Z300A LZ300A SUPPLEMENTARY SERVICE MANUAL 292211 6D0-28197-3F-1X
NOTICE This Supplementary Service Manual has been prepared to introduce new service and new data information for the Z300 and LZ300 which are based on the Z250 and LZ250. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the following manual.
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
General information How to use this manual .................................................................................... 1 Manual format............................................................................................... 1 Symbols........................................................................................................ 2 Identification...................................................................................................... 3 Applicable models ....................
Specifications General specifications.................................................................................... 16 Maintenance specifications ........................................................................... 18 Power unit................................................................................................... 18 Lower unit ................................................................................................... 20 Electrical ...........................................
Power unit Power unit........................................................................................................ 36 Removing the power unit............................................................................ 37 Crankcase ........................................................................................................ 39 Removing the crankcase covers ................................................................ 40 Installing the crankcase covers ................................
Electrical systems Electrical components.................................................................................... 72 Port view..................................................................................................... 72 Top view ..................................................................................................... 73 Troubleshooting Self-diagnosis..................................................................................................
GEN INFO General information How to use this manual 1 Only chapters containing revisions or additional items in the base manual have been included in this manual. All special service tools introduced in this manual are mentioned in Chapter 3. 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.
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 Identification 1 Applicable models This manual covers the following models. Applicable models Z300AETO, LZ300AETO 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 Z300AETO 6D0 LZ300AETO 6D1 3 Starting serial No.
Identification / Features and benefits Features and benefits 1 Crankcase and cylinders The following modifications have been adopted to increase the output as compared to the Z250 power unit. • The material of the crankshaft has been changed to a high-grade clean steel(*1) to increase durability against stress. • Wider exhaust ports with planed-off edges have been adopted and the exhaust timing has been changed to reduce the exchange loss of the exhaust gas.
GEN INFO General information • Newly-forged lightweight pistons with a hard anodic coating on the piston pin boss have been adopted to increase durability and reduce the inertia mass of the pistons. • The top piston rings are made of steel and are ion-plated to increase durability. • The heat treatments for the piston pins and connecting rods have been changed so that there is multiphase carbonization to increase durability.
Features and benefits • The anti-corrosion anodes in the cooling water passages of the cylinder block are larger to increase reliability and performance. 1 Anodes Intake system The openings in the throttle bodies were enlarged to a 46 mm (1.81 in) diameter to increase power output.
GEN INFO General information An oil groove has been added to each reed valve seat. Oil in the groove helps to reduce impact when the reed valve contacts the reed valve seat. The dimensions of the reed valve assembly are the same as those for the Z250. 1 Oil groove 2 Identification mark: 6D0 The oil pump has been newly designed to obtain optimal oil supply.
Features and benefits Upper case Water jackets have been incorporated to both sides of the lower part of the upper case. This structure reduces the heat transfer to the upper case from the exhaust gas. The cooling water discharged from the water pump is supplied to the upper case around the muffler from the pipe connected to the exhaust guide, flows down into the water jacket, and then drains to the lower case.
GEN INFO General information Lower case The propeller shaft housing and the ring are newly designed to reduce the exhaust back-pressure and cool the propeller damper. Cooling water is taken in from the front of the trim tab, flows through the pipe in the lower case and propeller shaft housing, and then is supplied directly to the propeller boss.
Features and benefits ECM (Electronic Control Module) ECMs have been adopted that are specific to each model to control the ignition and injection timing. NOTE: The diagnostic codes are the same as those for the Z250, and the latest version of the YDIS covers all previous models with fuel injection.
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 gear oil level 1. Check the gear oil level. Checking the fuel system 1. Check that the fuel hoses are securely connected and that the fuel tank is full with fuel. S60V1290 Checking the engine oil level 1. Check that the engine oil level is between the maximum and minimum level marks.
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. 2 a 1 S60V1040 3.
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. S60V1060 3.
GEN INFO General information Checking the cooling water pilot hole 1. Check that cooling water is discharged from the cooling water pilot hole. a b È 0 c 1 d 2 10 S60V1120 È Hour After test run S60V3140 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.
