reverse side>
[3] 6 mm
WASHER (2)
[2] 6 x 20 mm
HEX. BOLT (2)
[2] CONCAVE
[3]
PROJECTION
[1]
L. STERN
BRACKET
[7] UP (ENGINE SIDE)
[8] TRIM ANGLE
SENSOR WIRE
[6]
REARWARD
[10]
SPEED SENSOR
TUBE B
15-31
[9] POWER TILT
MOTOR WIRE
[4] MOTOR WIRE BUSHING
13) Check that the corrugated tube on the power tilt motor wire
stands erect as shown.
[1] CORRUGATED TUBE
(It must stand erect.)
[2] POWER TILT
MOTOR WIRE
14) Clamp the speed sensor tube B with the two speed sensor
tube plates and loosely tighten the two 6 x 8 mm screws.
[3] SPEED SENSOR
TUBE PLATE (2)
[2] 6 x 8 mm
SCREW (2)
15) Tighten the 6 x 8 mm screw securely so that the distance
from the gear case side speed sensor tube end to the end
of the speed sensor tube plate is 15 – 20 mm (0.6 – 0.8 in)
as shown.
Route the speed sensor tube B on the L. stern bracket and
tighten the 6 x 8 mm screw of the upper speed sensor tube
plate securely.
[1] SPEED
SENSOR
TUBE B
15 – 20 mm
(0.6 – 0.8 in)
16) Connect the speed sensor tube A to the joint A and fasten
the new wire band on the speed sensor tube A.
Connect the speed sensor tube B to the joint A and fasten
the new wire band on the speed sensor tube B.
[1]
MOTOR
WIRE
BUSHING
[2]
WIRE
BANDS
[3] SPEED
SENSOR
TUBE A
17) Adjust the distance from the end of the motor wire bushing
to the end of the speed sensor tube B so that it is
10 – 15 mm (0.4 – 0.6 in) as shown.
[4] JOINT A
[5] SPEED
SENSOR
TUBE B
15-32
10 – 15 mm
(0.4 – 0.6 in)
18) Wind the spiral tube around the trim angle sensor wire,
power tilt motor wire and the speed sensor tube A.
[1]
SPIRAL TUBE
19) Align the taped end of the power tilt motor wire with the
end of the motor wire bushing and install.
Clamp the trim angle sensor wire, power tilt motor wire
and the speed sensor tube A with the wire harness clip.
Avoid clamping on the spiral tube.
[8]
WIRE HARNESS
CLIP
[2]
TRIM ANGLE
SENSOR WIRE
[3]
MOTOR WIRE
BUSHING
[7]
SPEED SENSOR
TUBE A
[6] POWER TILT
MOTOR WIRE
[4] L. STERN
BRACKET
[5] TAPE
20) Pass the trim angle sensor wire, power tilt motor wire and
the speed sensor tube A through the undercase grommet
C.
[2] TRIM ANGLE
SENSOR WIRE
[3] POWER TILT
MOTOR WIRE
21) Align the taped ends of the trim angle sensor wire and the
power tilt motor wire with the end of the undercase
grommet C, and fasten the new wire band as shown.
After fastening the wire band, cut the excess of the wire
band so that the projected length is 5 – 10 mm (0.2 – 0.4 in)
(P. 2-44).
[1] SPEED
SENSOR
TUBE A
[4]
TAPED PARTS
[5] WIRE BAND
[6] UNDERCASE
GROMMET C
15-33
22) Apply grease to the inner wall and circumference of the new upper cylinder bushings and install them on the piston
rod of the power trim/tilt assembly.
23) Apply grease to the circumference of the upper cylinder pin.
24) Align the hole in the piston rod with the hole in the swivel case assembly and insert the upper cylinder pin into the
swivel case assembly.
Install the two 15 mm E-rings on the upper cylinder pin.
[3] SWIVEL CASE
ASSEMBLY
[2] UPPER CYLINDER PIN
[1]
15 mm E-RING (2)
[5] UPPER CYLINDER
BUSHING (2)
[4] PISTON ROD
25) Insert the 10 x 235 mm hex. bolt from the L. stern bracket
side and set the 10 mm washer.
Tighten the 10 mm self-locking nut to the specified torque.
[1]
10 mm SELFLOCKING NUT
TORQUE: 34 N.m (3.5 kgf.m, 25 lbf.ft)
[2] 10 mm WASHER
[3] 10 x 235 mm
HEX. BOLT
15-34
26) Check the anode metal for corrosion and replace with a
new one if necessary.
Tighten the anode metal with the two 6 x 25 mm hex. bolts
securely.
[2]
6 mm
WASHER (2)
[1] ANODE
METAL
[3]
6 x 25 mm
HEX. BOLT (2)
27) If the manual valve is tightened, loosen it fully.
Raise the swivel case assembly a little, unlock the tilt
stopper and lower the swivel case assembly to the
lowermost position.
28) Remove the following parts.
– Stern bracket/swivel case (P. 15-12)
– Gear case assembly (P. 14-5 and 44)
– L./R. engine under covers (P. 4-14)
– Engine cover (P. 4-2)
[1] MANUAL VALVE
15-35
4. POWER TRIM/TILT ASSEMBLY
a. REMOVAL
Remove the stern bracket, swivel case and the power trim/tilt assembly (P. 15-14).
b. DISASSEMBLY
• Do not reuse the O-rings.
• Do not try to disassemble the pump assembly. Replace the pump assembly as an assembly if it is faulty.
• Do not use a shop towel or equivalent cloth, and do not wear the gloves during this operation.
• Do not reuse the drained Automatic Transmission Fluid (ATF).
• When the operation is made by holding the cylinder comp. in a vice, do not tighten the vice excessively. It can damage
the cylinder comp.
• Clean the disassembled parts with the fresh Automatic Transmission Fluid (ATF) and blow the parts with compressed
air to remove dust and dirt. Store the parts neatly keeping them off dust, dirt, oil/grease, etc.
• Remove the piston rod comp. and the piston rod B with care not to damage the sliding surface of the parts.
With the power trim/tilt assembly removed from the outboard
motor, connect the power tilt motor 2P connector and operate
the power tilt motor until the piston rod comp. and the piston
rod B reach the fully extended position.
[1] OIL TANK CAP
1) Remove the oil tank cap.
Drain the Automatic Transmission Fluid (ATF) from the oil
tank.
• Do not drain the Automatic Transmission Fluid (ATF) by
pushing the piston rod comp. in.
2) Loosely tighten the oil tank cap on the oil tank.
[2]
OIL TANK
Remove the three hex. bolts and remove the oil tank from
the cylinder comp.
[1] O-RING
Drain the Automatic Transmission Fluid (ATF) from the oil
tank.
3) Remove the O-ring from the cylinder comp.
Replace the O-ring with a new one on assembly.
[3]
HEX. BOLT (3)
15-36
4) Remove the four hex. bolts and remove the power tilt
motor assembly from the pump assembly.
[1] HEX. BOLT (4)
Drain the Automatic Transmission Fluid (ATF) from the
pump assembly.
[2] POWER TILT
MOTOR
ASSEMBLY
[3]
PUMP ASSEMBLY
5) Remove the O-ring from the power tilt motor assembly.
[1] O-RING
Replace the O-ring with a new one on assembly.
[2] POWER TILT
MOTOR
ASSEMBLY
6) Remove the drive joint and the filter B from the pump
assembly.
Check the mesh of the filter B for blockage and tear. If it is
torn, replace the filter B with a new one. If it is clogged with
dust and dirt, blow the mesh with air to remove the
blockage. Take care not to damage the mesh.
[1] DRIVE JOINT
[2] FILTER B
Drain the residual Automatic Transmission Fluid (ATF) from
the pump assembly.
[3]
PUMP
ASSEMBLY
7) Remove the socket bolt A and Bs, and remove the pump
assembly from the cylinder comp.
Remove the five O-rings and orifice collar from the cylinder
comp.
Replace the O-rings with the new ones on assembly.
[3] O-RING (5)
[2] PUMP ASSEMBLY
[1]
SOCKET
BOLT B (2)
[5] SOCKET BOLT A
15-37
[4]
ORIFICE COLLAR
8) Remove the internal circlip and remove the manual valve
from the pump assembly.
Check the manual valve and the O-ring for deterioration,
wear and damage. Replace them if necessary.
Replace the manual valve with a new one on assembly.
[3] PUMP ASSEMBLY
[1] INTERNAL
CIRCLIP
[2]
MANUAL
VALVE
9) Set the cylinder comp. in a vice as shown.
[2]
CYLINDER COMP.
NOTICE
Do not tighten the vice excessively, as it can damage the
cylinder comp.
[1] VICE
10) Check that the left and right piston rods are in the fully
extended position.
11) Loosen the rod guide comp. fully using the special tool as
shown.
TOOL:
Pin wrench, 4 mm
[1]
ROD GUIDE
COMP.
07SPA-ZW10200
[2] PIN WRENCH, 4 mm
07SPA-ZW10200
12) Remove the rod guide comp. and the piston rod Bs from
the trim cylinders slowly.
• Do not push the piston rod Bs into the trim cylinders.
13) Drain the Automatic Transmission Fluid (ATF) from the trim
cylinders.
Remove the rod guide comps from the piston rod B.
[1]
ROD GUIDE
COMP. (2)
[2] PISTON
ROD B (2)
15-38
14) Remove the O-ring from the rod guide comp.
Replace the O-ring with a new one on assembly.
15) Insert a sharp-end screwdriver into the gap between the
dust seal and the rod guide comp. Raise the dust seal and
remove it from the rod guide comp.
Remove the oil seal in the rod guide comp. in the same
manner.
[1] DUST
SEAL
[2]
OIL SEAL
[4]
ROD GUIDE
COMP.
Replace the dust seal and the oil seal with the new ones on
assembly.
• Take care not to damage inside the rod guide comp.
during this operation.
[3]
O-RING
[3]
O-RING
[5]
SHARP-END
SCREWDRIVER
[1] DUST SEAL
[4] ROD GUIDE
COMP.
16) Remove the backup ring and the O-ring from the piston rod
B.
Replace the backup ring and the O-ring with the new ones
as a set on assembly.
[2]
OIL SEAL
[1]
PISTON ROD B
17) Check the piston rod B. If it is scored or scratched, or if the
rod is bent, replace the piston rod B with a new one.
[2]
BACKUP RING
[3]
O-RING
18) Hold the cylinder comp. in a vice (P. 15-38).
19) Check that the piston rod comp. is in the fully extended
position.
20) Using the special tool, loosen the cylinder cap fully as
shown.
TOOL:
Pin wrench, 6 mm
07SPA-ZW10100
[1]
PIN WRENCH,
6 mm
07SPA-ZW10100
[2] CYLINDER CAP
15-39
[6]
Raise the
seal.
21) Remove the piston rod comp. from the cylinder comp.
22) Remove the O-rings from the cylinder cap and the piston
rod comp.
[1]
CYLINDER COMP.
[2]
PISTON ROD
COMP.
Replace the O-rings with the new ones on assembly.
[3]
CYLINDER
CAP
[4]
O-RINGS
23) Remove the free piston from the cylinder comp.
Check the sliding surface of the free piston for wear and
damage. Replace the free piston if necessary.
24) Remove the backup ring and the O-ring from the free
piston.
[1] FREE
PISTON
[2]
BACKUP
RING
[4]
O-RING
Replace the backup ring and the O-ring as a set on
assembly.
Drain the residual Automatic Transmission Fluid (ATF) from
the cylinder comp.
c. INSPECTION
• POWER TILT MOTOR
Check for continuity between the terminals.
15-40
[3]
CYLINDER
COMP.
[1] POWER TILT MOTOR
2P CONNECTOR
d. COMPONENTS DRAWING
[3]
PISTON ROD COMP.
[5] CYLINDER CAP
162 N.m (16.5kgf.m,
119 lbf.ft)
[2]
POWER TILT MOTOR
ASSEMBLY
[6] FREE PISTON
[1] HEX. BOLT (4)
5 N.m (0.5 kgf.m,
3.6 lbf.ft)
[4]
O-RINGS
[7] BACKUP RING
[8]
O-RING
[9] OIL
TANK
[8] O-RING
[26] DRIVE JOINT
[10] HEX. BOLT (3)
5 N.m (0.5 kgf.m,
3.6 lbf.ft)
[11] OIL TANK CAP
2.5 N.m (0.25 kgf.m,
1.8 lbf.ft)
[12] DUST SEAL (2)
[27]
FILTER B
[25] PUMP
ASSEMBLY
[13]
OIL SEAL
(2)
[24] MANUAL VALVE
3.5 N.m (0.35 kgf.m,
2.5 lbf.ft)
[14] ROD GUIDE
COMP. (2)
78 N.m (8.0 kgf.m,
58 lbf.ft)
[15] O-RING (2)
[23]
INTERNAL
CIRCLIP
[20]
ORIFICE
COLLAR
[22] SOCKET BOLT A
8.5 N.m (0.85 kgf.m,
6.1 lbf.ft)
[16] PISTON ROD B (2)
[19] O-RING (5)
[18] CYLINDER
COMP.
[21] SOCKET BOLT B (2)
8.5 N.m (0.85 kgf.m,
6.1 lbf.ft)
15-41
[17] BACKUP RING (2)
[15] O-RING (2)
e. ASSEMBLY
• Do not reuse the O-rings.
• Do not use a shop towel or equivalent cloth, and do not wear the gloves during this operation.
• Do not reuse the drained Automatic Transmission Fluid (ATF).
• When the operation is made by holding the cylinder comp. in a vice, do not tighten the vice excessively. It can damage
the cylinder comp.
• Add the Automatic Transmission Fluid (ATF) slowly.
• Assemble the power trim/tilt assembly with the piston rod comp. and the piston rod B fully extended. Do not push in
the piston rod comp. and the piston rod B.
• Do not allow the dust, dirt and other foreign material enter the cylinder comp. and the pump assembly during
assembly.
• Clean the parts with the fresh Automatic Transmission Fluid (ATF) and blow each port with compressed air to remove
dust and dirt. Check that the parts are clean before assembly.
• After assembly, coat the joints or mating sections of the parts and the sections where the paint came off with rust
preventive paint of the same color.
1) Hold the cylinder comp. in a vice as shown.
NOTICE
[2]
CYLINDER
COMP.
Do not tighten the vice excessively as it can damage the
cylinder comp.
2) Pour approximately 30 cm3(1.0 fl oz.) of the Automatic
Transmission Fluid (ATF) in the piston rod chamber of the
cylinder comp.
Recommended oil
[1] VICE
Genuine Honda Automatic
Transmission Fluid (ATF)
DEXRON® or equivalent.
3) Apply Automatic Transmission Fluid (ATF) to the new Oring and the backup ring. Install the O-ring and backup ring
on the free piston.
4) Apply Automatic Transmission Fluid (ATF) to the
circumference of the free piston and push it in the piston
rod chamber slowly until it bottoms out.
NOTICE
Install the backup ring on the free piston with care not to
break it.
[1] FREE PISTON
[2] BACKUP
RING
(ATF)
[3] O-RING
[4]
CYLINDER
COMP.
15-42
5) After installing the free piston, pour the fresh Automatic
Transmission Fluid (ATF) slowly up to the top of the piston
rod chamber of the cylinder comp.
6) Apply Automatic Transmission Fluid (ATF) to the new Oring and install it on the piston rod comp.
[1] Pour slowly
up to the top
of the piston
rod chamber.
[1] CYLINDER
COMP.
7) Apply Automatic Transmission Fluid (ATF) to the new Oring and install it on the cylinder cap.
