F150A FL150A SERVICE MANUAL 290503 63P-28197-3F-11
NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.
Contents General information Specifications Periodic checks and adjustments Fuel system Power unit Lower unit Bracket unit GEN INFO SPEC CHK ADJ FUEL POWR LOWR BRKT – Electrical systems Troubleshooting Index + ELEC TRBL SHTG 1 2 3 4 5 6 7 8 9
GEN INFO General information How to use this manual ................................................................................. 1-1 Manual format............................................................................................ 1-1 Symbols..................................................................................................... 1-2 Safety while working......................................................................................1-3 Fire prevention.........................
Predelivery checks ......................................................................................1-22 Checking the fuel system ........................................................................1-22 Checking the gear oil level ...................................................................... 1-22 Checking the engine oil level................................................................... 1-22 Checking the battery..........................................................................
GEN INFO General information How to use this manual 1 Manual format The format of this manual has been designed to make service procedures clear and easy to understand. Use the information below as a guide for effective and quality service. 1 Parts are shown and detailed in an exploded diagram and are listed in the components list. 2 Tightening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions.
How to use this manual Symbols The symbols below are designed to indicate the content of a chapter. General information Fuel system GEN INFO Bracket unit FUEL Specifications BRKT Power unit SPEC Electrical systems POWR Periodic checks and adjustments Lower unit CHK ADJ – ELEC + Troubleshooting TRBL SHTG LOWR Symbols 1 to 6 indicate specific data. 1 2 3 4 5 6 T. R.
GEN INFO General information Safety while working 1 To prevent an accident or injury and to ensure quality service, follow the safety procedures provided below. Fire prevention Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames. Parts, lubricants, and sealants Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the outboard motor.
Safety while working 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc. Disassembly and assembly 1. Use compressed air to remove dust and dirt during disassembly. Good working practices Special service tools Use the recommended special service tools to protect parts from damage. Use the right tool in the right manner—do not improvise. Tightening torques Follow the tightening torque specifications provided throughout the manual.
GEN INFO General information Identification 1 Applicable models This manual covers the following models. Applicable models F150AET, FL150AET Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket. 1 2 3 4 Model name Approved model code Transom height Serial number Model name Approved model code F150AET 63P FL150AET 64P 1-5 Starting serial No.
Identification / Features and benefits Features and benefits 1 Crankshaft and cylinder The center of the crankshaft is offset 10 mm (0.39 in) from the center of the cylinder to make more space to incorporate the throttle body assembly. This design produces good engine balance and allows a compact design. Exhaust gas from each cylinder flows directly into the exhaust manifold to obtain a compact design for the exhaust system.
GEN INFO General information Balancer A two-piece balancer is used in the crankcase to reduce the secondary forces of inertia produced by reciprocating pistons. The balancer shaft 1 is driven by the gear on the crankshaft. The balancer shaft 2 is driven by the gear on the balancer shaft 1. The two counterrotating balancer shafts rotate at twice the speed of the crankshaft and reduce the forces of inertia of the connecting rods and each balancer shaft. Therefore, engine vibration is reduced.
Features and benefits Connecting rod A direction mark for installing the connecting rod to the crankshaft in the proper direction is on the connecting rod cap. The direction mark should face the flywheel. The connecting rod and connecting rod cap are manufactured as a single piece. Then, they are split using impact force. Only use the connecting rods and connecting rod caps in their original combinations, do not interchange them.
GEN INFO General information Intake system Multi-point, group fuel injection with four separate throttle valves is adopted for the intake system. Intake air volume is calculated according to engine speed, Intake air pressure, and throttle position, and then the fuel injection volume is determined by the intake air volume to obtain a precise air and fuel ratio under all operating conditions. The cylinders are grouped, #1/#4 and #2/#3.
Features and benefits The shape of the fuel injectors is the same for the F115, F150, F200 and F225. Therefore, each fuel injector is identified by color because the specifications of each fuel injector are different. È É Ê F115 732 F150 Ë Ì F200 F225 Í 741 731 S63P1130 È Model É Injector color Ê First three digits Ë Orange Ì Yellow Í Ivory Top cowling Water is separated from the intake air and flows down through the drain hoses before draining out through the bottom cowling.
GEN INFO General information 64E type power trim and tilt unit The 64E type clamp bracket and power trim and tilt unit used for current V4 and V6 outboard motors have been adopted. This allows easier interchanging of Yamaha outboards with the same classification because the mounting dimensions are the same. For the power trim and tilt unit, only the impact absorber valve opening pressure of the tilt piston fluid circuit has been changed.
Features and benefits Cooling system The cooling water flow diagram is as follows. To cool the propeller damper, the cooling system is designed so that fresh cooling water is taken in from the front of the trim tab and supplied to the exhaust passage of the lower case to cool the exhaust gas. Cooling water also accumulates around the exhaust muffler to cool the upper case and reduce exhaust noise.
GEN INFO General information Lubrication system The lubrication oil flow diagram is as follows. Crankcase Cylinder head Cylinder sleeve Camshaft Piston Balancer journal Crankpin IN/EX valve Camshaft journal Crankshaft main journal Main passage Oil filter Oil pressure sensor Oil filter bracket Relief valve Oil pump Oil strainer Oil pan S63P1260 There is a small hole in the relief valve to allow oil to drain from the oil filter bracket so that it does not remain in the oil filter.
Features and benefits A dual oil drain system is adopted. An oil drain bolt is located on the bottom of the oil pan. A long dipstick guide, which reaches the bottom of the oil pan, can also be used to pump out the oil completely with an oil-extracting tool.
GEN INFO General information Fuel system A fuel pressure regulator is incorporated onto the outlet of the electric fuel pump to obtain a compact design and simple fuel delivery. Fuel discharged from the pressure regulator returns to the vapor separator after being cooled in the fuel cooler. The pressure check valve is incorporated onto the fuel rail for easier servicing of the fuel system.
Features and benefits Rectifier Regulator A water-cooled Rectifier Regulator is incorporated onto the exhaust outer cover. This allows for a compact engine design and produces a large electric current output for charging the battery under low engine speed. 40 35 30 25 È 20 15 10 5 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 É S63P1210 È Charging current (A) É Engine speed (r/min) Isolator An isolator is incorporated into the Rectifier Regulator.
GEN INFO General information Technical tips 1 Electronic control system The electronic control system consists of the sensors and the ECM (electronic control module). Under various conditions, the ECM provides the best suitable engine operation.
Technical tips Fail-safe control If the electrical components malfunction, the ECM controls the ignition and fuel injection as shown in the table. Malfunctioning item Details Ignition control Fuel control Pulser coil No signal received during four consecutive crankshaft rotations Fixed to BTDC 10° Fixed to BTDC 10° Throttle position sensor Output voltage is 0.3 V or lower or 4.
GEN INFO General information Warning control This outboard motor is equipped with warning control functions to avoid serious engine damage. The engine speed is limited to approximately 2,000 r/min if the engine overheats, if the oil pressure is low, or if a dual engine system (DES) is operated. When a switch turns on, the engine speed is controlled as shown in the table. Thermoswitch Engine temperature sensor Oil pressure sensor On 130 °C (266 °F) or higher (0.
Technical tips Shift cut control This outboard motor is equipped with a shift cut control system for easier shifting. This device misfires and retards the ignition of some cylinders to fluctuate the engine speed instantly when the engine is running from 400 to 2,000 r/min. This allows smooth engagement and/or disengagement of the dog clutch. When shifting, the ignition is shut off as shown in the table.
GEN INFO General information Propeller selection 1 The performance of a boat and outboard motor will be critically affected by the size and type of propeller you choose. Propellers greatly affect boat speed, acceleration, engine life, fuel economy, and even boating and steering capabilities. An incorrect choice could adversely affect performance and could also seriously damage the engine.
Propeller selection / Predelivery checks Predelivery checks 1 To make the delivery process smooth and efficient, the predelivery checks should be completed as explained below. Checking the engine oil level 1. Check the engine oil level. Checking the fuel system 1. Check that the fuel hoses are securely connected and that the fuel tank is full with fuel.
GEN INFO General information Checking the outboard motor mounting height 1. Check that the anti-cavitation plate is aligned with the bottom of the boat. If the mounting height is too high, cavitation will occur and propulsion will be reduced. Also, the engine speed will increase abnormally and cause the engine to overheat. If the mounting height is too low, water resistance will increase and reduce engine efficiency.
Predelivery checks Checking the steering system 1. Check the steering friction for proper adjustment. 2. Check that smoothly. the steering operates Checking the power trim and tilt system 1. Check that the outboard motor tilts up and down smoothly when operating the power trim and tilt unit. 2. Check that there is no abnormal noise produced when the outboard motor is tilted up or down. 3. Check that there is no interference with wires or hoses when the tilted-up outboard motor is steered. 4.
GEN INFO General information Checking the cooling water pilot hole 1. Check that cooling water is discharged from the cooling water pilot hole. a È 0 b 1 c 2 10 S69J1240 È Hour After test run 1. Check for water in the gear oil. Test run 2. Check for fuel leakage in the cowling. 1. Start the engine, and then check that the gear shift operates smoothly. 3. Flush the cooling water passage with fresh water using the flushing kit and with the engine running at idle. 2.
SPEC Specifications General specifications................................................................................... 2-1 Maintenance specification ............................................................................2-3 Power unit..................................................................................................2-3 Lower unit ..................................................................................................2-6 Electrical .......................................
SPEC Specifications General specifications Item Dimension Overall length Overall width Overall height (L) (X) Boat transom height (L) (X) Weight (with aluminium propeller) (L) (X) (with stainless propeller) (L) (X) Performance Maximum output Full throttle operating range Maximum fuel consumption Engine idle speed Power unit Type Cylinder quantity Total displacement Bore × stroke Compression ratio Control system Starting system Fuel system Ignition system Maximum generator output Spark plug Cooling system
General specifications Item Fuel and oil Fuel type Fuel minimum rating Engine oil Engine oil grade Engine oil quantity (without oil filter replacement) (with oil filter replacement) Gear oil type Gear oil grade Gear oil quantity Bracket unit Trim angle (at 12° boat transom) Tilt-up angle Steering angle Drive unit Gear shift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction (rear view) Propeller mark Electrical Battery minimum capacity(*2) CCA/EN 20HR/IEC Unit RO
SPEC Specifications Maintenance specification 2 Power unit Item Power unit Minimum compression pressure(*1) Lubrication oil pressure(*2) Cylinder head Warpage limit (lines indicate straightedge position) Camshaft cap inside diameter Cylinders Bore size Taper limit Out-of-round limit Pistons Piston diameter (D) Measuring point (H) Piston-to-cylinder clearance Piston pin boss bore Piston rings Top ring Dimension B Dimension T End gap Side clearance 2nd piston ring Dimension B Dimension T End gap Side cle
Maintenance specification Item Oil ring Dimension B Dimension T End gap Side clearance Camshafts Intake (A) Exhaust (A) Intake and exhaust (B) Camshaft journal diameter Camshaft journal oil clearance Camshaft runout limit Valves Valve clearance (cold) Intake Exhaust Head diameter (A) Intake Exhaust Face width (B) Intake Exhaust Seat contact width (C) Intake Exhaust Margin thickness (D) Intake Exhaust Stem diameter Intake Exhaust Guide inside diameter Intake and exhaust Stem-to-guide clearance Intake and exh
SPEC Specifications Item Valve lifters Valve lifter outside diameter Valve lifter-to-cylinder head clearance Valve shims Valve shim thickness (in 0.
Maintenance specification Item Oil pump Discharge at 97–103 °C (207–217 °F) with 10W-30 engine oil Pressure Relief valve opening pressure Thermostats Opening temperature Fully open temperature Valve open lower limit Unit Model F150AET FL150AET L (US gal, lmp gal)/min 8.0 (2.113, 1.760) at 700 r/min kPa (kgf/cm2, psi) kPa (kgf/cm2, psi) 132.0–162.0 (1.32–1.62, 19.1–23.5) °C (°F) °C (°F) mm (in) 58–62 (136–144) 70 (158) 4.3 (0.17) 392–490 (3.92–4.90, 56.84–71.
SPEC Specifications Electrical Item Ignition and ignition control system Ignition timing (cylinder #1) Spark plug gap Ignition coil resistance Primary coil (R – B/W) at 20 °C (68 °F) Secondary coil at 20 °C (68 °F) ECM output peak voltage (B/O, B/W – B) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Pulser coil output peak voltage (W/R, W/B – B) at cranking (unloaded) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Pulser coil resistance(*1) (W/R, W/B – B) Pulser
Maintenance specification Item Starter motor Type Output Cranking time limit Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit Charging system Fuse Stator coil output peak voltage (G – G) at cranking (unloaded) at 1,500 r/min (unloaded) at 3,500 r/min (unloaded) Stator coil resistance(*1) at 20 °C (68 °F) (G – G) Rectifier Regulator output peak voltage (R – B) at 1,500 r/min (unloaded) at 3,500 r/min (unloaded) Power trim and tilt system Trim sensor
SPEC Specifications Dimensions Exterior 660 (26.0) 35˚ 256 (10.1) 433 (17.0) mm (in) L: 1,032 (40.7) X: 1,148 (45.2) 629 (24.8) 164 (6.5) 698 (27.5) ˚ L: 60 X: 80 (2.4) (3.1) L: 787 (31.0) X: 864 (34.0) 162(6.4) 66 16 (0.6) 45 (1.8) 455 (17.9) 769 (30.1) 210 (8.3) L: 516 (20.3) X: 643 (25.3) L: 946 (37.2) X: 1,073 (42.2) 915 (36.0) 75 (3.0) 27(1.1) 1 2˚ L: 35 (1.4) X: 43 (1.7) 4˚ 646 (25.
Maintenance specification Clamp bracket mm (in) 1 2 3 4 5 6 7 8 9 180 (7.1) 180 (7.1) 163.5 (6.4) 50.8 (2.0) 163.5 (6.4) 55.5 (2.2) 254 (10.0) 367 (14.4) 13 (0.5) 18.5 (0.7) 82 (3.2) 13 (0.5) 125.4 (4.9) 125.4 (4.