Predelivery checks / General specifications General specifications Item Dimension Overall length Overall width Overall height (X) (U) Boat transom height (X) (U) Weight (with stainless propeller) (X) (U) Performance Maximum output Full throttle operating range Maximum fuel consumption Engine idle speed Power unit Type Total displacement Bore × stroke Compression ratio Control system Starting system Enrichment system Ignition control system Maximum generator output Spark plug Cooling system Exhaust system L
SPEC Specifications Item Fuel and oil Fuel type Fuel minimum rating Engine oil(*2) Engine oil tank capacity Oil tank Remote oil tank 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(*3) CCA/EN 20HR/IEC Unit RON(*1) PON L (US gal, lmp gal) L (US gal, lmp g
General specifications / Maintenance specifications Maintenance specifications 2 Power unit Item Power unit Minimum compression pressure* Cylinder heads Warpage limit (lines indicate straightedge position) Cylinders Bore size Bore size limit Taper limit Out-of-round limit Pistons Piston diameter (D) Measuring point (H) Piston-to-cylinder clearance Piston pin boss bore Oversize piston 1st 2nd Oversize piston diameter 1st 2nd Piston pins Outside diameter Unit Model Z300AETO LZ300AETO kPa (kgf/cm2, psi
SPEC Specifications Item Piston rings Top ring Dimension B Dimension T End gap Side clearance 2nd piston ring Dimension B Dimension T End gap Side clearance Connecting rods Small end inside diameter Big end side clearance Small end axial play limit Crankshaft Crankshaft journal diameter Crankpin diameter Runout limit Thermostats Opening temperature Fully open temperature Valve open lower limit Oil pump Identification mark Bleeding Reed valves Valve stopper height limit Valve bending limit 19 Unit Model
Maintenance specifications Lower unit Item Unit Gear backlash Pinion-to-forward gear mm (in) Pinion-to-reverse gear Pinion shims Forward gear shims Reverse gear shims Propeller shaft shims mm (in) mm mm mm mm Propeller shaft End play mm (in) Model Z300AETO LZ300AETO 0.12–0.44 0.30–0.62 (0.0047–0.0173) (0.0118–0.0244) 0.61–0.90 (0.0240–0.0354) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 — 0.10, 0.12, 0.15, 0.18, 0.
SPEC Specifications Item Unit (*1) Pulser coil resistance (W/R, W/B, W/Y, W/G, W/L, W/Br – B) Throttle position sensor Input voltage (O – R) Output voltage (P – O) Crank position sensor output peak voltage (G/L – G/W) at cranking (unloaded) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Crank position sensor resistance(*1) (G/L – G/W) Crank position sensor air gap Intake air temperature sensor resistance at 0 °C (32 °F) at 80 °C (176 °F) Engine temperature sensor resistance (B/Y – B
Maintenance specifications 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 – ground) at 1,500 r/min (unloaded) at 3,500 r/min (unloaded) Power trim and tilt system Trim
SPEC Specifications Dimensions Exterior 284 (11.2) 30˚ 660 (26.0) 420 (16.5) mm (in) X: 1,152 (45.4) U: 1,270 (50.0) 628 (24.7) 211 (8.3) 645 (25.4) X: 67 (2 U: 86 .6) (3.4) ˚ 67 X: 848 (33.4) U: 925 (36.4) 45 (1.8) 404 (15.9) 32 (1.3) 757 (29.8) X: 640 (25.2) U: 766 (30.2) 245 (9.6) 216 (8.5) X: 1,074 (42.3) U: 1,201 (47.3) 907 (35.7) 75 (3.0) 25 (1.0) 1 2˚ 23 X: 48 (1.9) U: 55 (2.2) 3˚ 677 (26.