[2] PISTON
ROD
COMP.
[3]
CYLINDER
CAP
8) With the piston rod comp. fully extended, install the piston
rod comp. slowly in the piston rod chamber of the cylinder
comp.
Loosely tighten the cylinder cap.
• Do not install the piston rod comp. by pushing it in the
piston rod chamber.
[4] O-RINGS
(ATF)
9) Tighten the cylinder cap to the specified torque using the
special tool as shown.
TOOL:
Pin wrench, 6 mm
07SPA-ZW10100
TORQUE: 162 N.m (16.5 kgf.m, 119 lbf.ft)
[1] PIN WRENCH,
6 mm
07SPA-ZW10100
[2] CYLINDER
CAP
10) Pour the fresh Automatic Transmission Fluid (ATF) in the
right and left trim cylinder chambers up to the top of the
trim cylinder chamber.
15-43
[1]
Pour slowly up to the
top of the trim cylinder
chamber.
11) Apply Automatic Transmission Fluid (ATF) to the new Oring and the backup ring and install them on the piston rod
comp.
[1] PISTON
ROD B
• Install the backup ring on the free piston with care not to
break it.
[2]
BACKUP
RING
(ATF)
[3] O-RING
12) Apply Automatic Transmission Fluid (ATF) to the new oil
seal.
[1] DUST SEAL
Holding the oil seal in the shape of “U” with your fingers,
install it in the lower groove in the rod guide comp.
[2] OIL SEAL
13) Apply Automatic Transmission Fluid (ATF) to the new dust
seal.
Holding the dust seal in the shape of “U” with your fingers,
install it in the upper groove in the rod guide comp.
14) Apply Automatic Transmission Fluid (ATF) to the new Oring and install it on the rod guide comp.
[3] ROD
GUIDE
COMP.
(ATF)
[4] O-RING
[2] OIL SEAL
[4] O-RING
[3]
ROD GUIDE COMP.
[1] DUST SEAL
15) Install the rod guide comp. on the piston rod B.
Extend the piston rod fully and hold it in the position.
16) Holding the piston rod Bs aslant a little, set each of piston
rod Bs in the left and right trim cylinder chambers.
• Do not install the piston rod Bs by pushing them into
respective trim cylinders.
[1]
ROD GUIDE
COMP. (2)
17) Install the piston rod B in the trim cylinder chamber slowly.
[2]
PISTON
ROD B (2)
15-44
18) Holding the piston rod B in place, loosely tighten the rod
guide comp. on the cylinder comp.
• Do not install the piston rod Bs by pushing them into
respective trim cylinders.
[1]
ROD GUIDE
COMP.
19) Using the special tool, tighten the left and right rod guide
comps. to the specified torque as shown.
TOOL:
Pin wrench, 4 mm
07SPA-ZW10200
[2] PIN WRENCH,
4 mm
07SPA-ZW10200
TORQUE: 78 N.m (8.0 kgf.m, 58 lbf.ft)
20) Check the manual valve and the O-ring for deterioration,
wear and damage. Replace the manual valve with a new
one if necessary.
21) Apply Automatic Transmission Fluid (ATF) to the manual
valve O-ring.
[1] PUMP
ASSEMBLY
[2]MANUAL
VALVE
Set the manual valve on the pump assembly and tighten it
to the specified torque.
TORQUE: 3.5 N.m (0.35 kgf.m, 2.5 lbf.ft)
22) Install the internal circlip securely in the groove in the
pump assembly.
23) Apply Automatic Transmission Fluid (ATF) to the five new
O-rings and the orifice collar.
Set the five O-rings and the orifice collar in the indicated
position of the cylinder comp.
24) Install the pump assembly on the cylinder comp. with the
socket bolt A and B.
[3]INTERNAL
CIRCLIP
(ATF)
[2]
PUMP ASSEMBLY
[1]
SOCKET
BOLT B (2)
(ATF)
Tighten the socket bolt A and B to the specified torque.
TORQUE: 8.5 N.m (0.85 kgf.m, 6.1 lbf.ft)
[5] SOCKET BOLT A
25) Fill the pump assembly with the fresh Automatic
Transmission Fluid (ATF).
• Do not fill up the pump assembly quickly. Pour the
Automatic Transmission Fluid (ATF) in the pump
assembly slowly.
15-45
[1]
PUMP ASSEMBLY
[4] ORIFICE
COLLAR
[3]
O-RING (5)
26) Check the filter B for blockage and damage. Replace the
filter B if it is damaged.
Blow air through the filter B if it is clogged. Clean the filter
B carefully to avoid damage.
Install the filter B and the drive joint on the pump assembly.
[1]
DRIVE JOINT
[2]
FILTER B
[3]
PUMP
ASSEMBLY
27) After installation, check the filter B for bubbles. Remove the
bubbles with the oil bottle or equivalent tool if necessary.
[1] OIL BOTTLE
• Be sure to remove the air bubbles, or it will cause air in
the system.
28) After removing the air bubbles, fill the pump assembly fully
with the Automatic Transmission Fluid (ATF) again.
29) Apply Automatic Transmission Fluid (ATF) to the new Oring and install it on the power tilt motor assembly.
[1] O-RING
(ATF)
[2] POWER TILT
MOTOR
ASSEMBLY
30) Install the power tilt motor assembly on the pump
assembly aligning the projection on the power tilt motor
assembly with the recess in the drive joint and with the
motor wire of the power tilt motor assembly at the manual
valve side.
[1] MOTOR
WIRE
[3] PROJECTION
15-46
[2]
RECESS
IN DRIVE
JOINT
31) Set the four hex. bolts on the power tilt motor assembly
and tighten the bolts to the specified torque.
[1] HEX. BOLT (4)
TORQUE: 5 N.m (0.5 kgf.m, 3.6 lbf.ft)
[2]
POWER TILT
MOTOR
ASSEMBLY
[3] PUMP
ASSEMBLY
32) Apply Automatic Transmission Fluid (ATF) to the new Oring and install it on the cylinder comp.
[1] OIL TANK
33) Install the oil tank on the cylinder comp. and tighten the
three hex. bolts to the specified torque.
(ATF)
[2]
HEX. BOLT
(3)
TORQUE: 5 N.m (0.5 kgf.m, 3.6 lbf.ft)
[3] O-RING
34) Remove the oil tank cap. Pour fresh Automatic
Transmission Fluid (ATF) to the upper limit of the oil tank
filler port.
Oil capacity
0.68R (0.72 US qt, 0.60 Imp qt)
NOTICE
Do not overfill with Automatic Transmission Fluid (ATF).
Pouring the Automatic Transmission Fluid (ATF) while it is
flowing out of the filler port will overfill the tank, and that
will damage the oil seal of the motor when each rod is
compressed.
[1]
OIL TANK CAP
35) After filling the oil tank with Automatic Transmission Fluid
(ATF), bleed air from the power trim/tilt assembly <without
mounting on the outboard motor> (P. 15-48).
36) Tighten the oil tank cap to the specified torque.
TORQUE: 2.5 N.m (0.25 kgf.m, 1.8 lbf.ft)
15-47
[2]
UPPER
LIMIT
5. AIR BLEEDING
<Power trim/tilt assembly not mounted on the
outboard motor>
• Bleed air from the unit whenever the power trim/tilt assembly
is disassembled.
• Be sure to perform air bleeding in the following order.
Air bleeding without mounting the unit on the outboard
motor; Check on blow pressure; Air bleeding after mounting
the unit on the outboard motor.
[1]
POWER TILT MOTOR
2P CONNECTOR
Connect each cable to operate the power trim/tilt assembly.
– Connect the positive (+) and negative (–) starter cables.
– Connect the power tilt motor 2P connector to the power tilt
relay.
[1]
UPPER
LIMIT
– Be sure that the starter cables are connected to the battery.
1) Hold the power trim/tilt assembly vertically.
2) Push the “DN” side of the power tilt switch to compress
each rod fully.
3) Push the “UP” side of the power tilt switch to extend each
rod fully.
4) Remove the oil tank cap with each rod extended fully.
Check whether the Automatic Transmission Fluid (ATF) is at
the upper limit of the oil tank filler port.
If Automatic Transmission Fluid (ATF) does not flow out of
the filler port, add Automatic Transmission Fluid (ATF) up
to the upper limit of the filler port using a syringe or
equivalent tool.
• Check the fluid level with the rods fully extended.
Note that Automatic Transmission Fluid (ATF) will spurt
out when the oil tank cap is removed with the rods fully
compressed.
5) After adding Automatic Transmission Fluid (ATF), repeat
the procedure from step 2 through 4 two or three times to
bleed air from the unit.
6) Be sure that the rods extend and compress during the step
5 operation.
• When the rods extend and compress fully, perform the
blow pressure check (P. 15-50) and air bleeding with the
unit mounted on the outboard motor (P. 15-49).
• When the rods do not compress fully, perform the
procedure explained under <when the rods do not
compress fully> (P. 15-49).
15-48
[2] POWER TILT
SWITCH
<When the rods do not compress fully>
1) With the rods extended fully, push the “UP” side of the
power tilt switch until the unit blows again. Push the “DN”
side of the power tilt switch, and be sure that the rods
compress.
If the rods compress fully, go to the blow pressure
inspection (P. 15-50).
2) If the rods do not compress after the step 1 operation, push
the “DN” side of the power tilt switch while pushing the
piston rod B, and check whether the rods compress.
[1] POWER TILT
SWITCH
If the rods compress fully, go to the blow pressure
inspection (P. 15-50).
3) If the rods still do not compress after the step 2 operation,
loosen the manual valve and compress each rod. Tighten
the manual valve securely again. Push the “UP” side of the
power tilt switch to extend the rods fully, then push the
“DN” side of the switch and check whether the rods
compress fully.
If the rods compress fully, go to the blow pressure
inspection (P. 15-50).
[2]
PISTON RODS B
4) If the rods do not compress fully after the above operation,
disassemble (P. 15-36) and reassemble (P. 15-42) the power
trim/tilt assembly and bleed air with the power trim/tilt
assembly not mounted on the outboard motor (P. 15-48).
<Air bleeding with power trim/tilt assembly
mounted on the outboard motor>
Perform the following procedure after bleeding air without
mounting the power trim/tilt assembly on the outboard motor
(P. 15-48) and after blow pressure inspection (P. 15-50).
[3] MANUAL VALVE
1) Install the power trim/tilt assembly on the outboard motor
securely (P. 15-30).
[2]
UPPER
LIMIT
2) Push the “UP” side of the power tilt switch and raise the
outboard motor to the uppermost position.
Remove the oil tank cap, and check whether the Automatic
Transmission Fluid (ATF) is at the upper limit of the oil filler
port of the oil tank.
If the Automatic Transmission Fluid (ATF) does not flow out
of the oil filler port, add the Automatic Transmission Fluid
(ATF) up to the upper limit of the oil filler port using a
syringe or equivalent tool.
15-49
[1] OIL TANK CAP
3) Lower the outboard motor slowly to the lowermost
position by loosening the manual valve.
[1] MANUAL VALVE
4) Tighten the manual valve securely.
5) Hold the outboard motor in the lowermost position for five
minutes.
6) Then, push the “UP” side of the power tilt switch and raise
the outboard motor to the uppermost position. Hold the
outboard motor in this position for five minutes. After five
minutes, check the fluid level in the oil tank (P. 15-47).
[3] TO LOOSEN
7) Repeat the procedure from step 3 through 6 five times.
[2] TO TIGHTEN
6. BLOW PRESSURE INSPECTION
After bleeding air from the power trim/tilt assembly without
mounting on the outboard motor and checking each rod for
proper compression, perform the following operation in the
same manner as bleeding air without mounting on the
outboard motor.
[1]
INTERNAL
CIRCLIP
1) Operate each rod of the power trim/tilt assembly (i.e. move
them up and down) several times and set the rods in the
full extended position.
2) Check that the Automatic Transmission Fluid (ATF) is at the
upper level in the oil tank (P. 15-47).
[2] MANUAL VALVE
3) Using the special tools, check the blow pressure at the
upper and lower chambers of the cylinder.
a. LOWER CHAMBER BLOW PRESSURE
[1] OIL PRESSURE GAUGE
JOINT B (Lower chamber)
07SPJ-ZW10200
1) Remove the internal circlip and manual valve from the
power trim/tilt assembly.
• Note that Automatic Transmission Fluid (ATF) will spurt
out when the manual valve is removed without the rods
fully extended. Move each rod to the fully extended
position before removing the manual valve.
• A small amount of the Automatic Transmission Fluid
(ATF) will flow out when the manual valve is removed.
Attach the special tools quickly.
2) Attach the special tool (oil pressure gauge joint B) for
measurement of lower chamber blow pressure to the
manual valve installation section as shown.
[2]
OIL PRESSURE GAUGE
JOINT A (Upper chamber)
07SPJ-ZW10100
[3]
PRESSURE GAUGE
(Commercially available)
Tighten the special tool to the specified torque.
TOOL:
Oil pressure gauge joint B
07SPJ-ZW10200
TORQUE: 9 N.m (0.9 kgf.m, 6.5 lbf.ft)
3) Attach a commercially available pressure gauge [P/T 1/4]
which measures 14,710 kPa (150 kgf/cm2, 2,133 psi) or
above to the special tool (oil pressure gauge joint B).
15-50
[2] OIL PRESSURE GAUGE
JOINT B (Lower chamber)
07SPJ-ZW10200
4) Remove the oil tank cap. Check that Automatic
Transmission Fluid (ATF) is at the upper limit of the filler
port (P. 15-47).
5) Push the “DN” side of the power tilt switch to compress
each rod fully.
6) Push the “UP” side of the power tilt switch to extend each
rod fully again. Read the pressure gauge to measure the
lower chamber blow pressure.
Lower chamber
blow pressure
8,826 – 11,768 kPa (90 – 120 kgf/cm2,
1,280 – 1,707 psi)
7) If the blow pressure is lower than the specified pressure,
check each part of the power trim/tilt assembly for oil
leakage (P. 15-54).
8) If there is no oil leakage but the pressure dropped sharp
below the specification, check the power tilt motor
assembly for the damaged oil seal. Disassemble the power
tilt motor assembly (P. 15-53) and inspect (P. 15-55), and
measure the lower chamber blow pressure again (P. 15-50).
[1] POWER TILT
SWITCH
9) Measure the upper chamber blow pressure.
b. UPPER CHAMBER BLOW PRESSURE
1) After measuring the lower chamber blow pressure, remove
the special tool (oil pressure gauge joint B) and the
pressure gauge from the pump assembly with each rod full
extended.
• Note that Automatic Transmission Fluid (ATF) will spurt
out when the special tool is removed without the rods
fully extended. Move each rod to the fully extended
position before removing the special tool.
[1]
PRESSURE GAUGE
(Commercially
available)
• A small amount of the Automatic Transmission Fluid
(ATF) will flow out when the special tool (oil pressure
gauge joint B) is removed. Attach the special tool (oil
pressure gauge joint A) quickly.
2) Attach the special tool (oil pressure gauge joint A) for
measurement of upper chamber blow pressure to the
manual valve installation section as shown.
Tighten the special tool to the specified torque.
TOOL:
Oil pressure gauge joint A
07SPJ-ZW10100
TORQUE: 9 N.m (0.9 kgf.m, 6.5 lbf.ft)
3) Attach a commercially available pressure gauge [P/T 1/4]
which measures 14,710 kPa (150 kgf/cm2, 2,133 psi) or
above to the special tool (oil pressure gauge joint B).