SPEC Specifications Tightening torques 2 Specified torques Part to be tightened Thread size Fuel system Fuel filter holder bolt Fuel filter bracket bolt Fuel pump mounting bolt Fuel pump screw Fuel cooler bolt Vapor separator mounting bolt Fuel rail mounting bolt Throttle body mounting bolt Power unit Power unit mounting bolt Apron bolt Apron screw Flywheel magnet nut Starter motor bolt Starter motor terminal nut Starter relay lead bolt Ignition coil bolt Oil filter PTT relay nut PTT motor lead bolt P
Tightening torques Part to be tightened Exhaust cover bolt Thermostat cover bolt Thread size 1st 2nd 1st 2nd Oil filter union bolt 1st 2nd 1st 2nd Oil pump screw Crankcase bolt Main bearing cap bolt Connecting rod cap Lower unit (regular rotation model) Gear oil drain screw Gear oil check screw Lower case mounting bolt Trim tab bolt Propeller nut Ring nut Cooling water inlet cover screw Pinion nut Lower unit (counter rotation model) Gear oil drain screw Gear oil check screw Lower case mounting bolt Trim
SPEC Specifications Part to be tightened Muffler assembly bolt Engine oil drain bolt Baffle plate screw Muffler bolt Exhaust manifold bolt Oil pan bolt Oil strainer bolt Upper mounting nut Lower mounting nut Trim stopper nut Self-locking nut Trim sensor cam screw Grease nipple Power trim and tilt unit Reservoir cap Reservoir mounting bolt PTT motor mounting bolt Gear pump cover bolt Gear pump housing mounting bolt Manual valve Trim cylinder end screw Tilt cylinder end screw Tilt piston nut Thread size M8
CHK ADJ Periodic checks and adjustments Special service tools .....................................................................................3-1 Maintenance interval chart............................................................................3-2 Top cowling .................................................................................................... 3-3 Checking the top cowling...........................................................................3-3 Fuel system ......................
CHK ADJ Periodic checks and adjustments Special service tools 3 Oil filter wrench 90890-06830 Digital tachometer 90890-06760 Timing light 90890-03141 Leakage tester 90890-06840 3-1 63P3F11
Special service tools / Maintenance interval chart Maintenance interval chart 3 Use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor.
CHK ADJ Periodic checks and adjustments Top cowling 3 Checking the top cowling 1. Check the fitting by pushing the cowling with both hands. Adjust if necessary. S63P3030 Fuel system 3 Checking the fuel joint and fuel hoses (fuel joint-to-fuel injector) 2. Loosen the bolts 1. 3. Move the hook 2 up or down slightly to adjust its position. 1. Remove the spark plug wire cover. 2. Check the low-pressure fuel hose connections and fuel joints for leaks. Replace if necessary.
Top cowling / Fuel system / Power unit Changing the engine oil using an oil changer 1. Start the engine, warm it up, and then turn it off. 2. Remove the engine oil dipstick and oil filler cap 1. NOTE: Be sure not to spill any fuel when removing the fuel filter cup. Power unit 3 Checking the engine oil 1. Place the outboard motor in an upright position. 3. Insert the tube of the oil changer 2 into the dipstick guide 3. 2.
CHK ADJ Periodic checks and adjustments 6. Install the oil filler cap and dipstick, and then start the engine and warm it up for 5 minutes. 7. Turn the engine off, and then check the oil level and correct it if necessary. Changing the engine oil by draining it 1. Start the engine, warm it up, and then turn it off. 2. Remove the engine oil dipstick and oil filler cap 1.
Power unit a E b S63P3040 Replacing the timing belt S63P3100 T. R. Oil filter: 18 N·m (1.8 kgf·m, 13.3 ft·lb) 5. Pour the specified amount of the recommended engine oil into the oil filler hole. Recommended engine oil: 4-stroke motor oil API: SE, SF, SG, SH, or SJ SAE: 10W-30 or 10W-40 Oil quantity: With oil filter replacement: 5.4 L (5.7 US qt, 4.8 Imp qt) 6. Install the oil filler cap and dipstick, and then start the engine and warm it up for 5 minutes.
CHK ADJ Periodic checks and adjustments 4. Check the spark plug gap a. Adjust if out of specification. 3. Suspend the thermostat in a container of water. 4. Place a thermometer in the water and slowly heat the water. Specified spark plug: LFR5A-11 (NGK) Spark plug gap a: 1.0–1.1 mm (0.039–0.043 in) 5. Install the spark plugs, tighten them finger tight b, then to the specified torque using a spark plug wrench c. S69J5E40 5. Check the thermostat valve opening at the specified water temperatures.
Power unit / Control system Checking the cooling water passage 1. Check the cooling water inlet cover 1 and cooling water inlet for clogs. Clean if necessary. 1 S63P3140 Digital tachometer: 90890-06760 1 Engine idle speed: 700 ± 50 r/min 1 Adjusting the throttle link and throttle cable S60V3130 2. Place the lower unit in water, and then start the engine. 3. Check for water flow at the cooling water pilot hole. If there is no water flow, check the cooling water passage inside the outboard motor.
CHK ADJ Periodic checks and adjustments 4. Turn throttle lever 1 7 and the throttle cam 8 counterclockwise so that they are in the positions shown in the illustration. a 7 8 0 A S63P3160 5. Check that the throttle valves are fully closed, and then adjust the throttle link rod joint to align its hole with the ball joint 9 on throttle lever 1. S63P3180 NOTE: If there is no clearance, loosen the locknut 4 and the throttle link rod joint one turn, and then repeat steps 6 and 8. 9 9.
Control system 10. Contact the stopper 0 on the throttle lever 2 to the fully closed stopper A on the cylinder block and check that throttle cam roller B is aligned with the alignment mark c. Adjusting the throttle link and throttle cable operation (using a thickness gauge) 1. Remove the intake silencer. 2. Loosen the locknut 1, remove the clip 2, and then disconnect the throttle cable joint 3. B 3.
CHK ADJ Periodic checks and adjustments 5. Operate throttle lever 2 to check that the throttle valves fully close and fully open. b d 8 S63P3210 S63P3240 NOTE: The throttle valves are fully open when the throttle cam roller 8 is within the range b shown in the illustration. 6. Contact the stopper 4 on the throttle lever 2 to the fully closed stopper 5 on the cylinder block and check that throttle cam roller 8 is aligned with the alignment mark c.
Control system 1 b a S63P3270 6. Adjust the position of the shift cable joint until its hole is aligned with the set pin. S63P3140 Digital tachometer: 90890-06760 3. Attach the special service tool to spark plug wire #1. c S69J3370 CAUTION: The shift cable joint must be screwed in a minimum of 8.0 mm (0.31 in) c. S63P3280 Timing light: 90890-03141 7. Connect the cable joint, install the clip, and then tighten the locknut. 8.
CHK ADJ Periodic checks and adjustments Power trim and tilt unit 3 Checking the power trim and tilt operation 1. Fully tilt the outboard motor up and down a few times and check the entire trim and tilt range for smooth operation. Check the power trim and tilt fluid level if necessary. NOTE: Be sure to listen to the winding sound of the power trim and tilt motor for smooth operation. WARNING After tilting up the outboard motor, be sure to support it with the tilt stop lever.
Power trim and tilt unit / Lower unit 3. Check the oil for metal and discoloration, and its viscosity. Check the internal parts of the lower case if necessary. 4. Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible. 1 S60V3320 NOTE: If the oil is at the correct level, the oil should overflow out of the check hole when the check screw is removed. 3.
CHK ADJ Periodic checks and adjustments Checking the lower unit for air leakage 1. Remove the check screw 1, and then install the special service tool. S69J3580 General 3 Checking the anodes 1. Check the anodes and trim tab for scales, grease, or oil. Clean if necessary. Leakage tester: 90890-06840 2. Apply the specified pressure to check that the pressure is maintained in the lower unit for at least 10 seconds. CAUTION: Do not over pressurize the lower unit, otherwise the oil seals can be damaged.
Lower unit / General CAUTION: Do not oil, grease, or paint the anodes or the trim tab, otherwise they will be ineffective. 2. Replace the anodes or trim tab if excessively eroded. Checking the battery 1. Check the battery electrolyte level. If the level is at or below the minimum level mark a, add distilled water until the level is between the maximum and minimum level marks. a Batteries generate explosive, hydrogen gas.
CHK ADJ Periodic checks and adjustments NOTE: Apply grease to the grease nipple until it flows from the bushings a. 2. Apply low temperature resistant grease to the areas shown. A S63P3320 A C S63P3340 S60X3090 3. Apply corrosion resistant grease to the areas shown.
FUEL Fuel system Special service tools .....................................................................................4-1 Hose routing ...................................................................................................4-2 Fuel and blowby hoses..............................................................................4-2 Fuel filter, fuel pump, and intake silencer ................................................... 4-3 Checking the fuel pumps ........................................
FUEL Fuel system Special service tools Vacuum/pressure pump gauge set 90890-06756 4 Test harness (3 pins) 90890-06793 Fuel pressure gauge 90890-06786 Digital circuit tester 90890-03174 Vacuum gauge 90890-03159 Digital tachometer 90890-06760 4-1 63P3F11
Special service tools / Hose routing Hose routing 4 Fuel and blowby hoses 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 Blowby hoses Fuel hose (fuel tank-to-fuel filter) Fuel hoses (fuel filter-to-fuel pumps) Fuel hoses (fuel pumps-to-fuel filter) Fuel hose (fuel filter-to-vapor separator) High-pressure fuel hose (vapor separator-to-fuel rail) Fuel hose (pressure regulator-to-fuel cooler) Fuel hose (fuel cooler-to-vapor separator) 63P3F11 4-2
FUEL Fuel system Fuel filter, fuel pump, and intake silencer 4 14 13 12 7 6 11 6 5 10 8 9 4 15 3 2 T. R. 10 N · m (1.0 kgf · m, 7.4 ft · Ib) 1 S63P4070 No.
Fuel filter, fuel pump, and intake silencer 4 A 1 8 7 6 9 4 A 2 8 10 7 5 9 A 9 3 8 7 6 A S63P4080 No.
FUEL Fuel system 4 T. R. 8 N · m (0.8 kgf · m, 5.9 ft · Ib) 7 3 8 4 5 T. 9 R. 8 N · m (0.8 kgf · m, 5.9 ft · Ib) 1 10 2 11 6 12 13 S63P4040 No.
Fuel filter, fuel pump, and intake silencer 4 T. R. 4 N · m (0.4 kgf · m, 3.0 ft · Ib) 1 13 14 11 12 2 10 12 11 15 3 13 14 4 9 6 8 5 7 S63P4050 No.
FUEL Fuel system Checking the fuel pumps 1. Place a drain pan under the fuel hose connections, and then disconnect the fuel hoses from the fuel pumps. 6. Apply the specified positive pressure and check that there is no air leakage. Disassemble the fuel pump if necessary. 2. Connect the special service tool to the fuel pump inlet. 3. Cover the fuel pump outlet with a finger, and then apply the specified positive pressure. Check that there is no air leakage. S63P4110 Specified pressure: 50 kPa (0.
Fuel filter, fuel pump, and intake silencer 2. Push down on the plunger and the diaphragm, turn fuel pump body 1 1 approximately 90° to a position where the pin 2 can be removed easily, and then remove the pin. Assembling a fuel pump NOTE: Clean the parts and soak the valves and the diaphragm in gasoline before assembly to obtain prompt operation of the fuel pumps when starting the engine. 1. Align the plunger and diaphragm installation holes a, and then install the plunger into the diaphragm. 2.
FUEL Fuel system Intake assembly and vapor separator 4 5 6 7 4 3 8 2 T. R. 5 N · m (0.5 kgf · m, 3.7 ft · Ib) 1 9 T. R. 5 N · m (0.5 kgf · m, 3.7 ft · Ib) S63P4010 No.
Intake assembly and vapor separator 4 6 4 8 7 5 17 1 12 13 2 15 14 16 9 3 10 11 S63P4030 No.
FUEL Fuel system 4 T. R. 23 21 14 10 13 N · m (1.3 kgf · m, 9.6 ft · Ib) 22 27 28 26 24 T. R. 13 N · m (1.3 kgf · m, 9.6 ft · Ib) 15 20 11 25 12 16 13 5 3 6 8 29 9 4 32 33 30 17 1 7 31 8 28 2 27 18 19 2 S63P4020 No.
Intake assembly and vapor separator 4 T. R. 23 21 14 10 13 N · m (1.3 kgf · m, 9.6 ft · Ib) 22 27 28 26 24 T. R. 13 N · m (1.3 kgf · m, 9.6 ft · Ib) 15 20 11 25 12 16 13 5 3 6 8 29 9 4 32 33 30 17 1 7 31 8 28 2 27 18 19 2 S63P4020 No.
FUEL Fuel system Measuring the fuel pressure WARNING 1. Remove the cap 1. 2. Connect the fuel pressure gauge to the pressure check valve. 1 S63P4130 Fuel pressure gauge: 90890-06786 • Before measuring the fuel pressure, make sure that the drain screw is tightened securely. • Do not loosen the drain screw while measuring the fuel pressure. Loosening the drain screw can cause fuel to spray out creating a fire hazard.
Intake assembly and vapor separator WARNING • When connecting the fuel pressure gauge, first cover the connection between the gauge and the pressure check valve with a clean, dry rag to prevent fuel from leaking out. • Gently screw in the gauge until it is firmly connected. 4. Start the engine and let it idle. 5. Check that the fuel pressure reduces when vacuum pressure is applied to the pressure regulator. If the fuel pressure does not reduce, replace the pressure regulator.
FUEL Fuel system Reducing the fuel pressure Checking the vapor separator 1. Remove the cap 1. 1. Check the needle valve for bends or wear. Replace if necessary. 2. Cover the pressure check valve a of the fuel rail with a rag, and then press in the pressure check valve a using a thin screwdriver to release the fuel pressure. 1 a 2. Check the float for deterioration. Replace if necessary.
Intake assembly and vapor separator Synchronizing the throttle valves CAUTION: Do not adjust the throttle valve when it is operating properly. Excess adjustment may cause poor engine performance. 1. Remove the caps 1, and then attach the special service tool to the intake manifold as shown. NOTE: For best results, use a vacuum gauge (commercially available), like 2 or 3 shown in the illustration, that has four adapters. 2. Start the engine and warm it up for 5 minutes. 3.
FUEL Fuel system 5. Turn the synchronizing screw 5 so that the vacuum pressure of cylinder #3 or #4 is within 4 kPa (30 mmHg) based on the vacuum pressure of cylinder #1 or #2. 1. Remove the intake silencer. 2. Disconnect the throttle joint link rod 1 from the throttle lever 1. 1 b a 5 S63P4230 Direction a Vacuum pressure is increase. Direction b Vacuum pressure is decrease. S63P4260 3. Check that the throttle valves are in the fully closed position.
Intake assembly and vapor separator NOTE: To measure the output voltage, connect the positive tester probe to the pink wire of the test harness and the negative tester probe to the orange wire of the test harness. 1 Digital circuit tester: 90890-03174 S63P4280 Throttle position sensor output voltage: Pink (P) – Black (B) 0.70 ± 0.02 V 4. Loosen the throttle stop screw 2 and fully close the throttle valves #1 and #2. 2 7. Install the intake silencer. 8.
FUEL Fuel system 12. Install the throttle joint link rod 3 so the throttle cam roller 4 is aligned with the alignment mark a as shown. a 3 4 S63P4290 NOTE: Make sure that the throttle position sensor output voltage does not change when installing the throttle joint link rod. 13. Install the intake silencer. 14. Start the engine and measure the throttle position sensor output voltage. Adjust the throttle position sensor again if out of specification.