Maintenance specifications Clamp bracket mm (in) 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) 411 (16.2) 13 (0.5) 18.5 (0.7) 79 (3.1) 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 pump screw Emergency switch High pressure fuel pump bolt Power unit Negative battery terminal nut Drive belt tensioner bolt Starter motor bolt Intake air temperature sensor Rectifier Regulator bolt 1st 2nd PTT motor lead bolt Shift position switch screw Control lever stopper screw Connecting rod cap Crankshaft balancer nut Crankcase bolt Cylinder head cover bolt Exhaust outer cover bolt 1
Tightening torques Part to be tightened Thread size Shift cut switch mounting screw Spark plug Positive battery terminal nut Thermostat cover bolt Throttle body mounting bolt and nut Power unit mounting bolt Lower unit (regular rotation model) Exhaust guide bolt Gear oil check screw Lower case mounting bolt Pinion nut Propeller nut Propeller shaft housing bolt Trim tab mounting bolt Gear oil drain screw Grease nipple Lower unit (counter rotation model) Exhaust guide bolt Gear oil check screw Lower case mo
SPEC Specifications Part to be tightened Power trim and tilt unit Blind plug Gear pump housing mounting screw Gear pump housing bolt Trim down spring screw Main valve Manual valve PTT motor unit mounting bolt Oil pipe Relief valve cap screw Reservoir mounting bolt Reservoir cap Tilt cylinder end screw Tilt rod Trim cylinder end screw Trim rod Valve plate bolt PTT unit mounting bolt Thread size — M4 M5 M5 — — M8 — M5 M8 M12 — — — — M6 M10 Tightening torques N·m kgf·m ft·lb 7 2 4 4 11 2 19 15 4 19 7 90 55
Tightening torques / Special service tools Special service tools 3 Leakage tester 90890-06840 Shift rod push arm 90890-06052 Flywheel holder 90890-06522 Bearing housing puller claw L 90890-06502 Pinion height gauge 90890-06710 Stopper guide plate 90890-06501 Fixing plate 90890-06711 Center bolt 90890-06504 Digital caliper 90890-06704 Backlash indicator 90890-06706 6D03F1X 1 2 3 4 5 6 7 8 9 28
CHK ADJ Periodic checks and adjustments Magnet base plate 90890-07003 Ball bearing attachment 90890-06657 Dial gauge set 90890-01252 Driver rod LL 90890-06605 Magnet base B 90890-06844 Bearing outer race attachment 90890-06628 Needle bearing attachment 90890-06653, 90890-06654 Bearing outer race puller assembly 90890-06523 Driver rod L3 90890-06652 Driver rod SS 90890-06604 29 6D03F1X
Special service tools PTT oil pressure gauge assembly 90890-06580 PTT oil pressure gauge adapter 90890-06581 Diagnostic flash indicator B 90890-06865 6D03F1X 30
CHK ADJ Periodic checks and adjustments 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.
Maintenance interval chart / Oil injection system / Lower unit Oil injection system 3 Adjusting the oil pump link rod 1. Loosen the locknut 1 and then disconnect the oil pump link rod 2. Lower unit 3 Checking the lower unit for air leakage 1. Remove the check screw 1, and then install the special service tool. 2. Fully close the throttle valves. 3. Adjust the oil pump link rod so that there is a 0.5 mm (0.02 in) gap a between the oil pump lever 3 (in the fully closed position) and the stopper 4.
CHK ADJ Periodic checks and adjustments General 3 Lubricating the outboard motor 1. Apply water resistant grease to the areas shown.
General A S6D03010 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 C S60V3440 3. Apply corrosion resistant grease to the areas shown. 4. Apply injector grease to the areas shown.
FUEL Fuel system Fuel filter 4 9 T. R. 8 N · m (0.8 kgf · m, 5.9 ft · Ib) 12 11 13 14 10 1 2 5 15 4 3 6 16 8 7 S6D04010 No.
Fuel filter / Power unit Power unit 5 13 11 LT 12 572 10 9 6 LT 572 7 14 16 15 7 1 6 8 7 8 7 T. R. 32 N · m (3.2 kgf · m, 23.6 ft · Ib) 5 3 4 2 No.
POWR Power unit Removing the power unit NOTE: It is recommended to loosen the flywheel magnet nut before removing the power unit to improve working efficiency. 1. Disconnect the battery leads 1. 6. Remove the bracket 8 and disconnect the trim sensor coupler (or connector) 9. 8 9 2. Disconnect the shift cable 2 and the throttle cable 3. S6D05020 7. Disconnect the PTT switch coupler and the shift lever 0. 3. Disconnect the fuel hose 4 and the oil hose 5. 8. Disconnect the cooling water hose A. A 4.
Power unit 9. Remove the apron B and the hose joint assembly C. 10. Remove the bolts D, then the power unit. 11. Remove the shift rod assembly E and gasket F.