15-51
[2]
OIL PRESSURE GAUGE
JOINT A (Upper chamber)
07SPJ-ZW10100
4) Remove the oil tank cap. Check that Automatic
Transmission Fluid (ATF) is at the upper limit of the filler
port (P. 15-47).
5) Push the “DN” side of the power tilt switch to compress
each rod fully. Read the pressure gauge to measure the
upper chamber blow pressure.
Upper chamber
blow pressure
3,923 – 7.355 kPa (40 – 75 kgf/cm2,
569 – 1,067 psi)
6) If the blow pressure is lower than the specified pressure,
check each part of the power trim/tilt assembly for oil
leakage.
7) If there is no oil leakage but the pressure dropped sharp
below the specification, check the power tilt motor
assembly for the damaged oil seal. Disassemble the power
tilt motor assembly (P. 15-53) and inspect (P. 15-55), and
measure the upper chamber blow pressure again (P. 15-50).
[1] POWER TILT
SWITCH
8) After checking, push the “UP” side of the power tilt switch
and move each rod to the fully extended position.
9) Remove the special tool (oil pressure gauge joint A) and the
pressure gauge.
[1]
INTERNAL
CIRCLIP
10) Tighten the manual valve to the specified torque.
TORQUE: 3.5 N.m (0.35 kgf.m, 2.5 lbf.ft)
11) With each rod in the fully extended position, remove the oil
tank cap and check that the Automatic Transmission Fluid
(ATF) is at the upper limit of the oil filler port (P. 15-47).
If the Automatic Transmission Fluid (ATF) does not flow out
of the oil filler port, add the Automatic Transmission Fluid
(ATF) up to the upper limit of the oil tank using a syringe or
equivalent tool (P. 15-47).
15-52
[2] MANUAL
VALVE
7. POWER TILT MOTOR ASSEMBLY
[1] CORRUGATED
TUBE
a. DISASSEMBLY
1) Untape the corrugated tube and pull the tube to the
connector side.
2) Remove the 4 x 16 mm screw. Pull out the wire holder and
the two grommets from the yoke assembly and move them
to the corrugated tube side.
[5]
WIRE
HOLDER
[2] 4 x 16 mm SCREW
(Stainless steel)
[3]
YOKE
ASSEMBLY
NOTICE
Pull out the grommets with care not to damage them.
3) Remove the two 4 x 16 mm screws.
[4]
GROMMETS
4) Wrap the armature shaft with a shop towel or equivalent
material to protect, and hold the shaft with pliers.
Pushing the two motor wires toward the yoke assembly,
remove the armature/front bracket assembly from the yoke
assembly.
5) Remove the armature from the front bracket.
• Do not allow the commutator to become contaminated
with oil or grease.
[2] ARMATURE
[1] SHOP
TOWEL
6) Remove the two brush springs (P. 15-54).
7) Disconnect the motor wire (blue wire) terminal from the
breaker assembly while holding the breaker assembly with
a screwdriver.
[3] MOTOR
WIRES
NOTICE
Do not disconnect the blue wire terminal without holding
the breaker assembly, or it can cause damage to the brush
holder B. Be sure to disconnect the terminal while holding
the breaker assembly.
8) Remove the 4 x 10 mm screw from the brush holder A and
remove the brush assembly.
[5] PLIERS
[1]
FRONT
BRACKET
ASSEMBLY
• Take care not to touch the bimetal part of the breaker
assembly during removal.
9) Remove the oil seal from the front bracket assembly (P. 1554).
Check the metal part of the front bracket assembly for
damage and wear. Replace the front bracket assembly if
necessary.
15-53
[7]
BLUE
WIRE
[4]
YOKE ASSEMBLY
[2]
BRUSH
ASSEMBLY
[3]
BRUSH
HOLDER A
[4]
4 x 10 mm
SCREW
[6] TERMINAL
[5] GREEN WIRE
b. COMPONENTS DRAWING
[3]
4 x 16 mm SCREW
(Stainless steel)
1.4 N.m (0.14 kgf.m,
1.0 lbf.ft)
[2]
CORRUGATED TUBE
[1] ARMATURE
[4]
YOKE ASSEMBLY
[15
MOTOR WIRE
(Blue wire)
[14]
MOTOR WIRE
(Green wire)
[5]
4 x 10 mm SCREW (2)
[13]
BRUSH ASSEMBLY
[6]
BREAKER ASSEMBLY
[12]
BRUSH SPRING (2)
[7] O-RING
[11]
FRONT BRACKET
[8]
4 x 16 mm
SCREW (2)
[10]
FRONT BRACKET
ASSEMBLY
15-54
[9] OIL SEAL
c. INSPECTION
• BRUSH LENGTH
Measure the brush length.
If the brush length is less than the service limit, replace the
front bracket assembly.
STANDARD
SERVICE LIMIT
9.8 mm (0.39 in)
4.8 mm (0.19 in)
• BREAKER ASSEMBLY
1) Install the armature on the front bracket assembly.
[1]
BRACKET
HOLDER
[2] ARMATURE
2) Connect the motor 2P connector to the outboard motor.
3) Operate the power tilt switch and check the breaker
assembly for operation sound. The breaker is normal if
there is operation sound from the breaker assembly.
Replace the front bracket assembly if there is no operation
sound from the breaker assembly.
[3]
BREAKER
ASSEMBLY
• MICA DEPTH
If the grooves are clogged or mica depth is less than the
service limit, recut the groove using a hacksaw blade or a small
file.
If the mica depth is still less than the service limit, replace the
armature.
SERVICE LIMIT
0.5 mm (0.020 in)
• ARMATURE
Use the armature tester if it is available.
• CONTINUITY CHECK – SEGMENTS
Check for continuity between the segments. If an open circuit
exists between any two segments, replace the armature.
15-55
0.5 mm
(0.020 in)
• SHORT CIRCUIT TEST – CORE-TO-COMMUTATOR
Check for continuity between the commutator and armature
coil core.
If continuity exists, replace the armature.
• SHORT CIRCUIT TEST – SHAFT-TO-COMMUTATOR
Check for continuity between the commutator and armature
shaft.
If there is continuity, replace the armature.
• SHORT CIRCUIT TEST – ARMATURE
Place the armature on an armature tester.
Hold a hacksaw blade close to the armature core. If the blade is
attracted to the core or vibrates when the core is turned, the
armature is shorted. Replace the armature.
15-56
d. ASSEMBLY
• When the front bracket assembly is replaced with the new
one, remove the 4 x 10 mm screw that secures the brush
holder B.
1) Install the new O-ring and the oil seal on the front bracket
assembly (P. 15-54).
[1]
FRONT
BRACKET
ASSEMBLY
[3]
BRUSH
ASSEMBLY
[2]
BRUSH
SPRINGS
[4]
PROJECTION
Apply heat resisting grease to the oil seal lip.
2) Connect the motor wire (blue wire) terminal to the breaker
assembly terminal.
3) Check the magnet in the yoke assembly for washer and
other foreign material. There must be no washer, etc. on
the magnet.
Set the brush assembly terminal above the motor wire
(green wire) terminal and loosely tighten the 4 x 10 mm
screw. Be sure that the motor wire (green wire) terminal
and the brush assembly wire terminal contact the
respective projections on the brush holder A, then tighten
the 4 x 10 mm screw securely.
[10]
BREAKER
ASSEMBLY
[9]
BLUE
WIRE
[5]
BRUSH
HOLDER A
[8]
TERMINAL
[4]
PROJECTION
[6]
4 x 16 mm
SCREW
[7]
GREEN WIRE
4) Check that the commutator surface is not contaminated
with oil and grease. Set the two brush springs on the front
bracket assembly and install the armature on the front
bracket with the brush terminal pushed in the holder.
5) Wrap the armature shaft with a shop towel or equivalent
material and hold the shaft with the pliers.
6) Pulling the two motor wires of the yoke assembly side
slowly, install the armature/front bracket assembly on the
yoke assembly.
[2]
ARMATURE
[1]
SHOP
TOWEL
If it is hard to install the armature/front bracket assembly on
the yoke assembly, check whether the metal of yoke
assembly (i.e. where the armature shaft is installed) is out
of position and repeat the procedure from step 4.
[4]
MOTOR
WIRES
7) Check that the armature turns smoothly and tighten the
two 4 x 16 mm screws.
After tightening the two 4 x 16 mm screws, connect the
power tilt motor 2P connector and check whether the motor
turns.
If the motor does not turn, disassemble the power tilt
motor assembly again, and check whether the motor wire
(blue wire) terminal is disconnected.
15-57
[3]
YOKE ASSEMBLY
[6] PLIERS
[5] FRONT BRACKET
ASSEMBLY
8) Install the two grommets and the wire holder on the yoke
assembly.
Tighten the 4 x 16 mm screw (stainless steel screw) to the
specified torque. Take care not to overtighten it.
[1]
CORRUGATED
TUBE
[2] 4 x 16 mm SCREW
(Stainless steel)
TORQUE: 1.4 N.m (0.14 kgf.m, 1.0 lbf.ft)
[3]
GROMMET (2)
9) Tape the corrugated tube with the heat resisting tape so
that the distance from the wire holder end to the
corrugated tube end is 30 mm (1.2 in) or less as shown.
10) Install the power tilt motor assembly on the power trim/tilt
assembly (P. 15-46).
[4] WIRE
HOLDER
Coat the joints or mating sections of the parts and the
sections where the paint came off with rust preventive
paint of the same color.
11) Bleed air from the power trim/tilt assembly without
mounting on the outboard motor (P. 15-48).
[5]
HEAT RESISTING TAPE
(Wrap by two or three
winds.)
[1]
CORRUGATED
TUBE
[6]
30 mm
(1.2 in)
or below
15-58
16. STEERING ROD/REMOTE CONTROL
BOX
1. STEERING ROD
2. REMOTE CONTROL BOX
(OPTIONAL PART)
3. CONTROL PANEL (OPTIONAL PART)
4. INSPECTION
1. STEERING ROD
a. REMOVAL/INSTALLATION
[1]
STEERING CABLE
[2]
TILTING BOLT CAP
[3]
3/8-24 UNF BOLT
22 N.m (2.2 kgf.m, 16 lbf.ft)
[8]
STEERING ROD COLLAR
[4]
MOUNT FRAME
[7]
10 mm WASHER (4)
[6]
STEERING ROD
[5]
3/8-24 UNF SELFLOCKING NUT (2)
22 N.m (2.2 kgf.m, 16 lbf.ft)
16-1
2. REMOTE CONTROL BOX (OPTIONAL PART)
a. DISASSEMBLY/ASSEMBLY
• REMOTE CONTROL CABLE
[1]
SHIFT PIVOT (2)
INSTALLATION:
Screw in the shift pivot 8 mm or more onto the
threaded end of the cable.
[1]-1
8 mm or more
[10]
REMOTE CONTROL
BOX COVER C
[9]
5 x 12 mm OVAL
SCREW (2)
[2]
10-32 UNF
LOCK NUT
[3]
5 x 25 mm SELFTAPPING SCREW (7)
[4]
REMOTE CONTOL CABLE
(Throttle side)
ADJUSTMENT: P. 3-26
[8]
FAST IDLE LEVER
[5]
CABLE CLAMP
SPACER
[7]
REMOTE CONTOL
BOX COVER B
[6]
REMOTE CONTROL CABLE
(Shift side)
ADJUSTMENT: P. 3-24
16-2
• ELECTRIC COMPONENTS
[1]
WARNING BUZZER
INSPECTION: P. 16-10
[11]
5 x 8 mm SELFTAPPING SCREW (2)
[2]
EMERGENCY STOP SWITCH
INSPECTION: P. 16-9
[3]
IGNITION SWITCH
INSPECTION: P. 16-9
[10]
POWER TILT
CORD CLAMP
[9]
SPARE EMERGENCY
STOP SWITCH CLIP
[4]
16 mm HEX. NUT
1.5 N.m (0.15 kgf.m, 1.1 lbf.ft)
[8]
22 mm NUT
4.8 N.m (0.49 kgf.m, 3.5 lbf.ft)
[7]
INDICATOR LIGHT
[OIL PRESSURE LIGHT/
OVERHEAT LIGHT]
INSPECTION: P. 16-9
[6]
20 mm HEX. NUT
16-3
[5]
SOLENOID SWITCH
• SLIDING PLATE
[3]
5 mm WASHER
[4]
5 x 10 mm
SCREW
[2]
FAST IDLE WHEEL
[1]
FAST IDLE SPRING
[7]
7 mm E-CLIP
[8]
8 mm WASHER
[6]
[9]
6 mm WASHER (2)
5 mm HEX. NUT
[5]
4 mm E-CLIP
[10]
5 x 16 mm
HEX. BOLT
[25]
13 x 13 mm FAST IDLE
DETENT ROLLER
[11]
6 x 10 mm
SCREW
[24] 5 x 10 mm SELFTAPPING SCREW
[12]
LINK JOINT
BRACKET
[23]
SPRING SETTING PLATE
[13]
LINK JOINT ARM
[3]
5 mm WASHER
[14]
LINK JOINT
COLLAR (2)
[22] 4 x 10 mm SELFTAPPING SCREW
[21] 4 mm WASHER
[15]
SLIDING PLATE
[20] SWITCH START CAM
[16]
SLIDING PLATE
COLLAR
[19]
6 x 6 mm PIN
INSTALLATION:
Install in the concave area of
the control wheel as shown.
[17]
12.7 x 23.9 mm FAST IDLE
DETENT SPRING
[18]
CONTROL WHEEL
• SLIDING PLATE/COLLAR
INSTALLATION:
Install the sliding plate with the “UP” mark facing up.
Attach the sliding plate collar to the sliding plate with its
wider side toward the “UP” mark of the sliding plate.
[1] SLIDING PLATE
COLLAR
[2]
“UP” MARK
[3]
SLIDING PLATE
16-4
• REMOTE CONTROL LEVER ASSEMBLY/CONTROL WHEEL
[2]
8 x 35 mm HEX. BOLT
[1]
8 mm WASHER
[21]
CONTROL WHEEL
[4]
6 mm HEX. NUT
[3]
4 mm WASHER (2)
[5]
5 x 10 mm SELF-TAPPING SCREW
[6]
5 mm WASHER
[7]
NEUTRAL SWITCH
SPACER
[8]
FRICTION
ADJUSTING BOLT
[20]
28 mm WASHER
[19]
SHIFT LINK
ARM
[18]
9.8 x 27.1 mm SHIFT
DETENT SPRING
[17]
9 x 10 mm SHIFT
DETENT ROLLER
[16]
REMOTE CONTROL
BOX HOUSING A
[15]
NEUTRAL
LOCK BLOCK
[14]
REMOTE CONTROL
LEVER ASSEMBLY
16-5
[9]
THROTTLE
FRICTION BLOCK
[10]
3 mm E-RING
[5]
5 x 10 mm SELFTAPPING SCREW
[11]
SPRING SETTING PLATE
[12]
6 mm WASHER
[13]
6 x 16 mm SELFTAPPING SCREW (2)
• REMOTE CONTROL LEVER
[2]
REMOTE CONTROL
LEVER SPRING
[3]
NEUTRAL
RELEASE LEVER
[4]
5 x 10 mm SCREW
[1]
REMOTE CONTROL
LEVER GRIP
[5]
LEVER SETTING
PLATE
[10]
5 x 12 mm SELFTAPPING SCREW
[11]
POWER TRIM/TILT SWITCH
INSPECTION: P. 16-10
[9]
REMOTE CONTROL
LEVER
[8]
WIRE HARNESS CLIP
[7]
5 x 12 mm
OVAL SCREW
[6]
LEVER CAP
16-6
3. CONTROL PANEL (OPTIONAL PART)
a. DISASSEMBLY/ASSEMBLY
[1]
INDICATOR LIGHT
[MIL/ALTERNATOR
INDICATOR LIGHT]
[3]
IGNITION SWITCH
[5]
SWITCH PANEL HARNESS
CONNECTION: P. 16-8
INSPECTION: P. 16-9
[4]
WIRE HARNESS
BAND
INSPECTION: P. 16-9
[2]
BUZZER
BRACKET
[18]
CONTROL PANEL
[6]
SWITCH PANEL
CABLE
[17]
22 mm NUT
4.9 N.m (0.49 kgf.m,
3.5 lbf.ft)
[16]
16 mm HEX. NUT
1.5 N.m (0.15 kgf.m,
1.1 lbf.ft)
[8]
WARNING BUZZER
INSPECTION: P. 16-10
[15]
SPARE EMERGENCY
STOP SWITCH CLIP
[9]
EMERGENCY STOP SWITCH
INSPECTION: P. 16-9
[14]
EMERGENCY CORD
[13]
5 x 40 mm SCREW (4)
[12]
5 mm WASHER (4)
[10]
5 mm FLANGE NUT (4)
[11]
5 mm SPRING WASHER (4)
16-7
[7]
TIE CABLE (2)
Do not reuse.
b. SWITCH PANEL HARNESS
CONNECTION:
Connect the switch panel harnesses to the respective switches as shown.