Intake assembly and vapor separator — MEMO — 1 2 3 4 5 6 7 8 9 63P3F11 4-20
POWR Power unit Special service tools .....................................................................................5-1 Power unit....................................................................................................... 5-3 Checking the compression pressure .......................................................5-11 Checking the oil pressure ........................................................................5-11 Checking the oil pressure sensor ....................................
Cylinder block ..............................................................................................5-38 Disassembling the cylinder block ............................................................ 5-41 Checking the balancer assembly............................................................. 5-41 Checking the piston diameter .................................................................. 5-41 Checking the cylinder bore ......................................................................
POWR Power unit Special service tools 5 Compression gauge 90890-03160 Flywheel puller 90890-06521 Compression gauge extension 90890-06563 Valve spring compressor 90890-04019 Test harness (3 pins) New: 90890-06869 Current: 90890-06769 Valve spring compressor attachment 90890-06320 Flywheel holder 90890-06522 Oil filter wrench 90890-06830 5-1 Valve guide remover/installer 90890-06801 Valve guide installer 90890-06810 63P3F11
Special service tools Valve guide reamer 90890-06804 1 2 3 4 5 6 7 8 9 Piston ring compressor 90890-05158 Valve seat cutter holder 90890-06316 Valve seat cutter 90890-06324, 90890-06325, 90890-06326, 90890-06327 Needle bearing attachment 90890-06611, 90890-06654 Driver rod L3 90890-06652 63P3F11 5-2
POWR Power unit Power unit 5 T. 1 R. 2 8 N · m (0.8 kgf · m, 5.9 ft · Ib) 13 5 E 7 3 6 12 4 LT E LT 572 572 10 11 T. R. 8 42 N · m (4.2 kgf · m, 31.0 ft · Ib) 14 8 15 16 T. 9 R. 20 N · m (2.0 kgf · m, 14.8 ft · Ib) T. R. 4 N · m (0.4 kgf · m, 3.0 ft · Ib) S63P5560 No.
Power unit 5 No.
POWR Power unit 5 C 1 T. 2 R. 29 N · m (2.9 kgf · m, 21.4 ft · Ib) 8 10 9 9 3 4 8 11 12 5 T. R. 9 N · m (0.9 kgf · m, 6.6 ft · Ib) T. 14 R. 7 6 13 7 N · m (0.7 kgf · m, 5.2 ft · Ib) T. R. 18 N · m (1.8 kgf · m, 13.3 ft · Ib) E T. R. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 5-5 Part name Starter motor Bolt Terminal Nut Cap Bolt Starter motor lead Ignition coil Holder Holder Bracket Holder Bolt Oil filter 4 N · m (0.4 kgf · m, 3.
Power unit 5 3 1 7 3 2 2 4 8 6 4 9 4 5 1 10 13 11 12 7 9 9 10 11 S63P5600 No.
POWR Power unit 5 29 26 2 27 28 24 1 25 3 4 16 22 5 17 23 9 21 20 11 67 6 19 7 8 10 8 18 12 15 13 14 T. R. 4 N · m (0.4 kgf · m, 3.0 ft · Ib) S63P5610 No.
Power unit 5 29 26 2 27 28 24 1 25 3 4 16 22 5 17 23 9 21 20 11 67 6 19 7 8 10 8 18 12 15 13 14 T. R. 4 N · m (0.4 kgf · m, 3.0 ft · Ib) S63P5610 No.
POWR Power unit 5 No.
Power unit 5 No.
POWR Power unit Checking the compression pressure 1. Start the engine, warm it up for 5 minutes, and then turn it off. 2. Remove the engine stop lanyard from the engine stop lanyard switch on the remote control box. 3. Remove the spark plug wire cover and all spark plugs, and then install the special service tools into a spark plug hole. NOTE: • If the compression pressure increases, check the pistons and piston rings for wear. Replace if necessary.
Power unit Checking the oil pressure sensor Checking the valve clearance 1. Connect the test harness (3 pins) to the oil pressure sensor. 1. Remove the flywheel magnet cover and spark plug wire cover. 2. Start the engine and warm it up for 5 minutes. 2. Disconnect the fuel hoses from the fuel pumps. 3. Measure the oil pressure sensor input voltage. Check the wiring harness connection or replace the ECM if out of specification. 3.
POWR Power unit 5. Check the intake valve clearance for cylinders #1 and #2, and exhaust valve clearance for cylinders #1 and #3. Adjust if out of specification. 6. Turn the flywheel magnet 360° clockwise. 7. Check the intake valve clearance for cylinders #3 and #4, and exhaust valve clearance for cylinders #2 and #4. Adjust if out of specification. EX IN 9. Using a hexagon wrench, turn the timing belt tensioner 4 clockwise to push the timing belt, increase strength gradually, and then insert a ø5.
Power unit 1 5 1 5 2 2 4 4 3 3 17. Install the necessary valve shim into the valve lifter. 18. Install the camshafts into the cylinder head with new oil seals. E S63P5100 13. Remove the camshafts. 14. Remove the valve shim 7 from the valve lifter 8 using compressed air. 63P IN E 63P EX M S63P5110 S63P5C70 NOTE: Do not mix the valve train parts. Keep them organized in their proper groups.
POWR Power unit 19. Install the camshaft caps, and then tighten them to the specified torques in two stages and in the sequence shown in the illustration. 21. Check that “I” marks c and d on the driven sprockets are aligned. Adjust if necessary. d c 2 E E 5 5 1 1 4 4 2 2 3 3 1 2 S63P5140 3 4 5 6 7 8 9 10 S63P5120 NOTE: • Install the camshaft caps in the proper position as shown and with the stamped numbers facing upside down.
Power unit NOTE: Do not turn the flywheel magnet counterclockwise. c d 24. Check the valve clearances. Adjust if necessary. 25. Install the spark plugs, and then tighten them to the specified torque. 26. Install the cylinder head cover bolts, and then tighten them to the specified torques in two stages. T. R. Spark plug: 25 N·m (2.5 kgf·m, 18.4 ft·lb) Cylinder head cover bolt: 1st: 8 N·m (0.8 kgf·m, 5.9 ft·lb) 2nd: 8 N·m (0.8 kgf·m, 5.9 ft·lb) 27.
POWR Power unit 4. Remove the flywheel magnet. 6. Using a hexagon wrench, turn the timing belt tensioner 5 clockwise to push the timing belt, increase strength gradually, and then insert a ø5.0 mm (0.2 in) pin 6 into the hole e. NOTE: Leave the pin inserted into the timing belt tensioner until the timing belt has been installed. 7. Remove the timing belt 7 from the driven sprocket side.
Power unit 9. Install a new timing belt 7 from the drive sprocket side with its part number in the upright position, turn the belt a half turn counterclockwise to align it, and then remove the pin 6. 7 6 13. Install the flywheel magnet. S63P5330 CAUTION: CAUTION: • Do not twist, turn inside out, or bend the timing belt beyond the maximum limit of 25 mm (1.0 in) h, otherwise it can be damaged. • Do not get oil or grease on the timing belt.
POWR Power unit 2. Disconnect the battery leads 1. 6 1 S63P5420 S63P5380 3. Disconnect the throttle cable 2 and shift cable 3. 3 7. Disconnect the PTT switch coupler, shift cut switch coupler, neutral switch coupler, cooling water pilot hose, and flushing hose. 8. Remove the apron 7. 2 S63P5390 7 4. Remove the junction box cover, and then disconnect the PTT motor leads 4. S63P5430 9. Remove the power unit by removing the bolts 8. 4 S63P5400 5. Disconnect the fuel hose 5.
Power unit NOTE: Be sure to clean up any oil spills. Oil filter wrench: 90890-06830 Removing the timing belt and sprockets 1. Turn the drive sprocket clockwise and align the “ ” mark a on the plate with the “I” mark b on the cylinder block, and check that “I” marks c and d on the driven sprockets are aligned. c d CAUTION: To prevent damage to the engine or tools, screw in the puller set bolts evenly and completely so that the puller plate is parallel to the flywheel magnet.
POWR Power unit 2. Using a hexagon wrench, turn the timing belt tensioner 1 clockwise to push the timing belt, increase strength gradually, and then insert a ø5.0 mm (0.2 in) pin 2 into the hole e. Checking the timing belt and sprockets 1. Check the interior and exterior of the timing belt for cracks, damage, or wear. Replace if necessary. 3. Remove the timing belt 3 from the driven sprocket side. 3 2 1 e S63P5460 4. Remove the timing belt tensioner. 2.
Power unit T. 2 S1280B b R. a 1 E Drive sprocket bolt: 7 N·m (0.7 kgf·m, 5.2 ft·lb) Timing belt tensioner bolt: 39 N·m (3.9 kgf·m, 28.8 ft·lb) 6. Install the timing belt 5 from the drive sprocket side with its part number in the upright position, turn the belt a half turn counterclockwise to align it, and then remove the pin 6. 5 6 S63P5470 T. R. Driven sprocket bolt: 60 N·m (6.0 kgf·m, 44.3 ft·lb) Cylinder head cover bolt: 1st: 8 N·m (0.8 kgf·m, 5.9 ft·lb) 2nd: 8 N·m (0.8 kgf·m, 5.
POWR Power unit Cylinder head No.
Cylinder head 5 No.
POWR Power unit 5 T. R. 23 N · m (2.3 kgf · m, 17.0 ft · Ib) R. 12 N · m (1.2 kgf · m, 8.9 ft · Ib) 9 T. R. 44 5 45 8 T. 4 6 N · m (0.6 kgf · m, 4.4 ft · lb) 12 N · m (1.2 kgf · m, 8.9 ft · lb) 1 2 17 E 16 R. 7 15 T. 6 23 N · m (2.3 kgf · m, 17.0 ft · Ib) 18 19 20 1 2 21 24 T. 15 N · m (1.5 kgf · m, 11.1 ft · Ib) R. 25 22 4746 A LT 47 46 572 26 32 33 4746 27 28 40 10 E 12 3 30 31 35 29 41 47 46 11 LT A 34 271 47 46 42 36 37 43 E 55 N · m (5.5 kgf · m, 40.
Cylinder head 5 T. R. 23 N · m (2.3 kgf · m, 17.0 ft · Ib) R. 12 N · m (1.2 kgf · m, 8.9 ft · Ib) 9 T. R. 44 5 45 8 T. 4 6 N · m (0.6 kgf · m, 4.4 ft · lb) 12 N · m (1.2 kgf · m, 8.9 ft · lb) 1 2 17 E 16 R. 7 15 T. 6 23 N · m (2.3 kgf · m, 17.0 ft · Ib) 18 19 20 1 2 21 T. R. 24 15 N · m (1.5 kgf · m, 11.1 ft · Ib) 25 22 4746 A LT 47 46 572 26 32 33 4746 27 28 40 10 E 12 3 30 31 35 29 41 47 46 11 LT A 34 271 47 46 42 36 37 43 E 55 N · m (5.5 kgf · m, 40.
POWR Power unit 5 T. R. 23 N · m (2.3 kgf · m, 17.0 ft · Ib) R. 12 N · m (1.2 kgf · m, 8.9 ft · Ib) 9 T. R. 44 5 45 8 T. 4 6 N · m (0.6 kgf · m, 4.4 ft · lb) 12 N · m (1.2 kgf · m, 8.9 ft · lb) 1 2 17 E 16 R. 7 15 T. 6 23 N · m (2.3 kgf · m, 17.0 ft · Ib) 18 19 20 1 2 21 24 T. 15 N · m (1.5 kgf · m, 11.1 ft · Ib) R. 25 22 4746 A LT 47 46 572 26 32 33 4746 27 28 40 10 E 12 3 30 31 35 29 41 47 46 11 LT A 34 271 47 46 42 36 37 43 E 55 N · m (5.5 kgf · m, 40.
Cylinder head Removing the cylinder head 1. Remove the camshaft caps in the sequence shown. 1 5 1 5 2 2 4 4 3 3 4. Remove the intake valve and exhaust valves. S63P5100 2. Remove the camshafts and cylinder head bolts in the sequence shown. B A F E J 0 9G 7 5 C I 4 6 8 NOTE: Be sure to keep the valves, springs, and other parts in the order as they were removed. H 1 2 D 3 S63P5170 CAUTION: Do not scratch or damage the mating surfaces of the cylinder head and cylinder block. 3.
POWR Power unit 2. Measure the valve spring tilt b. Replace if out of specification. Valve stem diameter b: Intake: 5.477–5.492 mm (0.2156–0.2162 in) Exhaust: 5.464–5.479 mm (0.2151–0.2157 in) 4. Measure the valve stem runout. Replace if out of specification. Valve spring tilt limit b: 1.5 mm (0.06 in) Checking the valves 1. Check the valve face for pitting or wear. Replace if necessary. 2. Measure the valve margin thickness a. Replace if out of specification. Valve stem runout: 0.01 mm (0.
Cylinder head 2. Calculate the valve stem-to-valve guide clearance as follows. Replace the valve guide if out of specification. Valve stem-to-valve guide clearance = valve guide inside diameter – valve stem diameter: Intake and exhaust: 0.025–0.058 mm (0.0010–0.0023 in) Valve guide remover/installer: 90890-06801 Valve guide installer: 90890-06810 3. Insert the special service tool into the valve guide 2, and then ream the valve guide. Replacing the valve guides 1.
POWR Power unit Checking the valve seat 1. Eliminate carbon deposits from the valve with a scraper. 2. Apply a thin, even layer of Mechanic’s blueing dye (Dykem) onto the valve seat. 3. Lap the valve slowly on the valve seat with a valve lapper (commercially available) as shown. Valve seat contact width a: Intake: 1.1–1.4 mm (0.043–0.055 in) Exhaust: 1.4–1.7 mm (0.055–0.067 in) 4. Measure the valve seat contact width a where the blueing dye is adhered to the valve face.
Cylinder head b 60˚ S69J5890 S63P5240 b Previous contact width 5. Use a 45° cutter to adjust the contact width of the valve seat to specification. b c a Slag or rough surface 45˚ CAUTION: Do not over cut the valve seat. Be sure to turn the cutter evenly downward at a pressure of 40–50 N (4–5 kgf, 8.8–11 lbf) to prevent chatter marks. 3. Use a 30° cutter to adjust the contact width of the top edge of the valve seat. S69J5900 b Previous contact width c Specified contact width 6.
POWR Power unit 7. If the valve seat contact area is too narrow and situated near the top edge of the valve face, use a 30° cutter to cut the top edge of the valve seat. If necessary, use a 45° cutter to center the area and set its width. CAUTION: Do not get the lapping compound on the valve stem and valve guide. 10. After every lapping procedure, be sure to clean off any remaining lapping compound from the cylinder head and the valve. 11. Check the valve seat contact area of the valve again.
Cylinder head Checking the cylinder head 1. Eliminate carbon deposits from the combustion chambers and check for deterioration. 2. Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in seven directions as shown. Replace if out of specification. 1 2 S63P5180 Camshaft runout limit: 0.03 mm (0.0012 in) S63P5190 3. Measure the camshaft journal diameter c and cylinder head journal inside diameter d. Replace the camshaft and cylinder head if out of specification.