POWR Power unit Crankcase 5 1 T. R. T. R. 11 N · m (1.1 kgf · m, 8.1 ft · Ib) 4 5 6 11 N · m (1.1 kgf · m, 8.1 ft · Ib) 13 13 2 4 3 1 T. R. 11 N · m (1.1 kgf · m, 8.1 ft · Ib) 7 8 1 13 9 14 1014 13 9 11 13 14 14 12 No.
Crankcase Removing the crankcase covers Installing the power unit 1. Disconnect the hoses from the crankcase covers. 1. Clean the power unit mating surface, and then install new dowels 1, a new gasket 2, and the shift rod assembly 3. 2. Remove the crankcase cover bolts in the sequences shown. 4 1 1 1 6 2 0 3 3 8 D B F C F 7 A E B 8 9 C D 9 0 A E 4 3 5 6 4 5 4 A 3 7 2 D 9 3 5 1 4 1 5 9 8 4 3 8 7 C D B A C B S6D05100 T. R. Crankcase cover bolt: 11 N·m (1.
POWR Power unit 3. Install the hose joint assembly 6 and the apron 7. T. R. PTT motor lead bolt: 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8. Install the bracket B and connect the trim sensor coupler (or connector) C. 4. Connect the PTT switch coupler and the shift lever 8. B C S6D05130 9. Install the junction box cover. 10. Connect the fuel hose D and oil hose E. 5. Connect the cooling water hose 9. 9 S6D05110 6. Connect the cooling water hose 0 to the Rectifier Regulator. 7.
Crankcase 11. Connect the shift cable F and throttle cable G, and then adjust their lengths. 12. Install the Woodruff key and flywheel magnet. 13. Tighten the flywheel magnet nut to the specified torque. NOTE: Align the marks a on the pointer H, which you made during disassembly. 15. Install all removed parts. CAUTION: Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily. NOTE: Apply engine oil to the flywheel magnet nut before installation.
LOWR Lower unit Propeller shaft housing (regular rotation model) No.
Propeller shaft housing (regular rotation model) 6 No.
LOWR Lower unit Shimming (regular rotation model) 6 F P R B4 T3 B3 A3 65.0 A B B5 T1 T2 B1 39.4 41.
Shimming (regular rotation model) Selecting the pinion shims 1. Install the special service tools onto the drive shaft 1. Digital caliper 4: 90890-06704 4. Turn the thrust bearing 5 two or three times to seat the drive shaft housing 6, and then measure the housing height (M3) as shown. NOTE: • Select the shim thickness (T3) by using the specified measurement(s) and the calculation formula. • Install the special service tools onto the drive shaft so that the shaft is at the center of the hole.
LOWR Lower unit 5. Calculate the pinion shim thickness (T3) as shown in the examples below. Example: If “T3” is 0.68 mm, then the pinion shim is 0.65 mm. If “T3” is 0.70 mm, then the pinion shim is 0.68 mm. Backlash (regular rotation model) 6 Measuring the forward and reverse gear backlash 1. Remove the water pump assembly. 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.
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 0.12 mm (0.0047 in) To be decreased by (0.28 – M) × 0.81 More than 0.44 mm (0.0173 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: 0.61–0.90 mm (0.0240–0.0354 in) 11. Add or remove shim(s) if out of specification. Reverse gear backlash Shim thickness Less than 0.61 mm (0.0240 in) To be decreased by (0.76 – M) × 0.81 More than 0.90 mm (0.0354 in) To be increased by (M – 0.76) × 0.81 M: Measurement Available shim thicknesses: 0.10, 0.12, 0.15, 0.18, 0.30, 0.
Backlash (regular 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) / 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) Disassembling the reverse gear 1. Remove the needle bearing from the reverse gear using a chisel. CAUTION: Add or remove shim(s), if necessary, if replacing the forward gear or lower case. Ball bearing attachment 3: 90890-06657 Driver rod LL 4: 90890-06605 3. Install the needle bearing outer case into the lower case. Assembling the lower case 1. Install the needle bearing into the retainer to the specified depth.
LOWR Lower unit 5. Install the new needle bearing into the reverse gear to the specified depth. Needle bearing attachment 7: 90890-06653 Driver rod SS 8: 90890-06604 Depth b: 6.75–7.25 mm (0.266–0.285 in) 6. Install the thrust bearing and reverse gear into the lower case.