[1]
To SWITCH
PANEL CABLE
[2]
To POWER [3]
TRIM/TILT To EMERGENCY
SWITCH
STOP SWITCH
[4]
To METER HARNESS
[5]
SWITCH PANEL
HARNESS SIDE
[6]
CONTROL
PANEL SIDE
[10]
INDICATOR
LIGHT
[9]
IGNITION
SWITCH
[8] EMERGENCY [7] WARNING
BUZZER
STOP SWITCH
16-8
4. INSPECTION
Bl/W
Bl/R
• IGNITION SWITCH
Check for continuity between the terminals with the switch in
each position.
Wire
Position
E
(Bl)
IG
(Bl/R)
BAT
(W/Bl)
LO
(Bl/Y)
Bl/Y
Bl
ST
(Bl/W)
W/Bl
OFF (Stop)
ON (Run)
START (Start)
: Continuity
Bl: Black R: Red W: White Y: Yellow
• INDICATOR LIGHT [OIL PRESSURE LIGHT/
OVERHEAT LIGHT]
[1] SWITCH 1
NOTICE
[2] SWITCH 2
Use a known-good battery.
[3] SWITCH 3
Connect the black, red and yellow terminals to the switch 1, 2
and 3 respectively, and apply 12V battery voltage to the
black/yellow [gray] terminal.
When the switch 1 is ON: Green light is ON.
When the switch 2 and 3 are ON: Green light is ON.
When the switch 2 is ON: Red light is ON.
Color in the brackets [ ] is for the side mount remote control
type only.
[Gr]
[5]
COLOR IN BRACKETS [ ]:
SIDE MOUNT REMOTE CONTROL TYPE ONLY
• INDICTOR LIGHT [MIL/ALTERNATOR INDICATOR
LIGHT]
[1]
ALTERNATOR
INDICTOR
LIGHT
NOTICE
Use a known-good battery.
Connect the white/blue terminal to the switch 1, red/blue
terminal to the switch 2, and apply 12V battery voltage as
shown.
When the switch 1 is ON: Alternator indictor light is ON.
When the switch 2 is ON: MIL is ON.
[4]
12V BATTERY
R/Bu
W/Bu
Y/Bu
[5] MIL
[2] SWITCH 1
[3] SWITCH 2
[4]
12V
BATTERY
• EMERGENCY STOP SWITCH
Attach the tester leads to the terminals and check for
continuity.
Switch clip position
Continuity
Set
No
Not set
Yes
Switch is pushed with switch
clip being set
Yes
[1]
SWITCH CLIP
16-9
• WARNING BUZZER
NOTICE
Use a known-good battery.
Connect the black/yellow terminal of the warning buzzer to the
battery positive (+) terminal, and the yellow/green terminal to
the battery negative (–) terminal as shown. Check that the
buzzer sounds this time.
12 V
• POWER TRIM/TILT SWITCH (Side mount remote
control type only)
[1] UP
Check for continuity between the terminals with the switch in
each position.
Lb
W/Bl
Lb
Lg
UP
DN (DOWN)
: Continuity
Lb: Light blue W: White Bl: Black Lg: Light green
16-10
W/Bl
[2]
DN (DOWN)
Lg
17. CABLES/SHIFT LINK BRACKET/SHIFT
ARM/NEUTRAL SWITCH
1. REMOTE CONTROL CABLE/
GROMMET
2. SHIFT LINK BRACKET/NEUTRAL
SWITCH
3. SEAL HOLDER
2.5 N.m (0.25 kgf.m, 1.8 lbf.ft)
17-1
1. REMOTE CONTROL CABLE/GROMMET
a. REMOVAL
Remove the following parts.
– Engine cover (P. 4-2)
– Front separate cover (P. 4-7).
1) Remove the remote control cable (shift side) shift pivot from the shift arm shift link pin.
2) Remove the remote control cable (throttle side) shift pivot from the throttle arm link pin.
3) Remove the remote control cables (shift and throttle sides) from the remote control cable plate and the remote
control cable grommet.
[1]
SHIFT PIVOT (2)
[9]
THROTTLE ARM
[2]
REMOTE
CONTROL CABLE
(Throttle side)
[8]
LINK PIN
[7]
SHIFT LINK PIN
[6]
SHIFT ARM
[5]
REMOTE CONTROL
CABLE PLATE
4) Release the indicator light 6P connector and the remote
control cable 14P connector from the neutral switch
bracket.
[4]
REMOTE CONTROL
CABLE GROMMET
[3]
REMOTE CONTROL
CABLE
(Shift side)
[1] INDICATOR LIGHT [2] REMOTE CONTROL
6P CONNECTOR
CABLE 14P CONNECTOR
Disconnect the indicator light 6P connector and the remote
control cable 14P connector.
[3]
NEUTRAL SWITCH BRACKET
17-2
5) Remove the 6 x 16 mm hex. bolt and the 6 mm washer from the remote control cable plate, then remove the remote
control cable plate.
Release the starter cable from the cable bracket A and remove the remote control cable grommet from the under
cover front bracket.
[1]
6 x 16 mm HEX. BOLT
[2]
REMOTE CONTROL
CABLE PLATE
[7]
6 mm WASHER
[3]
REMOTE CONTROL
CABLE GROMMET
[6]
STARTER CABLE
[5]
CABLE
BRACKET A
[4]
UNDER COVER FRONT
BRACKET
6) Remove the speed sensor tube A, remote control cable, indicator light wire, starter cable and the fuel tube A from
the remote control cable grommet. Remove the remote control cable grommet.
[1]
INDICATOR
LIGHT WIRE
[2]
REMOTE CONTROL
CABLE
[3]
SPEED SENSOR
TUBE A
[4]
FUEL TUBE A
[5]
STARTER CABLE
[6]
REMOTE CONTROL
CABLE GROMMET
17-3
b. COMPONENTS DRAWING
[1]
SHIFT PIVOT (2)
[2]
LOCK NUT (2)
[3]
REMOTE CONTROL
CABLE
(Throttle side)
[4]
REMOTE CONTROL
CABLE
(Shift side)
[17]
6 x 16 mm HEX. BOLT
[16]
6 mm WASHER
[15]
REMOTE CONTROL
CABLE PLATE
[5]
SPEED
SENSOR
TUBE A
[14]
REMOTE CONTROL
CABLE GROMMET
[6]
REMOTE
CONTROL
CABLE
[9]
STARTER
CABLE
[7]
INDICATOR
LIGHT WIRE
[8]
FUEL TUBE A
[10]
6 x 17 mm
SPECIAL BOLT
[13]
FRONT SEPARATE
COVER
[12]
6 x 25 mm
SCREW (3)
17-4
[11]
UNDERCASE
GROMMET BAND
c. INSTALLATION
1) Set the indicator light wire and the remote control cable in
the specified positions in the remote control cable
grommet. Be sure that the tie wires on the indicator light
wire and the remote control cable are set against the
remote control cable grommet.
[1]
UNDER COVER
FRONT BRACKET
[2]
WHITE TAPE
2) Set the starter cable in the specified position in the remote
control cable grommet by aligning the end of the white
tape on the starter cable with the end of the under cover
front bracket as shown.
[3]
STARTER CABLE
3) Set the fuel tube A and the speed sensor tube A in the
specified positions of the remote control cable grommet.
[4] TIE WIRES
[5]
REMOTE
CONTROL CABLE
[6]
INDICATOR
LIGHT WIRE
[1]
INDICATOR LIGHT WIRE
[7] REMOTE CONTROL
CABLE GROMMET
[2]
REMOTE CONTROL
CABLE
[3]
SPEED SENSOR
TUBE A
[4]
FUEL TUBE A
[5]
STARTER
CABLE
[1]
INDICATOR
LIGHT WIRE
[2]
REMOTE
CONTROL
CABLE
[3]
SPEED
SENSOR
TUBE A
[6]
REMOTE CONTROL
CABLE GROMMET
17-5
[5]
STARTER
CABLE
[4]
FUEL
TUBE A
4) Install the remote control cable plate on the flat surface of the remote control cable grommet by aligning the
projection on the remote control cable plate with the groove in the under cover front bracket. Take care not to move
the alignments described in step 1 and 2 this time. Secure the remote control cable plate with the 6 x 16 mm hex.
bolt.
Secure the starter cable with the cable bracket A.
[1]
6 x 16 mm HEX. BOLT
[10]
6 mm WASHER
[9]
FLAT SURFACE
[2]
REMOTE CONTROL
CABLE PLATE
[3]
PROJECTION
[4]
REMOTE CONTROL
CABLE GROMMET
[8]
STARTER CABLE
[5]
GROOVE IN UNDER
COVER FRONT BRACKET
[7]
CABLE
BRACKET A
[6]
UNDER COVER FRONT
BRACKET
5) Connect the indicator light 6P connector and the remote control cable 14P connector.
Install the indicator light 6P connector and the remote control cable 14P connector on the neutral switch bracket.
[1] INDICATOR LIGHT
6P CONNECTOR
[3]
NEUTRAL SWITCH
BRACKET
17-6
[2] REMOTE CONTROL
CABLE 14P CONNECTOR
6) Install the lock nut and the shift pivot on each of the remote control cables.
Align the groove in each of the remote control cables (shift and throttle sides) with the cutouts in the remote control
cable plate, and install the remote control cables on the remote control cable plate.
Fasten the undercase grommet band securely (P. 4-8).
[1]
SHIFT PIVOT (2)
[2]
GROOVES
[3]
REMOTE
CONTROL CABLE
(Throttle side)
[4]
REMOTE
CONTROL
CABLE
(Shift side)
[7]
REMOTE CONTROL
CABLE PLATE
d. REMOTE CONTROL CABLE (SHIFT SIDE)
INSTALLATION
[5]
CUTOUTS
[6]
REMOTE CONTROL
CABLE GROMMET
[2] Align.
[1] FLAT PART OF
DETENT ARM
Check the following before installing the remote control cables
on the outboard motor.
– Remote control cables are securely connected to the remote
control box (P. 16-2).
– Shift arm is in the “N” (Neutral) position.
– Center of the neutral switch end is in line with the center of
the flat part of the detent arm, and the detent arm roller is in
the groove of the shift arm.
If the detent arm roller is in the groove of the shift arm but the
center of the neutral switch end is not in line with the center
of the flat part of the detent arm, check the detent arm.
Replace the detent arm with a new one if it is deformed or
damaged.
1) Install the shift pivot on the remove control cable (shift
side).
Apply marine grease to the mounting part of the shift link
pin on the shift pivot and to the shift link pin.
[3]
NEUTRAL
SWITCH END
[1]
INNER
CABLE
2) Check that the remote control cable (shift side) is detached
from the shift link pin.
Move the remote control lever fully to “F” (Forward)
position, then return it slowly to the “N” (Neutral) position.
3) With the remote control lever in the position described in
step 2, mark (A) at the end of the cable outer seal of the
inner cable.
17-7
[3] “N” (NEUTRAL)
[2]
CABLE OUTER
SEAL
[6]
MARK (A)
[7] (MARINE
GREASE)
[4]
“F” (FORWARD)
[5]
REMOTE CONTROL
BOX
4) Move the remove control lever fully to the “R” (Reverse)
position, then return it slowly to the “N” (Neutral) position.
[2] “N” (NEUTRAL)
[1]
“R” (REVERSE)
5) With the remote control lever in the position described in
step 4, mark (B) at the end of the cable outer seal of the
inner cable.
[3]
MARK (B)
6) Mark (C) at the midpoint between the mark (A) and the
mark (B).
[1]
MARK (B)
[2]
MARK (A)
[3]
MARK (C)
7) Align the mark (C), marked in step 6, with the end of the
cable outer seal.
[1]
MARK (C)
8) Move the shift link pin end lightly right and left. If the shift
link pin has a free play, set the shift link pin at the center of
the free play.
[1]
SHIFT LINK
PIN
17-8
9) With the remote control cable (shift side) in the position
described in step 7 (i.e. the mark (C) aligns with the cable
outer seal end), adjust the shift side remote control cable
length by turning the shift pivot so that the shift pivot sets
on the shift link pin smoothly.
[1]
REMOTE CONTROL CABLE
(Shift side)
NOTICE
Take care not to move the mark (C) out of alignment. Set
the shift pivot on the shift link pin with care not to move the
shift link pin from the center of the free play.
[2]
SHIFT PIVOT
[2]
SHIFT PIVOT
[3]
SHIFT LINK PIN
[1]
REMOTE CONTROL CABLE
(Shift side)
10) After connecting the cable, move the remote control lever
back and forth and check for shift.
NOTICE
When it is hard to put the remote control lever in the “F”
(Forward) or “R” (Reverse) position with the engine
stopped, shift the gear while turning the propeller or
propeller shaft. Do not shift the gear with force, or damage
to the shift system can result.
11) If the gear is not in neutral by moving the remote control
lever from the “F” (Forward) to the “N” (Neutral) position,
remove the shift side remote control cable from the shift
link pin and move the inner cable toward the mark (A).
Repeat the procedure from the step 8 (P. 17-8).
12) If the gear is not in neutral by moving the remote control
lever from the “R” (Reverse) to the “N” (Neutral) position,
remove the shift side remote control cable from the shift
link pin and move the inner cable toward the mark (B).
Repeat the procedure from the step 8 (P. 17-8).
[1]
ADJUSTMENT RANGE
[2]
MARK (A)
[3]
MARK (C)
[1]
ADJUSTMENT RANGE
13) After adjustment, set the remote control lever in each
position and check for operation. If the gear is not in neutral
securely, perform the step 11 or 12 again.
14) Adjust the shift side remote control cable after connection
(P. 3-24).
Tighten the shift pivot lock nut securely.
17-9
[2]
MARK (C)
[3]
MARK (B)
e. REMOTE CONTROL CABLE (THROTTLE SIDE)
INSTALLATION
1) Apply marine grease to the link pin and the mounting part
of the link pin on the shift pivot.
[1]
LINK PIN
2) Set the remote control cable (throttle side) shift pivot on the
throttle arm link pin.
[2] (MARINE
GREASE)
3) Adjust the throttle control cable/throttle link (P. 3-26).
Tighten the shift pivot lock nut securely.
4) Install the following parts.