POWR Power unit 2. Install the valve 2, valve spring 3, and valve spring retainer 4 in the sequence shown, and then attach the special service tool. S63P5210 NOTE: Apply engine oil to the valve shims and valve lifters before installation. Installing the cylinder head NOTE: The valve spring can be installed in any direction. Valve spring compressor 5: 90890-04019 Valve spring compressor attachment 6: 90890-06320 3.
Cylinder head 3. Install the camshaft caps, and then tighten the bolts to the specified torques in two stages and in the sequence shown. 2 E E 5 5 1 1 4 4 2 2 3 3 3 4 5 7 8 9 10 R. 2. Install the camshafts into the cylinder head with new oil seals. 2 6 T. Cylinder head bolt (M10): 1st: 19 N·m (1.9 kgf·m, 14.0 ft·lb) 2nd: 37 N·m (3.7 kgf·m, 27.3 ft·lb) 3rd: 90° Cylinder head bolt (M8): 1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb) 2nd: 28 N·m (2.8 kgf·m, 20.
POWR Power unit Removing the exhaust cover Installing the pressure control valve 1. Remove the cover 1 and thermostat 2. 1. Install a new gasket and the pressure control valve, and then tighten the bolts. 2 1 LT S63P3110 572 S63P5670 2. Remove the exhaust cover bolts in the sequence shown. Checking the pressure control valve 1. Remove the pressure control valve. 2. Check the pressure control valve 1 for wear or damage. Replace if necessary. 3. Check the grommet 2 for deformation.
Cylinder head / Cylinder block Cylinder block No.
POWR Power unit 5 No.
Cylinder block 5 T. R. T. R. 30 N · m (3.0 kgf · m, 22.1 ft · Ib) 90˚ 1 2 1 2 30 N · m (3.0 kgf · m, 22.1 ft · Ib) 90˚ 6 3 5 4 1 S1280B 1 E E E 7 2 E 8 E 11 9 17 16 15 13 E 9 9 9 12 14 T. R. 14 N · m (1.4 kgf · m, 10.3 ft · lb) 26 N · m (2.6 kgf · m, 19.2 ft · Ib) 1 2 T. R. E No.
POWR Power unit Disassembling the cylinder block 1. Remove the oil pump. 2. Remove the balancer bolts in the sequence shown. NOTE: • Be sure to keep the bearings in the order as they were removed. • Mark each piston with an identification number a of the corresponding cylinder. • Do not mix the connecting rods and caps. Keep them organized in their proper groups. 5. Remove the main bearing cap bolts in the sequence shown. 3. Remove the crankcase bolts in the sequence shown. 6. Remove the crankshaft.
Cylinder block 3. Calculate the out-of-round limit. Replace the cylinder block if out of specification. Out-of-round limit: D2–D1 (measuring point a) D6–D5 (measuring point c) 0.05 mm (0.0020 in) Checking the piston clearance 1. Replace the piston and piston rings as a set, or the cylinder block, or all parts if out of specification. Piston diameter a: 93.928–93.934 mm (3.6979–3.6982 in) Measuring point b: 5.0 mm (0.20 in) up from the bottom of the piston skirt Piston clearance: 0.075–0.080 mm (0.0030–0.
POWR Power unit 2. Level the piston ring 1 in the cylinder with a piston crown. 3. Check the piston ring end gap d at the specified measuring point. Replace if out of specification. Piston ring groove: Top ring a: 1.23–1.25 mm (0.048–0.049 in) Second ring b: 1.22–1.24 mm (0.048–0.049 in) Oil ring c: 2.51–2.53 mm (0.099–0.100 in) Checking the piston ring side clearance 1. Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification.
Cylinder block Connecting rod big end side clearance a: 0.14–0.31 mm (0.006–0.012 in) Checking the crankshaft 1. Check the teeth of the crankshaft gear for cracks or wear. Replace the crankshaft if necessary. Crankshaft journal diameter a: 51.980–52.000 mm (2.0465–2.0472 in) Crankpin diameter b: 49.980–50.000 mm (1.9677–1.9685 in) Crankpin width c: 22.00–22.10 mm (0.8661–0.8701 in) 3. Measure the crankshaft runout. Replace the crankshaft if out of specification. 2.
POWR Power unit Checking the crankpin oil clearance 1. Clean the bearings and the connecting rod. 2. Install the upper bearing into the connecting rod 1 and the lower bearing into the connecting rod cap 2. NOTE: Install the connecting rod bearings in their original positions. 3. Put a piece of Plastigauge (PG-1) onto the crankpin, parallel to the crankshaft. NOTE: Make sure that the mark a of the connecting rod faces towards the flywheel magnet side of the crankshaft. 5.
Cylinder block Example: T. R. Connecting rod bolt: 1st: 23 N·m (2.3 kgf·m, 17.0 ft·lb) 2nd: 43 N·m (4.3 kgf·m, 31.7 ft·lb) 3rd: 90° 6. Remove the connecting rod cap and measure the width of the compressed Plastigauge (PG-1) on each crankpin. Replace the connecting rod bearing if out of specification. Connecting rod big end inside diameter a Numerical value in table 53.035 mm 35 3. Check the crankpin mark b on the crankshaft. P1 P4 P2 P3 b P1 P2 P3 P4 S63P5530 Crankpin oil clearance: 0.027–0.
POWR Power unit 4. Select the suitable color c for the connecting rod bearing from the table. c c S63P5800 Connecting rod big end inside diameter a 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 80 h 81 82 83 g Crankpin mark b 84 85 NOTE: • Example: If the connecting rod big end inside diameter a is “35” and the crankpin mark b is “81,” then select the bearing colors in “g.
Cylinder block Selecting the crankshaft main bearing 1. When replacing the main bearing, select the suitable bearing as follows. 2. Check the crankshaft journal mark a on the crankshaft and the cylinder block mark b on the cylinder block. J1 J2 J3 J4 J5 NOTE: Do not put the Plastigauge (PG-1) over the oil hole in the main journals of the crankshaft. 5. Install the remaining half of the bearings into the main bearing cap and crankcase. NOTE: Install the main bearings in their original positions.
POWR Power unit 3. Select the suitable color c for the main bearing from the table. c c S63P5850 Cylinder block mark b 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 80 Checking the oil pump 81 Crankshaft journal mark a 82 i 83 84 85 h 86 87 88 g 89 1. Check the gear teeth for cracks or wear and the oil pump case for scratches. Replace the oil pump assembly if necessary. 90 91 Assembling the oil pump f 92 1. Install a new oil seal into the oil pump housing.
Cylinder block T. Screw 8: 4 N·m (0.4 kgf·m, 3.0 ft·lb) R. Assembling the pistons and cylinder block 1. Install the oil ring 1, second ring 2, and top ring 3 onto the pistons with the “RN” mark a of the second ring and the “R” mark a of the top ring facing upward. Needle bearing attachment 3: 90890-06611 Driver rod L3 4: 90890-06652 2. Offset the piston ring end gaps as shown. a #3 3. Install a new oil seal into the oil pump housing.
POWR Power unit 3. Install the upper bearing into the connecting rod 4 and the lower bearing into the connecting rod cap 5. NOTE: Install the connecting rod bearings in their original positions. NOTE: Apply engine oil to the inner oil seal before installation. 4. Install half of the main bearings 6 and the thrust bearing 7 into the cylinder block 8. 6. Install half of the main bearings A into the main bearing cap B. NOTE: Install the main bearings in their original positions.
Cylinder block NOTE: Apply engine oil to the side of the pistons and piston rings before installation. Piston ring compressor: 90890-05158 9. Install the connecting rod caps 5 to the connecting rods, and then tighten the connecting rod bolts to the specified torques in three stages. c NOTE: • Main bearing cap bolts 1–6 can be reused three times. • Apply engine oil to the main bearing cap bolts before installation.
POWR Power unit 10. Install half of the main bearings A into the crankcase. 11. Apply sealant to the mating surface of the crankcase. R. 12. Install the crankcase onto the cylinder block. T. NOTE: • Install the main bearings in their original positions. • Do not get any sealant on the main bearings. NOTE: • Crankcase bolts 1–4 can be reused three times. • Apply engine oil to the crankcase bolts before installation.
Cylinder block 16. Apply sealant to the mating surface of the balancer assembly. NOTE: Do not get any sealant inside the balancer assembly. 18. After installing the balancer assembly onto the crankcase, apply sealant around the periphery of the seals C, and then install them onto the balancer assembly. 19. Align the oil pump gear with the crankshaft, and then install the oil pump D. 17.
POWR Power unit 20. Before installing the oil filter, be sure to fill it with engine oil through the oil passage j of the oil filter bracket. j S63P5B20 T. R. 21. Install the oil filter, and then tighten it to the specified torque using a 72.5 mm (2.9 in) oil filter wrench. Exhaust cover bolt: 1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb) 2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb) 23. Install the thermostat E and cover F.
Cylinder block 6. Connect the fuel hose 8. 3 2 1 1 8 S63P5B80 4 LT 4 572 5 LT 572 LT 572 S63P5B40 7. Connect the PTT motor leads 9, and then install the junction box cover. 9 6 S63P5B90 S63P5B50 R. R. 4. Connect the PTT switch coupler, shift cut switch coupler, neutral switch coupler, cooling water pilot hose, and flushing hose. T. T. Power unit mounting bolt (M8) 4: 20 N·m (2.0 kgf·m, 14.8 ft·lb) Power unit mounting bolt (M10) 5: 42 N·m (4.2 kgf·m, 31.0 ft·lb) Apron bolt: 8 N·m (0.
POWR Power unit 9. Connect the battery leads B. Flywheel holder: 90890-06522 T. R. Flywheel magnet nut: 270 N·m (27.0 kgf·m, 199.1 ft·lb) 13. Install all parts removed during disassembly. B S63P5C10 T. R. Positive battery cable nut: 9 N·m (0.9 kgf·m, 6.6 ft·lb) 10. Install the stator coil assembly. 11. Install the Woodruff key. 12. Install the flywheel magnet. CAUTION: Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily.
Cylinder block — MEMO — 1 2 3 4 5 6 7 8 9 63P3F11 5-58
LOWR Lower unit Special service tools .....................................................................................6-1 Lower unit (regular rotation model) ............................................................. 6-4 Removing the lower unit ............................................................................6-8 Removing the water pump and shift rod.................................................... 6-8 Checking the water pump and shift rod ..............................................
Lower unit (counter rotation model) .......................................................... 6-32 Removing the lower unit ..........................................................................6-36 Removing the water pump and shift rod.................................................. 6-36 Checking the water pump and shift rod ...................................................6-37 Propeller shaft housing (counter rotation model) ....................................
LOWR Lower unit Special service tools 6 Ring nut wrench 4 90890-06512 Bearing separator 90890-06534 Ring nut wrench extension 90890-06513 Stopper guide stand 90890-06538 Bearing housing puller claw L 90890-06502 Bearing puller assembly 90890-06535 Stopper guide plate 90890-06501 Needle bearing attachment 90890-06610, 90890-06612, 90890-06653, 90890-06654 Center bolt 90890-06504 6-1 Driver rod L3 90890-06652 63P3F11
Special service tools Driver rod SS 90890-06604 Bearing outer race puller assembly 90890-06523 Bearing depth plate 90890-06603 Ball bearing attachment 90890-06633, 90890-06636, 90890-06629 Bearing inner race attachment 90890-06640, 90890-06660 Bearing outer race attachment 90890-06619 Drive shaft holder 6 90890-06520 Driver rod LL 90890-06605 Pinion nut holder New: 90890-06715 Current: 90890-06505 Driver rod LS 90890-06606 63P3F11 6-2 1 2 3 4 5 6 7 8 9
LOWR Lower unit Shift rod push arm 90890-06052 Magnet base plate 90890-07003 Pinion height gauge 90890-06710 Dial gauge set 90890-01252 Digital caliper 90890-06704 Magnet base B 90890-06844 Shimming plate 90890-06701 Ring nut wrench 90890-06578 Backlash indicator 90890-06706 Outer race puller claw B 90890-06533 6-3 63P3F11
Special service tools / Lower unit (regular rotation model) Lower unit (regular rotation model) No.
LOWR Lower unit 6 No.
Lower unit (regular rotation model) 6 No.
LOWR Lower unit 6 No.
Lower unit (regular rotation model) Removing the lower unit 1. Drain the gear oil. For draining procedures, see Chapter 3, “Changing the gear oil.” 2. Set the gear shift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller. È X-transom model WARNING • Do not hold the propeller with your hands when loosening or tightening it.
LOWR Lower unit Checking the water pump and shift rod 1. Check the water pump housing for deformation. Replace if necessary. S69J6045 S69J6030 2. Check the impeller 1 and insert cartridge 2 for cracks or wear. Replace if necessary. 1 2 S63P6050 3. Check the Woodruff key 3 and the keyway a in the drive shaft for wear. Replace if necessary. a 3 S69J6040 4. Check the shift rod for cracks or wear. Replace if necessary.
Lower unit (regular rotation model) / Propeller shaft housing (regular rotation model) Propeller shaft housing (regular rotation model) No.
LOWR Lower unit 6 No.
Propeller shaft housing (regular rotation model) Removing the propeller shaft housing assembly 1. Straighten the claw washer tabs a, and then remove the ring nut and claw washer. Disassembling the propeller shaft housing 1. Remove the reverse gear and thrust washer. Ring nut wrench 4 1: 90890-06512 Ring nut wrench extension 2: 90890-06513 2. Pull out the propeller shaft housing assembly.
LOWR Lower unit 2. Remove the ball bearing. Stopper guide plate 5: 90890-06501 Stopper guide stand 6: 90890-06538 Bearing puller assembly 7: 90890-06535 2. Check the teeth and dogs of the reverse gear for cracks or wear. Replace the gear if necessary. S62Y6640 3. Check the bearings for pitting or rumbling. Replace if necessary. 3. Remove the oil seals and needle bearing. S69J6115 Checking the propeller shaft 1. Check the propeller shaft for bends or wear. Replace if necessary.
Propeller shaft housing (regular rotation model) NOTE: • Install the needle bearing with the manufacture identification mark a facing toward the oil seal (propeller side). • When using the driver rod, do not strike the special service tool in a manner that will force the stopper c out of place. Assembling the propeller shaft assembly 1. Install the dog clutch as shown. Driver rod SS 1: 90890-06604 Needle bearing attachment 2: 90890-06610 Bearing depth plate 3: 90890-06603 Depth b: 24.75–25.25 mm (0.974–0.
LOWR Lower unit 3. Install the thrust washer 5 and new ball bearing 6 onto the reverse gear 7 using a press. NOTE: Install the ball bearing with the manufacture identification mark e facing outward (propeller side). Needle bearing attachment 8: 90890-06654 4. Install the reverse gear assembly into the propeller shaft housing using a press.
Propeller shaft housing (regular rotation model) / Drive shaft and lower case (regular rotation model) Drive shaft and lower case (regular rotation model) No.