Drive shaft and lower case (counter rotation model) / Shimming (counter rotation model) Shimming (counter rotation model) 6 F P R B4 T3 A3 B3 65.0 A B B8 B5 A5 T1 T2 B1 38.4 47.
LOWR Lower unit Selecting the pinion shims 1. Install the special service tools onto the drive shaft 1. Digital caliper 4: 90890-06704 4. Turn the thrust bearing 5 two or three times to seat the drive shaft housing 6, and then measure the housing height (M3) as shown. NOTE: • Select the shim thickness (T3) by using the specified measurement(s) and the calculation formula. • Install the special service tools onto the drive shaft so that the shaft is at the center of the hole.
Shimming (counter rotation model) / Backlash (counter rotation model) 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. Backlash (counter rotation model) 6 Measuring the forward and reverse gear backlash 1. Remove the water pump assembly. 2.
LOWR Lower unit 5. Set the lower unit upside down. 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 8. Remove the special service tools from the propeller shaft. 9. Turn the shift rod to the reverse position c with the shift rod push arm. 10. Turn the drive shaft clockwise until the dog clutch 8 is fully engaged. 6.
Backlash (counter rotation model) 13. Turn the shift rod to the reverse position c with the shift rod push arm. 14. Slowly turn the drive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction. NOTE: When measuring the reverse gear backlash, turn the shift rod push arm towards the reverse position c with force. Reverse gear backlash: 0.61–0.90 mm (0.0240–0.0354 in) 15. Add or remove shim(s) if out of specification.
BRKT Bracket unit Bottom cowling 7 36 37 28 37 35 29 A A A 39 34 30 5 26 24 40 33 27 32 25 7 16 15 14 6 33 32 5 23 4 22 20 19 18 28 31 21 38 26 1 A 13 12 9 1110 4 3 5 7 7 8 4 2 6 17 No.
Bottom cowling 7 36 37 28 37 35 29 A A A 39 34 30 5 26 24 40 33 27 32 25 7 16 15 14 6 33 32 5 23 4 22 20 19 18 28 31 21 38 26 1 A 13 12 9 1110 4 3 5 7 7 8 4 2 6 17 No.
BRKT Bracket unit 7 36 37 28 37 35 29 A A A 39 34 30 5 26 24 40 33 27 32 25 7 16 15 14 6 33 32 5 23 4 22 20 19 18 28 31 21 38 26 1 A 13 12 9 1110 4 3 5 7 7 8 4 2 6 17 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 No.
BRKT Bracket unit 7 No.
Upper case, steering arm, swivel bracket, and clamp brackets 7 No.
BRKT Bracket unit Power trim and tilt unit 7 Checking the hydraulic pressure Ram 1. Check the hydraulic pressure. Check the internal parts if out of specification. Down PTT motor lead Battery terminal Light green (Lg) + Sky blue (Sb) - 2. Fully extend the power trim and tilt rams. Hydraulic pressure (down): 4.7–6.7 MPa (47–67 kgf/cm2) 3. Loosen the pipe joints 1, and then remove the pipe joint a. 4. Install the oil pressure gauge 2. 6.
Power trim and tilt unit NOTE: Wrap the removed pipe joint b in a rag. PTT oil pressure gauge assembly: 90890-06580 14. Remove the oil pressure gauge 2. 15. Install the pipe joint b, and then tighten the pipe joints to the specified torque. T. R. 12. Connect the PTT motor leads to the battery terminals to extend the trim ram, and then measure the hydraulic pressure. Pipe joint 3: 15 N·m (1.5 kgf·m, 11.1 ft·lb) 16.
BRKT Bracket unit 18. If necessary, add fluid of the recommended type to the correct level. NOTE: If the fluid is at the correct level, the fluid should overflow out of the filler hole when the cap is removed. Recommended power trim and tilt fluid: ATF Dexron II 19. Install the reservoir cap. T. R. 71 Reservoir cap: 7 N·m (0.7 kgf·m, 5.