– Front separate cover (P. 4-7)
– Engine cover (P. 4-2)
[4]
SHIFT PIVOT
[3]
REMOTE CONTROL CABLE
(Throttle side)
17-10
2. SHIFT LINK BRACKET/NEUTRAL SWITCH
a. REMOVAL
Remove the following parts.
– Engine cover (P. 4-2)
– Front separate cover (P. 4-7)
– L./R. engine under cover (P. 4-9)
– Remote control cable/grommet (P. 17-2)
1) Remove the throttle rod linkage pivot from the throttle plate.
2) Remove the two 6 x 18 mm flange bolts from the shift link bracket assembly.
Remove the link pin of the shift link bracket assembly from the shift arm, and remove the shift link bracket assembly.
[1]
THROTTLE PLATE
[2]
THROTTLE ROD
6 x 18 (2)
[3]
SHIFT LINK BRACKET
ASSEMBLY
[4]
LINK PIN
[5]
SHIFT ARM
3) Move the shift arm to the “N” (Neutral) position. Remove
the 12 mm snap ring and the 12 mm washer from the shift
shaft B.
[1]
12 mm SNAP
RING
[2]
12 mm WASHER
[3]
SHIFT ARM
[Move to “N”
(Neutral) position.]
17-11
4) Remove the shift arm from the shift shaft B while pulling
the detent arm to your side.
[2]
SHIFT ARM
[1]
DETENT
ARM
[3]
SHIFT
SHAFT B
[4]
Pull to your side.
5) Remove the 6 x 14 mm flange bolt from the neutral switch
bracket while pulling the detent arm toward you, then
remove the neutral switch bracket.
[1]
(Pull in the direction
of the arrow.)
6 x 14
[3]
DETENT ARM
6) Release the fuel tube A from the fuel tube holder.
7) Remove the fuel tube holder from the neutral switch
bracket.
[2]
NEUTRAL SWITCH
BRACKET
[2]
NEUTRAL SWITCH
2P CONNECTOR
[1]
FUEL TUBE HOLDER
[3]
CONNECTOR
BRACKET A
8) Remove the neutral switch 2P connector from the
connector bracket A, then disconnect the connector.
9) Remove the harness band clip that secures the alternator
fuse cable from the neutral switch bracket.
[7]
NEUTRAL
SWITCH
BRACKET
10) Remove the clip A from the neutral switch wire.
[4]
CLIP A
[6]
ALTERNATOR
FUSE CABLE
17-12
[5]
HARNESS
BAND CLIP
11) Remove the 20 mm hex. nut from the neutral switch, then
remove the neutral switch from the neutral switch bracket.
[1]
20 mm HEX. NUT
[3]
NEUTRAL
SWITCH
12) Remove the 6 x 12 mm flange bolt from the detent arm,
then remove the 6 mm washer, detent arm and the detent
spring.
Check the detent arm bushing on the detent arm. Replace
the detent arm bushing if necessary.
13) Remove the detent arm bushing from the detent arm.
Replace the bushing with a new one on assembly.
Check the detent arm for deformation or damage, and
replace if necessary.
6 x 12
[1]
6 mm WASHER
[2]
DETENT
ARM
[3]
DETENT ARM
BUSHING
[4]
DETENT
SPRING
b. INSPECTION
• NEUTRAL SWITCH
Connect the tester between the terminals and push the switch
knob. There must be continuity when the switch knob is
pushed, and no continuity when the knob is released.
17-13
[1]
NEUTRAL SWITCH
[2]
NEUTRAL SWITCH
BRACKET
c. COMPONENTS DRAWING
[1]
THROTTLE ROD
6 x 18 (2)
[18]
12 mm SNAP RING
[17]
12 mm
WASHER
[2]
SHIFT LINK BRACKET
ASSEMBLY
[3]
CONNECTOR
BRACKET A
[16]
SHIFT ARM
[4]
FUEL TUBE A
[5]
FUEL TUBE
HOLDER
6 x 14
6 x 12
[15]
6 mm WASHER
[6]
CLIP A
[14]
DETENT ARM
[7]
NEUTRAL
SWITCH
[13]
DETENT SPRING
[12]
DETENT ARM
BUSHING
17-14
[10]
NEUTRAL SWITCH
BRACKET
[11]
20 mm HEX. NUT
2.5 N.m (0.25 kgf.m, 1.8 lbf.ft)
[8]
HARNESS BAND
CLIP
[9]
ALTERNATOR
FUSE CABLE
d. DISASSEMBLY OF SHIFT LINK BRACKET ASSEMBLY
1) Remove the throttle link.
2) Remove the throttle arm and remove the link pin.
3) Remove the shift link pin, link pin, shift slide pivot and the shift pivot plate.
4) Remove the throttle plate.
5) Check the two bushing As from the shift link bracket. If they are damaged, remove them and replace with the new
ones.
[3]
THROTTLE
PLATE
[1]
THROTTLE LINK
[4]
BUSHING A (2)
[2]
THROTTLE ARM
[5]
SHIFT LINK
BRACKET
[15]
6 mm WASHER
6 x 12
[14]
4 mm E-RING (3)
[6]
8 mm WASHER
[13]
LINK PIN
[7]
6 mm E-RING
[12]
PIVOT WASHER
[11]
SHIFT LINK PIN
17-15
[8]
SHIFT PIVOT
PLATE
[9]
SHIFT SLIDE
PIVOT
[10]
LINK PIN
e. ASSEMBLY OF SHIFT LINK BRACKET ASSEMBLY
1) Apply marine grease to the outer surface of the two bushing As and the inner wall at the mounting part of the bushing
A in the link bracket. Install the two bushing As in the shift link bracket.
2) Apply marine grease to the outer surface of the throttle plate shaft. Install the throttle plate on the shift link bracket.
Set the 8 mm washer on the throttle plate, and set the 6 mm E-ring in the groove in the throttle plate securely.
3) Apply marine grease to the outer surface of the throttle arm link pin. Set the link pin on the throttle arm and secure
with the pivot washer and the 4 mm E-ring.
4) Apply marine grease to the inner wall at the mounting part of the shift link bracket in the throttle arm.
Apply marine grease to the throttle arm mating surfaces on the shift link bracket, and install the throttle arm on the
shift link bracket.
5) Apply marine grease to the 6 mm washer and the throttle arm mating surfaces. Set the 6 mm washer on the throttle
arm and tighten the 6 x 12 mm flange bolt securely.
6) Apply marine grease to the mounting part of the throttle arm and the mounting part of the throttle plate in the throttle
link, then install the throttle link.
7) Apply marine grease to the shift slide pivot and the outer surface of the shift link pin. Apply marine grease to the
entire surface of the link pin. Apply marine grease to the chamfered side of the shift pivot plate.
8) Set the shift link pin and the link pin on the shift slide pivot. Install the shift slide pivot on the shift link bracket.
9) Install the shift pivot plate with its chamfer toward the shift link bracket. Set the 4 mm E-rings in the grooves in the
shift link pin and the link pin securely.
[2] (MARINE
GREASE)
[1]
THROTTLE LINK
[18]
THROTTLE ARM
[4]
THROTTLE
PLATE
[3]
LINK PIN
[5]
BUSHING A (2)
[2] (MARINE
GREASE)
[17]
6 mm WASHER
[2] (MARINE
GREASE)
[6]
SHIFT LINK
BRACKET
[16]
(Apply marine grease
to the reverse side of
the washer.)
6 x 12
[2] (MARINE
GREASE)
[2] (MARINE
GREASE)
[14]
4 mm E-RING (3)
[7]
8 mm WASHER
[15]
PIVOT WASHER
[8]
6 mm E-RING
[9]
SHIFT PIVOT PLATE
[13]
CHAMFER
[2] (MARINE
GREASE)
17-16
[12]
SHIFT LINK
PIN
[2] (MARINE
GREASE)
[11]
LINK PIN
[10]
SHIFT SLIDE PIVOT
f. INSTALLATION
6 x 12
1) Apply marine grease to the inner wall of a new detent arm
bushing. Set the detent arm bushing on the detent arm.
2) Apply marine grease to the seal holder shaft.
Apply marine grease to the roller area of the detent arm.
[1]
6 mm WASHER
[2]
CONCAVE
3) Align the hook (A) of the detent spring with the concave in
the detent arm as shown.
Align the other hook (B) with the seal holder hole and
install the detent spring.
[9]
DETENT
ARM
4) Set the 6 mm washer on the detent arm and tighten the 6 x
12 mm flange bolt securely.
[8]
DETENT ARM
BUSHING
[7]
HOOK (A)
[3] (MARINE
GREASE)
[6]
HOOK (B)
[4]
DETENT
SPRING
[5]
HOLE
[3] (MARINE
GREASE)
5) Set the neutral switch on the neutral switch bracket and
tighten the 20 mm hex. nut to the specified torque.
TORQUE: 2.5 N.m (0.25 kgf.m, 1.8 lbf.ft)
[1]
20 mm HEX. NUT
[3]
NEUTRAL
SWITCH
17-17
[2]
NEUTRAL SWITCH
BRACKET
6) Clamp the neutral switch wire with the clip A and set the
clip A on the neutral switch bracket.
7) Connect the neutral switch 2P connector and set the neutral
switch 2P connector on the connector bracket A.
[2]
NEUTRAL SWITCH
2P CONNECTOR
[1]
FUEL TUBE HOLDER
[3]
CONNECTOR
BRACKET A
8) Set the fuel tube holder on the connector bracket A.
9) Clamp the fuel tube A on the connector bracket A.
10) Set the harness band clip that clamps the alternator fuse
cable on the neutral switch bracket.
[7]
NEUTRAL
SWITCH
BRACKET
[4]
CLIP A
[6]
ALTERNATOR
FUSE CABLE
11) Install the neutral switch bracket by aligning a small hole in
the neutral switch bracket with the boss on the seal holder
while pulling the detent arm to your side. Tighten the 6 x 14
mm flange bolt securely.
6 x 14
[1] (Pull in the direction
of the arrow.)
[2]
HOLE
[5]
DETENT
ARM
12) Apply marine grease to the concave in the shift arm and to
the shift shaft B.
Pulling the detent arm to your side, install the shift arm on
the shift shaft B.
[5]
HARNESS
BAND CLIP
[4]
BOSS
[1]
DETENT
ARM
[3]
NEUTRAL SWITCH
BRACKET
[2]
SHIFT ARM
[3]
SHIFT
SHAFT B
[5]
Pull to your side.
[4] (MARINE
GREASE)
17-18
13) Set the 12 mm washer on the shift shaft B and secure with
the 12 mm snap ring.
[1]
12 mm SNAP
RING
[2]
12 mm WASHER
[3]
SHIFT ARM
[Set in the “N”
(Neutral) position.]
14) Apply marine grease to the outer surface of the link pin of the shift link bracket and to the long hole in the shift arm.
Set the link pin aligning with the long hole in the shift arm.
15) Tighten the shift link bracket assembly with the two 6 x 18 mm flange bolts securely.
16) Apply marine grease to the mounting part of the linkage pivot on the throttle plate and to the linkage pivot. Install
the linkage pivot on the throttle plate.
17) Apply marine grease to the outer surface of the shift link pin and install the remote control cable (shift side) (P. 17-7).
18) Apply marine grease to the outer surface of the link pin and install the remote control cable (throttle side) (P.17-10).
19) Remove the following parts.
– Remote control cable/grommet (P. 17-5)
– L./R. engine under covers (P. 4-14)
– Front separate cover (P. 4-7)
– Engine cover (P. 4-2)
[3]
THROTTLE ROD
[2] THROTTLE
PLATE
6 x 18 (2)
[1]
SHIFT ARM
[4] (MARINE
GREASE)
[5]
SHIFT LINK BRACKET
ASSEMBLY
[4] (MARINE
GREASE)
17-19
[4] (MARINE
GREASE)
[6]
LINK PIN
3. SEAL HOLDER
6 x 20 (2)
[1]
SEAL HOLDER
a. REMOVAL
Remove the following pars.
– Engine cover (P. 4-2)
– Front separate cover (P. 4-7)
– R. engine under cover (P. 4-9)
– Remote control cable/bracket (P. 17-2)
– Shift link bracket/neutral switch (P. 17-11)
1) Remove the 6 x 14 mm flange bolt from the cable bracket
A, and remove the cable bracket A.
Remove the starter cable and the alternator fuse cable from
the cable bracket A.
2) Remove the two 6 x 20 mm flange bolts from the seal
holder, and remove the seal holder.
NOTICE
• Remove the seal holder with care not to raise the shift
shaft B.
• Correct the shift shaft B if it is raised or if it is disengaged
from the shift shaft A in the mounting case (P. 17-21).
[4]
CABLE
BRACKET A
[2]
STARTER
CABLE
6 x 14
[3]
ALTERNATOR
FUSE CABLE
• Note that assembly with the shift shaft A and B out of
alignment will prevent proper shifting.
b. DISASSEMBLY
1) Before removing the 12 x 26 x 7 mm oil seal, check the oil
seal lip for cut or other damage. Replace if necessary.
[1]
12 x 26 x 7 mm
OIL SEAL
2) Remove the 12 x 26 x 7 mm oil seal from the seal holder
using a commercially available oil seal remover.
Replace the oil seal with a new one on assembly.
[2]
SEAL HOLDER
3) Remove the 25 x 2.4 mm O-ring from the seal holder.
Replace the O-ring with a new one on assembly.
[3]
25 x 2.4
mm O-RING
17-20
c. COMPONENTS DRAWING
[1]
12 x 26 x 7 mm
OIL SEAL
6 x 20 (2)
[7]
SEAL HOLDER
[2]
SHIFT SHAFT B
[6]
25 x 2.4
mm O-RING
[3]
ALTERNATOR FUSE
CABLE
[5]
CABLE BRACKET A
[4]
STARTER CABLE
6 x 14
17-21
d. SHIFT SHAFT B CORRECTION
[1]
STOPPER
[1] STOPPER
Correct the shift shaft B with the seal holder removed.
Correct the shift shaft B only when the shift shaft B is raised or
when it is disengaged from the shift shaft A in the mounting
case.
Remove the following pars before correction.
– Gear case assembly (P. 14-3, 42)
[3]
SHIFT
SHAFT A
[2]
SHIFT SHAFT B
(Raise the shift shaft B
and turn it clockwise.)
1) Turn the shift shaft B clockwise until the shift shaft A comes
in contact with the stopper in the mounting case as shown.
NOTICE
If the shift shaft B comes in contact with the stopper before
the shift shaft A does, raise the shift shaft B and turn it
counterclockwise until it engages with the shift shaft A.
Then turn the shift shaft B clockwise until the shift shaft A
comes in contact with the stopper.
2) Raise the shift shaft B slowly while holding the shift shaft A
in contact with the stopper in the mounting case.
[4]
SHIFT SHAFT B
(If the shift shaft B comes in contact with the
stopper before the shift shaft A does, raise the
shift shaft B and turn it counterclockwise.)
[3]
SHIFT
SHAFT A
[1]
STOPPER
3) With the raised shift shaft B pushed against the stopper in
the mounting case, lower the shift shaft B slowly and
engage it with the shift shaft A.
NOTICE
Hold the shift shaft A not to move when engaging it with
the shift shaft B.
[3]
SHIFT
SHAFT A
4) After correction, check for proper shifting of the gear.
5) Install the seal holder (P. 17-23) and the gear case assembly
(P. 14-5, 44).
[4]
SHIFT SHAFT B
(Lower slowly and engage
with the shift shaft A)
[3]
SHIFT
SHAFT A
17-22
[2]
SHIFT SHAFT B
(Turn clockwise.)
e. ASSEMBLY
1) Apply marine grease to a new 25 x 2.4 mm O-ring.