LOWR Lower unit Removing the drive shaft 1. Remove the drive shaft, drive shaft housing, and pinion, and then pull out the forward gear. 1 1 S69J6186 2 S68S6360J Drive shaft holder 6 1: 90890-06520 Pinion nut holder 2: New: 90890-06715 Current: 90890-06505 Disassembling the drive shaft housing CAUTION: Do not reuse the bearing, always replace it with a new one. Bearing separator 1: 90890-06534 2. Remove the needle bearings from the forward gear using a chisel. 1.
Drive shaft and lower case (regular rotation model) NOTE: Install the claws as shown. Bearing outer race puller assembly 1: 90890-06523 2. Remove the needle bearing. Checking the drive shaft 1. Check the drive shaft for bends or wear. Replace if necessary. Ball bearing attachment 2: 90890-06636 Driver rod LL 3: 90890-06605 Checking the pinion and forward gear 1. Check the teeth of the pinion, and the teeth and dogs of the forward gear for cracks or wear. Replace if necessary.
LOWR Lower unit Assembling the lower case 1. Install the original shim(s) and taper roller bearing outer race. NOTE: Apply gear oil or grease to the needle bearing before installation. Assembling the forward gear 1. Install new needle bearings into the forward gear to the specified depth. CAUTION: Add or remove shim(s), if necessary, if replacing the forward gear or lower case. Bearing outer race attachment 1: 90890-06619 Driver rod LL 2: 90890-06605 2.
Drive shaft and lower case (regular rotation model) 2. Install the drive shaft housing 1, thrust bearing 2, and original shim(s) 3 onto the drive shaft 4. Needle bearing attachment 1: 90890-06610 Driver rod SS 2: 90890-06604 Bearing depth plate 3: 90890-06603 Depth a: 5.75–6.25 mm (0.226–0.246 in) 2. Apply grease to a new oil seals, and then install them into the drive shaft housing to the specified depth. CAUTION: Add or remove shim(s), if necessary, if replacing the drive shaft housing or drive shaft.
LOWR Lower unit Installing the propeller shaft housing 1. Install the washer 1 and propeller shaft assembly 2 into the propeller shaft housing assembly 3. 2. Apply grease to a new O-ring, and then install it onto the propeller shaft housing. NOTE: • To secure the ring nut, bend one tab a of the claw washer into a slot in the ring nut. • Bend all other tabs toward the propeller shaft housing assembly. Ring nut wrench 4 9: 90890-06512 Ring nut wrench extension 0: 90890-06513 T. R. 3.
Drive shaft and lower case (regular rotation model) NOTE: • The collar and spacer should fit together firmly. • While pulling the drive shaft up, install the collar with an appropriate tool a that fits over the drive shaft as shown. 6. Install the new O-ring A and insert cartridge B into the pump housing C. C A c b A B b c 3. Install the Woodruff key into the drive shaft. 4. Align the groove in the impeller 5 with the Woodruff key 6, and then install the impeller onto the drive shaft.
LOWR Lower unit 7. Install the new O-ring D and pump housing assembly E into the lower case, tighten the bolts F, and then install the seal G and cover H. Shift rod push arm: 90890-06052 3. Install the two dowels 1 into the lower unit. 4. Install the lower unit into the upper case, and then tighten the lower case mounting bolts 2 to the specified torque.
Drive shaft and lower case (regular rotation model) T. R. 6. Install the propeller and propeller nut, and then tighten the nut finger tight. Place a block of wood between the anticavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque. Propeller nut 5: 52 N·m (5.2 kgf·m, 38.4 ft·lb) 1 2 3 4 5 6 7 8 9 WARNING • Do not hold the propeller with your hands when loosening or tightening it.
LOWR Lower unit Shimming (regular rotation model) 6 F P R B4 T3 A3 B3 61.0 T1 T2 B1 37.0 16.
Shimming (regular rotation model) Shimming T. R. NOTE: • Shimming is not required when assembling the original lower case and inner parts. • Shimming is required when assembling the original inner parts and a new lower case. • Shimming is required when replacing the inner part(s). Pinion nut: 93 N·m (9.3 kgf·m, 68.6 ft·lb) 3. Measure the distance (M4) between the special service tool and the pinion as shown. Selecting the pinion shims 1. Install the special service tools onto the drive shaft 1.
LOWR Lower unit 5. Calculate the pinion shim thickness (T3) as shown in the examples below. Example: If “T3” is 0.53 mm, then the pinion shim is 0.52 mm. If “T3” is 0.78 mm, then the pinion shim is 0.75 mm. Selecting the forward gear shims 1. Turn the taper roller bearing outer race 1 two or three times to seat the rollers, and then measure the bearing height (M1) as shown. NOTE: “P” is the deviation of the lower case dimension from standard.
Shimming (regular rotation model) Selecting the reverse gear shims 1. Install the ball bearing, thrust washer, and reverse gear onto the propeller shaft housing. 2. Measure the gear height (M2) from the thrust washer on the propeller shaft housing. NOTE: “F” is the deviation of the lower case dimension from standard. The “F” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units.
LOWR Lower unit 3. Calculate the reverse gear shim thickness (T2) as shown in the examples below. Example: If “T2” is 0.77 mm, then the reverse gear shim is 0.78 mm. If “T2” is 0.79 mm, then the reverse gear shim is 0.80 mm. Backlash (regular rotation model) 6 Measuring the forward and reverse gear backlash 1. Remove the water pump assembly. NOTE: “R” is the deviation of the lower case dimension from standard. The “R” mark a is stamped on the trim tab mounting surface of the lower case in 0.
Shimming (regular rotation model) / Backlash (regular rotation model) Bearing housing puller claw L 1: 90890-06502 Stopper guide plate 2: 90890-06501 Center bolt 3: 90890-06504 4. Install the backlash indicator onto the drive shaft (22.4 mm [0.88 in] in diameter), then the dial gauge onto the lower unit. 5. Set the lower unit upside down. Forward gear backlash Shim thickness Less than 0.14 mm (0.0055 in) To be decreased by (0.30 – M) × 0.67 More than 0.46 mm (0.0181 in) To be increased by (M – 0.
LOWR Lower unit 10. Slowly turn the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction. Reverse gear backlash: 0.32–0.67 mm (0.0126–0.0264 in) 11. Add or remove shim(s) if out of specification. Reverse gear backlash Shim thickness Less than 0.32 mm (0.0126 in) To be increased by (0.50 – M) × 0.67 More than 0.67 mm (0.0264 in) To be decreased by (M – 0.50) × 0.67 M: Measurement Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.
Backlash (regular rotation model) / Lower unit (counter rotation model) Lower unit (counter rotation model) No.
LOWR Lower unit 6 No.
Lower unit (counter rotation model) 6 No.
LOWR Lower unit 6 No.
Lower unit (counter rotation model) Removing the lower unit 1. Drain the gear oil. For draining procedures, see Chapter 3, “Changing the gear oil.” 2. Set the gear shift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller. È X-transom model WARNING • Do not hold the propeller with your hands when loosening or tightening it.
LOWR Lower unit Checking the water pump and shift rod 1. Check the water pump housing for deformation. Replace if necessary. S69J6360 S69J6030 2. Check the impeller 1 and insert cartridge 2 for cracks or wear. Replace if necessary. 1 2 S63P6050 3. Check the Woodruff key 3 and the keyway a in the drive shaft for wear. Replace if necessary. a 3 S69J6040 4. Check the shift rod for cracks or wear. Replace if necessary.
Lower unit (counter rotation model) / Propeller shaft housing (counter rotation model) Propeller shaft housing (counter rotation model) No.
LOWR Lower unit 6 No.
Propeller shaft housing (counter rotation model) Removing the propeller shaft housing assembly 1. Straighten the claw washer tabs a, and then remove the ring nut and claw washer. 1 2 3 S63P6500 Disassembling the forward gear Ring nut wrench 4 1: 90890-06512 Ring nut wrench extension 2: 90890-06513 2. Pull out the propeller shaft housing assembly. 1. Remove the bearing outer race, taper roller bearing, and thrust washer from the forward gear.
LOWR Lower unit Disassembling the propeller shaft housing 3. Check the bearings for pitting or rumbling. Replace if necessary. 1. Remove the oil seals and needle bearing. S69J6410 Checking the propeller shaft Needle bearing attachment 1: 90890-06653 Driver rod L3 2: 90890-06652 1. Check the propeller shaft for bends or wear. Replace if necessary. Checking the propeller shaft housing 1. Clean the propeller shaft housing using a soft brush and cleaning solvent, and then check it for cracks or damage.
Propeller shaft housing (counter rotation model) Depth d: 4.75–5.25 mm (0.187–0.207 in) 3. Install the original shim(s) 5 and thrust bearing 6 with the propeller shaft into the propeller shaft housing. 5 6 NOTE: • Install the needle bearing with the manufacture identification mark a facing toward the oil seal (propeller side). • When using the driver rod, do not strike the special service tool in a manner that will force the stopper c out of place.
LOWR Lower unit 5. Install the thrust washer 0, forward gear A, and dog clutch B using a press. NOTE: Install the dog clutch B with the “F” mark e facing toward the forward gear. Ring nut wrench 9: 90890-06578 6. Install the spring C, balls, and shift slider D into the propeller shaft, and then install the cross pin E and spring F.
Propeller shaft housing (counter rotation model) / Drive shaft and lower case (counter rotation model) Drive shaft and lower case (counter rotation model) No.
LOWR Lower unit 6 No.
Drive shaft and lower case (counter rotation model) Removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the reverse gear and thrust bearing. 1 1 S67H6270R 2 Bearing separator 1: 90890-06534 S68S6360J Drive shaft holder 6 1: 90890-06520 Pinion nut holder 2: New: 90890-06715 Current: 90890-06505 2. Remove the needle bearings from the reverse gear using a chisel. Disassembling the drive shaft housing 1. Remove the cover, oil seals, and needle bearing.
LOWR Lower unit 2. Remove the needle bearing from the lower case. S69J6210 Checking the lower case Ball bearing attachment 3: 90890-06636 Driver rod LL 4: 90890-06605 1. Check the skeg and torpedo for cracks or damage. Replace the lower case if necessary. Checking the pinion and reverse gear 1. Check the teeth of the pinion, and the teeth and dogs of the reverse gear for cracks or wear. Replace if necessary. Assembling the lower case 1.
Drive shaft and lower case (counter rotation model) 2. Install the needle bearing outer case into the lower case. Depth a: 20.95–21.45 mm (0.825–0.844 in) Depth b: 4.45–4.95 mm (0.175–0.195 in) 2. Install the roller bearing inner race into the reverse gear using a press. NOTE: Apply gear oil to the needle bearing outer case before installation. Ball bearing attachment 3: 90890-06633 Bearing outer race puller assembly 4: 90890-06523 3. Install the needle bearing into the needle bearing outer case.
LOWR Lower unit 2. Apply grease to new oil seals, and then install them into the drive shaft housing to the specified depth. 3. Install the sleeve, drive shaft, and drive shaft housing into the lower case, then the pinion and pinion nut, and then tighten the nut to the specified torque. 5 6 S63P6310 NOTE: Install an oil seal halfway into the drive shaft housing, then the other oil seal.
Drive shaft and lower case (counter rotation model) CAUTION: Add or remove shim(s), if necessary, if replacing the forward gear, taper roller bearing, propeller shaft housing, thrust washer, or lower case. 2. Tighten the ring nut to the specified torque. NOTE: • To secure the ring nut, bend one tab a of the claw washer into a slot in the ring nut. • Bend all other tabs toward the propeller shaft housing assembly. 2. Install a new gasket 2, the outer plate cartridge 3, and dowels 4.
LOWR Lower unit 3. Install the Woodruff key into the drive shaft. 4. Align the groove in the impeller 5 with the Woodruff key 6, and then install the impeller onto the drive shaft. NOTE: Align the insert cartridge projections b with the holes c in the pump housing. 7. Install the new O-ring D and pump housing assembly E into the lower case, tighten the bolts F, and then install the seal G and cover H. 5. Install the washers 7, wave washer 8, spacer 9, and collar 0 onto the drive shaft.
Drive shaft and lower case (counter rotation model) Installing the lower unit 1. Set the gear shift to the neutral position at the lower unit. 1 2 3 4 5 6 7 8 9 2. Align the center of the set pin a with the mark b on the bottom cowling. b a S63P3270 È X-transom model T. R. Lower case mounting bolt 2: 47 N·m (4.7 kgf·m, 34.7 ft·lb) Trim tab bolt 4: 42 N·m (4.2 kgf·m, 31.0 ft·lb) Shift rod push arm: 90890-06052 3. Install the two dowels 1 into the lower unit. 4.
LOWR Lower unit T. R. 6. Install the propeller and propeller nut, and then tighten the nut finger tight. Place a block of wood between the anticavitation plate and propeller to keep the propeller from turning, and then tighten the nut to the specified torque. Propeller nut 5: 52 N·m (5.2 kgf·m, 38.4 ft·lb) WARNING • Do not hold the propeller with your hands when loosening or tightening it.
Drive shaft and lower case (counter rotation model) / Shimming (counter rotation model) Shimming (counter rotation model) 6 F P 1 2 3 4 5 6 7 8 9 R B4 T3 A3 B3 61.0 T1 T2 T4 B1 36.5 B2 A1 16.
LOWR Lower unit Shimming T. R. NOTE: • Shimming is not required when assembling the original lower case and inner parts. • Shimming is required when assembling the original inner parts and a new lower case. • Shimming is required when replacing the inner part(s). Pinion nut: 93 N·m (9.3 kgf·m, 68.6 ft·lb) 3. Measure the distance (M4) between the special service tool and the pinion as shown. Selecting the pinion shims 1. Install the special service tools onto the drive shaft 1.
Shimming (counter rotation model) Selecting the reverse gear shims 1. Turn the thrust bearing 1 two or three times to seat the roller bearing 2, and then measure the bearing height (M1) as shown. NOTE: “P” is the deviation of the lower case dimension from standard. The “P” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the “P” mark is unreadable, assume that “P” is zero and check the backlash when the unit is assembled.
LOWR Lower unit 2. Calculate the reverse gear shim thickness (T1) as shown in the examples below. Example: If “T1” is 0.90 mm, then the reverse gear shim is 0.88 mm. If “T1” is 1.15 mm, then the reverse gear shim is 1.12 mm. Selecting the forward gear shims 1. Install the thrust washer 1 and taper roller bearing 2 onto the forward gear. NOTE: “F” is the deviation of the lower case dimension from standard. The “F” mark a is stamped on the trim tab mounting surface of the lower case in 0.01 mm units.
Shimming (counter rotation model) Shimming plate 3: 90890-06701 Digital caliper 4: 90890-06704 3. Calculate the forward gear shim thickness (T2) as shown in the examples below. Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm Example: If “T2” is 0.33 mm, then the forward gear shim is 0.35 mm. If “T2” is 0.79 mm, then the forward gear shim is 0.80 mm. Selecting the propeller shaft shims 1.