Power trim and tilt unit / Electrical components Electrical components 8 Port view 3 4 5 2 1 9 8 7 6 S6D08010 1 2 3 4 5 6 7 8 Throttle position sensor Emergency switch Pulser coil Oil level sensor Stator coil Water detection switch Atmospheric pressure sensor Electric oil pump 6D03F1X 9 Electric fuel pump 72 1 2 3 4 5 6 7 8 9
– ELEC + Electrical systems Top view 1 2 2 3 3 A 0 9 4 8 5 7 6 S6D08020 1 2 3 4 5 6 7 8 9 0 73 Ignition coil Fuel injector Spark plug Oil level sensor Emergency switch Throttle position sensor Power trim and tilt switch Shift position switch Shift cut switch Crank position sensor A Engine temperature sensor 6D03F1X
Electrical components / Self-diagnosis 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 indicates NOTE: When performing this diagnosis, all of the electrical wires must be properly connected. Diagnostic flash indicator B: 90890-06865 2.
TRBL SHTG Troubleshooting 4. If a flash pattern listed in the diagnostic code chart is displayed, check the malfunctioning part according to the flash pattern. NOTE: When more than one problem is detected, the light of the diagnostic flash indicator flashes in the pattern of the lowest numbered problem. After that problem is corrected, the light flashes in the pattern of the next lowest numbered problem. This continues until all of the problems are detected and corrected.
Index A. G. Adjusting the oil pump link rod ..................... 32 After test run ................................................ 15 Applicable models.......................................... 3 Assembling the lower case .......................... 54 B. Backlash (counter rotation model) ............... 58 Backlash (regular rotation model) ................ 47 Bottom cowling............................................. 61 Break-in........................................................ 15 General.....
Index S. Selecting the pinion shims .....................46, 57 Selection ...................................................... 11 Self-diagnosis .............................................. 74 Serial number................................................. 3 Shimming (counter rotation model).............. 56 Shimming (regular rotation model)............... 45 Special service tools .................................... 28 Specified torques ......................................... 25 Symbols .............
Index — MEMO — 6D03F1X 78
Wiring diagram Z300AETO, LZ300AETO 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 V W X Y Z [ \ ] _ Electric fuel pump Electric oil pump Oil level sensor Water detection switch Throttle position sensor Emergency switch Atmospheric pressure sensor Thermoswitch Power trim and tilt switch Fuel pressure sensor Pulser coil Stator coil Crank position sensor Fuel injector Fuel pump relay Injector driver Ignition coil Spark plug ECM Diode Engine temperature sensor Trim sensor Oil pump (remote oil ta
YAMAHA MOTOR CO., LTD. Printed in the Netherlands Jul. 2003 – 0.
Z300AETO, LZ300AETO 1 L G B W/Y W/B W/R W/B W/Y B R/Y L R W/Br W/L R W/G W/L W/Br G G G G G G G G/W C B B B R/Y G ` G A L 2L B W/R W/B W/Y W/G W/L W/Br B G Y3 R/Y 2 G G/L G/L G/W G 6 (*1) 4 3 2 (*2) B X B 3 E #2 D B L/R L/W L/R L/G L/W R/Y B R/Y D D F Pu/G Z \ B [ ] L/R 90ABCDE #6 B L/W F #3 Pu/Y O/Y B 12345678 NOPQRST IJK 0 7GH 56A 9 BCD N EFL M MLF EDCBAHG 7 65 9 KJI N0 1 2 3 4 V 8 U 12 8 34 R R R/W FGHIJKLM D D #5 Br/W R R Br R
! F G O/R O/R O/L Pu/L O/G O/B Pu/B 1 2 3 4 5 6 7 8 9 10 Pu/R Pu/Y O/Y Pu/W O/W Pu/G : : : : : : : : : : B R/W O/B Pu/B Pu/L Pu/W — O/W B R/W 11 12 13 14 15 16 17 18 19 20 : : : : : : : : : : Pu/B — Pu/W Pu/L G B R/W O/R Pu/R Pu/G 21 22 23 24 25 26 27 28 29 30 : : : : : : : : : : Pu/Y — O/Y B R/W Pu/R — Pu/Y Pu/G G : : : : : : : : : : : : : : : : : : : : L/W P — L/R L/R L/G G/R P B O P B/Y B/Y P P L/Y L/W L/G Y/R L 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 : : : : : : : :