Apply soapy water to the outer surface of the 12 x 26 x 7
mm oil seal.
[1]
12 x 26 x 7 mm
OIL SEAL
[2]
(Apply soapy
water to the
outer surface.)
Apply marine grease to the mounting part of the O-ring on
the seal holder.
[3]
SEAL
HOLDER
2) Install the 12 x 26 x 7 mm oil seal and 25 x 2.4 mm O-ring
on the seal holder.
[5]
(MARINE
GREASE)
[4]
25 x 2.4 mm
O-RING
f. INSTALLATION
1) Tighten the cable bracket A with the 6 x 14 mm flange bolt
securely.
6 x 20 (2)
[1]
(Apply marine
grease to the lip.)
2) Protect the shift shaft B by taping around the stepped part
of the shift shaft B.
3) Apply marine grease to the 12 x 26 x 7 mm oil seal lip
mounted on the seal holder.
4) Install the seal holder over the shift shaft B slowly and
tighten the seal holder with the two 6 x 20 mm flange bolts
securely.
[2] Tape around the
stepped part.
[5]
SEAL
HOLDER
NOTICE
• Install the seal holder with care not to raise the shift shaft
B.
• Correct the shift shaft B if it is raised or if it is disengaged
from the shift shaft A in the mounting case (P. 17-22).
• Note that assembly with the shift shaft A and B out of
alignment will prevent proper shifting.
[4]
CABLE
BRACKET A
6 x 14
[3] SHIFT
SHAFT B
5) Remove the tape from the shift shaft B.
NOTICE
Check that the oil seal lip is not turned up during removal
of the tape.
[1]
STARTER CABLE
6) Set the starter cable and the alternator fuse cable in the
cable bracket A as shown.
7) Install the following parts.
– Shift link bracket/neutral switch (P. 17-17)
– Remote control cable/grommet (P. 17-5)
– R. engine under covers (P. 4-15)
– Front separate cover (P. 4-7)
– Engine cover (P. 4-2)
17-23
[3]
CABLE BRACKET A
[2]
ALTERNATOR
FUSE CABLE
18. ELECTRICAL EQUIPMENT
1. STARTER MOTOR
2. STARTER CABLE
3. ECM/PGM-FI MAIN RELAY/FUSE BOX
4. POWER TILT RELAY/CONNECTOR
BRACKET A
1. STARTER MOTOR
a. REMOVAL
1) Disconnect the negative (–) cable from the battery negative terminal.
2) Disconnect the main relay (White) terminal from the magnetic switch.
3) Move the terminal cover aside and remove the 8 mm washer-nuts and the 8 mm washer. Disconnect the alternator
fuse cable and the starter cable from the starter magnetic switch.
4) Loosen the 10 x 90 mm flange bolt fully.
5) Remove the starter motor together with the 10 x 90 mm flange bolt.
6) Remove the O-ring from the starter motor.
• Replace the O-ring.
[1]
8 mm WASHER-NUT (2)
[2]
ALTERNATOR FUSE CABLE
[9]
8 mm WASHER
[8]
STARTER MOTOR
[3]
STARTER CABLE
[4]
MAIN RELAY
TERMINAL (W)
[5]
10 x 90
Loosen fully and remove
together with the starter
motor.
[6]
STARTER MAGNETIC
SWITCH
[7]
O-RING
Do not reuse.
18-1
b. DISASSEMBLY
[1] 8 mm WASHER-NUT
1) Move the terminal cover aside. Remove the 8 mm washernut and disconnect the motor wire from the S terminal.
[2]
MOTOR WIRE
[3]
S TERMINAL
[4] STARTER
MAGNETIC
SWITCH
2) Remove the 6 x 22 mm washer screws and the O-rings.
Remove the magnetic switch, spring and the plunger.
[1] STARTER MAGNETIC
SWITCH
[2]
SPRING
[3]
PLUNGER
[5]
6 x 22 mm
SCREW (2)
[4]
O-RING (2)
Do not reuse.
3) Remove the two through bolts and remove the yoke/rear
bracket assembly.
4) Remove the gasket and plate.
[1] THROUGH BOLT (2)
[5]
YOKE/REAR
BRACKET
ASSEMBLY
[2]
GASKET
[4]
FRONT BRACKET
ASSEMBLY
18-2
[3]
PLATE
5) Remove the yoke from the armature/rear bracket assembly.
[1]
ARMATURE/REAR
BRACKET
ASSEMBLY
[2]
YOKE
6) Remove the two 5 x 8 mm screws and remove the rear
bracket.
[1]
5 x 8 mm
SCREW (2)
[2]
REAR BRACKET
7) Remove the brush holder.
8) Remove the steel ball and planetary gear.
18-3
[1]
BRUSH HOLDER
[1]
PLANETARY
GEAR (3)
[2]
STEEL BALL
9) Remove the gasket.
[1]
GASKET
10) Remove the overrunning clutch.
[2]
CLUTCH FORK
11) Remove the clutch fork.
[1]
OVERRUNNING
CLUTCH
• OVERRUNNING CLUTCH DISASSEMBLY
1) Secure the gear shaft by placing a wood block under the
gear shaft assembly.
NOTICE
[1] PIPE
[I.D.: approx. 11mm (0.4 in),
O.D.: approx. 15 mm (0.6 in),
LENGTH: approx. 22 mm (0.8 in)]
Secure the gear shaft assembly with care not to contact the
internal gear.
2) Prepare a pipe of the following dimensions.
• I.D.: approx. 11 mm (0.4 in), O.D.: approx. 15 mm (0.6 in),
LENGTH: approx. 20 mm (0.8 in)
3) Set the pipe on the gear shaft stopper and drop the gear
shaft stopper by tapping on the pipe.
4) Remove the snap ring using a screwdriver or equivalent
tool.
[2]
GEAR SHAFT
[4]
SNAP RING
[3]
WOOD BLOCK
[5]
GEAR SHAFT
STOPPER
18-4
5) Remove the gear shaft and the gear shaft stopper. Remove
the internal gear and the overrunning clutch.
[1] GEAR SHAFT STOPPER
[2]
ONE-WAY CLUTCH
[4]
INTERNAL GEAR
[3]
GEAR SHAFT
• BRUSH HOLDER DISASSEMBLY
[1]
PLATE
1) Remove the clip and the plate.
2) Remove the brush sets and the brush springs.
[4]
BRUSH
SPRING (4)
[2] BRUSH SET
[3]
BRUSH HOLDER
c. INSPECTION
• BRUSH LENGTH
Measure the brush length. Replace the brushes as a set if the
measurement is less than the service limit.
STANDARD
SERVICE LIMIT
12.3 mm (0.48 in)
7.0 mm (0.28 in)
18-5
• MICA DEPTH
Measure the mica depth. If the grooves are clogged or mica
depth is less than the service limit, recut the grooves using a
hacksaw blade or a small file.
STANDARD
SERVICE LIMIT
0.4 – 0.5 mm
(0.016 – 0.020 in)
0.2 mm
(0.008 in)
• COMMUTATOR
1) Measure the commutator O.D. If the measurement is less
than the service limit, replace the armature with a new one.
2) Measure the commutator runout using a dial gauge.
If the measurement is more than the service limit, replace
the armature with a new one.
STANDARD
SERVICE LIMIT
29.4 mm (1.16 in)
28.8 mm (1.13 in)
3) Check the commutator (insulaor) for damage, dust, dirt and
metal particles.
If there is stain, irregularity and/or evidence of burning,
clean with an emery paper #500 or #600.
STANDARD
18-6
0.1 mm (0.004 in)
• ARMATURE
Check the armature and shaft gear for wear and damage.
• ARMATURE SHORT-CIRCUIT TEST
Place the armature in an armature tester (commercially
available).
Hold a hacksaw blade close to the armature core. If the blade is
attracted to the core or vibrates when the core is turned, the
armature is shorted. Replace the armature.
• CONTINUITY CHECK – SEGMENTS
Check for continuity between each segment.If an open circuit
exists between any two segments, replace the armature.
• SHORT-CIRCUIT TEST – SHAFT-TOCOMMUTATOR
Check for continuity between the commutator and armature
shaft. If there is continuity, replace the armature.
18-7
• SHORT-CIRCUIT TEST — CORE-TOCOMMUTATOR
Check for continuity between the commutator and armature
coil core. If continuity exists, replace the armature.
• SHORT-CIRCUIT TEST — SHAFT-TO-ARMATURE
Check for continuity between the armature and armature shaft.
If there is continuity, replace the armature.
• OVERRUNNING CLUTCH
1) Check the overrunning clutch for smooth axial movement.
If the overrunning clutch does not move smoothly, clean
the spline and coat it with grease before recheck.
If the overrunning clutch does not move smoothly after
cleaning or coated with grease, replace the overrunning
clutch assembly.
2) Turn the gear shaft assembly by holding the overrunning
clutch. The gear shaft assembly should turn only clockwise.
If the clutch turns freely in both directions or if it does not
turn at all, replace the overrunning clutch.
3) Check the pinion gear teeth for wear and damage and
replace if necessary.
NOTICE
If the pinion gear is worn or damaged, the flywheel ring
gear must be inspected.
18-8
• MAGNETIC SWITCH
[1] S TERMINAL
After assembly, check for continuity between the S terminal
and the yoke (ground). Check for continuity between the S
terminal and the M terminal.
[2]
M TERMINAL
d. ASSEMBLY
NOTICE
After assembling the starter motor, apply sufficient amount of
the water resisting sealant (Sumitomo 3M Padding Sealer
#8533 or equivalent) to the mating sections of each part (P. 1719).
[4]
BRUSH SET
Replace as a set.
[5]
PLATE
[1]
BRUSH HOLDER
[6]
REAR BRACKET
[7]
5 x 8 mm SCREW (2)
2.5 N.m (0.25 kgf.m, 1.8 lbf.ft)
[2]
BRUSH SPRING (4)
[3]
GASKET
[27]
YOKE
ASSEMBLY:
Check the inner wall of the
magnetic part for the foreign
material (nut, washer, etc.)
before assembly.
[26]
6 x 22 mm SCREW (2)
6 N.m (0.6 kgf.m,, 4.3 lbf.ft)
[23]
O-RING (2)
Do not reuse.
[22]
FRONT BRACKET
[21]
CLUTCH FORK
[8]
ARMATURE
[25]
SNAP RING
[24]
GEAR SHAFT
STOPPER
[9]
THROUGH BOLT (2)
5 N.m (0.5 kgf.m, 3.6 lbf.ft)
[10]
OVERRUNNING
CLUTCH
[11]
INTERNAL GEAR
[12]
GEAR SHAFT
[13]
STEEL BALL
[20]
PLUNGER
[19] PLATE
[18] SPRING
[17]
STARTER MAGNETIC
SWITCH
18-9
[16]
GASKET
[15]
8 mm WASHER-NUT
[14]
PLANETARY
GEAR (3)
• OVERRUNNING CLUTCH ASSEMBLY
1) Apply grease to the internal gear, inner wall of the
overrunning clutch, gear shaft sliding surface and the
surface of the gear shaft stopper.
[1] GEAR SHAFT STOPPER
[2]
ONE-WAY
CLUTCH
2) Assemble the overrunning clutch, gear shaft and the gear
shaft stopper with the internal gear.
3) Install the new snap ring.
4) Holding the overrunning clutch, push the gear shaft into
the overrunning clutch. Push the gear shaft stopper up to
set the snap ring in the groove of the gear shaft stopper
securely.
[4]
INTERNAL GEAR
[3]
GEAR SHAFT
[5]
SNAP RING
• BRUSH HOLDER ASSEMBLY
1) Install the brush springs and brushes on the brush holder.
Install the plate on the brush holder.
[1] PLATE
2) Secure the plate with the clip.
[4]
BRUSH SPRING
[6]
GEAR SHAFT
STOPPER
[2] BRUSH SET
[3]
BRUSH HOLDER
[5] CLIP
18-10
• FRONT BRACKET ASSEMBLY
1) Apply grease to the sliding surface of the clutch fork.
2) Set the clutch fork in the indicated position of the
overrunning clutch.
[2]
OVERRUNNING
CLUTCH
[1]
CLUTCH FORK
3) Install the overrunning clutch assembly on the front
bracket.
• Install by aligning the projection on the outer surface of
the ring gear with the groove in the front bracket.
[1]
GROOVE
[2]
PROJECTION
[3] OVERRUNNING
CLUTCH
[4]
CLUTCH
FORK
[5]
FRONT BRACKET
4) Install the gasket.
• Install by aligning the projections on the gasket with the
grooves in the front bracket.
[1] GASKET
[4]
PROJECTION
[2]
FRONT
BRACKET
[3]
GROOVE
5) Apply grease to the planetary gears, steel ball and the
internal gear.
6) Install the planetary gears, steel ball and the internal gear.
18-11
[2]
STEEL BALL
[1]
PLANETARY
GEAR (3)
• REAR BRACKET/YOKE ASSEMBLY
1) Install the brush holder on the armature.
2) Apply grease to the armature shaft and install the gear
bracket as shown.
3) Apply the water resisting sealant (Sumitomo 3M Padding
Sealer #8533 or equivalent) to the seat of each 5 x 8 mm
screw.
Tighten the 5 x 8 mm screws to the specified torque.
[1]
5 x 8 mm SCREW (2)
2.5 N.m (0.25 kgf.m, 1.8 lbf.ft)
[4]
REAR
BRACKET
TORQUE: 2.5 N.m (0.25 kgf.m, 1.8 lbf.ft)
[3]
ARMATURE
4) Check the inner wall of the yoke for foreign material and
install the rear bracket/armature assembly.
• Install the rear bracket/armature assembly by aligning the
grommet with the cutout in the yoke.
[2]
BRUSH
HOLDER
[1]
ARMATURE/REAR
BRACKET ASSEMBLY
[2]
YOKE
5) Install the plate and gasket on the front bracket.
6) Install the yoke/rear bracket assembly.
• Install by aligning the projection on the yoke with the
cutout in the front bracket.
[2] THROUGH BOLT (2)
[1] YOKE/REAR BRACKET
ASSEMBLY
7) Apply the water resisting sealant (Sumitomo 3M Padding
Sealer #8533 or equivalent) to the seat of each through bolt.
Tighten the through bolts to the specified torque.
[3]
GASKET
TORQUE: 5 N.m (0.5 kgf.m, 3.6 lbf.ft)
[5]
FRONT BRACKET
ASSEMBLY
18-12
[4]
PLATE
8) Apply the engine oil to the new O-rings and install the Orings on the 6 x 22 mm screws.
[1] 8 mm WASHER-NUT
9) Install the plunger, spring and the starter magnetic switch.
• Assemble the plunger and the clutch fork as shown.
[2]
STARTER MAGNETIC
SWITCH
10) Tighten the 6 x 22 mm screws to the specified torque.
TORQUE: 6 N.m (0.6 kgf.m, 4.3 lbf.ft)
11) Connect the brush terminal (M terminal) to the starter
magnetic switch and tighten the 8 mm washer-nut securely.
[3]
SPRING
[4]
PLUNGER
[4]
PLUNGER
[7]
O-RING (2)
Do not reuse.
12) After assembling the starter motor, apply sufficient amount
of the water resisting sealant (Sumitomo 3M Padding
Sealer #8533 or equivalent) to the following mating
sections.