LOWR Lower unit 2. Install the thrust bearing 4 onto the propeller shaft 5, and then measure the propeller shaft flange and thrust bearing thickness (M7) as shown. 3. Calculate the propeller shaft shim thickness (T4) as shown in the examples below. 4. Round the numerals for the propeller shaft shim(s) (T4) as follows. Calculated numeral at 1/100 place Rounded numeral 1, 2 0 3, 4, 5 2 6, 7, 8 5 9, 10 8 Example: If “T4” is 0.94 mm, then the propeller shaft shim is 0.92 mm. If “T4” is 1.
Shimming (counter rotation model) / Backlash (counter rotation model) 8. Measure the propeller shaft free play. Repeat steps 1–7 if out of specification. NOTE: Tighten the center bolt while turning the drive shaft until the drive shaft can no longer be turned. Propeller shaft free play: 0.25–0.35 mm (0.0098–0.
LOWR Lower unit 5. Set the lower unit upside down. 8. Remove the special service tools from the propeller shaft. 9. Install the propeller 8, the spacer 9 (without the washer 0), then the washer A as shown. NOTE: Install the dial gauge so that the plunger a contacts the mark b on the backlash indicator. Backlash indicator 4: 90890-06706 Magnet base plate 5: 90890-07003 Dial gauge set 6: 90890-01252 Magnet base B 7: 90890-06844 6.
Backlash (counter rotation model) Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm 17. Remove the special service tools, and then install the water pump assembly. 14. Turn the shift rod to the reverse position c with the shift rod push arm. 15. Slowly turn the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction.
LOWR Lower unit — MEMO — 6-63 63P3F11
BRKT Bracket unit Special service tools .....................................................................................7-1 Bottom cowling .............................................................................................. 7-2 Upper case, steering arm, swivel bracket and clamp brackets ................. 7-6 Draining the engine oil............................................................................. 7-12 Disassembling the oil pan.......................................................
BRKT Bracket unit Special service tools 7 Up relief fitting 90890-06773 Down relief fitting 90890-06774 Hydraulic pressure gauge 90890-06776 Trim and tilt wrench New: 90890-06587 Current: 90890-06548 7-1 63P3F11
Special service tools / Bottom cowling Bottom cowling 7 11 12 A 13 10 3 7 4 5 6 A 16 14 A 7 34 9 2 17 A 33 15 20 18 24 19 1 8 A 21 22 28 23 25 26 27 32 A T. R. T. R. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 3 N · m (0.3 kgf · m, 2.2 ft · Ib) 31 18 N · m (1.8 kgf · m, 13.
BRKT Bracket unit 7 11 12 A 13 10 3 7 4 5 6 A 16 14 A 7 34 9 2 17 A 33 15 20 18 24 19 1 8 A 21 22 28 23 25 26 27 32 A T. R. T. R. No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 7-3 3 N · m (0.3 kgf · m, 2.2 ft · Ib) 31 18 N · m (1.8 kgf · m, 13.
Bottom cowling 7 34 31 30 22 29 23 20 24 19 26 25 27 28 21 A 15 14 13 18 32 A 11 4 5 LT 572 12 9 17 9 16 33 10 6 1 3 7 8 2 S63P7070 No.
BRKT Bracket unit 7 34 31 30 22 29 23 20 24 19 26 25 27 28 21 A 15 14 13 18 32 A 11 4 5 LT 572 12 9 17 9 16 33 10 6 1 3 7 8 2 S63P7070 No.
Bottom cowling / Upper case, steering arm, swivel bracket and clamp brackets Upper case, steering arm, swivel bracket and clamp brackets No.
BRKT Bracket unit 7 No.
Upper case, steering arm, swivel bracket and clamp brackets 7 T. R. 54 N · m (5.4 kgf · m, 39.8 ft · Ib) 16 LT 572 30 T. R. 4 N · m (0.4 kgf · m, 3.0 ft · Ib) T. R. 20 N · m (2.0 kgf · m, 14.8 ft · Ib) 22 17 2120 19 18 5 T. R. 6 A 23 LT 27 N · m (2.7 kgf · m, 20.0 ft · Ib) T. R. 42 N · m (4.2 kgf · m, 31.0 ft · Ib) 271 24 3 LT LT 572 572 2 1 25 9 10 12 13 7 15 11 28 29 27 4 26 14 A 8 S63P7100 No.
BRKT Bracket unit 7 T. R. 54 N · m (5.4 kgf · m, 39.8 ft · Ib) 16 LT 572 30 T. R. 4 N · m (0.4 kgf · m, 3.0 ft · Ib) T. R. 20 N · m (2.0 kgf · m, 14.8 ft · Ib) 22 17 2120 19 18 5 T. R. 6 A 23 LT 27 N · m (2.7 kgf · m, 20.0 ft · Ib) T. R. 42 N · m (4.2 kgf · m, 31.0 ft · Ib) 271 24 3 LT LT 572 572 2 1 25 9 10 12 13 7 15 11 28 29 27 4 26 14 A 8 S63P7100 No.
Upper case, steering arm, swivel bracket and clamp brackets 7 20 11 LT 10 572 9 T. R. 20 N · m (2.0 kgf · m, 14.8 ft · Ib) 8 19 A T. R. 10 N · m (1.0 kgf · m, 7.4 ft · Ib) 18 7 6 16 15 17 14 4 12 13 3 5 LT A 572 2 T. R. 20 N · m (2.0 kgf · m, 14.8 ft · Ib) T. R. No.
BRKT Bracket unit 7 20 11 LT 10 572 9 T. R. 20 N · m (2.0 kgf · m, 14.8 ft · Ib) 8 19 A T. R. 10 N · m (1.0 kgf · m, 7.4 ft · Ib) 18 7 6 16 15 17 14 4 12 13 3 5 LT A 572 2 T. R. 20 N · m (2.0 kgf · m, 14.8 ft · Ib) T. R. No. 18 19 20 7-11 Part name Gasket Gasket Exhaust guide Q’ty 1 1 1 20 N · m (2.0 kgf · m, 14.
Upper case, steering arm, swivel bracket and clamp brackets Draining the engine oil 1. Place a drain pan under the drain hole, and then remove the drain bolt 1 and let the oil drain completely. 5 6 2. Remove the upper and lower mounting nut, and then remove the upper case. 4 S63P7160 3. Remove the muffler assembly from the upper case. Checking the oil strainer Disassembling the oil pan 1. Check the oil strainer for dirt and residue. Clean if necessary. 1.
BRKT Bracket unit T. R. Oil strainer bolt: 10 N·m (1.0 kgf·m, 7.4 ft·lb) 3. Install the oil pan 4, and then tighten the bolts finger tight. 8 0 4. Install the exhaust manifold 5 and bolts, and then tighten the bolts finger tight. 5. Tighten the exhaust manifold bolts 6, then the oil pan bolts 7, and then tighten them to the specified torques. LT 572 9 A A 4 7 S63P7200 6 5 T. R. LT LT 572 572 Muffler bolt: 20 N·m (2.0 kgf·m, 14.8 ft·lb) 9.
Upper case, steering arm, swivel bracket and clamp brackets T. R. Muffler assembly bolt C: 20 N·m (2.0 kgf·m, 14.8 ft·lb) Muffler assembly bolt D: 42 N·m (4.2 kgf·m, 31.0 ft·lb) 11. Install the upper mounts E and bolts into the upper case. 12. Install the bracket F and bolts, and then tighten the bolts to the specified torque. T. R. Upper mount bracket bolt: 54 N·m (5.4 kgf·m, 39.8 ft·lb) 3. Remove the steering arm from the swivel bracket by pulling the arm off the bracket.
BRKT Bracket unit 4. Install the steering yoke 9 to the steering arm 3 by aligning the center a of the yoke with the center b of the steering arm. Installing the upper case 5. Install the circlip 0. 2. Install the upper mounting nut 2 and lower mounting nut 3, and then tighten them to the specified torques. 1. Install the upper and lower mounting bolts into the swivel bracket 1 simultaneously. 3. Install the covers 4. 6.
Upper case, steering arm, swivel bracket and clamp brackets / Clamp brackets Clamp brackets No.
BRKT Bracket unit 7 No.
Clamp brackets Removing the clamp brackets T. R. 1. Remove the power trim and tilt unit. For removal procedures, see “Removing the power trim and tilt unit.” Self-locking nut: 15 N·m (1.5 kgf·m, 11.1 ft·lb) 5. Install the power trim and tilt unit, then the anode. 2. Remove the anode. 3. Remove the bolt and grease nipples, and then disconnect the ground leads. NOTE: Install the ground lead between the power trim and tilt unit and the anode. 4. Remove the self-locking nut and bolt. 5.
BRKT Bracket unit 2 Trim sensor resistance: Pink (P) – Black (B) 238.8–378.8 Ω at 20 °C (68 °F) B Gy P 1 S60X7160 Trim sensor setting resistance: Pink (P) – Black (B) 9–11 Ω at 20 °C (68 °F) T. R. Trim sensor cam screw 1: 2 N·m (0.2 kgf·m, 1.5 ft·lb) 4. Fully tilt the outboard motor up, and then support it with the tilt stop lever 3. 3 S60X7170 WARNING After tilting up the outboard motor, be sure to support it with the tilt stop lever.
Clamp brackets / Power trim and tilt unit Power trim and tilt unit 2 7 A 5 3 A 9 9 4 1 8 7 6 7 9 6 9 A A A 11 10 LT 242 S60X7010 No.
BRKT Bracket unit 7 7 1 T. R. 0.7 N · m (0.07 kgf · m, 0.5 ft · lb) T. 8 R. 5 N · m (0.5 kgf · m, 3.7 ft · Ib) 2 9 3 10 4 5 6 T. R. 5 N · m (0.5 kgf · m, 3.7 ft · Ib) S60X7180 No.
Power trim and tilt unit 7 No.
BRKT Bracket unit 7 T. R. 6 N · m (0.6 kgf · m, 4.4 ft · Ib) 1 T. R. 28 27 26 15 25 16 22 24 8 N · m (0.8 kgf · m, 5.9 ft · Ib) 17 18 19 21 3 4 5 6 7 23 2 20 8 T. R. 8 N · m (0.8 kgf · m, 5.9 ft · Ib) 9 14 13 12 11 T. R. 3 N · m (0.3 kgf · m, 2.2 ft · Ib) 10 S60X7200 No.
Power trim and tilt unit 7 T. R. 6 N · m (0.6 kgf · m, 4.4 ft · Ib) 1 T. R. 28 27 26 15 25 16 22 24 8 N · m (0.8 kgf · m, 5.9 ft · Ib) 17 18 19 21 3 4 5 6 7 23 2 20 8 T. R. 8 N · m (0.8 kgf · m, 5.9 ft · Ib) 9 14 13 12 11 T. R. 3 N · m (0.3 kgf · m, 2.2 ft · Ib) 10 S60X7200 No.
BRKT Bracket unit 7 13 1 A 16 15 13 14 T. R. 15 16 17 18 19 20 130 N · m (13.0 kgf · m, 96.0 ft · lb) 19 18 A 22 23 24 7 8 7 4 21 6 3 11 12 R. 5 6 8 T. 5 9 10 2 78 N · m (7.8 kgf · m, 57.5 ft · lb) 11 12 T. R. 96 N · m (9.6 kgf · m, 70.8 ft · Ib) S63P7350 No.
Power trim and tilt unit 7 13 1 A 16 15 13 14 T. R. 15 16 17 18 19 20 130 N · m (13.0 kgf · m, 96.0 ft · lb) 19 18 A 22 23 24 7 8 7 4 21 6 3 11 12 R. 5 6 8 T. 5 9 10 2 78 N · m (7.8 kgf · m, 57.5 ft · lb) 11 12 T. R. 96 N · m (9.6 kgf · m, 70.8 ft · Ib) S63P7350 No.
BRKT Bracket unit Removing the power trim and tilt unit 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. 2. Remove the bolt and disconnect the ground lead at the bottom of the power trim and tilt unit. 3. Remove the plastic ties, and then pull out the PTT motor leads. 1 S60X3020 4. Remove the bolts, then the lower mounting shaft. WARNING After tilting up the outboard motor, be sure to support it with the tilt stop lever.
Power trim and tilt unit Recommended power trim and tilt fluid: ATF Dexron II 3. Install the reservoir cap, and then tighten it to the specified torque. T. R. Reservoir cap: 0.7 N·m (0.07 kgf·m, 0.5 ft·lb) 4. Fully extend the trim and tilt rams. 5. Remove the circlip 1, then the manual valve 2. S60X7120 6. Install the up relief fitting 3 and hydraulic pressure gauge 4. NOTE: Hold the power trim and tilt unit with one hand, and pull the upper mount shaft out at a downward angle with the other. 6.
BRKT Bracket unit 7. Connect the PTT motor leads to the battery terminals to fully retract the trim and tilt rams. Down relief fitting 5: 90890-06774 Hydraulic pressure gauge: 90890-06776 Rams Down PTT motor lead Battery terminal Light green (Lg) + Sky blue (Sb) - 10. Remove the reservoir cap, and then check the fluid level. 8. Reverse the PTT motor leads between the battery terminals to fully extend the trim and tilt rams, and then measure the hydraulic pressure.
Power trim and tilt unit 13. Connect the PTT motor leads to the battery terminals to fully retract the trim and tilt rams, and then measure the hydraulic pressure. If out of specification, overhaul the power trim and tilt unit. NOTE: Quickly install the manual valve before any fluid flows out of the hole. Disassembling the power trim and tilt motor 1. Remove the power trim and tilt motor, Oring, gear pump filter, and joint from the gear pump housing.
BRKT Bracket unit 3. Remove the lead holder 1 and rubber spacers 2 from the stator, and then slide them away from the stator. 7. Remove the screw, disconnect the PTT motor lead (light green) 5, and then remove the brushes 6. 4. Remove the stator 3. NOTE: Place a clean cloth over the end of the armature shaft, hold it with a pair of pliers, and then carefully slide the stator off of the armature. CAUTION: 5. Remove the armature from the PTT motor base.
Power trim and tilt unit 2. Check the brush and circuit breaker for continuity. Replace if there is no continuity. CAUTION: Do not touch the bimetal b, otherwise the operation of the circuit breaker can be affected. 3. Measure the commutator diameter. Replace if out of specification. Armature continuity Commutator segments d Continuity Segment d – Armature core e No continuity Segment d – Armature shaft f No continuity 5. Check the base for cracks or damage. Replace if necessary.
BRKT Bracket unit Assembling the power trim and tilt motor 1. Connect the PTT motor leads 1, and then tighten the screws 2. Removing the reservoir 1. Hold the power trim and tilt unit in a vise using aluminum plates a on both sides. 1 2 S60X7310 CAUTION: 2. Push the brushes 3 into the brush holder, and then install the armature 4. Do not use rags or paper to clean the hydraulic system components. Small pieces of fibers remaining on them can cause the system to malfunction.