[1]
MAGNETIC SWITCH CASE
CAULKING SECTION
[2]
WIRE, GROMMET AND
REAR BRACKET
[6]
6 x 22 mm SCREW (2)
6 N.m (0.6 kgf.m,
4.3 lbf.ft)
[5]
CLUTCH FORK
[3]
SWITCH ASSEMBLY/FRONT
BRACKET MATING SECTION
[4]
SWITCH MOUNTING
SCREW
[5]
O-RING
INSTALLATION
PART
[8]
SCREW/THROUGH BOLT AND
REAR BRACKET MATING SECTIONS
18-13
[7]
ENGAGEMENT
SECTIONS WITH YOKE
[6]
GASKET/FRONT BRACKET
MATING SECTION
e. INSTALLATION
1) Apply the engine oil to the new O-ring.
2) Set the two 10 x 90 mm flange bolts on the starter motor, and install both the starter motor and the two 10 x 90 mm
flange bolts on the engine.
3) Tighten the two 10 x 90 mm flange bolts to the specified torque.
TORQUE: 44 N.m (4.5 kgf.m, 33 lbf.ft)
4) Connect the starter cable to the starter magnetic switch and tighten the 8 mm washer-nut to the specified torque.
TORQUE: 11 N.m (1.1 kgf.m, 8 lbf.ft)
5) Install the 8 mm washer and the alternator fuse cable on the starter magnetic switch and tighten the 8 mm washernut to the specified torque.
TORQUE: 11 N.m (1.1 kgf.m, 8 lbf.ft)
6) Connect the main relay (White) terminal to the starter magnetic switch.
7) Install the terminal cover securely.
[3]
8 mm WASHER
[1]
8 mm WASHER-NUT
11 N.m (1.1 kgf.m, 8 lbf.ft)
[1]
8 mm WASHER-NUT
11 N.m (1.1 kgf.m, 8 lbf.ft)
[4]
ALTERNATOR FUSE CABLE
[2]
STARTER MOTOR
[5]
STARTER CABLE
[6]
MAIN RELAY
TERMINAL (W)
[7]
10 x 90 (2)
Install on the engine together
with the starter motor.
TORQUE:
44 N.m (4.5 kgf.m, 33 lbf.ft)
[8]
STARTER MAGNETIC
SWITCH
[9]
O-RING
Do not reuse.
18-14
2. STARTER CABLE
a. REMOVAL
Remove the following parts.
– Engine cover (P. 4-2)
– Front separate cover (P. 4-7)
[1]
STARTER
CABLE 1P
CONNECTOR
(W WIRE)
NOTICE
Disconnect the starter cable from the battery before
disconnecting and connecting the starter cable.
1) Release the starter cable from the two harness clips.
[2]
CONNECTOR
BRACKET C
2) Release the starter cable 1P connector (White wire) from
the connector bracket C.
[3]
STARTER CABLE
3) Disconnect the starter cable 1P connector (White wire).
[4] HARNESS
CLIP (2)
4) Remove and disconnect the two 8 mm washer-nuts,
alternator fuse cable, 8 mm washer and the positive (+)
starter cable from the magnetic switch B terminal.
[1] 8 mm WASHERNUT (2)
[2] ALTERNATOR
FUSE CABLE
[3] 8 mm WASHER
[4]
STARTER
CABLE (+)
[5]
B TERMINAL
5) Remove the 8 x 18 mm flange bolt from the crankcase, then
disconnect the negative (–) starter cable.
[1] CABLE BRACKET B
6) Remove the harness band clip that secures the starter cable
from the cable bracket B.
Remove the wire harness clip.
[4]
HARNESS
BAND CLIP
18-15
[2]
STARTER
CABLE (–)
[3]
WIRE HARNESS CLIP
8 x 18
7) Release the starter cable from the cable bracket A.
[1]
CABLE BRACKET A
[2]
STARTER CABLE
b. COMPONENTS LOCATION
[1]
8 mm WASHER-NUT (2)
11 N.m (1.1 kgf.m, 8 lbf.ft)
[2]
ALTERNATOR FUSE CABLE
[3]
STARTER CABLE
1P CONNECTOR
(W WIRE)
[13]
8 mm WASHER
[12]
STARTER CABLE (+)
[4]
CABLE
BRACKET A
[11]
WIRE HARNESS
CLIP (2)
[10]
CONNECTOR
BRACKET C
[9]
HARNESS CLIP (2)
[8]
CABLE BRACKET B
[7]
HARNESS BAND
CLIP
18-16
[5]
STARTER CABLE
[6]
STARTER CABLE (–)
8 x 18
26 N.m (2.7 kgf.m, 20 lbf.ft)
c. INSTALLATION
1) Secure the alternator fuse cable and the starter cable with
the cable bracket A as shown.
[1]
CABLE BRACKET A
[2]
STARTER CABLE
[2]
STARTER CABLE
[3]
ALTERNATOR
FUSE CABLE
[1]
CABLE BRACKET A
2) Tighten the 8 x 18 mm flange bolt to the specified torque
while pushing the negative (–) starter cable against the
projection on the crankcase.
[1] CABLE BRACKET B
[2]
STARTER
CABLE (–)
TORQUE: 26 N.m (2.7 kgf.m, 20 lbf.ft)
3) Install the harness band clip, that clamps the starter cable,
on the cable bracket B.
4) Clamp the alternator fuse cable and the starter cable with
the wire harness clamp.
NOTICE
Check that the cables are not interfering with the shift arm.
[3]
[4]
8 x 18
WIRE HARNESS CLIP
HARNESS
BAND CLIP
[5]
PROJECTION
[6]
STARTER CABLE
(–) TERMINAL
18-17
5) Install the positive (+) starter cable on the magnetic switch
B terminal at right angles to the vertical center line of the
magnetic switch as shown. Tighten the 8 mm washer-nut to
the specified torque.
TORQUE: 11 N.m (1.1 kgf.m, 8 lbf.ft)
[1] 8 mm WASHERNUT
[2]
TERMINAL COVER
[6] ALTERNATOR
FUSE CABLE
[5] 8 mm WASHER
After tightening, set the 8 mm washer on the magnetic
switch B terminal.
6) Install the alternator fuse cable on the magnetic switch B
terminal at right angles to the vertical center line of the
magnetic switch as shown. Tighten the 8 mm washer-nut to
the specified torque.
[1]
8 mm WASHERNUT
[4]
STARTER
CABLE (+)
TORQUE: 11 N.m (1.1 kgf.m, 8 lbf.ft)
[3]
B TERMINAL
After tightening, set the terminal cover on the magnetic
switch B terminal.
90˚
[6]
ALTERNATOR
FUSE CABLE
[4]
STARTER CABLE (+)
7) Connect the starter cable 1P connector (White wire).
8) Set the starter cable 1P connector (White wire) on the
connector bracket C.
[1]
STARTER
CABLE 1P
CONNECTOR
(W WIRE)
9) Secure the starter cable with the two harness clips.
10) Install the following parts.
– Front separate cover (P. 4-7)
– Engine cover (P. 4-2)
[2]
CONNECTOR
BRACKET C
[4] HARNESS
CLIP (2)
18-18
[3]
STARTER CABLE
3. ECM/PGM-FI MAIN RELAY/FUSE BOX
a. ELECTRIC PART COVER/ECM REMOVAL/INSTALLATON
Remove the following parts.
– Engine cover (P. 4-2)
– R. engine under cover (P. 4-9)
On installation, position each connector and harness in the proper position (P. 2-48).
[2]
ECM CONNECTOR
C (6P CONNECTOR)
[3]
ECM CONNECTOR A
(26P CONNECTOR)
[5]
ECM (ELECTRONIC
CONTROL MODULE)
6 x 20 (2)
18-19
[4]
ECM CONNECTOR B
(34P CONNECTOR)
[1]
ELECTRIC
PART COVER
b. PGM-FI MAIN RELAY/CONNECTOR BRACKET B REMOVAL/INSTALLATION
Remove the following parts.
– Engine cover (P. 4-2)
– R. engine under cover (P. 4-9)
– Electric part cover/ECM (P. 18-19)
Disconnect the PGM-FI main relay connector wire and the alternator fuse cable from the starter motor.
On installation, position each connector and harness in the proper position (P. 2-48 through P. 2-51).
[1]
PGM-FI MAIN RELAY
6 x 16 (2)
5 N.m (0.5 kgf.m, 3.6 lbf.ft)
[2]
UNIT SUSPENSION (2)
INSPECTION: P. 18-24
[3]
RELAY
SUSPENSION
[9]
CONNECTOR
BRACKET B
6 x 10
[8]
HARNESS BAND
CLIP (4)
[7]
PGM-FI MAIN RELAY
CONNECTOR WIRE
[6]
ALTERNATOR
FUSE CABLE
[4]
LAF RELAY
INSPECTION: P. 18-25
[5]
POWER TILT SWITCH
INSPECTION: P. 4-12
18-20
c. FUSE BOX/ALLTERNATOR FUSE BOX (90A) REMOVAL/INSTALLATION
Remove the following parts.
– Engine cover (P. 4-2)
– R. engine under cover (P. 4-9)
– Electric part cover/ECM (P. 18-19)
– PGM-FI main relay/connector bracket B (P. 18-20)
On installation, position each connector and harness in the proper position (P. 2-48 through P. 2-51).
[1]
ALTERNATOR FUSE
BOX B TERMINAL
INSTALLATION: P. 2-48
[2]
6 mm WASHER-NUT (2)
8 N.m (0.8 kgf.m, 5.8 lbf.ft)
[14]
RELAY GROMMET (2)
[13]
90A FUSE
INSPECTION:
Check for the blown fuse.
[3]
FUSE BOX
COLLAR (2)
[12]
5 x 12 mm SCREWWASHER (2)
[11]
ALTERNATOR FUSE BOX
INSPECTION: P. 18-25
ASSEMBLY: P. 18-23
[10]
6 mm WASHER (2)
6 x 25 (2)
5 N.m (0.5 kgf.m,
3.6 lbf.ft)
[9] 6 x 16 mm BOLTWASHER (2)
[8]
ALTERNATOR
FUSE COVER
[7]
90A SPARE FUSE
[6]
3 x 7 mm SCREWWASHER (2)
[4] To STARTER MOTOR
B TERMINAL
[5] To ALTERNATOR
B TERMINAL
18-21
[1]
CASE GROMMET (4)
[2]
COLLAR (4)
[11]
6 mm WASHER (4)
6 x 25 (4)
[10]
FUSE BOX
BRACKET
[9]
CONNECTOR
HOLDER CLIP B
6 x 10
5 N.m (0.5 kgf.m, 3.6 lbf.ft)
[8]
FUSE BOX COVER
[3] CONNECTOR
BRACKET C
[7]
FUSE BOX
INSPECTION: P. 18-26
REMOVAL: P. 18-23
18-22
[6]
BLADE FUSE
[4]
HARNESS CLIP (3)
[5]
HARNESS BAND
CLIP (3)
• FUSE BOX
1) Insert a screwdriver or equivalent tool into the locking lugs
on the top and underside of the fuse box, and unlock.
2) With the lock unlocked, pull the fuse box toward you and
remove the fuse box from the fuse box bracket.
• ALTERNATOR FUSE BOX
ASSEMBLY:
Connect the alternator fuse cable (White wire) to the alternator
fuse box from the reverse side. Connect so that the “ ” marks
face the directions shown.
[1]
ALTERNATOR
FUSE BOX
[2]
“ ” MARKS
18-23
d. INSPECTION
NOTICE
• Use a known-good battery.
• Do not connect the battery for more than 30 seconds. Wait for
one minute or more before connecting the battery again.
• PGM-FI MAIN RELAY
1) Connect the battery positive (+) terminal to the Black/Yellow
terminal of the PGM-FI main relay 6P connector and the
battery negative (–) terminal to the Black terminal. There
must be the continuity between the following terminals of
the 4P connector.
• Between White/Yellow and White/Green terminals
• Between White/Yellow and White/Red terminals
• Between White/Yellow and White/Black terminals
[1]
CONNECTORS VIEWED
FROM THE FRONT SIDE
W/G
W/R
W/Bl
2) Connect the battery positive (+) terminal to the PGM-FI
main relay terminal and the battery negative (–) terminal to
the Light green/Red terminal. There must be the continuity
between the White/Black and the Blue/Red terminals of the
2P connector.
W/Bl
Bu/R
W/Y
Bl/Y
3) Connect the battery positive (+) terminal to the Black/White
terminal of the PGM-FI main relay 6P connector and the
battery negative (–) terminal to the Black/Blue terminal.
There must be continuity between the terminal and the
White/Yellow terminal of the 4P connector.
4) Connect the battery positive (+) terminal to the White/
Green terminal of the PGM-FI main relay 4P connector and
the battery negative (–) terminal to the 6P connector Light
green/Red terminal. There must be continuity between the
White/Black and the Blue/Red terminals of the 2P
connector.
5) If there is no continuity, replace the PGM-FI main relay.
Lg/R
Bl
[1]
4P CONNECTOR
W/G
W/R
W/Bl
W/Y
[3]
2P CONNECTOR
W/Bl
Bu/R
[4]
6P CONNECTOR
Bl/Bu
Bl/W
Lg/R
Bl/Y
Bl
[5] TERMINAL
18-24
Bl/Bu
Bl/W
[2]
PGM-FI MAIN RELAY
• LAF RRELAY
Connect the battery positive (+) terminal to the LAF relay No.3
terminal and the battery negative (–) terminal to the No.4
terminal. There must be continuity between the No.1 and No.2
terminal of the LAF relay.
[1]
LAF RELAY
[2]
CONNECTOR VIEWED FROM
THE FRONT SIDE
[3] NO.3 TERMINAL
[6] No. 4 TERMINAL
[4]
No. 1 TERMINAL
[5] No. 2 TERMINAL
• ALTERNATOR FUSE BOX/FUSE
[1]
ALTERNATOR
FUSE BOX
NOTICE
Disconnect the positive (+) and negative (–) starter cables from
the battery before inspection and replacement of the alternator
fuse box/fuse.
1) Check the 90A fuse for continuity.
– If there is no continuity, replace the 90A fuse with the
spare fuse.
– If there is continuity, install the 90A fuse on the alternator
fuse box and check for continuity between the cable
terminals.
[4]
To STARTER
MOTOR B
TERMINAL
[2]
To ALTERNATOR
B TERMINAL
2) When installing the spare fuse on the reverse side of the
cover, install so that the stamp of “90A” is at your side.
[3]
RED TAPE
18-25
• FUSE BOX/FUSE
[1]
TERMINAL
NOTICE
[2]
ALTERNATOR
FUSE BOX
Disconnect the positive (+) and negative (–) starter cables from
the battery before inspection and replacement of the fuse
box/fuse.
1) Remove the fuses from the fuse box and check for blown
fuse.
[3]
FUSE BOX
2) If the fuses are normal, install them in the fuse box and
check for continuity between the terminals shown below.
Fuse No.
Check point
1
Between the terminal and the No.3 terminal
of the C connector
2
Between the terminal and the No.2 terminal
of the C connector
3
Between the terminal and the No.1 terminal
of the C connector
4
Between the A connector No.3 terminal and
the B connector No.4 terminal
5
Between the A connector No.2 terminal and
the B connector No.1 terminal
6
Between the A connector No.1 terminal and
the B connector No.2 terminal
7
Between the terminal and the No.3 terminal
of the B connector
18-26
[6]
[5]
A CONNECTOR B CONNECTOR
(3P)
(4P)
[7] CONNECTORS VIEWED
FROM THE FRONT SIDE
[4]
C CONNECTOR
(4P)
4. POWER TILT RELAY/CONNECTOR BRACKET A
a. REMOVAL/INSTALLATION
Remove the following parts.
– Engine cover (P 4-2)
– L./R. engine under covers (P. 4-9)
– Under cover front bracket (P. 4-20)
Remove each connector from the connector bracket A, then remove the connector bracket A and the power tilt relay.
On installation, position the connectors and harnesses in the proper position (P. 2-53 through P. 2-56).
[2]
HARNESS BAND
CLIP (3)
[3]
TP SENSOR 3P
CONNECTOR
[4]
HARNESS CLIP
[1]
MAIN WIRE
HARNESS
INSTALLATION:
Clamp the taped part of
the water level sensor
wire and clamp the main
wire harness.
[5]
WATER LEVEL SENSOR
2P CONNECTOR
INSTALLATION: P. 3-21
INSPECTION: P. 3-19,20
[6]
POWER TILT RELAY
3P CONNECTOR
[12]
NEUTRAL
SWITCH 2P
CONNECTOR
[7]
TRIM ANGLE SENSOR
2P CONNECTOR
[11]
ALTERNATOR
FUSE CABLE
[8]
POWER TILT MOTOR
2P CONNECTOR
[10]
FUEL TUBE A
INSPECTION:
Check for deterioration and
cracks. Replace if necessary.
18-27
[9]
POWER TILT RELAY
1P CONNECTOR
[1]
FRAME GROUND
INSTALLATION: P. 18-29
6 x 12 (2)
[2]
WIRE HARNESS CLIP
INSTALLATION:
Clamp the power tilt
relay ground cable.
[3]
RELAY BRACKET
6 x 14 (4)
[12]
POWER TILT RELAY
GROUND CABLE
INSTALLATION: P. 18-29
[4]
WIRE HARNESS CLIP
6 x 12
[5]
WIRE HARNESS CLIP
INSTALLATION:
Clamp the power tilt
relay 3P connector wire,
2P connector wire and
the 1P connector wire.
[11]
COLLAR (2)
[10]
RELAY
GROMMET (2)
[9]
POWER TILT RELAY
INSPECTION: P. 18-29
[4]
WIRE HARNESS
CLIP
6 x 22 (2)
[6]
CONNECTOR
BRACKET A
[8]
HARNESS CLIP
18-28
[7]
14 mm FUEL
TUBE CLIP
• FRAME GROUND
INSTALLATION:
Tighten the 6 x 12 mm flange bolts while pushing each ground
terminal against the projection on the crankcase as shown.
• POWER TILT RELAY GROUND CABLE
[2]
FRAME GROUND
TERMINAL
[3]
[1]
POWER TILT RELAY
PROJECTIONS
GROUND TERMINAL
INSTALLATION:
1) Connect the Black, Blue, Green/White wire side of the
ground terminal to the upper connection, and the Green,
Green/Black, Blue, Black/White wire side of the ground
terminal to the lower connection as shown.
2) Tighten the 6 x 12 mm flange bolt while pushing each
frame ground terminal against the projection on the
crankcase.
[4]
PROJECTION
[5]
FRAME GROUND
TERMINAL
b. INSPECTION
• POWER TILT RELAY
Note that the power tilt relay inspection must be made on
single unit of the power tilt relay.
[1]
GROUND WIRE
1) Check for continuity between the terminals.
Green to Black terminals
Continuity
Blue to Black terminals
Continuity
Green to White terminals
No continuity
Blue to White terminals
No continuity
Bu
Bl
Lb
18-29
Lg
W
G
NOTICE
Use a known-good battery.
2) Connect the wires as shown, and check for continuity
between the following terminals.
• Connecting positive (+) battery terminal to Light green
terminal:
Green to Black terminals
No continuity
Blue to Black terminals
Continuity
Green to White terminals
Continuity
Blue to White terminals
No continuity
Bu
Lb
Lg
• Connecting positive (+) battery terminal to Light blue
terminal:
Green to Black terminals
Continuity
Blue to Black terminals
No continuity
Green to White terminals
No continuity
Blue to White terminals
Continuity
18-30
G
W
Bl
[1]
Connect
the (+)
battery
terminal.
19. OPERATION
1. DOHC (SWING ARM TYPE) + VTEC
2. CHAIN DRIVE CAM DRIVE SYSTEM
3. INDEPENDENT CYLINDER HEAD/
CYLINDER BLOCK COOLING SYSTEM
4. AIR/FUEL RATIO O2 FEEDBACK
CONTROL BY A/F SENSOR
1. DOHC (SWING ARM TYPE) + VTEC
STRUCTURE AND FEATURES
VTEC (BF150A only)
• The VTEC adapted on the BF150A outboard motors features the two cam profiles (for low and high engine speeds) and
the corresponding three rocker arms to drive the intake valve.
• Receiving the signal from the ECM, the VTEC solenoid valve turns the hydraulic pressure ON and OFF, moving the
rocker arm pistons built in the rocker arms and thereby combining and separating the three rocker arms to select either
of the two modes and two valve timings that are suitable for the running conditions (e.g. engine speed, load, etc.).
– When the engine speed is low [engine rpm is approx. 4,300 min–1 (rpm) or below], the rocker arm piston is retracted
in the rocker arm. Each rocker arm is separate from the other making the independent movement. The center rocker
arm, designed for the high engine speed, turns idle and the right and left rocker arms trace to the low engine speed
cams. Therefore, the two intake side valves are driven in the low engine speed cam profile.
Thus, improvement of the torque in full throttle low speed range was realized compared to the conventional fixed
valve timing method.
– When the engine speed is high [engine rpm is higher than approx. 4,300 min–1 (rpm)], the VTEC solenoid valve
functions according to the signal from the ECM, extruding the rocker arm pistons from the rocker arm and combining
the three rocker arms. As the center rocker arm, which is designed for the high engine speed, traces to the high speed
cam, the two intake side valves are driven in the high engine speed cam profile.
Thus, the two valves function in the valve timing that is specially designed for the high speed range, which assures
improvement in engine horsepower.
DOHC
• The DOHC engine is adopted on these models, which realized center plug layout designed to contribute to improved
fuel consumption efficiency.
• Though the engine is the DOHC type, it also adopted the swing arm rocker arm, which allows valve clearance
adjustment with the adjusting screw and eliminated shim engagement that is poor in operationability.
EXHAUST CAMSHAFT
EXHAUST ROCKER ARM
INTAKE CAMSHAFT
INTAKE ROCKER ARM
(SWING ARM TYPE)
Built in VTEC system
VALVE ADJUSTING
SCREW
VALVE ADJUSTING SCREW
CENTER PLUG ADOPTED
19-1
2. CHAIN DRIVE CAM DRIVE SYSTEM
STRUCTURE AND FEATURES
The intake/exhaust cam drive method was changed from the existing cogged belt drive to the silent chain drive type.
The chain tensioner was changed to the hydraulic type to make it maintenance free.
Structure:
As the basic structure of this chain drive cam drive system, the balancer is laid out in front of the crankshaft and the drive
valve system is laid out behind the crankshaft.
• The balancer and intake/exhaust cam drive were changed from the two-cogged belt type (BF115A•130A) to the twosilent chain type.
• Cam chain tension adjustment was changed from the existing manual adjustment with spring to the automatic
adjustment by drawing the main gallery oil pressure. This system is the same in structure as the system adopted on
car.
• As the unique feature of these outboard motors, the dedicated chain lubrication oil jets are provided on the crankshaft
sprocket, intake/exhaust camshaft sprocket and the driven sprocket. These oil jets feature the unique rib shape to collect
the lubrication oil around the respective sprockets.
Effects:
• The chain guide is provided regulating 80% or more of the chain line. It thereby regulates deflection of the chain and
eliminates wind noise of the chain.
• The existing spring type chain tensioner needs chain tension adjustment regularly (when chain sound was produced).
These outboard motors are equipped on the hydraulic tensioner that has the adjustment mechanism (one-way lock
mechanism) to maintain constant chain tension by means of the hydraulic pressure. It also adopted the unique
lubrication system. Maintenance free during the service life of the chain tension was realized by adoption of these new
features.
INTAKE CAMSHAFT
SPROCKET
OIL JET
CRANKSHAFT
SPROCKET
DRIVEN SPROCKET
EXHAUST CAMSHAFT
SPROCKET
HYDRAULIC CHAIN
TENSIONER
19-2
3. INDEPENDENT CYLINDER HEAD/CYLINDER BLOCK COOLING SYSTEM
STRUCTURE AND FEATURES
The cylinder head and cylinder block cooling passages are laid out independently from each other, each of which is
equipped with the thermostat to control the cooling water temperature of each passage.
Structure:
• The cooling water supplied from the water pump with force flows through the water tube and oil case, then it is drawn
into the mounting case.
In the mounting case, the cooling water separates into the two independent flows; one that goes to the cylinder head
and the other that goes to the cylinder block.
The cooling water temperature of each flow is regulated by the thermostat located at the outlet port of each passage.
• The thermostat valve open temperature for the cylinder head cooling water and for the cylinder block cooling water are
set at different temperature from each other.
At the cylinder block side, the thermostat valve open temperature is set at the optimum temperature (60˚C) to prevent
oil dilution (over-cooling) during cruising at low speeds with extremely low load.
At the cylinder head side, the thermostat valve open temperature is set at the temperature (50˚C) that can enhance the
knocking limit by flushing the water more. Setting the valve open temperature in this way realized improvement in
engine horsepower as well as toughness of the cylinder head against overheating.
COOLING CIRCUIT DIAGRAM
THERMOSTAT A (50˚C)
(FOR HEAD)
THERMOSTAT B (60˚C)
(FOR BLOCK)
HEAD COOLING
PASSAGE
OIL FILTER
FLANGE
BRANCHING
CHAMBER
VAPOR
SEPARATOR
INLET WATER
BLOCK COOLING
PASSAGES
RETURN
WATER
RELIEF VALVE
WATER
PUMP
19-3
WATER TUBE
WATER
CHECK HOLE
4. AIR/FUEL RATIO O2 FEEDBACK CONTROL BY A/F SENSOR
Receiving the current value signal from the A/F (Air Fuel Ratio) sensor, the ECM controls the fuel injection duration (fuel
amount) so that the engine’s suction air fuel mixture is at or near the target air/fuel ratio determined by the main CPU.
ECM
MAP SENSOR
CKP SENSOR
DECISION OF BASIC DECISION OF TARGET
INJECTION AMOUNT A/F RATIO
CMP SENSOR
IAT SENSOR
BASIC INJECTION AMOUNT
ENVIRONMENT COPENSATION
ECT SENSOR
BARO SENSOR
A/F SENSOR
TARGET A/F RATIO
COMPENSATION
DECISION OF ACTUAL
INJECTION AMOUNT
INJECTOR
A/F (AIR FUEL RATIO) SENSOR
The A/F sensor, mounted on the exhaust manifold, detects the oxygen density in the exhaust gas. The A/F sensor has the
built-in zirconia element coated with the platinum on the inner and outer surfaces and wrapped with the coarse diffused
resistance layer. The sensor is structured so that its inner surface is exposed to the atmosphere and the outer surface to
the exhaust gas.
When a given voltage is applied between the platinum electrodes, the current does not change by applying further
voltage between the electrodes. However, the current value changes in accordance with the oxygen density in the
exhaust gas that passed through the diffusion resistance layer. Utilizing this characteristic, the A/F sensor detects the
change in oxygen density in the exhaust gas linearly, and thereby it realized very precise control of the air/fuel ratio.
A/F SENSOR AIR FUEL RATIO/CURRENT
CHARACTERISTIC CHART
EXHAUST GAS
TIP OF THE
SENSOR
ZIRCONIA ELEMENT
10
ATMOSPHERE
CERAMIC HEATER
PLATINUM ELECTRODES
DIFFUSED RESISTANCE
LAYER
5
i
(mA)
0
10
15
20
A/F
–5
–10
19-4
BF135A•BF150A
Side Mount Remote Control Type
Top Mount Remote Control Type/Panel Mount Remote Control Type
20-2
BF135A•BF150A
PGM-FI System Diagram
1 VAPOR SEPARATOR
2 FUEL PUMP (HIGH PRESSURE SIDE)
3 FUEL STRAINER (HIGH PRESSURE SIDE)
4 VAPOR FILTER
5 BATTERY
6 IGNITION SWITCH
7 STARTER MOTOR
8 NEUTRAL SWITCH
9 TRIM METER (OPTION)
10 TRIM ANGLE SENSOR
11 A/F HEATER RELAY
12 PGM-FI MAIN RELAY
13 ECU
14 CMP SENSOR
15 ACG WARNING LIGHT
16 MIL
17 IC REGULATOR AC GENERATOR
18 OVERHEAT WARNING LIGHT
19 OIL INDICATOR LIGHT
20 WARNING BUZZER
21 TACHOMETER (OPTION)
22 EMERGENCY STOP SWITCH
23 DATA LINK CONNECTOR
24 TACHOMETER PULSE CHECK CONNECTOR
25 FUEL CONSUMPTION METER
26 BARO SENSOR
27 VTEC SOLENOID VALVE
28 SILENCER CASE
29 IAT SENSOR
30 TP SENSOR
31 MAP SENSOR
32 EACV
33 IAC VALVE
34 IAB CONTROL VALVE
35 DIAPHRAGM
36 IGNITION COIL
37 FUEL INJECTOR
38 PRESSURE REGULATOR
39 FUEL PUMP (HIGH PRESSURE SIDE
40 ECT SENSOR 2
41 ECT SENSOR 4
42 KNOCK SENSOR
43 CKP SENSOR
44 OIL PRESSURE SWITCH (LOW PRESSURE SIDE)
45 OIL PRESSURE SWITCH (HIGH PRESSURE SIDE)
46 ECT SENSOR 1
47 ECT SENSOR 3
48 A/F SENSOR
49 FUEL FILTER (LOW PRESSURE SIDE)
50 WATER LEVEL SWITCH
51 WATER SEPARATOR
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Specifications
6 - 10
Service Information
11 - 89
Maintenance
90 - 119
Engine cover/Cover Lock
120 - 153
Programmed Fuel Injection
154 - 311
Alternator
312 - 335
Engine removal/Installation
336 - 343
Thermostat/Relief valve/Flush valve
344 - 354
Crankshaft pulley/Cam chain
355 - 373
Cylinder head/Valves
374 - 415
Oil pump/Flywheel
416 - 429
Crankcase/Balancer
430 - 441
Cylinder block/Crankshaft/Pistons
442 - 467
Propeller/Gear case/Extension case/
Oil case
468 - 563
15. Mounting case/Stern bracket/Swivel
case/Power trim/Tilt assembly
564 - 621
16. Steering rod/Remote Control box
622 - 631
17. Cables/Shift link bracket/Shift arm/
Neutral switch
632 - 654
18. Electrical equipment
655 - 684
19. Operation
685 - 688
20. System diagram/Wiring diagram
689 - 691
Note: Make sure to select √ Shrink to fit in the
printer dialog box when printing wiring diagrams.
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Key Features
- 4-stroke, 4-cylinder engine
- 2,354 cm3 displacement
- 100.7 kW (135 HP) rated power
- Programmed fuel injection
- Forced water circulation cooling
- Electric starter
- Dog clutch
- Underwater exhaust
- Power trim & tilt
- Remote control
Frequently Answers and Questions
What is the maximum output power of the Honda Marine BF135A?
The Honda Marine BF135A has a rated power of 100.7 kW (135 HP).
What type of fuel system does the Honda Marine BF135A use?
The Honda Marine BF135A employs a programmed fuel injection system for precise fuel delivery.
What are the available shaft lengths for the Honda Marine BF135A?
The Honda Marine BF135A is available with both long shaft (L) and extra-long shaft (XL) options.
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