Power trim and tilt unit 3. Drain the fluid from the reservoir and check it for damage. Replace if necessary. 4. Check the reservoir cap and O-ring for damage. Replace if necessary. Disassembling the gear pump housing 1. Remove the gear pump housing. S60X7430 NOTE: Make sure that the shuttle pistons and balls are removed, since they tend to stick to the gear pump cover. S60X7410 NOTE: Make sure that the O-rings, valve pin, and valve seat assembly are removed. 4. Remove the up-relief valve assembly. 2.
BRKT Bracket unit Checking the gear pump 5. Remove the main valves. 1. Clean all the valves, pistons, and balls, and then check them for damage or wear. Check the filters for damage or clogs. Replace if necessary. 2. Check the drive gears for damage or wear. Replace the gear pump assembly if necessary. b a S60X7450 WARNING Never look into the pump housing opening while removing the main valves because the main valves and power trim and tilt fluid can be forcefully expelled out.
Power trim and tilt unit 2. Install new O-rings 6 onto the main valves 7, and then install the main valves into the gear pump housing. 5. Install the gear pump cover B into the gear pump housing, and then tighten the bolts. B S60X7520 3. Install the drive gears 8 into the gear pump housing. 6. Check that the gear pump turns smoothly, and then tighten the gear pump cover bolts to the specified torque. 8 T. R. Gear pump cover bolt: 6 N·m (0.6 kgf·m, 4.4 ft·lb) 7.
BRKT Bracket unit Disassembling the tilt cylinder and trim cylinder 1. Loosen the tilt cylinder end screw, and then remove the tilt piston assembly. 6. Cover the tilt cylinder opening with a clean cloth 1, and then blow compressed air through the hole a to remove the free piston 2. S63P7020 CAUTION: Make sure that the trim and tilt rams are fully extended before removing the tilt cylinder end screw. Trim and tilt wrench: New: 90890-06587 Current: 90890-06548 WARNING 2. Drain the fluid. 3.
Power trim and tilt unit Checking the tilt cylinder and trim cylinder 1. Disassemble the tilt piston assembly. 4. Check the tilt ram for bends or excessive corrosion. Polish with 400- to 600-grit sandpaper if there is light rust or replace if necessary. 5. Check the trim pistons for scratches. Replace if necessary. S60X7570 6. Check the trim rams for bends or excessive corrosion. Polish with 400- to 600grit sandpaper if there is light rust or replace if necessary. 2.
BRKT Bracket unit Assembling the tilt piston and trim pistons 1. Install the new dust seal 1 and new Orings 2 and 3 onto the tilt cylinder end screw. T. R. Tilt piston nut: 96 N·m (9.6 kgf·m, 70.8 ft·lb) 6. Install a new backup ring E and a new O-ring F onto the free piston D. 2. Install the tilt cylinder end screw 4 onto the tilt ram 5. 7. Install a new oil seal G, a new dust seal H, and a new O-ring I onto each trim cylinder end screw. 8.
Power trim and tilt unit Assembling the power trim and tilt unit 1. Fill the tilt cylinder with the specified amount of the recommended fluid through the hole a. 3. Fill the trim cylinders with the recommended fluid to the correct level through holes b and c, and d as shown. Recommended power trim and tilt fluid: ATF Dexron II Fluid quantity: 30 cm3 (1.0 US oz, 1.1 Imp oz) 2. Push the free piston 1 into the tilt cylinder until it bottoms out.
BRKT Bracket unit 4. Install the trim piston assemblies into the trim cylinders, and then tighten the trim cylinder end screws to the specified torque. S60X7730 T. R. Gear pump housing mounting bolt: 8 N·m (0.8 kgf·m, 5.9 ft·lb) S63P7040 7. Install the O-ring into the reservoir cap. CAUTION: • Make sure that the trim rams are fully extended when installing them. • Once installed, never push the trim rams down, otherwise fluid can spurt out. 8.
Power trim and tilt unit 10. Install the tilt piston assembly into the tilt cylinder, and then tighten the tilt cylinder end screw to the specified torque. 12. Fill the gear pump housing with the recommended fluid to the correct level as shown. Recommended power trim and tilt fluid: ATF Dexron II 13. Remove all of the air bubble using a syringe or suitable tool. S63P7060 NOTE: Turn the joint with a screwdriver to bleed the gear pump.
BRKT Bracket unit 15. Remove the reservoir cap, and then check the fluid level in the reservoir. NOTE: If the fluid is at the correct level, the fluid should overflow out of the filler hole when the reservoir cap is removed. 16. If necessary, add sufficient fluid of the recommended type until it overflows out of the filler hole.
Power trim and tilt unit CAUTION: After tilting the outboard motor up, be sure to support it with the tilt stop lever. 2. Install the collars. 3. Lift the power trim and tilt unit up, and then install the upper mounting shaft. Rams Up PTT motor lead Battery terminal Sky blue (Sb) + Light green (Lg) - NOTE: • Repeat this procedure so that the rams go up and down four or five times (be sure to wait a few seconds before switching the leads).
BRKT Bracket unit Bleeding the power trim and tilt unit (built-in) 1. Fully turn the manual valve counterclockwise. WARNING After tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could suddenly lower if the power trim and tilt unit should lose fluid pressure. 7. Remove the reservoir cap 2, and then check the fluid level in the reservoir. 2.
Power trim and tilt unit / Power trim and tilt electrical system Power trim and tilt electrical system 1 7 H I 2 3 4 R 2 R B R 17 3 R 4 B E 1DCBA098765432 G R F 5 R R R R B 6 Lg Sb Sb Lg Lg Sb Lg 9 Sb R Lg UP FREE Sb DOWN Lg Sb R Lg Lg Lg R R Sb Lg Sb Sb Lg È R Lg B Sb B Lg 7 Sb B B B 8 É P P Gy Gy S63P7270 1 2 3 4 5 6 7 8 9 Fuse holder Fuse (20 A) Fuse (50 A) Battery Power trim and tilt relay Power trim and tilt motor Diode Trim sensor Power trim and
BRKT Bracket unit Checking the fuse 1. Check the fuse for continuity. Replace if there is no continuity. 3. Connect the light green (Lg) lead to the positive battery terminal and the black (B) lead to the negative battery terminal as shown. 4. Check for continuity between terminals 2 and 3. Replace if there is no continuity. S69J7525 Checking the power trim and tilt relay 1. Check the power trim and tilt relay for continuity. Replace if out of specification. 5.
Power trim and tilt electrical system 1 2 3 4 5 6 7 8 9 Lead color Switch position Sky blue (Sb) Red (R) Light green (Lg) Up Free Down Checking the trim sensor 1. Measure the trim sensor resistance. Replace if out of specification. NOTE: Turn the lever 1 and measure the resistance as it gradually changes. Trim sensor resistance: Pink (P) – Black (B) 238.8–378.
BRKT Bracket unit — MEMO — 7-49 63P3F11
ELEC – + Electrical systems Special service tools .....................................................................................8-1 Checking the electrical components............................................................ 8-2 Measuring the peak voltage ...................................................................... 8-2 Measuring the lower resistance.................................................................8-2 Electrical components.................................................
ELEC – + Electrical systems Special service tools 8 Ignition tester 90890-06754 Test harness (3 pins) 90890-06793 Digital circuit tester 90890-03174 Test harness (3 pins) 90890-06847 Peak voltage adapter B 90890-03172 Test harness (3 pins) 90890-06846 Test harness (2 pins) 90890-06792 Test harness (3 pins) 90890-06791 8-1 63P3F11
Special service tools / Checking the electrical components Checking the electrical components Measuring the lower resistance 8 Measuring the peak voltage NOTE: Before troubleshooting the peak voltage, check that all electrical connections are tight and free from corrosion, and that the battery is fully charged to 12 V. The condition of the ignition system can be determined by measuring the peak voltage. Cranking speed is effected by many factors, such as fouled or weak spark plugs, or a weak battery.
– ELEC + Electrical systems Electrical components 8 Port view 2 3 4 1 5 8 7 6 S63P8010 1 2 3 4 5 6 7 8 ECM Starter motor Rectifier Regulator Thermoswitch Ignition coil Oil pressure sensor Junction box Fuse holder 8-3 63P3F11
Electrical components Junction box assembly 1 2 9 8 7 6 5 4 3 S63P8020 1 2 3 4 5 6 7 8 9 ECM Power trim and tilt relay Starter relay Diode Fuse (30 A) Main relay Fuse (20 A) Fuse (50 A) Intake air temperature sensor 63P3F11 8-4 1 2 3 4 5 6 7 8 9
ELEC – + Electrical systems Aft view 1 2 7 3 A A 6 3 8 A-A 4 5 S63P8030 1 2 3 4 5 6 7 8 Intake air pressure sensor Throttle position sensor Fuel injector Shift cut switch Neutral switch Ignition coil Thermoswitch Spark plug 8-5 63P3F11
Electrical components Top view 1 8 2 7 6 3 9 0 A 5 4 S63P8040 1 2 3 4 5 6 7 8 9 0 Fuel injector Ignition coil Starter motor Stator coil Engine temperature sensor Throttle position sensor Idle speed control Intake air pressure sensor Shift cut switch Neutral switch 63P3F11 A Power trim and tilt switch 8-6 1 2 3 4 5 6 7 8 9
– ELEC + Electrical systems Wiring harness : : : : : : : : : 1 2 3 4 5 6 7 8 9 G Y/G P W _ _ B/Y B L/Y 10 11 12 13 14 15 16 17 18 : : : : : : : : : O _ O _ W/R W/B _ L G/B 19 20 21 22 23 24 25 26 27 : : : : : : : : : G G/R G/Y B/O P/B P/W _ W/B L/W 28 29 30 31 32 33 34 35 36 : : : : : : : : : 37 38 39 40 41 42 43 44 Y P/W R/Y L/G B P/G P B/Y _ : : : : : : : : P Pu/Y Pu/B Pu/R _ B Pu/G B/W Y Lg W A L/W 7 2 B R G P P/B 21 Sb Br B P/W 0 35 46 7 8 9 0 A 9 5 5 B C D 34 6
Electrical components : : : : : : : : : 1 2 3 4 5 6 7 8 9 G Y/G P W _ _ B/Y B L/Y 10 11 12 13 14 15 16 17 18 : : : : : : : : : O _ O _ W/R W/B _ L G/B 19 20 21 22 23 24 25 26 27 : : : : : : : : : G G/R G/Y B/O P/B P/W _ W/B L/W 28 29 30 31 32 33 34 35 36 : : : : : : : : : 37 38 39 40 41 42 43 44 Y P/W R/Y L/G B P/G P B/Y _ : : : : : : : : P Pu/Y Pu/B Pu/R _ B Pu/G B/W Y Lg W A L/W 7 2 B R G P P/B 21 Sb Br B P/W 0 35 46 7 8 9 0 A 9 5 5 B C D 34 6 4 Lg Sb O E B F L
– ELEC + Electrical systems Ignition and ignition control system 8 3 B P B W/R B B O R/Y B/O R/Y B/W W/B W/R W/B 4 W/R B B R/Y P/W R/Y B 5 B/O R B/W R 2 3 B/W B/W R B/W Y/G 7 B/W R 2 4 2 B/Y O O W/R W/B G/B 24 P/W L/G L/Y 18 19 20 21 22 3 B 14 15 G/Y B/O B 1 1 P 12 B P/G P 42 44 B B/W G #2/3 #1/4 G/R 6 28 29 30 Y 31 32 33 34 35 2 1 5 7 8 9 10 B/Y P/W R/Y 37 P G 1 1 G G G B/Y B B/Y E B/Y B/Y D B B/Y B 8 R/Y B R/Y B/Y R
Ignition and ignition control system 8 3 B P B W/R B B O R/Y B/O R/Y B/W W/B W/R W/B 4 W/R B B R/Y P/W R/Y B 5 B/O R B/W R 2 3 B/W B/W R B/W Y/G 7 B/W R 2 4 2 B/Y O O W/R W/B G/B 24 P/W L/G L/Y 18 19 20 21 22 3 B 14 15 G/Y B/O B 1 1 P 12 B P/G P 42 44 B B/W G #2/3 #1/4 G/R 6 28 29 30 Y 31 32 33 34 35 2 1 5 7 8 9 10 B/Y P/W R/Y 37 P G 1 1 G G G B/Y B B/Y E B/Y B/Y D B B/Y B 8 R/Y B R/Y B/Y R R R/Y5 2 R/Y Y P G/Y 4 1G/
ELEC – + Electrical systems Checking the ignition spark gap Checking the spark plug wires 1. Remove the spark plug wire cover. 1. Remove the spark plug wires from the spark plugs. 2. Disconnect the spark plug caps from the spark plugs. 3. Connect a spark plug cap to the special service tool. 2. Remove the spark plug wires from the ignition coil. 3. Measure the spark plug wire resistance. Replace if out of specification. S63P8070 S60C8100 Ignition tester: 90890-06754 4.
Ignition and ignition control system Ignition coil resistance: Primary coil: Red (R) – Black/white (B/W) 1.53–2.07 Ω at 20 °C (68 °F) Secondary coil: 12.50–16.91 kΩ at 20 °C (68 °F) 3. Measure the pulser coil output peak voltage. Replace the pulser coil if below specification. Checking the ECM 1. Disconnect a ignition coil coupler. 2. Connect the test harness (2 pins) to the ignition coil.
ELEC – + Electrical systems Checking the throttle position sensor Checking the intake air temperature sensor 1. Remove the flywheel magnet cover. 1. Place the intake air temperature sensor in a container of water and slowly heat the water. 2. Connect the test harness (3 pins) to the throttle position sensor. 3. Turn the engine start switch to ON. 4. Measure the throttle position sensor input voltage. Check the wiring harness connection or replace the ECM if out of specification. 5.
Ignition and ignition control system Checking the thermoswitch 1. Place the thermoswitches in a container of water and slowly heat the water. Switch position Lead color Blue/yellow (L/Y) Black (B) Free a Push b Checking the neutral switch 1. Check the neutral switch for continuity. Replace if there is no continuity. S69J8250 a b 2. Check the switch for continuity at the specified temperatures. Replace if out of specification.
– ELEC + Electrical systems Fuel control system 8 W/R B B B W/B W/R W/B W/R B B 1 1 #2/3 B/Y B/Y B 2 3 Y/G 2 7 8 P B/Y 12 14 15 O W/R W/B 10 B G/B G 21 28 30 Y R/Y 32 33 34 35 P/G P 3G/B B 0 G6 Pw/Y Pw/B Pw/R B B 42 43 B 6 5 4 3 2 1 38 39 40 B/Y R/Y5 G/Y 4 2 R/Y G/R G/Y B 1G/R B/Y O 17 18 19 20 L 9 B/Y B/Y #1/4 Pw/G B B B B P Y P A 3 O B B/Y B B R/Y È Y/G B P/G R/Y R/Y R/Y Pu/R C #1 Pu/R 4 R/Y L E 1 D C B A 0 9 8 7 6 5 4 3
Fuel control system 8 W/R B B B W/B W/R W/B W/R B B 1 1 #2/3 B/Y B/Y B 2 3 Y/G 2 7 8 P B/Y 12 14 15 O W/R W/B 10 B G/B G 21 28 30 Y R/Y 32 33 34 35 P/G P 3G/B B 0 G6 Pw/Y Pw/B Pw/R B B 42 43 B 6 5 4 3 2 1 38 39 40 B/Y R/Y5 G/Y 4 2 R/Y G/R G/Y B 1G/R B/Y O 17 18 19 20 L 9 B/Y B/Y #1/4 Pw/G B B B B P Y P A 3 O B B/Y B B R/Y È Y/G B P/G R/Y R/Y R/Y Pu/R C #1 Pu/R 4 R/Y L E 1 D C B A 0 9 8 7 6 5 4 3 2 L L R/Y R/Y 6 R/Y Pu/B 5
ELEC – + Electrical systems Checking the injectors 1. Measure the resistance of the fuel injectors. Replace if out of specification. 1 3 2 S60V8450 Digital circuit tester: 90890-03174 Checking the electric fuel pump 1. Turn the engine start switch to ON. Fuel injector resistance (use as reference): 14.0–15.0 Ω at 20 °C (68 °F) 2. Listen for the operating sound of the electric fuel pump 1. Check the fuel system if there is no sound.
Fuel control system / Starting system Starting system 8 1 I H 7 3 4 2 R 3 4 B R 15 17 R R B E 1DCBA098765432 G F R R R R R 6 Br/W B 5 R Br B Br R È R B Br B S63P8220 1 2 3 4 5 6 7 Fuse holder Fuse (30 A) Fuse (20 A) Fuse (50 A) Starter relay Starter motor Battery B Br R Br/W : Black : Brown : Red : Brown/white È To remote control box/switch panel 63P3F11 8-18 1 2 3 4 5 6 7 8 9
ELEC – + Electrical systems Checking the fuses 1. Check the fuses for continuity. Replace if there is no continuity. S69J8340 Checking the starter relay 1. Connect the digital circuit tester leads to the starter relay terminals. 2. Connect the positive battery terminal to the brown (Br) lead. 3. Connect the negative battery terminal to the black (B) lead. 4. Check for continuity between the starter relay terminals. Replace if there is no continuity. 5.
Starting system / Starter motor Starter motor 8 1 2 3 4 15 5 16 6 7 17 18 19 20 19 21 22 19 8 9 10 27 28 26 11 29 19 30 31 23 12 13 24 14 25 No.
ELEC – + Electrical systems 8 1 2 3 4 15 5 16 6 7 17 18 19 20 19 21 22 19 8 9 10 27 28 26 11 29 19 30 31 23 12 13 24 14 25 No.
Starter motor Removing the starter motor pinion 1. Slide the pinion stopper 1 down as shown, and then remove the clip 2. 2. Measure the commutator diameter. Replace the armature if out of specification. NOTE: Remove the clip with a thin screwdriver. Checking the starter motor pinion 1. Check the teeth of the pinion for cracks or wear. Replace if necessary. Commutator diameter limit: 28.0 mm (1.10 in) 3. Measure the commutator undercut a. Replace the armature if out of specification. 2.
ELEC – + Electrical systems 4. Check the armature for continuity. Replace if out of specifications. Brush continuity Brush 1 – Brush 2 No continuity Checking the magnet switch 1. Connect the tester leads between the magnet switch terminals as shown. 2. Connect the positive battery lead to the brown and white (Br/W) lead. 3. Connect the negative battery lead to the starter motor body.
Starter motor / Charging system Charging system #2/3 8 #1/4 1 G G G G G G 2 B 3 R E 1 D C B A 0 9 8 7 6 5 4 3 2 G F R B 16 17 18 19 R 4 4 R R R I R R H R B B R B B 5 R R 6 B B S63P8230 1 2 3 4 5 6 Stator coil Rectifier Regulator Fuse holder Fuse (50 A) Accessory battery Battery 63P3F11 B G R : Black : Green : Red 8-24 1 2 3 4 5 6 7 8 9
ELEC – + Electrical systems Checking the stator coil 1. Disconnect the stator coil coupler. 2. Connect the test harness (3 pins) to the stator coil. 3. Measure the Rectifier Regulator output peak voltage. If below specification, measure the stator coil output peak voltage. Replace the Rectifier Regulator if the output peak voltage of the stator coil is above specification. 3. Measure the stator coil output peak voltage. Replace the stator coil assembly if below specification.
TRBL SHTG Troubleshooting Special service tools .....................................................................................9-1 Yamaha Diagnostic System ..........................................................................9-2 Introduction................................................................................................9-2 Power unit....................................................................................................... 9-5 Self-diagnosis...........................
TRBL SHTG Troubleshooting Special service tools 9 Yamaha Diagnostic System 60V-85300-02 YAMAHA DIAGNOSTIC SYSTEM INSTALLATION MANUAL Yamaha Diagnostic System 60V-WS853-02 Diagnostic flash indicator B 90890-06865 9-1 63P3F11
Special service tools / Yamaha Diagnostic System Yamaha Diagnostic System 9 Introduction Features The newly developed Yamaha Diagnostic System provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods. By connecting your computer to the ECM (Electronic Control Module) of an outboard motor using the communication cable, this software can be used to display sensor data and data stored in the ECM on a computer’s monitor.
TRBL SHTG Troubleshooting Hardware requirements Make sure that your computer meets the following requirements before using this software.
Yamaha Diagnostic System Connecting the communication cable to the outboard motor Models: F(L)150A Bow view 3-pin communication coupler S63P9030 63P3F11 9-4 1 2 3 4 5 6 7 8 9
TRBL SHTG Troubleshooting NOTE: • Before troubleshooting the outboard motor, check the compression pressure, the mounting and rigging of the outboard motor, and the operation of the engine start switch. Also, make sure that specified fuel has been used and that the battery is fully charged. • To diagnose a mechanical malfunction, use the troubleshooting charts for each trouble located in this chapter. Also, when checking and maintaining the outboard motor, see Chapters 3–8 for safe maintenance procedures.
Power unit Is there continuity? No 1 2 3 4 5 6 7 8 9 Replace the starter relay. Yes Check the wiring harness for continuity. Is there continuity? No Repair or replace the wiring harness. Yes Disassemble and check the starter motor.
TRBL SHTG Troubleshooting Ignition system Check the condition of the spark plugs. No Good condition? Clean, adjust, or replace the spark plugs. Yes Check the ignition spark using the spark gap tester. WARNING • Do not touch any of the connections of the spark gap tester leads. • Do not let sparks leak out of the removed spark plug caps. • Keep flammable gas and liquids away, since this test can produce sparks. Good spark? Yes Check the pulser coil output peak voltage or resistance.
Power unit Good condition? No Repair or replace the spark plug wires. Yes Check the main relay for continuity. Is there continuity? No Replace the main relay. Yes Check the ECM output peak voltage. Fuel system Check the electric fuel pump operation. Can the operation sound be heard? No Check the fuse holder, fuse, and wiring harness for continuity. Yes Is there continuity? No Repair or replace the defective parts. Yes Check the fuel filters for clogs and the hoses for leaks.
TRBL SHTG Troubleshooting Clogs or leaks? Yes Repair or replace the defective parts. No Check the fuel pump diaphragm. Cracks or damage? Yes Replace the diaphragm. No Check the vapor separator needle valve. Is the needle valve bent or worn? Yes Replace the needle valve. No Check the injector resistance and check the injectors for clogs. Good condition? No Replace the injectors. Yes Check the starting system or the ignition system.
Power unit Symptom 2: Engine speed at wide open throttle is low, engine speed decreases, or engine stalls (poor acceleration or poor deceleration). 1 2 3 4 5 6 7 8 9 Check the battery lead connections and check that the ground lead bolt is not loose or that it has not come off. Good condition? No Repair or replace the defective parts. Yes Check the throttle position sensor and check that the connector is securely connected. Good condition? No Repair or replace the defective part.
TRBL SHTG Troubleshooting Ignition system Check the condition of the spark plugs. No Good condition? Clean, adjust, or replace the spark plugs. Yes Check the ignition spark using the spark gap tester. WARNING • Do not touch any of the connections of the spark gap tester leads. • Do not let sparks leak out of the removed spark plug caps. • Keep flammable gas and liquids away, since this test can produce sparks. Good spark? Yes Check the pulser coil output peak voltage or resistance.
Power unit Good condition? No Repair or replace the spark plug wires. Yes Check the ECM output peak voltage. Fuel system Check the electric fuel pump operation. Can the operation sound be heard? No Check the fuse holder, fuse, and wiring harness for continuity. Yes Is there continuity? No Repair or replace the defective parts. Yes Check the fuel filters for clogs and the hoses for leaks. Good condition? Replace the electric fuel pump. No Repair or replace the defective parts.
TRBL SHTG Troubleshooting Cracks or damage? Yes Replace the diaphragm. No Check the vapor separator needle valve. Is the needle valve bent or worn? Yes Replace the needle valve. No Check the vapor separator pressure regulator. Good condition? No Replace the pressure regulator. Yes Check the injector resistance and check the injectors for clogs. Good condition? No Replace the injectors. Yes Check the starting system or the ignition system.
Power unit Lubrication system 1 2 3 4 5 6 7 8 9 Check the engine oil level. At specified level? No Add engine oil to the correct level. No Check the oil pump for debris or oil leaks. Yes Check the oil pressure. Within specification? Yes Debris or leaks? No Check the oil passage. Yes Clean or replace the defective parts. Check the oil pressure sensor. Good condition? No Replace the oil pressure sensor. Yes Check the ignition system or the fuel system.
TRBL SHTG Troubleshooting Symptom 3: Engine speed not stable at low speeds. Check the throttle position sensor and check that the connector is securely connected. Good condition? No Repair or replace the defective part. No Repair or replace the defective parts. Yes Check the neutral switch for continuity. Is there continuity? Yes Check the throttle valve opening of each cylinder. Are the throttle valve openings incorrect or are the throttle valve links worn? Yes Replace the throttle body.
Power unit Ignition system Check the condition of the spark plugs. No Good condition? Clean, adjust, or replace the spark plugs. Yes Check the ignition spark using the spark gap tester. WARNING • Do not touch any of the connections of the spark gap tester leads. • Do not let sparks leak out of the removed spark plug caps. • Keep flammable gas and liquids away, since this test can produce sparks. Good spark? Yes Check the fuel system. No Check the ignition coil resistance.
TRBL SHTG Troubleshooting Fuel system Check the fuel pump diaphragm. Cracks or damage? Yes Replace the diaphragm. No Check the vapor separator needle valve. Is the needle valve bent or worn? Yes Replace the needle valve. No Check the injector resistance and check the injectors for clogs. Good condition? No Replace the injectors. Yes Check the ignition system.
Power unit Symptom 4: Hunting occurs. Check the throttle valve opening of each cylinder. Are the throttle valves open excessively? Yes 1 2 3 4 5 6 7 8 9 Synchronize the throttle valves or replace the defective parts. No Adjust the throttle cable. Symptom 5: Engine speed rises even when the throttle position is fixed. Check the throttle cable operation. Good condition? No Adjust the throttle cable. Yes Synchronize the throttle valves.
TRBL SHTG Troubleshooting Self-diagnosis 9 Diagnosing the electronic control system 1. Connect the special service tool to the outboard motor as shown. • Trouble code indication Example: The illustration code number 23. a: Light on, 0.33 second b: Light off, 4.95 seconds c: Light off, 0.33 second d: Light off, 1.65 seconds L/W indicates S63P9010 NOTE: When performing this diagnosis, all of the electrical wires must be properly connected. Diagnostic flash indicator B: 90890-06865 2.
Self-diagnosis Code Symptom 1 Normal 13 Incorrect pulser coil signal 15 Incorrect engine temperature sensor signal 18 Incorrect throttle position sensor signal 19 Incorrect battery voltage 23 Incorrect intake air temperature sensor signal 28 Incorrect neutral switch signal 29 Incorrect intake air pressure sensor signal 37 Incorrect idle speed control signal 39 Incorrect oil pressure sensor signal 44 Incorrect engine stop lanyard switch signal 45 Incorrect shift cut switch signal 46
Index Numerics 64E type power trim and tilt unit................1-11 A. Adjusting the throttle link and throttle cable .............................................3-8 Adjusting the throttle link and throttle cable operation (using a thickness gauge) .......3-10 Adjusting the throttle position sensor ........4-17 Adjusting the throttle position sensor (when disassembling or replacing the throttle body) ...........................................4-18 Adjusting the trim sensor cam...................
Index Checking the injectors...............................8-17 Checking the intake air temperature sensor .....................................................8-13 Checking the lower case................. 6-18, 6-47 Checking the lower unit for air leakage.....3-15 Checking the magnet switch .....................8-23 Checking the main relay ...........................8-17 Checking the neutral switch ......................8-14 Checking the oil pressure .........................
Index E. ECM ..........................................................1-17 Electrical .....................................................2-7 Electrical components.................................8-3 Electronic control system ..........................1-17 F. Fail-safe control ........................................1-18 Features and benefits .................................1-6 Fire prevention ............................................1-3 Fuel and blowby hoses ...............................
Index Removing the steering arm.......................7-14 Removing the timing belt and sprockets ...5-20 Removing the water pump and shift rod ........................................... 6-8, 6-36 Replacing the oil filter..................................3-5 Replacing the timing belt................... 3-6, 5-16 Replacing the valve guides .......................5-30 Y. Yamaha Diagnostic System ....................... 9-2 1 2 3 4 5 6 7 8 9 S. Safety while working ...................................
Wiring diagram F150AET, FL150AET 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P Q R S T U Spark plug Ignition coil Thermoswitch Oil pressure sensor Diode Starter relay Starter motor Starting battery Accessory battery Fuse holder Fuse (30 A) Fuse (20 A) Fuse (50 A) Intake air temperature sensor Power trim and tilt relay Power trim and tilt motor ECM Pulser coil Stator coil Engine temperature sensor Rectifier Regulator Power trim and tilt switch Trim sensor Idle speed control Throttle position sensor In
YAMAHA MOTOR CO., LTD. Printed in the Netherlands Jul. 2003 – 1.
F150AET, FL150AET B/Y 1 2 3 4 G Y/G P W B/Y 12 14 15 O W/R W/B B L/Y O L G/B G 26 27 28 29 30 W/B L/W 31 32 33 34 35 B P/G P Y B/Y B/Y B W/R G/R 21 22 23 24 B B/Y B/Y B/Y G 17 18 19 20 G/Y B/O P/B P/W L/G J 7 8 9 10 B G/R G/B R/Y L/G Pu/G Pu/Y Pu/B W/B B W/R P/W R/Y 37 38 39 40 W/B B B P/W O B B/W B/O P P/W O W/R W/B B/Y G/R G/B G/Y G B P O P/G Pu/R L Pu/B Pu/Y Pu/G L/Y L/G P/W P/B W Y P G O P/W B/W R P B B/W B/W R B/W B/W 4 3 R 2 2 1 4 2 1 1 3 B B B
